JENSEN Healey 1972-1975 Factory Workshop Manual | PDF Download

JENSEN Healey 1972-1975 Factory Workshop Manual | PDF Download

Complete shop manual with easy, step by step instructions for the DIY mechanic or professional technician to help maintain, repair or restore the Jensen Healey.

This workshop manual is for the following Jensen models made between 1972-1975:

• Jensen Healey Mark 1
• Jensen Healey Mark 2

Transmissions

• 4 Speed Manual
• 5 Speed Manual

Carburettors

• Dellorto DHLA 40
• Dellorto DHLA 40E
• Stromberg 175 CD-2SE

below is a detailed list of topics in this Jensen Shop Manual:

• GENERAL SPECIFICATIONS AND CHARTS
• ROUTINE MAINTENANCE
• ENGINE
• GENERAL DESCRIPTION
• LUBRICATION SYSTEM
• COMPRESSION CHECK
• ENGINE REMOVAL
• REMOVE THE COOLING FAN
• REMOVE THE BELT GUARD
• REMOVE THE CAMSHAFTS (Toothed) DRIVING BELT
• REMOVE THE CAMSHAFT COVERS
• REMOVE THE AIR PUMP
• REMOVE THE CAMSHAFTS
• REMOVE THE FRONT COVER AND OIL SEAL
• REMOVE THE CAMSHAFTS DRIVING BELT ADJUSTER
• REMOVE THE WATER PUMP (North American Engines)
• REMOVE THE AIR CLEANER
• REMOVE THE AIR BOX( Prior to chassis No. 20038)
• REMOVE THE CARBURETTORS
• REMOVE THE INLET MANIFOLD
• REMOVE THE CYLINDER HEAD
• REMOVE THE VALVES
• REMOVE THE OIL SUMP
• REMOVE THE CONNECTING ROD BIG END BEARINGS
• REMOVE THE CRANKSHAFT
• REMOVE PISTONS, RINGS, CONNECTING RODS AND CYLINDER LINERS
• REMOVE THE OIL FILTER
• REMOVE THE IGNITION DISTRIBUTOR
• REMOVE THE 0IL PUMP AND AUXILIARY HOUSING
• DECARBONlSE CYLINDER HEAD AND PISTONS
• VALVE SEAT INSERTS
• VALVE GUIDES
• FLYWHEEL AND RING GEAR
• INSTALL THE OIL ·PUMP AND AUXILIARY HOUSING
• INSTALL THE IGNITION DISTRIBUTOR
• INSTALL THE OIL FILTER
• INSTALL THE CRANKSHAFT
• INSTALL PISTON RINGS, CONNECTING RODS AND CYLINDER LINERS . .
• INSTALL THE CONNECTING ROD BIG-END BEARINGS
• INSTALL THE FLYWHEEL AND CLUTCH ASSEMBLY
• INSTALL THE OIL SUMP
• INSTALL THE VALVES
• INSTALL THE CAMSHAFTS
• INSTALL THE CYLINDER HEAD
• INSTALL THE CAMSHAFT HOUSINGS
• INSTALL CAMSHAFT COVERS
• INSTALL THE INLET MANIFOLD
• CARBURETTOR FLOAT LEVEL ADJUSTMENT (DELLORTO ONLY)
• INSTALL THE CARBURETTORS
• INSTALL THE AIR CLEANER
• INSTALL THE AIR BOX (Prior to chassis No. 20038)
• INSTALL THE WATER PUMP
• INSTALL THE FRONT COVER AND OIL SEAL
• INSTALL THE CAMSHAFT DRIVING BELT ADJUST
• INSTALL THE CRANKSHAFT SPROCKET AND 'V' BELT PULLEY
• INSTALL THE BELT GUARD AND COOLING FAN
• ENGINE INSTALLATION
• SEALERS AND SPECIAL LUBRICANTS
• TRANSMISSION
• REMOVAL- GEARBOX ONLY- 5 SPEED
• COMPLETE WITH BELL HOUSING - 5 SPEED
• DISMANTLING - 5 SPEED
• EXAMINATION OF COMPONENTS - 5 SPEED
• ASSEMBLY - 5 SPEED
• GEAR CHANGE CONTROL - 5 SPEED
• INSTALLATION - 5 SPEED
• OUTPUT OIL SEAL - REMOVAL - 5 SPEED
• REMOVAL - 4 SPEED
• DISMANTLING - 4 SPEED
• EXAMINATION OF COMPONENTS - 4 SPEED
• ASSEMBLY - 4 SPEED
• INSTALLATION - 4 SPEED
• REAR AXLE
• AXLE SHAFTS
• HYPOID PINION SHAFT OIL SEAL
• REAR AXLE DISMANTLING AND ASSEMBLY
• FUEL SYSTEM
  
• TWIN DELLORTO DHLA 40 & DHLA 40E CARBURETTORS
• Description
• Operation
• Sychronisation & Tuning
• Checking Float level
• Fault Finding Chart
• TWIN STROMBERG, 175CD - 2SE CARBURETTORS
• Operation of each carburettor
• Starting from cold
• Idling
• Normal running
• Acceleration
• Tuning & Synchronisation
• Fault Finding Chart
• EMISSION CONTROL SYSTEMS
  
• DESCRIPTION
• TO CHECK EXHAUST EMISSION LEVEL (CO CONTENT)
• Catalyst and air pump equipped vehicles
• Vehicles not equipped with catalyst or air pump
• Vehicles equipped with Dellorto carburettors
• 03 STROMBERG CARBURETTORS - TYPE 175 CD 25E
• Design and operation - Emission control systems
• Biased needle
• The leak balance screw
• Temperature compensator
• The By-pass valve
• AIR PUMP
• Description and operation
• Testing the pump
• Servicing the pump
• To dismantle the pump
• To re-assemble the pump
• CATALYTIC CONVERTER
• FUEL EVAPORATION SYSTEM
• ANTI-RUN ON SYSTEM (A.R.O.)
• STEERING & SUSPENSION
  
• STEERING
• DESCRIPTION
• STEERING WHEEL
• DISMANTLING
• ASSEMBLY
• STEERING SHAFT & COLUMN
• INSPECTION FOR DAMAGE
• DISMANTLING
• ASSEMBLY
• STEERING GEAR
• DISMANTLING
• ASSEMBLY
• FRONT SUSPENSION
  • DESCRIPTION
  • STEERING GEOMETRY
  • FRONT HUBS
  • FRONT AXLE CONTROL RODS
  • FRONT SHOCK ABSORBERS, ROAD SPRINGS, STEERING ARMS & KNUCKLES
  • DISMANTLING
  • ASSEMBLY
• SUSPENSION UPPER AND LOWER ARMS AND BALL JOINTS
• DISMANTLING
• ASSEMBLY
• FRONT AXLE
• DISMANTLING
• ASSEMBLY
• REAR SUSPENSION
• DESCRIPTION
• REAR SHOCK ABSORBERS
• DISMANTLING
• ASSEMBLY
• REAR SPRINGS
• DISMANTLING
• ASSEMBLY
• SUSPENSION UPPER ARMS
• DISMANTLING
• ASSEMBLY
• SUSPENSION LOWER ARMS
• DISMANTLING
• ASSEMBLY
• BRAKES
  
• GENERAL DESCRIPTION
• BRAKE ADJUSTMENT
• BLEEDING THE HYDRAULIC SYSTEM
• BRAKE PEDAL AND SUPPORT
• MASTER CYLINDER
• Dismantling
• Assembly
• VACUUM SERVO
• Removal
• Installation
• Air Filter Removal
• BRAKE DRUMS
• BRAKE SHOES
• Brake shoe removal (After chassis No. 14064)
• REAR BRAKE CYLINDERS (After chassis No. 14064)
• Dismantling (After chassis No. 14064)
• Assembly (After chassis No. 14064)
• BRAKE SHOE RENEWAL (Prior to chassis No. 14064)
• Brake shoe adjusters (Prior to chassis No. 14064}
• REAR BRAKE CYLINDERS (Prior to chassis No. 14064}
• Dismantling
• Piston seal and dust cover renewal
• Assembly
• FRONT BRAKE FRICTION PADS
• Friction Pod renewal
• FRONT BRAKE CALIPERS
• Seal renewal
• FRONT BRAKE DISCS
• BODY
  
• REMOVAL OF WINDSCREEN
• INSTALLATION OF NEW WINDSCREEN
• FRONT EXTENSION ASSEMBLY IMPACT MEMBER
• NO-DAMAGE BUMPERS
• Description
• Rear bumper removal
• Rear bumper assembly
• Front bumper removal
• Front bumper assembly
• Cleaning and maintenance
• SEAT BELT INTERLOCK SYSTEM
• to test the logic unit
• to check the test equipment
• SPECIAL TOOLS
  
• WIRING DIAGRAM

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Language: English 

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