Haynes Hillman Avenger Owners Handbook Maintenance Manual 0900550627, 9780900550621

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Digitized by the Internet Archive in 2023 with funding from Kahle/Austin Foundation

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Hillman

Avenger Covers models 1970 onwards

Owners Handbook Maintenance Manual

by JZ.R.S. Hall

HAYNES

79p

Acknowledgements Thanks are due to many people for their help and enthusiasm in the production of this handbook. Further thanks are extended to the manufacturer af the Hillman Avenger for the use of certain illustrations and to Castrol Limited. A Handbook in the Haynes Owners and Maintenance Manual Series.

Handbook

Edited by Tim Parker

(¢)

J H Haynes and Company Limited

Published by J H Haynes and Company Sparkford, Yeovil, Somerset.

Set in 10 point IBM Univers Medium Printed in England

SBN

900550

62 7

Limited,

Contents Introductio Model Identification

Specifications, Dimensions, Capacities, Weights

Road Test Data Spares and Touring Pack

Tools

Routine Maintenance Bodywork - Maintenance, Cleaning, Minor Repairs Preparing your Car for the MOT Test

Buying and Selling a Used Avenger Wiring Diagrams

Metric Conversion Tables Fault Finding Charts Index

105

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Introduction This handbook is intended for the Hillman Avenger owner or prospective owner, who wishes to find out more about the car and wants to keep it regularly and properly serviced with the minimum of effort so that the car gives as trouble free transport as possible. The Avenger has been in production since February 1970 and earlier models are now available on the secondhand market at quite reasonable prices. As the purchase of a cheaper car is usually due to economic necessity it follows that garage servicing bills should be kept to a minimum. You will find in this handbook all routine maintenance tasks that are required with a list of tools needed to do the jobs.

At

the

time

of

writing

earlier

Avenger

models will shortly be subject to the yearly MOT Test; details of what the tester will be looking for, how to check these points yourself, and the remedy of any faults found are also given in this book. Most of you reading this introduction will have had the unpleasant experience at some time of having a car that, for some reason or other, simply ‘dies’ on you or just ‘will not go’. Much of the work involved in looking after a car depends on accurate fault diagnosis in the first place. Therefore a comprehensive, methodical and progressive way of fault finding is presented in this book. Much time can be wasted in hopping from one possible source of trouble to another. It is best to say at the start — ‘This could be one of several things — let’s get the book out’. After successfully using this handbook should you wish to tackle the more complicated type of repair a most useful Owners Workshop Manual is available direct from the publishers or through all good accessory shops and booksellers.

Model Identification The Hillman Avenger was first announced by Chrysler (UK) in February 1970. Initially three

variants

were

available,

the

De

Luxe,

Super and Grand Luxe models. The De Luxe and Super are powered by a new 1250 (1248 cc) five bearing crankshaft engine with a 1500 (1498 cc) engine available as an optional extra. The Grand Luxe is fitted with the 1500 engine as standard. From the outside the De Luxe and Super models look virtually identical apart from their badges but where the De Luxe has rubber flooring the Super has fitted carpets and other extras which include arm rests on all doors, centre console, front door storage pockets, twin horns and reversing lamps. They both have rectangular headlamps. The Grand Luxe incorporates all their refinements but has a four (round) headlamp system, exterior

coach

lines,

reclining front seats and

two speed wipers. In October 1970 a GT model was added to the range having a specially developed twin carburettor version of the 1500 engine. This model incorporates all the standard fittings of the Grand Luxe model but additional items include sculptured wheel trims, broad stripe along lower edges of the doors, matt black window pillars, sports style steering wheel and a rev counter. Borg-Warner automatic transmission is available as an optional extra on all models with the 1500 engine except the GT. Since its introduction the Avenger has provea

itself to be a worthy competitor for the small, medium saloon car market of this country and has also had considerable success in the USA where it is renamed the Plymouth Cricket. It is also sold in other export territories where it is known as the Sunbeam 1250 or 1500. In early 1972 a very basic standard 1250 version was announced (1500 engine optional) in an attempt to enter the fleet sale market to greater effect.

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Specifications, Dimensions, Weights, Capacities Engine 1250 models Type Bore Stroke Cubic capacity Compression ratio Maximum bhp Maximum torque Firing order Valve clearances (hot or cold) Inlet Exhaust Type of oil

4 cylinder in line, ohv, pushrod operated 78.6 mm (3.0945 in) 64.3 mm (2.53 in) 1248 cc (76.16 cu in) 9.2 to 1 53 at 5000 rpm

66 Ib ft (9.12 kg m) at 3000 rpm 1342 .008 in (.20 mm) .016 in (.40 mm) Castrol GTX

Engine 1500 models The 1500 engine is identical in all respects to the 1250 unit apart from the differences listed below: Bore 86.121 mm (3.906 in) Cubic capacity 1498 cc (91.41 cu in) Compression ratios High 9.2 to 1 8.0 to 1 Low 9.2 to 1 GT Maximum bhp HC 63 at 5000 rpm EG 57 at 5000 rpm 75 at 5400 rpm GT Valve clearances (cold) GT Inlet .010 in (.25 mm) .016 in (.40 mm) Exhaust Maximum torque 80 Ib ft (11.1 kg m) at 3000 rpm HC 74 |b ft (10.23 kg m) at 3000 rpm LC 81 Ib ft (11.2 kg m) at 3750 rpm GT

Cooling System Type Blow off pressure of radiator cap Fan Fuel System Carburettor type 1250 and 1500

GT Fuel pump

Pressurised, pump assisted and fan cooled

9 Ib sq in (.63 kg cm2) 4 blade

Single Stromberg 150CDS or emission controlled 150 CDSE Twin Stromberg 150CDS Mechanical, driven by eccentric on camshaft

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Specifications, Dimensions, Weights, Capacities ee ane

Ignition System Distributor type Contact points gap Static ignition settings 1250 and 1500 GT Emission controlled Spark plugs 1250 and 1500 GT Plug gap Clutch Type Diameter -

1250 1500 GT

Actuation

es

Lucas 25D4 .015 in (.38 mm)

6° — 89 BTDC 79 — 99 BTDC 7° BTDC Champion NOY Champion N7Y .025 in (.63 mm)

Single dry plate diaphragm spring 7.25 in (184 mm) 7.50 in (190 mm) Cable (adjustable)

|Gearbox Number of gears Synchromesh Ratios First gear Second gear Third gear Top gear Reverse gear Gearbox oil type Automatic gearbox (optional) Fluid

4 forward, 1 reverse On all forward gears

3.317 to 1 2.029 to 1 1.366 to 1 1.000 to 1 3.450 to 1 Castrol GTX Borg-Warner Type 35 Castrol TOF

Rear Axle

Semi-floating, hypoid

Type Ratios

De Luxe Super 4.375 to 1 4.375 to 1 3.889 to 1 3.889 to 1 automatic 3.889 to 1 3.889 to 1 Castrol Hypoy Oil type Overall gear ratios may be calculated by the use of the following equation: Gearbox ratio x rear axle ratio = Overall gear ratio 1250 1500 1500

GL and GT _ 3.889 to 1 3.889 to 1

Brakes

Type Handbrake Front disc diameter Pad material - standard GT Rear drum diameter Lining material

Servo type (optional) Suspension Front Rear

Hydraulic disc at front, drum at rear Mechanical to rear wheels only 9.5 in (241 mm) Mintex M108GH Ferodo 2430F 8.0 in (203.2 mm) DON202GG Girling Type 28

Independent by Macpherson Strut Coil spring and trailing links

12

Specifications, Dimensions, Weights, Capacities

ee

S hock absorbers front and rear

Telescopic hydraulic double acting

Steering Type No of turns lock to lock Turning circle Ratio

Rack and pinion 3.66 31 ft 9 in 17.65 to 1

Wheels

4 stud fitting, pressed steel

Sizes 1250 and 7500 GT

4%) x 13

5J x 13

Tyres

1250 and 1500 Pressures Ib sq in (kg cm2) normal erly

laden

Pressures Ib sq in (Kg cm2) Normal Heavily laden

Electrical System Battery type Earthed terminal Dynamo Control box Number of fuses Alternator (optional) Starter motor Bulbs Twin headlamp Outer Inner Single headlamp Side lamp Indicators Stop and tail lamps Rear number plate

Reversing lamp (if fitted) Interior light Panel lights

Dimensions Wheelbase

Overall length Overall width

Overall height Ground clearance Recommended roof rack load Towing capacity - 1250 1500

5.60 x 13 cross-ply Front 22 (1.6) 22 (1.6)

Rear 24 (1.& 30 (2.1)

155 x 13 radial Front 24 (1.7) 24 (1.7)

Rear 24 (1.7) 30 (2.1)

12 volt, lead acid

Negative (—) Lucas C40 Lucas RB340

3 of 35 amp rating Lucas 16ACR Lucas M35J

37%2/50w (sealed beam) 37'2w (sealed beam) 45/40w (sealed beam) 6w 21w

5/21w (two filaments) 6w 21w 6w (festoon) 2.2w

8ft 2 in (249 cm) 13 ft 5% in (409 cm) 5 ft 2% in (159 cm) 4 ft 8 in (142 cm) 5% in (14 cm) 100 Ibs (45 kg)

13 cwt (661 kg) 15 cwt (762 kg)

Specifications, Dimensions, Weights, Capacities

13

Weights

Standard GT De Luxe Super Grand Luxe

1863 1845 1892 1894 1911

Ib |b Ib Ib Ib

(845 (837 (858 (859 (867

kg) kg) kg) kg) kg)

The fitting of an automatic gearbox to any of the above models adds 31 Ib to the quoted weights. Capacities Engine sump (incl filter) Manual gearbox Automatic gearbox Rear axle Steering unit Coolant (including heater)

Fuel tank

7 pints (3.97 litres) 3 pints (1.7 litres) 11% pints (6.4 litres) 1% pints (.85 litre) % pint (.142 litre) 13 pints (7.4 litres)

9 gallons (40.9 litres)

/

SS

6

S& WV

Front interior view - De luxe Saloon

Oil type Castrol GTX Castrol GTX Castrol TOF Castrol Hypoy Castrol Hypoy

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Road Test Data Maximum Speed (mph) Cruising Speed (mph) Cruising range (miles) Maximum speed in gears: 3rd 2nd 1st

1 250 Super 83 70 280

1500 GL 91 75 260

GT 97 80 260 82 55 34

Acceleration through gears (secs) 0 - 30 mph 0-40 mph 0-50 mph 0 - 60 mph 0-70mph

3.8 6.0 Sa 12,5 17-6

Standing % mile (secs)

18.5

Average fuel consumption (mpg) Consumption at 50 mph (mpg)

26 36

Front and three-quarter views of the Avenger

Spares and Touring Pack Before undertaking any long journey, whether in this country or abroad, it is advisable to check your car and its contents thoroughly. It is better to have the car serviced early, before the exact required time if necessary, rather than put it off until your return. Breakdown services, accredited dealers and spare part availability for your Avenger are not always there when you need them particularly abroad and in outlying districts of Great Britain. There are two lists, one giving spares which you should always carry in the car and the other suggesting items which it is advisable to carry if undertaking a journey abroad. Some dealers are abie to supply manufacturers recommended touring packs on an hire/buy-if-you-use basis. Always carry First aid box and manual Spare set of keys Gallon can of petrol with filler spout (full) List of car main agents Breakdown triangle (compulsory on the Continent) Torch (with red flashing dome) Fan belt Finilec puncture sealer Roll of PVC insulation tape Temporary plastic windscreen Length of electrical cable (heavy duty lighting circuit) Screwdriver (medium sized) Electrical screwdriver

Pair of pliers

Adjustable spanner (parrot jaw) Distributor - rotor arm - condenser - set of points 1 tin of hand cleanser (Swarfega)

Going abroad The articles in the ‘Always carry’ list Tow rope Set of light bulbs Set of spark plugs correctly gapped Spare inner tube valves Set of radiator hoses Radiator sealer such as Holts Radweld Set of fuses Length of HT lead Fire extinguisher Tube of gasket jointing cement Tin of Lockheed Brake Fluid 1 quart tin of Castrol GTX 1 spare head gasket set As many other tools as you feel you may need Adequate set of maps List of Chrysler agents Always keep this handbook in the ca’ and produce it if you break down abroad. NonEnglish speaking mechanics will find valuable information about your ‘strange’ car, in it. There are many mechanical terms common to different languages - you can always point at the photographs, it may help!

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Tools To carry out the routine maintenance tasks in this book you will obviously need a reasonable set of tools. A really comprehensive tool kit will be expensive to purchase at one go - most home mechanics have built up a kit over the years as they have tackled new and more complicated maintenance and repair work. This way the cost is spread out. Remember though, buy only the best quality (some spanners do break), keep them clean and in a safe place. The following list suggests the tools needed to undertake the work described in this book:

1 set of open-ended

spanners

(5/16 in to

(5/16

in to 7/8 in

7/8 in AF) 1 set of ring spanners

AF) spark plug spanner engineer’s hammer (1 Ib ball pein) soft-headed hammer pair pliers pair long nosed pliers screwdrivers (small, medium, large) Phillips screwdrivers (small, medium) set of feeler gauges fine file oil can (Castrol Everyman)

grease gun (Castrol LM) brake adjusting spanner Non-fluffy rag 1 pair of overalls 1 tin of hand cleanser (Swarfega)

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Routine Maintenance Introduction No matter how well you look after your Avenger various components inevitably are going to wear out and need replacement, but by carrying out the regular maintenance tasks listed below, you will be able to get above average mileage from your car before replacement becomes a necessity. A great many of the maintenance tasks are purely a visual examination of components; many are vital to the roadworthiness of the car and safety of its occupants. The whole business of routine maintenance may become a bit tedious at times but do not neglect anything; your life or some innocent party’s life may depend on it and your car will appreciate the care you bestow on it by giving you as trouble free transport as possible.

Plan ahead Before starting, always read through work invoived when carrying out a service or a repair and make sure you have all the parts and lubricants that will be required. Most do-ityourself motorists do their work during the evenings or at weekends when the parts departments of garages are closed. Nothing is more annoying once started than to be unable to complete the job due to lack of spares. The following is a list of the parts that will probably be required for each particular service, but may have to individual needs. necessary for a be retained for a

be supplemented to meet any If the replacement part is not particular service then it may subsequent service.

Weekly

Engine oil - Castrol GTX Water - for radiator and screen washer Holts screen washer additive Distilled water - battery Vaseline - battery terminals Light bulbs

1000 mile service Hydraulic fluid - Castrol Girling Brake Fluid

5000 mile service Oil filter 1 gallon Castrol GTX Handipack dispenser of Castrol GTX - gearbox Set of contact points - distributor Dry rag - air filter cleaning Petrol in jar - cleaning fuel pump Paintbrush - cleaning fuel pump Rocker cover gasket Paraffin - cleaning flame trap Rear axle oil - Castrol Hypoy handipack dispen-

ser Automatic transmission fluid - Castrol TOF Split pin - hub adjustment Front brake pads Fan belt Can of Castrol Everyman - general lubricating oil 10000 mile service Set of spark plugs Air cleaner element Rear brake shoes

15000 mile service Castrol LM Grease - front hub bearings

Every 12 months (Autumn) Castrol Antifreeze

Weekly Every 250 miles or weekly 1 Under the bonnet: Check the oil level in the sump. The first reading taken on the dipstick should not be accepted as an accurate one. Wipe it clean and recheck. The difference between the high and low level marks on the dipstick is two pints. Top up if necessary with Castrol GTX. Check the radiator coolant level and top up if necessary. If the level has dropped appreciably

22

Routine Maintenance

since the signs of a leak will antifreeze

Check

previous occasion check around for leak. If antifreeze is in the coolant a be more apparent as the coloured will be sprayed about by the fan.

the level of the electrolyte in the

battery and top up with distilled water if this is low (see page 96). Do not overfill. If the battery is overfilled or any electrolyte spilled, immediately wipe away the excess as electrolyte, being a dilute solution of sulphuric acid, will attack and corrode any metal it comes into contact with. Check that the terminals are clean and coated with a petroleum jelly such as Vaseline to prevent corrosion.

2 Steering and Tyres Check the tyre pressures against the specifications earlier in this book and adjust them if necessary. If radial ply tyres are fitted to a model that normally fits cross-ply tyres, follow the manufacturer’s instructions for recommended pressures. Examine the tyres for unusual or excessive wear or damage. If an unusual wear pattern is developing take your car to your local garage to have the steering geometry checked. Check that the steering is smooth and accurate. If the steering pulls one way or there is excessive play at the steering wheel take the car to your local garage for testing on proper equipment.

Fig.1. Oil level dipstick (A) Engine oil filter (B)

3 Lights Check that all the bulbs in the lights are in working order including the brake lights and all four indicator bulbs. If any of the bulbs are found to be defective they can be replaced as follows:

CIRCULAR SEALED BEAM HEADLAMPS AND SIDE LAMP BULB Remove the radiator grille by undoing the seven retaining screws as shown in Fig 2. Slacken the three slotted retaining screws on the lamp assembly, rotate the whole unit slightly anticlockwise and withdraw it a short distance so that the wiring plug can be pulled off the back. The side lamp bulb is located in the base of the plug on outer units. The fitting of a new unit is a direct reversal of the above procedure.

RECTANGULAR SEALED BEAM LAMPS AND SIDELAMP BULB

HEAD—

Remove the radiator grille by undoing the five retaining screws as shown in Fig 3.

Fig.2. Sealed beam circular headlamp Top: Retaining screws (arrowed) Centre: Outer unit Bottom: Inner unit

Routine Maintenance Remove

23 the four screws holding the light unit

by its rim then draw the unit forwards away from the car a short distance so that the wiring plug can be pulled off the back. The sidelamp bulb is located in the base of the plug.

STOP, TAIL AND REAR INDICATOR LIGHTS These bulbs are accessible from inside the boot of the car. Simply pull off the protective cover from its clips and pull the appropriate bulb holder from the light cluster and replace any defective bulb.

FRONT FLASHER LIGHTS The bulb on the front flasher light is accessible after removing the two small screws on either side of the lens which hold it in place. The bulb is a push fit and can only be fitted in one way due to offset pins.

Fig.3. Sealed beam rectangular headlamp Top: Retaining screws (arrowed)

REAR NUMBER PLATE LIGHT Pull the spring clip on top of the cylindrical shaped lens to one side, lift the lens away and replace the bulb if defective. The bulb is of the normal push fit type with offset pins to prevent wrong fitting. 4

Windscreen Washer There is nothing more frustrating than operating the screen washer pump and finding no water comes out of the jets due to an empty reservoir. It is advisable to check this item weekly or more frequently if you have used the washer a lot on dirty roads. Holts offer an additive to stop the water freezing in winter and also the formation of ice on the windscreen in cold weather conditions. It also cleans greasy smears off the windscreen and is called Holts Winter Screen Wash. For summer motoring there is a companion called Summer Screen Wash which is able to remove the usual squashed flies and other accumulations of dirt.

1000 miles Every 1000 exceeded

Fig.4. Rear lamp unit 3 Reverse lamp (if fitted)

1

Flasher lamp

2

Stop/tail lamp

4

Lens and reflector

miles

or

monthly

if 1000

not

5 Brakes Check the level of the hydraulic fluid in the reservoir and top up with Castrol Girling Brake Fluid if necessary. If the level has dropped significantly examine the braking system for signs of a possible leak.

24

Routine

Maintenance

i

5000 miles Every 5000 miles or every 5 months not exceeded.

if 5000

6 Engine Run the engine until it has reached its normal working temperature. Place a container of at least 8 pints capacity under the sump drain plug which is on the right hand side of the sump, clean all the dirt from round the plug, remove it and allow the oil to drain for at least ten minutes. (Do not pour this old oil down the household drain. It is illegal. Take it to a local garage - they have special oil disposal facilities). The oil filter cartridge which is located on the right hand side of the block can now be unscrewed and removed. It cannot be re-used so throw it away. Before fitting a new filter, smear its rubber seal on the base with engine oil, then screw it on to the engine until the joint makes contact

with the block. Tighten it now no more than two thirds of a turn by hand only. Some filters will have a hexagon on the end, this must only be used for undoing the filter if it proves difficult to move. Replace the sump drain plug, making sure that it is thoroughly clean before doing so and fill the sump with 7 pints of Castrol GTX. Run the engine for a short while and check for leaks round the oil filter. If a leak is apparent the filter is not seated correctly, or dirt has been trapped between the filter and the block. Finally check the dipstick reading to ensure the oil level is correct. 7 Adjustment of Valve Clearances The valve clearances can be made with the engine either hot or cold, but never just warm or the wrong clearances will be obtained. The importance

arm

of correct

clearances cannot

valve

stem

to

be overstressed

rocker

as they

are vital to the performance of the engine. If the clearances are set too open the efficiency of the engine is reduced because the valves open later and close earlier than was intended. If, on the other hand, the clearances are set too tight there is a danger that the stems will expand upon heating and not allow the valves to close properly, which will cause burning of the valve head and seat and possible warping. Disconnect the vacuum advance pipe at the distributor and the crankcase breather pipe at either end to enable the rocker cover to be

Fig.6. Sump drain plug

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Fig.10. Plan view of valve rocker gear The inset shows the correct position for the rocker pedestals on the rocker shaft

26

Routine

Maintenance

ee

removed. Remove the six screws retaining the cover and lift it off the cylinder head care not to damage the cork gasket if it re-used. As it will be necessary to rotate the during adjustment of the valve clearances

rocker taking is to be engine remove

the plugs to relieve the compression and have handy a 15/16 in AF ring spanner or socket

to fit the crankshaft pulley nut to turn the engine. Numbering from the front of the engine valve Nos 1 3 5 and 7 are inlet valves and must be set at .008 in and Nos 2 4 6 and 8 are exhaust valves to be set at .016 in. It is important that the clearance of the valve is set when the tappet of the valve being adjusted is on the heel of the cam (ie opposite the peak). To ensure that this is done correctly carry out the adjustments in the following way: Turn the engine to bring No 1 cylinder to the TDC position on its compression stroke. In this position the TDC position on the crankshaft pulley will be opposite to the TDC line on the timing case and at the same time valve No 5 will just begin to open. If in doubt place a thumb over the plug hole of No 1 cylinder so you will feel the compression being created as the engine is rotated and the piston comes up its correct position. In this position adjust both clearances of No 1 cylinder’s valves. Now turn the engine exactly half a turn (180° on the spanner on the crankshaft nut) and adjust the valves on No 3 cylinder. Turn it another half a turn and adjust the clearances on No 4 cylinder; another half a turn will bring No 2 cylinder in the correct position for adjustment. Assuming you are working on No 1 valve which is an inlet valve, the correct clearance is obtained by slackening the hexagon locknut with a spanner while holding the ball pin against rotation with a screwdriver. Then, still pressing down with the screwdriver, insert a feeler gauge or gauges of .008 in thickness between the valve stem head and the rocker arm and adjust the ball pin with the screwdriver until the feeler gauge will just move in and out without pinching or catching in the gap. Now holding the ball pin firmly in the correct position with the screwdriver, tighten down the locknut. Follow the order already given previously and adjust all the seven remaining valves to their correct clearances, then replace the rocker cover

——————_—_—_=re—————

using a new cork gasket if the old one is in any way damaged, or has previously shown signs of leaking. 8 Spark Plugs Remove the spark plugs and clean off all carbon deposits. If your local garage has sand blasting equipment, this is the most effective method of cleaning plugs. Failing that a wire brush will suffice. Draw a fine file across the plug points to finally clear any remaining deposits then check the gap between the electrodes. This should be checked with feeler gauges and should be .025 in. If the gap is incorrect the electrode attached to the plug body should be gently bent until the correct setting is obtained. 9

Distributor contact breaker adjustment To adjust the contact breaker points to the correct gap, first pull off the two clips securing the distributor cap to the distributor body and lift away the cap. Clean it inside and out with a dry cloth. The four segments may be-badly burnt or scored. If they are, a newcap will have to be fitted. Push in the carbon brush located in the top of the cap once or twice to make sure that it moves freely. Gently prise the contact breaker points open to examine the condition of their faces. If they are rough, pitted, or dirty, it will be necessary to remove them for resurfacing, or for replacement points to be fitted. Presuming the points are satisfactory, or that they have been cleaned and replaced, measure the gap between the points by turning the engine over until the contact breaker arm is on the peak of one of the four cam lobes. A .015 in feeler gauge should now just fit between the points. If the gap varies from this amount, slacken the contact plate securing screw. Adjust the contact gap by inserting a screw-

driver in the notched

hole (16) Fig 12, at the

end of the plate. Tighten the securing screw and check the gap again and clip the spring blade retainers into position. 10 Contact breaker ment If the contact pitted:ofbadly worn, either teplaced or smooth. -

set - removal and replacebreaker points are burnt, they must be removed and their faces must be filed

Sample spark plugs

Plug too hot - white

Typical damage

deposits

caused by pre-ignition

Badly burnt electrode

A chipped electrode

Plug too cold - dry black deposits

A normal

plug with light tan deposits

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Maintenance

Fig.12. Contact breaker assembiy normal type (left); quickafit (right) 1 2 3

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5 6 7 8 9

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The contact breaker points can either be a pair of separate contacts or a ‘Quikafit’ contact set complete. Referring to Fig 12 to remove a separated contact set, remove the nut (7) the insulator (6), the LT lead (8) and the condenser lead (9). Now lift off the outer contact and its spring (5)

leaving the washer (12) still in place. To remove the other inner half of the set remove the screw and washer (11) then lift off the contact plate (2) together with its insulating washer (4). To remove the Quikafit type of set, remove the nut (7) the LT lead (8) and the condenser lead (9). Now remove the screw and washer (11) and lift off the complete set assembly (17). Replacement of both sets is a direct reversal of the removal procedure, but do not fully tighten down the screw (11) until the gap is correctly adjusted as described in the previous Section. To reface the points, rub their faces on a fine carborundum stone, or on fine emery paper. It is important that the faces are rubbed flat and parallel to each other so that there will be complete face to face contact when the points are closed. One of the points will be pitted and the other will have deposits on it.

10 11 12 13 14

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15 16 17

screw CB earth lead Contact gap adjustment slots for screwdriver Quickafit assembly

It is necessary to completely remove the built-up deposits but not necessary to rub the pitted point right down to the stage where all the pitting has disappeared, though obviously if this is done it will prolong the time before the Operation of refacing the points has to be repeated. After checking the points apply two drops of

engine oil (Castrol GTX) to the head of the large screw in the centre of the distributor. This lubricates the shaft bearings. Allow three drops of oil to flow past the base of the cam to the automatic timing mechanism. Smear a faint trace of oil on the cam itself. Apply a tiny spot of oil to the moving contact breaker pivot pin. Too much oil at this point will get onto the points and cause misfiring. 11 Air Cleaners On single carburettor models remove the two through bolts which hold the air cleaner assembly to the carburettor, disconnect the pipe to the flame trap and lift the air cleaner away. Scribe a mark on the cover and the casing to ensure correct positioning on reassembly then remove the four small screws holding the cover to the body and separate the two

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Maintenance

31

Remove the top sealing ring, the element and the bottom sealing ring then thoroughly clean out the body and the cover using a dry non-fluffy rag. Gently tap any surplus dust out of the element. If the element is damaged or torn it must be renewed. Reassembly is a reversal of the above procedure, but care must be taken to ensure that the element and sealing rings are correctly located or dust will be allowed to enter the carburettor and the purpose of having an air cleaner will be lost. To remove the element from the type of air cleaner fitted to twin carburettor GT models simply undo the centre screw and separate the two halves of the air cleaner. Clean the unit as described above. 12 Fuel Pump Unscrew the clamp nut on the top of the fuel pump, pull aside the clamp and remove the glass bowl. Thoroughly clean the glass bowl inside and out, remove the filter screen and use a small paintbrush and petrol to clean any sediment from the filter screen and the pump body. Ensure that the gasket which seats under the glass bowl is not pitted or split, refit the filter screen and glass bowl, then pull over the retaining clamp and tighten down the clamp nut with the fingers only.

Fig.15. Carburettor damper oil level

13 Carburettors Unscrew and remove the damper from the top of the carburettor or carburettors. Top up the damper bores with clean Castrol GTX oil. The oil level is correct when, using the damper plug as an oil measure, its threaded cap is about % in (6 mm) above the funnel of the suction chamber at the moment of oil resistance. Refit the damper plug or plugs. 14 Fuel Lines Check all fuel lines and unions for signs of leakage and replace any obviously defective components.

Fig.16. Flame trap

15 Flame Trap Slacken the clip holding the flame trap pipe to the rocker cover pipe and pull it off. Pull off the other pipe from the air cleaner. Allow the flame trap to soak in paraffin and swill it about to dislodge loose dirt then allow it to drain.

32

Routine Maintenance

If available dry the flame trap with compressed air line and refit it to the car.

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18 Rear Axle Move to the rear of the car and remove the rear axle combined level and filler plug from the rear of the axle casing. Check the level and top up if necessary with Castrol Hypoy to the bottom of the filler plug hole. Once again do not overfill and allow any surplus oil to drain away before replacing the plug.

19 Automatic Transmission Run the engine for a few minutes with the selector lever in the P position. Remove the dipstick, wipe it clean, replace it and quickly remove it again. Check the reading and top up if necessary with Castrol TOF automatic transmission fluid. 20 Front Hub Bearings Jack up the front of the car and by rocking the wheels check to see if there appears to be excessive play on the bearings. If adjustment is necessary it is done as follows: Remove the hub cap on the wheel to be adjusted, then with a screwdriver prise off the hub dust cap. Bend back the split pin running through the end of the stub axle and pull it out, then

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14.22 28.50 42.67 56.89 Wel? 85.34 99.56 113.79 128.00 — OANOOARPWNH 142.23

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103

Castrol craves Castrol Greases (continued)

Castrol Engine Oils

Castrol Gear Oils (continued)

Castrol GTX

Castrol Hypoy Light (80 EP)

Castrol CL

An ultra high performance SAE 20W/50 motor oil which exceeds the latest AP] MS requirements and manufacturers’ specifications. Castrol GTX with liquid tungstent generously protects engines at the extreme limits of

A very light-bodied powerful extreme pressure gear oil for use in hypoid rear axles in cold climates and in some gearboxes.

A semi-fluid calcium based grease, which is both waterproof and adhesive, intended for chassis lubrication.

Castrol Hypoy B (90 EP)

Castro! Medium

performance, and combines both good cold

A light-bodied powerful extreme pressure gear oil that complies with the requirements of the MIL-L-2105B specification, for use in certain gearboxes and rear axles.

A medium consistency calcium based grease.

starting with oil consumption control. Approved by leading car makers.

Castrol XL 20/50

Contains liquid tungstent; well suited to the majority of conditions giving good oil consumption control in both new and old cars.

Castrolite (Multi-grade) This is the lightest multi-grade oil of the Castrol motor oil family containing liquid tungstent. It is best suited to ensure easy winter starting and for those car models whose manufacturers specify lighter weight oils. Castro! Grand Prix

An SAE 50 engine oil for use where a heavy, full-bodied lubricant is required. Castrol Two-Stroke-Four

A premium SAE 30 motor oil possessing good detergency characteristics and corrosion inhibitors, coupled with low ash forming

Castro! Hi-Press (140 EP)

Castrol PH

A heavy-bodied extreme pressure gear oil for use in spiral bevel rear axles and some gearboxes.

A white grease for plunger housings and other moving parts on brake mechanisms. /t must NOT be allowed to come into contact with brake fluid when applied to the moving parts of hydraulic brakes.

Castrol ST (90)

A light-bodied gear oil with fortifying additives |

Castrol D (140) A heavy full-bodied gear oil with fortifying additives. Castrol Thio-Hypoy FD (90 EP) A light-bodied powerful extreme pressure gear oil. This is a special oil for running-in certain hypoid gears.

Automatic Transmission Fluids

Castrol TOF

Castro! CRI 10, 20, 30 Primarily for diesel engines, a range of heavily fortified, fully detergent oils, covering the requirements of DEF 2101-D and Supplement 1 specifications.

Castrol TQ Dexron®

(Automatic Transmission Fluid) Complies with the requirements of

Dexron® Automatic Transmission Fluids as laid down by General Motors Corporation.

Primarily designed and developed for highly stressed racing engines. Castrol ‘R’ should not be mixed with any other oil nor with any

grade of Castrol. tliguid Tungsten is an oil soluble long chain tertiary alky/ primary amine tungstate covered by British Patent No. 882,295.

Castrol Greases

Castrol Hypoy (90 EP) A light-bodied powerful extreme pressure gear oil for use in hypoid rear axles and in some gearboxes.

Castrol Girling Damper Oil Thin The oil for Girling piston type hydraulic dampers.

Castrol Shockol

A light viscosity oil for use in some piston type shock absorbers and in some hydraulic systems employing synthetic rubber seals. It must not be used in braking systems.

A leaf spring lubricant possessing a high degree of penetration and providing protection against rust.

Castrol LM A multi-purpose high melting point lithium based grease approved for most automotive

applications including chassis and wheel bearing lubrication.

Castrol Solvent Flushing Oil

A light-bodied solvent oil, designed for flushing engines, rear axles, gearboxes and gearcasings.

Castrol MS3

Castrollo

A high melting point lithium based grease

An upper cylinder lubricant for use in the proportion of 1 fluid ounce to two gallons of fuel.

containing molybdenum disulphide.

Castrol Gear Oils

Speciality Products

Castrol Penetrating Oil

Primarily for diesel engines, heavily fortified, fully detergent oils, covering the requirements Castrol R 40

Contains anti-corrosion additives with ethylene glycol. Recommended for the cooling systems of all petrol and diesel engines.

(Automatic Transmission Fluid) Approved for use in all Borg-Warner Automatic Transmission Units. Castrol TOF also meets Ford specification M2C 33F.

Castrol CRB 20, 30

of MIL-L-2104B.

Castrol Under-Water Grease

A grease for the under-water gears of outboard motors.

Castrol Anti-Freeze

and for two-stroke and small four-stroke horticultural machines.

A high quality engine oil of the SAE-20W /30 multi-grade type, suited to mixed fleet Operations.

Castrol Graphited Grease A graphited grease for the lubrication of transmission chains.

Anti-Freeze

tendency and excellent anti-scuff properties. It is suitable for all two-stroke motor-cycles,

Castrol CR (Multi-grade)

Castrol Heavy A heavy consistency calcium based grease.

Castrol BNS A high melting point grease for use where recommended by certain manufacturers in front wheel bearings when disc brakes are fitted.

Everyman Oil

A light-bodied machine oil containing anticorrosion additives for both general use and cycle lubrication.

Index EE

Air cleaners - 29, 36

A

Anti-freeze - 40 Automatic transmission - 32

B Battery

Distributor lubrication - 29 maintenance - 26

Door locks - 43 Dynamo - checking brush gear - 94

faults - 72, 97 maintenance

D

Dimensions and weights - 9

faults - 94 - 22

topping-up - 22 Bodywork cleaning - 37, 41, 43, 44 lubrication - 43 materials - 50 repairs - 44, 46, 49 Brakes bleeding - 37 data - 11 disc pads - 33, 81 faults - 77, 81, 100, 102 linings - 36, 81 maintenance - 40 Buying - 55 C Capacity, engine - 9 Carburettor data - 9 faults - 74, 84 maintenance - 31 Carpets, cleaning - 41 Chromium plating, polishing - 44 Clutch data - 11 faults - 77, 81 maintenance - 32

operating lever clearance - 32 slipping - 100 Compression ratio - 9 Contact breaker

cleaning points - 26 gap setting - 26 Control box - 97 Cooling system data - 9 faults - 89 flushing - 92 loss of water - 89 maintenance - 40 radiator blockage - 92

lubrication

- 36

E Electrical system data - 12 Engine data -9 faults - 84 lack of power - 84 maintenance - 24 misfires - 87 noises - 81 overheating - 89 pinks - 87

F Facia - 10 Fan belt adjustment - 33 Flame trap - 31 Flashing direction indicators - 23 Front hubs - 32, 36 Front suspension data - 11 Front wheel alignment - 102 balance - 98 Fuel pump servicing - 31 Fuel system data -9 faults - 74

leaks - 31 G Gearbox

data - 11 lubrication - 32

H Headlamps renewal - 22

History of marque/models - 7

Ignition data- 11

Index

Selling - 56 Service table - 20 Sidelamps - 22 Spares - 17, 59 Spark plugs maintenance - 26, 36 Starter motor faults - 72, 73 Lights - 22,77, Lubrication chart - 28 data - 106 M Maintenance material - 2

Pr

a,

Model identification - 7

ring wheel, excessive play - 98 Stop/tail lamps - 23

S

BB

Suspension data - 11

MOT test - 51

Number plate bulbs - 23

Oil Oil Oil Oil

a Wwadndér - 98

O changing - 24 consumption, excessive - 89 filter element, changing - 24 leaks - 89 P

Performance data - 15 Polishing the car — 44 Propeller shaft - 36

Thermostat - 90 Tools - 19 Touring pack — 17 Tyres data - 12 faults - 102 inspection - 22 pressures - 12

Upholstery - 41 V Valves, rocker clearance

adjustment - 24 R

Radiator flushing - 92 Rear axle data - 11 lubrication - 32 Rear lights - 23 Road tests - 15 Rust prevention - 43

Ww Washing the car - 44 Water pump faults - 92 Weekly attention - 21 Wheels - 12 Windscreen washer - 23 Wiring diagrams - 60

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All Hillman Avenger models from 1970 This

Maintenance

models

from

1970

Manual/Owners owners

who

Handbook

want

reliable trouble free motoring extend

is for all

to reduce

their

Hillman

motoring

Avenger

costs, enjoy

their car’s life and maintain its resale

value. Written specifically for the Hillman Avenger owner the contents show you how to maintain and service all models correctly to help give safer, more

enjoyable motoring. you

A further advantage is that by doing your own

will dramatically

your

reduce

car is in the garage.

your

Minor

motoring

maintenance

bills and not waste

repairs are

carefully explained

time

while

- even

ir

experienced amateurs can follow everything clearly. Extensive’ fault findir charts

pinpoint

breakdown.

troubles and will help get you.moving if you cannot start ¢

There

is also a complete

section

showingghow

to check

an

prepare your Avenger for the M.O.T. test. Specifications, road test dati production history, model identification’ and ‘how toy buy a good use Avenger’ are also included. Carry this book in your car and it should save you its modest cost man

times over.

Price 75p

ae

a

900550

62

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