Haynes Talbot Samba Owners Workshop Manual 1850101981, 9781850101987

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STRASMAN, P.G.

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ISBN 1 85010 198 1 © Haynes Publishing Group 1984, 1986 All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. Printed in England (823-2M7) ABCDE FGHIS

KLMNO PAR:

Haynes Publishing Group Sparkford Nr Yeovil Somerset

BA22

Je)

England

ee

=

British Library Cataloguing

aoe in Publication

Data

Strasman, Peter G.

Haynes 861

Publications,

Lawrence

Drive

Newbury Park California 91320

Talbot Samba owners workshop manual.—2nd

Inc

—(Owners Workshop Manuals/Haynes) 1. Talbot Samba automobile |. Title

USA

Il. Series

629.28'722 TL215.124 ISBN 1-85010-198-1

ed.

Acknowledgements Thanks are due to the Talbot Motor Company for the provision of technical information and certain illustrations. The Champion Sparking Plug Company supplied the illustrations showing the various spark

About

this manual

[ts aim The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work

must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work.

/ts arrangement The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc.

Introduction The Samba

plug conditions. Sykes-Pickavant provided some of the workshop tools. Thanks are also due to all those people at Sparkford who helped in the production of this manual.

was

introduced

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the.back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards.

Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

to the Talbot Samba into Great Britain in February

1982.

The basic body style is of three-door Hatchback type, but in early 1983 a Cabriolet (convertible) became available and various special editions have been launched. The Samba bears a strong similarity to the Peugeot 104, upon which it is based, and has inherited some characteristics which make life for the home mechanic difficult especially in respect of engine

operations. However, servicing and maintenance operations may be carried out quite easily with good accessibility. Any engine dismantling work during major overhauls can be combined into one session with the engine removed from the car. The car is generally well built, finished and economical. The wide range of models and options available should meet the needs of most purchasers looking for a practical car in this section of the market.

Contents Page Acknowledgements

2

About this manual

2

Introduction to the Talbot Samba

2

General dimensions, weights and capacities Buying spare parts and vehicle identification numbers Tools and working facilities

General repair procedures

10

Jacking and towing

11

Recommended

13

lubricants and fluids

Safety first!

14

Routine maintenance

15

Fault diagnosis

19

Chapter 1 Engine

23

Chapter 2 Cooling, heating and ventilation systems

51

Chapter 3 Fuel system

58

Chapter 4 Ignition system

70

Chapter 5 Clutch

80

Chapter 6 Transmission

88

Chapter 7 Driveshafts, hub bearings, roadwheels and tyres

105

Chapter 8 Steering system

113

Chapter 9 Braking system

119

Chapter 10 Electrical system

136

Chapter 11

154

Suspension

Chapter 12 Bodywork and fittings

Chapter 13 Supplement:

Revisions and information

163

on later models

177

Conversion factors

191

Index

19 Nh

yoqey equies S71

yajouqgesy equies joqjey

General dimensions, weights and capacities Dimensions Overall lerathitceseshrccecsseseeecoteeeccescrtssseres tenssercwoctoceaieltsaoseesvsectircemrerseses

3505

Overall width .cPeeeee ee poses aera eevee meer eer ere eee Overall height is: sece cots rete corres emesae here me cercae eae Ground \clearanCesery. acaecreitrrsctr catatatervivis farenvgetastsceaettnkive tes

1592 mm (60.2 in) 1361 mm (53.6 in) 119 mm (4.7 in)

mm

(138 in)

Weights S54 and 1124s cc8models® sacar recreate nest ccmteemtee teste istnaen aeserene 1360 cc models Except Sand): Cabriolet tr. csc enc css tee rs, omc reer cenec ten cannon nyoe

Ses

secde seis

a oe ae

OT

RON cree

eR

740 kg (1632 Ib) 790 kg (1742 Ib)

a

800 kg (1764 Ib)

Cabriolet \.c.ccetiecestecpere scoters ees atime every tetera: ore ee

850 kg (1874 Ib)

Maximum trailer load: With brakes

954 and il24ecc(modelStrr.recncstcc etter verceerer neers. 11360 cohimodels.. catetsstesss acrites eet eee eee ls ees: Without

750 kg (1654 Ib) 800 kg (1764 Ib)

brakes

954) andi ili2 AicestmOdels trecsc.cccsesscttesesctcastesrasesseecetrcemarecc-es 1360 ceimodel Striciatcc se ee ee eRe ROOf haCk 10aCertara ree eee ore eee ree ne Ree ee rere ee

370 kg (816 Ib) 390 kg (860 Ib) 75 kg (165 Ib)

Capacities Engine transmission: QB AIC crac ee

li

oR

ET ET

eliSOORcc FOlir=Sp GO tere cercceeras te eerste

Ava es cooe seer

EES

4.0 litre (7.0 pint)

eae ren

4.5 litre (7.9 pint)

eee

FIVE=SPCO Ceri eseree tere ean ccie dined cates cones ses eniniatirnreesmrriittec tries POONIMOLSYSTEMM ecrettec costes seas ctasei arts cs casos cacsdecassonsnse ensue rntesmtaseaeseeesete PTA FLIES Ln Ce ROS OAY APP DCC MEER RT ence rane Coen iertc ee eereona

5.0 litre (8.8 pint) 5.6 litre (10.56 pint) 40.0 litre (8.8 gal)

Buying spare parts and vehicle

identification

Buying spare parts Spare parts are available from many sources, for example: Peugeot Talbot garages, other garages and accessory shops, and motor factors. Out advice regarding spare part sources is as follows: Officially appointed Peugeot Talbot garage — This is the best source of parts which are peculiar to your car and are otherwise not generally available (eg complete cylinder heads, internal gearbox components, badges, interior trim etc). It is also the only place at which you should buy parts if your car is still under warranty — nonPeugeot Talbot components may invalidate the warranty. To be sure of obtaining the correct parts it will always be necessary to give the storeman your cars engine and chassis number, and if possible, to take the old part along for positive identification. Remember that many parts are available on a factory exchange scheme — any parts returned should always be clean. It obviously makes good sense to go straight to the specialists on your car for this type of part for they are best equipped to supply you. Other garages and accessory shops — These are often very good places to buy material and components needed for the maintenance of your car (eg oil filters, spark plugs, bulbs, fanbelts, oils and grease, touch-up paint, filler paste etc). They also sell general accessories, usually have convenient opening hours, charge lower prices and can often be found not far from home. Motor factors — Good factors will stock all of the more important components which wear out relatively quickly (eg clutch components, pistons, valves, exhaust systems, brake cylinders/pipes/

numbers hoses/shoes and pads etc). Motor factors will often provide new or reconditioned components on a part exchange basis — this can save a considerable amount of money.

Vehicle identification numbers Modifications are a continuing and unpublicised process in vehicle manufacture, quite apart from major model changes. Spare parts manuals and lists are compiled upon a numerical basis, the individual vehicle numbers being essential for correct identification of the component required. Although many individual parts, and in some cases, subassemblies, fit a number of different models it is dangerous to assume that, just because they look the same, they are the same. Differences are not always easy to detect except by serial, part or identity numbers. Make sure, therefore, that the appropriate numerical details for the model or sub-assembly are known and quoted when a spare part is ordered. Vehicle identification plate — This is located adjacent to the front suspension strut top mounting within the engine compartment. Body serial number — This is stamped onto the inner wing valance

(photo). Engine number — This is riveted on the engine block at the flywheel housing flange joint. Always quote this number in connection with transmission components as well. Paint code — This is shown in the form of a sticker located just forward of the right-hand suspension strut turret.

AUTOMOBILES

TALBOT

H16730 Vehicle identification plate Type approval number

NOES

s

wR

Vehicle identification number

Identification number Gross vehicle weight Gross train weight Maximum front axle loading Maximum rear axle loading

Tools and working facilities © Introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a

considerable expense, offsetting some of the savings made by doingit-yourself. However, provided that the tools purchased are of good quality, they will last for many years and prove an extremely worthwhile investment. To help the average owner to decide which tools are needed to carry out the various tasks detailed in this manual, we have compiled three lists of: tools under the following headings: Maintenance and minor repair, Repair and overhaul, and Special. The newcomer to practical mechanics should start off with the Maintenance and minor repair tool kit and confine himself to the simpler jobs around the vehicle. Then, as his confidence and experience grow, he can undertake more difficult tasks, buying extra tools as, and when, they are needed. In this way, a Maintenance and minor repair tool kit can be built-up into a Repair and overhaul tool kit over a considerable period of time without any major cash outlays. The experienced do-ityourselfer will have a tool kit good enough for most repair and overhaul procedures and will add tools from the Specia/ category when he feels the expense is justified by the amount of use to which these tools will be put. It is obviously not possible to cover the subject of tools fully here. For those who wish to learn more about tools and their use there is a book entitled How to Choose and Use Car Tools available from the

publishers of this manual.

Maintenance

be considered

as a minimum

requirement if routine maintenance, servicing and minor repair operations are to be undertaken. We recommend the purchase of combination spanners (ring one end, open-ended the other); although more expensive than open-ended ones, they do give the advantages of both types of spanner.

Combination spanners - 10, 11, 12, 13, 14 & 17 mm Adjustable spanner - 9 inch

Engine sump/drain plug key Spark plug spanner (with rubber insert) Set of feeler gauges Brake bleed nipple spanner

These tools are virtually essential for anyone undertaking any major repairs to a motor vehicle, and are additional to those given in the Maintenance and minor repair \ist. Included in this list is a comprehensive set of sockets. Although these are expensive they will be found invaluable as they are so versatile - particularly if various

drives are included in the set. We recommend the + in square-drive type, as this can be used with most proprietary torque wrenches. If you cannot afford a socket set, even bought piecemeal, then inexpensive tubular box spanners are a useful alternative. The tools in this list will occasionally need to be supplemented by tools from the Speci/a/ list.

Sockets (or box spanners) to cover range in previous list Reversible ratchet drive (for use with sockets) Extension piece,

10 inch (for use with sockets)

Universal joint (for use with sockets) Torque wrench (for use with sockets) ‘Mole’ wrench - 8 inch Ball pein hammer Soft-faced hammer,

plastic or rubber

Screwdriver - 6 in long x % in dia (flat blade) Screwdriver - 2 in long x % in square (flat blade)

Screwdriver - 14 in long x % in dia (cross blade) Screwdriver - 3 in long x 4 in dia (electricians) Pliers - electricians side cutters Pliers - needle nosed

Pliers - circlip (internal and external)

and minor repair tool kit

The tools given in this list should

Repair and overhaul tool kit

Cold chisel - 4 inch Scriber Scraper Centre punch Pin punch Hacksaw Valve grinding

tool

Stee/ rule/straight-edge Allen keys

Selection of files Wire brush (large) Axle-stands Jack (strong scissor or hydraulic type)

Screwdriver - 4 in long x % in dia (flat blade)

Screwdriver - 4 in long x + in dia (cross blade)

Special tools

Combination pliers - 6 inch Hacksaw (junior)

The tools in this list are those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturers’ instructions. Unless relatively difficult mechanical jobs are undertaken frequently, it will not be economic to buy many of

Tyre pump

Tyre pressure gauge Oil can Fine emery cloth (1 sheet)

Wire brush (small) Funnel (medium size)

these tools. Where this is the case, you could consider clubbing together with friends (or joining a motorists’ club) to make a joint purchase, or borrowing the tools against a deposit from a local garage or tool hire specialist.

Tools and working facilities

9

The following list contains only those tools and instruments freely available to the public, and not those special tools produced by the vehicle manufacturer specifically for its dealer network. You will find occasional references to these manufacturers’ special tools in the text

Spanner jaw gap comparison Jaw gap (in)

Spanner

of this manual. Generally, an alternative method of doing the job without the vehicle manufacturers’ special tool is given. However,

0.250

t in AF

sometimes, there is no alternative to using them. Where this is the case and the relevant tool cannot be bought or borrowed, you will have to entrust the work to a franchised garage.

0.276

0.313

Universal hub/bearing puller Impact screwdriver Micrometer and/or vernier gauge Dial gauge Stroboscopic timing light

Dwell angle meter/tachometer Universal electrical multi-meter Cylinder compression gauge Trolley jack

Light with extension lead

Buying tools For practically all tools, a tool factor is the best source since he will

have a very comprehensive range compared with the average garage or accessory shop. Having said that, accessory shops often offer excellent quality tools at discount prices, so it pays to shop around. Remember, you don't have to buy the most expensive items on the shelf, but it is always advisable to steer clear of the very cheap tools. There are plenty of good tools around at reasonable prices, so ask the proprietor or manager of the shop for advice before making a purchase.

7 mm

8 in AF 8 mm

0.344

gz in AF; ¢ in Whitworth

0.375

Piston ring compressor Balljoint separator

size

0.315 0.354

Valve spring compressor

table

:

9 mm

3 in AF

0.394

10 mm

0.433

11 mm

0.438

Z in AF

0.445

% in Whitworth; + in BSF

0.472

0.500

12 mm

4 in AF

0.512

13 mm

0.525

4 in Whitworth; % in BSF

0.551

0.563

14 mm

2 in AF

0.591

15 mm

0.600

% in Whitworth; 2 in BSF

0.625

8 in AF

0.630 0.669

16 mm 17 mm

0.686

Yin AF

0.709

18 mm 3 in Whitworth; % in BSF

0.710 0.748

19 mm

0.750 0.813

3 in AF 3 in AF

0.820

% in Whitworth; 4+ in BSF

0.866

22 mm

0.920

4+ in Whitworth; % in BSF

0.938

® in AF

0.945

24 mm

1.000 1.010

1 in AF % in Whitworth; £ in BSF

1.024

26 mm

1.063 1.100

1% in AF; 27 mm 2 in Whitworth; 7 in BSF

1.181

30 mm

1.200

ig in Whitworth; = in BSF

1.260

32 mm

1.300

3 in Whitworth; 2 in BSF

Working facilities

1.390

#3 in Whitworth; #2 in BSF

Not to be forgotten when discussing tools, is the workshop itself. If anything more than routine maintenance is to be carried out, some form of suitable working area becomes essential. It is appreciated that many an owner mechanic is forced by circumstances to remove an engine or similar item, without the benefit of a garage or workshop. Having done this, any repairs should always be done under the cover of a roof. Wherever possible, any dismantling should be done on a clean, flat workbench or table at a suitable working height. Any workbench needs a vice: one with a jaw opening of 4 in (100 mm) is suitable for most jobs. As mentioned previously, some clean

1.417

36 mm

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