The following information was copied from the TC shop manual. Use the following shortcuts to quickly get to the section you need.
DIMENSIONS
Wheelbase 233.7cm/92in
Track
Front 135.8cm/53.5in
Rear 134.6cm/53in
Overall
Length 400cm/157.5in
Width 163.8cm/64.5in
Height 107.9cm/42.5in
Ground Clearance (design) 15cm/6in
Turning Circle 12.5m/41ft
Weight (unladen) 686kg/1513lbs
CAPACITIES
Engine sump (including filter) 4lt/7.5 pts; 9 U.S. pts Transmission 1.75lt/3 pts; 3.6 U.S. pts Coolant (with heater) 10.8lt/19 pts; 22.8 U.S. pts Fuel 56lt/12.5 gal; 15 U.S. gal
ENGINE
General
Cylinders 4
Capacity 1558cc/95.06 cu.in.
Stroke 72.746mm/2.864in
Bore
Grade 1 82.550-82.558mm/3.2500-3.2503in
Grade 2 82.558-82.565mm/3.2503-3.2506in
Grade 3 82.565-82.573mm/3.2506-3.2509in
Grade 4 82.573-82.580mm/3.2509-3.2512in
Compression Ratio
TC (all territories) 9.5:1
Special (U.K. & export) 10.3:1
Special (N. America) 9.5:1
Pressure at sea level In excess of 11.248kg/cm/sq - 160lbs sq in
Each cyl. within 1.41kg.cm.sq - 20lbs sq in
of each other
Cylinder Head
Material Aluminum
Gasket Copper/asbestos
Valve timing
Inlet opens 26 degrees B.T.D.C.
Inlet closes 66 degrees A.B.D.C.
Exhaust opens 66 degrees B.B.D.C.
Exhaust closes 26 degrees A.T.D.C.
Angle of valve seats & faces 45 degrees
Head diameter - inlet
TC U.K. & export 38.760/38.862mm - 1.526/1.530in
TC N. America 39.624/39.776mm - 1.560/1.566in
Special all territories 39.624/39.776mm - 1.560/1.566in
Head diameter - exhaust
All models all territories 33.553/33.655mm - 1.321/1.325in
Stem diameter - inlet and exhaust 7.874/7.899mm - .310/.311in
Stem clearance in guide
inlet .007/.058mm - .0003/.0023in
exhaust .063/.076mm - .0025/.0030in
Clearance (cold)
inlet .127/.177mm - .005/.007in
exhaust .228/.279mm - .009/.011in
Valve springs:
Type Dual
Free length
inner 28.70mm - 1.130in
outer 36.83mm - 1.450in
Rate
inner 28.70mm - 1.130in
outer 36.83mm - 1.450in
Valve springs:
Length
inlet 36.608mm - 1.520in
exhaust 37.592mm - 1.480in
External diameter
Std. 12.700/12.713mm - .500/.5005in
Oversize 12.852/12.865mm - .5060/.5065in
Interference fit (all) .0127/.0381mm - .0005/.0015in
Fitted height above cylinder head 8.128 - .320in
Internal diameter (all)
ream after fitting 7.907/7.932mm - .3113/.3123in
Bore in cylinder head
Std. 12.674/12.687mm - .499/.4995in
Oversize 12.872/12.839mm - .505/.5055in
Camshafts
Journal diameter 25.4/25.413mm - 1.000/1.0005in
End float .076/.254mm - .003/.010in
Bearings
Number 5
Type Steel backed with white metal
Length
Front 19.05mm - .75in
Centre 16.26mm - .64in
Rear 19.05mm - .75in
Running clearance .013/.050mm - .0005/.002in
Cam followers:
Bore in head 34.925/34.940mm - 1.375/1.3756in
Outside diameter 34.904/34.912mm - 1.3742/1.3745in
Follower to head clearance .013/.036mm - .0005/.0014in
Jackshaft
Bearings
Number 3
Type Steel backed with white metal
Length
Front 19.05mm - .75in
Centre 16.26mm - .64in
Rear 19.05mm - .75in
Running clearance .025/.050mm - .001/.002in
Journal diameter 39.624/39.637mm - 1.560/1.5605in
End float .063/.190mm - .0025/.0075in
Crankshaft
Balance Within 14.42gr cm - 2oz in
Diameter
Main journals 53.987/54.000mm - 2.1255/2.1260in
Crankpin 49.199/49.211mm - 1.9370/1.9375in
End float
Dimension .076/.203mm - .003/.008in
Controlled by Thrust washers on centre main bearing
Bearings
Number 5
Type Steel backed, lead bronze with lead overlay
Running clearance .038/.076mm - .0015/.0030in
Max. undersize for re-grind .762mm - .03in
Flywheel
Max. runnout (lateral) .101mm - .004in
Starter ring gear runout
Lateral .406mm - .016in
Radial .152mm - .006in
Connecting Rod
Type 'H' section=
Material Steel forging
Distance between centres 12.19/12.24cm - 4.799/4.801in
Bearings
Type Steel backed, lead bronze with lead overlay
Running clearance .013/.513mm - .0005/.0022in
End float on crankpin .101/.254mm - .004/.010in
Small end bore (bushed):
Grade 'A' (silver) 20.635/20.637mm - .8124/.8125in
Grade 'B' (green) 20.637/20.642mm - .8125/.8127in
Gudgeon (piston) pin
Type Floating
Location Circlips
Diameter
Grade 'A' 20.627/20.628mm - .8121/.8122in
Grade 'B' 20.628/20.632mm - .8122/.8123in
Class of fit Finger push fit
Piston
Type Solid skirt
Material Tin plated aluminum alloy
Length 68.250mm - 2.687in
Compression height 39.014/39.065mm - 1.536/1.538in
Max. permissible weight variation per set 4 grams
Rings
Compression 2
Oil control 1
Diameter
Grade 1 82.466/82.474mm - 3.2467/3.2470in
Grade 2 82.474/82.481mm - 3.2470/3.2473in
Grade 3 82.481/82.489mm - 3.2473/3.2476in
Grade 4 82.489/82.497mm - 3.2476/3.2479in
Piston clearance in cylinder bore 1.016mm - .04in towards thrust face
Gudgeon pin bore offset .076/.091mm - .0030/.0036in
Ring gap (fitted)
Compression .229/.356mm - .009/.014in
Oil control .254/.508mm - .010/.020in
Piston ring to groove clearance
Compression .041/.091mm - .0016/.0036in
Oil control .046/.097mm - .0018/.0038in
Lubrication System
Pump
Type Eccentric lobe
Drive Gear on jackshaft
Inner and outer rotor clearance .15mm - .006in
Inner and outer rotor float .13mm - .005in
Outer rotor to housing clearance .25mm - .010in
Normal pressure (hot) 2.4/2.8kg.cm.sq - 35/40psi
Filter Full flow (throw away cannister)
Fuel System
Pump
Operation Lever by eccentric on jackshaft
Pressure .087/.176kg.cm.sq - 1.25/2.5psi
Air cleaner type paper element, dry
Carburetter
Type and number Dellorto 40 DHLA, two
Slow running speed 800 rpm
Settings
Choke 30mm
Main jet 115
Main air corrector jet 160
Slow running jet 50
Slow running air corrector jet 7850-2
Pump jet 8083.40
Starter jet 70
Main emulsion tube 7772-1
Starter emulsion tube 7482-1
Needle valve 7180-15
Air trumpet length 4.44cm - 1.75in
Carburetter
Type and number Zenith Stromberg 175 CD 2SE, two
Slow running speed 800/900 rpm
Settings
Needle B1G
Spring color Light blue
Damper oil SAE 20W/50
Ignition System
Type Coil and distributor
Firing order 1,3,4,2
No. 1 cylinder Nearest to front of car
Ignition advance control Fully automatic
Ignition timing (static)
Dellorto carburetters 12 deg B.T.D.C.
Zenith Stromberg carburetters 5 deg B.T.D.C.
Coil Lucas LA12
Spark plugs
Type Champion N7Y
Gap .584/.635mm - .023/.025in
Distributor
Type 23 D.4
Direction of rotation Anti-clockwise
Drive Gear on jackshaft
Contact breaker gap .35/.40mm - .014/.016in
Contact lever spring tension .51/.68kg - 18/24oz
Firing angles 0, 90, 180, 270 deg +-1 deg
Cam dwell angle 60 deg +- 3 deg
Despatch no.
Dellorto 41189
Zenith Stromberg 41225 when suction retard fitted
Centrifugal advance (all)
Crankshaft rpm Crank deg B.T.D.C. (add static setting)
Below 1000 No advance
1250 2.4
1500 4.6
1750 6.8
2000 9.2
2250 11.6
2500 14 max advance
Cooling System
Type Centrifugal pump and fan Radiator cap relief valve pressure .49 kg.cm.sq. - 7psi Thermostat nominal opening temp. 78 deg C. Alternator belt tension at top 9.52mm - .375in Impeller vanes to water pump housing clearance .508/.762mm - .020/.030in
Clutch
Type Borg and Beck, diaphragm spring Operation Cable Driven plate diameter 21.59mm - 8.5in Free movement of withdrawal lever 4.318mm - .170in
Transmission
Type 4 forward speeds and reverse
Bearings
Mainshaft Taper rollers
Secondary gear cluster Taper rollers
Bearings adjustment See section F of manual
Gear ratios:
4 speed 5 speed
O/D (5th) N/A 0.87:1
4th 1.03:1 1.21:1
3rd 1.48:1 1.61:1
2nd 2.25:1 2.33:1
1st 3.61:1 3.61:1
Reverse 3.08:1 3.08:1
Final drive:
Type Hypoid gear
Bearings Taper rollers
Diff./crown wheel Taper rollers
Drive shaft end-float .050/.076mm - .002/.004in
Bearings adjustment
Pinion bearing pre-load See section F of manual
Crown wheel/pinion .127/.254mm - .005/.010in
Number of teeth
Pinion 9 type 336/352 - 9 type 365
Crown wheel 32 type 336/352 - 34 type 365
Speedometer gears
Driving gear Driven gear
4th 3.666:1 4.574:1
3rd 5.268:1 6.086:1
2nd 8.010:1 8.807:1
1st 12.851:1 13.646:1
Reverse 10.964:1 11.642:1
Steering
Type Rack and pinion
Steering angles
Camber 0 deg to +- 30 min
Castor 2 deg 30 min +- 30 min
Swivel pin inclination 9 deg +- 30 min
Toe in 4.8mm to 1.6mm - 3/16 to 1/16in
Condition for checking toe in 15cm - 6in of ground clearance at
bottom of chassis closing plate
Front Suspension
Type Independant
Spring
No. of coils 13.5
Wire diameter 10.16mm - .40in
Length
Free 31.77cm - 12.51in
Fitted 20.01cm - 7.88in
Rate 1.33kg.m. - 116lb/in
Front hub end float .05/.10mm - .002/.004in<
Rear Suspension
Type Independant
Spring
No. of coils 19.6
Wire diameter 8.23mm - .324in
Length
Free 42.54cm - 16.75in
Fitted 25.04cm - 9.86in
Rate .865kg.m. - 75lb/in
Brakes
Make and type Girling hydralic (servo assisted)
Front brakes
Disc diameter 24.76cm - 9.75in
Pads material Ferodo FER .2430 F
Total disc run out .10mm - .004in
Rear brakes
Drum diameter & width - TC 20.3cm x 31.75mm - 8 x 1.25in
Drum diameter & width - Special 20.3cm x 38.10mm - 8 x 1.50in
Lining material Don.242
Handbrake type Mechanical on rear only
Wheels and Tyres
Standard Wheel type Pressed steel - bolt on Wheel size 4.5J Tyres Dunlop SP Sport with tubes Tyre size 155 x HR13 Optional Wheel type Alloy - bolt on Wheel size 5.5J x 13 Nuts, torque loading 5.53/6.22kg.cm.sq - 40/50lbs.ft. Tyres Firestone Cavalino wide oval Tyre size 175/185 x 13 Pressure (standard cold) Speeds below 160kph - 100mph Sustained speeds above 160kph - 100mph Front 1.27kg.cm.sq. - 18psi 1.69kg.cm.sq. - 24psi Rear 1.97kg.cm.sq. - 28psi 2.39kg.cm.sq. - 34psi Pressure (optional cold) Speeds below 160kph - 100mph Sustained speeds above 160kph - 100mph Front 1.125kg.cm.sq. - 16psi 1.547kg.cm.sq. - 22psi Rear 1.828kg.cm.sq. - 26psi 2.250kg.cm.sq. - 32psi
Electrical Equipment
Battery
Type Exide 6 VTA 29L
Capacity 39 amp hr. @ 20 hr. rating
Voltage and polarity 12 volt negative ground
Fuses
Quantity 4; 35 amp
Alternator
Type AC Delco DN 460
Max. output 35 amp @ 3600rpm
Ground polarity Negative
Number of poles 14
Stator phases 3
Starter
Type Lucas M.35 J
Drive SB (inboard)
Brush tension .80kg - 28ozs
Light running current 65 amp @ 8000/10,000rpm
Lock torque .97kg.m. - 7lb.ft. @ 350/375 amps
Lamp bulbs
Headlamp
RHD, LHD 410 (45/40W) with 989 (6W) pilot
France 410 (45/40W) yellow with 989 (6W) pilot
N. America Sealed beam unit
Front and rear indicators 382 (21W)
Indicator repeater 501 (5W capless)
Stop and tail lamps 380 (21/6W)
Rear number plate lamp 254 (6W festoon)
Reverse lamp 273 (21W festoon)
Interior lamp 254 (6W festoon)
Panel (instrument) lamps 987 (2.4W festoon)
Warning lamps 987 (2.4W festoon)
Bolt Torques
Engine
Cylinder head (tighten cold) pattern 60-65lb./ft. - 8.29-8.98kg.m.
Cylinder head to front cover 10-15lb./ft. - 1.38-2.07kg.m.
Spark plugs 24-28lb./ft. - 3.31-3.87kg.m.
Camshafts
Bearing caps 9lb./ft. - 1.24kg.m.
Sprockets 25-30lb./ft. - 3.45-4.14kg.m.
Crankshaft
Main bearing caps 55-60lb./ft. - 7.60-8.29kg.m.
Connecting rod (big end) caps 44-46lb./ft. - 6.08-6.36kg.m.
Pulley 24-28lb./ft. - 3.31-3.87kg.m.
Flywheel 45-50lb./ft. - 6.22-6.91kg.m.
Front timing cover 1/4" (UNF & UNC) 5-7lb./ft. - .69-.96kg.m.
5/16" (UNF & UNC) 10-15lb./ft. - 1.38-2.07kg.m.
Back plate to cylinder block 6-8lb./ft. - .83-1.10kg.m.
Timing chain tensioner
Sprocket pin 40-45lb./ft. - 5.53-6.22kg.m.
Retaining bolt 45-50lb./ft. - 6.22-6.91kg.m.
Pivot pin 40-45lb./ft. - 5.53-6.22kg.m.
Jackshaft
Sprocket 12-15lb./ft. - .65-2.07kg.m.
Thrust plate 5-7lb./ft. - .69-.96kg.m.
Oil filter centre bolt 12-15lb./ft. - 1.65-2.07kg.m.
Oil pump to cylinder block 12-15lb./ft. - 1.65-2.07kg.m.
Oil sump to cylinder block 6-8lb./ft. - .83-1.10kg.m.
Oil sump drain plug 20-25lb./ft. - 2.76-3.45kg.m.
Fuel pump to cylinder block 12-15lb./ft. - 1.65-2.07kg.m.
Exhaust manifold to cylinder head 12-15lb./ft. - 1.65-2.07kg.m.
Rear oil seal carrier (crank) to block 12-15lb./ft. - 1.65-2.07kg.m.
Generator to mounting bracket 15-18lb./ft. - 2.07-2.48kg.m.
Carburetter trumpet nuts 8lb./ft. - 1.101kg.m.
Engine mounting bracket to engine 18lb./ft. - 2.481kg.m.
Clutch
Clutch housing to gearbox 40-45lb./ft. - 5.53-6.22kg.m.
Clutch assembly to flywheel 12-15lb./ft. - 1.65-2.07kg.m.
Transmission
Gearbox casing (halves)
Differential bearing adjusting nuts 15lb./ft. - 2.07kg.m.
Pinion bearing nut 85lb./ft. - 11.75kg.m.
Side cover plates 15lb./ft. - 2.07kg.m.
Gearbox mounting bracket to chassis 35lb./ft. - 4.83kg.m.
Front Suspension & Steering
Stub axle retaining nut 65-75lb./ft. - 8.98-10.36kg.m.
Ball joint
To vertical link 38-42lb./ft. - 5.25-5.80kg.m.
To upper wishbone 12-15lb./ft. - 1.65-2.07kg.m.
Lower wishbone
To trunion * 35lb./ft. - 4.83kg.m.
To damper * 50lb./ft. - 6.91kg.m.
Inner wishbone retaining nut * 50lb./ft. - 6.91kg.m.
Caliper mounting plate to hub 22-27lb./ft. - 3.04-3.73kg.m.
Steering arm to vertical link 22-27lb./ft. - 3.04-3.73kg.m.
Steering tie rod ball joint 26-28lb./ft. - 3.59-3.87kg.m.
Steering tie rod adapter 50lb./ft. - 6.91kg.m.
Steering unit mounting clamps to chass. 10lb./ft. - 1.38kg.m.
Steering column impact clamp 26-32lb./ft. - 3.59-4.42kg.m.
* Tighten with suspension in static ride condition
Rear Suspension
Lower link & damper to bearing housing 55lb./ft. - 7.60kg.m.
Lower link to clutch housing 40lb./ft. - 5.53kg.m.
Lower link mounting bracket to trans 12lb./ft. - 1.65kg.m.
Bearing housing to radius arm 18lb./ft. - 2.48kg.m.
Radius arm front mounting bolt 35lb./ft. - 4.83kg.m.
Rear damper top mounting 40lb./ft. - 5.53kg.m.
Hubs
Rear hub to outboard drive shaft ** 150lb./ft. - 20.70kg.m.
Brake disc to front hub 22-27lb./ft. - 3.04-3.73kg.m.
Front hub to spindle nut *** 5-6lb./ft. - .69-.83kg.m.
** Assemble with Loctite "35". A rotational free play NOT EXCEEDING
.127mm (.005in) between the hub and shaft measured at the wheel stud
MUST be used for LEFT HAND hubs.
*** Tighten nut to this torque loading while rotating the hub to ensure
bedding of taper rollers. Slacken nut 'one flat', then insert split pin.
Brake Hydralic System Connections
3/8" UNF female (bundy & hose connection) 8-10lb./ft. - 1.10-1.38kg.m.
3/8" UNF male (bundy to master cylinder 5-7lb./ft. - .69-.96kg.m.
7/16" UNF male 14-21lb./ft. - 1.93-2.90kg.m.
3/8" bore servo bundy (5/8" male) 12-15lb./ft. - 1.65-2.07kg.m.
Stop light switch 12-15lb./ft. - 1.65-2.07kg.m.
Brake hose to banjo 12-15lb./ft. - 1.65-2.07kg.m.
General Nuts and Bolts
1/4" UNF and UNC 5-7lb./ft. - .69-.96kg.m.
5/16" UNF and UNC 12-15lb./ft. - 1.65-2.07kg.m.
3/8" UNC 17-22lb./ft. - 2.35-3.04kg.m.
3/8" UNF 22-27lb./ft. - 3.04-3.73kg.m.
7/16" UNC 30-35lb./ft. - 4.14-4.85kg.m.
7/16" UNF 40-45lb./ft. - 5.53-6.22kg.m.
1/2" UNC 45-50lb./ft. - 6.22-6.91kg.m.
1/2" UNF 50-60lb./ft. - 6.91-8.29kg.m.
9/16" UNC 60-70lb./ft. - 8.29-9.68kg.m.
9/16" UNF 65-75lb./ft. - 8.98-10.36kg.m.
5/8" UNC 75-85lb./ft. - 10.36-11.75kg.m.
5/8" UNF 110-110lb./ft. - 13.82-15.20kg.m.
Last update: 1 Jan. 2003