ROM Supplement - Triumph Wedge Owners Association

S rvice
Repair
Operation
Manual
Supplement
To b used with TR8
Repair Operation Manual AKM3971/A
Publication Part No. AKM5015
Published by BL Cars Service
© BLCARS
LIMITED1981
.~-:CZ’~-;Z
..
This supplement is intended for use with the TR8Repair Operation ManualAKM
3971/Aand
providesadditionalinformati0n,changesto vehiclespecificationsand revisionsto repair procedures.
CONTENTS
Opera- Page
tion No. No.
General Specification Data .........................................
Engine Tuning Data ...............................................
Torque WrenchSettings ............................................
Lubricantsand Anti-FreezeSolutions..... ,_. ...........................
Maintenance Summary.........................
...................
---
4
6
8
9
~.................
11
ENGINE
Connectingrods and pistons
---overhaul ...................................................
12.17.10
20
FUEL SYSTEM--CARBURETTERS
Manualcold start carburetters
left-hand removeand refit ...................................
---overhaul ...................................................
right-hand--remove and refit ..................................
tune and adjust .............................................
19.15.09
19.15.18
19.15.10
19.15.02
24
25
24
23
GEARBOX
Gear-changeremote control assembly---overhaul .......................
37.16.20
27
WIPERS AND WASHERS
Wiperdelay unit
--remove and refit .............................................
84.25.31
27
ELECTRICAL
Ignition distributor
--data--U.K ..........................................
Wiring diagrams
U.K .......................................................
--U.S.A .....................................................
~ ......
33
28
30
¯ - -
3
VEHICLE IDENTIFICATION NUMBER
Location
The vehicle identification number(V.I.N.) is stamped on a plate on the R.H. suspension tower and
should be quoted in full.
A sample V.I.N. is shown below:
SAT
MarqueIdentifier
(Marque Identifier not used before mid 1981)
Model range.
Class
Body.
TP
A D V
7 A A 402027
GENERAL SPECIFICATION
DATA
This information supersedes that given in the Repair Operation Manual
ENGINE
Compression ratio:
U.S.A ....................
U.K ...................
8.15 : 1
9.35: 1
I
LUBRICATION SYSTEM
Pump ................................
Pressure at 2400 rev/min ................
Oil filter ..............................
Oil filler ..............................
~
=.’;High capacity rotor pump
~2.5 kg/cm2 2)
,(35 lbf/in
:~Disposablefull flow type
Sealed cap on rocker cover
Engine
Steering/Transmission
Model Year/Change
Assembly Plant
Serial
31
IGNITION SYSTEM
Coil: U.S.A ............................
U.K .............................
Ballast resistor ........................
Distributor ............................
Lucas 22C12
Lucas 23C12
9 BR
Lucas electronic,
FUELSYSTEM-Carhnretters
Carburetter ...........................
Fuel pump ............................
Operating pressure ......................
!Refer to’ENGINE TUNINGDATA’
Electric immersedin fuel tank.
0.28 kgf/cm~ 2)
(4 lbf/in
FUEL SYSTEM--Fuel Injection
Make/type ...........................
Pump ................................
Operating pressure .....................
Fuel filter(s)
..........................
Air cleaner ............................
Lucas/digital
Electric beneath ear floor
Approximately3.0 kgf/cm2 2)
(43 lbf/in
In line, renewable
Replaceable element
type 35DE8
Number
L ........
TRANSMISSION(MANUAL) from VIN 402027
5th
Gearbox ratios to 1 ......................
Overall ratios to 1 .......................
Enginerev/min at
10m.p.h .............................
10 km/h ............................
Road speed at
1000 engine rev/min:
m.p.h ...............................
km/h ...............................
Maximumrecommended road speed in
intermediate gears corresponding to engine
speed of 5500 rev/min:
m.p.h ...............................
km/h ...............................
0.792
2.440
362
225
27.6
44.4
4th
3rd
2nd
1st
Rev
1.000 1.396 2.087 3.321 3.428
3.083 4.300 6.428 10.229 10.56
457
284
639
397
955
594
57.6
92.7
Automatic gearbox
1 III kg(2449
Ib)
1152 kg (2540 lb)
1420 kg (3131 lb)
765 kg (1687 lb)
695 kg (1532 lb)
WEIGHTS(APPROXIMATE)CONVERTIBLE--From VIN 402027
Manual gearbox
*Showroom: Minimum ...................
1098 kg (2421 lb)
*Unladen: Minimum.....................
1139 kg (2511 lb)
*Gross vehicle weight .....................
1420 kg (3131 lb)
*Maximumaxle load: Front ...............
765 kg (1687 lb)
695 kg (1532 lb)
Rear ................
Automatic gearbox
1088 kg (2399 lb)
1129 kg (2489 lb)
1420 kg (3131 lb)
765 kg (1687 lb)
695 kg (1532 lb)
1517
943
21.9
35.2
86.1
138.6
WEIGHTS(APPROXIMATE)COUPE--From VIN 402027
Manualgearbox
*Showroom: Minimum ...................
1121 kg (2471 lb)
*Unladen: Minimum.....................
1162 kg (2562 lb)
*Gross vehicle weight .....................
1420 kg (3131 lb)
765 kg (1687 lb)
*Maximumaxle load: Front ...............
Rear . ...............
695 kg (1532 lb)
36.3
58.4
*Thesefigures must be taken as a guide only and vary according to market, model, year and equipmentfitted.
Metric
Imperial
U.S.A.
CAPACITIES (NOMINAL)
Windscreen washer reservoir ...............
2.75 pt
3.3 pt
1,6 litres
Air conditioning system ...................
2.5 lb, 1.1 kg of Refrigerant 12
This information supersedes that given in the Repair Operation Manual
12 gal
14.4 gal
Fuel tank ...............................
54.5 litres
ENGINETUNING
DATA--Prior to VIN 402027
WARNING:
Before commencing
workon an ignition system, all high tension terminals, adaptors and
diagnostic equipmentfor testing should be inspectedto ensure that they are adequatelyinsulated and
shielded, to preventaccidental personalcontact and minimizethe risk of shock.
Wearersof surgically implantedpacemaker
devices shouldnot be in close proximityto ignition circuits
or diagnostic equipment.
This information supersedes that given in the Repair Operation Manual
Firing order ... ..........................
1--8 4 3--6--5--7--2
!
¢’
ENGINE TUNING DATANU.K,
WARNING:
Beforecommencing
workon an ignition system,all hightension terminals,adaptorsand
diagnosticequipment
for testing shouldbe inspectedto ensurethat theyare adequately
insulatedand
shielded,to preventaccidentalpersonalcontactandminimize
the risk of shock.
Wearers
ofsurgicaUy
implanted
pacemaker
devicesshouldnot be in close proximity
to ignitioncircuits
or diagnosticequipment.
ENGINE
Type .................................
Cylinder bore .........................
Crank stroke ..........................
Capacity .............................
Compressionratio ......................
Firing order ...........................
Number1 cylinder .....................
Cylinder pressures at 15°C (60°F) ambient
temperature, 150 to 200 rev/min ..........
Idle speed .............................
Fuel octane requirement ................
Ignition timing: Static ..................
Dynamic................
Location of timing marks ................
Valvetiming:
Inlet opens .........................
closes ..........................
Exhaust opens ......................
closes ......................
DISTRIBUTOR
Make/type ...........................
Rotation--viewedon rotor . ...... . .......
Pick-up air gap ........................
Refer tO 86.35.00
V8
88.90 mm(3.5 in)
71.12 mm(2.80 in)
3528cm3 8)
(215 in
9.35 : 1
1 8---4--3--6---5 7--2
Frontleft: Left bank1, 3, 5, 7
Rightbank2, 4, 6, 8
9.1 kgf/cm2 (130 lbf/in z) minimum
725 to 775 rev/min
97 R.O.N.(U.K.4 Star rating)
8° B.T.D.C.
8° B.T.D.C. at 600 rev/min with vacuumpipe
disconnected
Crankshaftdamperwith pointer on timing cover
30° B.T.D.C.
75° A.B.D.C.
68° B.B.D.C.
37° A.T.D.C.
Lucas 35 DE8
Clockwise
0.36 to0.41 mm(0.014 to 0.016 in)
SPARKPLUGS
Make................................
Type .................................
Gap: .................................
Championor Unipart
N12Yor GSP13
0.90 mm(0.035 in)
COIL
Primarywindingresistance ..............
Lucas 23C12
1.2 to 1.5 ohms
BALLAST
RESISTOR...................
9, BR
CARBURETTERS
Make/arrangement ....................
Type .................................
Needle ...............................
Twinside-draught Zenith
Zenith 175 CDSE
with manualcold start
B1FL
ENGINETUNINGDATA--U.S.A. From VIN 402027
WARNING:
Before commencing
workon an ignition system, all high tension terminals, adaptors and
diagnostic equipmentfor testing shouldbe inspected to ensurethat they are adequatelyinsulated and
shielded, to preventaccidental personalcontact andminimizethe risk of shock.
Wearers
of surgically implantedpacemaker
devices should not be in close proximityto ignition circuits
or diagnostic equipment.
ENGINE
Type .................................
Cylinder bore .........................
Crank stroke ..........................
Capacity .............................
Compression ratio .........
.............
Firing order ...........................
NumberI cylinder .......
. .............
.
Cylinder pressures at 15°C (60°F) ambient
temperature, 150 to 200 rev/min, ..........
Idle speed .............................
Fuel octane requirement ................
Ignition timing: Static ..................
Dynamic ... .............
Location of timing marks
Valve timing:
Inlet opens .............
: ............
closes ...........................
Exhaust opens ...............
i .......
closes ..................
~ ....
DISTRIBUTOR
Make/type ...........................
Rotation--viewed on rotor ...............
Pick-up air gap
Refer to 86.35.00
,.4
V8
88.90 mm(3.5 in)
71.12mm(2.80 in)
~(215in3)
3528cm
8.15: 1
1--8 4 3--6--5--7--2
Front left" Left bank 1, 3, 5, 7
Right bank2, 4, 6, 8
~
9.1 kgf/cm~ (130 lbf/in~) minimum
750 to 900 rev/min
91 R.O.N.--unleaded
T.D.C.
T.D.C. with vacuumpipe disconnected
Crankshaft damper with pointer on timing cover
30°
75°
68°
37°
B.T.D.C.
A.B.D.C.
B.B.D.C.
A.T.D.C.
Lucas 35 DE8
Clockwise
0.36 to 0.41 mm(0.014 to 0.016 in)
SPARK PLUGS
Make ................................
Type .................................
Gap: .................................
COIL ..................................
Primary winding resistance
Champion or Unipart
N12Yor GSP 13
0.90 mm(0.035 in)
..............
Lucas 22C12
1.2 to 1.5 ohms
BALLASTRESISTOR ...................
9 BR
FUEL INJECTION
Make/type ...........................
Operating pressure .....................
Lucas digital electronic
3.0 kgf/cm~ (43 lbf/in ~) approximate
r
TORQUE WRENCH SETTINGS
ANTI-FREEZE
Thisinformation
supersedes
that givenin the RepairOperation
Manual
Theoverall anti-freeze concentrationsshouldnot fall below30%by volumeto ensurethat the anticorrosionpropertiesof the coolant are maintained.
AIR CONDITIONING
Hoses--flare type
Compressorto condenser
Condenser
to receiver drier
Evaporatorto receiver drier
Rancovalve to receiver drier
Hoses-- ’O’ ring type
Compressorto condenser
Compressorend
Condenserend
Evaporatorto compressor
Compressorend
Evaporator end
Condenserto receiver drier
Evaporatorto receiver drier
Raneovalve to receiver drier
Description
Specifiedtorque
Nm lbf ft
3A"crimpbacknut
%"crimp back nut
5/8" crimpbacknut
~6"flare nut
40
28
28
12
30
21
¢~ 21
9
10 mmbolt
3/4"gasketnut
34
27
25
20
10 mmbolt
7/8" U.N.F.Nut
%"U.N.F. gasket nut
%"U.N.F. nut
~6" U.N.F.gasket nut
34
37
18
18
9
25
27
13
t3
7
SOLUTIONS--ALL
MARKETS
Use UNIPART
Universal anti-freeze to protect the cooling system.
If this is not available, use an ethyleneglycolbasedanti-freeze (containingno methanol)with nonphosphatecorrosioninhibitors suitable for use in aluminium
enginesto ensurethe protection of the
coolingsystemagainst frost andcorrosion.
CAUTION:
No other universal anti-freeze should be used with UNIPART
Universal anti-freeze.
RECOMMENDED LUBRICANTS
AND ANTI-FREEZE
SOLUTIONS--UK.
MARKET
PERFORMANCE
LEVEL
UNIPART
BP
CASTROL
DUCKHAMS
Engine
Carburetter
and Oil Can
BLCars Ltd.
specification
BLS
22.OL.02
Unipart
Super
MotorOil
15W/50
BP Super
Visco-Static
20w/50
Castrol
QTX
20W/50
Duckhams
Q Motor
Oil
Manual Gearbox
ATFmeeting
specification
M2C 33G
BP
Autran G
Castrol
TQF
Duckhams
Q-matic
Essoglide
Type G
Automatic
Gearbox
ATFmeeting
Specification
M2C~33G
BP
Autran G
Castrol
TQF
Duckhams
Q-matic
Final Drive
Unit*
MIL-L2105
API GL4
BP Gear
Oil 90 EP
Castrol
Hypoy
90 EP
NLGI-2
Multi-purpose
Lithium
based grease
BP
Energrease
L2
Castrol
LMGrease
COMPONENT
GreasePoints
Brake Cables
Steering Rack
and Rear Hubs~"
PETROFINA
TEXACO
SHELL
Fina
Supergrade
Motor Oil
15W/40
Havoline
MotorOil
15W/40
Shell Super
MotorOil
15W/40
Mobil
ATF210
Fina
Purfimatig
33G
Texamatic
Type G
Shell
Donax TF
Essoglide
Type G
Mobil
ATF210
Fina
Purfimatic
33G
Texamatic
Type G
Shell
Donax TF
Duckhams
Hypoid90
Esso Gear
Oil GX
85W/140
Mobilube
HD 90
Fina
Pontonie MP
80w/90
Texaco
Multigear
Lubricant
90 EP
Shell
Spirax 90EP
Duckhams
LB 1D
Esso
Multipurpose
Mobil
MP
Fina Marson
HIL 2
Grease
Marfak
All Purpose
Grease
Shell
Retinax A
2ow/5o
ESSO
MOBIL
Esso Uniflo ¯ Mobil Super
15W/50or Esso
MotorOil
Superlube
15w/4o
10W/40
or MobilI
Brake and Clutch
Reservoirs
Unipart Universal BrakeFluid
or other BrakeFluids having a minimum
boiling point of 260° C (500° F) and complyingwith FMVSS
116 DOT
Cooling system
Unipart UniversalAnti-Freeze
Windscreen
Washers
Unipart AlPSeasonsScreenwash
* If final drive unit is completelydrainedrefill with oil meetingBLCars specification BLS22.OL.03or MIL-L-2105B
"t Front Hubs. MobilgreaseSuper
/7
kJ
RECOMMENDED
LUBRICANTS
AND ANTI-FREEZE
OVERSEAS
SOLUTIONS
MARKETS
This information supersedes that given in the Repair Operation Manual
AMBIENT TEMPERATURE °C
SERVICE CLASSIFICATION
Performance Level
S.A.E.
Viscosity
G
ENGINE
CARBURETTER
DASH POTS
OIL CAN
-30
5w/20
L
5w/30
5w/40
lOW/30
10w/a0
10w/50
15W/40
15W/50
20W/40
20W/50
Use UNIPART
Super Multigrade
Motor Oil
ORother oils
meeting BL Cars
specification
BL 2ZOL.02
OR the requirements
of the CCMC
or API-SE
-20
-10
-0
+10
+20
II,
D.
IP
Hypoid 90
Hypoid 80W
FINAL DRIVE UNIT*
TOP UP ONLY
MIL-L-2105
API GL4
MANUAL
GEARBOX
ATFmeeting specification-~" ’~- *
M2C 33G
.AUTOMATIC
GEARBOX
ATFmeetingspecification
M2C 33G
REAR HUBS
GREASE GUN
) BRAKE CABLES
STEERING RACK
NLGi-2Multi-purpose lithium based grease
BRAKE AND CLUTCH
¯ RESERVOIRS
~
uNIPARTUNIVERSAL
BRAKEFLUID or other Brake Fluids
C (500 ° F) and complying with FMVSS116 DOT
II,
I1~
COOLING SYSTEM
UNIPART UNIVERSAL ANTI-FREEZE
WINDSCREEN
UNIPART ALL-SEASONS
WASHER
* Final Drive Unit if drained MUST
be filled
M IL-L-2105B
Front hubs NLGI-2High Melting Point Grease
having a minimum boiling
point of 260
SCREEN WASH
with an oil meeting BL Cars specification BLS.22.OL.03or having a minimumperformance level of
MAINTENANCE
SUMMARY
U.K.
After SalesService= 1,000miles/1500km
Intermediate
Service= Every6 monthsor 6,000miles/10000km
MainService= Every12 monthsor 12,000miles/20000km
AfterSales
Service
Intermediate
Service
MainService(24 denotesevery24 months,24,000miles (40 000km)
ACTION
X OPERATION
Fit car protectionkit
Checkconditionand security of seats andseat belts
Driveonlift. Stopengine
Checkoperation of lamps
Checkoperation of horns
Checkoperation of warningindicators
Check/adjustoperation of screen washers
Checkoperationof screen wipers
Checksecurity/operation of foot and handbrake: release fully after
checking
Openbonnet:fit wingcovers
Openboot
Disconnectbattery
Raiselift to convenientworkingheight withwheelsfree to rotate
Markstud to wheelrelationship front wheels
Markstud to wheelrelationship rear wheels
Removefront wheels
Removerear wheels
Inspect road wheelsfor damage
Checktyre tread depth
Checktyres visually for external cuts in fabric, exposureof ply or cord
structure, lumpsor bulges
Checktyres for unevenwear
Check/adjusttyre pressures
Inspect brake pads for wear and discs for condition. Renewpads if
necessary
Adjustfront hubbearing end-float
Remove
brake drums,washout dust, inspect shoes for wearand drumsfor
condition. Renewshoes if necessary. Refit drums
Inspect for fluid leaks fromdampers
Checkconditionandsecurity of steering unit, joints andgaiters
Refit roadwheelsin original position
Checktightness of road wheelfastenings
Raiselift to convenientworkingheight
Drainengineoil
Check/top-upgearboxoil
Check/top-uprear axle oil
7.,
AfterSales
Service
Intermediate
Service
MainService(24 denotesevery24 months,24,000miles (40 000kin)
¯ ACTION XOPERATION
Check.visuallybrakehoses,pipes and unionsfor chafing, cracks, leaks and
corrosion
Checkvisually fuel and clutch pipes and unions for chafing, leaks and
corrosion
Checkexhaust systemfor condition, leakageand security
Adjust handbrakecable (whereaccessible from below)
Checksecurity of accessible engine mountings
Checksecurity and conditionof suspensionjoints and fixings
Cheekpowersteering systemfor leaks, hydraulicpipes and unionsfor chafing and corrosion
Renewengineoil filter element(whereaccessible frombelow)
Cleanand refit drain plug
Checkfor oil leaks fromengineand transmission
Lubricate headlampfitting mechanism
pivots
Lowerlift
Fit exhaustextractor pipe
Renew
engine oil filter element(whereaccessible fromabove)
Fill enginewithoil
Lubricateall pedal pivots andcontrol linkages
Top-upcarburetter piston dampers
Renewair cleaner element(s)
Checksecurity of accessible engine mountings
Checkdriving belts, adjust or renew
Renewspark plugs
Openboot
Check/top-upbattery electrolyte
Cleanand grease battery connections
Checkbattery condition
Reconnectbattery
Check/top-up
clutch fluid reservoir
Check/top-upbrake fluid reservoir
Checkoperationof brakefluid level warninglight switch(wherefitted)..
Checkbrake servo hose for security and condition
Check/top-upscreen washerreservoir
Check/top-upcooling system
Pressuretest coolingand heater systemfor leaks
Renew
fuel line filter (wherefitted)
Checkvisually crankcasebreathingsystemfor leaks and hosesfor security
and condition
Renew
enginebreatherfilter (wherefitted)
Check/topup powersteering reservoir
Start engineandchecksealingof oil filter
Stop engine
Checkthrottle and chokeoperation
After Sales
Service
After Sales
Service
Intermediate
Service
MainService (24 denotes every 24 months,24,000 miles (40 000 km)
Intermediate
Service
¯
X
x
X
×
×
×
X
X
;K
~
IN
X
~
X
;N
X
~
X
X
~
ACTION
×OPERATION
Start engine
Checkignition distributor characteristics and timing, using electronic equipment. Adjust as necessary
Set to fast idle; leave engine running
Lubricate all locks, hinges and door check mechanisms(not steering lock)
Checkoperation of all door, bonnet and boot locks
Check operation of windowcontrols
Check/adjust carburetter for engine idle speed and emissions settings
Stop engine, disconnect instruments
Checkpowersteering systemfor leaks, hydraulic pipes and unions for chafing and corrosion
Start engine (auto only)
Check/top-up automatic gearbox fluid
Stop engine
Re-checktension if alternator driving belt has been renewed
Removewing covers
Fill in details and fix appropriate Unipart underbonnetstickers
Close bonnet
Removeexhaust extractor.pipe
Removespare wheel
Inspect wheel for damage
Checktyre tread depth
Checktyre visually for external cuts in fabric, exposureof ply or cord structure, lumpsor bulges
Checktyre for uneven wear
Check/adjust tyre pressure
Refit spare wheel
Close boot
Driveoff lift
Check headlamp alignment
Check/adjust front wheel alignment
Check front wheel alignment
Report additional work required
Removecar protection kit
Ensurecleanliness of controls, door handles, etc.
Carry out road or roller test
ljRo a dTest
Fit trade plates to vehicle
Check starter operation and inhibitor switch Automatic
Checkoperation of lights, horns, indicators, wipers and washers
Checkindicators self-cancel
Checkoperation of all warning indicators
Check foot and hand brakes
Checkengine noise levels, performanceand throttle operation
Checkclutch for free play, slipping and judder
Checkgear selection and noise level in all gears. Checkengagementof auto
box parking pawl
Check steering for noise, effort required, free play, wander and selfcentring
Checkalignment of steering wheel spokes
Checksuspension for noise, irregularity in ride (e.g. dampers) and wheel
imbalance
Check foot brake pedal effort, travel, braking efficiency, pulling and
binding
Check speedometer for steady operation, noise and operation of mileage
recorder
Checkoperation of all instruments
Check for abnormal body noises
Checkoperation of seat belts, including operation of inertia reels
Check handbrake ratchet and hold
Adjust engine idle speed while engine is hot
Position car on lift
Raise lift
Inspect engine and transmission for oil leaks
Checkexhaust system for condition, leakage and security
Lowerlift and drive vehicle off
Report on road test findings
Removecar protection kit
Ensurecleanliness of controls, door handles, etc.
Removetrade plates
....
This informationsupersedesthat given under
the followingheadingsin the RepairOperation
Manual.
Additional RecommendationsPages 19 and
29.
Preventative MaintenancePage 27
BRAKE PREVENTATIVE
MAINTENANCE
In addition to the recommended
periodical
inspectionof brake components
it is advisable
as the car ages, andas a precautionagainst the
effects of wear and deterioration to makea
moresearching inspection and renewparts as
necessary.
It is recommended
that:
i
Discbrakepads, drumbrakelinings, hoses
and pipes should be examinedat intervals
no greater than those laid downin the
’MAINTENANCESUMMARY’.
Undernormal0perating conditions brake
fluid should be changedcompletelyevery
18 monthsor 18,000 miles (30,000 km)
whicheveris the sooner. If the vehicleis
frequentlysubjectedto severe driving or
operatingconditions, it maybe necessary
to change the brake fluid at shorter
intervals.
2 All fluid seals in the hydraulicsystemand
all flexible hosesshouldbe renewedevery
3 years or 36,000 miles (60,000 km)
whicheveris the sooner. At the sametime
the workingsurfaces of the pistons and
bores of the mastercylinder, wheelcylinders, and all other cylinders should be
examined and new parts fitted where
necessary.
Care must be taken to observe the following
points.
At all times use the recommended
brake fluid.
Neverleave fluid in unsealed containers, it
absorbsmoisturequickly and can be dangerous
if usedin the brakingsystemin this condition.
Fluid drained from the system or used for
bleedingis best discarded.
Thenecessity for absolutecleanlinessthroughout cannot be over-emphasized.
I
IIIIIIIIIIIIIIII
II
MAINTENANCE
U,K.
SPECIFICATION
Renewcrankcasebreather filter
Usingthe fingers and thumb,prise the filter upwardsto release it from the rocker
/
cover.
2
3
ENGINE
Check/top-upengine oil
Discardthe filter.
Fit a newfilter, pressing it gently onto the
rocker coveruntil it clips into place.
NOTE:Allow time for the oil to drain back into
sumpafter running the engine.
Stand vehicle on level ground.
1 Withdrawthe dipstick, wipe it clean and
push fully homeagain before withdrawing
it for reading.
2
Addoil via the filler cap until the level
reache~ the ’High’ markon the dipstick.
DO NOT OVERFILL and ensure that
the dipstick and filler cap are replaced.
RM0230
Renewengine oil
Cleanengine flame trap
NOTE:This operation is best carried out when
the engine is warmand with the vehicle standing level on a rampor over a pit.
To drain the sump, unscrew the drain plug
and drain the oil into a receptacle. Refit the
plug and refill the sumpwith the appropriate
grade of engine oil The use of additives is
unnecessary.
2
3
4
5
Renew
oil filter element
RM0257
See 12.60.01.
Renewengine breatherfilter
1
2
Disconnect, from the filter, the two hoses
and removethe filter.
Fit the newfilter, ensuring that the word
’IN’ is towards the rocker cover.
Detach the hose from the flame trap.
Unscrewthe flame trap.
Clean the flame trap thoroughly, renew it
if satisfactory cleaning is not possible or
there are signs of deterioration or damage.
Refit the flame trap and reconnect the
hose.
Runthe engine until it is at normal operating temperature and, if necessary,
adjust the carburetters.
¯
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...............
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FUEL ¯SYSTEM
IGNITION
Renewcarburetter air intake air cleaner
elements
Renewsparkplugs
Foreach plug in turn
1 Withdrawthe ignition high tension lead
fromplug.
2 Unscrewthe plug from the engine using a
special plug spanneror a suitable tube
spanner.
3 Discardthe plug.
4 Visuallycheckthe newplug for damageto
the bodyand electrodes, discard the plug
if it is damaged.
5 Checkthe electrode gap on the newplug,
whichwhencorrect, will just allowa 0,90
mm(0.035in) feeler gaugeto slide slowly
between the electrodes under light
pressure.
6 If adjustmentis necessary,using a suitable tool, carefully movethe side electrode. Recheckthe gap and repeat this
procedureuntil the gapis correct.
7 Checkthe sealing washerfor cracks and
distortion, and renew the washer if
necessary.
8 Fit the newspark plugto the engine.
9 Tightenthe plug to 16 Nm(12 lbfft).
10 Refit the hightensionlead to the plug.
1
2
3
4
Disconnectthe air inlet hose(s) fromthe
air cleaner.
Releasethe twoair cleanercoverclips and
removethe cover.
Withdraw
the filter elementand discard.
Refit a newfilter element and reverse
instructions 1 and2.
RMO307A
Top-upcarburetterpiston dampers
1 Removethe air cleaner assembly, see
19.10.01or 19.10.02.
2 Remove
the carburetter damperassembly
from the carburetter by unscrewingthe
plastic plugin the top of thd carburetter.
3 Raisethe piston byinserting a finger into
the carburetter air intake hole. Withthe
piston raised, top-up the hollowdamper
guide with a recommended
engineoil until
the oil level is’6 mm(1/4 in) belowthe top
of the guide.
4 Releasethe piston and refit the damper
assembly;screwingdownthe plastic plug.
5 Refit the air cleanerassembly.
M0373
Check/adjust
carhuretteridle settings
See 19.15.02.in this supplement.
Brat
Renew
fuel line filter
1 Disconnectthe inlet andoutlet pipes from
the filter, takingprecautionsto collect any
fuel spilt.
2 Releasethe clampand removethe filter,
notingits positionfor refitting.
3 Fit a newfilter and connectthe inlet and
outlet pipes.
Lubricate
distributor
1 Remove
the distributor cap and rotor arm.
Usingan oil can, apply two drops of a
clean, recommended
engine oil into the
reservoirin the rotor carrier.
Remove
flash-over shield and inject five
dropsof the sameoil throughthe aperture
to lubricatethe centrifugaltimingcontrol.
Refit the flash-overshield.
Refit the rotor armand distributor cap.
RMO271A
TRANSMISSION
COOLING SYSTEM
1~~,
5
Checkthe fluid level on the side of the dipstick marked ’COLD’and if necessary,
add fluid; see Lubrication Recommendations.
Repeat instructions 1 to 5 until the fluid
level is correct.
Donot overfill the transmission.
.~"~
Check/top-upcooling system~
Check/top-upmanualgearbox oil
WARNING:
Do NOTremove the cooling system filler caps or plugs whenthe engine is hot.
1 Slowly turn the pressure cap anti-clockwise until the resistance of the safety stop
is felt. Leavethe cap in this position until
all pressure is released. Press the cap
downwardsagainst the spring to clear the
safety stops and continue turning until it
can be lifted off.
2
Maintain the level of the coolant, see
26.10.01
I
2
With the vehicle standing in a level position, removethe oil level/filler plug and,
using a suitable dispenser filled with the
correct grade oil, see ’LUBRICANTS
AND ANTI-FREEZE SOLUTIONS’,
top-up the gearbox until the oil is level
with the bottomof the filler hole threads.
Allowsurplus oil to drain away, then refit
the filler plug and wipeclean. "
6
Wherethe reverse side of the dipstick carries marksdenoted ’HOT’,the fluid level
check may be carried out with the transmission at normal operating temperature.
The procedure is as described above
except that the vehicle must be driven for
25 to 30 km (15 miles) to warmthe transmission. The check is then carried out
using the ’HOT’side of the dipstick.
Whenoperating at high ambient temperatures and on unmetalled roads, periodically inspect and remove dust and mud
deposits from the slots and screen on the
underside of the torque converter housing,
and from the underside of the transmission oil sump. These deposits can
adversely affect proper cooling of the unit.
Checkcooling/heater systems for leaks and
hoses for security andcondition
I
2
3
4
5
Checkfor leaks from engine and radiator
drain taps/plugs (where fitted).
Checkfor leaks from water hose joints.
Checkfor leaks from water hoses through
damageor porosity.
Check for leaks from the water pump,
thermostat housing, radiator and heater
unit.
Report any leaks found.
RM0273
Check/adiustoperation of all washersand topupreservoirs
1
2
Replenish the container with a mixture of
50% water and 50% UNIPART ’All
Seasons’ Screenwash (maximum). This
is an effective solution downto a temperature of-29°C.
Do not add anti-freeze solutions to the
container as this will discolour the paintwork and damage wiper blades and sealing rubber.
Check,if necesary renew,wiperblades
1
2
Examine each wiper blade in turn for
damage before wetting the windscreen
and operating the wiper motor control.
Replace wiper blades if they are damaged
or if they smear the screen.
Check/top-upautomatic gearbox fluid
j
Checkthe fluid level as follows:
1 Stand the car on level ground and apply
the handbrake firmly. Start the engine
from cold and, with the footbrake firmly
applied, run the engine at idle speed for
two to three minutes, passing the selector
lever through the complete range of positions to ensure that the transmission is
primed.
2
Select the ’P’ (Park) position and apply
the handbrake. Leave the engine running
at idle speed.
3
Removethe transmission dipstick and
wipeit with a clean, non-fluffy cloth.
4
Replace the dipstick, ensuring that it is
pushedfully into the tube and withdrawit
immediately for reading.
I
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LM0362
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I
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Check/top-up
clutch fluid reservoir
1 Wipe clean the area round the reservoir
cap.
2
Unscrewthe cap.
3
If necessary top-up the reservoir to within
6 mm(~A in) of the top with new brake
fluid taken from a sealed container.
4. Replacethe reservoir cap.
Check/top-up
rear axle/final drive oil
STEERING AND SUSPENSION
Withthe vehicle standing in a level position, removethe oil level/filler plug and
top-up the final drive unit with the correct
grade of oil, see ’LUBRICANTSAND
ANTI-FREEZESOLUTIONS’, until the
oil is level withthe bottomof the filler hole
threads. Allowsurplus oil to drain away,
then refit the filler plug andwip~eclean.
Check/adjustfront wheel alignment
See 57.65.01.
Adjustfront hubbearing end-float
1
2
3
4
I
5
6
7
Removethe road wheel.
Checkthe hub for end-float.
If adjustment is required, remove the
grease cap, split pin and nut retaining cap.
Tighten the nut as required to eliminate
end-float. A torque of 0,691 kgf m(5 lbf
ft), must not be exceeded or damagemay
be caused to bearings and bearing tracks.
Slacken the nut one flat and fit the nut
retaining cap.
Insert and lock the split pin.
Cleanthe grease cap and refit.
Fit the road wheel.
3
RM0365
Lubricatesteering rack and pinion
1
RM0388
RM0274
2
3
4
5
6
7
-,,J
Wipe clean the plug and surrounding
area.
Removethe grease nipple plug, taking
care not to disturb the larger damperplug.
Fit a suitable grease nipple in place of the
plug.
Turn the steering wheel to full right-hand
lock.
Applya grease gun filled with the correct
grade of grease, see ’LUBRICANTS
AND
ANTI-FREEZE SOLUTIONS, to the
grease nipple and give five strokes only.
CAUTION:Over-greasing
can cause
damageto the protective gaiters and/or
seals.
Removethe grease nipple and refit the
plug.
Wipe away any surplus grease.
2
O0
Check/top-up
fluid in powersteeringreservoir
Stand
thevehicle
onlevel
ground.
I Wipecleanthereservoir
capandsurrounding
area.
2 Remove
thereservoir
capanddipstick.
3 Wipethedipstick
clean
andrepiace
itin
position.
4 Withdraw
thedipstick
again
andnotethe
fluid
level.
If topping-upis necessary:
5 Addrecommended
fluid via the filler cap
to bring the level just belowthe highmark
onthe dipstick.Donotoverfill.
6 Replacethe reservoir cap.
RM0363
BRAKES
Inspect brake pads for wearanddiscs for
condition
1 Jack up the front of the car and support
the bodyon stands.
2 Remove
the road wheel.
3 Remove
the disc brake pads, as follows:
a Withdrawthe brake pad split pins, and
removethe anti-rattle spring.
b Lift the brake pads complete with
dampingshims.
CAUTION:
Do not depress the brake
pedal whilst the padsare removed.
4 Checkthe pad condition. If the friction
lining has beenreducedto 3 mm(0.125in)
or if thereis not sufficientmaterialto provide a thickness of 3 mm(0.125 in)at the
completion of a further 6,000 miles
( 10 000km)motoring,the pads should
renewed.
5 Checkthe brakedisc for excessivescoring
andrun-outandreportif this is present.
6 If newbrakepadsarebeingfitted press the
caliper pistonsinto their respectivebores.
7 Clean the brake pad locations in the
caliper.
8 Fit the brake pads completewith damping
shims.
9 Fit the anti-rattle spring and secure the
brakepadsusing newsplit pins.
10 Fit the front wheeland lowerthe car off
the stands.
11 Firmlydepressthefootbrakeseveral times
tOcorrectlylocatethe friction pads.
60366
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I
Inspectthe brakelinings for wear,drumsfor
condition
1 Jackup the rear of the car andsupportthe
bodyon stands.
2 Remove
the car road wheels.
3 Remove
the rear brake drum,as follows:
a Release the handbrake.
b Remove the countersunk screws
securing the brake drumto the hub
and withdrawthe brake drum.
4 Checkthe brakelinings for wear.If they
are excessively worn, damaged,or contaminated by oil or grease the linings
should be replaced. Removeany surplus
oil, grease or dust from the linings and
drum.
5 Replacethe brake drum.
6 Fit the rear roadwheelsandlowerthe car.
Check/top-up
brakefluid reservoir
Top-upwhenrequiredwithnewfluid of the correct type recommended--see ’LUBRICANTS
ANDANTI-FREEZESOLUTIONS.’Do not
allowthe fluid level to drop belowthe danger
markon the reservoir.
WARNING:
Use only newbrake fluid of the
correct specification. DONOTuse fluid of
unknown
origin, or fluid that has beenexposed
to the atmosphere,
or discharged
duringbleeding operations.
If significanttopping
is required,
checkthe hydraulicsystemfor leaks.
CAUTION:Paintwork can be damaged by
direct contactwithbrakefluid.
RM0389
Replacingbrake-shoes
Whenit becomesnecessaryto renewthe brakeshoes,it is essential that only genuineshoes,
with the correct grade of lining, are used.
Alwaysfit newshoes as completesets, never
individuallyor as a single wheelset. Serious
consequencescould result fromout-of-tolerancebrakingdue to the mixingof lining.
[I
I
ELECTRICAL
Check/top-upbattery electrolyte
Using DISTILLED WATERONLYtop-up;
the electrolyte level is correct whenit just
covers the separators.
Clean and grease battery connections
1
2
3
4
5
Check the battery and surrounding area
for corrosion from battery chemicals.
Clean off any corrosion found.
Cheekvisually for any cracks in the battery case and report on any case cracks
found.
Checksecurity of terminal connections,
Coat terminals with petroleum jelly.
Check/adjust headlampalignment
See 86.40.17
Checkdriving belts: adjust or renew
Checkcondition where belt is visibly worn or
damaged.Fit newbelt if necessary.
Check and adjust:
a
Alternator drive belt, see 86.10.05.
Power steering pump drive belt, see
b
57.20.02.
c Push the screw forward until the nut
contacts the thrust race.
d Locate the piston adaptor 18G 1150 E
with its long spigot inside the bore of
the hexagon body.
e Fit the remover/replacer bush of 18G
1150 on the centre screw with the
flanged end away from the gudgeon
pin.
f Screw the stop-nut aboul~ half-way
onto the smaller threaded end of the
centre screw, leaving a gap ’A’ of
V8in (3 mm)between this nut and the
remover/replacer bush.
g Lock the stop-nut securely with the
lock screw,
h Check that the remover/replacer bush
is correctly positionedin the bore of the
piston.
i Push the connecting rod to the right to
expose the end of the gudgeon pin,
whichmust be located in the end of the
adaptor ’d’;
j Screw the large nut up to the thrust
race.
k Hold the lock screw and turn the large
nut until the gudgeon pin has been
withdrawn from the piston. Dismantle
the tool.
CONNECTING RODS AND
PISTONS
12.17.10
Overhaul
These instructions supersede those given in the
Repair Operation Manual.
Service tools: lgG 537, 18G 587 or 605350,
18G 1150, 18G 1150 E
Dismantling
1
Removethe connecting rods and pistons,
see 12.17.01.
NOTE:The connecting rods, caps and
bearing shells mustbe retained in sets, and
in the correct sequence.
2
Removethe piston rings over the crown of
the piston.
3 If the same piston is to be refitted, markit
relative to its connectingrod to ensure that
the original assemblyis maintained.
4
Withdraw the gudgeon pin, using tool
18G1150 as follows:
a Clamp the hexagon body of 18G 1150
In a vice.
b Position the large nut flush with the
end of the centre screw.
5
As an alternative to tool 18G1150, press
the gudgeonpin from the piston using an
hydraulic press and the componentswhich
comprise tool 605350as follows:
a Place the base of tool 605350 on the
bed of an hydraulic press which has a
capacity of 8 tons (8 tonnes).
b Fit the guide tube into the bore of
the base with its countersunk face
uppermost.
c Push the piston to one side so as to
expose one end of the gudgeonpin and
locate this end in the guide tube.
d Fit the spigot end of the small diameter
mandrel into the gudgeonpin.
e Press out the gudgeon pin, using the
hydraulic press.
Newpistons
NOTE:A single standard piston 0,0254
mm(0.001 in) oversize is available only
for service purposes. Should it be necessary to fit a newpiston to a standard bore,
the bore must be honed to accommodate
the piston with the correct clearance--see
DATA.
Check the cylinder bore dimension at
8
right angles to the gudgeonpin, 90 to 100
mm(3.5 to 4.0 in) from the top.
Checkthe piston dimensionat right angles
9
to the gudgeonpin, at the bottom of the
skirt.
10 The piston dimension must be 0,018 to
0,033 mm(0.0007 to 0.0013 in) smaller
than the cylinder.
Overhaulingpistons
Original pistons
6 Removecarbon and deposits, particularly
from the ring grooves.
7
Examinethe pistons for damageor excess
wear--see DATAfor clearances--fit
new
replacements as necessary.
NOTE:
The temperature of the piston and
cylinder block must be the sameto ensure
accurate measurements.
5
RM 0187
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11
12
13
If newpiston rings are to be fitted without
reboring, deglaze the cylinder walls with
a hone, without increasing the bore
diameter.
NOTE: A deglazed bore must have a
cross-hatch finish.
Check the compression ring gaps in the
applicable cylinder, held square to the
bore with the piston. Gaplimits: 0,46 to
0,60 mm(0.017 to 0.022 in.) Use a finecut flat file to increase the gapif required.
Select a newpiston ring if the gap exceeds
the limit.
NOTE:Gappingdoes not apply to oil control rings.
Temporarily fit the compression rings to
the piston with the chrome compression
ring in the top grooveand the stepped ring
in the second groove with the marking T’
or ’TOP’ uppermost.
.....................
~,~
14 Check the compression ring clearance in
the piston groove. Clearance limits: 0,08
to 0,13 mm(0.003 to 0.005 in).
22
Fitting piston rings
15 Fit the expander ring into the bottom
groove makingsure that the ends abut and
do not overlap.
16 Fit two ring rails to the bottomgroove, one
above and one below the expander ring.
17 Fit the chromecompressionring in the top
groove and the stepped ring in the second
groove with the marking ’T’ or ’TOP’
uppermost.
24
23
25
26
Place a piece of Plastigauge 605238,
across the centre of the lower half of the
crankshaft journal.
Locate the bearing lower shell into the
connecting rod cap.
Locate the cap and shell on to the connecting rod. Note that the rib on the edge
of the cap must be the same side as the
domedshape boss on the connecting rod.
Secure the connecting rod cap. Torque 41
to 47 Nm(30 to 35 lbf ft).
NOTE:Do not rotate the crankshaft while
the Plastigaugeis fitted.
Removethe connecting rod cap and shell.
Connectingrods
18 Check the alignment of the connecting
rod.
19 Checkthe connecting rod small-end; the
gudgeonpin must be an interference fit.
Big-endbearings
20 Locate the bearing upper shell into the
connecting rod.
21 Locate the connecting rod and bearing on
to the applicable crankshaft journal, noting that the domedshape boss on the connecting rod must face towards the front of
the engine on the right-hand bank of cylinders and towards the rear on the left hand
bank. Whenboth connecting rods are fitted, the bosses will face inwards towards
each other.
27
27
RM 0186
28
14
29
30
31
RM 0189
~ ~= ~-’~--_
0188
Using the scale printed on the Plastigauge
packet, measurethe flattened Plastigauge
at its widest point. The graduation that
most closely corresponds to the width of
the Plastigauge indicates the bearing
clearance.
The correct bearing clearance with newor
overhauled components is 0,015 to 0,055
mm(0.0006 to 0.0022 in).
If a bearinghas beenin service, it is advisable to fit a newbearing if the clearance
exceeds 0,08 mm(0.003 in).
If a newbearing is being fitted, use selective assembly to obtain the correct
clearance.
Wipeoff the Plastigauge with an oily rag.
DONOTscrape it off.
NOTE: The connecting rods, caps and
bearing shells mustbe retained in sets, and
in the correct sequence.
4~’mw~’~m~ ~ ¯
Reassembling
32 If an hydraulic press and tool 605350were
used for dismantling, refit each piston to
its connectingrod as follows:
a Checkthat the base of tool 605350 and
the guidetube are fitted as in 5a and 5b.
b Fit the long mandrel inside the guide
tube.
c Fit the connecting rod into the piston
with the markingstogether if the original pair are being used, then place the
piston and connecting rod assembly
over the long mandrel until the gudgeon pin boss rests on the guide tube.
d Fit the gudgeonpin into the piston up
to the connecting rod, and the spigot
end of the small diameter mandrel into
the gudgeonpin.
e Press in the gudgeonpin until it abuts
the shoulder of the long mandrel.
If tool 18G1150wasused for dismantling,
refit each piston to its connectingrod as
follows:
a Clampthe hexagonbody of 18G1150
ma vice, with the adaptor18Gl 150E
positionedas in 4d.
b Removethe large nut of 18G1150 and
push the centre screwapproximately2
in (50 ram) into the body until the
.shoulderis exposed.
c Slide the parallel guidesleeve, grooved
(end last, onto the centre screwand up
to the shoulder.
d Lubricate the gudgeonpin and bores of
the connectingrod and piston withgrao
phited oil (Acheson’sColloids ’Oildag’). Alsolubricate the ball race and
centre screw of 18G1150.
e Fit the connecting rod and piston
together onto the tool with the markings together if the original pair are
beingused and with the connectingrod
aroundthe sleeveup to the groove.
f Fit the gudgeon
pin into the piston bore
up to the connectingrod.
g Fit the remover/replacer bush 18G
1150/3w’ith its flanged end towards
the gudgeonpin.
33
h Screw the stop-nut onto the centre
screwandadjust this nut to obtaina ~2
in (1 ram) end-float ’A’ on the whole
assembly and lock the nut securely
with the screw.
i Slide the assembly back into the
hexagonbodyand screw on the large
nut up to the thrust race.
j Set the torque wrench18G537 to 12
Ibf ft. This represents the minimum
load for an acceptableinterferencefit
of the gudgeonpin in the connecting
rod.
k Using the torque wrench and socket
18G587on the large nut, and holding
the lock screw, pull the gudgeon
pin in until the flange of the
remover/replacer bush is 0.160 in
(4 mm)’B fromthe face of the piston.
Under no circumstances must this
flangebe allowedto contactthe piston.
CAUTION:
If the torque wrench has
not brokenthroughoutthe pull, the fit
of the gudgeonpin to the connecting
rod is not acceptableand necessitates
the renewalof components.The large
nut andcentre screwof the tool mustbe
kept well-oiled.
the tool.
1 Remove
34 Checkthat the piston pivots freely on the
gudgeon
pin, andis free to slide sideways.
If stiffness exists, washthe assemblyin
fuel or paraffin (kerosene),lubricate the
gudgeonpin with Acheson’sColloids’Oildag’andre-check.If stiffnesspersists, dismantleand re-checkfor ingraineddirt or
damage.
35 Fit the connectingrods and pistons, see
12.17.01, carrying out the following
checksduringfitting.
36 Check that the connecting rods move
freely sidewayson the crankshaft. Tightness indicates insufficient bearingclearance or a mis-alignedconnectingrod.
37 Checkthe end-float betweenthe connecting rods on each crankshaft journal.
Clearancelimits: 0.15 to 0.37 mm(0.006
to 0.014in).
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3NC838
FUELSYSTEM
--CARBURETTERS
CARBURETTERSWITH
MANUALCOLDSTART
Tuneandadjust
19.15.02
Special equipment:
Mixtureadjusting tool S 353
Air-flowbalance meter
Infra-red gas analyser
Generalrequirements
priorto tuning
A Whenadjustment is required on carburetters with tamperproofshroudsfitted to
the idling and/or mixture adjusting
screws, the shrouds must be removedand
discarded. Newshrouds must be fitted
whereregulationsrequire this to be done.
B Accurateenginespeedis essential during
carburetter tuning; therefore the contact
breaker gap, ignition timing and vacuum
advance system must be checked and
adjustedas required.
C Whencheckingengine speed, use an independent and accurate tachometer. The
rev/minindicator fitted to the car is not
suitable.
D Beforeany attempt is madeto checksettings a thoroughcheckshould be carried
out to see that the throttle linkagebetween
the pedal and the carburetters is free and
has no tendancyto stick.
E Top-upthe damperoil level in both carburetters as follows:
Unscrewthe damperplug and raise the
piston by inserting a finger into the carburetterair intake. Withthe pistonraised,
top up the hollowdamperwith engine oil
until the level is 6 mm(¼in) belowthe top
of the guide.
;i
!i
Carburetter
balanceandidle speedadjustment
1 Remove
the air cleaners, see 19.10.01and
19.10.02.
"
2 Disconnectthe throttle cable link rod.
3 Disconnectthe throttle link rod between
the twocarburetters.
4,10
\
~
~~::~
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~
~
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17 Commencingwith either carburetter,
insert the tool S 353into the piston guide
rod ensuringthat the peg onthe outer barrel of the tool locates in the slot in the
guide rod end.
CAUTION:
Failure to locate the tool correctly mayresult in the diaphragmbeing
twisted with consequent permanent
damage.
18 Push the Allen key downuntil it engages
in the hexagonof the metering needle
housing,
i
~/~~3
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4
5
6
7
8
9
10
11
12
13
Turnthe lost motionadjusting screwuntil
it is clear of the springloadedpad.
Connectthe air-flow balancemeterto the
carburetters.
Start the engine and run it at fast idle
speeduntil normaloperatingtemperature
is reached.
Increase the engine speed to 2,500
rev/minfor one minute.
Turnthe idle adjustingscrewsonbothcarburetters until a balancedflowis achieved
at the correct idle speed, see ENGINE
TUNINGDATA.
Connect the link rod between the carburetters. This will cause the left hand
carburetter to goout of balance.
Torestore the balance,holdthe left hand
carburetterthrottle lever against it’s stop
and turn the lost motionadjusting screw
until it just contactsthe springloadedpad.
Tightenthe lock nut and check the idle
speedand balance.
Fit the throttle cable link rod, whilst
checking that the idle speed does not
change.
Remove
the air-flow balancemeterand fit
the air cleaners.
~z~le
1156
118
RM037
~
19 Whilstholdingthe outer barrel, turn the
Allenkey clockwiseto enrich the mixture
or anti-clockwiseto weaken.
NOTE:Both carburetters should be
adjusted in turn by equal amountsunti]
the fastest speedis attained and the CC
readingis withinlimits. Theadjustingtoo]
mustbe removedfromthe guide rod aftel
each adjustmentto allow the engineto be
run at 2,000 rev/minfor a fewsecondst¢
’clearout’ andstabilize.
[-
1-1....
20
Checkand if necessarytop-up the damper
oil level. Fit bothpiston dampers.
21 Runthe engine at 2,000 rev/min for 20
secondsbefore makingfinal checksand, if
necessary, adjustmentto the idle speed
and COlevel.
22 Removethe gas analyser probe and disconnect the COmeter.
Coldstart unit
23 Whenoperating the vehicle in temperatures above18 ° C (64° F), pushthe adjuster screwinwardsand turn it through90
degreesto retain its position.
24 Whenoperating the vehicle in temperatures below 18°C(64° F), the adjuster
mustbe fully outward.
Fast idle adjustment
25 Withthe cold start unit in the fully off
position,turn the fast idle screwto obtain
a clearance of 0,5 mm(0.020 in) between
the coldstart camlever andthe headof the
fast idle screw~
CARBURETTERS
WITH
MANUAL
COLDSTART
Remove
andrefit
L.H. 19.15.09
R.H.19.15.10
Removing
! Remove
the air cleaner, see 19.10.01 or
19.10.02.
-~
Disconnectthe engine breather hose.
2
3, Disconnectthe float chambervent pipe.
4 L.H. carburetter disconnect the vacuum
pipe.
5 Disconnectthe fuel feed pipe from the
carburetter.
6 Disconnect
the cold start fuel supplyline.
7 L.H.carburetter disconnectthe cold start
cable and removethe abutmentbracket.
8 Disconnectthe throttle link rod fromthe
appropriatecarburetter.
9 L.H. carburetter disconnectthe throttle
cablelink rod.
10 Removethe nuts securing the carburetter to the manifoldand withdrawthe
carburetter fromthe engine.
11 Remove
the outer joint washer.
12 Remove
the liner.
13 Remove
the insulator.
14 Remove
the inner joint washer.
Refitting
15 Cleanthe carburetter and manifoldmatingfaces.
16 Fit a newinner joint washer.
17 Fit the insulator withthe arrowuppermost
and pointing inwards.
18 Fit the liner ensuringthat the lugs locate
in the insulator and the blade points
downwards.
19 Fit a newouter joint washer.
20 Fit the earburetter and secure with the
four nuts and spring washers.
21 Reverseinstructions 2 to 9.
22 Fit the air cleaner, see 19.10.01 or
19.10.02.
23 Tuneand adjust the earburetters, see
19.15.02.
23.24
25
RM0379
18 19 17 16
RMO2O9
CARBURETTER
COLDSTART
KEY TO ILLUSTRATION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Piston damper
Cover
Cover screw
Specificationtag
Piston return spring
Retainingring screw
Retainingring
Diaphragm
Piston assembly
Needleretaining screw
Needle
Temperaturecompensatorunit
Temperaturecompensatorcover
Temperaturecompensatorcover screw
Carburetter body
Float
Float chambergasket
Float chamber
Float needle valve and washer
Sealing plug
Float chamberscrew
Idle speedadjusting screw
Throttle spindle
Coldstart gasket
Coldstart face
Coldstart discs
Spring
Springretaining clip
Coldstart cover
Return spring
Coldstart lever
Coldstart cover screw
Overhaul
1
WITH
MANUAL
19.15.18
Remove
the carburetter, see 19.15.09 or
19.15.10.
5
Dismantling
2 Removethe piston damperand sealing
washer.
3 Remove
the top cover and spring.
4 Remove the piston and diaphragm
assembly.
the mixture adjusting screw.
5 Remove
6 Removethe grub screw and withdrawthe
needle assembly.
7 Removethe diaphragm and retainer
plates fromthe piston.
Removethe float chamber, gasket and
8
needlevalve, see 19.15.24.
12
14
23
16
26
Carburetter
cleaning
17 Whencleaning fuel passages, do not use
metaltools (files, scrapers, drills etc.)
whichcould cause dimensionalchangesin
the drillings or jets. Cleaningshould be
effeotedusingclean fuel and, wherenecessary, a moisturefree air blast.
29
32
Dismantling
the carburetterbody
9 Addlocation marksto the throttle butterfly andspindle.
10 Remove
the throttle butterfly taking care
not to damage
the poppetvalve.
11 Remove
the fast idle lever and throttle
lever and withdrawthe throttle spindle.
12 Removethe temperature compensator.
13 Removethe temperature compensator
cover.
14 Remove
the hi-metal strip and valve.
15 Remove
the cold start assembly.
16 Dismantlethe cold start assemblybut DO
NOTremovethe discs fromthe spindle.
31
RM0216
ZENITH 175 CDSE CARBURETTER
Joint faces
18 Examinethe faces for deep scores which
wouldlead to leakage taking place when
assembled.
Joint gasket and seals
19 New gaskets and seals should be used
throughout carburetter .rebuild. A complete set of gaskets is available for replacement purposes.
20 Inspect the metering needle, it is
machinedto very close limits and should
be handled with care. Examinefor wear,
bend and twist, renewif necessary.
Diaphragm
21 In common with other products made
from rubber compounds, any contact of
the diaphragmwith volite cleaners should
be avoided;
use only CLEANRAG.
Examinefor damageand deterioration.
Reassembly
25 Place the spring on the cold start spindle.
26 Fit the spring retaining clip.
27 Checkthat the discs slide easily on the
spindle.
28 Place the cold start spindle on the starter
face.
29 Place the starter cover in position.
30 Fit the return spring over the spindle.
31 Rotate the spindle until the oval port in the
enddisc is aligned with the oval port in the
starter face.
32 Fit the cold start lever.
33 Engagethe return spring over the lug on
the starter cover and the back of the cold
start lever.
34 Fit the cold start assembly and gasket to
the carburetter body, and checkfor ease of
operation.
Inspection
22 Examinethe float for puncture or damage,
and the chamber for corrosion. Examine
the retaining clips for wear.
23 Examine the cold start bushes for wear,
renewas necessary.
24 Examinethe throttle spindle for wear.
35
36
37
38
39
Fit the bi-metal strip and valve to the temperature compensator and secure the
cover.
Fit the temperature compensator to the
carburetter.
Fit the throttle spindle to the carburetter.
Fit and align the butterfly to the throttle
spindle.
Fit the return spring to the throttle
spindle.
40
41
42
43
44
45
46
47
48
Fit the fast idle and throttle levers.
Fit the float chamber, gasket and needle
valve, see 19.15.24.
Fit and align the diaphragmto the piston.
Fit the diaphragm retaining plate and
secure with screws.
Fit the needle assemblyto the piston, and
secure it with the grub screw.
Fit the mixture adjusting screw.
Fit the piston and diaphragm assembly to
the carburetter and align the diaphragm.
Fit the top cover and spring.
Fit the piston damperand sealing washer.
Refitting
49 Fit the carburetter,
19.15.10.
see 19.15.09 or
GEAR CHANGE REMOTE
CONTROL ASSEMBLY
Overhaul
23
37.16.20
Fit the remoteControl assemblyto the
gearbox.
Operationsto be carried out followingthe
fitting of the remotecontrol assemblyto
the gearbox.
Fit the gearlever.
Theseinstructions supersedethose givenin the
Repair Operation Manual.
24
Dismantling
1 Remove
the remotecontrol assemblyfrom
the gearbox.
2 Removethe two bolts and two countersunk screws securing the bias spring
bridgeplates.
3 Removethe two bridge plates, bridge
plate liners andthe bias spring.
4 Removethe bias spring adjusting bolts
and locknuts.
5 Remove
the two bolts and washerssecuring the reverse baulk plate assemblyand
withdrawthe reverse baulkplate, springs
and spacers.
6 Remove
the four bolts and washerssecuring the bottomcoverplate.
7 Remove
the bottomcover plate.
8 Removethe reverse light swilch and
loeknut.
9 Removethe square-headed pinchbolt
securingthe selector shaft elbow.
10 Remove
the selector shaft elbow.
11 Withdraw
the selector shaft.
12 Press out the twoselector shaft bushesin
the remotecontrol casing.
the circlips securingthe pivot ball
13 Remove
andbushesin the selector shaft elbowsand
press out the bushesandpivot balls.
Adjusting
the reversebaulkplate
Adjustmentof the reverse baulk plate mustbe
carried out on a completegearboxassembly.
25 Remove
the bottomcover plate of the gear
lever remotecontrol assembly.
26 Locatethe gearlever in neutralin a vertical position.
27 Slackenthe baulk plate adjusting bolts
andlocknutsuntil the baulkplate is in contact withthe backingplate.
28 Tightenthe adjusting bolts equally until
they just start to movethe baulkplate out
of contactwiththe backingplate.
29 Adjustmentshould be such that an effort
of 30to 35lbf ( 13,6to 15,9kgf)is required
to overcomethe resistance of the baulk
plate. This maybe checkedusing a spring
balance attached to the threaded end of
the gear lever (gear knobend). Adjust
tightening or slackeningthe twoadjacent
bolts and locknuts located on the right
handside ofthe reverse baulkplate.
NOTE:A minimum
clearance of 0.010 in
(0,254 mm)must exist betweenthe upper
face of the baulkplate and the loweredge
of the gear-leverbush.
Assembling
14 Press in newselector shaft bushesin the
remotecontrol casing.
15 Fit newbushes,pivot balls andcirelips to
the selector shaft elbow.
16 Fit the selectorshaft to the casing.
17 Fit the rear elbow and secure with the
square-headedpinchbolt.
18 Fit the baulk plate assembly.
19 Fit the reverseswitchandlocknut.
20 Fit the bottomcoverplate.
21 Fit the bias spring adjusting bolts and
locknuts.
22 Fit the bias spring, bridgeplate liners and
bridgeplates.
Adjustment
of gearlever bias spring
34 Unit completely assembled, engage 3rd
gear.
35 Adjustthe screwsto position both legs of
spring0,5 mmclear of lever crosspin.
36 Applya light load to gear lever in L.H.
direction taking up play. Adjust R.H.
screwdownward
until R.H.spring leg just
makescontact with crosspin.
37 Repeatinstruction 36 on the other side.
Playwill still be presentbutat extremes
of
gear lever travel the crosspinshouldmake
contactwiththe springlegs.
38 Return lever to neutral and rock across
gate several times. Levershouldreturn to
3rd/4th gate.
39 Tightenthe locknuts.
40 Adjustthe reverseswitch, see 86.65.20.
WINDSCREEN
WASHERS
WIPERS
AND
WINDSCREENWIPER DELAYUNIT
Remove
andrefit
84.25.31
Removing
1 Disconnectboth multi-pin plugs from the
delayunit.
2 Removethe mountingscrews and nuts,
and withdrawthe delay unit and insulating plate.
Refitting
3 Reverseinstructions 1 and 2, ensuring
that the earth lead is fitted to one of the
mountingscrews.
Adjustment
of lst/2nd gate stop
This operation mustbe carried out following
the adjustmentof the reverse baulkplate.
30 Engage Istgear.
31 Checkthe clearance betweenthe side of
the gear lever and the edgeof the baulk
plate. This should be 0.010 to 0.049 in
(0,25 to 1,25 mm).Adjust by adding
removingshimsas necessary.
32 Engage2nd gear and repeat the above
operation.
33 Fit the bottomcoverplate.
\
Oo
MAIN WIRING DIAGRAM--
TR8 --
1981
U.K.
MARKET
1
19
:B
27
I0
30
46
40
45
69
65
66
82
84
85
83
95
96
99
98
102
Battery
Alternator
Starter motor
Starter relay
Start inhibit switch-automatics only
6 Ignition switch
7 Heater blower unit
8 Temperature transmitter
9 Voltmeter
10 Temperature gauge
11 Tachometer
12 Fuel gauge
13 Lowcoolant warning light
14 Handbrake warning light
15 Brake warning light
16 Oil warning light
17 Ignition warning light
18 Headlamp relay--R.H.
19 Headlampmotor circuit breaker
20 Headlamp relay-- L.H.
21 Headlamp motor -- L.H.
22 Headlamp motor-- R.H.
23 Master light switch
24 Headlampflash unit
25 Headlampflash relay
26 Clock
1
2
3
4
5
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Cigar lighter
Horn push
Horn relay
Horn
Lowfuel warning light
Lowfuel delay unit
Tank unit
Handbrake switch
Brake pressure differential
switch
Heated rear screen switch
(Coup6 only)
Heated rear screen warning light
(Coup6 only)
Heated rear screen relay
(Coup6 only)
Heated rear screen (Coup6 only)
Speakers
Radio
Main/dip/flash switch
Hazard unit
Windscreen wiper/washer switch
Windscreen washer motor
Windscreenwiper delay unit
Windscreen wiper motor
Distributor
Coil
Ballast resistor
Main beam warning light
Main beam -- R.H.
53 Main beam-~- L.H.
54 Dip beam-- R.H.
55 Dip beam-- L.H.
56 Side lamp -- R.H.
57 Side lamp-- L.H.
58: Front fog lamp-- R.H.
59 Front fog lamp-- L.H.
60 Rear fog lamp-- R.H.
61 Rear fog lamp-- L.H.
62 Tail lamp -- LH.
63 Tail lamp-- R.H.
64 Number plate lamp
65 Aerial motor junction
66 Boot lamp
67 Boot lamp switch
68 Courtesy light
69 Door switch
70 Oil pressure switch
71 Inertia switch
72 Fuel pump
73 Driver’s belt switch
74 Seat belt warning light
75 Passenger belt switch
76 Passenger seat switch
77 Reverse light switch
78 Reverse lamp-- R.H.
COLOURCODE
N
U
R
Brown
Blue
Red
P
G
K
Purple
Green
Pink
LG Light
Green
W White
Y Yellow
S Slate
B Black
O Orange
79 Reverse lamp-- L.H.
80! Rear fog lamp warning light
81 Fog lamp switch
82 Hazard warning light
83 Hazard switch
84: Flasher unit
85 Lowcoolant level indicator
86 Lowcoolant level sensor
87: Stop lamp switch
88 Stop lamp-- R.H.
89 Stop lamp-- L.H.
90 Choke switch
91 Choke warning light
92 Selector panel illumination -automatics only
93 Cigar lighter illumination
94 Panel rheostat
95 Heater control illumination
96 Panel illumination
97 Switch panel illumination
98 Direction indicator switch
99 Rear indicator-- R.H.
100 Indicator warning light-- R.H.
101 Front indicator-- R.H.
102 Rear indicator-- L.H.
103 Indicator warning light-- L.H.
104 Front indicator-- L.H.
A To heated rear
)
screen relay
B To heated rear
screen switch
I
SEEINSET
MAIN WIRING DIAGRAM~ TR8 ~ 1981 U.S.A. MARKET~ FUEL INJECTION CARS WITH
AIR CONDITIONING
EF
16
17
D
24
L__
54
105
RW
RM0208
IIIIIIIIII
IIIIIIII
,,, ,,,,,,~,,, , ......,,,,, ,,, , ,, ~rii~
1 Battery
2 Alternator
3 Starter motor
4 Headlamprelay-- R.H.
5 ~ Headlamp
relay -- L.H.
6 Starter motorrelay
7 Headlampmotorcircuit breaker
8! Start inhibit Switch-automaticsonly
9 Ignition switch
10 Highspeed -- relay
11 Lowspeed relay
12 Fan motor
13 Highspeed + relay
14 Idle solenoidvalve
15 Heater/air conditioning blower
unit
16 Thermostat
17 Air conditioningcut-out switch
18 Radiator low’temperatureswitch
19 Highpressure cut-in switch
20 Enginehigh temperatureswitch
21 Air conditioningrelay
22 Thermalfuse
clutch coil
23 Compressor
24 Superheat switch
25 Temperaturetransmitter
26 Voltmeter
27 Temperature gauge
28 Tachometer
29 Fuel gauge
30 Lowcoolant warninglight
31 Handbrakewarninglight
32 Brakewarninglight
33 Oil warninglight
3zLIgnition warninglight
~,
35 Lowfuel warninglight
36 Lowfuel delay unit
37 Tankunit
38 Oil pressure switch
39 Handbrakeswitch
40 Brakepressure differential
switch
41 Headlampmotor -- L.H.
42 Headlampmotor -- R.H.
43 Masterlight switch
44 Buzzertimer unit
45 Seat belt warninglight
46 Buckleswitch
47 Door switch
48 Audible warning
49 Speakers
50 Radio
51 Main/dip/flash switch
52 Hazardunit
53 Hazardswitch
54 Flasher unit
55 Cigar lighter
56 Horn push
57 Hornrelay
58 Horn
59 Windscreenwiper/washerswitch
60 Windscreenwiper delay unit
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
Windscreenwiper motor
Windscreenwasher motor
Distributor
Coil
Ballastresistor
Courtesylight
Doorswitch
Mainbeamwarninglight
Main beam -- R.H.
Main beam-- L.H.
Dip beam-- R.H.
Dip beam-- L.H.
Side lamp- R.H.
Side lamp-- L.H.
Front marker lamp-- R.H.
Front marker lamp-- L.H.
Tail lamp-- R.H.
Numberplate lamp
Rear marker lamp-- R.H.
Tail lamp-- L.H,
Rear marker lamp-- L.H.
Front fog lamp
Rear fog lamp
Fog lampswitch
Rear fog lampwarninglight
Aerial motorjunction
Clock
Boot lamp
Boot lampswitch
Lowcoolant level indicator
COLOURCODE
N Brown
U Blue
R Red
P Purple
G Green
K Pink
LGLight
Green
W White
Y Yellow
S Slate
B Black
O Orange
91 Lowcoolant level sensor
92 Reverselight switch
93 Reverse lamp-- R.H.
94 Reverse lamp-- L.H.
95 Hotre-start solenoidvalve
96 Stop light switch
97 Stop lamp -- R.H.
98 Stop lamp -- L.H.
99 Serviceinterval counter
100 Serviceinterval counterwarning
light
101 Heatercontrol illumination
102 Selectorpanel illumination-automaticsonly
103 Cigarlighter illumination
104 Panel rheostat
105 Panelillumination
106Switchpanel illumination
107 Heatedrear screen switch
108 Heatedrear screen warninglight
109 Heatedrear screen
110 Heatedrear screen relay
111 Indicator warninglight -- R.H.
112 Indicator warninglight -- L.H.
113 Front indicator -- R.H.
114 Front indicator -- L.H.
115Directionindicator switch
116 Rear indicator-- R.H.
117 Rear indicator-- L.H.
A Toheated rear screen
relay
B Toheated rear screen
SEEINSET
switch
C Toheated rear screen
relay
D Toinjector and E.C.U.
relay
SEE FUEL
E Tofuel pumprelay
INJECTION
F Todioderesistor pack
WIRING
G Todioderesistor pack
DIAGRAM
H Fuel injection timing
signal
FUELINJECTIONCIRCUITSWIRINGDIAGRAM
~ TR8 -- 1981 U.S.A. MARKET
!
2
3
4
5
6
7
8
9
I0
I1
12
13
14
15
16
17
18
19
20
21
22
23
Digital control box
Throttle potentiometer
Lambda sensor
Feedback monitor point
Extra air valve
Cold start injector
Thermo time switch
Air flow meter
Injector and E.C.U. relay
Dioderesistor pack
Inertia switch
Fuel pumprelay
Fuel pump
Water thermistor
No. 6 injector
No. 8 injector
No. 1 injector
No. 3 injector
No. 5 injector
No. 7 injector
No. 2 injector
No. 4 injector
Injector ballast resistors
5
4
R y
l
I
YP
Ii
14
15
16
17
13
IGNITION DISTRIBUTOR --
U.K.
MARKET
86.35.00
DATA
Manufacturer ...........................
Type ...................................
Lucas part number .......................
Triumphpart number.....................
Lucas
35DE8
41888
ERC7170
Polarity ................................
Pick-up air gap ..........................
Rotation--viewedon rotor .................
Firing angle .............................
Engine firing order .......................
Negativeearth only
0.014to 0.016 in (0.35 to 0.40 mm)
Clockwise
45__+_1 degree
1--8 ~ d 3--6--5--7--2
!
Centrifugaladvance
Degs.distributor advance
Distributor
rev/min
Crankshaft
rev/min
20O
750
1000
1600
2400
2750
Minimum
Maximum
0
3
6
8.5
11
10.5
1
4.5
8
10.5
13
13
400
1500
2000
3200
4800
5500
Degs.crankshaft
advance
Minimum
Maximum
0
6
12
17
22
21
2
9
14
21
26
26
Vacuum
advance
Inches of mercuryvacuum
3
6
12
16
21
t~
Degs.distributor advance
Degs. crankshaft advance
Minimum
Maximum
Minimum
Maximum
0
0
1
4
6.5
1
2
4
8
8.5
0
0
2
8
13
2
4
8
16
17