Haynes Vauxhall Viva HC Owners Workshop Manual 0900550473, 9780900550478

Citation preview

) \KAN mn

SS

SI

SS

Digitized by the Internet Archive in 2022 with funding from Kahle/Austin Foundation

httos://archive.org/details/vauxhallvivahcow0000hayn

Vauxhall Viva HC Owners

Workshop ~ Manual by J H Haynes Member of the Guild of Motoring Writers

and DH

Stead

Models covered: Viva Viva Viva Viva Viva Viva Viva Viva Viva Viva

two-door saloon De-Luxe two-door saloon De-Luxe two-door estate car De-Luxe four-door saloon SL two-door saloon SL two-door estate car SL four-door saloon 1300 1300L 1300 SL

Viva E (saloon only) and GLS October 1970 onwards, fitted with 1159 cc 1159 cc extra performance and 1256 cc ohv engines

ISBN ©

90055

047 3

Haynes Publishing Group 1971 and 1977

All rights any form recording in writing

reserved. No part of this book may be reproduced or transmitted in or by any means, electronic or mechanical, including photocopying, or by any information storage or retrieval system, without permission from the copyright holder.

Printed in England

HAYNES PUBLISHING GROUP SPARKFORD

YEOVIL

SOMERSET

distributed in the USA by

HAYNES PUBLICATIONS INC 861 LAWRENCE DRIVE NEWBURY PARK CALIFORNIA 91320 USA

ENGLAND

Fon),

Acknowledgements Thanks are due to General Motors for the assistance given in the supply of technical material and illustrations. To Castrol Limited for advice on lubrication. The Champion Sparking Plug Company for the illustrations showing the various spark plug conditions. The bodywork repair photographs used in this manual were provided by Lloyds Industries Limited who supply ‘Turtle Wax’, ‘Dupli-color Holts’, and other Holts range products. Lastly, thanks are due to all of those people at Sparkford who

helped in the production of this manual. Particularly, Peter Ward, who originated Chapter 13, Ted Frenchum and Stanley Randolph for designing the layout of each page and John Rose for the editorial work. Whilst every care is taken to ensure that the information in this manual is correct no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Photographic captions and cross references The book is divided into thirteen chapters. Each chapter is divided into numbered sections which are headed in bold type between horizontal lines. Each section consists of serially numbered

paragraphs.

There are two types of illustration: (1) Figures which are numbered according to Chapter and sequence of occurrence in that chapter

and having an individual caption to each figure. (2) Photographs which have a reference number in the bottom left hand corner. All photographs apply to the chapter in which they occur so that the reference figures pinpoint the pertinent section and paragraph numbers. Procedures, once described in the text, are not normally repeated. If it is necessary to refer to another chapter the reference will be given

in chapter number and section number thus: Chapter 1/6. If it is considered necessary to refer to a particular paragraph

in

another chapter the reference is eg ‘Chapter 1/6:5’. Cross references given without use of the word ‘Chapter’ apply to sections and/or paragraphs in the same chapter, eg, ‘see Section 8’ means also ‘in this Chapter’. When the left or right hand side of a car is mentioned it is as if one

were looking in the forward direction of travel. Chapter 13 is in the form of a Supplement, which has been added to bring this manual up-to-date by describing all modifi-

cations and changes applicable to the 1256 cc models built after September 1973. Wherever possible, modifications have also been incorporated into the existing Chapter.

1256 VIVA SL

VIVA SL ESTATE

Introduction This owners workshop manual is intended for the owner of an HC series Vauxhall Viva, who, having acquired his car either new or secondhand, does not wish to spend a fortune in keeping it in a safe, economical and good value condition. No one, however, particularly with all round commitments and interests, wishes to spend all his leisure time in looking after his transport. This manual is designed, therefore, to enable the practically minded owner to maintain his car and at the same time show him the way to carry out most of the repairs that a car normally requires during its life, as economically and quickly as possible. Modern trends in motor car design and production are towards the fitting of components which are renewed completely if they fail the economics being that the cost of the time required to repair them is little less than the combined cost of labour and material needed to produce them in the first place. However, this trend has not yet moved things completely out of the owner’s control and many items such as starter motors, fuel pumps, distributors, brake cylinders, and so on can be repaired for an expenditure of pence on parts where replacement would cost pounds. Where a component is only obtain-

able as a complete unit, an owner should be quite able to insta!I it correctly with the aid of this manual. The HC Viva, the latest model in the range which started production in 1963, shows developments in assembly and design which make access to, and removal of, many parts much simpler than it was on the earlier HA and HB series. For the do-it-yourself owner, careful study of the electrical system, for example, (and all the ‘fiddly’ bits that one tends to associate with it) will show how it has beeri simplified in a most sensible manner. The same goes for other parts as well.

Modifications and changes applicable only to 1256 cc models

built after September Chapter 13.

1973

are

contained

in the supplementary

Safety is of permanent concern to the responsible owner who appreciates the hazards of increased traffic volume and motorway speeds. All the checks for safety are fully covered in this manual and the conscientious do-it-yourself maintenance man will not just regard these checks as something to pay attention to only when the DOE test becomes a regular necessity. A three year old car that has been totally neglected can be a far more lethal article than a ten year old one that has been properly looked after. For

the more

ambitious

owner,

this manual

gives step by step

details of all the other repairs and overhauls which we consider are within the capabilities of a practically minded person who is in possession

of a reasonably

comprehensive

set of tools. With regard

to the latter, this is one area where only good quality equipment will do. Borrowing of tools is discouraged except for certain special items which may only be used once in a blue moon. Certainly we would say that you should not be annoyed if someone should refuse to lend them. Appreciate how much they cost if lost or damaged apart from the fact that keen owners regard their tools as particularly personal belongings. Much of the work involved in looking after a car and carrying out repairs depends on accurate diagnosis in the first place. Where possible, therefore, a methodical and progressive way of diagnosis is presented. The time that can be wasted in hopping from one possible source of trouble to another, suggested at random quite often by self styled ‘experts’ must have been experienced by many people. It is

best to say at the start therefore, ‘This could be one of several things - let’s get the book out’.

Contents Chapter

Section Routine maintenance Recommended lubricants

1 Engine

Page 6 8

Section

Page

Lubrication chart Ordering spare parts

9 10

28

General description

14

Decarbonisation

Removal

18

Reassembly

29

Dismantling

18

Replacement

42

Examination

26 ~=—-Fault finding chart

45

2 Cooling system

General description Draining, flushing, filling Radiator Thermostat

46 47 47 47

Water pump Antifreeze Fan belt Fault finding chart

47 50 50 52

3 Fuel system and carburation

General description Air filter

54 54

Fuel pump Fuel gauge

68 70

4

Ignition system

5 Clutch and Actuating mechanism

6 Gearbox

Carburettors

54

Exhaust system

70

Fuel tank

68

Fault finding chart

73

General description

75

Ignition timing

78

Condenser Distributor

76 ~~ Spark plugs 76 ~=Faults

78 80

General description Clutch cable

83 83

Removal; inspection Replacement

86 86

Adjustment

83

Fault finding chart

88

General description Removal and replacement

90 90

Dismantling

94

Reassembly Automatic transmission Fault finding chart

98 106 112

Universal joints

113

7

Propeller shaft and universal joints

General description Propeller shaft

8

Rear axle

General description

117

Half shafts

117

Removal and replacement

117

Pinion, crownwheel and differential

120

General description Adjustment Drum brakes Handbrake

124 125 125 128

Disc brakes Vacuum servo unit Bleeding hydraulic system Fault finding chart

128 136 138 140

10 Electrical system

General description Battery Alternator Starter motor

143 143 144 144

Horn; lamps Windscreen wiper Instruments Wiring diagrams

158 158 164 169

11 Suspension, dampers and steering

General description

174

Steering mechanism

182

Front suspension Rear suspension

175 181

Steering gear Wheels and tyres

182 190

Front hub bearings

181

Fault finding chart

192

General description Repairs Doors

193 194 196

Bonnet Heater Seats

198 203 209

9

Braking system

12 Bodywork and underframe

113 113

SS SSS SSS SASS SSS

13 Supplement

Wiring diagram Metric conversion tables Index

Specifications Engine

210-211 211

SSS

Gearbox Rear axle Braking system

SD

216 DAV

Cooling system

212

Fuel system

213 ~~ Electtical system

218

Ignition system Clutch

216 216

221 221

Suspension and steering Body and underframe

217

222-223 224-225 226-228

Routine maintenance The manufacturers base their own servicing operations on a time rather than mileage factor. They take 12000 miles per annum as an average to base this service plan. This system is very satisfactory as it enables both owner and service station to plan servicing in advance on a regular basis and confirms that deterioration of a vehicle’s performance and safety is not necessarily connected with the number of miles covered. Where mileage is consistently and significantly in excess of the average the time intervals between services may be reduced in proportion. By implication the servicing cycle recommended by the manufacturers gives a 6000 mile interval between engine oil changes. Many owners prefer to change the oil more frequently particularly where much of the driving is in short runs, or stop/start situations, where the engine either does not get many opportunities to warm up completely or operates constantly in heavy traffic. These conditions take far more out of an engine than steady runs along motorways in

top gear. The maintenance information given is not detailed in this Section as the full information is given in the appropriate Chapters of the book.

INTERVALS THREE MONTHS COMPLETE CYCLE TWO YEARS

Weekly

COOLANT LEVEL IN RADIATOR 1 inch (25 mm) below bottom edge of filler neck ENGINE OIL LEVEL WITH THE DIPSTICK

=

Illustration of the servicing cycle which includes checks under the ‘S’ service covering all safety requirements for the DOE Test

Level must be above ‘Add oil’ mark. Quantity required from ‘Add oil’ to ‘Full’ is 2 pints. BATTERY ELECTROLYTE LEVEL Should just cover the plate separators. Wipe away any moisture or dirt.

TYRE PRESSURES Also examine tread depth and for signs of damage.

Safety Check Service ‘S’ BRAKES Master cylinder fluid Jevel Hydraulic pipes and hoses inspection Wheel cylinder inspection

Shoes - adjustment Handbrake lever setting

STEERING Tyre condition

Front wheel hub bearings adjustment Track rods and ball joints damage and/or wear

cS Gearbox filler/level plug

Routine Maintenance SUSPENSION Suspension arm upper and lower ball joints - wear

Springs - level and unbroken AUTOMATIC TRANSMISSION Fluid level correct

GENERAL Lights in order Exhaust system intact Windscreen wipers - blades serviceable

Seat belts and anchorage points in order Service ‘A’

BRAKES Examine pads and linings for wear - renew if necessary and adjust.

CLUTCH AND TRANSMISSION Check and adjust clutch pedal free play Gearbox oil level - check and top up Rear axle oil level - check and top up ENGINE Renew oil and oil filter element Clean crankcase ventilator air cleaner Carburettor air cleaner - clean filter element Carburettor damper dashpot (Stromberg carburettors) - check oil level Fuel pump - clean filter Spark plugs - remove, clean and reset Distributor contact breaker points - adjust gap. Clean or renew if necessary Valve clearances - check and adjust Crankcase ventilation valve - clean and check Fan belt - adjust tension if required. Engine idling speed - adjust carburettor if required. Service ‘B’

Service ‘A’ to be carried out with the following additons: BRAKES Disc brake servo filter - renew SUSPENSION Grease upper and lower arm ball joints AUTOMATIC TRANSMISSION Clean all ventilation holes and slots around cover. also.

Scrape

all accumulations

the torque converter

of dirt from

surrounding

areas

ENGINE Renew Renew

spark plugs paper element

in air cleaner

Service ‘C’ Service ‘B’ to be carried out with the following additions: STEERING Remove front wheel

bearings

- clean and repack

with

grease.

BRAKES Renew

hydraulic fluid

AUTOMATIC TRANSMISSION Renew fluid

Hydraulic fluid reservoir

2

Se

ee

SS *sabuiy

ee

SS adA} uo1xaq

psepuels 4406 AVS O} |!0 128 aseas6 Ajo] 10 a314ydeis

ZGLE/LGLE ISA EHYOL AVS PIN} 1/NeEIPAH

a

—

a

ee

‘* (ANLLNOY LON) NOISSINSNVYL

ee

DILVWOLNV

YsaddN

HOLLSAYNEYVO

YAGNITAD

HOLN19 GNV ANVda

AZSAYSILNV

NOISNAdSNS LNOYS

(ANILNOY LON) YV49 ONIYS4SLS

YALSVW

SLNIOf11V48

SYSGNITAOD

LNVOIYSNT

LOdHSVG

STVNINYSAL AY3LLVE

O£/MOL |!0 au16u3 Ayjaf Winajoiad

S31d8V9 3NVYE

YOLVYAN]AD GNV YOLNAIYLSIG

WV9 Y¥3ayV3IYE LOVLNOOD

SONIHV4E

aseai6 asodind-ijnwW apes winipal\

eee

JOOP a3911qQN] 0} Pasn aq ued KX1D |O43SeD ‘Aj|EUO!IPPY pue $490] uaasds Jas ‘sayo}eo pue sabury ‘s}90] JUaWsedWOd au!bua Pue yeuUOg ‘s9Buly PU $19}14}S ‘S49O|

2 OL 1043889

AodAp j0438e9 aseaiB SSI) 1043829

azaaspiUuYy [O4}seD pin}y Y93NID pue aye1g jesuaaiug) Bulyats josyseD

ojouysed

juewAIIAZ, |01}SeD

aseasd IN] JO43seD

“* aseai6 asodind-iyjnwW apes Winipay\|

SaNH LNOYWS

jo 7y6tj 40 auibug

aseald IN] 1043829

aseai6b asodind-ijnwW apeidy Wwinipal|

JAIYG IVNISd/XOEYVAD

XLD J043seD

aseai5 IN 10438eD

paepueis d406 AVS $0 |!0 1e8D

ae

eae

eae

LNANOdWOD

ISS

a

aa

JANISNS

AodAp{ 10438289

AO AdAL

“

0S/MOZ 1!0 aul6ua apes6-1n)ny\) ginida ¥O LNVOIHYENT

ne

seeEEEEEE EEE

XLD 1043s8eD

TOYLSVD L93YHHOD

nnn nn nn SLONGOYd ee

SJUBDLGN] papusawili0se8Y

Routine Maintenance

| 5 —

IORI

Ow

6

1 Engine Oil Weekly Check the oil level using the dipstick (Item 7) and, if necessary, add sufficient Castrol GTX to bring the level up to the ‘Full’ mark. Two pints are needed to raise the level from ‘Add oil’ to ‘Full’.

the filler plug orifice with Castrol Hypoy 90 Gear Oil (Castrol Hypoy is available in 1 pint ‘Handipacks’ fitted with a filling tube which greatly facilitates this operation). Examine casing for signs of leakage. Capacity:— 1% pints.

Service ‘A’

6 Gearbox oil Service ‘A’ Remove the filler plug and, if necessary, replenish to the bottom of the filler plug orifice with Castrol Hypoy 90. If for any reason the gearbox has been drained, or a new gearbox fitted, refill with fresh. Castrol Hypoy 90 (Castrol Hypoy is available in 1 pint ‘Handipacks’ fitted with a filling tube which greatly facilitates this operation). Examine casing for signs of leakage. Capacity:— 0.9 pint

When warm undo the sump drain plug and drain off the engine oil. Renew the oil filter element also. Replace the drain plug and refill with fresh Castrol GT X.-Under the adverse conditions encountered in town area operation with frequent stops and starts, particularly in cold weather or where much driving is done over dusty roads, it is recommended that the oil is changed more frequently. Capacity:— 5% pints, dry 5 pints, filter element change 2,10 Front suspension arm ball joints - 2 nipples each side Service ‘B’ Apply Castrol MS3 Grease with the grease gun to the top and bottom nipples. 3 Hydraulic brake master cylinder reservoir Service ‘S’ Check fluid level and, if necessary, top up with the recommended fluid to within % inch below the filler neck.

4 Air cleaner Service ‘B’ With a wire gauze type filter element, remove, wash in paraffin, oil

7

Engine oil level dipstick - see Item 1.

8 Distributor Service ‘B’ Remove distributor cap and rotor arm. Impregnate felt pad in top of spindle with a few drops of Castrol ‘Everyman’ or GTX oil and put a few drops also through the indicated hole. Smear the spindle cam faces sparingly with petroleum jelly. 9

Engine oil filter - see Item 1.

10 As for 2.

with Castrol GTX, drain and replace.

5 Rear axle oil Service ‘A’ Remove filler plug and, if necessary, replenish to the bottom of

11 Front wheel bearings Service ‘C’ Remove bearings, flush with paraffin and repack with Castrol LM Grease.

Buying

spare parts

and vehicle

identification

Buying spare parts Spare

parts

are

available

from

many

sources,

for example

Vauxhall garages, other garages and accessory shops, and motor factors. Our advice regarding spare part sources is as follows: Officially appointed Vauxhall garages - This is the best source of parts which are peculiar to your car and are otherwise not generally available (eg; complete cylinder heads, internal gearbox components, badges, interior trim etc). It is also the only place at which you should buy parts if your car is still under warranty; nonVauxhall components may invalidate the warranty. To be sure of obtaining the correct parts, it will always be necessary to give the storeman your car’s engine and chassis number, and if possible, to take the ‘old’ part along for positive identification. Remember that many parts are available on a factory exchange scheme - any

parts returned should always be clean! It obviously makes good sense to go straight to the specialists on your car for this type of part for they are best equipped to supply you. Other garages and accessory shops - These are often very good places to buy materials and components needed for the mainten-

numbers ance of your car (eg spark plugs, bulbs, fanbelts, oils and greases, touch-up paint, filler paste, etc). They also sell general accessories, usually have convenient opening hours, charge lower prices and can often be found not far from home. Motor factors - Good factors will stock all of the more important components which wear out relatively quickly (eg cylinders/

pipes/hoses/seals/shoes

and

pads etc). Motor

Vehicle identification numbers The

car identification

number

is attached

to the top of the

instrument panel on the left hand side and can be read through the windscreen. A further identification plate, giving the model designation and service numbers with other code numbers, is fitted.to the right hand wheel arch panel in front of the battery.

The engine number is stamped the front two spark plugs.

Car Identification

Engine serial number

factors will often

provide new or reconditioned components on a part exchange basis - this can save a considerable amount of money.

a

on the block just underneath

Number

Chapter 1 Engine Contents

General description ... ... . aS aes Major operations with eagine inAVpiace Major operations for which the engine must be removed .We

ate ee Methods of engine removal Engine removal - WITHEGeAbDOXecmemectters sea ccer meee eee Engine removal - WithoutieanbOxcy mses wn rere ass Engine dismantling - general Engine dismantling - ancillary components

Beets

Stel

des) eee

Wash eee

Cylinder head removal- engine out of car Cylinder head removal - EM GIMectI: Calhccuresseee

ates eealaes. one aes Valve rocker arms - removal Valves - removal Valve guides- FecondiUcning Sump - removal Crankshaft pulley- oaanoecover,feprosees aa Sain’ renova