MG GHN5, GHN4, MGB GT GHD5, MGB GT GHD4 User Manual

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Page 1

Page 2

means

Highest quality cost-controlled work

Competent operators following

predetermined servicing schedule

involves the use of efficient, modern methods and equipment, eliminates guesswork and cuts down servicing time. We don't plan to make servicing more expensive, just more efficient.

Leycare follows a predetermined servicing se-

quence which must be rigidly followed by our

trained operators. There's no room for corner

cutting in Leycare.

. . .

new standard in car maintenance

. . .

Page 3

TOURER

and

(GHN5

(GHD5

and

GHN4)

GHD4)

Handbook

Publication Part

N3.

AKD

7598 (8th Edition)

Includes a Supplement for Cars with Impact Absorbing Bumpers

Leyland Cars-Sales

Longbridge, Birmingham B31

2TB.

England

Leyland Cars-Service

Cowley, Oxford

BRITISH LEYLAND

OX4

2PG.

England

LIMITED

1976

Page 4

FOREWORD

This Handbook introduces you to your British Leyland car. Your car is built to a high standard of quality and reliability and with good driving, correct car care and regular maintenance should give you carefree and economical motoring.

The introductory pages cover the operation and function of the controls, switches and general equipment fitted.

The main part of the Handbook gives detailed information on jacking, wheel changing, bulb renewal, lubrication and the servicing procedure of components.

Regular maintenance at the recommended intervals is essential to maintain your car at the original standard of efficiency and you will find our detailed recommendations under 'MAINTENANCE SUMMARY'. Those items which require specialized equipment should be carried out by a Distributor or Dealer. Refer to the 'GENERAL DATA' for information required during servicing and the dayto-day running of the vehicle such as tyre pressures, oil capacities, etc.

Our Distributors and Dealers are trained and available to service your car for you, and details of our maintenance scheme are included in your Passport Service. Look for the Leycare Service sign.

References to right- or left-hand are made as if the car is being viewed from the rear.

Page 5

INTRODUCTION TO THE CAR

CONTROLS INSTRUMENTS SWITCHES BODY FITTINGS SEATS

SEAT BELTS

HEATING AND VENTlLATlNG

RUNNING INSTRUCTIONS

AUTOMATIC TRANSMISSION

CARE OF THE CAR

CLEANING

COOLING SYSTEM WHEELS AND TYRES BRAKES ELECTRICAL

IGNITION

. . . .

....

......

. . .

....

Wiring Diagrams . .

. . .

. .

ENGINE FUELSYSTEM TRANSMISSION STEERING/SUSPENSION TUNING MODIFICATIONS GENERAL DATA

ROUTINE MAINTENANCE SUMMARY SERVICE

LUBRICATION SUPPLEMENT FOR EARLY CARS SUPPLEMENT FOR CARS WITH IMPACT ABSORBING BUMPERS

. . . .

....

. .

....

. . . . .

....

. . . . . . . . . . .

. . .

....

. .

. . . . .

....

. .

. . . . . . . . . . . .

inchrding wiring diagrann

. .

82 84 86

Page 6

CONTROLS

Fig.

Synchromesh gearbox

Fig.

Automatic transmission

Gear lever

(1)

Selector lever

(2)

Hand brake

(3)

Pedals

(4)

(5)

(7)

Mixture

control

(Choke)

The gear positions are indicated on the lever knob. To engage reverse gear move the lever to the left in the neutral position until resistance is felt, apply further side pressure to overcome the resistance and then pull the lever back to engage the gear. The reverse lights operate autoniatically when reverse is selected with the ignition switched on.

Synchromesh engagement is

prokidcd on all forward gears.

The manual selection positions are indicated on the selector lever quadrant plate.

Full driving instructions for cars fitted with a~~toniatic transmission are given on page

The hand brake is of the pull-LIP lever type, operating mechanically on the rear

wheels only. To release the hand brake pull the lever up 4ightly, depress the button on the end of the lever and push the lever down.

The pedals are arranged in the conventional positions. The brake pedal operates the brake hydraulic system and applies

the

brakes on all four wheels, also bringing the stop uarning lights into operation when the ignition is switched on.

To enrich the fuel air mixture and assist starting when the engine is cold, pull out the knob and turn a quarter of a turn clockwise to lock the control in the

position selected. To release the control turn it in an anti-clockwise direction

and push it inwards.

DO NOT MOVE the control in or out whilst it is in the locked position. Notes

on setting the control are given on page

Sce

'RUNlrlING INSTRUCTIONS'.

28.

Page 7

Steering

lock

One type of steering lock (inset

Fig.

either 'HALT', 'GARAGE', 'FAHRT', and 'START' or 'O', 'l', 'II', '111'. These locks use a single entry type key and have 180" of key movement.

Alternative type

of lock has a double entry key and only 120" of key movement.

(inset

B).

To lock the steering. Turn the key to the 'HALT' or

the key. The steering lock is set during withdrawal of the key and rotation of the steering-wheel engages the lock. When unlocking, turn the steering to assist disengagement of the locking plunger.

Alternative type.

while maintaining pressure turn anti-clockwise to position the key.

Turn the key to the position marked 'I', press the key in and

fitted to your car has the lock face marked

The lock face is marked 'O', '1'' 'II', '111'. This type

'0'

position and withdraw

'0'

UNDER NO CIRCUMSTANCES MUST THE KEY BE MOVED FROM THE 'I' POSITION TOWARDS THE

'0'

POSITION WHEN THE CAR

IS IN MOTION. GARAGE

switched off. Accessory electrical items-heater blower motor, windscreen wipers and radio-may be operated if desired. The car may be towed for recovery with the key in the lock at position

'FAHRT'

movement against spring resistance to the the starter. before re-operating the starter.

'1'.

In this position the steering is unlocked and the ignition is

'1'.

or '11'. Turn the key to this position to switch on the ignition; further

'START' or '111' position engages

If the engine does not start, release the key and allow a short pause

WARNING.-The lock fitted to the steering-column works in conjunction and

is integral with the ignition starter switch. The designed operating sequence prevents the engine being started with the steering

quences may result from alterations or substitutions of the ignition start switch which would permit the engine to be started with the no circumstances must the ignition switch or the ignition-engine-start function be separated from the steering lock.

LOCKED. Serious conse-

LOCK ENGAGED. Under

DO NOT lubricate the steering lock/switch.

is most important that OWNERS MAKE A NOTE OF THE KEY NUMBERS

IMMEDIATELY

a label attached to windscreen. Consult your Distributor or Dealer regarding

steering lock key replacements.

on taking delivery of the car. The key number is printed on

and withdraw

Page 8

INSTRUMENTS

Speedometer

(1)

Tachometer

(5)

Oil

pressure

gauge

(6)

Temperature

gauge

(7)

Fuel gauge

(8)

Fig.

In addition to recording the road speed this instrument also records the total distance

trip recorder, turn the knob upwards and turn it clockwise); it is important that all the counters are returned to zero.

The instrument indicates the revolutions per minute of the engine and assists the driver to use the most effective engine speed range for maximum performance in

any gear.*

The gauge indicates the pressure of the oil in the engine lubrtcation \y\tem.*

Nornlal operating temperature is reached when the pointer is in the

When the ignition is switched on the fuel gauge needle moves slowly across the scale, taking approximately

(2),

and the distance travelled in any particular trip

(4) anti-clockwise (on early cars push the knob

seconds to indicate the amount

See

'RUNNING INSTRUCTIONS'.

(3).

To reset the

'N.

sector.*

fuel in the tank.*

Page 9

SWITCHES

Ignition

starter

Fig. 7 and

and

Steering lock fitted. The ignition and starter are both controlled by a switch

integral with the steering lock. The switch is,operated by the steering lock key.

DO NOT lubricate the steering lock/switch. To switch on the ignition, insert the key in the steering lock and turn to the

position marked 'FAHRT' or

'11'.

To operate the starter, turn the key against spring resistance to the 'START' or

'111'

position.

the engine does not start, release the key and allow a short

pause before re-operating the starter.

(1)

Ignition warning light (red). The warning lamp

fitted in the tachometer serves the dual purpose of reminding the driver to switch off the ignition and of acting as a no-charge indicator.*

Early cars

The ignition and starter are both controlled by a single switch operated by a

removable key. To switch on the ignition insert the key and turn it in a clockwise

direction until a slight resistance is felt. Further movement in the same direction

operates the starter motor. Release the key immediately the engine starts.

To operate the auxiliary electrical services when the car is parked without the necessity of loading the ignition circuit or starting the engine, turn the ignition

key in an anti-clockwise direction. The heater blower motor, windscreen wipers,

and the radio may then be operated by switching on the appropriate switch. The key can only be withdrawn when the switch is in the 'off' position.

See 'RUNNING INSTRUCTIONS'.

Fig.

Page 10

Switches

FASCIA

Blower switch

SWITCHES

Lighting

switch

and heater

controls

(2)

Fog and spot

lamp switch

(If

fitted)

(3)

Fig.

Press the lower end of the switch rocker in to the first position to switch on the sidelamps and fully in to switch on the headlamps.

)

For operating instructions see

'HEATING AND VENTILATING'.

The two lamps use one common switch which is provided with two positions as follows:

To operate the fog lamp, press the lower end of the switch rocker to the first position. The fog lamp will only illuminate when the headlamps are switched to low beam, and will automatically extinguish when the headlamps are switched to main beam.

To operate the spot lamp, press the switch rocker to the second position. The lamp will only illuminate when the main headlamps are on high beam, and will extinguish when the main headlamps are switched to low beam.

Page 11

Windscreen

washer

(4)

With each depression of the control knob water is sprayed onto the windscreen. When the windscreen is dirty the washer should be operated several times before the wiper blades are set in motion.

In cold weather the washer reservoir should be filled with a mixture of water and a recommended washer solvent to prevent the water freezing. On no account should radiator anti-freeze or methylated spirits (denatured alcohol) be used in the windscreen washer.

Windscreen

wiper switch

(5)

Panel lamp

(6)

Overdrive

(If fitted)

(7)

Press the lower end

the switch rocker in to the first position to operate the wipers at slow speed, and fully in to operate the wipers at high speed. The wiper blades park automatically when the switch is returned to the off position.

When the sidelamps are switched on the instruments may be illuminated by turning the switch knob clockwise. The initial movement of the knob switches on

the panel lights; further turning dims them.

The two positions panel; for operating instructions see

'NORMAL'

and

'OVERDRIVE'

are marked on the switch

'RUNNING INSTRUCTIONS'.

Page 12

Switches

STEERING-COLUMN

Headlamp

beam

)

SWITCHES

With the headlamps switched on at the lighting switch, move the lever down ahay from the steering-wheel in the direction of arrow main beam. Lifting thelever from the low beam position wheel in the direction of arrow tive of whether the headlamps are switched on at the lighting switch or not.

Beam dipping

(early cars)

Warning light Headlamp main-beam.

(blue)

Direction

indicators

The switch mounted on the toeboard adjacent to the clutch pedal lowers the beams on one application and raises them on the next.

the beam is in the raised position. The light goes out when the beam is dipped.

(4)

The switch is self-cancelling and will operate the indicators only when the ignition is switched on. Move the lever in the direction of arrow hand direction indicators and in the direction of arrow right-hand indicators. when after switching on an indicator, the warning lamp and the serviceable bulb on the affected side give a continuous light.

Warning light Direction indicator.

(green)

operate with the flashing direction indicators.

(7)

Horn

The horn is sounded by pressing the centre disc of the steering-wheel.

Eurly

GHNIGHD

operate the horn.

Fig.

(2)

to overate the headlamps'

(l),

(3),

will flash the headlamp main beams irrespec-

towards the steering-

The light glows when the headlamps are switched on and

(5)

to operate the left-

(6)

visual warning of a front or rear bulb failure is given

to operate the

The arrow-shaped lights show the direction selected and

curs.

Press the knob

(1)

on the end of the switch lever to

Fig.

Page 13

CENTRE CONSOLE SWITCHES

Courtesy lamp

The courtesy lamp is controlled by a switch operated by the doors. With both doors closed the lamp may be switched on or

)

off using the switch on the lamp. Opening either door switches on the lamp and closing the door extinguishes it.

Early

cars:

The lamp is provided as a map light. Pull out the switch knob to operate the lamp. The map light only operates when thesidelampsare switched on and is not provided with door-operated switches.

Figs. 5 and

(2)

on the lamp and also by switches

Cigar-lighter

(If fitted)

(3)

Heated rear

window (GT)

(If fitted)

(4)

Hazard

warning

(6)

Fig. 5 (7973 model

Press the knob right in to heat the lighter element. When heated sufficiently, the

lighter unit will

partially ejected and it is then ready to be withdrawn for

lighting purposes.

Press the lower end of the switch rocker

(4)

to operate the heated rear window,

which will operate only when the ignition is switched on. The indicator light

glows as a reminder that the heater is operating.

Early cars.

The electrically heated back-light is controlled by a switch mounted on the fascia panel in the position normally occupied by the heater blower switch, the blower being repositioned on the under-side of the fascia panel below the windscreen wiper switch. The heated back-light will operate only when the ignition is switched on; an indicator lamp in the switch will glow when the switch knob is pulled out to the 'on' position.

To use the direction indicators as hazard warning lights, press the lower end of the switch rocker; all the direction indicators and the warning lamps will operate, irrespective of whether the ignition is switched on or off.

year)

Fig. 6 (7974 model

year)

(5)

Page 14

Switches

INTERIOR OR TAILGATE LAMP SWITCH

The lamp mounted above the seats is controlled by a switch on the lamp and

also by a switch operated by the tailgate. The lamp lights as the tailgate is raised

and switches off as the tailgate is lowered.

On early switch on each door hinge post which operates as the doors are opened or closed.

switch is also provided on the lamp for use when both doors are closed.

cars an interior lamp mounted above the seats is controlled by

Page 15

BODY

FITTINGS

Keys

Two keys and a duplicate set are provided, the large key for the steering lock and the ignition switch, and the small key for the front doors, glovebox and luggage compartment.

To reduce the possibility of theft, locks are not marked with a number. It is most important that owners

ATELY

or Dealer regard& steering lock key replacements.

on taking deliverv of the car and at the same time consult the Distributor

MAKE A NOTE OF

THE

KEY

NUMBERS IMMEDI-

Door locks

Fig.

Window

regulators

Fig.

Fig. 7 the internal door handle.

Turn the handle

Both doors may be locked from the outside with the key or from the inside with

To lock the doors from the outside insert the key in the lock and turn it slightly towards the rear of the car. To unlock the doors turn the key slightly towards the front of the car. Grasp the handle and depress the button which will be retained in the fully open position by the check strap.

After locking or unlocking the doors return the key to the vertical position and withdraw it.

To lock the doors from inside the car, close the door and move the locking

(3)

latch towards the front of the car and pull the release lever can be opened from the outside when the locking latch is in the forward position. The locking latch cannot be set to the lock position while the door is open.

towards the rear of the car. To open the doors move the locking latch

(1)

on each door to open or close the windows.

(4)

(2)

to open the door

rearwards. The doors

Page 16

Body

Fittings

Glovebox

Luggage

compartment

Fig.

locked with the key to retain

Tourer

Fig.

To open, depress the lock plunger and raise the lid. When fully

in the closed position.

raised the support stay will automatically spring into engagement and the lid will be held in the open position. Opening the luggage compartment lid automatically switches on the luggage compartment lamp.

To close the tourer luggage compartment, raise the lid slightly, push the catch on the support stay forward to release the locking mechanism, and lower the lid. Closing the luggage compartment lid automatically switches off the luggage compartment lamp.

To open, insert the key and turn it anti-clockwise. The glovebox door must

Fig.

To open, depress the lock plunger and raise the tailgate. Springs retain the tailgate in the open position. The interior lamp will automatically switch on as the tailgate is raised and switch off when the tailgate is lowered.

Fig.

(1)

Fig.

Page 17

Bonnet

Fig.

To raise the bonnet, pull the knob (l) located inside the car on the left-hand side

below the fascia panel. Press up the safety catch

(2)

under the front of the bonnet. Raise the bonnet and when fully raised the support stay will automatically spring into engagement and the bonnet

wiH be held in the open position.

Heated rear

window

luggage area

(GT)

(If fitted)

Fig.

Increased

(GT)

Fig.

To close, raise the bonnet slightly, push the catch

(3)

on the bonnet stay rearwards to release the locking mechanism, and lower the bonnet. Apply light pressure with the palms of the hands at the front corners of the bonnet and press down quickly; undue force is not necessary and may cause damage. The safety catch

and lock will be heard to engage.

The heated rear window has a heating element (arrowed) on the surface of the glass and with reasonable care will last indefinitely.

The following practices will damage the circuit and must be avoided.

Scratching off labels and advertising stickers.

Wiping the glass with the back of a ringed hand.

Stowing hard and metal objects so that they abrade the glass.

4. Cleaning with harsh abrasives.

To increase the luggage capacity the back of the rear seat can be folded down. Release the locks by moving the catch handles

back of the seat

(2)

forward.

(1)

downwards and moving the

To return the seat to the normal position, lift the seat and lock in position by moving the catch handles upwards.

Page 18

Body

Fittings

Mirrors

Arm-rest and

ashtray

Fig.

Exterior

(iffirted)

Fig.

The mirror head can be adjusted from the seat position

when the window is open.

Interior

Fig.

The mirror stem with anti-dazzle head is designed to break away

from the mounting bracket on impact. The stem may be refitted in the mounting

(l)

bracket as follows. Align the stem ball

the small protrusion

(3)

on the stem aligns with the indent of the mounting

with the bracket cup

bracket. Give the stem a smart tap with a soft instrument to join the two components.

Anti-dazzle

Fig.

To reduce interior mirror dazzle, press the lever

the windscreen.

To gain access to the compartment below the arm-rest, raise the forward end of the arm-rest. To empty the ashtray, raise the lid

Fig. 8 by lifting under the stubber

(2).

(1)

and remove the ashtray

Do not attempt to remove the ashtray by pulling on the lid.

FI~.

(2)

ensuring that

(4)

towards

Fig.

Page 19

Front

ventilator

windows

Fig.

To open, move the catch lever

(1)

upwards and push the window outwards.

To close, pull the catch inwards and then push it forward until the catch is in the locked position.

Rear

ventilator

windows

Fig.

Body and door

drainage

points

Fig.

To open, pull the catch

(1)

forward and then push the catch outwards.

To close, pull the centre of the catch inwards and then push it backwards until the catch, snaps over into the locked position.

Periodic examination of the drain holes should be made to ensure that they are clear of obstruction; use a piece of stiff wire to probe the apertures.

Careless application of underseal can result in restricted drainage. Masking

or plugs used when underseal is being applied must be removed immediately the operation is completed.

Jacking up beneath the underfloor may deform the drain apertures; always use the jacking points provided.

Fig.

tap

Fig.

Page 20

Body

Fittings

Lowering the

hood

Fig.

It is most important that the instructions given for raising, lowering, and folding

the hood are followed.

not fold or stow the hood when it is wet or damp.

Release both windscreen frame toggle catches Release the two fasteners

the cant rails and the two fasteners

Release the four fasteners from each rear quarter panel

slightly forwards to disengage the hook

not use undue force on the hood frame members.

(1).

(2)

on the windscreen rails, the two fasteners

(4)

on the hood mounting brackets.

(5)

(7)

from the socket

and pull the hood

(8)

on the body side

(3)

(6)

panel.

Move the seat tilt catch forward and incline the seat backs towards the front

of the car.

(11)

until

Raise the hood header rail

is poised approximately midway over the

door aperture.

(9)

Disengage the hood rear rail from the anchor plates

(10)

Fold each quarter-light material forward to the header rail

onto the back-light and continue the fold in the

(11).

ENSURE THAT THE FOLD IS

on the tonneau panel.

MADE IN THE HOOD MATERIAL BETWEEN THE QUARTER-LIGHT AND THE BACK-LIGHT. FAILURE TO DO THIS MAY CAUSE PERMANENT DAMAGE TO THE BACK-LIGHT MATERIAL.

Push the header rail

and hood material

(I I)

rearwards and at the same time draw the back-light

(12)

out over the luggage compartment lid ensuring that the

hood material does not become trapped between the hood sticks.

Fia.

Fig.

Page 21

Fig.

Fully lower the hood. Fold the two windscreen frame toggle catches wards to prevent them damaging the back-light.

(13)

rear-

Raising

Roll the back-light and material forward over the folded hood. Position and secure the two retaining straps

(14).

Return the seat back-rests to their original positions.

Remove the hood cover. Move the seat tilt catch forward and incline the seat

the

hood

backs towards the front of the car. Raise the header rail

(9).

plates

(8)

Pull the hood slightly forward and engage each hook

on the body side panel. Position the header rail on the windscreen ensuring

and unfold the hood. Engage the rear rail in the anchor

the rail seal is forward of the seal flange. Secure the windscreen frame toggle

(3),

(4),

and

(5)

catches and fasteners Secure the fasteners

(6)

at each rear quarter.

inside the car.

Reposition the seats.

(7)

in its socket

Fig.

Page 22

Body

Fittings

Fitting the

hood cover

Fig.

and

Removing the

hood cover

Stowage

Assemble the hood cover rail (IS) and fit it into the hood support sockets with the cross-rod towards the rear.

Lay the hood cover over the rail and thread the two seat belt quick-release fasteners

Engage the cover rear rail in the two anchor plates (17) on the tonneau panel. Pull the cover slightly forwards and engage each side hook in its socket

the body panel. Secure the fasteners Secure the four fasteners

Reverse the fitting procedure.

Stowage bags are provided to protect the hood cover and hood cover rail. The stowage bags, together with the tool bag, are stowed in the luggage compartment and secured with the straps provided.

(16)

through the holes in the cover.

(19)

at each quarter side panel.

(20)

inside the car.

(18)

Fig.

Page 23

Tonneau cover

Fig.

and

(If fitted)

Fitting.

Assemble the hood cover tonneau rail and fit it into the support brackets

with the cross-rod towards the rear. Lay the tonneau cover over the cockpit, engage the rear edge retainer with the

slotted plates on the tonneau panel, and secure to each quarter panel with the fasteners.

Extend the tonneau cover forward and attach the front of the cover to the

fasteners on the fascia panel top.

Usage.

The centre zip allows the cover to be folded down to give access to the driving seat or to both seats. Fold the cover down behind the seat, release the press stud (arrowed), or the zip on the early cars, and secure it with the fasteners

on the flap to the heelboard.

Fig.

Hard

(If fitted)

top

Removing.

Fitting.

Reverse the fitting procedure.

Remove the hood.

Fit the hard top side brackets into the support sockets and secure with the bolts

and spring washers. Position the hard top on the car, engaging the rear securing plates with the

20),

slotted anchor plates on the tonneau panel (inset, Fig.

ensuring that the

sealing rubber does not foul the slots. Line up the hard top drip moulding with the rear wing top beading. Push the

hard top forward and engage the toggle catch tongues in the sockets on the windscreen frame.

Fit the bolts into the side fixing brackets; screw in but do not tighten. Ensure

that the front sealing rubber is correctly positioned forward of the windscreen

frame. Adjust the toggle catches to give adequate tension when fastened (the

securing bolt slots allow movement), tighten the securing bolts, fasten the catches

and lock them with the securing clips (inset, Fig.

21).

Page 24

Body

Fittings

Check that the sealing rubbers are correctly positioned, then

tighten the side fixing bolts until the hard top seals evenly to the body.

OVERTIGHTENING.

fixing brackets (arrowed, Fig.

brackets to the thickness of the gap. Refit and tighten the bolts.

Wind up both windows and check that a gap of approximately exists between the rear edge of the window and the hard top quarter channel.

Adjust

hard top.

Ensure that there is an adequate seal between the window and hard top rubber and that the doors. when opened with the windows up, do not foul the opening surround.

Removing.

fixing bolts. Raise the front of the hard top to disengage the toggle fastener tongues from the windscreen sockets, move the hard top to the rear to disengage the anchor plates, then lift

Reniove the side fixing brackets from the hood support sockets. Assemble the fittings loosely to

necessary by loosening the side fixing bolts and repositioning the

Unlock and release the windscreen toggle fasteners. Rernovc the side

Measure the gap between the hard top and body side

20).

Remove the bolts and

clear of the car.

thc hard top to prevent loss.

~10\\1y

and evenly

AVOID

fit

washers between the

in.

mm.)

Fig.

Page 25

SEATS

adjustment

Both seats are adjustable and can be moved easily into the most comfortable

Seat

position. Move the lever the lever in this position while the seat position is adjusted. The locking pin is

Fig.

spring-loaded and will automatically lock the seat in the required position when the lever is released.

The rake of the back or squab of the seat may also be adjusted. Ease the body weight from the seat back, move the lever Release the lever and ensure the seat back is fully locked in position; check by applying back pressure on the seat.

(I)

located beneath the front of the seat outwards; hold

(2)

in the direction of the arrow.

To gain access to the rear compartment, and fold the back of the seat against the steering-wheel. The tilt catch will automatically re-engage when the rear of the seat is moved back to the correct driving position.

move the seat tilt catch

(3)

forward,

Page 26

SEAT

Rear

Static type

BELTS

fixing

The long belt is attached at the rear end by a quick-release fastener to the tonneau panel

Fig.

To release, press down the black plastic locking plate bracket

To secure, position the large hole in the belt bracket over the securing stud, slide the bracket forward until it engages in the securing stud slot and locks in position with the locking plate. Check that the belt webbing is not twisted.

('B'

tourer,

'A'

wheel arch

(2)

out of engagement with the securing stud slot.

GT).

(I)

and slide the belt

Static

Tourer and

Fig.

Never attempt to wear the belt other than as a complete diagonal and lap

assembly. Do not try to use the belt for more than one person at any one time,

even children. To fasten,

later cars:

shoulder and across the chest. Push it into the locking clip

lift the engagement tongue

(3)

and draw the belt over the

(4)

of the short belt

nearest the wearer. To fasten,

early cars:

netic buckle tongue

ensure that the belt webbing is not twisted, lift up the mag-

(8)

and engage the hook

(9)

into the hinged part of the

tongue. To release, To release,

To adjust,

later cars: early cars:

later cars:

through until the belt is comfortably tight. Slide the end of the belt

press the release button

(5)

lift the magnetic buckle tongue

tilt the edge of the adjuster

(6)

on the short belt.

(8).

upwards and pull the webbing

(7)

webbing to take up any slack after final adjustment. To adjust,

early cars:

tighten the short belt with the adjuster at the buckle until the buckle rests on the side of the hip (see illustration). With the adjuster at the sill tighten the belt until the lap belt fits comfortably and a hand clearance between the diagonal belt and the chest is just possible. Slight re-adjustment may be necessary during use.

To stow,

later cars:

after releasing the belt, push the tongue into the parking

pocket. To stow,

early cars:

hook the buckle on the long belt into the slot in the stowing bracket mounted just to the rear of the door post. Attach the magnetic buckle on the short belt to the seat frame.

along the

Page 27

Automatic

only

Fig.

Care

the

belts

Never attempt to wear the belt other than as a complete diagonal and lap assembly. Do not try to use the belt for more than one person at any one time,

even children.

To fasten,

later cars:

lift the engagement tongue (1) from the parking device and

draw the belt over the shoulder and across the chest. Push it into the locking clip

(2)

of the short belt nearest the wearer.

To fasten,

twisted, and engage the buckle tongue into the hooked end fitting

early cars:

lift the magnetic buckle (5), ensure the webbing is not

(6)

diagonal belt.

To release, To release,

To adjust,

(8)

later cars: early cars:

early cars:

press the release button

lift the buckle (5).

raise the adjuster clip

(3)

on the short belt.

(7)

and pull the free end

until the buckle rests on the side of the hip (see illustration). The belt reel will ensure correct tension of the seat belt yet allow the wearer freedom for normal movements. Hard braking or fast cornering of the car locks the seat belt reel.

Later cars:

ensure that while the belt is retracted the engagement tongue

has not moved on the belt to a point near the sill mounting; this can be rectified

(4)

by moving the tongue and belt clip

towards the reel.

Testing. WARNING-This test must be carried out under safe road conditions,

i.e. level dry road with no following or oncoming vehicles. With the belts in use

drive the car at 5 m.p.h.

krn.p.h.) and brake sharply. The automatic locking

device should operate and lock the belt. It is essential that the driver and passenger

are sitting in a normal relaxed position when making the test. The retarding

effect of braking must not be anticipated. If a belt fails to lock, consult your

Distributor or Dealer.

No unauthorized alterations or additions to the belts shoulc' be made. Inspect the webbing periodically for signs of abrasion, cuts, fraying, and general wear; pay particular attention to the fixing points and adjusters. Replace belts that are defective or have been subjected to severe strain.

of the

the belt

(9)

(l)

Fia.

Cleaning

Refer to page

34.

Page 28

HEATING AND VENTILATING

Hood and

tonneau

covers

Fresh air

Fig.

Face-level

vents

Fig.

Air

distribution

Holes are provided in the hood cover and tonneau cover to accommodate the seat belt quick-release fasteners mounted on the tonneau panel. After fitting the hood cover or tonneau cover attach the seat belts to the fasteners.

Fresh air is admitted to the car for cooling and ventilation through an adjustable

vent mounted behind the centre console. The flow of air may be adjusted by moving the control knob

(1)

to one of the three open positions; move the knob

to the most forward position to close the vent. Air distribution for heating

(1)

should

is independent of the fresh air system. The control knob

closed position when heated air is being distributed.

Air flow for cooling and ventilation from the face-level vents mounted on the fascia panel may be adjusted by turning the serrated control wheel

outer side of each vent. Move the wheel downwards to open.

(2)

The direction of the air flow is adjusted by moving the shutter control knob mounted in the centre of each vent.

The heating and ventilating system is designed to provide fresh air either heated by the engine cooling system or at outside temperature to the car at floor level and for demisting and defrosting to the windscreen.

in the

on the

(3)

Page 29

Heater Air temperature.

controls

Fig.

temperature.

Air flow.

Turn the knob

distribution.

Booster

fan.

air flow booster.

Turn the knob

(l)

in the direction of the arrow to raise the air

(2)

in the direction of the arrow to direct the air

Press the lower half of the rocker switch

(3)

down to switch on the

Fig.

Usage

The heater and air flow controls may be set at the position marked on the control

knobs or to any other intermediate positions.

varying the control settings, and utilizing the booster blower, a wide range of settings can be obtained to suit prevailing conditions.

Page 30

RUNNING INSTRUCTIONS

WARNING. Exhaust fumes will be drawn into the car if it is driven with the boot lidltailgate open, causing a health hazard to passengers and driver.

If it is imperative that the car effects can

(l)

(2)

(3)

(4)

(5)

minimised by adopting the following procedure: Close all windows. Open the face vents fully. Set the heater controls to circulate the maximum amount of cold or hot air. Switch on the blower motor to maximum speed. Do not travel at high speed.

driven with the boot lidltailgate open, adverse

Choice

Filling up with fuel

fuel

Starting

The octane number of a motor fuel is an indication given by the fuel technicians

of its knock resistance (pinking). High-octane fuels have been produced to improve the efficiency of engines by allowing them to operate on high compression ratios, resulting in better fuel economy and greater power. Fuels with an octane rating of below not suitable. Should it be necessary to use a fuel with a lower octane number,

the car must be used very carefully until the correct fuel can be obtained.

When filling up with fuel avoid filling the tank until fuel is visible in the filler

intake tube. Should this be done and the car left in the sun, there will be a considerable risk of fuel leakage due to expansion, and consequent danger from exposed fuel. If inadvertently overfilled and the car is to be parked, take care

to park it in the shade with the filler intake as high as possible.

The fuel tank is vented through the filler cap.

filler cap to fit this model.

Check that the gear lever is in the neutral position. If the engine is cold, pull out the mixture control (choke) and lock it in the desired

position by turning the control knob a quarter of a turn clockwise. In extremely cold conditions it may be necessary to pull the control out to its fullest extent.

Switch on the ignition, check that the ignition warning light glows and that the fuel gauge registers, then operate the starter.

As soon as the engine starts, release the ignition key and warm up the engine at a fairly fast speed (see 'Warming up'). Check that the oil pressure gauge is registering and that the ignition warning light has gone out. Unlock the mixture control (choke) and push it in completely as soon as the engine will run evenly without its use.

See page

when automatic transmission is

(high compression) or

fitted.

(low compression) are

UNIPART

market a lockable

Starter

Do not operate the starter for longer than five to six seconds. To prevent damage the starter cannot be operated while the engine is running.

If the engine fails to start, the ignition key must be returned to the 'off' position before the starter can be operated again.

If after a reasonable number of attempts the engine should fail to start, switch off the ignition and investigate the cause. Continued use of the starter when the engine will not start not only discharges the battery but may also damage the starter.

Page 31

Mixture contro

(choke)

Always use the minimum setting for the shortest possible time. As soon as possible after the engine has started, push the control completely

home.

To obtain a fast engine idling speed, set the control to within the first

(12

mm.) approx. of its initial movement.

The control may be locked in the required position by turning the knob a quarter of a turn clockwise.

in.

Ignition

warning light

Oil pressure

gauge

Warming up

Temperature

gauge

The light should glow when the ignition is switched on, and go out and stay out at all times while the engine is running above normal idling speed. Failure to do so indicates correctly tensioned before consulting your Distributor or Dealer.

The gauge should register a pressure as soon as the engine is started up. The pressure may rise above from cold and as the oil is circulated and warmed the pressure should then drop

to between

and to approximately

Should the gauge fail to register any pressure, stop the engine immediately and

investigate the cause. Start by checking the oil level.

Research has proved that the practice of warming up an engine by allowing it to

idle slowly is definitely harmful. The correct procedure is to let the engine run

fairly fast, approximately

temperature as quickly as possible. Allowing the engine to work slowly in a cold

state leads to excessive cylinder wear, and far less damage is done by driving the

car straight onto the road from cold than by letting the engine idle slowly in

the garage.

For automatic transmission see page

Normal operating temperature is reached when the pointer is in the

Overheating may cause serious damage. Investigate immediately any upward

change in the temperature gauge reading. Check coolant level and fan belt tension.

fault in the battery charging system. Check that the fan belt is

and

lb./sq. in.

1,000

(5.6

kg./an2) when the engine is started

(33

5.6

Ib./sq. in.

r.p.m., so that it attains its correct working

kg./~m.~) at normal running speeds

(.7

1.7

kg./cm.=) at idling speed.

32.

'N'

sector.

Running in

The treatment given to a new car will have an important bearing on its subsequent

life, and engine speeds during this early period must be limited. The following

instructions should be strictly adhered to.

500

miles

(800

(72

km.):

km.p.h.).

During the first

DO NOT

exceed operate at full throttle in any gear. allow the engine to labour in any gear.

m.p,h.

Page 32

Running Instructions

Tachometer For normal road work, and to obtain the most satisfactory service from your

Wet brakes If the car has been washed, driven through water, or over wet roads for pro-

Towing Should it become necessary to tow the car, use the towing eyes provided (see

Vehicle loading Due consideration

Towing

engine, select the appropriate gear to maintain engine speeds of between and 4,500 r.p.m.

When maximum acceleration is required upward gear selections should be made when the needle reaches the yellow sector (5,500-6,000 excessive use of the highest engine speeds will tend to shorten the life of the engine. Allowing the engine to pull hard at low engine speeds must as this also has a detrimental effect on the engine.

(6,000

The beginning of the red sector for the engine. Never allow the needle to enter the red sector.

longed periods full braking power may not be available. Dry the brakes by applying the foot brake lightly several times while the car is in motion. Keep the hand brake applied while using high-pressure washing equipment.

'AUTOMATIC TRANSMISSION').

must

be the car. Any loads carried on a luggage rack (Tourer), or roof rack (GT), or downward load from a towing hitch must also be included in the maximum loading-see 'GENERAL DATA'.

The towing weight of using bottom gear a gradient of up to 1 in weight not exceeding this figure. It may be necessary to adjust the maximum towing weight to comply with local conditions and regulations. The recom-

mended downward load of a trailer or caravan on the towing hitch is

(34 to 45 kg.), but this may be reduced or exceeded at the discretion of the driver.

Any load carried on the roof or downward load from a towing hitch must also be included in the maximum loading of the vehicle.

given to the overall weight carried when fully loading

1,680

lb.

(762

r.p.m.) indicates the maximum safe speed

kg.) is the maximum that is permissible. When

can be ascended while towing a

r.p.m.). Prolonged or

2,000

avoided

to 100 lb.

Overdrive The overdrive unit, controlled by a switch on the fascia, provides a higher

(When

fitted)

driving ratio for use with third or fourth gear. To engage overdrive move the switch down to the 'OVERDRIVE' position; to disengage, move the lever to 'NORMAL'. Accelerator pedal pressure should necessary to depress the clutch pedal during engagement or disengagement.

The overdrive can be engaged at any throttle opening when in third or top gear. If increased acceleration is required the overdrive can alteration to the throttle setting. Do not 'switch out' the overdrive when travelling at speeds exceeding normal third or top gear road speeds.

In certain driving conditions while travelling in third gear, the overdrive can switched in to provide a top gear ratio or out to provide third gear acceleration without the necessity of changing gear.

If for any reason the overdrive does not disengage, do not reverse the car otherwise extensive damage may result.

maintained and it is not

'switched out' without

Page 33

AUTOMATIC TRANSMISSION

(If

fitted)

Description The usual flywheel and clutch are replaced by a fluid torque converter which is

Driving

features box, which will soon become apparent in time saved, safer driving, and less

Selector The positions for manual selection are marked

positions the selector lever quadrant plate.

coupled to a hydraulically operated planetary gearbox providing three forward ratios and reverse. All forward ratios are automatically engaged in accordance with accelerator position, speed of the car, and road load.

Automatic selection may be over-ridden by manual selection of first or second ratio using the selector lever when engine braking or increased acceleration is desired.

The automatic transmission has many advantages over a manually selected geardriving fatigue.

The technique of driving a car fitted with automatic transmission to its fullest advantage is very soon mastered. The following points, however, must always be observed.

'P'

'R'

DO NOT select before selecting

DO NOT select with the car stationary.

DO NOT select

Fig.

The stop (1) provided between

'P'

of To select

raising the spring-loaded slide also be raised when selecting the other positions with the lever at DO NOT raise the slide when the car is in motion.

Park. In this position the transmission is mechanically locked. Use this position

when parked, starting, or when the car is stationary with the engine running for tuning or adjustment.

DO NOT select before selecting

Reverse. DO NOT select operate automatically when

Neutral. The hand brake must be applied at all times when the lever is in

Use this position for starting.

Drive. This position is used when driving in normal traffic and road conditions. Changes of all forward ratios are automatic.

Lock-up second ratio. Automatic changes are confined to first and second ratios

only. This position is used when rapid acceleration or engine braking is required. DO NOT select

Lock-up first ratio. In this position the transmission is locked to provide first

ratio only.

'P'.

'D',

'L2'

'R'

while the car is moving.

'P'

'R'

'P'

'P'.

'L2'

while the car is moving; always apply the hand brake

'LT, 'Ll',

at speeds above

from any of the other positions, move the lever forward,

when the car is moving, and always apply the hand brake

at speeds above

'R'

when the engine is running at high speed

m.p.h.

l0 km.p.h.).

'P',

'R',

'N',

'D',

'N'

and

'R'

is to minimize inadvertent selection

(2)

sufficiently to clear the stop. The slide must

'R'

when the car is moving forward. The reverse lights

'R'

is selected with the ignition switched on.

m.p.h.

km.p.h.).

'LT,

'P'

'Ll',

'R'.

'N'.

Page 34

Automatic

Transmission

(If fitted)

Starting the

engine

Driving

The procedure given in 'RUNNING INSTRUCTIONS' for starting the engine also applies to cars fitted with automatic transmission. The following points, however, should

The starter will only operate when the selector lever is in the Driving with a cold engine may result in stalling. Before driving the car, warm

a cold engine by setting the mixture control (choke) to the fast idle position page

28),

drive with the mixture control in the fast idle position as this may cause sudden acceleration when the brakes are released.

Selecting a driving position. Always release the accelerator pedal and apply the foot brake before moving the selector lever to the required position. This will prevent the car from 'creeping' (i.; a tendency for the car to move very slowly forward if This creeping feature can space.

Moving

off. The selector can

'Ll',

or stances. After releasing the brakes, moving off will much the accelerator pedal is depressed. Discretion in the use of the accelerator must be exercised when in slippery road conditions or if optimum fuel economy is to be achieved.

Selector in gressively up or down in accordance with changes in road speed, accelerator position, and road load.

The effect of the engine acting as a partial brake (engine braking) when the accelerator is released, as with a manual gearbox, is not present when driving

with the selector in

noted.

'P'

'N'

positions.

until the engine warms and will run without its use. Take care not to

'D',

'Ll',

'L2'

is selected or backwards when

used to advantage when manoeuvring in a confined

'LT,

selection of the position being dependent on prevailing circum-

'D'.

The automatic selection of all forward ratios takes place pro-

in any one of the forward driving positions

smooth regardless of how

'R'

(see

is selected).

'D',

'D'.

Fig.

Page 35

Selector in

'L2'.

Selection of first and second ratios only will occur automatically

in accordance with changing conditions. Appropriate engine braking is available

'LT

when the accelerator pedal is released. Manual selection of when driving in

a smooth down-change to second ratio. Use

'D'

at any speed below 68 m.p.h.

10 km.p.h.) and will provide

'LT

when road conditions demand

can be made

rapid acceleration or full engine braking; for example, when overtaking, ap-

'LT

proaching or negotiating bends or gradients. It is recommended that

is used

when towing a caravan or other vehicles at speeds up to 40 m.p.h. (64 km.p.h.).

'Ll'.

Selector in

The transmission will remain in first ratio irrespective of changes in road or driving conditions. This position provides full engine braking and full engine power for example, when starting off on, or ascending, very steep gradients. Avoid overspeeding the engine.

Stopping. Release the accelerator and apply the brakes. Soft surfaces. When the rear wheels fail to grip on muddy or snow-covered

roads, the car may be rocked backwards and forwards by alternately selecting

'D'

'Ryand

while using light accelerator pressure.

Increased

When lower gear acceleration is required for overtaking or hill-climbing, etc.,

acceleration down-changes of gear can be made by depressing the accelerator pedal. The

Fig.

maximum down-change speeds are preset to give optimum performance without overspeeding the engine.

At speeds up to 30 m.p,h. (48 km.p.h.) in top gear, depression of the accelerator pedakwithin the limits of its normal travel (1) will produce a down-change to second gear. Fully depressing the pedal beyond its normal travel (2) (termed 'kick-down') will produce a down-change to first gear.

At speeds above 30 m.p.h. (48 km.p.h.) within the 'kick-down' speed range, downchanges may be made by depressing the pedal to the 'kick-down' position.

The speeds below which 'kick-down' changes can

made are: From third to second gear, 52 to 56 m.p.h. (82 to 90 km.p.h.). From second to first gear, 28 to 32 m.p.h. (45 to 52 km.p.h.).

Towing

For recovery the car may be towed with the selector lever at

extra

pints (34

US.

pints, 1.7 litres) of fluid are added to the transmission

'N',

provided an

and, even then, the car should be towed at speed no faster than 30 m.p.h.

km.p.h.) and for a distance not exceeding 40 miles (64 km.).

(48 If the transmission is inoperativg, remove the propeller shaft or lift the rear

wheels.

NOTE.-The car cannot

tow-started.

Selector The lamp for illuminating the selector lever and quadrant is controlled by the

illumination lever-type switch adjacent to it and will only operate when the panel lights are

(inset Fig.

early cars)

switched on. The brilliance of the light may be varied by the panel light switch (see page 9), and the area of illumination may be altered by moving the sliding

hood (3) up or down the lamp body.

Page 36

CLEANING

Interior Carpets: Clean with a semi-stiff brush or a vacuum cleaner, preferably before

washing the outside of the car. Occasionally give the carpets a thorough cleaning; dilute one part UNIPART Upholstery Cleaner with eight parts warm water, apply vigorously with a semi-stiff brush and wipe over with a damp sponge or cloth. Carpets must not be 'dry-cleaned'.

Plastic faced upholstery: Clean with diluted upholstery cleaner. Spot clean with UNIPART Upholstery Cleaner spread thinly over the surface with a brush or cloth, leave for five minutes, then wipe over with a damp sponge or cloth.

Nylon faced upholstery: Remove loose dirt with a brush or vacuum cleaner. The nylon pile has been chemically treated to resist soiling and care must be taken when cleaning. Use UNIPART Nylon Cleaner. To remove a stain, apply the cleaner, then pat and wipe with a clean cloth in the direction of the pile until the stain is removed. DO NOT RUB. When dry, gently brush against the

pile, then with the pile.

Body Regular care of the body finish is necessary if the new appearance of the car

exterior is to be maintained against the effects of air pollution, rain, and mud.

Wash the bodywork frequently, using a soft sponge and plenty of water containing UNIPART Car Shampoo. Large deposits of mud must water before using the sponge. Smears should be removed by a second wash in clean water, and with the sponge if necessary. When dry, clean the surface of the car with a damp chamois-leather. In addition to the regular maintenance, special attention is required if the car is driven in extreme conditions such as sea spray or on salted roads. In these conditions and with other forms of severe tion an additional washing overation is necessarv which should include underbody hosing. Any damage; aieas should be irnmddiate~~ covered with paint and a complete repair effected as soon as possible. Before touching-in light scratches and abrasions with paint, thoroughly clean the surface. Use petrollwhite spirit (gasoline/hydrocarbon solvent) to remove spots of grease or tar.

The application of UNIPART Hi-shine Car Polish is all that is required to remove traffic film and to ensure the retention of the new appearance.

softened with

contan&-

Bright trim Never use an abrasive on stainless, chromium, aluminium, or plastic bright parts

Windscreen

Seat belts Do not attempt to bleach the belt webbing or re-dye it. If the belts become soiled,

and on no account clean them with metal polish. Remove spots of grease or tar with petrol/white spirit (gasoline/hydrocarbon solvent) and wash frequently with water containing UNIPART Car Shampoo. When the dirt has been removed

polish with a clean dry cloth or chamois-leather until bright. Any slight tarnish found on stainless or plated components which have not received regular attention may be removed with UNIPART Chrome Cleaner. An occasional application of light mineral oil or grease will help to preserve the finish, particularly during winter when salt may be used on the roads, but these protectives must

not be applied to plastic finishes.

If windscreen smearing has occurred it can be removed with UNIPART Glass Cleaner.

sponge with warm water using a non-detergent soap and allow to dry naturally.

Do not use caustic soap, chemical cleaners or detergents for cleaning: do not dry with artificial heat or by direct exposure to the sun.

UNIPART products mentioned above are obtainable from your Distributor or Dealer.

Page 37

COOLING SYSTEM

Radiator

filler cap

Draining the

cooling

system

Filling the

cooling

system

The system is pressurized to

Ib./sq. in.

(.7

kg./cm." when hot, and the pressure

must be released gradually when the filler cap is removed. It is advisable to

)

protect the hands against escaping steam and turn the cap slowly anti-clockwise until the resistance of the safety stops is felt. Leave the cap in this position until

all pressure is released. Press the cap downwards against the spring to clear the safety stops, and continue turning until it can be lifted off.

To drain the cooling system on cars not fitted with drain taps or plugs, slacken

the hose clip and remove the bottom hose at its connection to the radiator.

drain plug is provided on the engine cylinder block.

(2)

On early cars the radiator is provided with a drain tap

(3)

or tap

(4)

a drain plug

on the right-hand side of the cylinder block.

and the engine with

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 from 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.

Collect the coolant in a clean container if it is to be used again, as cars are filled

333

with a

per cent solution of anti-freeze before they leave the factory.

'To avoid wastage by overflow add just sufficient coolant to cover the bottom of the header tank. Run the enrvnc bring the surface to the level ot

uqtil

it is hot and add sufficient coolant to

~dicator positioned inside the header tank

thi

below the filler neck.

NOTE.-If

draining or filling the system.

a heater

fitted ensure that the heater control

set to

'HOT'

when

Page 38

Cooling

Frost

precautions

System

Water expands when it freezes, and if precautions are not taken there is considerable risk of bursting the radiator, cylinder block, or heater. The heater unit cannot be drained with the cooling system; it is therefore essential to use anti-

freeze in the cooling system in freezing conditions.

We recommend the use of

Bluecol U universal

anti-freeze to protect the cooling

system.

Bluecol

If B.S. compatible with Bluecol

universal is not available any anti-freeze conforming to specification

3151

or B.S.

3152

may be used. Anti-freezes to these specifications are

universal and can be used with it. Bluecol U universal

should not be mixed with other universal anti-freezes. After filling with anti-freeze solution, attach a warning label to a prominent

position on the car stating the type of anti-freeze contained in the cooling system to ensure that the correct type is used for topping-up.

Anti-freeze can remain in the cooling system for two years provided that the specific gravity of the coolant is checked periodically and anti-freeze added as necessary. The specific gravity check should be carried out by an authorized Distributor or Dealer. After the second year the system should be drained and flushed by inserting a hose in the filling orifice and allowing water to flow through

until clean. Make sure that the cooling system is water-tight, examine all joints and replace any defective hose with a new one. Refill with the appropriate anti-freeze solution.

The recommended quantities of anti-freeze solution are given below.

Do not use radiator anti-freeze solution in the windscreen-washing equipment.

Use the correct washer solvent, which will not damage the paintwork.

Anti-

freeze

25 33$

Commences

to freeze

"C.

-19

-36

"F.

-2

-33

Frozen solid

"C.

-36

-48

"F.

--l5

-33

-53

Amount of anti-fleeze

Pfs.

US.

24 3f

Pfs.

Litres

1.5

Page 39

WHEELS

AND

TYRES

Jacking up

Fig.

maintenance

Pressed type

Removing and wheel hub

Jack

WHEELS

Preventive

fefitting the

cap

Fig.

The jack is designed to lift one side of the car at a time. Apply the hand brake

and block the wheels on the opposite side to that being jacked; use a wood block

jammed tight against the tyre tread, Insert the lifting arm of the jack into the socket located in the door sill panel.

Make certain that the jack lifting arm is pushed fully into the socket and that the

base of the jack is on firm ground.

The jack should lean slightly outwards at the

top to allow for the radial movement of the car as it is raised.

WARNING.-Do

means of support.

not work beneath the vehicle

with

the lifting jack as the sole

Place suitable supports under the front side-members or rear

axle to give adequate support and safety while working. If the jack is neglected it may be difficult to use in a roadside emergency. Examine

it occasionally, clean off accumulated dust, and lightly oil the thread to prevent

the formation of rust.

Owners are recommended to check the wheel nuts for tightness each week in addition to checking the other items listed. Take care not to overtighten. Torque wrench setting

lb. ft.

(8.3

to 9 kg. m.).

lnsert the wheel hub cap lever into the recess formed in the wheel. Lever the hub

cap from its retaining button using a sideways motion.

To refit the hub cap, place the hub cap over two of the retaining buttons and

resting on the third. Give the face of the hub cap a sharp blow with the hand in the vicinity of the third button. Check that the rim is fully engaging all retaining buttons.

Fig.

Page 40

Wheels

and

Tyres

Removing and

refitting

and Fig.

Removing and

Fig.

(1)

Wire

type

refitting

(2)

Fig.

Maintenance

Slacken the four nuts securing the road wheel to the hub; turn anti-clockwise to

loosen and clockwise to tighten. Raise the car with the jack to lift the wheel

clear of the ground and remove the nuts. Withdraw the road wheel from the hub. When refitting the road wheel locate the wheel on the hub, lightly tighten the

(1)

nuts side

with the wheel nyt spanner (securing nuts must be fitted with the taper

towards the wheel), and lower the jack. Fully tighten the wheel nuts, tighten-

ing them diagonally and progressively, at the same time avoid over-tightening.

(2)

The wheel centre trim

must be removed and fitted to the wheel in use.

Use the mallet to slacken the winged hub nut or the spanner to slacken the octagonal hub nut used.

Always jack up a wheel before using the hammer, and always hammer the nuts tight.

'LEFT'

Locknuts are marked

'RIGHT'

must be fitted, and also with the word

to show to which side of the car they

'UNDO'

and an arrow.

Before replacing a wheel wipe all serrations, threads, and cones of the wheel and hub and then lightly coat them with grease. If a forced change is made on the road, remove, clean, and grease as soon as convenient.

When the car is new, after the first long run or after

miles

(80

km.) of short

runs, jack up the wheels and hammer the nuts to make sure that they are tight.

year remove the wheels for examination and regreasing.

Once

Fin

Fig.

Page 41

Spare wheel

The spare wheel is secured to the floor of the luggage compartment on tourer cars and below the luggage compartment floorboard on GT cars. To gain access

to the spare wheel on GT cars (Fig.

turn back the luggage compartment floor

covering, unscrew the two quick-release screws and lift the floorboard.

The spare wheel supplied with new cars is inflated above the recommended

running pressure. The pressure must be checked and adjusted before use.

Wheel and

tyre balancing

Radial-ply

tyres

FIO

Unbalanced wheel and tyre assemblies may be responsible for abnormal wear of the tyres and vibration in the steering. Consult your

Distributor/Dealer.

Radial-ply tyres should only be fitted in sets of four, although in certain circum-

stances it is permissible to fit

struction must not be used on the same axle.

pair on the rear wheels; tyres of different con-

pair must never be fitted to the

front wheels with conventional tyres at the rear. Consult your Distributor or

Dealer before changing to radial-ply tyres.

The positional changing of wheels must not

undertaken if radial-ply tyres

have been fitted to the rear wheels only.

Fia.

Page 42

Wheels

maintenance

and

Tyres

Tyre

To obtain the best tyre mileage and to suppress the development of uneven wear on the tyres the wheels can be interchanged diagonally bringing the spare

Fig.

wheel into use (see Excessive local distortion as a result of striking a kerb, a large stone, a deep

pot-hole, etc., may cause the casing cords to fracture. Tyres, including the spare, must be maintained at the pressures recommended

'GENERAL DATA');

(see week, and regulate as necessary. Pressures should cold; do not reduce the pressure in warm tyres where the increase above the normal pressure is die to temperature.

See that the valve caps are screwed down firmly by hand. The cap prevents the entry of dirt into the valve mechanism and forms an additional seal on the valve. preventing any leakage if the valve core is damaged.

Flints and other sharp objects should be removed with a penknife or similar tool.

If neglected, they may work through the cover. Any oil or grease which may get onto the tyres should be cleaned off by using fuel

sparingly. Do not use paraffin (kerosene), which has a detrimental effect on rubber.

When repairing tubes have punctures or injuries vulcanized. Ordinary patches should only be used for emergencies.

Vulcanizing is absolutely essential in the case of tubes manufactured from synthetic rubber.

Radial-ply tyres).

check with an accurate tyre gauge at least once a

checked when the tyres are

Page 43

BRAKES

Brake and

clutch master

cylinder

Fig.

Front brakes

Fig.

To check the level of the fluid in the brake reservoirs, remove the plastic filler caps.

The fluid level must be maintained at 4 in. (13 mm.) below the bottom of the filler cap. Top up if necessary with UNIPART high-boiling-point brake fluid conforming to specification S.A.E. J1703c with a minimum boiling point of 260" type of fluid. Frequent topping-up is indicative of a leak in the system whch

must be checked and the leak rectified immediately. Before refitting the filler caps, separate the dome (3) from the filler cap and check

that the breather holes indicated by the arrows are clear. Snap-fit the dome onto the filler cap.

NOTE.-Brake fluid can have a detrimental effect on paintwork. Ensure that

brake fluid is not allowed to contact paint-finished surfaces.

Wear on the disc brake friction pads (arrowed) is automatically compensated

for and manual adjustment is therefore not required. Before the lining material has worn down to the minimum thickness of in. (1.6 mm.) the brake pads should be renewed. Special equipment is required to renew brake pads; this work should be entrusted to your Distributor or Dealer.

(500" F.) may be used. Do not use any other

(l)

and clutch

550

Brake

(2)

master cylinder

Fluid;

alternatively

Page 44

Brakes

Rear brakes

Adjusting

Fig.

Inspecting rear

brake linings

Fig.

Excessive brake pedal travel is an indication that the rear brake-shoes require

adjusting. The brakes on both rear wheels must

adjusted to regain even and

efficient braking.

Block the front wheels, fully release the hand brake and jack up each rear wheel

in turn. Turn the adjuster (arrowed) in a clockwise direction (viewed from the centre of the car) until the wheel is locked, then turn the adjuster back until the wheel is free to rotate without the shoes rubbing. Repeat the adjustment on the

other rear brake.

Chock the front wheels and release the hand brake. Jack up each wheel in turn,

placing suitable supports beneath the vehicle-see

'WARNING'

on page 37.

Remove the road wheel and slacken the brake-shoe adjuster.

(1)

Remove the two countersunk screws

wheels) and withdraw the brake-drum

(pressed wheels) or the four nuts (wire

(2).

Inspect the linings (3) for wear, and clean the dust from the backplate assembly and drum, preferably using methylated spirit (denatured alcohol). Brake lining dust is dangerous to health if inhaled and therefore should not be blown from the drums. Make certain that sufficient lining material remains to allow the car to run until the next regular inspection is due without the thickness falling below

the safe limit. Refit the brake-drums and road wheel, and adjust the brake-shoes.

Fig.

Page 45

Replacing

brake-shoes

and pads

When it becomes necessary to renew the brake-shoes or pads it is essential that only genuine replacements, with the correct grade of lining, are used. Always fit new shoes as complete axle sets, never individually or as a single wheel set. Serious consequences could result from out-of-balance braking due to mixing of linings.

Replacement brake-shoes are obtainable from your Distributor or Dealer under the Service Exchange Scheme, see page

85.

Hand brake

Lubrication

Servo filter

Visual check

Fig.

The hand brake is automatically adjusted with the rear brakes. If there is excessive movement of the hand brake lever, consult your Distributor or Dealer.

Charge the nipple on the hand brake cable with one of the recommended

Fig.

greases.

The filter should be cleaned at the recommended intervals with compressed air

Fig.

at low pressure. Do not use cleaning fluid or lubricant of any description on the filter.

Removing

the

filter.

Lever the dome

(1)

off the valve cover, remove and clean

the filter (2).

(3)

When refitting, make sure that the air valve spring the valve, refit the filter (2) and snap-fit the dome

is securely located onto

(1)

onto the valve cover.

Examine the clutch and brake hoses, pipes, unions, and joints for tightness and general condition. It is most important to ensure that no chafing of connections or pipes develops at any time, and that leakages are rectified immediately.

Fig.

Page 46

Brakes

Preventive In additian to the recommended periodical inspection of brake components it

maintenance is advisable as the car ages, and as a precaution against the effects of wear and

deterioration, to make a more searching inspection and renew parts as necessary.

It is recommended that:

(I)

Disc brake pads, drum brake linings, hoses, and pipes should at intervals no greater than those laid down in the Passport to Service.

(2)

Brake fluid should be changed completely every 18 months or 18,000 miles (30000 km.) whichever is the sooner.

(3) All fluid seals in the hydraulic system should be renewed, and all flexible

hoses should be examined and renewed if necessary every 3 years or 36,000

miles (60000 km.) whichever is the sooner. At the same time the working

surface of the piston and of the bores of the master cylinder, wheel cylinders, and other slave cylinders should be examined and new parts fitted where necessary.

Care must

(a)

At all times use the recommended brake fluid.

(b)

Never leave fluid in unsealed containers. It absorbs moisture quickly and

this can

(C)

Fluid drained from the system or used for bleeding is best discarded.

(d)

The necessity for absolute cleanliness throughout cannot be over-emphasized.

taken always to observe the following points:

dangerous if used in the braking system.

examined

Page 47

ELECTRICAL

POLARITY

BATTERIES

Access

Fig.

Checking

t,opping-up

Fig.

The electrical installation on this car is correct polarity must be maintained at all times. Reversed polarity will permanently damage semi-conductor devices in the alternator and tachometer, and the radio transistors (when fitted).

Before fitting a radio or any other electrical equipment, make certain that it has the correct polarity for installation in this vehicle.

Remove the carpet covering the rear compartment floor. Turn the five quickrelease fasteners

partment cover panel (2).

The vehicle must

DO NOT USE A NAKED LIGHT WHEN CHECKING THE LEVELS.

Remove the battery vent cover; use the grip at the centre of the cover will ensure that the filling valves are operated correctly. If no electrolyte is visible inside the battery, pour distilled water into the filling trough until the three tubes (2), and the connecting trough Check the second battery.

Except when topping-up or taking hydrometer readings the vent cover must fitted. The electrolyte will flood if the cover is removed for long periods during

or within thirty minutes of the battery being normal (5 amp.), or fast charged

(30-40

amps.). Single-cell discharge testers cannot Operation of the filling device will punctured.

Early

batteries.

weekly and maintained so that the separator g~~ards (5) are just covered. Top up the cells as necessary with distilled water.

(1)

anti-clockwise one half turn and remove the battery com-

on level ground when the electrolyte is being checked.

Remove the filler plugs

NEGATIVE

(3),

destroyed if the battery case is drilled or

(4);

the electrolyte levels must be checked

(-)

earth return and the

are filled. Refit the vent cover.

used on these batteries.

(l),

this

More frequent topping-up may be necessary in hot weather or when long

journeys are made.

Page 48

Electrical

General

Battery

boosting

Fig.

Battery

charging

FUSES

Fig.

The batteries must be kept dry and clean; cable and battery terminals should

smeared with petroleum jelly.

BATTERY BOOSTING CAUTION: The following precautions must be observed to avoid the possibility of

serious damage to the charging system or electrical components of the vehicle.

AND

CHARGING

When connecting an additional battery to boost a discharged battery in the vehicle, ensure that:

-the booster battery is of the same nominal voltage as the vehicle battery;

-the interconnecting cables are of sufficient capacity to carry starting current;

-the cables are interconnected one at a time and to the booster battery first;

-the cables are connected between the battery terminals in the following order:

first,

-the engine speed is reduced to the boost battery. The vehicle battery must never

(positive) to + (positive) and then - (negative) to - (negative);

1,000

r.p.m. or below before disconnecting

disconnected while the

engine is running.

When charging the battery in the vehicle from an outside source such as a trickle charger, ensure that:

-the charger voltage is the same as the nominal voltage of the battery;

-the charger positive

;

battery

-the charger negative

(+)

lead is connected to the positive

(-)

lead is connected to the negative

(+)

terminal of the

(-)

terminal of the

battery.

The fuses are housed under the fuse cover

(1)

mounted in the engine compart-

ment on the right-hand wing valance.

Fuse connecting

1-2.

The fuse

(2)

protects one parking lamp, one tail lamp, and

one number-plate lamp.

Fig.

Page 49

Fuse connecting

3-4.

The fuse (3) protects one parking lamp, one tail lamp, and

one number-plate lamp.

Line fuses

Fig.

Spare fuses

Fig.

Blown

fuses

Fuse connecting

5-6.

The fuse

(4)

protects the circuits which operate only when

the ignition is switched on. These circuits are for the direction indicators, brake stop lamps, reverse lamps, temperature and fuel gauges, and the heated rear window (if fitted).

Fuse connecting

7-8.

The fuse (5) protects the circuits which operate independently of the ignition switch, namely horns, interior and luggage compartment lamps, headlamp flasher, and the cigar-lighter (if fitted).

Auxiliary equipment.

line fuse (7) protects the windscreen wiper, windscreen washer, heater blower

The 17-amp. continuous current rated (35 amp. blow rated)

motor, and radio circuits when the ignition steering lock key is in position

Hazard warning.

line fuse

(8)

The 17 amp. continuous current rated (35 amp. blow rated)

protects the hazard warning lamps and is located behind the hazard warning switch. It is accessible only when the centre console is withdrawn (see page 52).

Radio.

separate additional line fuse protects the radio (if fitted). See the

instructions supplied with the radio for the correct fuse ratings.

To change a line fuse,

hold one end of the cylindrical fuse holder

(9);

and twist the other end (10). Remove the fuse (11) from the cylindrical holder.

Two spare fuses

ment fuse. The fusing value, current rated 17 amp continuous (35 amp blow

(6)

are provided and it is important to use the correct replace-

rated), is marked on a coloured slip of paper inside the glass tube of the fuse.

blown fuse is indicated by the failure of all the units protected by it, and is confirmed by examination of the fuse when withdrawn. Before renewing a blown fuse inspect the wiring of the units that have failed for evidence of a short-circuit or othe; fault.

'1'.

push in

Page 50

Electrical

Accessories

Fig.

HEADLAMPS

Light unit

Fig.

If an electrical accessory is being fitted and it is required to operate independently of the ignition circuit it should be connected to terminal

if it is required to operate only when the ignition is switched on, connect terminal

Sealed-beam or renewable-bulb light units are used, w~th alternative types of

bulb holders, the type fitted being dependent on the lighting regulations existing in the country for which the car was produced.

'6'.

The terminal numbers are marked on the fuse block.

'8'

on the fuse block;

Replacement

Fig.

The method of gaining access to the light unit for replacement is the same for

both types. The different types of bulbs and holders are shown

Removing.

and lift it off the retaining lugs at the top of the lamp. Unscrew the three inner rim retaining screws

Sealed-beams.

and remove the light unit.

Captype

and withdraw the bulb. Fit a new bulb into the reflector, ensuring that the notch

in the bulb flange locates on the ridge in the reflector. Engage the cap lugs reflector slots, press and turn the cap clockwise.

Ease the bottom of the outer rim

(2),

remove the inner rim

(5)

Withdraw the three-pin connector from the back of the reflector,

bulb

holder

(6).

Press and turn the cap anti-clockwise, lift off the cap

(1)

forwards away from the lamp.

(3)

and withdraw the light unit

in Fig.

(4).

the

Page 51

Beam

setting

Fig.

Spring clip type

(7).

Withdraw the three-pin connector, disengage the spring clip from the reflector lugs, and withdraw the bulb. Fit the new bulb into the reflector, ensuring that the pip on the bulb flange engages the slot in the reflector. Refit the spring clip ensuring that the coils in the clip are resting on the base of the bulb and that the legs of the clip are fully engaged under the reflector lugs. Fit

the three-pin connector.

(8).

Headlamp pilot lamp

Withdraw the holder from the reflector, press and turn the bulb anti-clockwise and withdraw it from the holder. Engage the pins of the new bulb in the grooves of the holder, press and turn the bulb clockwise. Press the holder into its hole in the reflector.

Refitting. Locate the three lugs on the rear outer edge of the light unit in the slots formed in the lamp body, and refit the inner rim and its retaining screws.

Position the outer rim on the retaining lugs at the top of the lamp, and press the

rim downwards and inwards.

Two adjusting screws are provided on each headlamp for setting the main beams. The screw

(9)

is for adjusting the beam in the vertical plane, and the screw

(10)

is for horizontal adjustment. The beams must be set in accordance with local regulations; resetting and checking should be entrusted to 9our Distributor or Dealer, who will have special equipment available for this purpose.

Fig.

LAM

Side and

direction

indicator

Courtesy

Fig.

To gain access to the sidelight two retaining screws

(1)

(3)

and withdraw the rim and lens.

and direction indicator

(2)

bulbs, unscrew the

To replace a defective bulb, remove the two screws securing the lamp lens.

Withdraw the festoon-type bulb fjo~ the retaining clips.

Fig.

Page 52

Electrical

Stop.

and direction

tail

indicator

Fig.

Remove the lens retaining screws to the direction indicator

The direction indicator lamps have a single filament bulb

(2)

(1)

and slide the lens upwards to gain access

and stop/tail (3) bulbs.

either way round in the socket. The tail and stop lamp bulb

and offset bayonet fixing to ensure correct replacement.

(2)

which may be fitted

(3)

has a twin filament

Number-plate

Fig.

Reverse

Fig.

To change a bulb, remove the two screws and nuts, remove the lamp hood

and lift off the lens

(2).

When refitting the lens on later cars, check that the lens

is pushed into the gasket (3). Ensure that the wedge shaped gasket (3) on later

(4)

cars, or the wedge shaped distance piece

on early cars, is fitted with its

thickest edge towards the rear.

To renew a bulb remove the two securing screws

Press the bulb

(2)

down towards the lower contact and withdraw it from the

(1)

and withdraw the lens.

lamp. Fit one end of the new bulb into the hole in the lower contact, then press the top

of the bulb into the

lamp until the point of the cap engages in the hole in the

upper contact.

Fig.

(1)

Page 53

Tailgate or

interior (GT)

Fig.

The plastic lens on the interior lamp is held in position by four locating lugs. To gain access to the bulb, gently squeeze the lens sides and pull outwards.

Withdraw the festoon-type bulb from the retaining clips.

Luggage

compartment

lamp (Tourer)

Fig.

Selector

illumination

(Automatic)

Fig.

Fia.

The lens is held in the lamp by four locating lugs. To gain access to the bulb, gently squeeze the sides of the lens together and withdraw it from the lamp The bulb may then

withdrawn from its contacts.

Early

cars.

To gain access to the bulb, slide the hood

(1)

up the lamp body.

Page 54

Electrical

Centre console

To gain access to the bulbs the centre console must be withdrawn.

warning and

illumination Centre console.

Fig.

screws the retaining screw screw the four screws rearwards.

Heated rear window warning lamp

centre console. Remove the push-fit bulb holder

the bulb

Cigar-lighter illumination bulb

the centre console. Squeeze the sides of the bulb hood Remove the bulb holder

Warning

and panel

Fig.

The warning and panel lamps are a push-fit into the back of the instrument and warning lamps, and are located in the positions shown.

(1)

Fuel gauge and temperaturelwater gauge illumination lights.

(2)

Ignition and main beam warning lights.

(3)

Speedometer and tachometer illumination, and direction indicator warning

lights.

The lamps are accessible from below the fascia panel. Remove the push-fit bulb holder and unscrew the bulb from the holder.

Fig.

(2)

securing the gaiter retaining ring. Raise the hinged arm-rest, unscrew

(3)

and remove the arm-rest complete with gaiter

(5)

retaining the console and withdraw the console

(iffirred).

screw fixing bulb. Withdraw the

(7)

(8).

Remove the gear lever knob and locknut

(iffitted).

(10)

from the hood clip and remove the bulb

bulb with bayonet fixing. Withdraw

(l).

Unscrew the four

from the lamp and unscrew

(9)

and remove the hood.

(11).

(4).

Un-

(6)

Page 55

Replacement

bulbs

Headlamp-Home and R.H.D. Export (English

sealed beam)

Headlamp-North America (American sealed

beam)

Headlamp-Europe except France (European Headlamp-France (bulb type

Sidelamp-all markets except North America Sidelamp (with flasher)-North America and Stop/tail-all markets

Reverse-all markets except France Reverse-France Number-plate lamp: Early cars

Direction indicator

Ignition warning-all markets except North Ignition warning-North America. Sweden. and Main beam-all markets except North America. Main beam-North America. Sweden. and West Direction indicator warning lamp

Panel illumination lamp Cigar-lighter illumination

Heated back-light warning Boot lamp Tailgate or interior lamp (GT) Courtesy or map lamp Map lamp Courtesy lamp

beam)

sealed

and Italy

Italy

America. Sweden. and West Germany West Germany

Sweden. and West Germany Germany

Brake warning lamp-North America. Sweden.

and West Germany

. .

......

. . . .

. .

. . . .

41 1

. .

. . .

....

Later cars

. . .

. .

. . . .

....

. .

....

.... . .

. . . . . .

. . .

. . . .

. .

....

yellow)

. .

....

. . .

. .

. . . . .

. . .

. .

....

. .

. . . .

. . .

. . . . .

......

. . .

. .

. . .

. .

. . . .

.... . .

. . .

. .

. . .

....

. .

Volts

Wafts Part

75/50

12 6 12 5/21

12 5/21 12 18 12 15 12 6

12 4 12 21

12 2.2 12 2

12 2.2

12 2.2 12 1.5

12 2.2

12 2.2 24 12 6 12 6 12 6 12 6 12 6

GLU101

GLB

989

GLB

380

GLB

380

BFS

272

BFS

267

GLB

989

BFS

233

GLB

382

GLB

987

GLB281

GLB

987

GLB

281

GLB

987

GLB

280

GLB

987

BFS

2.8 13H 2424

GLB GLB GLB GLB

GLB

643

254 254 989 989 254

Page 56

Electrical

WINDSCREEN WIPER AND WASHER

Screw fixing type the screw head to release the splined locking wedge To remove a wiper blade rubber, depress the rubber stop at one end of the blade and slide the rubber through the retaining clips.

Spring clip fixing clear of the retaining groove in the spindle and withdraw the arm. Place the arm in the required position and press it on the spindle clip. To remove a wiper blade rubber, withdraw the retaining rubber stop from

one end of the blade and slide the rubber from the retaining clips.

Plain fastener type down the arm against the spring fastener Insert the end of the wiper arm push the blade into engagement with the arm.

Slotted fastener type from the windscreen and press the fastener the blade from the arm with a gentle pull. Insert the end of the arm into the slotted spring fastener of the new blade, and push the blade into engagement with the arm.

To ensure efficient wiping it is recommended that wiper blades are renewed annually.

(Fig. 17):

(Fig. 16):

(Fig. 17):

To reposition a wiper arm, slacken the screw

To reposition a wiper arm, hold the spring clip

Pull the wiper arm away from the windscreen, press

(4)

(3)

into the spring fastener of the new blade and

To renew a wiper blade pull the wiper arm away

(3)

(2),

and withdraw the arm.

(2)

until it is secured by the

and pull the blade from the arm.

towards the blade and withdraw

(1).

Tap

(l)

Page 57

Windscreen

washer

Fig.

The windscreen washer system should be checked for correct operation and the reservoir refilled if necessary every week and before a long journey in addition to

the mileage intervals given in

'MAINTENANCE SUMMARY'.

ALTERNATOR

STARTER

FUEL

PUMP

Washer reservoir.

To fill the reservoir, remove the cap

(1)

and lift the reservoir

(2)

from its mounting.

The reservoir should be filled with a mixture of water and

UNIPART Screenwash

in the recommended proportions. On no account should radiator anti-freeze or methylated spirits (denatured alcohol) be used in the windscreen washer.

In freezing conditions use

Jet adjusting.

Turn the jet

UNIPART Four Seasons Screen Wash.

(3)

using a small screwdriver to adjust the height of

the spray. The spray should strike the top of the windscreen.

The following precautions must be observed to prevent inadvertent damage to the alternator and its control equipment.

Polarity.

Ensure that the correct battery polarity is maintained at all times;

reversed battery or charger connections will damage the alternator rectifiers.

Battery connections.

The battery must never

disconnected while the engine is

running.

Testing semi-conductor devices.

Never use an ohmmeter of the type incorporating

a hand-driven generator for checking the rectifiers or the transistors.

The starter motor is mounted on the right-hand side of the engine on the flywheel

housing. It requires no lubrication.

Fuel is delivered to the carburetters by an

S.U.

electric fuel pump.

The pump is situated beneath the luggage compartment on the right-hand side.

Page 58

WIRING DIAGRAMS

KEY

Use the one key to identify components on these wiring diagrams. Refer to the appropriate wiring diagram for your car, and disregard any additional

numbered items appearing in the key and not on your diagram.

WIRING DIAGRAMS

Alternator (with integral control unit). Control box (early cars). Batteries-6 volt. Starter solenoid. Starter motor. Lighting switch. Headlamp dip switch. Headlamp dip beam. Headlamp high beam

Headlamp high-beam warning lamp. R.H. sidelamp. L.H. sidelamp. Panel lamp rheostat. Panel lamps. Number-plate illumination lamp.

Stop lamps. R.H. tail lamp. Stop lamp switch. Fuse unit. Interior courtesy lamp. Interior lamp door switches. L.H. tail lamp. Horns. Horn-push.

Flasher unit. Direction indicator switch. Direction indicator warning lamp. R.H. front direction indicator lamp. L.H. front direction indicator lamp. R.H. rear direction indicator lamp. L.H. rear direction indicator lamp. Heater or fresh-air motor switch. Heater or fresh-air motor. Fuel gauge. Fuel gauge tank unit.

Windscreen wiper switch. Windscreen wiper motor. Ignitionlstarter switch. Ignition coil.

40. Distributor.

41. Fuel pump.

43. Oil pressure gauge.

44. Ignition warning lamp.

45. Headlamp flasher switch.

46. Coolant temperature gauge.

49. Reverse lamp switch.

50. Reverse lamp.

53. Fog lamp switch.*

54. Fog lamp.*

55. Driving lamp.*

57. Cigar lighter-illuminated.*

58. Driving lamp switch.*

60. Radio.*

64. Bi-metal instrument voltage stabilizer.

65. Luggage compartment lamp switch.

66. Luggage compartment lamp.

67. Line fuse (when fitted).

71. Overdrive solenoid.

72. Overdrive manual control switch.

73. Overdrive gear switch.

76. Automatic gearbox gear selector illumination lamp (early cars).

82. Illumination lamp switch (automatic gearbox selector) (early cars).

95. Tachometer.

101. Courtesy or map lamp switch.

102. Courtesy or map lamp.

115. Heated

116. Heated back-light

131. Combined reverse lamp switch and auto-

150. Heated back-light warning lamp

153. Hazard warning switch.

154. Hazard warning flasher unit.

174. Starter solenoid relay.

back-light switch

matic transmission safety switch.

only).*

only.

(GT

Optional items.

CABLE COLOUR CODE

B. Black. U.

Blue.

Rrown.

When a cable has two colour code letters the first denotes the main

colour and the sefond denotes the tracer colour.

G. Green. W. White. P. Purple. Y. Yellow.

Red. L.G.Light Green.

Pink.

Page 59

WIRING DIAGRAM

(1973-74)

Page 60

WIRING DIAGRAM

(1972-73)

(Refer

page

for

key)

Page 61

WIRING DIAGRAM

(1971-72)

(Refer

page

for

key)

Page 62

WERING DIAGRAM

(1970-71)

(Refer to page

for key)

Page 63

Wiring Diagram (1

969-70)

(Refer

page

for

key)

Page 64

IGNITION

Ignition timing

Distributor

Fig.

The ignition timing is set dynamically to give optimum engine performance with efficient engine emission control. Electronic test equipment must be used to check the ignition timing setting and the automatic advance (see 'GENERAL DATA'). Checking and adjustment to the ignition timing setting should a Distributor or Dealer.

The dynamic ignition timing must be checked after cleaning, re-setting, or renewing of the distributor contacts.

(1)

Cleaning contacts. Inspect the contact points emery cloth or fine carborundum stone. Wipe the contacts clean with a fuel-

moistened cloth. Renew pitted or worn points.

Lubrication. Very lightly smear the pivot post grease. Add a few drops of oil through the hole lubricate the centrifugal weights and around the screw cam spindle (do not remove this screw as clearance is provided for oil to pass). Avoid over-lubricating. Carefully wipe away all surplus lubricant and see that the

contact breaker points are perfectly clean and dry.

Contact breaker gap. Turn the crankshaft until the points are fully open. Check the contact gap should be a sliding fit in the gap.

If the gap varies appreciably from the gauge thickness, slacken the contact plate securing screw (6) and adjust the gap by inserting a screwdriver in the notched

(7)

hole clockwise to increase the gap. Tighten the securing screw. Turn the crankshaft

recheck the gap. Refit the rotor, wipe the inside of the distributor cover

and clean and refit.

Contact set renewing. Removing. Remove the nut and both leads from the stud. Remove the securing screw (6) with its spring and plain washers, and lift off the one-piece contact set. If removal of the moving

contact only is required, leave the securing screw (6) in position.

(1)

with a feeler gauge (see 'GENERAL DATA'); the gauge

at the end of the plate and turning clockwise to decrease and anti-

and, if burned, clean with fine

(2)

and around the cam

(4) in the contact breaker plate to

(g),

lift the top insulating bush

carried out by

(5)

in the centre of the

(3)

with

Page 65

Fitting. Before fitting a new contact set, wipe the points clean with fuel or spirit. Lubricate the pivot post positioned below the spring loop. Position the contact set on the distributor plate and lightly tighten the securing screw the insulating bush so that they make contact with the spring and tighten the

(8).

nut

Set the contact gap.

(2)

and check that the insulating bush

(6).

Locate the lead terminals around

(9)

is correctly

Ignition

Sparking plugs

cables

Fig.

Whenever a new contact set has been fitted, recheck the gap after the first miles. During this period, the heel of the contact will have bedded in and reduced the gap.

The high-tension cables connecting the distributor to the sparking plugs may, after long use, show signs of perishing. They must then be replaced by the correct type of ignition cable.

The sparking plugs should be cleaned, preferably with an air-blast service unit.

Check the plug gaps, and reset if necessary to the recommended gap (see

'GENERAL DATA'). To reset, use a special Champion sparking plug gauge and

setting tool; move the side electrode, never the centre one. When refitting the plugs make sure that the washers are not defective in any

way. 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 overtighten a plug, but ensure that a good joint is made between the plug body, washer, and cylinder head. Wipe clean the outside of the plugs before reconnecting the

When fitting new sparking plugs ensure that only the recommended type and grade are used (see 'GENERAL DATA').

Fig.

H.T.

leads.

500

:....

Page 66

ENGINE

LUBRICATION

Checking

Fig.

The level of the oil in the englne sump is indicated by the dipst~ck

right-hand side of the engine. Maintain the level between the 'MAX' and 'MIN'

marks on the dipstick and never allow it to fall below the

(2)

The filler quick-action cap. The filler cap also incorporates a filter for the closed-circuit crankcase breathing intake.

is on the forward end of the rocker cover and is provided with

'MIN'

(1)

mark.

on the

Fig.

Draining

Filling

The oil level should always be checked before

To drain the engine oil, remove the drain plug at the rear of the sump. This operation should is warm.

Clean the drain plug; check that its copper sealing washer is in a satisfactory condition, and refit.

Fill the engine with the correct quantity of a recommended oil. Run the engine

for a short while, then allow it to stand for

level with the dipstick.

long journey.

(3)

located on the right-hand side

carried out while the engine

few minutes before checking the

Page 67

Oil

filter

The external oil filter is of the disposable cartridge type and is located on the right-hand side of the engine. Early cars are fitted with the renewable element type of filter.

Early Cars

Fig.

Later cars

Fig.

ITO renew the element, drain the filter by removing the plug

(1);

unscrew the filter body securing bolt (2) and lift off the body. Wash out the casing with petrol (gasoline), dry it before fitting a new element. Check that the sealing

(3)

and

(5)

rings

and the rubber washer

(4)

are in a satisfactory condition.

Reassemble the filter, ensuring that the components are correctly positioned.

To change the filter cartridge, unscrew the old filter cartridge head

(2)

and discard it. Smear the seal

(3)

of the new filter cartridge with oil,

(1)

from the filter

locate on the filter head (2) and tighten with the hands only.

DO NOT USE A SPANNER TO TIGHTEN. DO NOT OVERTIGHTEN.

Fig.

Page 68

Engine

FAN BELT

Tension

When correctly tensioned, a total deflection, under moderate hand pressure, of

in.

(12

mm.) should be possible at the midway point of the longest belt run

between the pulleys.

Adjusting

To adjust the belt tension, slacken the securing bolts

Fig.

nut

(2),

and move the alternator to the required position. Apply any leverage

necessary to drive end bracket (3), only and not to any other part; to avoid damaging the end bracket the lever used should preferably be of wood or soft metal. Tighten the bolts and re-check the belt tension. DO NOT OVERTENSION as this will impose an excess loading on the drive bearings and stretch the belt.

VALVE ROCKER CLEARANCE

Checking

Remove the rocker cover and insert a

Fig.

the valve rocker arms and valve stems (inset). The gauge should be a sliding fit

when the engine is cold. Check each clearance in the following order:

valve with No. 8 fully open. Check No. 8 valve with No. 1 fully open.

Adjusting

Check No.

Slacken the adjusting screw locknut in the opposite end of the rocker arm and

rotate the screw clockwise to reduce the clearance or anti-clockwise to increase it.

Retighten the locknut when the clearance is correct, holding the screw against

rotation with a screwdriver.

(l),

and the adjusting link

.015

in. (.38 mm.) feeler gauge between

,, 6 ,,

1, 7 1,

,, , 3 ,

2,)

591

Page 69

CRANKCASE EMISSION CONTROL

Oil filler cap

An air filter is incorporated in the oil filler cap

only as a complete assembly.

Fig.

(1).

The cap and filter are renewed

Closed circuit

breathing

Control valve

Testing

Servicing

Fig.

Crankcase breathing is by a direct connection from the oil separator to the

carburetters. Servicing is confined to the oil filler cap, as recommended in the

maintenance summary.

Early cars:

With the engine at normal operating temperature, run it at idling speed. Remove the oil filler cap. If the valve is functioning correctly the engine speed will rise slightly as the cap is removed, the change in speed being audibly noticeable. If no change in speed occurs, renew the valve or service it as follows.

(2)

Remove the spring clip

and dismantle the valve. Clean all metal parts with solvent (trichlorethylene, fuel, etc.). If deposits are difficult to remove, immerse in boiling water before applying the solvent. Do not use an abrasive.

(3)

Clean the diaphragm

with detergent or methylated spirit.

Replace components showing signs of wear or damage.

(4)

Reassemble the valve, making sure the metering needle

(5)

guides

and the diaphragm is seated correctly.

is in the cruciform

Fig.

Page 70

FUEL SYSTEM

AIR CLEANERS

Fig.

The elements of both air cleaners must be renewed kvery 12,000 miles (20000 km.)

or 12 months; more frequent changes may be necessary in dusty operating conditions.

Renewing

To renew an element, unscrew the bolts (1) securing the air cleaner assembly to the carburetter and lift it from the car. Remove the base plate (2) and withdraw the element. (3) Clean the inside of the casing

new element.

using

CARBURETTERS-Type HS4

Lubrication

Fig.

Each damper reservoir must be topped up periodically with a recommended

engine oil.

Unscrew the damper cap, withdraw the damper, and top up the reservoir until the oil level (arrowed) is Push the damper assembly back into position and screw the cap firmly into the reservoir.

Accelerator

Lubricate the carburetter accelerator and choke linkages and cables, and the accelerator pedal fulcrum.

Carburetter

tuning

Fig, 3 and

The efficient operation of theengine and any exhaust emission control equipment which may be fitted depends on correct carburetter settings, ignition timing,

valve rocker. clearance, distributor contact breaker and plug gaps. It is essential that these items are ckaked before adjusting the carburetters.

Carburetter tuning must mixture at idle speed. A reliable tachometer and a carburetter intake balancing meter should be used if possible.

Remove the air cleaners.

2. Top up the carburetter piston dampers if necessaiy with a recommended engine oil to the correct level.

3. Check that the throttle functions correctly.

Ensure that the mixture control (choke) will return fully, that the cable has

in. (2 mm.) free play

clearance exists between the fast idle screws (2) and the cams.

Under

(4)

thoroughly and reassemble

circumstances should heavy-bodied lubricant

in. (12

mm.)

above the top of the hollow piston rod.

confined to setting the idle and fast idle speeds

(1)

before it starts to pull on the lever and a small

used.

and

. .

Fig.

Page 71

5. Raise each carburetter piston lifting pin

(3),

release the pin and check that

the piston falls freely onto the bridge of the carburetter, indicated by a distinct metallic click. Consult your Distributor or Dealer if the piston fails to fall freely.

6. Connect a reliable tachometer.

'P'

Select

Start the engine and run it at a fast idle speed until it attains normal running

on Automatic transmission models.

temperature, then run it for a further five minutes.

Increase the engine speed to 2,500 r.p.m. for

seconds.

NOTE.-Tuning can now be commenced. If the adjustments cannot be completed within three minutes, increase the engine speed to 2,500 r.p.m. for

seconds and then continue tuning. Repeat this clearing procedure at three-minute intervals until tuning is completed.

Check the idle speed with a tachometer (see 'GENERAL DATA') and check the carburetters for balanced air intake using a balance meter.

10. If the balance is not correct, adjust by tuning the throttle adjusting screw (4) on one of the carburetters. Then adjust the idle speed by turning the throttle

adjusting screw (4) on each carburetter by the same amount until the correct idle speed is obtained. Recheck the carburetter balance. Check the throMe shaft pin clearance and adjust if necessary-see paragraph 15.

If a smooth idle at the correct speed and balance is not obtainable, adjust the idle speed mixture setting as follows:

11. Stop the engine. Remove each suction chamber and piston, and turn the jet

adjusting nut (5) up until the jets are flush with the bridge (6) of the carburetter or as high as possible without exceeding the bridge height. Ensure that both jets are in the same relative position to the bridge of their respective

carburetters. Turn the jet adjusting nut (5) on each carburetter down two

complete turns. Refit the piston and suction chambers and top up the piston damper oil levels.

NOTE.-This operation need not be carried out if it is known that the jets

are in the same relative position.

12. Re-start the engine and run it at idle speed.

Fia.

Page 72

Fuel

System

Turn the jet adjusting nut (5) on both carburetters in the same direction, one flat at a time, up to weaken or down to enrich, until the fastest speed is recorded on the tachometer. Now turn both nuts up slowly until the speed

just commences to fall. Turn the nuts down equally very slowly by the

minimum amount until the maximum speed is regained. Re-check the idle speed and carburetter intake balance; adjust as necessary

with the throttle adjusting screws. Set the throttle interconnection clamping levers so that the link pin is

0.012 in. (0.3 mm.) away from the lower edge of the forks (see inset, follows:

Stop the engine and slacken both clamping bolts (7) on the throttle spindle interconnection.

Insert a feeler gauge (9) of

in. (0.70 mm.) for Automatic transmission between the throttle shaft lever and the cold start interconnection rod. Move each lost motion pick-up lever in turn until the tag of the lever rests on the lower arm of the carburetter

throttle fork. Tighten the clamping bolts (7, Fig. that there is approximately in. (0.79 mm.) end-float on the interconnection rod. Remove the feeler gauge. The pins on the throttle spindle lever should then have clearance (8) in the throttle fork.

With the fast idle cams of both carburetters against their respective stops, set the cold start interconnection so that both cams commence to move

simultaneously.

With the fast idle cams against their stops check that a free movement (1) of the mixture control (choke) cable exists before the cable moves the cams.

Run the engine at 1,500 Pull out the mixture control (choke) until the linkage is about to move the

carburetter jets, and lock the control in this position.

Using the balancing meter to ensure equal adjustment, turn the fast idle

adjusting screws to give the correct fast idle speed (see 'GENERAL DATA').

Unlock and return the mixture control, and stop the engine. Refit the air cleaners.

0.060 in. (132 mm.) for Manual gearbox or 0.028

on each fork, ensuring

in. (1.59 mm.)

r.p.m. and check the carburetters for balance.

Page 73

Air pollution

control

The carburetter incorporates features which assist in reducing exhaust emissions. Maladjustment or the fitting of parts not to the required specification may render these features ineffective.

Lubrication

Accelerator

Carburetter

tuning

Fig. 6 and

Each damper reservoir must be topped up periodically with a recommended

Fig. 5 engine oil. Under no circumstances should

Unscrew the damper cap, withdraw the damper, and top up the reservoir until

the oil level (arrowed) is

Push the damper assembly back into position and screw the cap firmly into the

reservoir.

Lubricate the carburetter accelerator and choke linkages and cables, and the

accelerator pedal fulcrum.

The efficient operation of the engine and any exhaust emission control equipment

which may be fitted depends on correct carburetter settings, ignition timing,

valve rocker clearance, distributor contact breaker and plug gaps. It is essential

that these items are checked before adjusting the carburetters. Tuning of the carburetters is confined to setting the idle and fast idle speeds and

the mixture setting at idle speed. Adjustments should only be undertaken on cars required to conform with exhaust emission control regulations if the use of a reliable tachometer, carburetter balance meter and an exhaust gas analyser (CO meter) is. available.

1. Remove the air cleaners.

Top up the carburetter piston dampers with recommended engine oil to the correct level if necessary.

Check the throttle control for correct functioning.

in. (12 mm.) above the top of the hollow piston rod.

heavy-bodied

lubricant be used.

Fiu.

Page 74

Fuel

System

NOTE.-Tuning can now be commenced. If delay prevents the adjustment being completed within three minutes, increase the engine speed to 2,500 r.p.m. for thirty seconds and then continue tuning. Repeat this clearing procedure at threeminute intervals until tuning is completed.

10.

Ensure that the mixture control (choke) will return fully, that the cable has

in. free play exists between the fast idle screws and their cams when the cams are against their stops

5. Raise each carburetter piston with the lifting pin check that the piston falls freely onto the bridge of the carburetter, indicated by a distinct metallic click. If the piston fails to fall freely, consult your Distributor or Dealer.

Connect a reliable tachometer.

Start the engine and run it at a fast idle speed until it attains normal running

temperature then run it for a further five minutes.

8. Increase the engine speed to 2,500

Check the idle speed (tachometer) see 'GENERAL

carburetters for balanced air intake using a balance meter.

If the balance is not correct, adjust as follows: release a throttle connector

(9)

between the carburetters and turn the adjusting screw (5) on one of the carburetters until the balance is correct. Then adjust the idle speed by turning the throttle adjusting screw (5) on each carburetter by the same amount. Re-check the carburetter balance.

Check the throttle shaft pin clearance and adjust if necessary-see para-

graph (18).

(1)

before it starts to pull on the lever and a small clearance (2)

(3).

(4),

release the pin and

r.p.m. for thirty seconds.

DATA'

and check the

Page 75

If a smooth idle at the correct speed and balance is not obtainable, adjust the idle speed mixture setting as follows.

11.

Stop the engine. Remove each suction chambe~ and piston and screw the jet adjusting screw (6) in until the jets are flush with the bridge of the carburetter or as high as possible without exceeding the height of the bridge. Turn the

jet adjusting screw (6) on each carburetter clockwise

piston and suction chambers and top up the piston damper oil levels. NOTE.-This operation need not be carried out if it is known that the jets

are in the same relative position.

12. Restart the engine and run it at idle speed.

13. Turn the jet adjusting screw (6) on each carburetter clockwise to enrich or anti-clockwise to weaken, by the same amount until the fastest speed is indicated; turn each screw anti-clockwise until the engine speed just commences to fall. Turn each screw very slowly clockwise by the minimum amount until the maximum speed is regained.

14. Using the exhaust gas analyser, check that the percentage within the prescribed limits. If the reading falls outside the limits, reset both

jet adjusting screws by the minimum amount necessary to bring the reading just within the limits.

15. Re-check the idle speed and carburetter balance and adjust as necessary with the throttle adjusting screws.

16. Set the throttle interconnection clamping levers so that the link pin is ,012 in. away from the lower edge of the forks (see inset 10) as follows:

17. Stop the engine and slacken both clamping bolts (9) on the throttle spindle interconnection.

18.

Insert a 0.060 in. feeler gauge between the throttle shaft lever and the cold

start interconnection rod. Move each lost motion pick-up lever in turn until

the tag of the lever rests on the lower arm of the carburetter throttle fork. Tighten the clamping bolts (9, Fig. approximately in. end-float on the interconnection rod. Remove the feeler gauge. The pins on the throttle spindle lever should then have clearance (10) in the throttle fork.

19. With the fast idle cams of both set the cold start interconnection so that both cams commence to move

simultaneously.

20. With the fast idle cams against their stops check that a of the mixture control (choke) cable exists before the cable moves the cams.

21. Run the engine at 1,500 r.p.m. and check the carburetters for balance.

22. Pull out the mixture control (choke) until the arrow (7) marked on the cam is positioned under the fast idle adjusting screw

23. Using the balancing meter to ensure equal adjustment, turn the fast idle

adjusting screws to give the correct fast idle speed (see 'GENERAL DATA').

Stop the engine.

on each fork, ensuring that there is

carburetters against their respective stops,

2+ turns. Refit the

in. free movement

(8)

of each carburetter.

reading is

24. Refit the air cleaners.

Page 76

Fuel

FUEL

System

LINE

FILTER

The filter must be renewed every 12,000 miles

(20000

km.) or 12 months.

Renewing the

filter

Fig.

Remove the screw body. Slacken the hose clips and remove carburetter feed hose delivery hose

Fit the hoses to the new filter, ensuring that the end of the filter where the arrow is etched is connected to the carburetter feed hose secure the carburetter feed hose retaining clip to the body.

(1)

to release the carburetter feed hose retaining clip from the

(3)

from the filter

(4)

and discard the filter.

(2)

and fuel tank

(2).

Tighten the hose clips and

Fig.

Page 77

TRANSMISSION

EAR

BOX

Checking

Early cars:

lift the carpet on the right-hand side of the gearbox cover at the rear of the radio

Fig.

console and remove the rubber plug (2).

To gain access to the gearbox combined oil filler and dipstick

(l),

OVERDRIVE

Draining

Sump

Relief valve

Fig.

Later cars:

underneath the car, remove the filler/level plug Clean around the dipstick before removing it.

The oil level must

Remove the plug

filter

Drain the gearbox and overdrive unit. Clean the sump cover and its immediate surroundings.

Remove the cover securing screws, withdraw the cover

Clean all metallic particles from the two magnets fitted to the inside of the cover, wash the cover and filter in petrol (gasoline). Refit the filter and cover.

Remove the plug and the seal

filter

in. (12 (gasoline). Fit the filter to the relief valve, push the valve fully home and refit the plug and seal.

The correct level is at the bottom of the filler level plug hole. From

maintained at the

(3)

to drain the oil from the gearbox and overdrive unit.

(6),

mm.)

and remove the filter

withdraw the relief valve approximately

(7).

(8)

and check the oil level.

'HIGH'

mark on the dipstick.

(4)

and the filter

Wash the filter, plug and seal in petrol

(5).

Page 78

Transmission

Filling

Fill the gearbox and overdrive unit through the combined oil filler correct quantity of one of the recommended oils. Run the car for a short distance allow it to stand for a few minutes, then re-check the level with the dipstick.

AUTOMATIC TRANSMISSION

Dipstick This dipstick is housed in the filler tube located at the rear of the engine and

is accessible when the bonnet is raised.

Checking

The fluid level must be checked only while the transmission is at normal running temperature. With the car standing level apply the hand brake and move the

'P'.

selector lever to

Run the engine at idling speed and normal operating temperature for at least two minutes. With the engine still idling in dipstick from the filler tube and wipe it clean with a piece of paper or nylon material. Do not use rag.

Reinsert the dipstick, withdraw it again immediately and check the fluid level indication. The level must be maintained at the 'MAX' mark.

The difference between the 'MAX' and 'MIN' marks on the dipstick is equivalent

pint

(1.2

U.S.

pints;

litre).

Topping

When topping up use only a recommended Automatic Transmission Fluid.

Observe scrupulous cleanliness; DO NOT OVERFILL.

REAR AXLE

(1)

Checking A combined oil filler and level plug

Fig.

level must be maintained at the bottom of the plug aperture; ensure that the car

is located on the rear of the axle. The oil

is standing level when checking. After topping up the oil level, allow sufficient time for any surplus oil, which may have been added accidentally, to run out of the aperture before replacing the plug.

Ensure that the rear axle oil is not drained when the After-sales Service is carried out.

(1)

'P'

withdraw the

with the

PROPELLER SHAFT

Lubrication

Fig.

sliding yoke. To lubricate, give three or four strokes of a gun filled with a recommended grease.

Fio.

nipple

(1)

is provided at the front end of the propeller shaft for lubricating the

Fio.

Page 79

STEERING

Wheel

alignment

Fig.

Incorrect wheel alignment can cause excessive and uneven tyre wear.

The front wheels must be set so that the distance

(2.4

mm.) (toe in) less than the distance

(B).

(A)

in.

(1.6

mm.) to A in.

SUSPENSION

Lubrication

Fig.

Wheel alignment requires the use of a special gauge and this work should entrusted to your Distributor or Dealer.

The three lubricating nipples (arrowed) on each of the swivel pins sho~lld be

charged periodically with one of the recommended greases.

Fig.

Page 80

TUNING MODIFICATIONS

Owners

Service

Statement

Air

pollution,

noise, safety

regulations

The car as delivered from the factory in its standard form is tuned to give maximum performance with complete reliability, but any super-tuning must inevitably tend to reduce this reliability. For this reason the new car

Service Statement will be invalidated by any form of super-tuning.

Owners are reminded that in some countries legislation exists covering air pollution, safety or noise limitations on motor vehicles.

tuned or modified,

alterations and additions are either approved by the appropriate authority for use on the road, or do not contravene the standards set by legislation.

Leyland ST Pluspacs are obtainable from your Leyland

Replacement parts and additional parts are designated when a replacement is required advise your Dealer that a Leyland ST Pluspart is required.

Full details of progressive stages of tune and Pluspacs are contained in

Tuning Booklet C-AKD

For further details see your Dealer or ST Stockist or write to:

Leyland

Abingdon-on-Thames, Oxfordshire OX1 4 1 AU

it is the owner's responsibility to ensure that the proposed

4034.

Before a car is super-

Distributor/Stockist.

Leyland ST Plusparts,

Owners

Page 81

GENERAL DATA

The vehicle specification may vary according to market requirements and from model to model. The manufacturers reserve the right to alter specifications with or without notice at any time. The policy of constant product improvement by the manufacturers may involve major or minor changes to the vehicle specification. Whilst every effort is made to ensure accuracy of the particulars contained in this Handbook, no liability for inaccuracies or the consequences thereof can be accepted by the manufacturer or the Dealer or Distributor who supplied the Handbook. During running-in from new certain adjustments vary from the specification figures detailed. They will be set to specification by your Dealer or Distributor at the After Sales Free Service and should thereafter be maintained throughout

the car's life.

Engine

Ignition

Type

....

Early cars

....

Bore Stroke No. of cylinders Capacity Compression ratio

High compression

18V* (all types) 18GG, 18GD*

Low compression

18V (earlv cars).

Firing order

Valve clearance (hot)

Oil pressure: Idling Idling setting:

18V 779F, 18V 780F* 18V* (early cars) 18GG, 18GD*

Fast idle setting:

18V779Fand18V780F* 18V (early cars), 18GG, 18GD*.

Static ignition timing:

High compression:

18V779F, 18V780F*

18V (early cars), 18GG, 18GD*

Low compression

18V* (early cars) 18GG,18GD*..

Stroboscopic timing (with vacuum disconnected):

High compression:

18V 779F, 18V 780F* 18V* (early cars) 18GG,18GD*..

Low compression

18V* (early cars)

18GG, 18GD*

Contact breaker gap Sparking plugs Plug gap

. . . . . .

.... . . . .

. . . . . .

. .

. . . .

. .

. . ..

. .

18V 779F and 18V 780F* 18V 581F, 18V 582F and 18V 583F* 18V 581Y, 18V 582Y, and 18V 583Y* 18GG and 18GD*

3.16 in. (80.26 mm.)

. .

3.5 in. (89 mm.)

. .

1798

. . . .

(cold)

Normal

. . . .

Denotes engine number prefix.

. .

. ..

. . . .

1,3,4,2

0.015 in. (.038 mm.)

0.015 mm. (0.33 mm.)

. .

10 to 25 lb./sq. in. (0.7 to 1.7 kg./~rn.~)

50 to 80 lb./sq. in. (3.5 to 5.6 kg./cma)

. . . .

......

....

750 to 800 r.p.m.

500 r.p.m.

1,100 r.p.m.

....

. . .

.. . .

. . ..

. .

......

. .

....

6"B.T.D.C.

10" B.T.D.C. 10" B.T.D.C.

8" B.T.D.C.

11" B.T.D.C. at 1,000 r.p.m.

. .

13" B.T.D.C. at 600 r.p.m.

14" B.T.D.C. at 600 r.p.m.

13" B.T.D.C. at 600 r.p.m. 12" B.T.D.C. at 600 r.p.m.

. .

0.014 to 0.016 in. (0.36 to 0.41

. .

Champion N-9Y 0025 in. (0.64 mm.)

850 r,p.m.

1,100to1,200r.p.m.

C.C.

(109.8 cu. in.)

mm.)

Page 82

General

Data

Fuel system

Gearbox and

overdrive

Capacities

Carburetters:

18V 779F, 18V 780F* 18V 581F, 18V 582F, 18V 583F* Two S.U. type HS4 18V

581Y, 18V 582Y, 18V 583Y* Two S.U. type HIF4

18GG, 18GD*

Needle: 18V* (all types) Fuel pump

Recommended octane rating Exhaust gas content (carbon mon-

Overdrive ratio Overall ratios: First

Top gear speed per 1,000 r.p.m.:

Fuel tank Cooling system Cooling system with heater. Sump: 18V* engines

Sump with cooler:

Gearbox Gearbox and overdrive Automatic transmission Rear axle

18GG, 18GD*

. . . . . .

oxide) at idle speed

Second

Third

Fourth Reverse

Standard Overdrive

. .

. . . .

. .

18GG, 18GD* engines

18V* engines 18GG, 18GD* engines

. . .

. . . . .

. . . .

. . . . . .

. . ..

. . .

. .

. . ..

. . . . . .

. . . .

. . .

. .

. . .

. . . . . .

. . .

.. ..

. . .

. .

. . .

. .

. . .

. .

. . .

Two S.U. type HIF4

Two S.U. type HS4 AAU FX

S.U. Type HP or AUF 300 electric 98 and above

3to4.5%

0.82 : 1

13.45

8.47

5.4 : 1 4.43 : 1

. . .

1 3.2 : 1

3.909

12.098

12 gallons (54 litres, 14 U.S. gal.) 9: pints (5.4 litres, 11.4 U.S. pints) 10 pints (5.6 litres, 12 U.S. pints) 5f pints (3 litres, 6.3 U.S. pints) 72 pints (4.26 litres, 9 U.S. pints)

6 pints (3.4 litres, 7.25 U.S. pints) 84 pints (4.5 litres, 9.6 U.S. pints) 5% pints (3 litres, 6 U.S. pints)

pints (3.4 litres, 7 U.S. pints) 10: pints (6 litres, 12.7 U.S. pints) 1: pints (0.85 litre, 2 U.S. pints)

Overdrive

Dimensions

Wheels

Length Length with over-riders Width Height, hood erected Ground clearance (minimum)

Track: Front

Wheelbase Turning circle-kerb to kerb Toe-in

Type:

Pressed disc Pressed spoked Wire (optional)

. . . . . .

Rear

. . .

. . . . .

. . .

. .

. . .

Denotes engine number prefix:

. .

. . .

. .

12 ft. 84 in. (3.8 m.)

12 ft. 9& in. (3.89 m.)

4 ft. 11 in. (152.3 cm.)

4 ft. 14 in. (125.4 cm.)

5 in. (12.7 cm.)

4 ft. 1 in. (124.4 cm.)

. .

4 ft. If in. (125.0 cm.)

. .

7 ft. 7 in. (231.1 cm.)

. .

32ft. (9.75 m.)

to & in. (1.6 to 2.4 mm.)

. .

4J X l4 (Tourer) 5J X 14 (GT)

5JF/Hx14

4+J X 14 (60-spoke)

Page 83

Tyre pressures

5.60-148

Cross-ply tyres Radial-ply tyres

Front

Rear

155SR-14

Front

Rear

19 lb./sq. in.

(1.34 kg./cm?)

Maximum weight

Normal

car

Maximum weight

is recommended that for sustained speeds at or near the maximum the above tyre pressures

increased

Weiahts

weight

by 6 Ib./sq. in. (.42 kg./~m.~).

19 Ib./sq. in.

(1.34 kg./crn.')

20 Ib./sq. in.

(1.4 kg./cm.=)

20 Ib./sq. in.

(1.4

condition

rnding

kg./cm.*)

2,347 lb.

(1065 kg.:

2,647 lb.

(1201 kg.:

2,797 lb.

(1269 kg.:

jNO-l

fuel tank and all optional extras

Kerbside weight including driver and passenger

Maximum weight

condition-refer

(1.55 kg./cm.*) (1.69 kg./cme)

(1.69 kg./cma) (1.83

Total weight

Tourer

22 Ib./sq. in.

24 Ib./sq. in.

24 Ib./sq. in. 26 Ib./sq. in.

kg./cm2)

21 Ib./sq. in.

(1.48 kg./cma)

21 Ib./sq. in.

kg./~m.~)

(1.48

Tyre size 165SR-14 Pressures as Tourer

Front

(1.69 kg./crn.=) (1.83

Distribution

24 lb./sq. in. 26 Ib./sq. in.

kg./cmP)

are

Maximum permissible towing weight

Maximum towbar hitch load

Maximum roof rack load

1,680 lb.

(762 kg.)

1,680 lb.

100 lb.

50 lb.

NOTE: Due consideration must

Any load carried on a luggage rack (Tourer) or roof rack

hitch must also

included in the maximum loading.

given to the overall weight carried when fully loading the car.

(GT)

or downward load from a towing

Page 84

ROUTINE MAINTENANCE SUMMARY

LEYCARE SERVICE

British Leyland Distributors and Dealers operating Leycare Service will, on request, provide a copy of the Leycare Service Job Sheet giving exact details of the work carried out at the prescribed interval and of any further work required. Leycare Service Job Sheets are updated routine maintenance are introduced and as a result may differ from the Maintenance Summary content published in this Handbook.

Detailed maintenance instructions will In addition to the periodic maintenance the following checks should

Checkltop up engine oil (64) Checkltop up brake fluid reservoir (41) ternal cuts in fabric, exposure of ply or cord Checkltop up battery electrolyte (45, 103) structure, lumps and bulges Check/top up cooling system (35) Checkladjust tyre pressures, including spare Checkltop up washer reservoir (55) Check function of original eauivment. i.e. ex-

terior lamps, wiper< and warning indicators

found on the page in brackets after each item.

Check tyres for tread depth, visually for ex-

(40, 81)

Check tightness of wheel fastenings (37)

MAINTENANCE INTERVALS

Carry out the services indicated by X in column

A at 6,000-mile B

at 12,000-mile (20000-km) or 12-month intervals

(10000-km.)

or 6-month intervals

Items included in the 3,000-mile (5000-km.) or 3-month interval

Inspection Check are indicated in

column C

ENGINE

Checkltop up engine oil (64) Renew engine oil and filter (65)

Renew carburetter air cleaner elements (68) ..........................................................

Top up carburetter piston dampers (68 and 71)

Checkladjust carburetter idle speed and mixture settings (68 and 71) Renew fuel filter (74) Clean and test crankcase breather valve (67) Renew engine filler cap

Checkladjust valve clearances (66)

Check cooling/heater systems for leaks and hoses for security and

cond~t~on Checkltop up cooling system (35) Checkladjust operation of screen washers and top up reservoir (55) Check driving belt; adjust or renew (66) Lubricate accelerator control linkage (and pedal pivot)--check

operat~on (88)

..............................................................................................................

..................................................................................................

......................................................................................

...................................

....................................................................................................

(67)

........................................................................................

............................................................................

....................................................................

............................

......................................................

.................................*.....

................................................

...

modifications affecting

made weekly:

....

.....

....

.....

..........

......................

............

.....

....

.....

....

.....

....

.....

....

.....

....

IGNITION

Clean/adjust spark plugs (63) Renew spark plugs (63) Check distributor points; adjust or renew (62) Lubricate distributor (62) Checkladjust ignition timing and distributor characteristics using

electronic equipment

..............................................................................

................................................................................................

......................................................................................

*..

..............................................

TRANSMISSION

Checkltop up gearbox and rear axle oil (75 and 76) Checkltop up clutch fluid reservior (41) Lubricate propeller shaft Checkltov UD automatic gearbox fluid Check' automatic gearboxparking pawl engagement Gearbox with overdrive--drain, clean filters, and fill with new oil (75)

- -

......................................................................................

..........................................................

...........................................................

...................................... X ....

....

.....

..,..

....

.....

..,..

X..

.....

....

.....

....

.....

....

........

Every 24,000 miles

Page 85

STEERING AND SUSPENSION

Check steering rack for oil leaks Check hydraulic dampers for fluid leaks

..........................

............................................................

Check condition and security of steering unit joints and gaiters Checkladjust front wheel alignment Lubricate all grease points, excluding hubs

.........................................................

(77)*

(86)

........................................

....

.....................

..................................................

BRAKES

Check visually hydraulic pipes and unions for chafing, leaks and

corrosion Check/top up brake fluid reservoir Check/adjust foot brake and hand brake operation Inspect brake pads for wear, discs for condition Ins~ect brake linings/pads for wear, drums/discs for condition

42)

Lubricate hand brake mechanical linkage (and cables) Clean servo filter element

..............................................................................................................

..............................................................................................................................

....................................................................................

(43)

............................................................

(41)

(42

and

..........................................

(41)

(37)

....................

43) (41

and

..........................

ELECTRICAL

Check function of orlginal equipment, i.e. interior and exterior lamps,

screen wipers, horns, and warning indicators

Checkltop up battery electrolyte

Clean and grease battery connections Checkladjust headlamp alignment

(45, 103)

..................................................................

(48)*

Check, if necessary renew, windscreen wiper blades

EXHAUST,

FUEL AND CLUTCH PIPES

.................................................

........................................................

...........................................................

..................................

(54)

Check visually fuel and clutch pipes and unions for chafing, leaks and

corrosion Check exhaust system for leakage and security Check fuel filler pipeltank connections

..............................................................................................................

..................................................

................................................................

WHEELS AND TYRES

Check that tyres comply with manufacturer's specification Check/adjust tyre pressures including spare

(40, 81)

........................................

......................

(81)

Check tyres for tread depth, visually for cuts in fabric, exposure of ply

or cord structure, lumps or bulges Check tightness of road wheel fastenings

....................................................................

....................................................

(37)

BODY

Lubricate all locks and hinges

(not steering lock)

Check condition and security of seats and seat belts Check rear view mirrors for cracks and crazing

..............................................

..........................................

..................................................

GENERAL

Road/roller test and check function of all instrumentation

.........................

X X... X X X

X... X

X....

X..

X X.. X

X X X

X X

X X X

....

.... X .....

....

.....

.............

....

.....

.... X .....

.............

.... X .....

....

.....

.............

....

.....

.... X .....

....

X...

.... X .....

....

X..

....

.....

.... X .....

.............

....

.....

...

.....

.............

...

Your Distributor or Dealer 'should check these items

NOTE: Take the advice of your Distributor or Dealer on the need

More frequent engine oil changes;

Additional brake maintenance.

for:

Page 86

SERVICE

Identification When communicating with your Distributor or Dealer always quote the car

Service parts Genuine BRITISH LEYLAND and UMPART parts and accessories are designed

accessories Owner's Service Statement. ONLY WHEN GENUINE BRITISH LEYLAND

engine numbers. When the communication concerns the transmission units or body details it is necessary to quote also the transmission casing and

Car number. Stamped on a plate secured to the left-hand inner wheel arch, under the

Engine number. Stamped on a plate secured to the right-hand side of the cylinder block, or stamped directly onto the cylinder block.

Gearbox number. Stamped on the left-hand side of the gearbox casing. Rear axle number. Stamped on the front of the left-hand rear axle tube near the

spring seating.

and and tested for your vehicle and have the full backing of the British Leyland

AND UNIPART PARTS SIDERED UNDER THE TERMS OF

For more information on UNIPART, see your British Leyland Distributor or Dealer.

Genuine British Leyland and UNIPART parts and accessories are supplied in cartons and packs bearing either or both of these symbols.

bonnet.

ARE

USED CAN RESPONSIBILITY BE CON-

THE

STATEMENT.

body

numbers.

and

Safety features embodied in the car may be impaired if other than genuine parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the vehicle manufacturer's specification. Owners purchasing accessories while travelling abroad should ensure that the accessory and its fitted location on the car conform to mandatory requirements existing in their country of origin.

Page 87

Service

Exchange

Scheme

The Service Exchange Scheme has been designed as a m6ney-saver. Your Distributor or Dealer will supply any exchange assembly offered for your

vehicle at a price which allows for the return of the old one to us for rebuilding to 'as new' standard, at one of our specialist factories or by the original supplier.

The use of this technique reduces the cost but not the quality, and each replacement assembly carries the same warranty as a new one.

Ask your Distributor or Dealer for full details and for examples of the money you can save by taking advantage of the Service Exchange Scheme.

Supplementary

tool

kit

UNIPART

car care

A UNIPART Tool Kit is obtainable from all Distributors and Dealers. The kit, in a waterproof roll, contains the following tools:

combination spanners

adjustable spanner

pairs pliers

This kit can hand tools which are also available.

Use of the following products selected from the UNIPART range will ensure maximum effectiveness in maintaining the appearance and condition of your car.

Engine grime and grease Carpets Seats and trim Headlining Washing

Glass . .

Bodywork

Chrome and bright trim . .

Winter

Iced-up windscreen and windows Washer reservoir

supplemented from a comprehensive range of UNIPART quality

......

........

......

........

....

aids:

. . .

screwdrivers

feeler gauge set

UNIPART Engine Cleaner UNIPART Upholstery Cleaner

....

UNIPART Car Shampoo UNIPART Car Sponges UNIPART Chamois-leather

UNIPART Glass Cleaner UNIPART Hi-shine Car Polish UNIPART Chrome Cleaner

UNIPART De-icer Spray UNIPART Four Seasons Screen

wash

Page 88

LUBRICATION

Engine

S.A.E.

VISCOSITY

The lubrication systems of your new car are filled with high quality oils. You should always use gearbox and rear axle during subsequent maintenance operations or when topping up. The use of oils not to the recommended specification can lead to high oil and fuel consumption and, ultimately, damage to the engine, gearbox or rear axle components.

Oils to the recommended specification contain additives which disperse the

corrosive acids formed by combustion and also prevent the formation of sludge

which can block oilways. intervals must

Use a well known brand of oil to B.L.S. O.L.

SE quality, with a viscosity band spanning the temperature range of your locality.

high quality oil of the correct viscosity range in the engine,

adhered to.

Additional oil additives should not

O.R.

or MIL-L-2104B or A.P.1.

used.

Servicing

Synchromesh

gearbox

Automatic

transmission

Rear axle and

steering rack

Grease points

Use the same oil selected for the engine.

Use Automatic Transmission Fluid Type F.

Top up and refill with (MIL-L-2105B) below -5°C (20°F).

Use Multipurpose Lithium Grease N.L.G.l consistency No. 2.

H.D.

90 (MIL-L-2105B) above - 10°C (10°F) or

H.D.

Page 89

~omponent

Climatic

conditions Minimum

performance

level

SERVICE LUBRICANTS

Engine. Synchromesh Gearbox and Carburetter

All temperatures Temperatures

above -10°C. 10" to -20°C

(15°F) (50" to -5°F)

British Leyland Service Fill Lubricating Oil Specification for Passenger Car and Light Commercial Petrol engines

BLS L02

All temperatures

below -10°C

(15°F)

Rear Axle and Stedng Gear Grease Points Lubricatm I Transmission

All temperatures

above -10°C

(15°F)

MIL-G2105B

All temperatures

below -10°C

(15°F)

MIL-G21OSB

All

conditions

Multipurpose

Lithium Grease

N.L.G.I.

Upper Cyl/nder I Automatic

All

conditions

Upper Cylinder

Lubricant

Transmission Fluid Tvoe F

*l!

condltlons

Automatic

CASTROL

ESSO

MOBIL

TEXACO Havoline Havoline

PETROMNA Fina Fina

CRISWl20

Esso Uniflo

lOW/SO

Mobiloil

Special 20W/50 Super 10W/50

or Suuer 10W/50

BP Super BP Super,

Visco-Static Visco-Statrc

20150 10W/30 or

or low140 10W/40

2OWI5O or IOW140

10W/40

Supergrade Supergradc

20W/50 or 10W/50 or

Esso Uniflo

~astrolite

Duckhams

lOW/SO

Mobiloil

lOW/SO

Castrol GTZ

Esso Extra

Motor Oil

SW120

Mobiloil Mobilube Mobilube Mobilgrease

SW120

BP Super

Visco-Static

BP Super

'isco-Static SW120

Shell Super

SW130

Duckhams

5-30

Havoline

SW130

Fina

Supergrade

SW120

Castrol

Hypoy B 90

Gear Oil

GX 90/140

HD90

Hypogear 90

Shell Spirax

Heavy Duty 90

Duckhams

Hypoid 90s

Multigear Lubricant

EP 90

Fina

Pentonic

XP 90-140

Castrol

Hypoy B 80

Esso Gear Oil GX 80

HD8O

BP Hypogear 80

Shell Spirax

Heavy Duty 80

Duckhams

Hypoid 80s

Multigear Lubricant

EP 80

Fina

Pentonic

MP 80

Castrol LM

Multi-purpose

BP Energrease

Shell Retinax A

Duckhams

LB 10 Grease

All Purpose

Grease

Esso

Grease

MP or MS Upperlube ATF 210

L 2

Marfak

Fina

HLT 2

Castrollo

Esso

Upper Cylinder

Lubricant

Mobil

BP Upper

Cylinder

Lubricant

Shell

Upper Cylinder

Lubricant

Duckhams

Adcoid Liquid

Special

upper

Cyhnder

Lubricant

Fina

Cyltonic

Castrol TQF

Esso Glide

Mobil

BP Autran B

Shell

Donax T

Duckhams

Q-matic

Texmatic

Type F

Fina

Purfimatic

Page 90

Lubrication

IND

2316

Page 91

NOTE.-Ensure that the vehicle is standing on a level surface when checking the oil levels.

Weekly

(1)

ENGINE. Check oil level, and top up if necessary

Every

6,000

miles or 6 months

(2)

ENGINE. Drain and refill with new oil.

(3)

ENGINE OIL FILTER. Remove the disposable cartridge, fit new. Early cars: Drain filter, wash filter bowl in fuel and fit new element.

(4)

CARBURETTERS. Top up carburetter piston dampers.

(5)

ACCELERATOR. Lubricate accelerator control linkage, cable and pedal fulcrum.

(6)

DISTRIBUTOR. Lubricate all parts as necessary.

(7)

REAR AXLE. Check oil level, and top up if necessary.

(g)

GEARBOX AND OVERDRIVE. Check oil level, and top up if necessary.

(9)

AUTOMATIC TRANSMISSION. Check fluid level, and top up if necessary.

(10)

FRONT SUSPENSION

(11)

HAND BRAKE CABLE AND MECHANICAL LINKAGE

nipples)

nipple)

Give three or four strokes with a grease gun.

(12)

PROPELLER SHAFT LOCKS AND HINGES. Lubricate the bonnet release safety catch and all locks and hinges.

nipple)

Do not oil the steering lock.

Every

24,000

miles or

(13)

GEARBOX WITH OVERDRIVE. Drain, clean overdrive filters and refill with new oil-

ref. page

Optional lubrication

(1)

ENGINE.

59.

Check

months

3,000

miles or 3 months

oil level and top up if necessary.

Recommended oils and greases are given on page

87.

Page 92

SUPPLEMENT FOR EARLY CARS

HOODS

!Standard

It is most important that the instructions given for raising, lowering, and folding

the hood are followed. Do not use undue force on the hood frame members. Do

fold

stow the hood when

Removing. Release the press studs on the windscreen frame and hood hinge

hood

frame members (see Fig. (inset, Fig.

1).

is wet

damp.

1).

Open the toggle catches on the windscreen rail

Release the four fasteners from each rear quarter panel, and pull each hood quarter-light slightly forward to disengage the retaining clips from the sockets on the body side panels (Fig.

2).

Slide the rear edge of the hood backwards to clear

the slotted anchor plates on the tonneau panel and lift the hood from its frame.

Lay the hood on the luggage compartment lid (the inside linings upwards) and fold the back-light and quarter-lights as shown (Fig.

3).

Carefully roll up the hood, commencing at the back-light. Close the hood frame, lift it from the wpport sockets and separate the two halves.

Place the hood and frame in

their respective stowage bags and stow in the

luggage compartment.

Fig.

not

Page 93

Fitting.

Assemble the frame and mount it in the support sockets with the highest

stick to the front, then pull the front stick forward (Fig.

4).

Unfold the hood and lay it over the frame. Engage the rear edge of the hood with the slotted anchor plates on the tonneau panel.

Engage the hood quarter-light clips in their retaining sockets on the body side panels and secure the four fasteners on each rear quarter panel. Pull the hood

header rail forward and engage the toggle fastener tongues in their sockets on

the windscreen frame. Check that the rubber sealing strip is correctly positioned

forward of the windscreen frame, then fasten the toggle catches.

Move the rear stick back, and press down the connecting links. Secure the hood

with the press-stud fasteners on the windscreen pillars and hood frame.

Optional hood Lowering the hood.

hood frame, and hood hinge plates (Fig. toggle catches (inset, Fig.

Release the four fasteners from each rear quarter panel, pull the hood slightly

forward to disengage the clips from the sockets on the body side panels. Move the seats forward, release the operating lever, and incline the squabs to-

wards the front of the car. From inside the car, pull the header rail back sufficiently to allow the hood rear

rail to be disengaged from the slotted anchor plates on the tonneau panel (see

6).

Fig. Fold the quarter-lights onto the back-light, ensuring that the fdds are formed

in the hood material, then continue the folds along the hood forward to the

header rail (Fig.

Push the hinge link inwards and at the same time pull the front frame stick rearwards, then pull the header rail towards the rear keeping the hood material clear of the frame. As the frame is collapsed into the rear cockpit allow the back-light and hood material to pass down onto the rear seat.

Roll tip the back-light and quarter-lights, folding the hood material to protect it. Secure the hood with the straps attached to the rear cockpit panel and fit the hood cover.

Fig.

Release the press-stud fasteners from the windscreen pillars.

5).

Release the windscreen frame

5).

7).

Fig.

Page 94

Supplement

for Early Cars

Fitting the sockets with the cross-rod towards the rear (Fig.

Lay the hood cover over the tonneau rail and engage the rear edge retainer with the two slotted anchor plates on the tonneau panel.

Engage the hood cover clips with their sockets on the body side panels and secure the four fasteners on each rear quarter panel.

Secure the press-stud fasteners on the rear cockpit side panels. Removing the hood cover. Reverse the fitting procedure. Raising the hood. Move the seats forward. Release the hood securing straps, and

lift the hood header rail Pull the rear of the hood back allowing the back-light to unroll, rest it on the

tonneau panel, and unfold the quarler-lights. Engage the hood rear rail with the slotted anchor plates on the tonneau panel. Engage the hood quarter-light clips in their retaining sockets on the body side

panels.

Move the header rail forward to an approximately half-way position. Return the seats to

From inside the car move the header rail upwards; at the same time assist the extension of the frame hinge links by pressing outwards on the link hinges and forward on the front frame stick. Straighten the hinge links, and p~~ll the header

rail fully forward after first moving the sun visors to one side. Engage the toggle fastener tongues in their sockets on the windscreen frame,

check that the rubber sealing strip is correctly positioned forward of the windscreen frame, and then fasten the toggle catches. Secure the press-stud fasteners to the windscreen pillars, hood frame, and hood hinge plates. Secure the four fasteners on each rear quarter panel.

hood

cover. Assemble the tonneau rall and fit it into the hood support

~~pwards from the rear cockpit.

normal position.

8).

Fig.

Page 95

From Car No. GHN4-158371 (Tourer), and from Car No. GHD4-158231 (GT)

for

(Refer to page

key)

Page 96

Supplement

for Early Cars

EARLY CARS

(Refer

page

for key)

Page 97

SUPPLEMENT

ABSORBING

BUMPERS

FOR

CARS

WITH INIPACT-

CONTROLS AND SWITCHES

. .

Controls Ignition starter switch and steering lock Fascia switches Console switches Steering-column switches

INSTRUMENTS AND WARNING LAMPS

Instruments Warning lamps

ELECTRICAL

Battery Headlamps Pilot lamp Direction indicator lamp Number-plate lamp Panel

and

warning lamp

Redacement bulbs

IGNITION

Distributor

GENERAL DATA

Engine Ignition

Fuel system Dimensions Weights

....

...... . .

...... .... . .

. . .

. . . . . .

. .

. . .

. .

.... . .

. .

. . .

. ......

....

. . . . . .

. .

. . . . . . .

..........

....

. . . .

. .

....

. .

. . . . . .

. . .

. . . . . .

......

. . .

. .

. . .

. . . .

. . .

....

. . . . . . .

. . . .

. . . . . . . .

. . . .

.... . .

. . .

. .

Page

96 97 98 99

100

WIRING DIAGRAM

Page 98

Supplement for Cars with Impact-absorbing Bumpers

CONTROLS

Gear lever

Hand brake

(2)

Pedals

(3)

(4)

(5)

control (choke)

Mixture

(61

Fig.

The gear positions are indicated on the lever knob. To engage reverse gear move

)

the lever to the left in the neutral position until resistance is felt, apply further side pressure to overcome the resistance and then pull the lever back to engage the

gear. The reverse lights operate automatically when reverse is selected with the ignition switched on.

Synchromesh engagement is provided on all forward gears.

The hand brake is of the pull-up lever type, operatin mechanically on the rear

wheels only. To release the hand brake, pull the lever up slightly, depress the

button on the end of the lever and ~ush the lever down.

The brake pedal operates the brake hydraulic system and applies the brakes on all four wheels. The brake stop warning lights function automatically when the brake

pedal is depressed with the ignition switched on.

Use the control to enrich the mixture and assist starting when the engine is cold. The fuellair mixture is progressively enriched as the control is pulled out.

Pull out the control to the required position and lock it by turning the control clockwise one-quarter of a turn.

'OFF'

To re-position the control or return it to the

position, turn the knob

anti-clockwise one-quarter of a turn and push inwards.

DO NOT

Notes on the use of the control are given in

MOVE

the control in or out whilst it is in the 'locked' position.

'RUNNING INSTRUCTIONS'.

Fig.

Page 99

IGNITION STARTER SWITCH AND STEERING LOCK

Key

number

The key number appears on the key, on the number tag supplied or on a label attached to the windscreen of a new car.

NOTE THE KEY NUMBER in your DIARY and in a reference book at HOME and then REMOVE THE LABEL FROM THE CAR. Consult your Distributor1 Dealer regarding key replacements for the steering-column lock.

Fig.

Unlocking

Ignition and

Locking

Fig.

The steering-column lock

(4),

if used properly, will greatly reduce the possibility

of the car being stolen.

To unlock the steering, insert the key and turn it to position

'1'.

wheel has been turned to engage the lock, slight movement of the steering-wheel will assist disengagement of the lock plunger.

'I'

With the key in the position marked

the ignition is switched off and the steering lock disengaged. The heater blower motor, windscreen wipers/washers, and the radio may be operated with the key in this position. The key must this position when towing the car for recovery.

To switch on the ignition, turn the key to position

spring resistance to position

start

'111'

operates the starter motor. Release the key

'11'.

Further movement against

immediately the engine starts.

To lock the steering, turn the key anti-clockwise to the position marked

the button

WARNING.

(5),

turn the key to the

'0'

position and withdraw it.

The steering lock/ignition/starter switch and its electrical circuits are designed to prevent the ignition system and starter from being energized while the steering lock is engaged. Serious consequences could substitution of the steering lock/ignition switch or its wiring.

re@ from alterations or

must the ignition switch be separated from the steering lock.

Do not lubricate the steering lock.

If the steering-

'I',

press

no circumstances

Page 100

Supplement for Cars with Impact-absorbing Bumpers

FASCIA SWITCHES

Blower switch

and heater

controls

Lighting switch

Panel

lamp switch

For operating instructions see

Press the lower end of the switch rocker to the first position to switch on the side

(2)

and tail lamps, and to the second position to switch on the headlamps.

With the side lamps switched on, illumination of the instruments may be varied

by rotating the panel lamp switch knob. Turning the switch knob clockwise

switches on the panel lamps; further clockwise movement of the knob reduces

(3)

the light brilliance.

Fig.

'HEATING AND VENTILATING'.

MG GHN5, GHN4, MGB GT GHD5, MGB GT GHD4 User Manual

FOREWORD

CONTENTS

CONTROLS

INSTRUMENTS

SWITCHES

SEATS

RUNNING INSTRUCTIONS

AUTOMATIC TRANSMISSION

CLEANING

COOLING SYSTEM

BRAKES

ELECTRICAL

WIRING DIAGRAMS

IGNITION

ENGINE

FUEL SYSTEM

TRANSMISSION

TUNING MODIFICATIONS

GENERAL DATA

ROUTINE MAINTENANCE SUMMARY

SERVICE

LUBRICATION