JENSEN Healey 1972-1975 Factory Workshop Manual | PDF Download

Description

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
- STEERING GEOMETRY
- FRONT HUBS
- FRONT AXLE CONTROL RODS
- FRONT SHOCK ABSORBERS, ROAD SPRINGS, STEERING ARMS & KNUCKLES
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

File Format: PDF

Language: English

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