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 ......................................... -- 4
Engine Tuning Data ............................................... -- 6
Torque WrenchSettings ............................................ 8
Lubricantsand Anti-FreezeSolutions..... ,_. ........................... 9
Maintenance Summary......................... ................... ~.................
11

ENGINE
Connectingrods and pistons
---overhaul ................................................... 12.17.10 20

FUEL SYSTEM--CARBURETTERS
Manualcold start carburetters
left-hand removeand refit ................................... 19.15.09 24
---overhaul ................................................... 19.15.18 25
right-hand--remove and refit .................................. 19.15.10 24
tune and adjust ............................................. 19.15.02 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 .......................................... ~ ...... 33
Wiring diagrams
U.K ....................................................... 28
--U.S.A ..................................................... 30

¯ - - 3
VEHICLE IDENTIFICATION NUMBER GENERAL SPECIFICATION DATA
Location
The vehicle identification number(V.I.N.) is stamped on a plate on the R.H. suspension tower and This information supersedes that given in the Repair Operation Manual
should be quoted in full.
A sample V.I.N. is shown below: ENGINE
Compression ratio: U.S.A .................... 8.15 : 1
SAT TP A D V 7 A A 402027 U.K ................... 9.35: 1

MarqueIdentifier
(Marque Identifier not used before mid 1981)
I
Model range. LUBRICATION SYSTEM ~
Pump ................................ =.’;High capacity rotor pump
Class Pressure at 2400 rev/min ................ ~2.5 kg/cm2 2)
,(35 lbf/in
Oil filter .............................. :~Disposablefull flow type
Body. Oil filler .............................. Sealed cap on rocker cover

Engine

Steering/Transmission
IGNITION SYSTEM
Model Year/Change Coil: U.S.A ............................ Lucas 22C12
U.K ............................. Lucas 23C12
Assembly Plant Ballast resistor ........................ 9 BR
Distributor ............................ Lucas electronic, type 35DE8
Serial Number

FUELSYSTEM-Carhnretters
Carburetter ........................... !Refer to’ENGINE TUNINGDATA’
Fuel pump ............................ Electric immersedin fuel tank.
Operating pressure ...................... 0.28 kgf/cm~ 2)
(4 lbf/in

FUEL SYSTEM--Fuel Injection

Make/type ........................... Lucas/digital
Pump ................................ Electric beneath ear floor
Operating pressure ..................... Approximately3.0 kgf/cm2 2)(43 lbf/in
Fuel filter(s) .......................... In line, renewable
Air cleaner ............................ Replaceable element

31 L ........
TRANSMISSION(MANUAL) from VIN 402027 WEIGHTS(APPROXIMATE)COUPE--From VIN 402027
Manualgearbox Automatic gearbox
5th 4th 3rd 2nd 1st Rev *Showroom: Minimum ................... 1121 kg (2471 lb) 1 III kg(2449 Ib)
*Unladen: Minimum..................... 1162 kg (2562 lb) 1152 kg (2540 lb)
*Gross vehicle weight ..................... 1420 kg (3131 lb) 1420 kg (3131 lb)
Gearbox ratios to 1 ...................... 0.792 1.000 1.396 2.087 3.321 3.428 *Maximumaxle load: Front ............... 765 kg (1687 lb) 765 kg (1687 lb)
Overall ratios to 1 ....................... 2.440 3.083 4.300 6.428 10.229 10.56 Rear . ............... 695 kg (1532 lb) 695 kg (1532 lb)
Enginerev/min at
10m.p.h ............................. 362 457 639 955 1517
10 km/h ............................ 225 284 397 594 943
WEIGHTS(APPROXIMATE)CONVERTIBLE--From VIN 402027
Road speed at Manual gearbox Automatic gearbox
1000 engine rev/min: *Showroom: Minimum ................... 1098 kg (2421 lb) 1088 kg (2399 lb)
m.p.h ............................... 27.6 21.9 *Unladen: Minimum..................... 1139 kg (2511 lb) 1129 kg (2489 lb)
km/h ............................... 44.4 35.2 *Gross vehicle weight ..................... 1420 kg (3131 lb) 1420 kg (3131 lb)
*Maximumaxle load: Front ............... 765 kg (1687 lb) 765 kg (1687 lb)
Rear ................ 695 kg (1532 lb) 695 kg (1532 lb)
Maximumrecommended road speed in
intermediate gears corresponding to engine
speed of 5500 rev/min: *Thesefigures must be taken as a guide only and vary according to market, model, year and equip-
m.p.h ............................... 86.1 57.6 36.3 mentfitted.
km/h ............................... 138.6 92.7 58.4

CAPACITIES (NOMINAL) Metric Imperial U.S.A.

Windscreen washer reservoir ............... 1,6 litres 2.75 pt 3.3 pt
Air conditioning system ................... 2.5 lb, 1.1 kg of Refrigerant 12
This information supersedes that given in the Repair Operation Manual
Fuel tank ............................... 54.5 litres 12 gal 14.4 gal

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, SPARKPLUGS
Make................................ Championor Unipart
WARNING:Beforecommencing workon an ignition system,all hightension terminals,adaptorsand Type ................................. N12Yor GSP13
diagnosticequipmentfor testing shouldbe inspectedto ensurethat theyare adequately insulatedand Gap: ................................. 0.90 mm(0.035 in)
shielded,to preventaccidentalpersonalcontactandminimize the risk of shock.
WearersofsurgicaUy
implanted pacemakerdevicesshouldnot be in close proximityto ignitioncircuits
or diagnosticequipment.
ENGINE COIL Lucas 23C12
Type ................................. V8 Primarywindingresistance .............. 1.2 to 1.5 ohms
Cylinder bore ......................... 88.90 mm(3.5 in)
Crank stroke .......................... 71.12 mm(2.80 in)
Capacity ............................. 3528cm3 8)
(215 in
Compressionratio ...................... 9.35 : 1
Firing order ........................... 1 8---4--3--6---5 7--2 BALLAST
RESISTOR................... 9, BR
Number1 cylinder ..................... Frontleft: Left bank1, 3, 5, 7
Rightbank2, 4, 6, 8
Cylinder pressures at 15°C (60°F) ambient
temperature, 150 to 200 rev/min .......... 9.1 kgf/cm2 (130 lbf/in z) minimum
Idle speed ............................. 725 to 775 rev/min CARBURETTERS
Fuel octane requirement ................ 97 R.O.N.(U.K.4 Star rating) Make/arrangement .................... Twinside-draught Zenith
Ignition timing: Static .................. 8° B.T.D.C. Type ................................. Zenith 175 CDSE
with manualcold start
Dynamic................ 8° B.T.D.C. at 600 rev/min with vacuumpipe Needle ............................... B1FL
disconnected
Location of timing marks ................ Crankshaftdamperwith pointer on timing cover
Valvetiming:
Inlet opens ......................... 30° B.T.D.C.
closes .......................... 75° A.B.D.C.
Exhaust opens ...................... 68° B.B.D.C.
closes ...................... 37° A.T.D.C.

DISTRIBUTOR
Make/type ........................... Lucas 35 DE8
Rotation--viewedon rotor . ...... . ....... Clockwise
Pick-up air gap ........................ 0.36 to0.41 mm(0.014 to 0.016 in)
Refer tO 86.35.00
 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.
Wearersof surgically implantedpacemaker devices should not be in close proximityto ignition circuits
or diagnostic equipment.

ENGINE ~ SPARK PLUGS

Type ................................. V8 Make ................................ Champion or Unipart
Cylinder bore ......................... 88.90 mm(3.5 in) Type ................................. N12Yor GSP 13
Crank stroke .......................... 71.12mm(2.80 in) Gap: ................................. 0.90 mm(0.035 in)
Capacity ............................. . ~(215in3)
3528cm
Compression ratio ......... ............. 8.15: 1
Firing order ........................... 1--8 4 3--6--5--7--2
NumberI cylinder ....... . ............. Front left" Left bank 1, 3, 5, 7
Right bank2, 4, 6, 8 COIL .................................. Lucas 22C12
Cylinder pressures at 15°C (60°F) ambient Primary winding resistance .............. 1.2 to 1.5 ohms
temperature, 150 to 200 rev/min, .......... 9.1 kgf/cm~ (130 lbf/in~) minimum
Idle speed ............................. 750 to 900 rev/min
Fuel octane requirement ................ 91 R.O.N.--unleaded
Ignition timing: Static .................. T.D.C.
Dynamic ... ............. T.D.C. with vacuumpipe disconnected BALLASTRESISTOR ................... 9 BR
Location of timing marks Crankshaft damper with pointer on timing cover
Valve timing:
Inlet opens ............. : ............ 30° B.T.D.C.
closes ........................... 75° A.B.D.C.
Exhaust opens ............... i ....... 68° B.B.D.C. FUEL INJECTION r
closes .................. ~ .... 37° A.T.D.C. Make/type ........................... Lucas digital electronic
Operating pressure ..................... 3.0 kgf/cm~ (43 lbf/in ~) approximate

DISTRIBUTOR
Make/type ........................... Lucas 35 DE8
Rotation--viewed on rotor ............... Clockwise
Pick-up air gap 0.36 to 0.41 mm(0.014 to 0.016 in)
Refer to 86.35.00

,.4
TORQUE WRENCH SETTINGS ANTI-FREEZE SOLUTIONS--ALL MARKETS

Thisinformation
supersedes
that givenin the RepairOperation
Manual Theoverall anti-freeze concentrationsshouldnot fall below30%by volumeto ensurethat the anti-
corrosionpropertiesof the coolant are maintained.
AIR CONDITIONING Description Specifiedtorque
Nm lbf ft Use UNIPART
Universal anti-freeze to protect the cooling system.
Hoses--flare type
Compressorto condenser 3A"crimpbacknut 40 30 If this is not available, use an ethyleneglycolbasedanti-freeze (containingno methanol)with non-
Condenser to receiver drier %"crimp back nut 28 21 phosphatecorrosioninhibitors suitable for use in aluminium enginesto ensurethe protection of the
Evaporatorto receiver drier 5/8" crimpbacknut 28 ¢~ 21 coolingsystemagainst frost andcorrosion.
Rancovalve to receiver drier ~6"flare nut 12 9
Hoses-- ’O’ ring type CAUTION:
No other universal anti-freeze should be used with UNIPART
Universal anti-freeze.
Compressorto condenser
Compressorend 10 mmbolt 34 25
Condenserend 3/4"gasketnut 27 20
Evaporatorto compressor
Compressorend 10 mmbolt 34 25
Evaporator end 7/8" U.N.F.Nut 37 27
Condenserto receiver drier %"U.N.F. gasket nut 18 13
Evaporatorto receiver drier %"U.N.F. nut 18 t3
Raneovalve to receiver drier ~6" U.N.F.gasket nut 9 7
RECOMMENDED LUBRICANTS AND ANTI-FREEZE SOLUTIONS--UK. MARKET

PERFOR-
MANCE
COMPONENT LEVEL UNIPART BP CASTROL DUCKHAMS ESSO MOBIL PETROFINA TEXACO SHELL

Engine BLCars Ltd. Unipart BP Super Castrol Duckhams Esso Uniflo ¯ Mobil Super Fina Havoline Shell Super
Carburetter specification Super Visco-Static QTX Q Motor 15W/50or Esso MotorOil Supergrade MotorOil MotorOil
and Oil Can BLS MotorOil 20w/50 20W/50 Oil Superlube 15w/4o Motor Oil 15W/40 15W/40
22.OL.02 15W/50 2ow/5o 10W/40 or MobilI 15W/40

Manual Gearbox ATFmeeting BP Castrol Duckhams Essoglide Mobil Fina Texamatic Shell
specification Autran G TQF Q-matic Type G ATF210 Purfimatig Type G Donax TF
M2C 33G 33G

Automatic ATFmeeting BP Castrol Duckhams Essoglide Mobil Fina Texamatic Shell

Gearbox Specification Autran G TQF Q-matic Type G ATF210 Purfimatic Type G Donax TF
M2C~33G 33G

Final Drive MIL-L- BP Gear Castrol Duckhams Esso Gear Mobilube Fina Texaco Shell
Unit* 2105 Oil 90 EP Hypoy Hypoid90 Oil GX HD 90 Pontonie MP Multigear Spirax 90EP
API GL4 90 EP 85W/140 80w/90 Lubricant
90 EP

GreasePoints NLGI-2 BP Castrol Duckhams Esso Mobil Fina Marson Marfak Shell
Brake Cables Multi-purpose Energrease LMGrease LB 1D Multi- MP HIL 2 All Purpose Retinax A
Steering Rack Lithium L2 purpose Grease Grease
and Rear Hubs~" based grease

Brake and Clutch Unipart Universal BrakeFluid

Reservoirs boiling point of 260° C (500° F) and complyingwith FMVSS
or other BrakeFluids having a minimum 116 DOT

Cooling system Unipart UniversalAnti-Freeze

Windscreen Unipart AlPSeasonsScreenwash

Washers

* 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 SOLUTIONS OVERSEAS MARKETS

This information supersedes that given in the Repair Operation Manual

SERVICE CLASSIFICATION AMBIENT TEMPERATURE °C

Performance Level S.A.E. -30 -20 -10 -0 +10 +20

Viscosity
G

ENGINE Use UNIPART 5w/20

L
II,
CARBURETTER Super Multigrade 5w/30
DASH POTS Motor Oil 5w/40
OIL CAN ORother oils lOW/30 D.
meeting BL Cars 10w/a0
specification 10w/50
BL 2ZOL.02 15W/40
OR the requirements 15W/50
of the CCMC 20W/40
or API-SE 20W/50 IP

FINAL DRIVE UNIT* MIL-L-2105 Hypoid 90

TOP UP ONLY API GL4 Hypoid 80W II,

MANUAL ATFmeeting specification-~" ’~- *

GEARBOX M2C 33G
I1~

.AUTOMATIC ATFmeetingspecification
GEARBOX M2C 33G

REAR HUBS
GREASE GUN NLGi-2Multi-purpose lithium based grease Front hubs NLGI-2High Melting Point Grease
) BRAKE CABLES
STEERING RACK
~
uNIPARTUNIVERSAL BRAKEFLUID or other Brake Fluids having a minimum boiling point of 260
BRAKE AND CLUTCH
¯ RESERVOIRS C (500 ° F) and complying with FMVSS116 DOT

COOLING SYSTEM UNIPART UNIVERSAL ANTI-FREEZE

WINDSCREEN WASHER UNIPART ALL-SEASONS SCREEN WASH

* Final Drive Unit if drained MUST

be filled with an oil meeting BL Cars specification BLS.22.OL.03or having a minimumperformance level of
M IL-L-2105B
 MAINTENANCE SUMMARY U.K.
AfterSales
After SalesService= 1,000miles/1500km Service
Intermediate
Service= Every6 monthsor 6,000miles/10000km Intermediate
MainService= Every12 monthsor 12,000miles/20000km Service
MainService(24 denotesevery24 months,24,000miles (40 000kin)
AfterSales
Service
¯ ACTION XOPERATION
Intermediate Check.visuallybrakehoses,pipes and unionsfor chafing, cracks, leaks and
Service corrosion
Checkvisually fuel and clutch pipes and unions for chafing, leaks and
MainService(24 denotesevery24 months,24,000miles (40 000km) corrosion
Checkexhaust systemfor condition, leakageand security
Adjust handbrakecable (whereaccessible from below)
ACTION X OPERATION Checksecurity of accessible engine mountings
Fit car protectionkit Checksecurity and conditionof suspensionjoints and fixings
Checkconditionand security of seats andseat belts Cheekpowersteering systemfor leaks, hydraulicpipes and unionsfor chaf-
Driveonlift. Stopengine ing and corrosion
Checkoperation of lamps Renewengineoil filter element(whereaccessible frombelow)
Checkoperation of horns Cleanand refit drain plug
Checkoperation of warningindicators Checkfor oil leaks fromengineand transmission
Check/adjustoperation of screen washers Lubricate headlampfitting mechanism pivots
Checkoperationof screen wipers Lowerlift
Checksecurity/operation of foot and handbrake: release fully after Fit exhaustextractor pipe
checking Renew engine oil filter element(whereaccessible fromabove)
Openbonnet:fit wingcovers Fill enginewithoil
Openboot Lubricateall pedal pivots andcontrol linkages
Disconnectbattery Top-upcarburetter piston dampers
Raiselift to convenientworkingheight withwheelsfree to rotate Renewair cleaner element(s)
Markstud to wheelrelationship front wheels Checksecurity of accessible engine mountings
Markstud to wheelrelationship rear wheels Checkdriving belts, adjust or renew
Removefront wheels Renewspark plugs
Removerear wheels Openboot
Inspect road wheelsfor damage Check/top-upbattery electrolyte
Checktyre tread depth Cleanand grease battery connections
Checktyres visually for external cuts in fabric, exposureof ply or cord Checkbattery condition
structure, lumpsor bulges Reconnectbattery
Checktyres for unevenwear Check/top-up clutch fluid reservoir
Check/adjusttyre pressures Check/top-upbrake fluid reservoir
Inspect brake pads for wear and discs for condition. Renewpads if Checkoperationof brakefluid level warninglight switch(wherefitted)..
necessary Checkbrake servo hose for security and condition
Adjustfront hubbearing end-float Check/top-upscreen washerreservoir
Remove brake drums,washout dust, inspect shoes for wearand drumsfor Check/top-upcooling system
condition. Renewshoes if necessary. Refit drums Pressuretest coolingand heater systemfor leaks
Inspect for fluid leaks fromdampers Renew fuel line filter (wherefitted)
Checkconditionandsecurity of steering unit, joints andgaiters Checkvisually crankcasebreathingsystemfor leaks and hosesfor security
Refit roadwheelsin original position and condition
Checktightness of road wheelfastenings Renew enginebreatherfilter (wherefitted)
Raiselift to convenientworkingheight Check/topup powersteering reservoir
Drainengineoil Start engineandchecksealingof oil filter
Check/top-upgearboxoil Stop engine
Check/top-uprear axle oil Checkthrottle and chokeoperation
7.,
 After Sales After Sales
Service Service
Intermediate Intermediate
Service Service
MainService (24 denotes every 24 months,24,000 miles (40 000 km)

¯ ACTION ×OPERATION
Start engine
X

X
x

X
Checkignition distributor characteristics and timing, using electronic equip-
ment. Adjust as necessary
Set to fast idle; leave engine running
Lubricate all locks, hinges and door check mechanisms(not steering lock)
ljRo a dTest
Fit trade plates to vehicle
× Checkoperation of all door, bonnet and boot locks
× Check operation of windowcontrols Check starter operation and inhibitor switch Automatic
× ~ Check/adjust carburetter for engine idle speed and emissions settings Checkoperation of lights, horns, indicators, wipers and washers
Stop engine, disconnect instruments Checkindicators self-cancel
X ;K Checkpowersteering systemfor leaks, hydraulic pipes and unions for chaf- Checkoperation of all warning indicators
ing and corrosion Check foot and hand brakes
Start engine (auto only) Checkengine noise levels, performanceand throttle operation
Check/top-up automatic gearbox fluid Checkclutch for free play, slipping and judder
Stop engine Checkgear selection and noise level in all gears. Checkengagementof auto
IN Re-checktension if alternator driving belt has been renewed box parking pawl
Removewing covers Check steering for noise, effort required, free play, wander and self-
Fill in details and fix appropriate Unipart underbonnetstickers centring
Close bonnet Checkalignment of steering wheel spokes
Removeexhaust extractor.pipe Checksuspension for noise, irregularity in ride (e.g. dampers) and wheel
Removespare wheel imbalance
X ~ Inspect wheel for damage Check foot brake pedal effort, travel, braking efficiency, pulling and
Checktyre tread depth binding
X ;N Checktyre visually for external cuts in fabric, exposureof ply or cord struc- Check speedometer for steady operation, noise and operation of mileage
ture, lumpsor bulges recorder
Checktyre for uneven wear Checkoperation of all instruments
X ~ Check/adjust tyre pressure Check for abnormal body noises
Refit spare wheel Checkoperation of seat belts, including operation of inertia reels
Close boot Check handbrake ratchet and hold
Driveoff lift Adjust engine idle speed while engine is hot
Check headlamp alignment Position car on lift
X Check/adjust front wheel alignment Raise lift
Check front wheel alignment Inspect engine and transmission for oil leaks
X ~ Report additional work required Checkexhaust system for condition, leakage and security
Removecar protection kit Lowerlift and drive vehicle off
Ensurecleanliness of controls, door handles, etc. Report on road test findings
Carry out road or roller test 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, wheelcylin-
ders, 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 absolutecleanlinessthrough-
out cannot be over-emphasized.

I IIIIIIIIIIIIIIII II
MAINTENANCE Renewcrankcasebreather filter
U,K. SPECIFICATION Usingthe fingers and thumb,prise the fil-

/ 2
ter upwardsto release it from the rocker
cover.
Discardthe filter.
ENGINE 3 Fit a newfilter, pressing it gently onto the
rocker coveruntil it clips into place.
Check/top-upengine oil
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
RM0230
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.

Renewengine oil Cleanengine flame trap

NOTE:This operation is best carried out when
the engine is warmand with the vehicle stand-
ing 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.
Renew
oil filter element
Detach the hose from the flame trap.
2 Unscrewthe flame trap.
3 Clean the flame trap thoroughly, renew it
if satisfactory cleaning is not possible or
there are signs of deterioration or damage.
4 Refit the flame trap and reconnect the
hose.
5 Runthe engine until it is at normal oper-
ating temperature and, if necessary,
adjust the carburetters.
RM0257

See 12.60.01.

Renewengine breatherfilter ¯ f
1 Disconnect, from the filter, the two hoses /,
and removethe filter.
2 Fit the newfilter, ensuring that the word
’IN’ is towards the rocker cover.
 ~-7~i ~-~ ............... i .......
FUEL ¯SYSTEM
Renewcarburetter air intake air cleaner
elements
1 Disconnectthe air inlet hose(s) fromthe
air cleaner.
2 Releasethe twoair cleanercoverclips and
removethe cover.
3 Withdraw the filter elementand discard.
4 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/adjustcarhuretteridle settings
See 19.15.02.in this supplement.
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
Brat
outlet pipes.
IGNITION
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 RMO271A
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 suit-
able tool, carefully movethe side elec-
trode. 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.
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.
COOLING SYSTEM
1~~,
Check/top-upcooling system~
WARNING: Do NOTremove the cooling sys-
tem filler caps or plugs whenthe engine is hot.
1 Slowly turn the pressure cap anti-clock-
wise 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
Checkcooling/heater systems for leaks and
hoses for security andcondition
I Checkfor leaks from engine and radiator
drain taps/plugs (where fitted).
2 Checkfor leaks from water hose joints.
3 Checkfor leaks from water hoses through
damageor porosity.
4 Check for leaks from the water pump,
thermostat housing, radiator and heater
unit.
5 Report any leaks found.
Check/adiustoperation of all washersand top-
upreservoirs
1 Replenish the container with a mixture of
50% water and 50% UNIPART ’All
Seasons’ Screenwash (maximum). This
is an effective solution downto a tempera-
ture of-29°C.
Do not add anti-freeze solutions to the
2 j
container as this will discolour the paint-
work and damage wiper blades and seal-
ing rubber.
Check,if necesary renew,wiperblades
1 Examine each wiper blade in turn for
damage before wetting the windscreen
and operating the wiper motor control.
2 Replace wiper blades if they are damaged
or if they smear the screen.
TRANSMISSION
.~"~
Check/top-upmanualgearbox oil
I With the vehicle standing in a level posi-
tion, 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.
2 Allowsurplus oil to drain away, then refit
the filler plug and wipeclean. "
RM0273
Check/top-upautomatic gearbox fluid
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 posi-
tions 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 " I[
5 Checkthe fluid level on the side of the dip-
stick marked ’COLD’and if necessary,
add fluid; see Lubrication Recommen-
dations.
6 Repeat instructions 1 to 5 until the fluid
level is correct.
Donot overfill the transmission.
Wherethe reverse side of the dipstick car-
ries marksdenoted ’HOT’,the fluid level
check may be carried out with the trans-
mission 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 trans-
mission. The check is then carried out
using the ’HOT’side of the dipstick.
Whenoperating at high ambient tempera-
tures and on unmetalled roads, period-
ically 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 trans-
mission oil sump. These deposits can
adversely affect proper cooling of the unit.
k$3
m
LM0362
I I [I ]1

Check/top-upclutch 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.
I 5
RM0388
-,,J
Check/top-up
rear axle/final drive oil
Withthe vehicle standing in a level posi-
tion, 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.
RM0274
:,2 ¯
STEERING AND SUSPENSION
Check/adjustfront wheel alignment
See 57.65.01.
Adjustfront hubbearing end-float
1 Removethe road wheel.
2 Checkthe hub for end-float.
3 If adjustment is required, remove the
grease cap, split pin and nut retaining cap.
4 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 3
retaining cap. RM0365
Insert and lock the split pin.
6 Cleanthe grease cap and refit.
7 Fit the road wheel.
Lubricatesteering rack and pinion
1 Wipe clean the plug and surrounding
area.
2 Removethe grease nipple plug, taking
care not to disturb the larger damperplug.
3 Fit a suitable grease nipple in place of the 2
plug.
4 Turn the steering wheel to full right-hand
lock.
5 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.
6 Removethe grease nipple and refit the
plug.
7 Wipe away any surplus grease.
 O0 Check/top-up
fluid in powersteeringreservoir BRAKES Inspectthe brakelinings for wear,drumsfor Check/top-up brakefluid reservoir
condition
Stand
thevehicle onlevelground. Inspect brake pads for wearanddiscs for Top-upwhenrequiredwithnewfluid of the cor-
I Wipecleanthereservoir capandsur- condition 1 Jackup the rear of the car andsupportthe rect type recommended--see ’LUBRICANTS
rounding area. bodyon stands. ANDANTI-FREEZESOLUTIONS.’Do not
2 Remove thereservoir capanddipstick. 1 Jack up the front of the car and support 2 Remove the car road wheels. allowthe fluid level to drop belowthe danger
3 Wipethedipstick clean andrepiaceitin the bodyon stands. 3 Remove the rear brake drum,as follows: markon the reservoir.
position. 2 Remove the road wheel. a Release the handbrake. WARNING: Use only newbrake fluid of the
4 Withdraw thedipstickagain andnotethe 3 Remove the disc brake pads, as follows: b Remove the countersunk screws correct specification. DONOTuse fluid of
fluidlevel. a Withdrawthe brake pad split pins, and securing the brake drumto the hub unknown origin, or fluid that has beenexposed
removethe anti-rattle spring. and withdrawthe brake drum. to the atmosphere, or dischargedduringbleed-
b Lift the brake pads complete with 4 Checkthe brakelinings for wear.If they ing operations.
If significanttoppingis required,
If topping-upis necessary: dampingshims. are excessively worn, damaged,or con- checkthe hydraulicsystemfor leaks.
5 Addrecommended fluid via the filler cap CAUTION: Do not depress the brake taminated by oil or grease the linings CAUTION:Paintwork can be damaged by
to bring the level just belowthe highmark pedal whilst the padsare removed. should be replaced. Removeany surplus direct contactwithbrakefluid.
onthe dipstick.Donotoverfill. 4 Checkthe pad condition. If the friction oil, grease or dust from the linings and
6 Replacethe reservoir cap. lining has beenreducedto 3 mm(0.125in) drum.
or if thereis not sufficientmaterialto pro- 5 Replacethe brake drum.
vide a thickness of 3 mm(0.125 in)at the 6 Fit the rear roadwheelsandlowerthe car.
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 RM0389
shims.
9 Fit the anti-rattle spring and secure the
brakepadsusing newsplit pins.
RM0363 10 Fit the front wheeland lowerthe car off
the stands.
11 Firmlydepressthefootbrakeseveral times
tOcorrectlylocatethe friction pads.

Replacingbrake-shoes
Whenit becomesnecessaryto renewthe brake-
shoes,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
60366 consequencescould result fromout-of-toler-
ancebrakingdue to the mixingof lining.

[I I
IIIII IIIII I Al~lml11111Ill[ IIIII I I~lll 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 Check the battery and surrounding area
for corrosion from battery chemicals.
2 Clean off any corrosion found.
3 Cheekvisually for any cracks in the bat-
tery case and report on any case cracks
found.
4 Checksecurity of terminal connections,
5 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.
b Power steering pump drive belt, see
57.20.02.
 CONNECTING RODS AND
PISTONS
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.
g f
~-nll///ll//lll/ll/llllllll
iiE2~ " Jill ......................................
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
12.17.10 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.
e d a c
I
I/////////////////////1/1//////////1!/////////////////////]
]NC837
I I II II I 0"1111111g
"=" ~’ , Ir I
" " ’ ’ ’
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.
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
F fllllilIlffiifllllil l’r " F i[ [ ¯ .....
Newpistons
NOTE:A single standard piston 0,0254
mm(0.001 in) oversize is available only
for service purposes. Should it be neces-
sary to fit a newpiston to a standard bore,
the bore must be honed to accommodate
the piston with the correct clearance--see
DATA.
8 Check the cylinder bore dimension at
right angles to the gudgeonpin, 90 to 100
mm(3.5 to 4.0 in) from the top.
9 Checkthe piston dimensionat right angles
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.
RM 0187
.....................................
~ .................
t
 ~F~----~--~~ ..................... ~,~ ~ ~= ~-’~--_ 4~’mw~’~m~ ~ ¯

11 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.
12 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 fine-
cut flat file to increase the gapif required.
Select a newpiston ring if the gap exceeds
the limit.
NOTE:Gappingdoes not apply to oil con-
trol rings.
13 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).
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.
Connectingrods
18 Check the alignment of the connecting
rod.
19 Checkthe connecting rod small-end; the
gudgeonpin must be an interference fit.
22 Place a piece of Plastigauge 605238,
across the centre of the lower half of the
crankshaft journal.
23 Locate the bearing lower shell into the
connecting rod cap.
24 Locate the cap and shell on to the con-
necting rod. Note that the rib on the edge
of the cap must be the same side as the
domedshape boss on the connecting rod.
25 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.
26 Removethe connecting rod cap and shell.
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 orig-
inal pair are being used, then place the
piston and connecting rod assembly
over the long mandrel until the gud-
geon 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.

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, not-
ing that the domedshape boss on the con-
necting rod must face towards the front of
the engine on the right-hand bank of cylin-
ders and towards the rear on the left hand
bank. Whenboth connecting rods are fit-
ted, the bosses will face inwards towards
each other.
RM 0186
14
RM 0189 0188
27
27 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.
28 The correct bearing clearance with newor
overhauled components is 0,015 to 0,055
mm(0.0006 to 0.0022 in).
29 If a bearinghas beenin service, it is advis-
able to fit a newbearing if the clearance
exceeds 0,08 mm(0.003 in).
30 If a newbearing is being fitted, use selec-
tive assembly to obtain the correct
clearance.
31 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.
33 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 ’Oil-
dag’). Alsolubricate the ball race and
centre screw of 18G1150.
e Fit the connecting rod and piston
together onto the tool with the mark-
ings 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.
k h g e
~--I1~//~//1~11//////1/1/~
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.
1 Remove the tool.
/l/A,
c a ! ’
bj
3NC838
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’Oil-
dag’andre-check.If stiffnesspersists, dis-
mantleand 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. Tight-
ness indicates insufficient bearingclear-
ance or a mis-alignedconnectingrod.
37 Checkthe end-float betweenthe connect-
ing rods on each crankshaft journal.
Clearancelimits: 0.15 to 0.37 mm(0.006
to 0.014in).
r
~ 0152
ii
 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 carbur-
etters 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 inde-
pendent and accurate tachometer. The
rev/minindicator fitted to the car is not
suitable.
D Beforeany attempt is madeto checkset-
tings 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 car-
buretters as follows:
Unscrewthe damperplug and raise the
piston by inserting a finger into the car-
buretterair intake. Withthe pistonraised,
top up the hollowdamperwith engine oil
until the level is 6 mm(¼in) belowthe top
of the guide.
;i
!i
Carburetterbalanceandidle 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.
~~::~
~/~~3
/ / M939
4 Turnthe lost motionadjusting screwuntil
it is clear of the springloadedpad.
5 Connectthe air-flow balancemeterto the
carburetters.
6 Start the engine and run it at fast idle
speeduntil normaloperatingtemperature
is reached.
7 Increase the engine speed to 2,500
rev/minfor one minute.
8 Turnthe idle adjustingscrewsonbothcar-
buretters until a balancedflowis achieved
at the correct idle speed, see ENGINE
TUNINGDATA.
9 Connect the link rod between the car-
buretters. This will cause the left hand
carburetter to goout of balance.
10 Torestore the balance,holdthe left hand
carburetterthrottle lever against it’s stop
and turn the lost motionadjusting screw
until it just contactsthe springloadedpad.
11 Tightenthe lock nut and check the idle
speedand balance.
12 Fit the throttle cable link rod, whilst
checking that the idle speed does not
change.
13 Remove the air-flow balancemeterand fit
the air cleaners.
17 Commencingwith either carburetter,
insert the tool S 353into the piston guide
rod ensuringthat the peg onthe outer bar-
"" rel of the tool locates in the slot in the
4,10 ~
\ ~ guide rod end.
/ CAUTION: Failure to locate the tool cor-
~ rectly 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
~z~le
1156
RM037
118 ~
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 dis-
connect the COmeter.
Coldstart unit
23 Whenoperating the vehicle in tempera-
tures above18 ° C (64° F), pushthe adjus-
ter screwinwardsand turn it through90
degreesto retain its position.
24 Whenoperating the vehicle in tempera-
tures 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~
23.24
25 RM0379
CARBURETTERS
WITH Refitting
MANUAL
COLDSTART 15 Cleanthe carburetter and manifoldmat-
ingfaces.
16 Fit a newinner joint washer.
Remove
andrefit L.H. 19.15.09 17 Fit the insulator withthe arrowuppermost
R.H.19.15.10 and pointing inwards.
18 Fit the liner ensuringthat the lugs locate
Removing in the insulator and the blade points
! Remove the air cleaner, see 19.10.01 or downwards.
19.10.02. -~ 19 Fit a newouter joint washer.
2 Disconnectthe engine breather hose. 20 Fit the earburetter and secure with the
3, Disconnectthe float chambervent pipe.
four nuts and spring washers.
4 L.H. carburetter disconnect the vacuum 21 Reverseinstructions 2 to 9.
pipe.
22 Fit the air cleaner, see 19.10.01 or
5 Disconnectthe fuel feed pipe from the 19.10.02.
carburetter.
23 Tuneand adjust the earburetters, see
6 Disconnect the cold start fuel supplyline.
7 L.H.carburetter disconnectthe cold start 19.15.02.
cable and removethe abutmentbracket.
8 Disconnectthe throttle link rod fromthe
appropriatecarburetter.
9 L.H. carburetter disconnectthe throttle
cablelink rod.
10 Removethe nuts securing the car-
buretter 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.
18 19 17 16 RMO2O9
KEY TO ILLUSTRATION CARBURETTER WITH MANUAL
COLDSTART
1 Piston damper
2 Cover Overhaul 19.15.18
3 Cover screw
4 Specificationtag 1 Removethe carburetter, see 19.15.09 or
5 Piston return spring 19.15.10.
6 Retainingring screw 5
7 Retainingring
8 Diaphragm Dismantling
9 Piston assembly 2 Removethe piston damperand sealing
10 Needleretaining screw washer.
11 Needle 3 Remove the top cover and spring.
12 Temperaturecompensatorunit 4 Remove the piston and diaphragm
13 Temperaturecompensatorcover assembly.
14 Temperaturecompensatorcover screw 5 Remove the mixture adjusting screw.
15 Carburetter body 6 Removethe grub screw and withdrawthe
16 Float needle assembly.
17 Float chambergasket 7 Removethe diaphragm and retainer
18 Float chamber plates fromthe piston.
19 Float needle valve and washer 8 Removethe float chamber, gasket and
20 Sealing plug needlevalve, see 19.15.24.
21 Float chamberscrew
22 Idle speedadjusting screw 12
23 Throttle spindle Dismantling
the carburetterbody
24 Coldstart gasket 9 Addlocation marksto the throttle butter-
25 Coldstart face fly andspindle.
26 Coldstart discs 14 10 Remove the throttle butterfly taking care
27 Spring not to damage the poppetvalve.
28 Springretaining clip 11 Remove the fast idle lever and throttle
29 Coldstart cover lever and withdrawthe throttle spindle.
30 Return spring 12 Removethe temperature compensator.
31 Coldstart lever 23 13 Removethe temperature compensator
32 Coldstart cover screw cover.
14 Remove the hi-metal strip and valve.
15 Remove the cold start assembly.
16 16 Dismantlethe cold start assemblybut DO
NOTremovethe discs fromthe spindle.

26 Carburettercleaning
17 Whencleaning fuel passages, do not use
metaltools (files, scrapers, drills etc.)
29 whichcould cause dimensionalchangesin
the drillings or jets. Cleaningshould be
32 effeotedusingclean fuel and, whereneces-
31 sary, a moisturefree air blast.
RM0216

Joint faces
ZENITH 175 CDSE CARBURETTER 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 com-
plete set of gaskets is available for replace-
ment 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.
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.
Reassembly 40 Fit the fast idle and throttle levers.
25 Place the spring on the cold start spindle. 41 Fit the float chamber, gasket and needle
26 Fit the spring retaining clip. valve, see 19.15.24.
27 Checkthat the discs slide easily on the 42 Fit and align the diaphragmto the piston.
spindle. 43 Fit the diaphragm retaining plate and
28 Place the cold start spindle on the starter secure with screws.
face. 44 Fit the needle assemblyto the piston, and
29 Place the starter cover in position. secure it with the grub screw.
30 Fit the return spring over the spindle. 45 Fit the mixture adjusting screw.
31 Rotate the spindle until the oval port in the 46 Fit the piston and diaphragm assembly to
enddisc is aligned with the oval port in the the carburetter and align the diaphragm.
starter face. 47 Fit the top cover and spring.
32 Fit the cold start lever. 48 Fit the piston damperand sealing washer.
33 Engagethe return spring over the lug on
the starter cover and the back of the cold
start lever. Refitting
34 Fit the cold start assembly and gasket to 49 Fit the carburetter, see 19.15.09 or
the carburetter body, and checkfor ease of 19.15.10.
operation.
35 Fit the bi-metal strip and valve to the tem-
perature compensator and secure the
cover.
36 Fit the temperature compensator to the
carburetter.
37 Fit the throttle spindle to the carburetter.
38 Fit and align the butterfly to the throttle
spindle.
39 Fit the return spring to the throttle
spindle.
GEAR CHANGE REMOTE
CONTROL ASSEMBLY
Overhaul 37.16.20
Theseinstructions supersedethose givenin the
Repair Operation Manual.
Dismantling
1 Remove the remotecontrol assemblyfrom
the gearbox.
2 Removethe two bolts and two counter-
sunk 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 washerssecur-
ing the reverse baulk plate assemblyand
withdrawthe reverse baulkplate, springs
and spacers.
6 Remove the four bolts and washerssecur-
ing 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.
13 Remove the circlips securingthe pivot ball
andbushesin the selector shaft elbowsand
press out the bushesandpivot balls.
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.
23 Fit the remoteControl assemblyto the Adjustmentof gearlever bias spring WINDSCREEN WIPERS AND
gearbox. 34 Unit completely assembled, engage 3rd WASHERS
Operationsto be carried out followingthe gear.
fitting of the remotecontrol assemblyto 35 Adjustthe screwsto position both legs of
the gearbox. spring0,5 mmclear of lever crosspin. WINDSCREENWIPER DELAYUNIT
24 Fit the gearlever. 36 Applya light load to gear lever in L.H. Remove
andrefit 84.25.31
direction taking up play. Adjust R.H.
screwdownward until R.H.spring leg just Removing
Adjusting the reversebaulkplate makescontact with crosspin. 1 Disconnectboth multi-pin plugs from the
Adjustmentof the reverse baulk plate mustbe 37 Repeatinstruction 36 on the other side. delayunit.
carried out on a completegearboxassembly. Playwill still be presentbutat extremes
of 2 Removethe mountingscrews and nuts,
25 Remove the bottomcover plate of the gear gear lever travel the crosspinshouldmake and withdrawthe delay unit and insulat-
lever remotecontrol assembly. contactwiththe springlegs. ing plate.
26 Locatethe gearlever in neutralin a verti- 38 Return lever to neutral and rock across
cal position. gate several times. Levershouldreturn to
27 Slackenthe baulk plate adjusting bolts 3rd/4th gate. Refitting
andlocknutsuntil the baulkplate is in con- 39 Tightenthe locknuts. 3 Reverseinstructions 1 and 2, ensuring
tact withthe backingplate. 40 Adjustthe reverseswitch, see 86.65.20. that the earth lead is fitted to one of the
28 Tightenthe adjusting bolts equally until mountingscrews.
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.
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

19

:B

27

I0 30
46

40
45

65 69

66

82
84 85

83

95 96 98
99 102
1 Battery 27 Cigar lighter 53 Main beam-~- L.H. 79 Reverse lamp-- L.H.
2 Alternator 28 Horn push 54 Dip beam-- R.H. 80! Rear fog lamp warning light
3 Starter motor 29 Horn relay 55 Dip beam-- L.H. 81 Fog lamp switch
4 Starter relay 30 Horn 56 Side lamp -- R.H. 82 Hazard warning light
5 Start inhibit switch-- 31 Lowfuel warning light 57 Side lamp-- L.H. 83 Hazard switch
automatics only 32 Lowfuel delay unit 58: Front fog lamp-- R.H. 84: Flasher unit
6 Ignition switch 33 Tank unit 59 Front fog lamp-- L.H. 85 Lowcoolant level indicator
7 Heater blower unit 34 Handbrake switch 60 Rear fog lamp-- R.H. 86 Lowcoolant level sensor
8 Temperature transmitter 35 Brake pressure differential 61 Rear fog lamp-- L.H. 87: Stop lamp switch
9 Voltmeter switch 62 Tail lamp -- LH. 88 Stop lamp-- R.H.
10 Temperature gauge 36 Heated rear screen switch 63 Tail lamp-- R.H. 89 Stop lamp-- L.H.
11 Tachometer (Coup6 only) 64 Number plate lamp 90 Choke switch
12 Fuel gauge 37 Heated rear screen warning light 65 Aerial motor junction 91 Choke warning light
13 Lowcoolant warning light (Coup6 only) 66 Boot lamp 92 Selector panel illumination --
14 Handbrake warning light 38 Heated rear screen relay 67 Boot lamp switch automatics only
15 Brake warning light (Coup6 only) 68 Courtesy light 93 Cigar lighter illumination
16 Oil warning light 39 Heated rear screen (Coup6 only) 69 Door switch 94 Panel rheostat
17 Ignition warning light 40 Speakers 70 Oil pressure switch 95 Heater control illumination
18 Headlamp relay--R.H. 41 Radio 71 Inertia switch 96 Panel illumination
19 Headlampmotor circuit breaker 42 Main/dip/flash switch 72 Fuel pump 97 Switch panel illumination
20 Headlamp relay-- L.H. 43 Hazard unit 73 Driver’s belt switch 98 Direction indicator switch
21 Headlamp motor -- L.H. 44 Windscreen wiper/washer switch 74 Seat belt warning light 99 Rear indicator-- R.H.
22 Headlamp motor-- R.H. 45 Windscreen washer motor 75 Passenger belt switch 100 Indicator warning light-- R.H.
23 Master light switch 46 Windscreenwiper delay unit 76 Passenger seat switch 101 Front indicator-- R.H.
24 Headlampflash unit 47 Windscreen wiper motor 77 Reverse light switch 102 Rear indicator-- L.H.
25 Headlampflash relay 48 Distributor 78 Reverse lamp-- R.H. 103 Indicator warning light-- L.H.
26 Clock 49 Coil 104 Front indicator-- L.H.
50 Ballast resistor A To heated rear )
51 Main beam warning light screen relay
52 Main beam -- R.H. B To heated rear
screen switch I SEEINSET

COLOURCODE

N Brown P Purple LG Light S Slate

U Blue G Green Green B Black
R Red K Pink W White O Orange
Y Yellow
 MAIN WIRING DIAGRAM~ TR8 ~ 1981 U.S.A. MARKET~ FUEL INJECTION CARS WITH
AIR CONDITIONING

EF

16
17

24

L__
54

105

RW

RM0208

IIIIIIIIII IIIIIIII ,,, ,,,,,,~,,, , ......,,,,, ,,, , ,, ~rii~

 1 Battery 31 Handbrakewarninglight 61 Windscreenwiper motor 91 Lowcoolant level sensor
2 Alternator 32 Brakewarninglight 62 Windscreenwasher motor 92 Reverselight switch
3 Starter motor 33 Oil warninglight 63 Distributor 93 Reverse lamp-- R.H.
4 Headlamprelay-- R.H. 3zLIgnition warninglight ~, 64 Coil 94 Reverse lamp-- L.H.
5 ~ Headlamp relay -- L.H. 35 Lowfuel warninglight 65 Ballastresistor 95 Hotre-start solenoidvalve
6 Starter motorrelay 36 Lowfuel delay unit 66 Courtesylight 96 Stop light switch
7 Headlampmotorcircuit breaker 37 Tankunit 67 Doorswitch 97 Stop lamp -- R.H.
8! Start inhibit Switch-- 38 Oil pressure switch 68 Mainbeamwarninglight 98 Stop lamp -- L.H.
automaticsonly 39 Handbrakeswitch 69 Main beam -- R.H. 99 Serviceinterval counter
9 Ignition switch 40 Brakepressure differential 70 Main beam-- L.H. 100 Serviceinterval counterwarning
10 Highspeed -- relay switch 71 Dip beam-- R.H. light
11 Lowspeed relay 41 Headlampmotor -- L.H. 72 Dip beam-- L.H. 101 Heatercontrol illumination
12 Fan motor 42 Headlampmotor -- R.H. 73 Side lamp- R.H. 102 Selectorpanel illumination--
13 Highspeed + relay 43 Masterlight switch 74 Side lamp-- L.H. automaticsonly
14 Idle solenoidvalve 44 Buzzertimer unit 75 Front marker lamp-- R.H. 103 Cigarlighter illumination
15 Heater/air conditioning blower 45 Seat belt warninglight 76 Front marker lamp-- L.H. 104 Panel rheostat
unit 46 Buckleswitch 77 Tail lamp-- R.H. 105 Panelillumination
16 Thermostat 47 Door switch 78 Numberplate lamp 106Switchpanel illumination
17 Air conditioningcut-out switch 48 Audible warning 79 Rear marker lamp-- R.H. 107 Heatedrear screen switch
18 Radiator low’temperatureswitch 49 Speakers 80 Tail lamp-- L.H, 108 Heatedrear screen warninglight
19 Highpressure cut-in switch 50 Radio 81 Rear marker lamp-- L.H. 109 Heatedrear screen
20 Enginehigh temperatureswitch 51 Main/dip/flash switch 82 Front fog lamp 110 Heatedrear screen relay
21 Air conditioningrelay 52 Hazardunit 83 Rear fog lamp 111 Indicator warninglight -- R.H.
22 Thermalfuse 53 Hazardswitch 84 Fog lampswitch 112 Indicator warninglight -- L.H.
23 Compressor clutch coil 54 Flasher unit 85 Rear fog lampwarninglight 113 Front indicator -- R.H.
24 Superheat switch 55 Cigar lighter 86 Aerial motorjunction 114 Front indicator -- L.H.
25 Temperaturetransmitter 56 Horn push 87 Clock 115Directionindicator switch
26 Voltmeter 57 Hornrelay 88 Boot lamp 116 Rear indicator-- R.H.
27 Temperature gauge 58 Horn 89 Boot lampswitch 117 Rear indicator-- L.H.
28 Tachometer 59 Windscreenwiper/washerswitch 90 Lowcoolant level indicator A Toheated rear screen
29 Fuel gauge 60 Windscreenwiper delay unit relay
30 Lowcoolant warninglight B Toheated rear screen SEEINSET
switch
COLOURCODE C Toheated rear screen
relay
N Brown P Purple LGLight S Slate D Toinjector and E.C.U.
U Blue G Green Green B Black relay
R Red K Pink W White O Orange E Tofuel pumprelay SEE FUEL
Y Yellow F Todioderesistor pack INJECTION
G Todioderesistor pack WIRING
DIAGRAM
H Fuel injection timing
signal
 FUELINJECTIONCIRCUITSWIRINGDIAGRAM
~ TR8 -- 1981 U.S.A. MARKET

! Digital control box

2 Throttle potentiometer
3 Lambda sensor 5
4 Feedback monitor point 4
5 Extra air valve
6 Cold start injector R y
7 Thermo time switch
8 Air flow meter
9 Injector and E.C.U. relay
I0 Dioderesistor pack
I1 Inertia switch
12 Fuel pumprelay
13 Fuel pump
14 Water thermistor
15 No. 6 injector
16 No. 8 injector
17 No. 1 injector
18 No. 3 injector
19 No. 5 injector
20 No. 7 injector
21 No. 2 injector
22 No. 4 injector
23 Injector ballast resistors
I l 13

YP
Ii

14 15 16 17
 IGNITION DISTRIBUTOR -- U.K. MARKET
DATA 86.35.00
Manufacturer ........................... Lucas
Type ................................... 35DE8
Lucas part number ....................... 41888
Triumphpart number..................... ERC7170
Polarity ................................ Negativeearth only
Pick-up air gap .......................... 0.014to 0.016 in (0.35 to 0.40 mm)
Rotation--viewedon rotor ................. Clockwise
Firing angle ............................. 45__+_1 degree
Engine firing order ....................... 1--8 ~ d 3--6--5--7--2
!

Centrifugaladvance
Degs.distributor advance Degs.crankshaft
Distributor Crankshaft advance
rev/min rev/min
Minimum Maximum Minimum Maximum
20O 0 1 400 0 2
750 3 4.5 1500 6 9
1000 6 8 2000 12 14
1600 8.5 10.5 3200 17 21
2400 11 13 4800 22 26
2750 10.5 13 5500 21 26

Vacuum
advance
Degs.distributor advance Degs. crankshaft advance
Inches of mercuryvacuum
Minimum Maximum Minimum Maximum
3 0 1 0 2
6 0 2 0 4
12 1 4 2 8
16 4 8 8 16
21 6.5 8.5 13 17

t~