Page 1
97H 1S83A
AUSTIN-HEALEY
SPRITE
DRIVER'8 HANDBOOK
Page 2
AUSTIN-HENLEY
SPRITE
DRIVER'S
HANDBOOK
A copy of this Driver's Handbook is sent out
with every Austin-Healey Sprite. Ad ditional
copies are obtainable only from your Austin
Dealer and Part No. 97H1583A should be quoted
when ordering.
JULY 1958
THE AUSTIN MOTOR CO. LTD.
LONGBRIDGE, BIRM INGHAM
BOX 41 G.P.O.
Page 3
T
HE information contained in: this Operation
Manual has been confined to the essentials
necessary for the proper running and driving. of
the car. Nevertheless, the owner will find all the
information required to maintain the car in firstclass condition and to enable him to give it those
.all-important items of attention which go so far to-
ensure trouble-free and satisfactory service.
Every car leaving the Wor ks is ca pable of
giving absolute satisfaction if attention is given
to the essential maintenance operations detailed
in this book. Remember that Austin Distributors/
Dealers are better equipped to provide routine
and repair service than the owner-driver; therefore, '
if you encounter trouble consult the Distributor
or Dealer or the Service Department of Austin
Motors Limited — they are at your- service.
An exchange scheme for many major items and
assemblies is run by B.M.C. Service Limited; ask
your Distributor or Dealer for details.
For those requiring in
formation of a more detailed
and technical nature than is contained in the
Operation Manual, a Workshop Manual is available
at a reasonable price
from your Distributor or
Dealer.
INDEX
FOREWORD
SPECIFICATION
REGULAR ATTENTIONS
DRIVING INSTRUCTIONS
PROPRIETARY EQUIPMENT
GENERAL MAINTENANCE ..
RECOMM E N D ED LUBRICANTS
INSTRUMENTS AND CONTROLS
36-57
20-35
33
16
10
Page
6
59
IDENTIFICATION
When communicating with the Company or your
Distributor/Dealer always quote the car a n d
engine numbers; the registration number is of no
use and is not required.
Page 4
pp
C
Page 5
GENERAL SPECIFICATION
AUSTIN-HKALKY SPRITE
SPECIFICATION
the vehicle, which is addressed to the Austin Motor Co. Ltd. or its
Dealers. The number will be found on a plate attached to the lefthand valance inside the engine compartment.
In addition, the engine number is located oh the right side of the
cylinder block, adjacent to the cylinder head.
ENGINE
Bore
Stroke
Capacity
B.H.P.
Maximum Torque
Compression ratio
Firing Order
Valves
Valve Timing: Inlet opens
Inlet closes
Exhaust opens
Exhaust closes
Valve Clearance (hot or cold)
Number of cylinders
A LWAYS quote the car number in any correspondence, relating to
4
2.48 in. (62.9 mm.)
3.00 in. (76.2 mm.)
.. 57.87 cu. in. (948 c.c.)
43 at 5,200 r.p.m.
52 lbs. ft. at 3,300 r.p.m.
83to 1
1, 3, 4, 2
.. Overhead push rod operation
5' B.T.D.C.
45' A.B.D.C.
40' B.B.D.C.
10' A.T.D.C.
.012 in. (.305 mm.)
IGNITION
Type
Coil
Distributor
Contact breaker gap
Timing
Sparking Plugs
Plug Gap
CLUTCH
Make
Type
Diameter
Method of operation
GEARBOX
Type
. Gear ratios: 1st
2nd
3rd
Top
Reverse
4 speed synchromesh (on 2nd, 3rd k top)
Lucas 12 volt
Lucas type LA12
Lucas type DM2 PH4
.014 to .016 in. (.356 to .406 mm.)
5' before T.D.C. (Premimn Fuel)
Champion N.5. Long reach
.025 in. (.64 mm.)
.. Borg and Beck
.. Single dry plate
6z in. (15.88 cm.)
Hydraulic
3.627 to 1
2.374 to 1
1.412 to 1
1 to 1
4.664 to 1
2$ Imp. pints (1.33 litres)
Oil 'capacity
LUBRICATION
Type
Pump
Pressure (Normal)
Filter
Sump capacity
Filter capacity
FUEL SYSTEM
Carburetters
Model
Needle
Tank capacity
Pump
Wet sump
Hobourn Eaton or Burman Rotor type
Running , . 60 lbs./sq. in. (4.2 kg./cm.')
Idling . . 15 lbs./sq. in. (1.05 kg./cm.')
6 Imp. pints (3.41 litres)
1 Imp. pint (0.57 litres)
A.C. Sphinx 'Y'
Two S.U. semi-downdraught
GG
., 6 Imp. galls. (27 litres)
Full flow
Type
Make
Type
PROPELLER SHAFT
REAR AXLE
Oil capacity
Overall ratios: 1st
2nd
3rd
Top
Reverse
.. Hypoid three-quarter floating
le Imp. pints (1.0 litre)
15.32 to 1
10.02 to 1
5.96 to 1
4.22 to 1
19.69 to 1
Hardy Spicer
Open shaft
Hl
COOLING SYSTEM
Pres surised
Pump, fan and thermostat
164'F. (73'C.)
10 Imp. pints (5.68 litres)
STEERING
Type
Ratio
Track toe-in
Adjustment
Rack and pinion
2~ turns lock to lock
Parallel to $ in. (0 — 3.18 mm.)
Shims
Type
Circulation
Normal operating temperature
Capacity
Page 6
GENERAL SPECIFICATION
AUSTIN-HEAI,EY SPRITE
SUSPENSION GENERAL DIMENSIONS
Make
Type
Rear: Type
SHOCK ABSORBERS
Front: Type . . Independent
Castor Angle
Camber Angle
Swivel pin inclination
by coil springs and wishbones,
3
0
1
0
6p
Quarter-elliptic leaf springs
Overall Length
Overall Width
Overall Height
Wheelbase
Track (front)
Track (rear)
Turning Circle
Approx. Weight
11 ft. 0$ m. (3.37 m.)
4 ft. 5 in. (1.35 m.)
4 ft. 1( in. (1.26 m.)
6 ft. 8 in. (2.32 m.)
3 ft. 9
4' in. (1.16.m.)
3 ft. 8 —,' in. (1.14 m.)
32 ft. approx. (9.7 m.)'
13 cwt. (660 kg;)
Armstrong
Double acting hydraulic piston
BRAKES
Make
Frontbrake: Type
Front
Rear
Handbrake: Type
Drum Diameter
Lockheed
Hydraulic with two leading shoes
Hydraulic
Pull-up operating mechanically
on rear wheels
7 in. (17.8 cm.)
WHEELS
Type 13 x 3.50D pressed steel disc with
ventilation holes
TYRES
Type
Pressures:
Durilop 5.20-13 E.L.P. Tubeless
18 lbs./sq. in. (1.27 kg. cm.') front
20 lbs./sq. in. (1.41 kg./cm.') rear
JACKING SYSTEM
Smith's 'Steady-lift'
Ratchet spanner
Type
Operation
ELECTRICAL EQUIPMENT
Lucas 12 volt
Lucas B.T. 7A
43 amp. hrs at 20 hr. rate
Lucas type LA 12
Lucas type C39PV2
Lucas type M3561
Lucas type RB106/2
Lucas type SF6
Lucas type HF 1849
Lucas type DR2
Type
Battery
Capacity
Coil
Dynamo
Starter motor
Cut-out and Regulator
Fuse Unit
Horn
Windscreen Wipers
Page 7
INSTRUMENTS 4 CONTROLS
AUSTIN-HEALKY SPRITE
INSTRUMENTS AND CON TROLS
INSTRUMENTS
Speedometer: Indicates the vehicle speed and total mileage.
The trip figures at the top of the speedometer face can be reset
to zero by pushing up the knob at the bottom of the speedometer
and tmning it to the right.
Tachometer: This instrument indicates the revolutions per
minute of the engine and thus assists the driver in determining
the most effective engine speed range for maximum performance
in any gear.
Oil Pressure Gauge: Indicates the engine oil pressure. The
pressure may rise to over 60 lb. per sq. in. (4.2 kg./cmP) when the
engine is started up from cold, but after the oil has circulated and
become warm the pressure should drop to approximately 60 lb.
per sq. in. (4.2 kg./cm.') with a proportionately lower idling
pressure. Should the gauge fail to register any pressure at all,
stop the engine immediately and investigate the cause.
Ignition Warning Light: Should glow red when ignition is
switched on and fade out when the generator starts charging the
battery. Failure to do so should be investigated immediately.
Main Beam Warning Light: A red glow appears when the head-,
lights are switched on, with the two beams straight ahead. The
light goes out when the headlights are dipped.
Fuel Gauge: The fuel gauge indicates the contents of the tank
when the ignition switch is 'On'.
Always ascertain that the ignition is switched off before
replenishing the fuel tank.
Water Temperature Gauge: This records the temperature of
the cooling water circulating in the cylinder block and radiator.
Under normal operating conditions this should be 164'F. (73'C.).
Instruments and Controls
1.
2.
3.
4
Windscreen washer control.
Choke control.
Windscreen wiper control.
Ignition and lights switch.
5.
Flashing direction indicator
switch.
6.
Heating and demisting control.
7.
Oil pressure gauge.
8.
Water temperature gauge.
Starter control.
Tachometer.
Headlight beam warning light.
light.
12. Direction indicator warning
13. Speedometer.
14. Ignition warning light.
15. Fuel gauge.
16. Handbrake.
17. Gear lever.
18. Dip switch.
19. Clutch pedal.
20. Horn button.
21. Brake pedal.
22. Accelerator pedal.
23. Panel light switch.
- 9.
10.
11,
10
Page 8
A.USTIN-HKALEY SPRITE
INSTRUMENTS 4 CONTROLS
FOOT CONTROLS
Accelerator: The small right-hand pedal which operates the
carburetter throttle.
Brake: The centre pedal which operates the brakes on all
four wheels.
Clutch: The left-hand pedal. The foot should be kept clear of
the pedal except when engagement or disengagement of any gear
is intended, or when in heavy traffic. Press to the floor for
complete disengagement.
Dip Switch: This is located in the floor to the left of the clutch
pedal. To dip the headlight beams depress the switch. Depress
again to return them to the straight ahead position.
8'indscreen 8'iper Switch: To start the windscreen wipers pull
out the switch marked "W" on the fascia panel. To park, push
in the switch; when the wiper arms will automatically return to
the parked position,-
Pane/ Light Switch: Situated on the lower edge of the fascia
panel. No light will be obtained unless the sidelights are also on.
Horn Button: Mounted at the centre of the steering wheel
and can be operated when the ignition switch is 'off'.
Seats: The driver's seat is mounted on slides and is instantly
adjustable by means of the lever located at the front of the seat..
The passenger's seat is not adjustable. The backs of the seats
can be folded forward.
Crankcase Oil Fillert Incorporated in the valve rocker cover.
Bayonet fitting cap, with anchor cable to prevent loss.
HAND CONTROLS
Hand Brake: Pull-up lever type, situated between the driver' s
and passenger's seat. Operates mechanically on the rear wheels
only.
Gear Lever: Should always be in neutral when starting the
engine. The gear positions are indicated on the top of the lever
knob. Move the lever hard right (to overcome pressure of springloaded stop) and then back to engage reverse gear.
Choke Control: Pull the control out to its limit when starting
the engine from cold. Push in the choke control completely as
soon as the engine will run evenly without its use.
Ignition Switch: Turn the key in a clockwise direction to switch
on. Do not leave the switch 'on' when the vehicle is stationarythe red warning light is a reminder.
Lights Switch: The cehtral moulding which surrounds the
ignition switch. Turn clockwise to the first notch.to switch on the
sidelights and to the second to switch on the headlights.
Starter Switch Knob: Pull out the control knob to start, and
release as soon as the engine fires. If the engine fails to start
after a few revolutions, do not operate the starter again until the
engine is stationary.
' Direction Indicators: To operate, move the switch to the left
. or right, according to whichever indicator is required. A warning
light on the instrument panel flashes green for as long. as the
indicators are in use.
Heater and' Demister Control: This is s i tuated centrally
on the fascia and provides the means for regulating the heating
and demisting system. Full operating instructions are given on
page 47.
Release the extra bonnet
prop from its securing clip
'A' and insert the endin the
hole 'B' on the underside of
the bonnet.
Bonnet lock: To release the bonnet turn the plated locking
. handle, situated behind the front number plate, in a clockwise
direction. Lift the safety catch lever (see illustration on page 46)
at the same time raising the bonnet. The bonnet is held open by
two telescopic prop rods which lock automatically in the fully extended position.
As a safety measure an extra prop is provided and should
always be used to prevent any possibility of an accident. Release
the prop from the clip at the side of the radiator and insert the
13
12
Page 9
A.USTIN-HEALKY SPRITE
DRIVING INSTRUCTIONS
DRIVING INSTRUCTIONS
highly stressed. Beyond all doubt the owner or operator will
find that careful, considerate treatment during the vital running-in
period will be fully compensated by the resulting dependability
and efficiency that will be obtained throughout its life.
T HE importance of running-in the new vehicle canfiot be too
Fuel Pump Priming Lever
'A' is the priming lever of
the fuel pump located on
the left side of the cylinder
block.
RUNNING-IN
The following-speeds should not be exceeded in the gears for the
first 500 miles (800 kilometres):
1st 2nd 3rd top
7 15
25
40 m.p.h.
10 24 40 , 64 k.p.li.
It is most import'ant to remember that at no time during the runningin period must the engine be overloaded, as in attempting to ascend
hills in top gear at low vehicle speed. The load should be eased by
changing down to a lower gear.
Fierce acceleration must also be avoided, and remember that the
engine should never be raced in neutral.
On completion of the first 500 miles (800 km.) the running-in speed
may be progressively increased, but full power should not be used
until at least 1,500 miles (2,400 km.) have been covered, and even then
only for short periods at a time. During this mileage a slight fallingoft in engine power may develop, in which case it is beneficial to
lightly grind-in the valves and re-set the valve clearances. No engine
or complete vehicle can be considered fully run-in until it achieves
2-3,000 miles (4-5,000 km.).
The use of upper cylinder lubricant is recommended at all times,
but most particularly during the running-in period. See page 33
for recommended brands.
STARTING
the water level in the radiator. Ensure that the gear lever is in
- neutral and the handbrake is applied. If the engine is cold pull out
the choke control.
-Switch on the ignition, ensure that the ignition warning light glows
and that the fuel gauge registers, then pull the starter control firmly.
Release it if the engine fails to start within five or six seconds, wait
for the engine to stop rotating and then pull the starter again.
Should the engine not start after a reasonable number of attempts,
check up on possible causes. Do not persist in operating the starter,
as a great strain is imposed on the battery by so doing.
As soon as the engine starts, release the starter control and warm
up the engine at a fairly fast idling speed. Should the oil gauge fail
to register any pressure or if the pressure is very low, stop the engine
8 EFORE starting the engine check the oil level in the sump and
immediately and investigate the cause. Failure to do so may result in
serious damage to the engine. Also check that the ignition warning
light goes out when the engine is running above idling speed, as this
indicates that the dynamo is charging the battery.
A thermostat is incorporated in the cooling system to assist the
engine in warming up from cold, but do not, under any circumstances,
race the engine in an attempt to speed up the process.
Push in the choke control completely as soon as the engirie will
run evenly without its use.
When the vehicle has been out of action for several days the fuel in
the carburetter may have evaporated. In these circumstances, before
attempting to start the engine, refill the carburetter by operating the
priming lever on the fuel pump, this being located low down on the
left side of the engine.
DRIVING
pedal and moving the gear lever into the appropriate position.
Should the gear not readily engage, momentarily release the clutch
pedal, after which, with the clutch again depressed, it should be
possible to engage the gear. Gradually release the clutch pedal, at
the same time gently depressing the accelerator and releasing the
handbrake. The vehicle will move forward, gathering speed in
accordance with the amount the accelerator is depressed.
Second gear is engaged by depressing the clutch pedal, moving the
gear lever out of first into the next higher gear and then releasing
the clutch pedal. Ease up the accelerator whilst changing to a higher
gear, and gradually depress the accelerator when the higher gear is
engaged.
S TART only in f
irst gear, which is engaged by depressing the clutch
16 17
Page 10
AUSTIN-HKALEY SPRITE
DRIVING INSTRUCTIONS
Third'and top gears are engaged by employing the same procedure
as that given for engaging second.
Changing down is an exact reversal of the method outlined for
changing up, except that the accelerator must be kept depressed
whilst the gear is being changed, in order to speed up the engine in
accordance with the lower gear.
Do not change gear rapidly or forcibly. Always move the lever
with a smooth deliberate action that will allow the synchromesh
mechanism to operate properly.
To stop the vehicle, release the accelerator, apply the footbrake
and depress the clutch pedal before the vehicle comes to a standstill.
After applying the handbrake and moving the gear lever into neutral,
release the clutch and footbrake.
%hen in reverse, which must only be engaged when the vehicle is
stationary, remember that the gearing is lower than first gear;
Consequently release the clutch slowly until the vehicle just begins to
move, and then gently depress the accelerator to give the speed
desired.
Do not slip the clutch instead of using the handbrake when temporarily halted on an ascent and do not allow the weight of the foot
to be taken by the clutch pedal when it is not being used, as either
practice will result in excessive clutch wear.
Before descending a steep hill it is advisable to engage an inter-
mediate or low gear. The engine will then provide a useful braking
action.
DRIVING HINTS .
Never operate the starter control when the vehicle is in gear.
Remember to switch on the ignition before attempting to start the
engine.
Do not persist in pulling the starter control if the engine will not
fire.
Release the choke control as soon as the engine will run evenly
without its use.
Do not leave the ignition switched on when the engine is not
running.
Never leave the vehicle in gear with the handbrake unapplied.
Do not engage reverse gear when the vehicle is moving forwards
or forward gear when the vehicle is moving backwards. -,Serious
damage may result.
Avoid slipping the clutch in traffic or on an ascent.
Never coast the vehicle with a gear engaged and the clutch pedal
depressed.
A FTER the vehicle has been washed or driven through water the
results.
SKIDDING
Skidding is usually due to sudden acceleration, braking or change
of direction on an icy, greasy or loose road surface. If the rear
wheels skid, release the accelerator or brake pedal (as the case may be)
and turn the steering wheel towards the direction of the skid to regain
wheel grip on the road.
WET BRAKES
brake linings may become wet. To dry them, apply the brakes
several times with the vehicle moving slowly. Emergency braking
with wet brakes is extremely dangerous and is to be avoided at all
Do not race the engine in neutral at any time.
Never run the vehicle with the radiator completely blanked otf.
Avoid running the engine at high speeds for the first 500 miles
(800 km.).
Never fill the radiator with cold water when the engine is hot.
Do not, under any circumstances, run the engine in a closed garage
or similar restricted atmosphere. The exhaust fumes are highly
poisonous and if inhaled will quickly produce grave, if not f atal,
costs.
18
19
Page 11
REGULAR A.TTENTIONSAUSTIN-HEALEY SPRITE
REGULAR ATTENTIONS
HE following is a summary of the regular attentions required to
T
necessary.
adjustment.
butor points.
necessary.
if necessary.
and the bonnet safety catch.
and manifold to recommended torque. settings.
up if necessary. Clean and tighten terminals.
springs, wheel nuts, universal joints, etc.
top-up if necessary.
maintain the Austin-Healey Sprite in perfect running order.
These instructions should be closely followed, whether the attentions
are undertaken by the operator or by the local Austin Dealer. Under
arduous conditions, as, for instance, very dusty or muddy roads and
tracks or high speeds, it vM be advisable to attend to the oiling
points more frequently than every 1,000.miles (1,600 km.).
POST DELIVERY CHECK
Dealers are under agreement to carry out a 'Post Delivery Check'
on Austin vehicles purchased from them. This service is undertaken
once during the period of the first 500 miles or as soon as possible
afterwards. Except for materials used, they will perform the following
operations free of charge:
(1) Change oil in the engine, gearbox and rear axle.
(2) Lubricate all chassis points.
(3) Check and lubricate all door catches, hinges, striking plates
(4) Tighten nuts of cylinder head and valve rocker shaft brackets
(5) Check valve clearances and reset if necessary.
(6) Tighten fan' belt if necessary.
(7) Check all water pipe connections and tighten clips if necessary.
. (8) Examine and clean the carburetters and reset the slow running
(9) Check all fuel pipe union nuts.
(10) Examine and adjust if necessary sparking plugs and distri(11) Check working of automatic ignition control and reset if
(12) Check front wheel alignment and steering connections, adjust
(13) Check braking system functionally, adjust and bleed if
(14) Check brake and clutch Auld reservoir and top-up if necessary.
(15) Check electrical system functionally, examine battery and top-'
(16) Check tightness of all nuts and bolts on shock absorbers,
(17) Inspect shock absorbers for leaks, examine oil levels and
(18) Check tyre pressures.
(19) Check operation of all instruments.
(20) Road test.
0
g
a.
0
CJ
0
Co
D
0 Q
2120
Page 12
AUSTIN-HEALEY SPRITE
REGULAR ATTENTIONS
DAILY
sary to the 'FULL' mark on the dipstick. The oil filler is in the
valve rocker cover and the dipstick is on the right side of the
engine.
After adding oil, allow a few seconds to elapse for the oil to
reach the sump from the valve rocker cover before checking the
Radiator: Check the level of water in the radiator and top-up
if necessary. Fill to the bottom of the filler cap well, when the
engine is cold.
' X.B.— Do not remove the filler cap if the coolant temperature
is above boiling point or if the engine is running.
Engine: Check the level of oil in the sump and top-up if neces-
Gearbox Oil Filler Plug
1. Filler plug.
2. Rubber cover.
Access.
level.
WEEKLY
infiate, if necessary, to the recommended pressures. Ensure the
valves are fitted with screw caps and inspect the tyres for possible
damage and wipe off any oil or grease. See page 50 for correct
pressures.
EVERY 1,000 MILES (1,600 km.)
the filler plug, turn back the rubber fioor covering and remove
the rubber plug from the left side of the gearbox covering.
Remove the filler plug and fill up to the bottom of the threads.
This gives the correct level.
Tyrest Check all ty re pressures, using a tyre g auge and
Rear Axle: Check the level and top-up if necessary. The
filler plug is located on the rear side of the axle and also serves
as an oil level indicator.
After topping-up allow time for any surplus oil to run out
should too much have been injected. This is most important
as if the axle is overfilled, the lubricant may leak through to the
brake linings and lessen their efficiency.
Brakes: Apply an oil gun to the brake balance lever nipple on the
rear axle, and to the handbrake cable nipple located just forward
of the rear axle.
Gearbox.' Check the level and top-up if 'necessary. To reach
Rear Axle and Rear
Universal Joint.
Radiator Header Tank and
The engine cooling system is
sealed and pressurised and
for this reason the radiator
jiller cap should never,
under any circumstances, be
removed when the coolant
is above boiling point or
the engine is running.
Filler Cap.
' "J
1. Combined oil filler and
level plug.
2. Drain plug.
3. Propeller shaft rear uni-
versal joint nipple.
!
' A'8.l A,
22
Page 13
AUSTIN-HKALEY SPRITE
REGULAR ATTENTIONS
Oiling Points.
Rear Brake Balance Lever
Front Suspension and Tie
1. Shock absorber filler
plug.
2. Swivel axle pin upper
bush.
3. Swivel axle pin lower
bush.~
4. Tie rod balljoint.
5. Suspension lower fulcrum
pin.
Rod Oiling Points.
1. L.H. pull rodjoint pin.
2. Balance lever nipple.
3. R.H. pull rodjoint pin.
4. Balance lever arm joint
pin.
Front Suspension: Apply an oil gun to the lower arm joints
where they meet the swivel axle housing.
Swivel Axle Pins: Apply an oil gun to the two nipples on each
swivel axle. This is best done when the vehicle is partly jacked
up, as the oil is then able to penetrate properly around the
bushes.
Steering Connections: Apply an oil gun to the nipple on each
tie-rod ba!1 joint.
Propeller Shaft Universal Joints: Apply an oil gun to the uni-
versal joint nipple at each end of the propeller shaft. If necessary,
move the vehicle to obtain access to the nipples.
Propeller Shaft Front
Universal Joint Nipple.
Lift the fioor covering and
remove the rabber plug tn
the propeller shaft tunnel to
gain access to the oil nipple
Brake and Clutch Fluid
1. Reservoir filler opening.
Top up to the bottom of
the filler plug threads.
2. Clutch pedal linkage oil-
ing point,
-3. Brake pedal linkage oil-
ing point.
Reservoir.
Handbrake Cable Nipple.
'A' indicates the position of
the cable grease nipple.
24
25
Page 14
REGULAR ATTENTIONS
AUSTIN-HEALEY SPRITE
EVERY 3,000 MILES (4,800 km.)
Throttle Linkage.
Apply a few drops of oil to
each of the linkage joints
indicated.
Engine: Drain the oil in the engine smnp while it is warm
(i.e. immediately after using the vehicle) and refill with new oil
to the 'FULL' mark on the dipstick. The drain plug is located
at the rear right-hand extremity of the sump and care should
be taken to ensure that no dirt or grit enters the smnp when
replacing the plug. Capacity is 6 pints (3.41 litres).
Bonnet Lock: Apply a few drops of engine oil to the bonnet
locg and safety catch.
Fan Belt: Check the adjustment of the fan belt. It should be
sufliciently tight to prevent slip at the generator and water
pump, yet at the same time it should be possible to move it
laterally about 1 inch (2.54 cm.).
To make any necessary adjustment slacken the bolts and
raise or lower the generator until' the desired tension of the
belt is obtained. Then securely lock the generator in that
position.
Distributor Spindle: Lubricate the distributor bearings by
withdrawing the moulded rotating arm from the top of the
distributor spindle and carefully adding a few drops of oil round
the screw exposed to view. See page 33 for recommended oils.
Take care to refit the arm correctly by pushing it on to the shaft
and turning until the key is properly located.
Distributor Came Apply a trace of engine oil to the distributor
cam. Be careful not to let any oil or dirt reach the contact
breaker points.
- Distributor Automatic Advance: Remove the distributor cap
and add a few drops of engine oil through the hole in the contact
breaker base through which the cam passes.
8'jteelst Change over the wheels diagonally (including the
spare wheel) in order to obtain maximum service with even
wear from each tyre.
Shock Absorberst Ensure that there are no visible signs of
leakage and that the rubber bushes of the shock absorbers
arms are undamaged.
Control Linkages: With an oil can, oil all the brake, clutch
and throttle linkage joints.
Brakes: Inspect the hydraulic fluid lines and Qexible hoses.
Brake and Clutch Fluid Reservoir: Ascertain that the fluid
level in the supply reservoir, mounted on the steering side of the
engine compartment, is up to the bottom of the fiiier plug
threads. Top-up if necessary using only the recommended
Quid.
Carbttretterst Remove the suction chamber cap and 'damper
assembly on each carburetter and replenish the reservoir with
S.A.E. 20 oil as necessary.
Battery: Ascertain the state of charge of the battery by taking
hydrometer readings.
Check 'that the electrolyte in the cells is level with the top
of the separators. If necessary add a few drops of distilled water.
Never use tap water as it contains impurities detrimental to the
batte
ry.
Never leave the battery in a discharged condition. If the
vehicle is to be out of use for any length of time, have the
battery removed and charged once a fortnight.
8"jteelst Check the security of the wheel nuts and tighten them
if necessary.
lan Belt Adjustment
I. Dynamo hinge bolts.
'2. Adjusting link nut.
3. Adj usting link setpin.
EVERY 2,000 MILES (3,200 km.)
Carry out the 1,000 mile (1,600 km.) service.
26 27
Page 15
AUSTIN-HKALKY SPRITE REGULAR ATTENTIONS
Brakes: Check the brakes and adjust if necessary.
Contact Breaker Points: Clean the contact breaker points.
Cleaning of the contacts is made easier if the contact breaker
lever carrying the moving contact is removed. Before replacing,
smear the pivot on which the contact breaker operates with
engine oil.
Check and reset the contact breaker points to the correct gap
of .014 to .016 in. (.36 to .41 mm.) (see page 43).
EVERY 4,000 MILES (6,400 km.)
EVERY 5,000 MILES (8,000 km.}
addition:
EVERY 6,000 MILES (9,600 km.)
vehicle) and refill to the level of the filler plug with new oil.
Capacity 2$ pints (1.33 litres).
Rear Axle: Drain when the oil is warm, and refill to the level
of the filler plug opening with new oil. Capacity 1 f pints (1.00
litre).
Engine Oil Filter: At the same time as the engine oil is changed,
drain the full-flow filter and renew the filter element, not for-
getting to top-up the filter container with new oil before refitting
it to the head casting on the engine crankcase (see page 38).
N.B.: On no account must this attention be neglected as it is
essential that the oil filter does not become clogged with dirt.
Carry out the 1,000 mile (1,600 km.) service.
Carry out the 1,000 mile (1,600 km.) service with the following
Sparking Plugs: Remove the plugs and clean off all carbon
deposit from the electrodes, insulators and plug threads.
Re-set the plug points to the correct gap of .025 in. (.64 mm.)
Shock Absorbers: Check the flmd level, and top-up if necessary.
The correct level is just below the filler plug threads (see page 33
for recommended fiuid). Carefully clear away all road dirt and
grit from the vicinity of the filler plugs before removal.
N.B.— Where the recommended fluid is not available the follow-
ing are acceptable alternatives:-
Shell Donax A.2, Wakefields Castrolite, Mobiloil Arctic, Esso
Hydraulic (Medium), Duckham's N.P.20, B.P. Energol S.A.E.20.
Fr'ont Wheel Alignment: Check the alignment of the front
wheels. This is correct when there is r's to 3 in. (1.6 to 3.2mm.)
toe-in.
Ignition Timing: Check the setting and adjust if necessary.
Water Pump: Remove the oiling plug on the water pump casing
and add a small quantity of SAE 140 oil. The oiling of the
pump must be done very sparingly otherwise oil will flow past the
bearings on to the face of the carbon sealing ring and impair
its efficiency.
Front Road Whee/ Hubs: Remove the wheel, lever out the
hub cap with a screw-driver, and recharge with grease. It is
important that the hubs are not overgreased, due to the fact that
any surplus may find its
ways to the brake linings, thus reducing
their efficiency.
Air Cleaners: The air cleaners should be removed, cleaned and
re-oiled. Swill each cleaner in petrol, drain, immerse in engine
oil and again drain before refitting.
Valve Clearance Adjustment: Check the rocker clearances and
adjust if necessary. The correct clearance is .012 in. (.31 mm.)
with the engine hot.
Fuel Pump: Clean the fuel pump filter and sediment chamber.
See page 39.
Gearbox: Drain when the oil is warm (i.e. after using the
Valve .Clearance
Adj ustment
1. Screwdriver blade.
2. Adjusting screw.
3. Locknut.
4 .012in. (.31 mm.) feeler
3
~4
Water Pump Oiling Plug.
'A' indicates the position of
the plug on the water pump
body.
gauge.
H30.108.B.
29
28
Page 16
RKGI.Z AR ATTENTIONSAI.JSTIN-HEALEY SPRITE
EVERY 7,000 MILES (11,200 km.)
EVERY 8,000 MILES (12,800 km.)
EVERY 9,000 MILES (14,400 km.)
EVERY 10,000 MILES (16,000 km.)
Carbtsretters: The flow of fuel at each carburetter inlet t
each float chamber should be checked and if necessary the filter
in the unions should be cleaned.
Remove the bowl of the carburetter for cleaning by disconnect
ing the fuel supply pipe and slackening the lid retaining nui
Unscrew the chamber holding-up bolt, being careful to note th
positions of the brass and fibre washers, and then take off the lid
Do not lose the float needle.
In addition, clean out each suction chamber assembly b
removing the three securing screws and lifting off the body it
the same plane to avoid damage to the needle.
Lift out the hydraulic damper and wash the assembly in petrol
Dry thoroughly, refit and replenish the damper with oil. Wher
fully re-assembled lift the piston to its fullest extent, thus ex.
pelling surplus oil which lubricates the piston rod and eventuall>
finds its way into the induction pipe.
This is the only part which reqmres lubrication, the piston
itself and the inside of the suction chamber should be left dry.
Bodyworkt With an oil can, lub ricate the door locks and
hinges, and other moving joints on the bodywork.
Genera/: Examine and tighten if necessary, all nuts, bolts,
unions, connections and linkage joints, especially after the
vehicle has completed its first 6,000 miles (9,600 km.).
Carry out the 1,000.mile (1,600 km.) service.
Carry out th: 1,000 mile (1,600 km.) s:rvice.
Carry out the 3,000 mile (2,800 km.) service.
Carry out the 1 000 mile (1,600 km.) service with the follow-
ing additions:
Sparking Plugs: Renew the sparking plugs. Use only Cham-
pion N5 Long Reach Plugs.
EVERY 11,000 MILES (17,600 km.)
EVERY 12,000 MILES (19,200 km.)
with the instructions given on page 45. Normally this operation
is carried out twice annually upon the addition and removal
of anti-freeze. In countries where- anti-freeze is not required,
however, the cooling system should be flushed out every 12,000
miles (19,200 km.).
grease.
Generator Bearing,
Unscrew the lab>icator cap
'A'
and re~lenish with
Speedometer and Tachometer Drives: Disconnect the cable from
the instrument end and pull the inner member out of the casing.
This should be lubricated sparingly by smearing it with light
grease. It is important that the drive is not overlubricated, other-
wise damage will be caused to the instrument head should the
lubricant find its way in to the head.
To re-assemble, thread the cable with a twisting movement
into the casing, since this will help the cable to engage easily
with its union at the drive end. When this engagement is felt
the cable can be pushed home so that the square end stands
out approximately s
3inch (9.63mm.) from the casing.
Generator Bearing: Un screw the cap of the lubricator on
the side of the bearing housing, lift out the felt pad and spring
Steering Rack Oil Nipple.
'A' indicates the position of
the rack oil nipple.
Carry out the 1,000 mile (1,600 km.) service,
Cooling System: Flush out the cooling system in accordance
30
31
Page 17
AUSTIN-HKALKY SPRITE
REGUI AR ATTENTIONS
and approximately half-fill the lubricator cap with a recommended grease (see page 33). Replace the spring and felt pad
and screw the lubricator cap back into position.
Oil Sump: Drain the oil, remove the sump, and clean it
throughly in petrol. Also clean the oil pump strainer gauze.
Replace the sump and refill with new oil.
Front and Rear Hub Bearings: Check for signs of wear.
Starter Commutator: Clean and check condition and freedom
of brusheS in their holders.
Steering: An oil nipple provided at the left-hand side of the
rack housing (right-hand side on L.H.D. vehicles) is accessible
when the bonnet is raised. Replenish the rack housing via this
nipple with S.A.E. 90 hypoid oil. Give 10 strokes of the oil gun
only.
Decarbonising and Valve Grinding: This attention may not be
needed so frequently on vehicles used for long journeys. As a
general guide, a falling off in engine)power indicates when
decarbonizing is due.
Headlamp Beam Setting. The headlamp beam settings should
be checked and re-set if necessary, every 12,000 miles (19,200km.)
or at least once a year.
Checking and adjustment (see page 52) may well be undertaken when the thinner engine oil and anti-freeze is introduced
in preparation for. winter service.
EVERY 24,000 MILES (38,400 km.)
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General Check: The vehicle should be subjected to a thorough
examination for wear at; least every 24,000 miles. Particular
attention should be given lo the steering gear and tie rod ball
joints, front and rear suspensions, brake linkages, shoe linings,
fluid lines and flexible hoses, propeller shaft universals and wheel
hub bearings.
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32 - 33
Page 18
REGULAR ATTENTIONSAUSTIN-HEALEY SPRITE
Page
No.
REGULAR ATTENTIONS
c
DAILY
Oil Engine sump. Check oil level and top-up
if necessary 22C
1,000 MILES (1,600 km.)
Oil B
I
,C
D
Oil
Oil Can
Oil Can
Oil Gun
Examine
D
Gearbox and rear axle. Check oil levels
and top-up if necessary
Propeller shaft universal joints
Swivel axles and suspension lower joints
Steering tie rod ball joints
Rear brake cable and balance lever
Brake, clutch and throttle linkage joints
Carburetter damper assembly reservoirs
with S.A.E.20 oil.
Brake and clutch 'Cud reservoir level.
Top-up if necessary
Shock absorbers. Check for leakage
3,000 MILES (5,000 km.)
Engine sump. Drain and refill
Distributor
22 23
24
24
24
23
26
26
26
27
6,000 MILES (10,000 km.)
I I I
Oil
Grease
Examine
K
H
Gearbox and rear axle. Drain and refill.
Water pump
Front hubs
Shock absorbers. Check levels and top-
up if necessary 29
28
29'
29
C
i(
12,000 MILES (20,000 km.)
Oil Gun
D
Grease
Lubricate steering rack with S.A.E. 90
Hypoid oil
Generator bearing. Replenish lubricator
cap with grease .. 31
32
AS.46.A.
35
Page 19
AUSTIN-HEALEY SPRITE
GENERAL MAINTENANCE
GENERAL MAINTKNANCK
'/HE following information covers those attentions which are
should be used.
essential to the efficient operation of the vehicle, and is additional
to or more detailed than that given in 'Regular Attentions'.
ENGINE
to the engine, which may have to operate at sustained high
temperatures and speeds, and it is therefore essential that only
oils of the highest quality and correct grade are used. Inferior
oils will cause excessive wear in an unduly short time.
The colour or appearance of an oil at atmospheric temperatures gives no indication as to its efficiency under operating
conditions and owners are advised to use the officially recommended lubricants as listed on page 33. It is appreciated that
in some areas these oils are not available, in which case, only
good quality oils conforming with the S.A E. numbers listed
The letters S.A.E. followed by a number constitute a classification of the lubricant in terms of viscosity or fluidity.
For instance, a low S.A.E. number indicates that the oil is of
low viscosity, which means that it flows more readily than oil
with a high viscosity rating.
lt will be appreciated, therefore, that oil with a low S.A.E.
number is essential if easy starting is to be obtained in cold
weather, whereas in hot weather a high viscosity oil is desirable
in order to keep oil consumption within normal limits.
The use of upper cylinder lubricant is recommended at all
times, but most particularly during the running-in period. See
page 33 for recommended brands.
Even the best oils in the engine become contaminated during
use, with unburnt fuel, carbon, metallic particles, and moisture,
and it is therefore most important that the oil is changed at the
recommended mileages.
Multigrade Motor Oils: In a d d ition to t he r ecommended
lubricants listed on page 33, we approve the use of multigrade
oils, as produced by the oil companies shown on our list, for all
climatic temperatures unless the engine is old and in poor
mechanical condition. Some are more expensive than the recommended motor oils because of their special properties and
greater fl
uidity at low temperatures.
Oil Level: The oil should never be allowed to fall more than
—',in. (12.7mm.) from the 'FULL' mark on the dipstick. It
is advisable to wipe the dipstick before taking the reading, which
must only be taken when the engine is stationary and the vehicle
on level ground if a true result is to be obtained.
Lubrication: Correct lubrication is of the utmost importance
R~
~%I L. gj
PJ
I
S
1
~~R
CS ~
Cu
bp
0 0
0
CJ
8
Q c
t p
P
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37
Page 20
GENERAL MAINTENANCE
AIJSTIN-HFALEY SPRITE
reaches the bearings at. a reduced pressure of approximately
35 lbs. per sq. in (2.46 kg./cm.'). Therefore, to ensure only
filtered oil is supplied to the bearings it is essential to renew the
filter element at 6,000 miles (10,000 km.) or when the oil pressure
gauge indicates the change is necessary by a fall in pressure.
Rertewing Filter Element: First drain the filter by removing the
centre fixing bolt from the base of the container. With the bolt
removed it will be necessary to support the container by hand
until all the oil has drained away. Withdraw the container complete with the element. Slide out the filter element and, using a
non-fluffy cloth, thoroughly clean out the container internally and
externally. Insert a new element in the container, and holding
the centre fixing bolt in position against the bottom of th e
container, fill with new oil. Now, still holding the bolt in this
position, locate it in the filter head casting and tighten just
sufficiently to make an oil tight joint.
This is the only attention likely to be required. The filter con-
tainer should not be removed or drained, once a new element has
been fitted, until element renewal is required.
Oil Pressure: The oil pressure gauge indicates whether the oiling
system is working properly. It should be looked at occasionally
while the engine is running.
The engine oil pressure may rise to over 60 lbs. per sq. in. (4.2
kg./cm.') when the engine is first started up in cold weather, but
after the oil has circulated and become warm the pressure will drop
to 60 lbs. per sq. in. (4.2 kg./cm.') with a proportionately lower
idling pressure.
Never run the engine if the gauge fails to register a pressure or
if the prbssure is very low. Switch off and investigate the cause of
the failure as otherwise serious damage might result.
Full Flow Filter: Before reaching the engine bearings the oil is
passed through a full flow filter at a controlled pressure of
approximately 60 lbs. per sq. in. (4.2 kg./cm.'). Some pressure
is lost in passing the oil through the filter element and this pressure
loss will become more pronounced as the element becomes
coated by foreign matter removed from the oil.
A balance valve is provided in the filter unit to guard against
the possibility of the filter becoming completely choked and
thereby preventing the oil from reaching the bearings. This
balance valve is set to open when there is a pressure difference
between the oil on the inside and the oil on the outside of the
filter element of 15 lbs. per sq. in. (1.06 kg./cm.'). When the
valve is open, un-filtered oil by-passes the filter element and
FUEL SYSTEM
FUEL is stored in a rear mounted tank of 6 gallons (27 litres)
capacity. An A.C. mechanical'Y' type fuel pump, operated by
the engine camshaft, draws fuel from the tank and delivers it under
pressure to two S.U. type H.l carburetters. Twin 'pancake'
type air cleaners filter the air to the carburetter intakes.
Fuel Pump: This is bolted on the left-hand forward side of the
engine crankcase and has a suction pipe from the tank and an
outlet pipe to the carburetters. A priming lever is fitted to
enable the carburetters to be primed by hand, should the fioat
chambers become dry due to evaporation. If petrol appears to
be leaking from the edge of the pump diaphragm, tighten the
covers screws alternately. Sometimes such leakage may actually '
come from one of the pipe unions causing the fuel to run down
to the pump and collect around the diaphragm flange.
The pump filter should be examined and cleaned if necessary.
Access to it is gained by removing the dome cover, after unscrewing the retaining screw, when the filter gauze itself may be
lifted off its seating. Clean out the sediment chamber and clean
the filter gauze in an air jet or petrol. The gasket under the filter
cover should be replaced if broken or if it has hardened.
When refitting the cover, make certain that the fibre washer is
replaced under the head of the screw. Tighten the filter cover
retaining screw just sufficiently to make a fuel tight joint.
Engine Details.
1. Oil level dipstick.
2. Oil Jilter securing bolt.
3. Distributor micrometer
adj uster.
39
38
Page 21
AUSTIN-HEALEY SPRITE GENERAL MAINTENANCE
The Fuel Pump
1. Retaining screw and
washer.
2. Cover.
3. Cork gasket.
4. Filter gauze.
5. Outlet union.
6. Inlet union.
7. Priming lever.
7
H30.4.C.
throttles are completely closed.
In order to adjust the carburetters successfully it is necessary
to remove the air cleaners and intake pipe assembly from the
carburetters and engine valve cover and make sure the pistons
work freely and the jets are properly centred.
Adjusting the Jets:
(1) Slacken oK the pinch-bolt of one of the spring coupling
clips locating the carburetter interconnecting shaft to
the carburetter throttle spindles and also release the two
screws securing the choke spring to the jet levers, so that
each carburetter can be operated independently.
(2) Release the throttle lever adjusting screws until bo th
(3) Turn the throttle lever adjusting screw for the rear car-
buretter clockwise until it is just touching the web on
the carburetter body and then give it one full turn. This
will set the rear carburetter for fast idling and leave the
front one out of action. This can be ensured further by
' in.
lifting the front carburetter piston a matter of —,
(13 mm.).
(4) With the engine running, set the jet adjusting screw for
the rear carburetter so that a mixture strength is obtained
which will give the best running speed for this throttle
opening, taking care to see that the jet head is kept in firm
contact with the adjusting nut the whole time.
(5) The correctness or otherwise of this setting can be checked
by raising the suction piston with a small screwdriver,
or similar instrument to the extent of
+, in. (.8 mm.).
This should cause a very slight momentary increase in the
engine speed without impairing the evenness of running
in any way.
Check pump to e ngine mounting setscrews and fuel pipe
unions for tightness.
Fuel pump service is available at all Austin dealers and A.C.
service stations. They are stocked with parts and fittings for any
repairs and adjustments that may become necessary.
Carburetters: The carburetters fitted to the Austin-Healey
Sprite engine are two S.U. type H.l , and providing that the
regular attentions are carried out at the recommended mileage,
will be found to give efficient and trouble-free service.
The twin carburetters are carefully balanced to ensure perfect
running of the engine, and it is therefore important that only
qualified p'eople should be allowed to attend to any major faults.
Should the engine run erratically, having previously given good
results, look for a minor fault rather than a major one.
In the event of poor running, first make sure that the pistons
are able to move freely; if they are not, the cause may be due
to dirt in the suction chambers, the cure for which is given
u'nder 'Every 6,000 miles (9,600 km.)' (page 30).
The only carburetter adjustments are by means of the jet
adjusting screws and the throttle stop screws.
It is first essential to run the engine until it has attained its
normal running temperature before commencing any mixture
or slow-running adjustments.
The slow-running is governed by the setting of the jet adjusting
screws and the throttle lever adjusting screws, all of which must
be correctly set and synchronised if satisfactory results are to be
Carburetter Adj ustntent
1. & 3. Throttle lever
adjusting screws.
2. Throttle/mixture control
inter-connecting lever
adjuster.
obtained.
8461 .'
41
Page 22
GENERAL MAINTENANCE
AUSTIN-HEALEY SPRITE
If this operation has the effect of stopping the engme it
is an indication that the mixture setting is too weak.
If an appreciable speed increase occurs and continues to
occur when the piston is raised as much as ~ in. (6 mm.)
it is an indication that the mixture is too rich.
(6) When the rear carburetter mixture setting has been carried
out correctly release its throttle adjusting screw so that
it is clear of the stop and the throttle is completely closed,
and lift the piston $ in. (13 mm.) to render it inoperative.
Then repeat the jet-adjusting operations on the front
carburetter.
(7) When both carburetters are correctly adjusted individually
for mixture strength the throttles of each should be set so
as to give the required slow-running and synchronisation.
A. 12-volt battery provides the current necessary to operate the
IGNITION SYSTEM
ignition system. A high voltage is induced by the coil, and the
distributor, as its name implies, distributes this voltage to the sparking
plugs in the correct firing sequence.
etc.
Distvtbutort The DM2 type Lucas distributor is fitted with an
automatic timing control operated by centrifugal force together
with a vacuum timing control operated by the depression in the
engine induction manifold. The combined effects of the two
controls gives added efficiency over the full engine operating
range, with a corresponding economy in fuel consumption.
A micrometer adjuster is also provided in order that fine
adjustments to timing may be made to allow for changes in
running conditions, e.g. state of caibonisation, change of fuel,
To gain access to the distributor contacts for cleaning and refacing, first remove the distributor cover and rotor arm. Next,
unscrew the nut on the terminal post, lift off the spring and
remove the contact adjusting screw '1', after which both contacts
inay be removed.
Examine the contacts, which must be free from grease or oil.
lf they are burned or blackened, clean them with a very fine
carborundum stone or with very fine emery cloth. Afterwards
wipe away any trace of dirt or metal dust with a petrol moistened
cloth.
If the contacts are badly burned, they should be renewed.
Replacement contacts must only be fitted in pairs.
When refitting the contacts take care that the fibre insulating
washer is replaced in its correct position.
Slow-running and Synchronisationt Screw each throttle lever
adjusting screw so that its end is only just making contact with
the web on the carburetter body, then give each screw one full
turn exactly.
Start the engine, which will now idle on the fast side.
Unscrew each throttle lever adjusting screw an equal amount,
a fraction of a t urn at a tim e until the desired slow-running
speed is achieved.
Correct synchronisation can be checked by listening at each
carburetter air intake in turn through a length of rubber tube
and noticing if the noise produced by the incoming air is the same
in both. Any variation in intensity of the sound indicates that
one throttle is set more widely open than the other — the louder
sound indicates the throttle with the greater opening.
When the same intensity of sound is produced by both car-
buretters the intercoupling shaft clip should be tightened up
firmly to ensure that the throttles work in unison.
Since the delivery characteristics, when both carburetters
are operating together, vary somewhat from those existing when
each is working separately it will be found necessary to check
them again for correctness of mixture strength by lifting the
pistons in turn as described in 'Adjusting the jets,' making such
adjustments of the jet adjusting screws as are required to balance
the mixture strength and to ensure that it is not too rich.
1. Contact adtusnng scte»»
2. Contact adjustmg slot.
3. Cam and dna e shajt
oiling point.
4. Contact points.
5. Micrometer adjuster.
The Distributor
H 30. (5) 193.A.
43
42
Page 23
AUSTIN-HKALEY SPRITE GENERAL MAINTENANCE
To adjust the contact breaker points, turn the engine with the
starting handle until the contacts are fully open. Slacken the
fixed contact plate securing screw '1'. insert a screw-driver in the
slot '2' and move the plate until the gap gauge is a sliding fit
between the contacts
(.014 to .016 in. or .36 to .41 mm.) and
then fully tighten the securing screw. Finally recheck the gap and
replace the rotor arm. Before replacing the distributor cap
wipe the inside and outside with a soft dry cloth, paying particular
attention to the space between the terminals. Ascertain that the
small carbon brush on the inside of the cap works freely in its
holder and that the terminals are secure.
Coi/t The L.A.12 type Lucas ignition coil requires no attention
beyond checking that the terminal connections are tight and that
the exterior is kept clean, particularly between the terminals.
H.T. Cables: The high tension cables must be ca refully
examined and any which have the insulation cracked, perished or
damaged in any way must be replaced.
Sparking Plugs: The sparking plugs fitted to the Austin-Healey
Sprite are of the Champion N.5 Long Reach type, and as they
are of great importance to satisfactory engine performance, every
care should be taken to fit only the recommended type when
replacements become necessary.
Every 5,000 miles (8,000 km.), remove the plugs and clean off
all carbon deposit from the electrodes and plug threads with a
stiff brush dipped in paraffin.
Alternatively the plugs may be taken to the local Austin dealer
for cleaning and testing on a special 'Air Blast' service unit.
Check the plug gaps with the gauge provided and reset if
necessary to the recommended clearance of .025 in. (.64 mm.).
When resetting, bend the side electrode only. Never bend the
centre electrode as this may split the insulator tip.
When refitting the plugs, make sure that the copper washers
are not defective in any way. If they have become worn and
flattened, fit new ones to ensure obtaining a gastight joint.
Screw the plug down by hand as far as possible, then use a
spanner for tightening only. Always use a tubular box spanner
to avoid possible damage to the insulator, and do not under any
circumstances use a movable wrench. Never over-tighten a
plug, but ensure that a good joint is made between the plug
body, washer and cylinder head.
The sparking plugs should be wiped frequently with a clean
rag, as paint splashes, accumulation of oil and dust, etc., on the
insulator are often responsible for poor plug performance.
T .
— Sparking Plug Gap
The clearance 'A' should be
set at .025 ln. (.64 mm.).
COOLING SYSTEM
HE engine cooling system is sealed and pressurised, thus raising
the coolant boiling point to 224'F. (107'C,). A pressure relief
valve located in the radiator filler cap, opens at approximately 4 lbs.
per sq. in. Circulation is by means of a centrifugal type pump and a
thermostat regulates the coolant temperature.
H40.258.A.
Topping Upt This should only be necessary very occasionally
to replace water lost through evaporation. Use only rain water,
if available, or clean soft water, and fill to the bottom of the
filler cap well when the engine is cold.
¹B.— Under no circumstances should the radiator filler cap
be removed if the coolant temperature is above boiling point or
if the engine is running.
Draining the System: There are two drain cocks; one
positioned at the bottom of the radiator, and the other on the
left side of the cylinder block. Open both cocks and ascertain
that the vehicle is standing on level ground while draining.
When draining in freezing weather, do so when the engine is
hot. Run the engine slowly for one minute when the water has
ceased flowing to clear any water left in the pump and other
places where it might collect. Finally, leave a reminder on the
vehicle to the effect that the cooling system has been drained.
45
Page 24
AUSTIN-HEALKY SPRITE GENERAL MAINTENANCE
Frost Precautions: During freezing weather an anti-freeze com-
pound should be added to the coolant in the radiator.
Always flush the cooling system before adding an anti-freeze
solution, and again when removing it in the Spring.
The manufacturers of anti-freeze will provide a table indicating
the quantity to be used in providing full protection against any
degree of frost.
The strength of the solution must be maintained by topping-up
with anti-freeze solution as necessary. Excessive topping-up
with water will reduce the degree of frost protection.
The following are oflicially approved anti-freeze compounds:
Smith's 'Bluecol'; Shell 'Snowflake'; Esso 'Antifreeze'.
N.B. Where a heater is fltted under no circumstances resort
to draining the cooling system as an alternative to the use of
anti-freeze, due to the fact that it is not possible to drain the
heater unit completely by means of the cylinder block and
radiator drain cocks.
Radiator Drain Cock.
i. Drain cock.
2. Bonnet safety catch.
Turn the cock tn an anti-
clockwise direction to open.
Flushing the Radiator: To ensure efficient circulation of the
coolant and to reduce the formation of scale and sediment in the
radiator, the system should be periodically flushed with clean
running water, preferably before putting in anti-freeze in the
Autumn and again when taking it out in the Spring.
The water should be allowed to run through until it comes out
clean from the drain cocks.
HEATING AND DEMISTING~
heated fresh air to the car interior at floor level and to the wind-
screen for demisting and defrosting.
A tap controlling the flow of hot water through the heater unit is
fitted at the rear of the cylinder head. The tap is opened by turning in
an anti-clockwise direction when heating is required or shut off by
turning clockwise when the
system'is to be used for cool air ventila-
tion.
Air is drawn in to the system through a forward-facing intake and
the ram effect caused by the car's motion will provide sufficient quan-
tity of air for the heater's requirements at speeds above 25 m.p.h.
A blower motor is provided for use at lower speeds or when a greater
quantity of air is required. The blower is switched on by turning the
control on the fascia marked 'H' in a clockwise direction.
A shut off valve is incorporated in the air intake to prevent fumes
entering the car in traflic and is operated by pulling out the control
marked 'H'. The blower motor must be switched off before the valve
is closed and cannot be switched on again until the valve is returned
to the open position.
Two doors located forward at either side of the gearbox tunnel
control distribution of air between screen and car interior. For
heating, open the doors. For defrosting
(i.e., boosting flow of hot
air to screen) close the doors.
T HE Smith's heating and demisting system is designed to provide
Cylinder Bloclc Drain Cock.
The drain cock 'A' is lo-
cated on the left side of the
cylinder block, adjacent to
the engine rear mounting
plate. Turn in an a nti-
clockwise direction to open.
46 47
Page 25
AUSTIN-HKALKY SPRITE GENERAL MAINTENANCE
BRAKING SYSTEM
shoe brakes at the front, with a dual purpose expander- unit on the
rear brake shoes, enabling them to be operated hydraulically or
mechanically. A pull-up type handbrake operates directly on the
mechanical linkage to the rear wheels, whilst the foot brake operates
on all four wheels.
every 1,000 miles {1,600km.) to maintain them at maximum
efficiency'.
Front Brakes: Apply the handbrake, jack up one front road
wheel until it is free to revolve. Spin the wheel in a forward
direction and apply the foot-brake firmly to centralize the shoes
in the drum. Remove the road wheel cap and align the hole in
the wheel and the brake drum with the screw-driver slot on
one wheel cylinder. Insert a screw-driver and turn in a clockwise
direction until the brake shoe bears hard against the drum. Back
off the adjustment the least possible amount {usually two or
three clicks) until the wheel is free to revolve. Repeat these
operations at the other wheel cylinder. Replace the road wheel
cap. Adjust the opposite front wheel brakes in a similar manner.
Rear Brakes: Place chocks under the front wheels, release the
handbrake and jack up one rear wheel until it is free to revolve.
Remove the road wheel cap and proceed as for the front brakes,
but, as there is only one adjusting point for both shoes, the
adjuster must be turned until one shoe bears against the drum,
then continue turning until both shoes bear hard. Back off the
adjustment the least possible amount until the wheel can be
. revolved {the amount of backing off may be slightly more than
was needed for the front brakes). Replace the road wheel cap.
Adjust the opposite rear wheel brakes in a similar manner.
THE Lockheed hydraulic braking system employs two-leading
Adjustment: The brakes may require adjustment approximately
Rear Brake Adjustment.
'A' indicates the position oj
the rear brake shoe ad-
justerr.
WHEELS AND TYRES
steel disc type with ventilation slots. A spare wheel and tyre is
carried in the luggage compartment.
Tubeless tyres are now fitted as standard equipment and they
provide many advantages over the orthodox tyre with its separate
inner tube.
Normally a tubeless tyre will not leak as a result of penetration
by a nail or other normal puncturing object, provided that it is
left in the tyre. It is, however, necessary to examine the tyres every
3,000 miles and withdraw such 'objects at a time when loss of air
pressure will cause the least inconvenience.
If a hole in the tyre fails to seal, an effective repair can be carried
out with a Dunlop 'Reddiplug'. Dunlop 'Reddiplug' Repair Kits
are available at low cost and full instructions are provided with
each Kit. This repair method has the advantage of not requiring
removal of the tyre from the wheel.
checked when the tyres are cold; otherwise an allowance must be
made for the increase in pressure resulting from the heat generated during running. Pressures should never be reduced in
warm tyres where increases above the recommended figures are
due to temperature.
Regular attention should be given to the spare tyre as well as to
the tyres in use.
A tyre that loses more than three to four pounds per square
inch in a week should be suspected of a slow puncture, but first
make sure that the valve is not the cause. The pressures given
should be maintained to ensure long tyre life and best running
and riding conditions for the vehicle.
T HE wheels fitted to the Austin-Healey Sprite are of the pressed
Checking Pressures: For accurate results, pressures should be
Front Brake Adj ustment.
'A' indicates the position of
one of the front brake shoe
adj usters.
49
48
Page 26
AUSTIN-HEALEY. SPRITE
GENERAL MAINTENANCE
N.B. The front and rear tyres, on the side nearer to the curb,
should be inflated to a pressure of 2/3 lb. per sq. in. above the
pressure in the tyres on the opposite side.
The benefit of this differential pressure will be found in easier
handling and less tyre wear, particularly in countries where roads
are winding and heavily, or only moderately, cambered.
Valve Caps: See that the valve caps are in position and that
they are in good condition; renew them if necessary. Valve caps
provide a second air seal and protect the valve mechanism from
dust, oil and road material.
Tyre Pressures:
Rim Size
13 — 3.50
Tyre Size
5.20 — 13
Rear
20 lbs./sq. in.
1.41 kg./cm'
Jacking: The jacking of the vehicle is effected by a Smith's
'Steadylift' jack which operates from two points, one under-
neath each side of the vehicle enabling either the right or left side
of the vehicle to be raised.
• Before jacking the vehicle first apply the handbrake firmly.
Ensure that the jack lug is fully enaged in the socket and that
the jack base has a firm footing on the ground; then proceed to
operate the ratchet type jack handle, in a clockwise direction
until the vehicle has been raised to the height desired.
Changing a Wheel: Before removing a wheel ascertain th'at the
vehicle is securely jacked with the handbrake firmly applied and
if on a hill it is advisable to scotch one or both of the wheels.
When replacing a wheel, tighten the nuts alternately and
progressively. Finally check the nuts for security with the wheel
on the ground.
Front
18 lbs./sq. in.
1.27 kg./cm'.
ELECTRICAL EQUIPMENT
In the event of any fault developing in the electrical equipment
the owner is advised to contact the nearest Austin dealer or Lucas
Service Depot.
Those attentions and replacements which the owner should be
able to undertake are as follows:
well smeared with petroleum jelly. Also check the security and
good electrical contact of the battery earthing clip on the engine
rear mounting plate.
Ascertain the state of charge of the battery by taking hydro-
meter readings. The specific gravity readings should be:
Fully charged ..
. . . . .. 1.280 to 1.300
Half charged .. . .
. . .. (. Approx. 1.210
Discharged .. . . . .
. . .. Below 1.150
These figures are for an assumed electrolyte temperature of
60'F. (15.6'C.).
Headligjttst Each headlight consists of a combined reflector
and front glass assembly provided with a mounting flange by
means of, which it is secured in the body housing. The bulb,
which is of Lucas pre-focus type, is located accurately in the
reflector and is secured by a bayonet fixed backshell which also
provides the contpt t o the bulb. The design of the bulb and
holder is such that the bulb is correctly positioned in relation to
the .reflector and no focussing is required when a replacement
Battery: Keep the battery top clean and the terminals tight and
bulb is fitted.
Jacking Position.
Headlight Rim S ecuring
This illustration shows the
position of the headlight rim.
securing screw 'A' under-
'' neath the bonnet.
Screw.
Make sure that thejack lug
is fully inserted in t he
socket and that the jack
base is jtrmly positioned
immediately below t h is
socket,
. 'II
4
50
51
Page 27
GENERAL MARTI'ENANCEAUSTIN-HEALEY SPRITE
Rear Flasher Light.
1. Glass cover retaining
ring.
2. Flasher glass cover.
3. Bulb.
Headlight Beam
Adjustment.
1 and 3. Horizontal
adjustment screws.
2. Vertical adjustment
screw.
@kg<;4
s
BULB FITTING
pressing it in against the tension of the adjustment screw springs
and turning it in an anti-clockwise direction until the heads of~
the screws can be disengaged from the slotted holes in the light
unit rim. Do not disturb the setting of the screws when removing
the light unit or the alignment will be altered.
Twist the backshell of the light unit in an anti-clockwise
direction and pull oK. The bulb can then be removed.
Place the replacement bulb in the holder, taking care to locate
it correctly. Engage the projections on the inside of the backshell
with the slots i
+he holder, press on and secure by twisting it to
the right. Replace the light unit in the body housing by reversing
the removal procedure.
Headlights: Remove the light unit from the body housing by
Headlight Alignment: The headlights must be set correctly in
relation to the r oad and to each other. Should adjustment
become necessary proceed as follows:
Remove the front rim by unscrewing the rim securing screw
(see illustration) and lifting oK the rim. Next remove the rubber
dust excluder, when three spring-loaded adjustment screws will
be visible, by means of which the setting can be altered as desired.
If vertical adjustment is required, set the light unit to t he
required position by means of the vertical adjustment screw at
the top of the reflector unit. Turn the screw in a clockwise direction to raise the beam and in an anti-clockwise direction to lower
it. If horizontal adjustment is required, set by means of the
two adjustment screws (one on each side of the light unit).
Headlight Assembly
1. Light unit.
2. Rubber dust excluding
ring.
3. Bulb.
4. Bulb backshelh
Rear Stop/Tail Light.
1. Light cover.
2. Rubber sealing ring.
3. Stop/tail bulb.
53
52
Page 28
AUSTIN-HEALEY SPRITE GENERAL MAINTENANCE
LH FLASHER dSIDE LAMP L.H. HEADLAMP
R.H HEADLAMP R.H.PLASHER dSIDELAMP
Rear Number Plate Light.
-1. Bulb.
2. Light glass.
3. Light cover.
18
57
9 9 HORN
DYNAMO
STOP LAMP
SWITCH
Do — 25
12 V. +~
I
SWITCH
I=
IGNITION COIL
Side and Flasher Lights: Move back the rubber lip, insert
a coin or screw-driver blade under the glass retaining collar and
gently lever the collar out from the light body. This will
enable the light glass to be completely removed, leaving the
bulb accessible in its socket.
Stop-Tail Lights: Remove the two cover securing screws and
lift off the cover to gain access to the bulb.
Rear Number Plate Light: Undo the one bolt and the cover
can be removed to give access to the bulb.
Panel Lights: The holders can be pulled from their fittings at
the back of the instrument panel and the bulbs are then easily
Ignition and Head1ight Beam Warning Lights: The bulbs can
be unscrewed from their holders when pulled out from the back
of the instrument panel.
Fuses: The fuse unit is situated adjacent to the voltage regu-
lator on )he right-hand side of the engine bulkhead and contains
two fuses and two spare.
IL~
't'-t
removed.
I
WIPER
MOTOR
o -
'
WIPI.R
SW IT C H
WD LAMP
57
(WVEH OT EDI
P
TI Iv
FLASVER SWITCH
I
~j,r,(V:M ~ <..'..
I
REG. d
CUT-OUT
57
YF HEATER HOTOR
(WHEW FITTED)
DISTRIBUTOR
17-
-- — — — — — 4
!AI A2
IT
J
41
HORN
PUSH
U NIT
I
SPEEDOMETER
R.H. STOP d
TAIL LAMP
TACHOMETER
!WHEW FITTED
)
I — 41
COLOUR CODE
57
Regulator and Fuse Unit
1. Regulator cover.
2. AUX. IGN. fuse
(35 amps.)
3. Fuse unit.
4. AUX. fuse (35 amps.)
5. Spare fuses.
BLUE
2 BL UE
4 BL UE
WHITE 5 5
9 W HITE
16 WHIIE • BLACK
17 GREEN
IB GREEN IDEO
21 GAEEN » 'TIHITE
22 GREEN PURPLE
25 GREEN BROWN
24 GREEN BLACK
25
RED 29
SB
4O
41
44
57
62
66 LIGHT GREEN
YELLOW
YELLOW w TH GREEN
BROWN
BROWN • BLU E
BROWN w TH GREEN
BROWN w<TH BLACK
RED
RED w T H W HIT E
BLACK
BLACK' GREEN
TAH. LAMP
LH. FLASHER
LAMP
E.I495.
LAMP
Wiring Diagram.
54
Page 29
AUSTIN-HKAI,KY SPRITE
GENERAL MAINTENANCE
One fuse protects the accessories which are operative only
when the ignition is switched on (e.g., stop-lights, fuel gauge,
and direction indicators). The other fuse protects those accessories which can 'be operated independently of the ignition. If a
new fuse blows, the cause of the trouble must be determined.
FUSES
BUL'BS
Accessories (AUX)
Accessories (AUX. IGN)
Headlights:
R.H.
L.H.
R.H. and L.H. Europe (except France)
Side and Flasher Lights
Stop- and Tail-lights
Flasher Lights
Number Plate Illumination Light ..
Panel Lights
Ignition and Headlight Beam Warning
Lights
RADIO
T'HREE models are available as optional extras, Radiomobile Models
x 20X, 22X and 230R,.
For tuning and operating instructions reference should be made to
the booklet issued with each radio supplied by the manufacturer<.
Two of the models available are manually tuned. Model 20X
operates on the. Medium and Long Wavebands. On the left of the
unit a volume control and on/off switch is fitted whilst on the right
there is a tuning control concentric with a Waveband switch. Model
22X is identical except that it operates only on the Medium Waveband.
The other model is the 230R which is a short wave receiver. The
volume — on/off control is on the left of the unit forward of, and
concentric with, the tone control wbich gives three tone settings.
There are two further controls on the right of the unit, the forward
control being for tuning, with the wave-change switch behind it.
Volts
]2
12
12
12
12
12
12
12
12
42/36
42/36
45/40
21/6
21/6
21
6
2.2
2.2
Watts
35 amps.
35 amps.
354
355
370
380
380
382
989
987
987
Lucas
No.
DUST on the vehicle may be lightly flicked off with a duster,
BOD YWORK
but on all other occasions the vehicle should be thoroughly washed
and dried before a non-abrasive polish is used. Any attempt to rub
dirt off the vehicle will result in severe scratching of the smooth
surface of the high lustre enameL Grease and tar splashes must be
very carefully removed with a soft rag dipped in petrol.
will greatly assist in maintaining the high lustre finish of the
pain twork.
When washing the vehicle, start at the top and work downward,
using a slow fiow of water and a sponge free from grit and oil.
Leather off all surplus moisture.
Should the finish become dull after several months, the use of
an emulsion polish of reputable manufacture will restore it to
its original condition.
Chromium plated parts sho dd be washed with soap and warm
water and cleaned with a damp leather. On no account should
ihetal polish or any kind of abrasive substance by used.
The hood should be cleaned regularly,, particularly when it
is new, to combat any initial chemical reaction which may occur
during its early life.
To clean the hood, it is only necessary to use soap and water,
with a soft brush to remove any ingrained dirt. Frequent
washing with soap and water considerably improves the appear-
ance and wearing qualities of the hood, and it should be washed
at least as often as the rest of the car.
If dust and grime have been allowed to remain on the hood
for a long time so that it has become really dirty, and the ordinary
soap and water method is not completely effective, then benzine
may be used with the same type of brush.
The interior of the hood can be cleaned by the sparing use
of trichlorethylene or a reputable brand of proprietary clothes
cleaner. On no account should spirit cleaners be used inside the
hood as their use would damage the proofing and wearing
qualities of the fabric.
It will be found that by cleaning by the methods outlined, the
hood will continue to look as good as new.
The leather-cloth upholstery and trimming should be wiped
over occasionally with a cloth damped in warm soapy water.
Repeat the operation using a fresh cloth and water — avoid
flooding — and finish by drying and polishing with a good qua1ity
leather cream.
IT IS IMPORTANT TO USE A MILD, NON-CAUSTlC
SOAP OF THE TOILET KIND and to avoid the use of
PETROL and DETERGENTS.
57
8'ashing and Polishing: Frequent washing with clean cold water
56
Page 30
AUSTIN-HEALKY SPRITE PROPRIETARY EQUIPMENT
IMPORTANT
Your attention is drawn to the following points, compliance with
which, we suggest, will prove mutually beneficial.
Warranty Certificate
(a) Completion of the Warranty Certificate 'Tear off slip' at the
time of vehicle purchase, when sent to the Factory, will ensure
registration of ownership by the British Motor Corporation.
(b) Retention of the Owner's portion of the Certificate, signed by
the Distributor and Owner, in a safe place in the vehicle
(by
quickly establishing ownership) will help to expedite any
adjustments under Warranty if such adjustments are required to be carried out by a B.M.C. Distributor or Dealer
other than the supplier of your vehicle.
INDEX
Air Cleaners ..
Battery
Bodywork
Braking System
Bulbs
Carburetters
Coil
Controls
Distributor
Draining Coolant
Driving Instructions
Engine
Fuel Pump
Fuses
Gearbox
General Maintenance
Generator
Heating Unit
Hubs
Instruments
Jacking
Lubrication Chart
Oil Filter
~ Post Delivery Check
Propeller Shaft
Radio
Rear Axle
Recommended Lubricants
Regular Attentions
Shock Absorbers
Sparking Plugs
Specification ..
Steering
Tyre Pressures
Wheels and Tyres
Wiring Diagram
Page
29
26, 51
30, 57
26, 48
. 56
26, 40
44
12
27, 43
30, 45
16
36
29, 39
54, 56
22, 28
36 — 57
21, 27, 31
47
29
10
50
34
28, 38
20
24
56
23, 28
33
20 — 35
26, 29
28, 31, 44
6
32
50
49
55
Claims Under Warranty
Claims for replacement of material or parts under warranty must
always be submitted to the supplying Distributor or Dealer, or when
this is not possible, to the nearest Distributor or Dealer informing
them of the Vendor's name and address.
Preventive Maintenance
Service vouchers are produced for your convenience and the use
of these is the best safeguard against the possibility of abnormal
repair bills at a later date.
Prevent rather than Cure.
Replacement Parts
When service parts are required insist on genuine B. M.C.
(MOWOG) Parts as these are designed and tested for your vehicle and
in addition warranted for twelve months by the British Mot or
Corporation. ONLY WHEN GENUINE PARTS ARE USED
CAN B.M.C. ACCEPT RESPONSIBILITY.
Our worldwide network of Distributors and Dealers is at your
service.
59
Page 31
NOTES
NOTES
60
Page 32
NOTES
NOTES
62
63
Page 33
W/T. 19731. 1 0m. 12/58.
Printed in En d.
Page 34
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