MG Midget 1979 User Manual

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Page 1

Page 2

DGET

MARK

III

(GAN

6UL)

Driver's

Handbook

Publication Part No. AKM

4386

British

Leyland

Motors

Inc.

500 Wi

llow

Tree Road, Leonia

New

Jersey

07605

BRITISH

LEYLAND

UK LI

MITED

197 8

BRITISH

LEYLAND

UK LI

MITED

197 8

Page 3

WARNING Many

liquids

and

other

substances

usedinmotor

vehicles

are

poisonous

and

should

under

no circumstances be consumed

and

shouldsofar

as possible be

~ept

a~ay.

fro~.

open

.wo~n'!S.

These

s~bstan~~~.among

others

incl';lde

~nti-

FOREWORD

This

Handbook

provides an

introductiontoyour

car,

together

with

information

on the care u

periodic maintenance required to

combine

trouble-free

motoring

with minimal

running

costs.

Claims

for the replacementofparts

under

warranty

must

be submitted to the

supplying

authoriz I

AustinMG

Dealer, or

when

this is

not

possible, to

the

nearest

authorized

AustinMGD al

~I"

informing

themofthe

vendor's

name

and

address. Except in emergency,

warranty

work

h uld

always be carried

out

by an

appointed

authorized

AustinMGDealer.

By keeping the

Passport

to Service, signed by the

authorized

AustinMGDealer, or

vendor

in til'

vehicle, you

can

quickly establish the

dateofpurchase

and

provide the necessary details if

adjustm

cn t..

are

required to be carried

out

under

warranty.

Regular

use of the

Passport

to Service

Maintenance

Scheme is

the

best safeguard against th

possibilityofabnormal

repair

bills at a

later

date.

Failure

to have

your

car

correctly

maintain

could

invalidate

the

termsofthe

Warranty

and

may result in unsatisfactory

operationofthe

emission

control

systems.

Safety features

embodied

in the

car

may be

impairedifother

than

genuine

parts

are

fitted. In certain

territories, legislation

prohibits

the

fittingofparts

not

to the vehicle

manufacturer's

specification.

Owners

purchasing accessories while travelling

abroad

should

ensure

that

the

accessory

and

its

fitted

locationonthe

car

conformtomandatory

requirements existing in

their

countryoforigin.

Your

authorized

AustinMGDealer

is provided with the latest

information

concerning speci I

service tools

and

workshop

techniques. This enables

himtoundertake

your

service

and

repairs in

the

most

efficient

and

economic

manner.

The

operations

carried

outbyyour

authorized

Austin

Dealer

will be in

accordance

with

current

recommendations

and

may be subject to revision fron

time to time. Further details on Service

Parts

will be

found

under

'SERVICE'

on page 75. Please note

that

referenc \

to right- or left-hand in this Handbook

are

made as if viewing the car from the rear.

Specification details set

out

in this

Handbook

apply

to a range of vehicles

and

nottoany

particula ·

vehicle.

For

the specificationofany

particular

vehicle owners

should

consult their

authorized

Austin

Dealer.

During

running-in

from

new,

certain

adjustments

vary

from

specification figures detailed. They will

be set to specification by

your

authorized

AustinMGDealer

at the 1,000 Mile

Free

Service

and

should

maintained

throughout

your

car's

life.

The

Manufacturers

reserve

the

right

to vary

their

specifications with or

without

notice,

and

at such

times

and

in such

manner

as they

think

fit.

Major

as well as

minor

changes may be involve d jn

accordance

with

the

Manufacturer's

policyofconstant

product

improvement.

Whilst every effort is

made

to ensure the accuracyofthe particulars

contained

in this

Handbo

ok,

neither

the

Manufacturer

nor

the

authorized

AustinMGDealer, by

whom

this

Handbook

is supplied,

shall in any circumstances be held liable for

any

inaccuracy or the consequences thereof.

Whilst every effort is

made

to ensure the accuracyofthe particulars

contained

in this

Handbo

ok,

neither

the

Manufacturer

nor

the

authorized

AustinMGDealer, by

whom

this

Handbook

is supplied,

shall in any circumstances be held liable for

any

inaccuracy or the consequences thereof.

IJo,

Emission Controls

Your

car

is fitted with emission controls

and

devices required by the

United

States Clean

Air

Act.

Please read carefully the

'EMISSION

CONTROL

SYSTEMS'

sectionofthe

Handbook

which

contains

informationonthe

emission

control

systems fitted to

your

car

and

recognition of

symptoms

of malfunctions which

could

affect emissions.

It is imperative

that

you familiarize yourself with

the

contentsofthis section,

and

ensure th a t

the

car

you

have

purchased

will

remain

in compliance with

the

intentionsofthe

above

act.

All

EMISSION

CONTROL

maintenance checks

and

adjustments

shouldbeentrusted

to your

authorized

AustinMGDealer.

CONTENTS

INTRODUCTIONTOTHE

CAR

CATALYTIC

CONVERTER

PRECAUTIONS

CONTROLS

INSTRUMENTS

AND

SWITCHES

STARTING

AND

RUNNING

INSTRUCTIONS

LOCKS,

FITTINGS

AND

BODY

SEATS

AND

SEAT

BELTS

HEATING

AND

VENTILATING

CAREOF'PHE

CAR

CLEANING

COOLING

SYSTEM

WHEELS

AND

TYR

BRAKES

AND

MAS T R Y IN RS

ELECTRICAL

IGNITION

ENGINE

EMISSION

CONTROL

SYST

EMS-EXCEPT

CALIFORNIA

- CA LI FOR NIA

FUEL

SYSTEM

.. TRANSMISSION

STEERING

AND

SUSPENSION

t'U~L

~Y~

·ltM

TRANSMISSION

STEERING

AND

SUSPENSION

GENERAL

DATA

SERVICE

MAINTENANCE

SUMMARY

LUBRICATION

Page

67 70

Page 4

CATALYTIC CONVERTER

PRECAUTIONS

1. Use unleaded fuel only. This is essential to maintain the efficiency of til

emission control system. Unleaded fuel has the additional advantage that il minimizes spark plug fouling, thereby giving improved engine performanc '.

2. Have your car maintained in accordance with the Maintenance Summary outlined in this handbook. A correctly tuned engine minimizes exhaust emissions and achieves the optimum performance and fuel economy.

3. Do not continue to operate your car if you detect any engine malfunction. Misfire, or engine run-on may cause unusually high catalytic converter temperatures. Damage to the catalytic converter 'may occur if any such engine malfunctions are not rectified immediately.

4. DO

NOT

LEAVE

YOUR

CAR

UNATTENDED

WITH

THE

ENG

INE

RUNNING

AT ANY

TIME

as an unobserved rise in engine temper ature

may cause damage to the engine and catalytic converter.

5. The use of a catalytic converter increases exhaust system temperatures . Do not operate or park your car in areas where combustible materials such as dry grass or leaves may come in contact with the exhaust system. The exhaust system could ignite such materials under certain weather conditions.

6. Do not run the engine with a spark plug lead disconnected or a spark pili removed or use any device that requires an insert into a spark plug hole in order to generate air pressure (e.g. tyre pump, paint spray attachment , etc.) as this could also result in catalytic converter damage.

7. Do not push or tow your car to start it. Use jumper cables. Under certai

conditions, pushing 'or towing could damage the catalytic converter.

S. The catalytic converter contains a ceramic material. Avoid heavy impact.

on the converter casing.

CONTROLS

Fig. 1

Pedals

The pedals are arranged in the conventional positions.

(1) (2) (3)

The brake pedal operates the dual hydraulic braking system applying the brakes on all four wheels, and bringing the stop warning lights into operation when the ignition is switched on.

Hand

brake

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

(4) wheels only. To release the hand brake pull the lever upwards slightly, depress

the button on the end of the lever and push the lever down.

Gear

lever

The gear positions are indicated on the lever knob. To engage reverse gear mov

-e

(5) the lever to the right in the neutral position as far as possible. Lift the lever

and move it forward to engage the gear. Synchromesh is provided on first, second, third, and fourth gears.

The reverse lights operate automatically when reverse is selected with the ignition

switched on.

Fig. 1

~\\

)1~lffZ=5S

Fig. 1

Page 5

INSTRUMENTS

AND

SWITCHES

IGNITION/STARTER

SWITCH

AND

STEERING

LOCK

Fig.l

Key

number

The key number appears on the key, on the number tag supplied or on a lab" attached to the windscreen of a new car.

NOTE

THE

KEY NUMBER in your DIARY and in a reference

bookatHOM

and then

REMOVE

THE

LABEL with the key number

FROM

THE

CAR.

Consult your authorized Austin MG Dealer regarding key replacements for th steering-column lock.

The steering-column lock (4), if used properly, will greatly reduce the possibil ity of the car being stolen. ,

Unlocking

To unlock the steering, insert the

keyand

turn it to position

'I'.

If the steering-

wheel has been turned to engage the lock, slight movement of the steering-wh e

will assist disengagement of the lock plunger. \ With the key in the position marked

'I'

the ignition is switched off and th

steering lock disengaged. The radio may be operated

with

the key in this positi on.

The key must be in this position when towing the car for recovery.

Ignition

and

To switch on the ignition,

turn

the key to position

'II'.

Further

movement agai n t

start

spring resistance to position

'III'

operates the starter motor. Release the key

immediately the engine starts.

Locking

To lock the steering, turn the key anti-clockwise to the-position marked"I' , pre the button

(5), turn the key to the

'0'

position and withdraw it.

WARNING: The steering lock/ignition/starter switch and its electrical circuits ar designed to prevent the ignition system and starter from being energized while th steering lock is engaged. Serious consequences could result from alterations or substitution of the steering lock/ignition switch or its wiring. In no circumstance must the ignition switch be separated from the steering lock.

Do not lubricate the steering lock.

Fig. 1

INSTRUMENTS

Fig. 2

Speedometer

In addition to indicating the

road

speed this instrument also records the total

(1 ) distance (3) and the distance travelled for any particular trip (2). To .reset the

trip recorder, press the knob

(4)

and

all the counters will return to zero.

Tachometer

This instrument indicates the revolutions per minute of the engine and assists

(5)

the driver to use the most effective engine speed range for maximum performance in any gear (see page 15).

Coolant

The gauge indicates the temperature of the coolant as it Ieaves the engine cylinder

temperature

head. An important note about temperature is on page 14.

gauge

(6)

Fuel

gauge

When the ignition is switched on the fuel gauge indicates approximately the

(7)

amount

of fuel in the tank. An important note on filling with fuel is given on

pages 13 and 54 or 62.

Fig. 2

1--

Do not lubricate the steering lock.

Fig. 2

Page 6

Instrument

d vvitches

WARNING

LIGHTS

AND

SYSTEMS

Fig. 3

Haza rd

REE

N. The direction indicator warning lights will flash when the

hazard

warnin

(1) lights are operating.

Ignition

RED. This light serves the dual purposeofreminding the driver to switch off th

(3)

ignition andofbeing a no-charge indicator.

Main

beam

LUE.

The

light glows when the headlights are switched on with the beams in

(4) the raised position. The light goes

out

when the beams are dipped.

THE

WARNING

LAMP

(5)

GLOWS

AT ANY

TIME

EXCEPT

WHEN

STARTINGORWHEN

THE

IGNITIONISSWITCHED

ON ANDTHE

HAND BRAKE IS APPLIED,

THE

CAUSE

MUST

BE INVESTIGATED

IMMEDIATELY.

Unless as a result of your investigation you are satisfied

that

it is safe to proce ed,

you should leave the vehicle where it is

and

call for assistance. Even if you are

satisfied

that

it is safe to proceed, the

car

should only be driven in cases of real emergency,extreme care should be taken and heavy braking avoided. In deciding whether

it is safe to proceed you should cons ider whether you will be infringing

the law.

Braking

system

The hydraulic brake system has two independent circuits.Ifhydraulic pressure fails in one circuit, the remaining circuit will provide an emergency brake condition on the

other

two wheels

and

allow the

car

to be brought to rest by

brake

pedal appl ication. This would be accompanied by the warning

lamp

(5) glowing

on the instrument panel.

AMBER.

The

warning light will glow when the ignition is switched on and

out

soon

after the engine is running, see 'STARTING AND RUNNING IN-

STRUCTIONS'.

Direction

REE

N. The warning light flashes when the direction indicators are operating,

indicator

Additional warning is also given by the audible 'clicking'ofthe flasher unit.

(1)

Oil

pressure

(2)

Brake

RED.The

warning light serves two separate functions. Firstly, if the brak

(5)

system hydraulic pressure fails the lamp glows; secondly, the

lamp

glows as (l

hand

brake

'on' indicator. The warning light will only operate when the ignition

is switched on

-see

NOTE.

Seat

belt

RED.

The

warning light will glow for eight seconds each time the ignition start

(6) switch is operated, irrespective of whether the driver's seat belt is fastened- s

NOTE.

Anti-theft

A combined ignition and steering lock with warn ing buzzer is fitted to the car.

warning

buzzer

The warning buzzer will sound if the driver's door is opened while the key is in the lock. The buzzer will not operate if the key is removed from the lock.

When leaving the car unatt nded a

lway:

Set the

hand

brake.

Lock the steering by removin g the k

y fr n th ignition teer ing lock.

. Lock the car

door

s and rernov th k y.

Further

information on the seat belt warning system will be found on page 24.

NOTE:

As an automatic check the

'BRAKE'

and

'SEAT

BELT'

warning la mp.

will glow each time the ignition key is turned to position

'III'

(starter

mo~or

operating). Consult

your

authorized AustinMGDealer

if anyofthese warrun

lamps fail to glow when the

starter

is operating.

Fig. 3

Page 7

Instrument

nd Svvitches

COLUMN

SWITCH

Windscreen

washer

and

wiper

control

Fig. 4

Direction

indicators,

main

beam

and

horn

control

Fig . 4

Direction

The switch operates the indicators only when the ignition is switched on.

indicators

Move the lever to position

'A'

when turning left and to position

'B'

when turnin '

right. After making a turn the signal is self-cancelledwhen the steering-wheel is returned

to the straight-ahead position. The switch lever may be held against spring pressure to select either left or right

indicator and willcancel the indication immediately it is released without mov ment of the steering-wheel.

A visual warning of a front

.rear bulb failure is given when, after switching on

an indicator, the warning lamp and the serviceable bulb on the affected side giv a continuous light.

Headlamp

With the headlamps switched on at the lighting switch, move the lever forward

dipper

('C')

to use the main beams; the warning light willglow (BLUE). Return the lever

to the midway position to dip the beams.

Headlamp

Lift the lever towards the steering-wheel

('D')

to flash the headlamps irrespectiv

flasher

of whether they have been switched on at the lighting switch or not.

Horns

Press the end of the lever

('E')

inwards to sound the horns.

Fig. 4

Windscreen

Press the end of the lever inwards

('F')

to operate the washer jets.

washer

In cold weather the washer reservoir should be filled with a mixture of water and a recommended washer solvent to prevent the water freezing.

To avoid possible damage to paintwork do not use radiator anti-freeze in the windscreen washer.

Windscreen

Move the lever upwards

('G')

and then release it to obtain a single wipe. The

wiper

lever will return to the 'off' position and the blades will park automatically at the completion of the wipe.

To operate the wipers at normal speed move the lever down to the first position

('H')

and to the second position

('J')

when a higher wiping speed is required .

NOTE:

Neither the windscreen wiper nor the washer can operate until the

ignition has been switched on.

S~.-

Page 8

Instrument

s and Svvitches

SWITCHES

Fig. 5

Lighting

Press the lower end of the switch rocker to the first positiontcoperate the parkin

(1)

and

tail lamps

and

to the second position to operate the headlamps. The marking

on the switch is illuminated when the panel lamps are switched on.

Panel

lamps

The panel lights will function only when the side lamps are switched on. Turnin

(2) the switch

knob

clockwise switches on the panel lights; further clockwise move-

ment of the

knob

increases the light brilliance.

Hazard

To use the direction indicators as ahazard warning to other

road

users, press the

warning

lower end of the switch rocker, when all the direction indicators

and

their warnin T

(3) lights will operate together, irrespective of whether the ignition is on or off. Th

green illumination light on the face of the switch glows when the panel lights ar switched on.

Return

the switch to the off position to cancel the warning.

Blower

switch

For

operating instructions see

'HEATING

AND

VENTILATING'.

and

heater

controls

(4)

Cigar-lighter

To operate, press the

knob

inwards and release. When the element has becom

(5) sufficiently heated the lighter will be partially ejected,

and

may be withdrawn for use. The rim of the cigar-lighter is illuminated when the panel lights ar switched on.

Courtesy

light

The courtesy light is controlled by a switch in the light

and

by a switch fitted t

(6) each

door

pillar. With the doors closed the light may be switched on by slidinu

the switch towards the steering column. Opening either

door

will switch on the

light,

and

closing the

door

will extinguish the light.

Fig. 5

STARTING

AND

RUNNING

INSTRUCTIONS

The following instr uctions are a guide for starting, running

and

loading the car,

and

include notes on the use of the controls

and

the indications of the instruments. .

Running

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.

During

the first 500 miles (800 km):

NOT

exceed 45 m.p.h. (72 km/h).

NOT

operate at full throttle in any gear.

NOT

allow the engine to

labour

in any gear.

Exhaust

1. The catalytic converter contains ceramic material. Avoid heavy impacts on

catalytic

the converter casing.

converter

2. Use unleaded fuel only (91 octane). The use of leaded fuel will seriously impair the efficiency of the emission control system.

3. The reaction in the catalytic converter increases exhaust system temperatures. Care

must

be taken to avoid exhaust system co ntact with easily combustible

materials such as dry grass.

4. If the engine misfires, the cause mu

t b immediately rectified to prevent

catalytic converter damage.

5. The use

any device which require an in rt into a

spark

plug hole in

order to generate an air pressure, i.e. tyre pump or pa int spray attachment, could also result in catalytic converter

dam

age. .

Choiceoffuel

The engine has been designed to operate only on unleaded fuel. It is essential

that unleaded fuel is used otherwise serious damage can be caused in the catalytic converter.

Filling

with

The

filler neck of the fuel

tank

is designed to accept fuel dispenser nozzlesofthe

fuel

type specified only for unleaded fuel.

The

dispenser nozzle

must

be inserted into

the filler neck sufficiently to open the

trap

door

for fuel to flow into the fuel tank.

Filling

with

The

filler neck of the fuel

tank

is designed to accept fuel dispenser nozzlesofthe

fuel

type specified only for unleaded fuel. The dispenser nozzle

must

be inserted into

the filler neck sufficiently to open the

trap

door

for fuel to flow into the fuel tank.

Page 9

15 m.p.h. (24 km /h) 25 m.p.h. (40 krn/h) 40 m.p.h. (64 krn /h)

Starting

and Running

Instructions

Starting

Sit in the car, then wear and fasten the seat belts; this applies to both driver an d passenger.

Switch on the ignition and check:

That

the ignition warning light glows.

That

the fuel gauge registers. Depress the throttle pedal fully and release. Operate the starter. Do not depress the throttle pedal while the starter is operated. As soon as the engine is started check:

That

the oil pressure gauge registers.

The ignition warning light has gone out.

Quickly depress and release the throttle pedal to set the automatic choke to its correct position.

NOTE:

For cars operating in sub-zero temperatures, slowly depress the throttle

pedal until 2,500 rev

fmin is attained; maintain this speed until the engine reaches

normal operating temperature.

Ignition

The lamp shou ld glow when the ignition is switched on,

andgoout

and stay out

warning

lamp

at all times while the engine is running above normal idling speed. Failure to do

so indicates a fault in the battery charging system. Check

that

the fan belt is

correctly tensioned before consulting your authorized Austin MG Dealer.

Gear

change

Under normal dr iving conditions, it is recommended that to maintain the most

speeds

favourable exhaust emissions and fuel economy, the gears are selected at the following speeds:

1st to 2nd

.. 2nd to 3rd . . 3rd to 4th . .

Tachometer

For

normal

road

work, and to obtain the most satisfactory service from you r engine, select the appropriate gear to maintain engine speeds of between 2,000 and

4,500 revImin.

When maximum acceleration is required upward gear selections should be

made when the needle reaches the yellow sector (5,500-6,300 rev/min). Prolonged or 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 be avoided

as this also has a detrimental effect on the engine. The beginning of the red sector (6,300rev/min) indicates the maximum safe speed

for the engine. Never allow the needle to enter the red sector.

Wet

brakes

If the car has been washed, driven through water, or over wet roads for prolonged periods full braking power may not b v ilabl . Dry the brakes by applying the foot brake lightly several times, while th r i in motion. Keep the hand brake applied while using high pressure wa hing uipment.

Oil

pressure

warning

lamp

The lamp will glow when the ignition is switched on

and

go out soon after the

engine is running.

Vehicle

Due

consideration must be given to the overa ll weight carried when fully loading the car. Any loads carried on a luggage rack or downward load from a towing hitch must also be included in the maximu m loading.

Towing

Should it become necessary to tow the car, use the towing eyes provided.

for

recovery

The ignition/steering lock key must be at positions

'I'or'II'

and

must

not

removed during the tow.

For

tow starting the key must be at position

'II'.

the light continues to glow, stop the engine immediately

and

investigate th e

cause. Start by checking the oil level.

Starter

not operate the starter for longer than five to six seconds.

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

Starter

Do not operate the starter for longer

than

five to six seconds.

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 th e starter.

If the starter pinion fails to engage .with the flywheel ring, or fails to disenga ge when the engine starts, the starter will emit a high-pitched whine; release the ignition key immediately. Should the starter pinion become

jammed

in mesh with

the flywheel ring, turn the squared end of the armature spindle with a spanner.

Temperature

Normal operating temperature is reached when the pointer is in the

'N'

sector.

gauge

Overheating may cause serious damage. Investigate any upward change in the temperature gauge reading immediately. Check coolant level

and

fan belt tension.

Towing

The towing weight of 1,3441b (610 kg) is the maximum that is permissible.

When

using

bottom

gear a gradient of up to 1 in 8 can be ascended while towing a

weight not exceeding this figure. It may be necessary to adjust the maximum

towing weight to comply with local conditions and regulations. The recommended

downward load of a trailer or caravan on the towing hitch is 75 lb (34 kg), but

this may be reduced or exceeded at the discretion of the driver. Any load carried on the luggage rack or downward load from a towing hitch must also be included

thP

TY":llV;1"Y"InJ:Y\ lrv:u-1UHT

th""

"""h..

i£"l"" -

weight not exceeding this figure. It may be necessary to adjust the maximum towing weight to comply with local conditions and regulations. The recommended downward load of a trailer or caravan on the towing hitch is 75 lb (34 kg), but this may be reduced or exceeded at the discretion of the driver. Any load carried on the luggage rack or downward load from a towing hitch must also be included in the maximum loading of the vehicle.

Page 10

ENERGY CONSERVATION It is essential that owners wishing to achieve the best possible degree of fuel

economy ensure, as a first priority, that their vehicle is tuned to its optimum level of performance by regular maintenance in accordance with Leyland recom mendations.

Apart

from regular maintenance there are a number of areas where deliberate

and conscious actions on the

part

of the owner can achieve further quite marked

improvements. The following are recommended:

• After starting from cold, quickly depress and release the throttle pedal to set the automatic choke to its correct position.

• Switch off the ignition if the vehicle is expected to be stationary for more than half a minute.

• Avoid short stop-start journeys.

• Anticipate obstructions, junctions and sharp corners and adjust speed as necessary. Do not generate unnecessary speed.

• Accelerate gently through the gears.

• Decelerate gently whenever possible and avoid heavy braking.

• Stay in top gear as long as possible without labouring the engine.

• Ensure tyres are correctly inflated.

• Remove any unnecessary weight. CAUTION: Carburetter piston damper

An incorrectly fitted or lubricated carburetter piston damper can cause a marked increase in fuel consumption. The cautionary note and instructions on carburetter damper topping-up given on page 68 of this handbook

MUST

be observed.

LOCKS, FITTINGS

AND

BODY

Keys

Two keys and a duplicate set are provided, the large key for the steering lock/ ignition switch, and the all metal key for the glovebox, the doors and luggage

compartment. To reduce the possibility of theft, locks are not marked with a number.

NOTE

THE

KEY NUMBERS IMMEDIATELY on taking delivery of the car, see page

Lubrication

To ensure trouble-free operation it is essential that the locks, hinges and catches

are adequately lubricated. Locks. Inject a small quantity of thin oil, through the key slots and around the

push-buttons. Do not oil the steering lock. Hinges. Apply grease or oil to the joints of the hinges. Bonnet catches. Apply grease to the moving surfaces of the bonnet release

mechanism and oil to the release lever and safety-catch pivot points.

Doors

The

door

key can only be inserted or withdrawn when the key

and

key slot (1)

Fig.

1 are vertical. Forward key movement locks, opposite unlocks. To lock the doors

from inside the car, turn the locking lever (2), downwards.

Cubby

box

To open. Press the button (1) and lower the flap (2).

Fig.

To lock. Insert the key and turn clockwise. To unlock.

Turn

the key anti-clockwise.

Fig. 1

"""""

Fig. 1

Fig. 2

Page 11

Locks,

Fittings

and

Body

Driving

mirrors

Fig. 3 External. The mirror head is adjustable from the driving position when the

window is open.

Fig.4

Interior. 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 bracket as follows. Align the stem ball (1) with the bracket cup (2), ensuring that

the small protrusion (3) on the stem aligns with the indent of the mounting

bracket. Give the stem a smart tap with a soft instrument

join the two

components. Anti-dazzle. To reduce mirror dazzle, pull the lever (4) away from the windscreen.

Bonnet

To raise the bonnet, pull the

knob

(1) located inside the car on the left-hand side

Fig. 6 below the fascia panel.

Press the safety catch

(2) under the front of the bonnet

and

raise the bonnet. When fully raised the support stay will automatically spring into engagement and the bonnet will be held in the open position.

To close, raise the bonnet slightly, pushthe catch

(3) on the bonnet stay rearw ard

to release the locking mechanism and lower the bonnet. Apply light pressur 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 eard to engage.

Windows

and

Rotate

the handle (1) on each

door

to open and close the windows. The venti la-

ventilators

tion panels adjacent to each window may be opened after releasing the catch (2).

Fig. 5

Bumpers

Spilling fuel on the bumper may cause temporary local swelling of the rubber. Remove stains by lightly wiping the whole of the bumper with petrol (gasolin e) or warm water and liquid detergent.

Fig. 3

Luggage

To open , insert the key and

turn

it clockwise,

turn

the handle in an anti-clockwise

compartment

direction

and

fully raise the lid. The support stay will automatically spring into

(boot)

engagement and the lid will be retained in the open position. Ope ning the

Fig .7 luggage compartment lid automatically switches on the courtesy lamp.

To close, raise the lid slightly, push the catch (1) on the support stay forward

to release the locking mechanism, and lower the lid. Clo sing the luggage compartment lid

automa

tically switches off the courtesy lamp.

Fig. 7

I~II

If it is imperative that the car b driv n with th luggage com

par

tment lid open,

adverse effects can be minimized by adoptin th following pr ocedure :

1. Close all windo ws.

2. Open the face vents fully.

3. Set the heater controls to circ ulate the maximum

amount

of cold or hot air.

4. Switch on the blower

motor

to maximum speed.

not

travel at high speed.

To lock,

turn

the key anti-clockwise and withd raw the key.

WARNING:

Exhaust fumes will b d awn j to the car if it is driven with the

luggage compartment lid open, cau ing a h lth h zard to passengers and driver.

Fig. 6

3ND242

Fig. 5

1\\

&\\ /i

Iii

3ND242

Fig. 4

Page 12

Locks,

Fittings

and

Bodv

Drain po i

nts

The body and doors are provided with drain holes to allow rain-water and

Fig. 8 condensation to flow freely from the panels, thus preventing accumulated water

from causing rust and corrosion. It is essential

that

the drain holes are kept

clear

and

are not inadvertently blocked. When painting or applying underseal to the body underpanels or doors, temporarily seal or mask the drain holes to prevent the ingress of sealant. Periodically inspect the drain holes and clear any obstruction using a piece of stiff wire or a suitable tool.

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

Hard

top

Fitting. Lower the hood.

Fiqs.9and

10 Position the

hard

top on the car

and

engage the toggle fastener tongues in their

sockets on the windscreen rail. Check

that

the rubber sealing strip is correctly

positioned forward of the rail. Fasten the toggle links

and

lock them with the

securing brackets (inset, Fig.

9).

Fit

the bolts into

both

side-fixing brackets and

tighten them down gently

and

evenly until the

hard

top

seals at

both

sides an d

the rear.

not tighten the bolts

hard

down.

Check the width of the gap between the flanges of the side-fixing brackets ( Fig. 10), remove the bolts

and

fit packing washers between the flanges to th

thickness of the gap. Refit

and

tighten the securing bolts.

Hood

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

(Soft

top)

are carried out in the sequence given. Do not apply pressure to the frame-members other than the header rail; undue force is not necessary and should be avoided. Do not fold or stow the hood when

it is wet or damp.

Fig. 8

5118 4 0

Lowering (1) Unclip the sun visor and move to one side. Release the press studs on the

windscreen frame and

hood

frame links (Fig. 11).

(2) Release the "hood from the If-fa tening tr ip an d the three fasteners on

each rear quarter panel. (3) Open the toggle catches on the wind cr en rail (inset, Fig. 11). (4) Press the header rail rearward to

p the hinge links, at the same time

keeping the hood materia l pu ll d out t w rd the rear away from the frame

(Fig. 12).

Fig. 12

/ J I I

Fig. 11

SIIU

D I

((

Fig. 10

;/I'

----

Q....II

-c...

Fig. 9

Page 13

Locks,

Fittings

and

Body

(5) Collapse the frame int o its stowage position in

the

rear

compa

rtment

and

lay

the

hood

mate

rial on

the

luggage

compartment

lid.

(6)

Fold

the

quarte

r-light inwards, on a line between

the

qua

rter-light

and

back-

light (Fig. 13).

(7)

Fold

the

hood

over the frame into the rear

compartment

(Fig. 14).

(8)

Lay the

hood

cover over the

hood

and

secure the

rear

edge with the fasten ers

(Fig. 15).

(9)

Arrange

the cover

and

secure it at the sides with

the

fasteners provided at

each

quarter;

secure

the

front

edge to the cockpit rea r panel with the four

press

studs (Fig . 15). Reposition the

sun

visors.

Raising (1) . Remove the

hood

cover

and

open

both

doors.

(2)

Lift

the

hood

over

theframe

and

lay it on the luggage

compartment

lid.

(3)

Unfold

the qua rter-lights

and

pull the header rail forward

and

upwards at

the

point

indicated by the label. Ensure

that

the

hood

material

takes

up its

correct position as

the

frame is erected.

(4) Engage the

hood

toggle fastener tongues in their sockets on the windscreen

rail, check

that

the

rubber

sealing strip is correctly positioned forward of

the rail , and fasten the toggle links.

(5) Secure the ho od with the fasteners on the

rear

quarte

rs, windsc reen side-

posts, and frame hinge links.

(6) Stow the

hood

cover.

Tonneau

cover

Fitting. Lay the cove r over the cockpit

and

secure the

rear

edge

and

sides with

the fasteners on the

tonneau

and

quarter-panels.

Extend the cover forward

and

secure

the

front edge to the fasteners on the

fascia panel

top

and

windscreen pillars.

Usage. The centre zip allows the cover to be folded down to give access to the driving seat or

both

seats.

Fold

the

cover down behind

the

seat

and

secure it

with the fasteners to the heel

board

(see Fig. 16).

The

short

side zips permit th

use of seat belts when the cover is folded down. Removing. Reverse the fitting procedure.

Fig. 13

Fig.

Fig. 15

Fig. 16

Page 14

SEATS

AND

SEAT BELTS

SEATS

Fig. 1

Seat

Driving position. Both seats are adjustable and can be moved easily into the

adjustment

most comfortable position. Move the lever (1) located beneath the front of the seat outwards; hold the lever in this position while the seat position is adjusted. The locking pin is spring-loaded and will automatically lock the seat in the required position when the lever is released.

Seat back adjustment. The rake of the back or squab of the seats can also be adjusted. Ease the body weight from the seat back and move the lever (2) rearwards. Release the lever

and

ensure

that

the seat back is fully locked in position ;

check by applying back pressure on the seat.

Head

restraint

The vertical position of the head restraint (3) may be adjusted.

To lower, push the head restraint down towards the seat.

fasten

Lift the engagement tongue (1) from the stowing device (2)

and

draw

the belt

over the shoulder and across the chest

and

push

it into the locking device (3)

nearest the wearer. NOTE:

Withdraw the belt from the reel with a steady pull: sudden snatches

should be avoided as these will lock the reel.

release

Depress the panel (4) marked

'PRESS'

on the locking device.

stow

Allow the belt to retract fully, manually assist the last few inches to retract.

Hoo

the engagement tongue (1)

onto

the stowing device (2). To prevent the tongue

sliding down the belt, ensure

that

the slide (5) is close to the tongue when the

belt is stowed on the stowing

device,

To raise, place both hands under the restraint pad and lift the head restraint up away from the seat.

SEAT

BELTS Fig. 2

Warning

The seat belt warning system functions when the ignition /starter switch is opera-

system

ted. The

'FASTEN

BELTS'

lamp will be switched on for eight seconds each time the ignition /starter switch is operated. The warning buzzer will sound for eight seconds if the ignition/starter switch is operated before the driver's seat belt is fastened.

Testing

Careofthe

belts

WARNING: This test must be carried out under safe road conditions, i.e. on a dry, straight paved road, during a period when the road is free from traffic. With the belts in use, drive the car at 5 m.p.h. (8 km./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 the braking must not be anticipated. If a belt fails to lock, consult y

ourauth

orized Aust

in/MG

Dealer.

No unauthorized alterations or additions to the belts

should

be made. Inspect the webbing periodically for signs of abrasion, cuts, fraying and general wear; pay particular attention to the fixing points

and

adjusters.

~ig

•.1

Fig•.

Wearing

Always wear a belt as a complete lap and diagonal assembly

and

never at any time

wear it loosely, as this reduces its protection. Ensure

that

the belt is lying flat

and

not

twisted. Always stow a seat belt

thatisnot

in use.

Never

attempt

to use a seat belt for more

than

one person, even for small children .

Fig. 2

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

Renew a seat belt assembly that has withstood the strain of a severe impact.

Page 15

HEATING

AND

VENTILATING

CLEANING

HEATE R The heating and ventilating system is designed to pro vide 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.

Interior

Carpets: Clean with a semi-stiff brush or a vacuum cleaner, preferably before washing the outs ide of the car. Occasionally give the carpets a

thor

ough cleaning

with a suitable uph olstery cleaner. Car pets must not be 'dry-cleaned'.

Air

Two doors, located one at each side of the gearbox tunnel, control distribution

distribution

of air between screen and car interior. To supply air to the car, open the doo rs ; to boost the flow of air to the screen, close the doors.

Plastic faced upholstery: Clean with diluted

uph

olstery cleaner. Spot clean with upholstery cleaner spread thinly over the surface with a brush or cloth, leave for five minutes, then wipe over with a damp spo nge or cloth .

Controls

Heater

(Fig. 1). A valve controlling the flow of coolant through the heater unit is fitted on the bulkhead beside the battery. The valve is opened (1) by movin g the lever towards the battery. Moving the lever away from the battery closes (2) the valve.

Air flow (Fig . 2). The

knob

(1) operates a valve in the air intake and controls the

flow of air to the car interior.

Turn

the

knob

anti-clockwise from the '

OFF

position to open the valve, the valve is fully open when the

knob

is turned to

the 'ON' position. Booster. Press the lower end of the switch rocker (2) to boost the air flow.

Illumination

The markings on the booster switch, the control dial and the position indicator on the rotary c

ontr

ol knob are illuminated when the panel lamps are switched on.

Body

Regular care of the body finish is necessary if the new appearance of the r exterior is to be maintained agains t the effects of air pollution, rain,

and

mud .

Wash the bodywork frequently, using a soft sponge

and

plenty of water con taining car shampoo. Large deposits of mu d must be softe ned with 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 addit ion to the regular maintenance, special attention is required if the car is driven in extr eme conditions such as sea spray or on salted roads. In these conditions and with other forms of severe contamina tion an add itional washing operation is necessary which shoul d include underbody hosing. Any damaged areas should be immediately covered with pa int and a complete repair effected as soon as possi ble. Before touching-in light scratches and

abras ions with pa int, thoroughly clean the surface. Use petrol/white spirit

(gasoline/hydr ocarbon so lvent) to remove spots of grease or tar.

Usag

e By varying the sett ings of the air flow control, opening or closing the air distri-

bution doors, and ut ilizing the booster blower, a wide range of settings

can

be obtained for heating, when the heater valve is open, or for ventilating when the valve is shut , to suit prevailing conditions.

Bright

trim

Never use an abrasive on stainles , chromium, luminium, or plastic bright parts and

on no account clean them with m ta l pol i h. Remove spots of grease or

tar

with petro l/white spirit (gasoline/hydroc rbon lvent)

and

wash frequently with water containing car shampoo. Wh n th dirt ha been removed polish with a clean dry cloth or chamois-leather un til bright. Any slight tarnish found on stainless or plated components which have not received regular attention may be removed with chrome cleaner. An occa ional application of light mineral oil or grease will help to pre serve the fini h, particularly during winter when salt may be used on the roads, but these protectives must not be appl ied to plastic finishes.

Fig. 2

rg·~~

I I I I I II~II

III

II II

" "''']

Page 16

COOLING

SYSTEM

Expansion The expansion tank (1) and the spill tank (2) collects the coolant displaced by

tank

and cap expansion when the engine is heated to normal running temperature. The

Fig. 1 displaced coolant is.returned to the radiator when the system cools. The cap (3)

on the expansion tank maintains the pressure in the cooling system to

15 lbf/in"

(1·05 kgf/cm") maximum when the engine is running. If the sytem is hot, protect

the hands against escaping steam, turn the cap an ti-clockwise until the stop is felt, wait until all pressure has escaped, then press down and 'turn further until the cap can be lifted off.

Checking The coolant level must only be checked when the system is cold.' Remove the

expansion

tank

cap to check the coolant level which must be maintained to the

half-full point of the tank.

Draining

To drain the cooling system, stand the car on level ground, remove the expansion

Fig. 1 tank cap (3), and the filler plug (4) from the coolant outlet elbow. Slacken the

hose clip and disconnect the bottom hose (5) at its connection to the radiator. Remove the drain plug (6) on the cylinder block.

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

with a

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

There is no provision for draining the heater, expansion tank or spill tank.

FiII ing Anti-freeze must be used in the cooling system when freezing conditions are

Fig. 1 encountered.

Refit the drain plug (6), re-connect the bottom hose to the radiator, and check all other hose connections.

Fill the system with coolant through the filler orifice until the level is up to the bottom of the threads. Refit the filler plug. Top up the expansion tank with coolant to the half-full point and refit the cap.

Run

the engine until normal operating temperature is reached. Stop the engine, allow the system to cool, and remove the expansion tank cap. Remove the filler plug and 'top up to the bottom of the threads and refit the filler plug. Top up the expansion tank to the half full point and refit the cap.

Fig. 1

Frost

Water expands when it freezes, and if precautions are not taken there is con-

precautions

siderable 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 antifreeze in the cooling system in freezing conditions. '

When freezing conditions are likely to

be encountered, have the specific gravity

of the coolant checked by your authorized Austin MG Dealer, and add an tifreeze to give the required protection.

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. Ma 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 and add

0·25 pint

U.S.. pint, 0·15 litre) of neat anti-freeze to the expansion

tank. We recommend owners to use an ethylene glycol based anti-freeze to specification

B.S.

3151/2 or S.A.E. JI034 to protect the cooling system during frosty weather

and reduce corrosion to the minimum.

The correct quantities of anti-freeze for different degrees of frost protection are:

Anti-

'Commences

freeze

to fre eze Frozen solid

Amountofanti-freeze

°C

Pts.

U.S. Pts.

Litres

-13

9 - 26

- 15

1·42

33t

-19

- 2

- 36 - 33

1·84

-36

- 33 - 48

- 53

2·7

Page 17

WHEELS

AND

TYRES

Jacking

The jack is designed to lift

one

side of the car at a time. Apply the

handbrake

Fig. 1 and block the wheels on the opposite side to that being jacked; use a wood block

jammed tight against the tyre tread. Remove the plug (1) from the socket in the sill panel

and

insert the

arm

of the

jack into the socket.

Make

certain that the 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 not work beneath the vehicle with the lifting jack as the sole means of support. Place suitable supports under the front side-members or

rear

axle to give adequate support

and

safety while working.

Jack

the

jac

k is neglected it may be difficult to use in a roadside emergency. Examine

maintenance

it occasionally, clean off accumulated dust,

and

lightly oil the thread to prevent

the formation of rust.

WHEELS

Preventive

Owners are recommended to check the wheel nuts on pressed-type wheels for

maintenance

tightness each week. Take care

not

to overtighten (torque wrench setting

45lbf

(6·22 kgf m) .

Spare

wheel

The spare wheel is stowed in the well of the Iuggage compartment.

Fig. 2

Unscrew the clamp plate (1) to release the spare wheel. When refitting , position the wheel face down in'the well of the luggage compart-

ment

and

retain in position with the clamp plate.

The spare wheel tyre on new cars is inflated above the recommended running pressure. The pressure must be checked

and

adjusted before use.

Pressed

type

Slacken the four nuts securing the

road

wheel to the

hub;

turn

anti-clockwise to

Removing

and

loosen

and

clockwise to tighten. Raise the car with the

jack

to lift the wheel

refitting clear of the ground

and

remove the nuts. Withdraw the

road

wheel from the

hub.

Fig. 3

When

refitting the

road

wheel locate the wheel on the hub, lightly tighten the

nuts (1) with the wheel nut spanner,

and

lower the jack. Fully tighten the wheel

nuts, tightening

them

diagonally

and

progressively to the correct torque wrench

setting. If the spare wheel is to be fitted, remove the centre trim (2) from the original

wheel

and

fit it to the wheel in use.

Replace the wheel disc

and

jack

socket plug.

Wire

type

Use the spanner and hammer to slacken

and

tighten the octagonal

hub

nut.

(When

fitted)

Removing

and

Always

jack

up a wheel before using the tools

and

always tighten the

hub

nuts

refitting

fully.

Fig. 4

Hub

nuts are

marked

'LE

FT'or'RIGHT'

to show to which side of the car they

must be fitted,

and

also with the word

'UNDO'and

an arrow.

Before replacing a wheel wipe all serrations, thr eads,

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 conv nien t.

Maintenance

When

the car is new, after the first long

run

or aft r 50 miles (80 km) of short

runs, jack up the wheels and use th

hammrand

spanner to

make

sure they

are tight.

Fig. 1

\t\1

Fig. 3

Fig. 4

Fig.

Page 18

Wheels

and

'Tyres

TYRES

Tyremarki

ngs

Max.

load and inflation figures. Tyres are marked with the maximum load and inflation pressure figures. When fitting replacement tyres ensure that they are to the same specification

and

marking. The permissible load and tyre pressures

are shown on page 73 of this handbook.

Wear indicator. Tyres fitted as original equipment have wear indicators incorporated in their tread pattern. When the tyre tread has worn down until 0·06 in

(1'5 mm) of the tread is remaining the wear indicator

bar

will appear across the

full width of the tread pattern.

Tyre

Tyres, including the spare, must be maintained at the pressures recommended

maintenance

(see 'GENERAL DATA'); check with an accurate tyre gauge at least once a week,

and

regulate as necessary. Pressures should be checked when the tyres are cold; do not reduce the pressure in warm tyres where the increase above th e normal pressure is due 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. The spare wheel supplied with new cars is inflated above the recommended running pressure. The pressure must be checked and adjusted before use.

Excessive local distortion can cause the casing of a tyre to fracture and may lead to premature tyre failure. Tyres should be examined regularly, especially for cracked walls, exposed cords, etc. Flints and other sharp objects should be removed from the tyre tread; if neglected, they may work through the cover. Any oil or grease which may get onto the tyres should be cleaned off by usin g fuel sparingly.

not use paraffin (kerosene), which has a detrimental effect on

rubber.

Tubeless tyres Normally a tubeless tyre will not leak as a result of penetration by a nail or other

puncturing object, provided

that

it is left in the tyre. At a convenient time have

the tyre removed for vulcanizing.

a small diameter puncture has been made a

temporary repair can be carried out with the tyre manufacturer's plugging kit. NOTE:

The insertion of a plug to repair a puncture in a tubeless tyre must be regarded as a temporary measure and a permanent vulcanized repair must be made as soon as

possible; In no circumstances should a plug repair be made to the

side wall of a tyre.

BRAKES

AND

MASTER

CYLI'NDERS

Brake

and

The level of the fluid in the brake master cylinder reservoir is visible through the

clutch

master

plastic reservoir (1); the level must be maintained up to the position marked (2)

cylinder

on the side of the reservoir.

Fig. 1

To check the level of the fluid in the clutch master cylinder reservoir (3), remove the plastic filler cap. The fluid level must be maintained at the

bottom

of the filler

neck.

Use only Lockheed Universal Brake Fluid (Series 329S) or Castro" Girling Brake Fluid; alternatively, use a brake fluid conforming to F.M.V.S.S. 116

D.O

.T.3 specification with a minimum boiling-point of 260° C (500°F). Before refitt ing the filler caps check that the breather holes (indicated by the arrows) in the caps are clear. The centre disc (4) of the brake reservoir cap may be removed for cleaning.

Brake

pedal

A free movement of t in (3'2 mm) (A), measured at the pedal pad must be

Fig. ·2 maintained on the pedal. To adjust the free movement, slacken the stop light

switch locknut

(1) and turn the switch (2) clockwise to decrease or anti-clockwise

to increase the clearance. Tighten the stop light switch locknut.

The instructions gi 'en for

the

temporary repair of tubeless tyres must be dis-

regarded when tubes are fitted. If in any doubt, consult your authorized Austin

regarueuasa

tempo

rary

measure

anu

permanent

vuicamzeu

repair

mustDemau

as soon as possible. In no circumstances should a plug repair be made to the side wall of a tyre.

Fig. 1

Fig. 2

The instructions gi 'en for

the

temporary repair of tubeless tyres must be dis-

regarded when tubes are fitted. If in any doubt, consult your authorized Austin

Dealer.

Tu bes When repairing tubes, have punctures or injuries vulcanised. Ordinary patches

should only be used for emergencies. Vulcanising is absolutely essential for tubes manufactured from synthetic rubber.

Replacement

Radial-ply tyres are standard equipment and replacements must be of the radial-

ply type.

Wheel

and

tyre

Unbalanced wheel and tyre assemblies may be

responsibl~~

for.

a~n~rm~l~~~

Fig. 1

Fig. 2

Page 19

Brakes and

Master

Cylinders

Front

brakes

just

ment

of the disc brakes to compensate for fric

tion

pad

wear is

automa

tic

Fig. 3

and

manual

adjustment is

therefore

not

required. Before the lining material

(arrowed) has

worn

down to the minimum permissible thickness of

-rlr

in (1·6 mm)

or will have

done

so before the next inspection is due, the brake pads

must

renewed. Special equipment is required,

and

new

pads

should be fitted by an

authorized Austin

Dealer.

Rear

brakes

Excessive

brake

pedal travel is an indication

that

the

rear

brake-shoes require

adjusting. The brakes on

both

rear

wheels must be adjusted to regain even and

efficient braking.

Adjusting

Block the

front

wheels, fully release the

hand

brake

and

jack

up each rear wheel

Fig. 4 in turn.

Turn

the adjuster (1) in a clockwise direction (viewed from the centre

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.

Inspecting

Block the front wheels, release the

hand

brake,

and

jack

up each rear wheel in

rear

brake

turn. Remove the

road

wheel

and

slacken off the brake-shoe adjuster fully.

linings

Remove the two countersunk screws (pressed wheels) or the four nuts (wire wheels)

and

withdraw the brake-drum.

Inspect the linings for wear,

and

clean out the dust from the backplate assembly

and

drum.

Refit the

drum

and

road

wheel

and

adjust the brake-shoes.

Hand

brake

The hand

brakeisauto

matically adjusted with the rea r brakes.Ifthere is excessive

movement of the

hand

brake lever, consult

your

autho

rized

AustinMG

Dealer.

Preventive

In addition to the recommended periodical inspec tion of b

rake

components it

maintenance

is advisable as the

car

ages,

and

as a

precau

tion against the effects of wear

and

deterioration, to

make

a more searching inspection and renew

part

s as necessary.

It is recommended

that:

(1) Disc

brake

pads,

drum

brake linings, hoses,

and

pipes should be examined

at intervals no greater

than

those laid

down

in the Maintenance Summary.

(2)

Under

normal operating conditions

brake

fluid should be changed com pletely

every 18

months

or 19,000 miles whichever is the sooner.

(3) All fluid seals in the hydraulic system

and

all flexible hoses

should

be renewe d

every

3 years or 37,500 miles whicheve r is the sooner. At the same time the

working surface of th e pisto n and of the bores of the master cylinder, wheel cylinders, and other slave cylinders

shou

ld be exam ined

and

new parts fitted

where necessary.

Care

mustbetake

n always to observe the following points :

(a) At all times use the recommended brake fluid.

(b)

Neverleave

fluid in unsealed

cont

ainers. It absorbs moisture quickly

and

canbedang

erous if used in th e braking system in this condition .

(c)

Fluid

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

(d)

The

necessity for absolute cleanlines t

hro

ughout cann ot be over-

emphasized.

Replacing

brake-shoes

or pads

When

it becomes necessary to renew the brake-shoes or

pads

it is essential th at

only genuine shoes or pads, with the correct grade of lining, are used. Always

fit new shoes or pads 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

pads

are obtainable from

your

authorized Austin

Dealer.

Fig. 3

Fig. 4

1\\

Fig. 3

MGb~r.

~\\\I\

Fig. 4

Page 20

ELECTRICAL

Polarity

The

electrical installation on this car is NEGATIVE

(-)

earth

return

and

the correct polarity must be maintained at all times. Reversed polarity will per- manently damage semi-conductor devices in the tachometer, and the radi transistors (when fitted).

BATTERY

BOOSTING

AND

CHARGING

CAUTION:

The following precautions must be observed to avoid the possibility of

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

Battery

A high speed charger may only be used if the battery has been completely

charging

disconnected from the vehicle electrical system. Certain types of maintenance-free batteries, for example the lead-calcium type, can be damaged by high speed chargers.

in doubt, consult your

autho

rized AustinMGDealer.

rninal voltage of the battery ;

d t the positive

(

terminal of the

When charging the battery in the v

hid

fr m an outside source such as a trickle

charger, ensure

that:

- the charger voltage i th

- the charger positive (

+ ) 1 d i

battery;

- the charger nega tive ( - ) lead

i conn ected to the negative ( - ) terminal of the

battery.

Battery

boost

A high speed battery charger must

not

be used as a starting aid.

starting

and

charging

When connecting an additional battery to boost a discharged battery in the

Fig. 2 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 curr

nt :

- 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,

+ (positive) to + (positive)

and

then - (negative) to - (negati ve);

- the engine speed is reduced to 1,000 revfmin or below before disconnecting the boost battery. The vehicle battery must never be disconnected while the engine is running.

The electrolyte levels

(1) in each cell are visible through the translucent battery

case or may be checked by fully raising the vent cover

(2)

and

tilting it to one side.

The electrolyte level in each cell

must

be maintained so

that

the separator plate

(3) are

just

covered. To avoid flooding, the battery must

not

be topped up within

halfanhour

of it having been charged from any source

other

than

the generating

system fitted to the car.

NOTE:Donot

leave the battery in a discharged state for any length of time.

When

not

in regular use have the battery fully charged,

and

every fortnight give

a short refresher charge to prevent permanent damage to the battery plates.

frequent topping-up of the electrolyte levels may be necessary in hot

weather or when long journeys are made.

To top up the levels raise the vent cover

and

pour

distilled water into the

tro

ugh

(4) until all the rectangular filling slots (5) are full

and

the

bottom

of the

tro

ugh

just

covered. Press the cover firmly intoposition; the correctquantity of distilled water will automatically be distributed to each cell. In extremely cold conditions, run

the engine immediately after topping-up to mix the electrolyte.

NOT

USE

A NAKED

LIGHT

WHEN

CHECKING

THE

LEVELS and do

not use tap water for topping-up.

Before fitting a radio or any

other

electrical equipment, make certain that it

has the correct polarity for installation in this vehicle.

Battery

The battery must be kept clean

and

dry, and the terminals should be smeared

Fig. 1 with petroleum jelly. The vehicle must be level when the electrolyte in the cell

is being checked.

IMPORTANT:

The vent cover must be kept closed at all times, except when topping-up. The electrolyte will flood if the cover is raised while either tric kle- or fast-charging the battery.

Fast

charging should only be undertaken in extr eme

circumstances, and must

not

exceed 40 amps for a maximum period of one hour.

A single-cell' heavy discharge tester cannot be used on this type of battery.

no occasion should the vent cover be detached from the battery.

UVlrU.KlA1"'l.l: i ne

vent

cover

mUST

xept

ciosec

all urnes, except wnen topping-up. The electrolyte will flood if the cover is raised while either trickleor fast-charging the battery.

Fast

charging should only be undertaken in extreme

circumstances, and must

not

exceed 40 amps for a maximum period of one hour.

A single-cell' heavy discharge tester cannot be used on this type of battery.

no occasion should the vent cover be detached from the battery.

Fig. 1

Fig. 2

-----..

Page 21

Electrica

ALTERNATOR

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

Polarity. Ensure that the correct battery polarity (negative ground) is maintained at all times; reversed battery or charger connections will damage the alternator rectifiers.

Battery connections. The battery must never be disconnected while the engine is running.

FUSES The fuses are housed under the fuse cover (1) mounted in the engine compart-

Fig. 3 ment adjacent to the battery.

Fuse connecting

-2.

The fuse (2) protects one parking lamp, one tail lamp, one

number-plate lamp, and one front and rear side marker lamp. Fuse connecting

-4.

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

one number-plate lamp, and one front and rear side marker lamp. Fuse connecting

-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 and seat belt warning.

Fuse connecting

-8.

The fuse (5) protects the equipment which operates independently of the ignition switch, namely horns, interior and luggage compartment lamps, headlamp flasher, brake failure warn ing lamp,

door

and seat belt audible

warning and the cigar-lighter (if fitted) Two spare fuses (6) are provided

and

it is important to use the correct replace-

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

(35_amp. blow

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

Line

fuses

Running-on control valve(if fitted). The 17amp. continuous current rated (35amp.

Fig. 3 blow rated) line fuse (7) protects the running-on control valve circuit which

operates when the ignition is switched off.

Hazard warning. The 17 amp. continuous current rated (35 amp. blow rated) line fuse (8) 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 42).

Radio (if fitted). A separate additional line fuse protects the radio. See the instructions supplied with the radio for the correct fuse ratings.

To change line fuse, hold one end of the cylindrical fuse holder (9), push in,

and twist the other end

(10). Remove the fuse (11) from the cylindrical holder.

Blown

fuses

A 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 other fault.

HEADLAMPS

Light

unit

To remove a light unit, ease the

bottom

of the outer rim (1) forwards

and

lift

Fig. 4 it off the retaining lugs at the top of the lamp . Unscrew the three inner rim

retaining screws (2), remove the inner rim

(3), withdraw the light unit (4),

and

disconnect the three-pin plug (5).

To fit a light unit, connect the th ree-pin plug, position the light unit in the headlamp body ensuring that th

thr

e lug formed on the outer edge of the

light unit engage in the slots form d in th body, and fit the inner retaining rim.

Refit the outer rim.

Beam

setting

Two adjusting screws are provided on each headlamp for setting the

main

beams. The screw (6) is for adjusting the beam in the vertical plane,

and

the screw (7) is for horizontal adjustment. The beams must be set in accordance with local regulations; resetting and checking should be entrusted to your

auth

orized

Austin MG Dealer, who will have special equipment available for this purpose.

Fig. 3

)))~::II

Fig. 4

-- - - - -_nL _ _

.. --- --- . - - r - -----~--r-------

- .

----------

----- s: -

-r

---'

Page 22

Electrical

LAMPS

Parking and To gain access to the parking and direction indicator bulb, unscrew the two

direction

retaining screws (1) and withdraw the lens (2).

indicator

lamps

Fig.

Stop,

tail,

Remove the lens retaining screws (1) and slide the lens upwards to gain access

and

direction

to the direction indicator and stop/tail bulbs.

indicator

lamps

Fig. 6

Number-plate

,To change a bulb, remove the screw (1), lift and pull the lens

(2)

clear of the lamp

lamp

body and unclip the bulb (3) from its contacts. When refitting ensure that the

Fig. 7 lens engages in the seal lip. '

Side

marker

(1) Front (amber). To renew a bulb, remove the securing screw (1) and lift ofI'the

lamps lamp lens, noting

that

one end is secured by a locating tab (2). When refitting,

Fig. 8 ensure that the

seali

rubber is positioned correctly and that the lens tab (2)

is located beneath the lamp body rim before refitting the securing screw.

(2) Rear (red). To gain access to the bulb (3), the rubber lips retaining the chrom bezel and lamp lens should be eased open with a screwdriver

and

the bezel (1), and lens (2), removed. When refitting ensure that the thick end of the wedgeshaped lens faces rearwards.

Reverse lamps To renew a bulb, remove the two securing screws and withdraw the lens. Press

Fig. 9 (A) the bulb down towards the lower contact and withdraw it from the 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. 5

~-----I

Fig. 6

Interior

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

courtesy

lamp

Withdraw the festoon-type bulb from the retaining clips.

Fig. 9 ·

(B)

Luggage The lens is held in

the

lamp by four 1 ating lugs. To gain access to the bulb,

compartment

gently squeeze the sides of the I n tog th r and withdraw it from the lamp.

lamp

The bulb may then be withdrawn from it contact .

Fig. 9 (C)

Fig. 7

Fig

Fig. 9

786

Page 23

Electrical

Warning

Access to the bulbs is gained from the back of the fascia or by removing th e

panel

and

centre console.

illumination

lamps

Centre console. Remove the

four

screws (12) on each side, securing the centre

Figs. 10

and

11 console. Withdraw the console, tilting the top forward slightly to clear the unde r

edge of the fascia. ' Heater

control lamp bulb. Remove the push-fit bulb holder

(l)

from the control

and

remove the bayonet fixing type bulb (2).

Instrument panel lamp bulbs. Remove the push-fit bulb holders (3) from the instruments and unscrew the bulb (4).

Warning lamp bulbs. Remove the push-fit bulb holders (5) from the lamps an d remove the bayonet type fixing bulbs (6). To remove the ignition and high beam warning bulbs the centre console must also be withdrawn.

Lights and heater booster switch bulbs. Remove the push-fit bulb holders (7) from the switches and remove the bayonet type fixing bulbs (8). To remove the lights switch bulb the centre console must also be withdrawn.

Brake failure warning lamp. Remove the retaining spring clip (9)

and

withdraw

the holderftest-push assembly from the fascia.

Through

the two pivot holes in

the holder depress the pivot legs (10)

and

remove the test-push rocker from its

holder. Unscrew and remove the bulb (11).

Fig. 10

Fig. 11

Hazard switch bulb.

~thdraw

the centre console. Remove the push-fit bulb

holder (13) from the switch, and rem ove the bayonet fixing type bulbs (14).

Seat

belt warning lamp bulb. Withdraw the centre console. Remove the push-fit

bulb holder (16) from the lamp

and

remove the bayonet fixing type bulb (15).

Cigar lighter illumination bulb. Withdraw the centre console. Squeeze the sides of

the bulb .hood (17) and remove the hood. Remove the bulb holder (18) from

the

hood

clip

and

remove the bayonet fixing type bulb (19).

f:G

15 16

Page 24

Electrical

Press the

arm

down

onto

the spindle until 'it is retained in position by the clip.

Fig. 12 Ensure

that

there is a distance between the top wiper blade pivot (1)

and

the

windscreen rubber (2) in the position shown as follows:

'A'-Left-hand

arm

t to 1 in.

'B'-Centre

and

right-hand

arm

--§-totin.

WINDSCREEN

WIPER

AND

WASHER

Wiper

arms

To re-position a wiper

arm

on the spindle, hold the spring clip (1) clear of the

Fig. 13 retaining groove in the spindle and withdraw the arm. Position the

arm

on the

spindle (2).

Windscreen

'The windscreen washer system should be checked for borrect operation and the

' w asher reservoir refilled if necessary every week

and

before a long journey in addition to

Fig. 14 the mileage intervalsgiven in

'MAINTENANCE

SUMMARY'.

Washer reservoir. To fill the reservoir (2), remove the cap (1) and lift the reserv ir from its mounting.

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.

Jet

adjusting.

Turn

the jet (3) using a small screwdriver to adjust the height of the

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

Wiper

blade

To renew a wiper blade pull the

arm

away from the windscreen.

Hold

the fastener

Fig. 13 (3)

and

the spring retainer (4) away from the wiper

arm

(5)

and

withdraw the

blade assembly from the arm.

Insert the end of the wiper arm into the spring fastener of the new blade

and

push

the blade into engagement

(6) with the arm.

To ensure efficient wipingit is recommended that wiper

blades

are renewed annually.

Fig. 13

Part No.

BHA

5382

GLB 380 GLB 380 BFS 273 BFS 254 GLB 382 BFS 501 GLB 281 GLB 281 GLB 281 GLB 281

GLB 280 GLB 987

,BFS 643

GLB 254 GLB 254

GLB

281

'GLB 281 GLB

281

Watts

60/50

5/21 5/21

1·5

2'2

2·2 6 6

2 2

Volts

112

112 112

.12

12 12

112

Replacement

Headlamp-sealed

beam

bulbs

Sidelamp (with flasher) . . Stop/tail

.. Reverse Number-plate lamp Direction indicator Side marker lamp, front and rear Ignition warning

.. Main beam Direction indicator warning lamp Oil pressure warning lamp Brake warning lamp

Panel illumination lamp Cigar-lighter illumination Luggage compartment lamp Courtesy lamp

Seat belt warning lamp

.. Switch illumination Heater

rotary

control illumination

Fig. 12

Fig. 14

240

Fig. 12

Fig. 14

Page 25

IGNIIION

Ignition

The,ignition ,timing,is ,set dynam ically to give optimum engine performance with

timing

efficient engine emission cont rol. Electronic test equipment must be used to

check the ignition timing setting

and

the automatic advance (see 'GENERAL

DA~A').

Checking and adjustment to the ignition timing setting should be

carried out by your authorized Aust in MG Dealer control service station.

Basic tuning

data

will be found on the Vehicle Emission Control Information

Label located in the engine compartment.

Distributor

Release the retaining clips and remove the cover (1). Remove the rotor arm (2)

Fig. 1 and the anti-flash shield (3).

LUbricatio~.

Add

a few drops of oil to the felt pad (4) in the top of the timing

rotor

carrier.

Remove the anti-flash shield and lubricate the pick-up plate centre bearing with

a drop of oil in each of the two holes (5) in the base plate. CAUTION: Do not disturb the screw (6) securing the base plate. Cleaning.

With

a clean nap-free cloth wipe the inside of the distributor cover

the

rotor

Cl:rm

and

.the

ant~-flash

s~iel~.

'Refit the anti-flash shield, ensuring

that

the cut-outs are aligned WIththe distributor cover retaining clips. Refit the

rotor

arm and the cover.

Spark

plugs Disconnect the H.T. lead from each spark plug, and partly unscrew each plug.

Fig. 2 Clean the area of the cylinder head surrounding the seating of each plug, then

unscrew each 'plug

and

discard it.

Check the gaps of new plugs, and reset if necessary to the recommended gap (see 'GENERAL DATA'). To reset, use a Champion spark plug gauge and setting

tool; move the side electrode, never the centre one. NOTE:

Ensure

that

only the recommended type and grade of spark plug are

used (see 'GENERAL DATA').

Screw the plug down by

hand

as far as possible, then use a spanner for tightenin only. Always use a tubular box spanner to avoid possible damage to the insulat r, 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 H.T. leads.

Fig. 1

Fig. 2

Fig. 1

6ND1l6

Page 26

ENGINE

LUBRICATION

Checking

The levelofthe oil in the engine sump is indicated by the dipstick (1) dn

the

Fig. 1 right-hand side

the engine . Maintain the level between the

'MAX'

(3~

and

'MIN'

(2)

marks

on the dipstick

and

never allow it to fall below the

'MIN'

mark.

The oil level should always be checked before a long journey. The filler cap (4) is on the

rear

endofthe rocker cover.

Draining

drain

the engine oil, remove the

drain

plug (5) located on the left-hand side

Fig. 1 at the

rear

of the sump. This operation should be carried

out

while the engine

is warm. Clean the

drain

plug,

and

refit.

Filling

Fill the engine with the correct

quantity

of recommended oil.

Run

the engine

Fig. J for a

short

while

then

allow it to

stand

for a few minutes before checking

the

level with the dipstick.

DRIVE

BELT

Fan Tension.

When

correctly tensioned, a total deflection of i in (19 mm) under

Fig.3

moderate

hand

pressure, should be possible at the midway point (1) of the

<, longest belt

run

between the pulleys.

Adjusting. To adjust the belt tension, slacken the securing

nut

and??It (2)

and

adjusting link bolts (3),

and

move the alternator to the required position.

App

any leverage necessary to the alternator

end

bracket (4) only

and

not

to any other

part;

to avoid damaging the drive-end bracket the lever should prefera bly be

~ood.

Tighten the bolts

and

re-check the belt tension.

OVER-

TIGHTEN

as this will impose an excess loading on the drive

beanng

Oil fi

Iter

The oil filter is a disposable cartridge type

and

is located on the left-hand side

Fig. 2 of the engine.

To renew the filter, disconnect the hose (1) from the air

pump,

unscrew

the

cartridge (2) from the cylinder block.Ifthe

adaptor

(3) remains attached to the

cartridge, unscrew the

adaptor

from the cartridge

and

screw it into the cylinder

block. Discard the cartridge.

NOTE:

If difficulty in unscrewing the cartridge is experienced, consult

your

authorized AustinMGDealer. Wipe the engine

joint

face (4) clean and smear with oil. Smear the ,new seal (5)

with oil

and

fit it into the groove in the new cartridge. Screw the cartridge to the

adaptor,

using hand force only. Connect the hose to the air pump.

Refill the engine with the correct quantity of a recommended oil,

start

the engine

and

check for oil leakage.

Fig. 1

Fig. 2

Fig. 3

/4~=~

)

Page 27

Engine

MISSION

CONTROL

SYSTEMS-except

California

VALVE

ROCKER

CLEARANCE

Checking

Disconnect the purge pipe (1) from the r

ocker

cover

and

unscrewthe retaining

Fig 4 screws (2). R elease the collar and seal (3) from the rocker cover. Remove the

rocker cover

(4) and insert a 0·010 in (0,25 mm) feeler gauge (5) between the

val~e

r?cker arms and valve stems.

The

gauge should be a sliding fit when the

engine

IS cold. Check each clearance in the following

order:

You

and

each su bseq uent owner of the

car

are urged to

make

sure

that

the

recommended

maint

enance procedures are

carr

ied out at the intervals specified .

For

the emiss ion

cont

rols to continue to function effectively, it is strongly

recommended

that

you

arrange

for regular maintenance inspections to be carried

out by y

our

authorized AustinMGDea

ler or by any other qualified service

outlet which regularly performs such service on British Leyland cars.

Check

No.1

valve withNo.8

fully open. Check

No.8

valve with

No.1

fully

open

3 6

5 ' " 4 4 " 5

2 7 7 2

Adjusting

Slacken

the

adjusting screw

locknut

(6) on the opposite

endofthe

rocker

arm

and

rotate

the screw (7) clockwise to decrease or

anti

-clockwise to increase

the

clearance. Retighten

the

locknut

when

the

clearance is correct, holding

the

screw

against

rotatio

n with a scre

wdr

iver. Re-check the cle

ara

nce.

Refitting

Clean the rocker cover sealing face

and

fit a new gasket (8) to the rocker cover.

Refit the cove r, the brackets,

and

connect the pu rge pipe.

You have been provided with a Passport to Service which co nta ins a facility to recor d tha t maintenance has been carried

out

at the rec

ommen

ded mileages.

You should have the maintenance rec

ord

completed by y

our

authorized Austin

Dealer (or by

other

dealer or

station

equipped to render such service) at

the regular mileage intervals indicated in the Schedule.

The

Handboo

k and

Passport to Service should be

handed

to subsequent purchasers of the vehicl

at the tim e of sale so

that

the maintenance instructions are available

and

that

the recor d of maintenance

can

be continued.

You are also urged to study with care the section covering

'MALFUNCTION

IDE

NTIFICATIO

N' . Study of this section will be of aid to you in detecting

possible malfunctions of the em ission con

tro

ls so that necessa ry service measu res

can immediately be

tak

en.

IMPORTA

Your

atten

tion is

par

ticula rly drawn to the following:

Fig. 4

The basic engine tuning

data

will be f

ound

on the emission control inf rrnat ion

label located in the front of the engine

com

partmen t.

General

This section gives a general

description

evaporative emi ssion control their individual co mponent .

mu t b emphasized that correct ca

rbur

etter

adjustment

and

ignition timing which hav been pre-set at the factory are essential for the efficient functioning of th xhau t emission control s. Should it become necessary to check or adjust th e ttings this work

shou

ld be carried out by

an authorized Au stin

or riti h Leyland

Dea

ler who has the specialist

Ortn;nn"H~

1"'\t~1"'\rltr

~;1"'\

;1"'\

lInrlrta Ir

h~c~

arl'llctn"~

1"'\tc

their individual component . Jt n 1I t b mphasized

that

correct ca

rburetter

adjustment

and

ignition timing whi h h v been pre-s et at the factory are essential for the efficient functioning of th xh ust emission controls. Should it become necessary to check or ad

just

th ttings this work should be carried out by

an authorized Au stin MG or Briti h Leylan d

Dea

ler who has the specialist

equipment

and

trai ning to undertake these adj

ustm

ents.

Fig. 4

Page 28

mission

Control

Systems-except

California

Crankcase

The engin.e crankcase breather outlet incorporates an oil sepa

rator

flame-trap

emission

(arrester) In the topo~the valve rocker cover which is connected by hoses to

control

the controlled depression

chamber

between the

piston

and the throttle disc of

the

carburette

r. Piston blowby fumes are drawn into the depression chamber

of.the

carburetter

from the rocker cover, and are joined by purged air from the

pnm~ry

c~arcoal

canisterofthe fuel evaporate loss system. These fumes

combine with the Inlet charge for combustion

in the normal way.

Exhaust

The exhaust emission control system is designed to give the required degree of

emission

control of the ca

rbon

monoxide,

unburnt

hydrocarbons and oxides of nit rogen

control

content of exhaust gases.

The emission control system is a combination of engine components

and

air

injection techniques

and

consistsofa special carburetter, air injection into the

exhaust manifold

and

exhaust gas recirculation.

THE

EMISSION

CONTROL

COMPONENTS

17 8

ND141C

The quantity of air-polluting elements in the gases leaving the exhaust pipe is reduced by adding air to the hot gases immediately they leave the combu tion chambers of the engine. The injection of air into the exhaust gases promote

continued conversion of the undesirable hydrocarbon

and

carbon mon oxid

components of the exhaust gases to relatively harmless

carbon

dioxide and wat r.

The exhaust gas recirculation valve mounted on the exhaust

man

ifold will re-circulate a controlled quantity of the exhaust gases to reduce combu tion chamber temperature.

The catalytic converter is fitted into the exhaust system in order to reduce c

arbon

monoxide

and

hydrocarbon emissions. .

An air

pump

mounted on the front of the engine,

and

belt driven from the crankshaft pulley, supplies air unde r pressure through a hose, a check valve, and

distribution pipe to the exhaust manifold. The check valve prevents high

pressure exhaust gases from blowing back into the

pump

due to , for example,

pump

drive failure.

The carburetter is

manuf

actur d to xhau t emission specification and

is tuned to give the maximum mi

i n I n i tent with retaining vehicle

performance and drivabili y. Th m t rin n

J i arranged in such a ma nner

that

it is alwa ys lightly prin I d d in t th ide of the jet to ensure con-

sistency of fuel metering. A

thr

t 1 y..p valve limits the inlet manifold

depression

and

ensures that durin c nd itions of engine overrun the air/fuel

mixture enters the engine cylind r in

burna

ble condition consistent with low

emission levels.

1. Secondary charcoal adsorption canister

2. Canister inter-connecting pipe

3. Primary charcoal adsorption canister

Vapour

lines

5. Purge line

6. Restricted connection

7. Restrictor

8. Sealed oil filler

cap

· Oil separator/flame

trap

(arrester)

O. Fuel pipe

l:'

n.al

........~.....

13. Air

pump

14. Check valve

15. Air temperature control valve

16.

Hot

air hose

17. Exhaust gas recirculation valve

18.

E.G.R.

valve pipe

19. Flame

trap

20. Flame

trap

line to carburetter

21. Flame

trap

line to

E.G.R.

valve

22. Flame trap line to distributor vacuum unit

Page 29

Emission

Control

Systems-except

California

Fuel

To prevent air pollution by vapours from the fuel

tank

and

the carburetter vents,

evaporative

the control equipment stores the vapour in both of the charcoal-filled canisters

loss

control

while the engine is stopped

and

disposes of it via the engine crankcase emission

control system when the engine .is running. The fuel

tank

venting is designed to ensure that no liquid fuel is carried to the

storage canisters with the vapours and that vapours are vented through the

control system.

The capacity of the fuel tank is limited by a specially positioned filler vent tube and ensures sufficient volume is available after filling to accommodate fuel which would otherwise be displaced as a result of a high temperature rise.

Warning: When filling with fuel do not attempt to add more

than

the capacity

given in

'GENERAL

DATA'. Slow filling, or allowing the level to drop and then

adding more fuel, is not recommended and can result in spillage due to expansion.

MALFUNCTION

IDENTIFICATION

Check the following items regularly for visual signs of a malfunction and also if any of the driving symptoms listed should persistently occur.

you are unable to locate and/or correct the malfunction you are advised to contact your authorized Austin MG Dealer immediately.

Visual

checks

1. Condition and adjustment of drive belts.

2. Baked or overheated hose between air pump, diverter valve and check valve.

3. All hoses for security, damage and deterioration.

4. Fuel leakage.

5. Oil filler cap for sealing.

6. Fuel filler cap for sealing.

THE

LAYOUT OF

THE

FUEL EVAPORATIVE

LOSS

CONTROL

SYSTEM

7ND138C

Driving

symptoms

1. Violent backfire in exhaust system.

2. Hesitation to accelerate on re-opening the throttle after sudden throttle closure.

3. Engine surges (erratic operation at varying throttle openings).

4. Engine idles erratically or stalls.

5. Noisy air pump.

6. Ignition warning light on a bove idle speed (slack or broken fan belt).

7. Smell of fuel vapours.

8. Engine stops after short runnin g period (fuel tarvation).

9. Lack of power.

10. Excessive fuel consumption.

11. Engine misfires (engine jerk on crui and acceleration).

12. High temperature indicated ( verh a ting of coolant).

1. Secondary charcoal adsorption canister

2. Primary charcoal adsorption canister

3. Canister inter-connecting pipe

4. Vapour lines

5. Purge line

6. Restricted connection

7. Restrictor

8. Sealed oil filler

cap

9. Oil separator flame

trap

(arrester)

10. Fuel pipe

11. Fuel pump

12. Fuel

tank

13. Sealed fuel filler cap

14. Vapour line

15. Vapour tube

16. Capacity limiting

tank

17. Separation

tank

18. Vent pipes

Page 30

Emission

Control

Systems-except

California

MAINTENANCE

OPERATIONS

All items

marked

* in the

'MAINTENANCE

SUMMARY'

given on pages 76

to 82 are emission control related.

Adsorption

The charcoal adsorption canisters (5) and (10) must be renewed every 50,000 miles.

canisters

Fig. 1 To remove the secondary canister. "Disconnect two

outer

vent pipes (1) and the

c:ntral

vent pipe (2) from.the topofthe canister. Disconnect the inter-connecting

pipe (3) from Its connection on the canister. Remove the securing bracket

nut

and bolt (4) and remove the secondary canister (5). To

~~move

the

pri~ary.

canister. Disconnect the purge pipe (6),

vapour

pipes (7)

and

inter-connectmg

pipe

(8) from their connections in the canister. Remove the

securing

nut

and

bolt (9) and remove the primary canister (10).

NOTE:

Transfer the restrictor in the primary canister outlet pipe (6) to the

new canister. Refltting.

When

refitting, ensure

that

all connections to the secondary

and

primary

canisters are secure.

Air

pump

Drive belt tension.

When

correctly tensioned, a total deflection of t in (13 mm)

Fig. 2

under

moderate

hand

pressure, should be possible at the midway pointofthe

belt run. Adjusting. Slacken the securing bolt

(1)

and

the two adjusting link bolts (2),

move the air

pump

to the required position. Tighten the bolts

and

re-check the

belt tension.

NOT

OVERTIGHTEN.

Purge

and

To check, disconnect the purge line (1) from the primary

adsorption

canister,

vapour

line

and

the purge line (2) from the carburetter, also disconnect the hose (3) from the

restrictors

vapour

pipe.

Figs. 3

and

Examine the orifice of the primary canister restrictor (4), the carburetter

restrictor (5)

and

the

vapour

line restrictor (6) for obstruction. Clear any dirt

or deposit from a restrictor orifice, using a length of wire. WARNING:DONOT

use air pressure to clear any dirt.

Exhaust

gas

Servicing the

E.G

.R. valve (7) should be carried

out

by your authorized Austin

recirculation

Dealer.

valve

Fig. 4

Fig. 3

Fig. 1

Fig. 4

\~./7

J BN014 6

Fig. 1

Page 31

Emission

Control

Systems-except

California

Filler

caps

Both

the engine oil filler cap (1)

and

the fuel

tank

filler cap (2) are non-venting

Fig. 5

and

form a seal on the filling apertures .

IT IS ESSENTIAL TO

THE

SATISFACTORY

OPERATIONOFTHE

EVAPORATIVE

LOSS

SYSTEM

THAT

BOTH

CAPS

ARE ALWAYS

REFITTED

CORRECTLY. A

DEFECTIVE

CAP OR CAP SEAL (3)

MUST

BE REPLACED.

MISSION

CONTROL

SYSTEMS-California

You

and

each subsequ ent owner of the

car

are urged to

make

sure

that

the

recommended main ten ance procedures

are

carried out at the intervals specified.

For

the emission controls to continue to function effectively, it is strongly

recommended

that

you arrange for regular maintenance inspectio ns to be carried

outbyyour

author

ized AustinMGDealer

or by any

othe

r q ualified ser vice

outlet which regularly performs such service on British Leyland

car

You

have been provided with a Passport to Service which contains a facility to

record

that

maintenance has been carried

out

at the recommended mileages.

You

should have the ma intenance record completed by

your

autho

rized Austin

Dealer

(or by

othe

r dealer or station

equipped

to render such service) at

the regular mileage intervals indicated in the Schedule . The

Handbookand

Passport

to Service should be

handed

to subsequent purchasers of the vehicle

at the time of sale so

that

the maintenance instructions are ava ilable an d

that

the record of maintenance can be continued .

You

are also urged to study with care the section cover ing

'MALFUNC

TIO N

IDENTIFICATION'.

Stud

y of this section will be of

aid

to you in detecting

possible malfunctions of the emiss ion co nt rols so tha t necessa ry service measures

can immediately be

tak

en.

IMPORTANT

Your attention is particularly drawn to the following :

1. Maintenance

and

servicecha rges applicable to the emission con trol system

are

not covered by the w

arr

anty and are not reimbursable, unless shown to have

been caused by defects in material and workmanship covered by the warranty.

The

engine has been designed for the re zular use of unleaded fuel. Le

aded fuel or low lead fuel must not be used a such fuels will seriously impair the efficiency of the emission contro l system and cause

permanent

damage to

the catalytic converter.

Fig. 5

~\\

General

This section gives a general descripti on o f the crankcase,

exhaust

and fuel

des

cri

ption

evaporative emiss ion control system

sfi

ttcd to this vehicle

and

the function of

their individual components.

n1U

t be emphasized

that

correct

carb

uretter

adjustment

and

ignition timing which have been pre-set at the factory are essential for the efficient functioning of the exhaust em ission controls. Should it become necessary to check or adj ust th ese cuing th is

work

should be carried

out

by an authorized Austin MG or British Leyland Dealer who has the specialist equipment

and

trai ning to undertak e these adj ustments.

CT'~JJ"~,u

..o t

1•• \ • •0 "'- •• r L p "

~ 'VJ~

..c ..

for the efficient functioning of the exhau t em ission controls. Sho uld it become necessary to check or adjust these setting this

work

should be carried

out

by an authorized Austin MG or British Leyland Dealer who has the specialist equipment

and

training to undertake these adjustments.

The basic engine

tun

ing

data

will be foun d on the emission control informatio n

label located in the front of the engine compartment.

Page 32

Emission

Control

Systems-California

Crankcase

The engine crankcase breather outlet incorporat es an oil separator flame-trap

emission

(arrester) in the top of the valve rocker cover which is connected by hoses to

control

the controlled depression chamber between the piston

and

the throttle disc of

the carburetter. Piston blowby fumes are drawn into the depression chamber

of the carburetter from the rocker cover, and are joined by purged air from the primary charcoal canister of the fuel evaporative loss system . These fumes

combine with the inlet charge for combustion in the normal way.

Exhaust

The exhaust emission control system is designed to give the required degree of

emission

control of the carbon monoxide, unburnt hydrocarbons and oxides of nitrogen

control

content of exhau st gases.

The emission co ntrol system is a combination of engine components and air

injection techniques and consists of a special carburetter, air injection into the

exhaust

man

ifold and exhaust gas recirculation.

THE

EMISSION CONTROL COMPONENTS

1. Primary charcoal adsorption canister

vnT'~;~~OI

The catalytic converter is fitted into the exhaust system in order to reduce carbo n monoxide

and

hydrocarbon emissions.

The carburetter

is man ufactured t pecial exha ust emission specification a nd

is tuned to give the maximum erni i n control consistent with retaining vehicle performance and drivability. The meterin g needle is

arra

nged in such a manner

that

it is always lightly spring loaded against the side of the jet to ensure con-

sistency of fuel metering.

A t hrottle by-pass valve limits the inlet ma nifold

depression and ensures that durin g conditions of engine overrun the air/fuel mixture enters the engine cylinders in a burnable condition consistent with low

emission levels.

The carburetter

is manufactured t pecial exha ust emission specification and

is tuned to give the ma ximum emi i n co ntrol consistent with retaining vehicle performance and drivability. The m tering needle is

arra

nged in such a manner

that

it is always lightly spring loaded against the side of the jet to ensure con-

comoustlon In rne

englll

t; CYIII I\..It:::I :'l I II l

\,;

Vllll

v\'uy.··

' . . 1 • 1 . _ u

~r_1.J

The exhaust gas recirculation valve mounted on the exhaust manifold will re-circulate a controlled quantity of the exhaust gases to reduce combustion chamber temperature.

When the gulp valve opens, a small

q iantity f air is admitted directly into the

inlet manifold to lean off the rich air/f

"I n i ture which is present in the manifold

under conditions immediately

win 1 thr ttle closure. This mixture, having been reduced to a burn able c n lition, ' n bines with engine inlet charge for combustion in the engine cylind rs in the normal way.

An air pump mounted on the front of the engine, and belt driven from the crankshaft pulley, supplies air under pressure through a hose, a check valve, and distrib ution pipe to the exhau t manifold. The check valve prevents high pressure exhaust gases from blowing back into the pump due to , for example, pump

drive failure.

The quantity of air-polluting elements in the gases leaving the exhaust pipe is reduced by adding air to the

hot

gases immediately they leave the combustion chambers of the engine. The injection of air into the exhaust gases promotes a continued conversion of the undesirable hydrocarbon and carbon monox ide components of the exhaust gases to relatively harmless carbo n dioxide

and

water.

7NDlLil D

15. Air injection pipe

16. Air pump

17. Check valve

18. Air temperature control valve

19.

Hot

air pipe

20. Exhaust gas recirculation valve

21. E.G.R. valve pipe

22.

E.G

.R. valve flame

trap

23. E.G .R. valve flame

trap

line to carburetter

24. Flame

trap

line to E.G.R. valve

25. Dist ributor flame

trap

26. Distributor flame

trap

line to carburetter

27. Flame

trap

line to distributor vacuum unit

28. Air vent pipe

15. Air injection pipe

{

19 1329/ 8

·5

1. Primary charcoal adsor ption canister

2. Vapour lines

3. Purge line

4. Connect ing pipe

5. Secondary cha rcoal adso

rpt

ion canister

6. Restricted con nection

7. Rest rictor

8. Sealed oil filler cap

9. Oil separator/flame trap (arrester)

10. Fuel pipe

11. Fuel

pump

12. Running-on cont rol valve

13. Sensing pipe

14. Running-on control hose

Page 33

ALFU N CTION

IDENTIFICATION

Check the following items regularly for visual signs of a malfunction

and

also

if any of the driving symptoms listed should persistently occur. If you are

un~ble

to locate and/or correct the malfunction you are advised to contact your authorized Austin

Dealer immediately.

Emission

Control

Systems-C

alif

ornia

Fuel

To prevent air pollution by vapours from the fuel

tank

and

the carburetter vents,

evaporative

the control equipment stores the vapo ur in

both

of the charcoal-filled canisters

loss

control

while the engine is stopped

and

disposes of it via the engine crankcase emission

control system when the engine is running. The fuel

tank

venting is designed to ensure

that

no liquid fuel is carried to the

storage canisters with the vapours and

that

vapours are vented through

the

control system. The capacity of the fuel

tank

is limited by a specially positioned filler vent

tube and ensures sufficient volume is available after filling to accommodate fuel which would otherwise be displaced as a result of a high temperature rise.

Warning: When filling with fuel do

not

attempt to add more

than

the capacity

given in

'GENERAL

DATA'. Slow filling, or allowing the level to

drop

and

then adding more fuel, is

not

recommended

and

can result in spillage due to expansion.

THE LAYOUT

THE

FUEL

EVAPORATIVE

LOSS

CONTROL

SYSTEM

Visual

checks

1. Condition

and

adjustment of drive belts.

2. Baked or overheated hose between air pump, diverter valve and check valve.

3. All hoses for security , damage

and

deterioration.

4. Fuel leakage.

5. Oil filler

cap

for sealing.

6. Fuel filler cap for sealing.

7. Catalytic converter warning light on.

7~j813

81J

Driving

1. Violent backfire in exhaust system.

symptoms

2. Hesitation to accelerate on re-open ing the throttle after sudden

throttle

closure.

3. Engine surges (errat ic operation at varyin g throttle openings).

4. Engine idles erratically or stalls.

5. Noisy air pump.

6. Ignition warning light on above idle speed (slack or brok.en fa n belt).

7. Smell of fuel vapours.

8. Engine stops after short runnin ' periods (fuel starvation).

Lack

of power.

10. Excessive fuel consumption.

11. Engine misfires (engine jerk s n cruise and acceleration) .

12. High temperature indicated (overheating

f coo lant).

1. Primary charcoal adsorption canister

Vapour

lines

3. Purge line

4. Connecting pipe

5. Secondary charcoal adsorption canister

6. Restricted connection

7. Restrictor

8. Sealed oil filler cap

9. Oil separator/flame

trap

(arrester)

10. Fuel pipe

12. Running-on control valve

13. Sensing pipe

14. Running-on control hose

15. Air vent pipe

16. Fuel

tank

17. Sealed fuel filler

cap

18. Vapour line

19. Vapour tube

20. Capacity limiting

tank

21. Separation

tank

Page 34

Emission

Control

Systems-California

MAINTENANCE

OPERATIONS

All

items marked

in the

'MAINTENANCE

SUMMARY'

given on pages 76

to 82 are emission control related.

Adsorption

The charcoal adsorption canisters

(6)

and

(11)

must be renewed every

50,000

miles.

canisters

Fig.

1 To remove the secondary canister. D isconnect the two outer vent pipes (1) and

the central vent pipe (2) from the top of the canister. Disconnect the running-on control hose (3) from its connection on the canister. Remove the securing bracket nut and bolt (4) and the running-on control valve bracket nut and bolt (5) and remove the secondary canister (6).

To .prevent the engine running on after the ignition has been switched off, a control valve is fitted to the air vent pipe of the secondary adsorption canister. The valve is a self-conta ined unit

and

requires no regular maintenance. Care

should be taken when renewing the secondary adsorption canister not to disturb the valve or its connections .

Purge

and

To chec k, disconnect -the purge line

(1)

from the .primary adsorp tion canis ter,

vapour

line

and

the purge line

(2)

from the carburetter, also disco nnec t the hose

(3)

from the

restrictors

vapour line.

Figs.

and

Examine the orifice of the pr imary canister retr ictor (4), the carburetter restric tor (5)

and

the vapour line restrictor (6) for

obst~uct

ion

Clear any dirt or deposit

from the restric

tor

orifice, using a length of

WIre.

WARNING:

NOT

use air pressure to clear any d irt.

Exhaust

gas

Servicing the

E.G.R.

valve

(7)

should be carr ied out by your aut horized Austin

recircu lat ion

Dealer.

valve

Fig.

ig. 4

.&"'1

~,.

\ ,

belt tension.

NO~

rl(JHlE~.

Adjusting. Slacken the securing bolt (1) and the two adjusting

link

bolts (2),

move the air

pump

to the required position. Tighten the bolts and re-check the

belt tension.

NOT

OVERTIGHTEN.

Air

pump

Drive belt tension. When correctly tensioned, a total deflection of

(13 rom)

Fig.2

under moderate

hand

pressure, should be possible at the midway point of the

belt run.

Refitting. Whe n refitting, ensure

that

all connect ions to the primary and secondary

canisters are secure.

NOTE:

Tran sfer the restrictor in the primary canister outlet pipe (7) to the new

canister.

To remove the primary canister. Disconnect the purge pipe (7), vapour pipes (8) and the connecting pipe (9) from their connections on the canister. Remove the securing bracket nut and bolt

(10)

and remove the primary canister

(11).

Fig.

Page 35

Emission

Control

Systems-California

UEL

SYSTEM

CLEANER

Filler

caps

Both

the engine oil filler

cap

(1)

and

the fuel

tank

filler

cap

(2) are non-venting

Fig.5

and

form a seal on

the

filling apertures.

IT IS ESSENTIAL TO THE SATISFACTORY OPERATION OF THE EVAPORATIVE LOSS SYSTEM THAT BOTH CAPS ARE ALWAYS REFITTED CORRECTLY. A DEFECTIVE CAP OR CAP SEAL (3) MUST BE REPLACED.

Element

changing

Fig. 1

The element of the air cleaner

must

be renewed every 12,500 miles or 12

months;

frequent changes may be necessary in dusty operating conditions.

Disconnect the hot air pipe

(1) from the air temperature control valve (2).

Release the two clips (3) on the top of the casing (4). Move the cover (5) a nd

element (6) away from the casing and then withdraw. Discard the element. Thoroughly clean the air cleaner cover and casing.

Fit

a new element into the cover, ensuring the seal of the element faces the casing. To refit the cover, locate the spigots of the cover in the lower lip of the casing and secure with the two clips.

Connect

the hot air pipe to th e air temperature control valve.

Air

intake

tem

peratu

control

Fig. 1

The

temperature

of the a ir entering the ca rburetter is controlled by a va lve

fitted to the intake of the air clea ner. Th e control valve (2) s hould be inspected

for condition

and

oper ation by

your

author ized AustinMGDealer.

I . 1

Fig. 5

Fig.

Page 36

Fuel

System

FU EL PU MP

The

fuel

pumpismounted

on the left-hand side of

the

engine.

The

cover should

removed

and

the filter gauze cleaned.

Cleaning

Slacken the hose clip

and

remove the hose (1) from the

pump

top cover. Unscrew

Fig. 2 the centre

bolt

(2), withdraw the

top

cover (3)

and

remove the filter gauze (4) .

Wash

the filter gauze in clean fuel. Check

that

the gasket (5) is in position

and

good

condition;

renew if necessary.

Fit

the filter gauze

and

top

cover,

and

secure with the centre bolt.

IMPORTANT:

Tighten the centre bolt to 10 to 14 lbf in (0'11 to 0·16 kgf m).

After

starting

the engine inspect the fuel

pump

for

air

and

fuel leaks. Check the

inlet (1)

and

outlet (6) hoses for leaks

and

serviceability.

CARBURETTER

Air

pollution

The

carburetter

incorporates features which assist in reducing exhaust emissions.

control

Maladjustment

or the fitting of

parts

not

to the required specification may render

these features ineffective.

Carburetter

Checking oil level. Unscrew the

damper

cap (1) from the

carburetter

top cover.

damper

Carefully ra ise the

damper

to the

top

of its travel. Lower the

damper

back

into

Fig. 3 the hollow piston rod. If the oil level in the hollow piston

rod

is correct, resistance

should be felt when there is a gap of approximately

t in (A) between the cap

and

the carburetter top cover.

Top

up if necessary. Screw the

damper

cap firmly

into

the carburetter top cover.

Topping-up the oil level. Remove

the

air

cleaner. Unscrew the

damper

cap (1)

from the

carburetter

top cover. Raise the piston (2) with a finger,

and

at the same

time lift the

damper

(1)

and

carefully ease the retaining

c~p

(3)

fr~m

the

h~llow

piston

rod

to release the

damper

assembly from the piston.

~Ith

.the p.lston

raised

top

up the hollow piston

rod

with a recommended engme 011

unt

il the

level is

-!in below the top of the hollow

piston

rod. Lower the piston. UNDER

CIRCUMSTANCES

SHOULD

A HEAVY BODIED LUBRICANT BE

USED.

Ensure

the oil level is correct. Raise the piston

and

carefully pr ess the

retaining cup

into

the hollow piston

rod.

Screw the

damper

cap firmly Into the

carburetter

top

cover. Refit the air cleaner.

Tuning

The

tuning of the

carbu

retter is con fined to setting the idle speed

and

mixtur

strength (CO percentage).

Adjustment

should only

und~rtaken.

by you

authorized

AustinMGDealer

who will have the essential special equipment f r

this purpose.

Fig. 2

Fig. 3

Fig. 2

Page 37

TRANSMISSION

STEERING

AND

SUSPENSION

Ensure

that

the car is standing on a level surface when checking the oil levels.

Do not drain the gearbox or the

rear

axle

during the 1,000 Mile

Free

Service.

Gearbox

The gearbox combined oil filler

and

level plug is located on the right-hand side

Fig. 1 of the gearbox. Clean

around

the filler plug before removing it.

The oil level should be maintained at the

bottom

of the filler plug

aperture

threads.

Rear

axle

A combined oil filler

and

level plug is located on the

rear

of the axle. The oil

Fig. 2 level should be maintained at the

bottom

of the plug aperture. 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.

Propeller

A nipple (1) is provided at the front end of the propeller shaft for lubricating the

shaft

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

Fig. 3 recommended grease.

Fig. 1

LUBRICATION

Swivel

axle

Two

lubricating nipples (1)

and

(2) are provided in each swivel pin. To lubricate,

pins

charge the nipples with one of the recommended greases. To ensure full penetra-

Fig. 1 tion of the lubricant, this operation is best carried

out

with the

car

partly

jacked

up.

Front

A lubricating nipple (3) is provided on each of the

outer

fulcrum pins . To lubri-

suspension

cate, charge the nipples with one of the recommended greases.

outer

fulcrum

pins

Fig. 1

STEERING

Inspect the gaiters or bellows of the steering

rack

for leakage of lubricant and

RACK

deterioration.Ifleakageoflubricant is evident, consult

your

authorized Austin

Dealer.

FRONTWHEEL

Incorrect wheel alignment can cause excessive and uneven tyre wear. The front

ALIGNMENT

wheels

must

be set so tha t the distance

~A'

is (Ir in to

in (toe in) less than the

Fig. 2 distance

'B'.

Wheel alignment require, the use o f a pecial gauge and this

work

should

entrustedtoyour

auth

orized Au tin MG Dealer.

Fig. 2

hl(~

. I

'II

l1li

Fig. 3

Fig. 1

Fig. 2

~~II

Fig. 2

Fig.

Fig. 1

Fig. 2

~nl

t}!t·

t1I

Page 38

GENERAL

DATA

During

running-in from new certain adjustments vary

from

the specification

figures detailed. They will be set to specification by

your

authorized Austin

Dealer

at the 1,000 .Mile Free Service

and

should thereafter be maintained

throughout

the car's life.

3 to 7

%(5%nominal)

Engine

Engine type

Bore

.. Stroke Cubic capacity Compression ratio: L.C. Firing

order

.. Valve rocker clearance (cold) Idle speed Oil pressure:

Normal

(approx.)

Idling (approx.)

Exhaust gas content (carbon

mon-

oxide) at idle speed

PE 94J 2·9 in 3·44 in 91'0

in"

7·5 : 1 1,3,4,2 0·010 in. 700 to 900 rev/min 40 to 60

Ibf/in

20lbf/in

73·7 rom 87·5 mm 1493

ern"

0·25 rom

2·81 to 4·2 kgf/crn'' 1·4 kgf/crn!

Dimensions

Track:

Pressed spoked wheel:

Front Rear

Wire wheel:

Front Rear

Turning circle: Left lock

Right lock

Front

wheel alignment toe-in Wheelbase Overall length Overall width: Pressed spoke wheel

Wire wheel . . Overall height Ground

clearance

3 ft

10k

in.

3 ft 9 in

3 ft

10-&

3 ft 9* in

32 ft

31 ft

2-!-

Parallel to

t in

6 ft 8 in

11 ft 9 in

4ft

4 ft 8!- in 4 ft t in

tin

118·27 em 114·30 em

117·63 ern 114·93 em 9·79 m

9·51

oto 3·2

2·03 m 3·6m 1·41 m

1·44 m

1·13 m 82·55

29 litres 4·5litres 1'3 litres 1·0 litre

5·42 litres

0·25 litre

6-!-

gal

8 pt

It pt

Ii pt

9!-pt

t pt

J,' I

I ' R- I

Radial ply (with

tub

e when wire wheels

fitt

7'5 U.S. gal 9·6 U.S. pt

],75 U.S. pt

2·] U.S. pt

11·4 U. .

0·6 U

Capacities

Fuel

tank Engine sump including filter Gearbox Rear

axle Cooling system (with heat er) Heater

Wheels

and

Wheel size: Pressed spoked

tyres

Wire

Tyres: Size

Type

Lucas type 45DE4

41697-all

States except California

41698-California

only

Champion

N12Y

0·025 in 0·64

rom

10° B.T.D.C. at idle speed 2° A.T.D.C. at idle speed Notch

on crankshaft pulley, pointers on

timing chain cover

Spark

plugs

Spark

plug gap

Stroboscopic ignition timing:

All States except California California only

Timing

marks

Ignition

Distributor

Serial

number

Fuel

system

Recommended fuel

Carburetter

. .

Carburetter

needle

Transmission

Rear

axle ratio

Overall gear ratios:

rFirst

With ISecond

synchromesh

Third

Fourth

lReverse

rut=1

:»Y:»lt=1I1

Pump

.I'..~~UllHll~llU~U1U~l

••

Carburetter

needle

Pump

Unleaded fuel (91 octane) Zenith Stromberg type

CD4T

45Q-all

States except California

45R-California

only

A.C. mechanically operated diaphragm

Ul11~i:lU~U

lU~l

\.71

U~li:lll~)

Zenith Stromberg type

CD4T

45Q-all

States except California

45R-California

only

A.C. mechanically operated diaphragm

3·72 :

12·69 : 1

7·86 : 1

5·33 :

3·72 : 1

13·96 : 1

Tyre

pressures

Normal driving Sustained high speed

Condition

Ibffin

gfl

cm"

bars

Ibflin

kgflcm"

bars

Front

1'55

1'52

26 1·8 1·79

J---.----.

Normal driving Sustained high speed

Condition

Ibflin

kgf[cm"

bars

Ibflin

kgflcm"

bars

Front

1'55

1·52 26

1·8

1·79

Normal

load

Rear

24 1·7

1·66

2·0 1·93

Front

1'55 1'52

1·8

1·79

Maximum

load

Rear

1·8 1·79

2'1

2·07

Refer to page 74 for 'Weights'.

Top

gear speed per 1,000 rev/min . . 17·3

m.p.h,

27·7

km/h

Page 39

General

Data

Weights

Distribution

Loading conditions Total weight

Front Rear

Kerbside Including full fuel

1,8491b 941 lb

908 Ib

tank

and all optional

(839 kg) (427 kg)

(412 kg)

extras

Normal Kerbside weight

2,1491b 1,0341b 1,115 Ib

including driver and

(975 kg)

(469 kg)

(506 kg)

passenger

Gross

Maximum weight

2,2291b 1,0031b

1,2261b

condition, refer to (1011 kg)

(455 kg)

(556 kg)

note below

Maximum permissible towing weight

1,3441b

(610 kg)

Recommended towbar hitch load

75lb

(34 kg)

NOTE:

Due

consideration must be given to the overall weight when fully loading the car.

Any

~oads

carried on a luggage rack or downward load from a towing hitch must also be included in the

maximum loading.

SERVICE

Service

Your

authorized Austin MG Dealer is provided with the latest information

concerning special service tools

and

workshop techniques. This enables him to

undertake your service and repairs in the most efficient and economic manner.

Identification

When communicating with your authorized AustinMGDealer always quote the commission and engine numbers. When the communication concerns the transmission units or body details it is necessary to quote also the transmission casing and body numbers.

Car number. Stamped on a plate secured to the left-hand

door

post and to a plate

secured to the top of the fascia.

Engine number. Stamped on a plate secured to the left-hand side of the cylinder

block, or stamped directly onto the cylinder block.

British

Leyland

Motors

Inc.

600

Willow

Tree

Road,

leonia

New

Jersey

07605

Telephone:

(201)

461/7300

Telex: 135491

Page 40

MAINTENANCE

SUMMARY

Basic engine tuning

data

will be found on the Vehicle Emission Control Information label located in

the engine compartment.

Detailed

maintenance

instructions

will be

foundonthe

page

indicated

after

each

item.

The

following items should be checked weekly by the driver:

Engine

oil level (48)

Brake

fluid level (33)

Radiator

coolant

level (28)

Battery

electrolyte level (36)

Windshield

washer

reservoir fluid level (45)

All

tyre

pressures (73).

All lights for

ope

ration

Horn

operation

Windshie

ld wipers

opera

tion

MAINTENANCE

INTERVALS

* These items

are

emission related

Service

Mileage

x 1000

Monthly intervals

Page

No.

A 1 1

3, 9, 16, 22, 28, 34, 41, 47

6, 19, 31, 44

12'5,37

25, 50

NOTE:

The

service inte rvals

are

basedonan

annual

mileageofapproximately

12,500 miles.

Should

the

vehicle

complete

substantially

less miles

than

this

per

annum,

it is

recommended

thata'C

' service

completed

at si

x-month

intervals,

and

'D'

service at twelve-month intervals.

'A'SERVICE Lubrication

Lubricate

all grease

points

(except

hubs

and

steering

rack)

(84).

Renew

engine oil (48).

Check/topupbra

ke fluid reservoir (33).

Check/topupclutch

fluid reservoir (33) .

Check

/topupbattery

electrolyte (36).

Check/top

up cooling system (28).

Check/top

up gea

rbox

oil (70).

Check/tooUDrear

axle oil (70),

Check/topupbrake

fluid reservoir (33).

Check

/top

up clutch fluid reservoir (33).

Check

/topupbattery

electrolyte (36).

Check/top

up cooling system (28).

Check/top

up gea

rbox

oil (70).

Check/topuprear

axle oil (70).

Check

transmission for oil leaks.

*Lubricate

accelerator

cont

rol linkage

(and

pedal

pivot);

check

operation

(84).

Lubricate

all locks

and

hinges (not steering lock).

Engine

Check

for oil leaks.

*Check

driving belts;

adjustorrenew (49

and56or

65).

*Check

cooling

and

heater

systems for leaks

and

hoses for security

and

condition.

*Check

crankcase

brea

thing

and

evaporat

ive loss system hoses for security.

Check

securityofengine

mountings.

*Check/adjust

torqueofcylinder

head

nuts.

*Check/adjust

valve clearances (50).

*rheck

secnritv

F _n .R .

valve

onerarinz

lines

ERV ICE- continued

IHo

'heck ignitio n wiring for fraying, ch afing a nd

deteriorat

ion .

'hec k/a djust ignit ion t iming, using electronic equipmen t.

heck security

distributor

vacuum unit line (all

States

except

Califor

nia).

'heck security

distributor

vac

uum

unit line and

operationofvacuum

unit

(Californi a on l

y).

uel ystem

heck fuel system for leak s, pipes

and

unions for cha fing

and

corrosio

p up

carburetter

pis

ton

dampe

r (68). 'heck/a djust deceleration by-pass valve. 'heck/adjust ca

rburetter

idle settings.

eck/

adjust

ope

rat

ion

of all

washer

s a nd top up reservoir (45).

heck tyres for external cuts in tyre fabric, expo

sure

of ply or co rd st ructure, lu mps or bul ges.

heck/adjust

tyre

pressures, including sp are (73).

heck tightness of

road

wheel fast enin gs (30).

"heck

condition

and secu rity of stee ring unit , j oints and gaiters.

heck security of suspension fixings.

heck steering

rack/gear

for oil/flu id leaks.

heck

shock

absorbers

for fluid

leak

'heck/adj ust

foot

and

hand

brake (34).

heck visually

hyd

raulic hoses, pip es and un ions forchafing, crac ks, leak s a nd c

orro

sion .

'heck/adj ust front wheel alignment.

heck

outpu

t of

charging

system.

heck funct

ion

of original equipment, i.c. illl.r io r

lIH

', l .rio:: Ian px, horn s,

wip

ers, and

warning

ind icators.

heck/ adjust headl

amp

alignme nt

(J9)

heck

operationofall

door

, bo nnet and boo t locks.

heck

ope

ration

of window

contr

ols.

heck

condition

and

security of seats and sea l hells.

nad

Test

Roa

d/roller test

and

check function o f all in

xuurn

cnt.ui

on .

Repor t

additional

work

req uired.

IJ'SE

RVI CE

ubrication

ubr icate all grease points (except

hub

s an d stcc rin J rack) (84).

,<.....,v'J.'"' U U U

.I V .l1 U l · VY

V1.n.'

""'\:i~U1."'U.

n'SE

RVI CE

ubrication

ubr icate all grease points (except hubs a nd

stccrin J rack) (84).

heck

/top

up engine oil (48).

heck

/topupbrake

fluid reser voir (33).

heck

/top

up clutch fluid reservo ir (33).

heck/ top up

batte

ry electrolyte (36).

heck

/top

up cooling sy

stem

(28).

eck/topupgearbox

oil (70).

heck/ top up

rear

axle oil (70).

heck

transm

ission for oil leaks.

':ngine

heck for oil leaks.

"heck cooling and

heater

systems for leaks

and

hoses for security and co nd ition.

Page 41

Maintenance

Summary

'B'

SERVICE-continu

Fuel system

*Check fuel system for leaks, pipes and unions for chafing

and

corrosion.

Safety

Check/adjust operation of all washers and top up reservoir (45). Check tyres for tread depth, and visually for external cuts in fabric, exposure of ply or

cord

struc-

ture, lumps or bulges.

Check

that

tyres comply with manufacturer's specification (73). Check/adjust tyre pressures, including spare (73). Check tightness of

road

wheel fastenings (30).

Check condition and security of steering unit,

joints

and

gaiters. Check steering rack/gear for oil/fluid leaks. Check shock absorbers for fluid leaks. Check/adjust foot and

hand

brake (34).

Check visually hydraulic hoses, pipes

and

unions for chafing, cracks, leaks

and

corrosion.

Check function of original equipment, i.e. interior

and

exterior lamps, horns, wipers,

and

warning

indicators. Check, if necessary renew, wiper blades (45). Check/adjust headlamp alignment

(39). .

Check condition and security of seats

and

seat belts.

Check

operation

of seat belt warning system.

Check

rear

view

mirror

for cracks

and

crazing.

Road test

Report

additional work required.

'C'SERVICE

Lubrication

Lubricate all grease points (except hubs

and

steering rack) (84). Renew engine oil. Renew engine oil filter (48). Check/top up brake fluid reservoir (33). Check/top up clutch fluid reservoir (33). Check/top up battery electrolyte (36). Check/top up cooling system (28). Check/top up gearbox oil (70). Check/top up rear axle oil (70). Check transmission for oil leaks.

Check/top up clutch

t1UIQ

reservoir

{JJ).

Check/top up battery electrolyte (36). Check/top up cooling system (28). Check/top up gearbox oil (70). Check/top up rear axle oil (70). Check transmission for oil leaks. Lubricate

hand

brake mechanical linkage.

*Lubricate accelerator control linkage (and pedal pivot); check operation (84.)

Lubricate all locks and hi nges (not steering lock).

Engine

Check for oil leaks.

*Check cooling

and

heater system for leaks,

and

hoses for security

and

condition.

*Check exhaust system for leaks

and

security.

Fuel system

*Check fuel system for leaks, pipes

and

unions for chafing

and

corrosion.

'. ERVICE- continued

fcty

"heck/adjust operation of all washers a nd top up reservoir (45).

heck tyres for tread depth , and visually for external cuts in fabric, exposure of ply or cord struc-

ture, lumps or bulges.

heck

that

tyres comply with manufacturer's specification (73). heck/adjust tyre pressures, including spare (73). heck tightness of

road

wheel fastening s (30).

heck condition

and

security of steering unit, joints

and

gaiters. heck security of suspension fixings. heck steering rack/gear for oil/fluid leaks.

heck

shock

absorbers for fluid leaks.

Jnspect

brake

pads for wear

and

discs for condition (34).

heck/adjust foot

and

hand

brake (34). .

heck visually hydraulic hoses, pipes and unions for chafing, cracks, leaks and

corro

sion .

heck/adjust .fron t wheel alignment. l

ean

and

grease battery connections.

heck

output

of charging system. . '

heck function of original equipment, i.e. interior and exterior

amp

s, horn s,

WIp

ers, a nd

warn

ing

indicators.

heck, if necessary renew, wiper blad es

(45).

heck/adjust headlamp alignment (39). heck operation of all door, bonnet, and boot locks.

heck condition

and

security of seats and sca t belts,

heck operation of seat belt warning syste m .

heck rear view

mirror

for cracks and cravin

oad test

Road/roller test

and

check functi on orall lustr um .ntut io u .

Report additional work required.

fakes hi dditi

I k

It is further recommended

that

at 19,000 miles the brake flui d is renewed.

IS a mon a wor

should be carried

out

by your authorized Austin MCJDealer.

0 '

SERVICE

Lubrication

Lubricate all grease points (except hubs) (84). Lubricate steering

rack

(every 37,500 miles only).

0 '

SERVICE

J ubrication

Lubricate all grease points (except hub s) (84). Lubricate steering

rack

(every 37,500 miles only). Renew engine oil (48). Renew engine oil filter (48).

heck/top up

brake

fluid reservoir (33). heck/top up clutch fluid reservoir (33). heck/top up battery electrolyte (36).

Check/top up cooling system (28).

Check/top up gearbox oil (70).

Check/top up

rear

axle oil (70). Check transmission for oil leaks. Lubricate

hand

brake

mechanical linkage.

-L

ubricate distributor (46). .

- Lubricate accelerator control linkage (and pedal pivot) ; check operation (84).

...l

1_~~f_~~

~~~~_:_

......l .....

.nlr\

Page 42

Maintenance

Summary

'D'SERVICE-continued

Engine

Check

for oil leaks.

*Check

driving belts;

adjust

or renew (49

and

56 or 65).

*Check

cooling

and

heater

systems for leaks,

and

hoses for security

and

condition.

*Renew

carburetter

air cleaner element (67).

*Check

air injection system hoses/pipes for

condition

and

security.

*Check

air

intake

temperature

control

system.

*Check crankcase

breathing

and

evaporative loss systems. Check hoses/pipes

and

restrictors

for

blockage, security

and

condition.

*Check/adjust

valve clearances (50).

*Check

exhaust

system for leaks

and

security.

Ignition

*Check

ignition wiring for fraying, chafing

and

deterioration.

*Renew

spark

plugs (47).

*Check securityofdistributor

vacuum

unit

line (all States except California).

*Check securityofdistributor

vacuum

unit

line

and

operationofvacuum

unit

(California only).

*Clean

distributor

cap;

check

for cracks

and

tracking. *Check coil performance on oscilloscope. *Check/adjust

ignition timing, using electronic

equipment.

Fuel system

*Clean fuel

pump

filter (68).

*Check

fuel system for leaks, pipes

and

unions

for chafing

and

corrosion.

*Topupcarburetter

piston

damper

(68). *Check/adjust deceleration by-pass valve. *Check/adjust

carburetter

idle settings.

*Check

condition

of fuel filler

cap

seal.

Safety

Check/adjust

operationofall washers

and

top

up reservoir

(4.5).

Check

tyres for

tread

depth

and

visually for external cuts in fabric, exposureofply or

cord

struc-

ture, lumps or bulges.

Check

that

tyres comply with

manufacturer's

specification (73).

Check/adjust

tyre pressures, including

spare

(73).

Check

tightness of

road

wheel fastenings (30).

Check

condition

and

security of steering unit,

joints

and

gaiters.

Check

security of suspension fixings.

Check

steering rack/gear for oil/fluid leaks.

Check

shock

absorbers

for fluid leaks.

Insoect

brake

Iininzs/n ad s for wear.

drum

/discs for condition (34)

Check

tightness of

road

wheel fastenings (30). .

Check

condition

and

security of steering unit,

joints

and

gaiters.

Check

security of suspension fixings.

Check

steering rack/gear for oil/fluid leaks.

Check

shock

absorbers

for fluid leaks.

Inspect

brake

linings/pads for wear, drum/discs for

condition

(34).

Check/adjust

foot

and

hand

brake

(34).

Check

visually hydraulic hoses, pipes

and

unions for chafing, cracks, leaks

and

corrosion.

Clean

and

grease battery connections.

Check/adjust

front

wheel alignment.

Check

output

of charging system.

Check

function of original

equipment

, i.e.

interior

and

exterior lamps, horns, wipers,

and

warning

indicators. Check, if necessary renew, wiper blades (45). Check/adjust

headlamp

alignment (39).

Check

operationofall

door,

bonnet,

and

boot

locks.

Check

operation

of window controls.

~~ec~

conditi.on

a~d

security of seats

and

seat belts.

ERVICE-continued

uad test

R ad/r oller test

and

check function of all in

strumentation.

eport

additional

work

required.

IIrukes

It is

further

recommended

that

every 37,500 miles the

brake

fluid, hydraulic seals,

and

hoses in the

brake

and

clutch hydraulic systems are renewed.

Examine

working surfaces of pistons and bores

in,

master,

slave

and

wheel cylinders,

and

renew

parts

as necessary. This

additional

work should

carried

outbyyour

authorized

Austin MG Dealer.

.'zerlng

At every 37,000 miles the steering

rack

sho uld be lubri cated. This additio nal

work

sho uld he

car ried

outbyyour

authorized

Austin M G Dea ler.

SERVI CE

_oJ brication

Lubricate all grease

points

(except hub and steering rack) (84). Renew engine oil (48). Renew engine oil filter (48).

heck/topupbrake

fluid reservoir (33).

heck/top

up clutch fluid reservoir (33).

heck/topupbattery

electrolyte (36).

heck/top

up cooling system (28). heck/topupgearbox oil (70). heck/topuprear

axle oil (70).

heck transmission for oil leaks.

Lubricate

hand

brake

mechanical link age.

*Lubricate

distributor

(46).

• ubricate accelerator

control

linkage (and pedal pivot ): check

operation

(84).

ubricate all locks

and

hinges (not steering

lock)

ngine

heck for oil leaks.

ubncate

au locks and runges

(not

steenng

rock).

ngine

heck for oil leaks.

...

heck driving belts;

adjust

or renew (49

and

56 or 65).

...

heck cooling

and

heater

systems for leak s,

and

hoses for security

and

condition.

...

Renew

carburetter

air

cleaner element (67).

...

heck

air

injection system hoses/pipes for condition

and

security.

...

heck

air

intake

temperature

control

system.

• heck

crankcase

breathing

and

evapor

ative loss systems.

Check

hoses/pipes

and

restrictors for

blockage, security

and

condition.

.. heck/adjust valve clearances (50).

• heck

E.G.R.

system .

}(every50,000 miles only).

Renew

adsorption

canisters (56

64)

...

heck

exhaust

system for leaks

and

security.

Page 43

Maintenance

Summary

UBRICATION

'E'

SERVICE

- continued

Ignition

*Check ignition wiring for fraying, chafing

and

deterioration.

*Renew

spark

plugs (47).

*Check securityofdistrib

uto

r vacuum unit line (all States except California). .

*Check

s~cu!ity

dist

ributor

vacuum unit line

and

operationofvacuum unit (California only).

*Clean distributor cap; check for cracks

and

tracking. *Check coil per form ance on oscilloscope. "Check/adjust ignition timin g, using electronic equipment.

The lubrication

systems of your new vehicle are filled with high quality oils.

You

should always use a high quality oil of the correct viscosity ran ge in the

engine, gearbox and rear axle during subsequent maintenance operations or when

topping-up. The use of oils not to the correct specification can lead to high

oil

and

fuel consumption and ultimately to damage to the engine, gearbox or rear

axle components . Oil to the correct specification contains additives which disperse the corrosive

acids formed by combustion and also prevent the formation of sludge which can block oilways. Additional oil additives should not be used. Servicing intervals

must

be adhered to.

Engine

Use a well-known

brand

of oil to B.L.S.

OL.2

or MIL-L-2104B or

A.P

.I. SE

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

Fuel system

*Clean fuel

pump

filter (68).

*Check fuel system for leaks, pipes

and

unions for chafing

and

corrosion.

*Top

up carburetter piston

damper

(68). *Check/adjust decleration by-pass valve. "Check/adjust carburetter idle settings. *Check condition of fuel filler cap seal.

-20

8NAOIS

Steering

rack

Use Multipurpose Lithium Grease

N.L.G.I,

consistency

No.2.

and

grease

points

I I

I I I

I -

S.A.E.

20w/50

viscosity

20w/40 15w/50

15w/40 lOw/50 10w/40 10w/30 5w/40 5w/30 5w/20

ynchromesh

Top

up with

H.D.

90 (MIL-

L-210513)

above

-IOoe

(10°F).

____

L._u__....

'T'

...........

.,o

.v.:

......

'r.r

(f'

'!LfTII"IAC'D\

~1~...

,or

'''AOC\

-30

-20° -10° 0° 10°

20°

30°

8NAOIS

ynchromesh

Top

up with

H.D.

90 (MIL-L-21

0513)

above

-IOoe

(10°F).

gearbox

and

Top

up with

H.D.

80 (MIL-L-2105B) below

-5°C

(20°F).

rear

axle

Top

up with

H.D.

75W (MIL-L-2l05B) below

-30

(-20

°F).

Complete fill with E.P. 80 (MIL-L-2105B) all temperatures.

Safety

Check/adjust operation of all washers

and

top up reservoir (45).

Check tyres for tread depth,

and

visually for external cuts in fabric, expos ureofply or

cord

struc-

ture, lumps or bulges.

Check

that

tyres comply with manufacturer's specification (73).

Check/adjust tyre pressures, including spare (73).

Check tightness of

road

wheel fastenings (30).

Check condition

and

security of steering unit, joints

and

gaiters. Check security of suspension fixings. Check steering rack/gear for oil/fluid leaks. Check shock absorbers for fluid leaks.

Inspect brake linings/pads for wear, drums/discs for condition (34).

Check/adjust foot

and

hand

brake (34).

Check visually hydraulic hoses , pipes

and

unions for chafing , cracks, leaks and corrosion.

Check/adjust fr

ont

wheel alignment.

Clean and grease

batt

ery connections.

Check

outputof

charging system .

C~ec~

function of original equipment, i.e. interior

and

exterior lamps , hor ns, wipers,

and

warning

indicators.

Check, if necessary renew, wiper blades (45).

r"1-~~l_.'~..J.;

__ L 1-

..J l_~l~-~r--

J:':' '''' '''

Clean

and

grease battery connections.

Check

output

of charging system.

C~ec~

function of original equipment, i.e. interior

and

exterior lamps, horns, wipers,

andwarning

indicators. 4" Check, if necessary renew, wiper blades (45). Check/adjust headlamp alignment (39). Check operation of all

door

, bonnet,

andboot

locks.

Check operation of window

contr

ols.

Check condition

and

security of seats

and

seat belts. Check operation of seat belt warning system. Check

rear

view mirror for cracks

and

crazing.

Road test

Road/roller

test

and

check function of all instrumentation.

Report

additional

work

required.

Page 44

Lubrication

ERVICE

ENGINE.

Check oil level

and

top up if neccs ary.

THROTTLE.

Lubricate

throttle

contro l linkage, cable and accelerator pedal fulcrum.

REAR

AXLE.

Check oil level, and top up if nee ary.

GEARBOX.

Check oil level, and top up if ncccs a ry.

FRONT

SUSPENSION

(6 niPPleS)} Gi ve three or f

our

stro ke. with a grease gun .

PROPELLER

SHAFT

(1 nippl e)

WIRE

WHEELS

ONLY.

Gre

ase whc I and hub splines.

FRICTION

POINTS.

Spray lubricant on all fri ·ti n p iint».

TE:

Ensure

that

the vehicle is standing on a level surface when checking the oil levels.

EKLY

ENGINE.

Check oil level

and

top up if nece ary.

A'SERVICE

ENGINE.

Drain

and

refill with new oil.

THROTTLE.

Lubricate

throttle

control linkage, cable

and

accelerator pedal fulcrum.

()

CARBURETTER.

Top

up carburetter piston damper.

REAR

AXLE.

Check oil level, and top up if necessary.

(7)

GEARBOX.

Check oil level,

and

top up if necessary.

)

FRONT

SUSPENSION

(6 nipples),,- . .

GIve three or four strokes WIth a grease gun.

10)

PROPELLER

SHAFT(lnipple)

II)

WIRE

WHEELS.

Lubricate wire wheel and hub splines.

LOCKS,

HINGES

AND

LINKAGES.

Lubricate all

door,

bonnet, luggage

compartment

locks

and

hinges (not steering lock).

FRICTION

POINTS.

Spray lubricant on all friction points.

SERVICE

)

ENGINE.

Drain

and

refill with new oil.

)

ENGINE

OIL

FILTER.

Remove d isposa hl \ .artrid 'C, fit new.

THROTTLE.

Lubricate throttle cont rol linka c, cab le and accelerator pedal fulcrum.

)

REAR

AXLE.

Check oil level, and top

LIp

if I cccssary.

(7)

GEARBO

'X. Check oil level, and top 1I p if necessary.

( )

FRONT

SUSPENSION

(6 niPPleS)} . .

Give thr ee

I' f

our

strokes WIth a grease gun.

I )

PROPELLER

SHAFT

(1 nipple)

)

WIRE

WHEELS

ONLY.

Grease wheel and hub splines.

LOCKS,

HINGES

AND

LINKAG

ES. Lub ricate all

door

, bonnet, luggage

compartm

ent locks

(7 )

U.t:AKtlU

'X. Check

all

level, and top up II nc .cssary.

)

FRONT

SUSPENSION

(6 niPPleS)} . .

Give thr ee or f

our

strokes WIth a grease gun.

I )

PROPELLER

SHAFT(lnipple)

)

WIRE

WHEELS

ONLY.

Grease wheel and hub splines.

LOCKS,

HINGES

AND

LINKAG

ES. Lubricate all d

oor

, bonnet, luggage

compartm

ent locks

and

hinges (not steering lock); and th e hand brak e rnechanical linkage.

FRICTION

POINTS.

Spray lubricant on a ll fricti on points.

'AND

'E'

SERVICES

arry

outa'C'

service in

addition

to the followin g item (5)

and

(12).

CARBURETTERS.

Top

up carburetter piston damper.

)

STEERING.

Lubricate steering rack (every 37,500 miles).

I )

DISTRIBUTOR.

Lubricate all parts as necessary.

11\

Page 45

Lithographed

by The

Nuffield

Press L

imited,Cowley

, Oxford, England. 29

/27

(148

85)3/78-6

,517

Page 46

AKM 4386 MG M IDG E

T-US