Haynes Vauxhall Viva HC Series 1970 to 1979 Owners Workshop Manual 0856966169, 9780856966163

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EDINBURGH CITY LIBRARIES Reference Department q THis BOOK MUST NOT BE REMOVED UNDER ANY PRETEXT FROM THE REFERENCE DEPARTMENT. INFRINGEMENT OF THIS RULE RENDERS THE OFFENDER LIABLE TO PROSECUTION.

Before leaving the Library readers must return the books to one of the attendants at the issue desk, or they will be held responsible for them.

Readers are required to take care of the books. Writing or drawing with pen or pencil on any part of a book, or turning down the leaves, or cutting or mutilating them, will be treated as serious damage. q CONVERSATION IN THE REFERENCE DEPARTMENT IS ANNOYING TO STUDENTS, AND IS NOT PERMITTED. Class.

:

Location.

:

Accession.

Vauxhall Viva HC

Owners Workshop Manual re by JH Haynes re

~~

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 1300 L 1300 SL

Viva E (saloon only) and GLS October 1970 onwards, fitted with

1159cc

1159cc extra performance and 1256cc ohv engines

ISBN 0 85696 616 9

©

Haynes Publishing Group 1971, 1977, 1981, 1987, 1988

All rights any form recording in writing

reserved. or by any or by any from the

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

Printed in England

(047-3P4)

Haynes Publishing Group Sparkford Nr Yeovil

-Somerset

BA22

7JJ

England

Haynes Publications, Inc 861 Lawrence Drive Newbury Park California 91320 USA

PIP TLE RENE TOTO RAO {(ORSESRAE EDINBURGH CITY LIBRARIES

Acknowledgements Thanks are due to General Motors for the assistance given in the supply of technical material and illustrations, to Duckhams Oils who provided lubrication data and to the Champion Sparking Plug Company for the illustrations showing the various spark plug conditions.

About

this

manual

Its aim The aim of this manual is to help you get the best value from your car. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may

even

be quicker than booking the car into a garage and going

there twice to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs the garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work.

[ts arrangement The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers

Introduction

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.

following on from the Section they are in, eg 5.1, 5.2, 5.3 etc. It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according

to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards.

Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. 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.

to the Vauxhall

Introduced in 1970, the HC Vauxhall Viva is the last in aline which started with the introduction of the HA in 1963. The tenyear production run of the HC, with only minor changes to the major mechanical components, is ample evidence that Vauxhall were successful in developing the shorter-lived HA and HB versions into a car which was a best-seller in its class.

For the do-it-yourself owner, the main Viva over its predecessors is the improved

advantage of the HC access to both major

Viva

and minor components. The electrical system is also considerably simpler. All systems of the car have, of course, benefited from advances in automobile technology, and later models in particular are quieter at speed, and smoother at low revs, than their older counterparts. Instrumentation and trim have also been improved in keeping with the higher standards which have come to be expected over the years.

1256 VIVA SL

VIVA SL ESTATE

Safety first! ines Siraipe

erties

nee

eee

Professional motor mechanics are trained in safe working procedures. However enthusiastic you may be about getting on with the job in hand, do take the time to ensure that your safety is not put at risk. A moment's lack of attention can result in an accident, as can failure to observe certain elementary precautions. There will always be new ways of having accidents, and the following points do not pretend to be a comprehensive list of all dangers; they are intended rather to make you aware of the risks and to

encourage a safety-conscious approach to all work you carry out on your vehicle.

;

Essential DOs and DON'Ts DON'T

rely on a single jack when working underneath the vehicle.

Always use reliable additional means of support, such as axle stands, securely placed under a part of the vehicle that you know will not give

way. DON'T attempt to loosen or tighten high-torque nuts (e.g. wheel hub nuts) while the vehicle is on a jack; it may be pulled off. DON'T start the engine without first ascertaining that the transmission is in neutral (or ‘Park’ where applicable) and the parking brake applied. DON’T suddenly remove the filler cap from a hot cooling system — cover it with a cloth and release the pressure gradually first, or you may get scalded by escaping coolant. DON'T attempt to drain oil until you are sure it has cooled sufficiently to avoid scalding you. DON'T grasp any part of the engine, exhaust or catalytic converter without first ascertaining that it is sufficiently cool to avoid burning

you. DON’T DON'T mouth, DON'T below). DON'T straight DON'T

allow brake syphon toxic or allow them inhale dust

fluid or antifreeze to contact vehicle paintwork. liquids such as fuel, brake fluid or antifreeze by to remain on your skin. — it may be injurious to health (see Asbestos

Fire

Remember at all times that petrol (gasoline) is highly flammable. Never smoke, or have any kind of naked flame around, when working on the vehicle. But the risk does not end there — a spark caused by an electrical short-circuit, by two metal surfaces contacting each other, by careless use of tools, or even by static electricity built up in your body under certain conditions, can ignite petrol vapour, which in a confined space is highly explosive. Always disconnect the battery earth (ground) terminal before working on any part of the fuel or electrical system, and never risk spilling fuel on to a hot engine or exhaust. It is recommended that a fire extinguisher of a type suitable for fuel and electrical fires is kept handy in the garage or workplace at all times. Never try to extinguish a fuel or electrical fire with water.

Fumes Certain fumes are highly toxic and can quickly cause unconsciousness and even death if inhaled to any extent. Petrol (gasoline) vapour comes into this category, as do the vapours from certain solvents such as trichloroethylene. Any draining or pouring of such volatile fluids should be done in a well ventilated area. When using cleaning fluids and solvents, read the instructions carefully. Never use materials from unmarked containers — they may give off poisonous vapours. Never run the engine of a motor vehicle in an enclosed space such as a garage. Exhaust fumes contain carbon monoxide which is extremely poisonous; if you need to run the engine, always do so in the open air or at least have the rear of the vehicle outside the workplace. If you are fortunate enough to have the use of an inspection pit, never drain or pour petrol, and never run the engine, while the vehicle is standing over it; the fumes, being heavier than air, will concentrate in the pit with possibly lethal results.

The battery allow any spilt oil or grease to remain on the floor — wipe it up away, before someone slips on it. use ill-fitting spanners or other tools which may slip and cause

injury. DON'T attempt to lift a heavy component which may be beyond your capability — get assistance. DON'T rush to finish a job, or take unverified short cuts.

DON'T allow children or animals in or around an unattended vehicle. DO wear eye protection when using power tools such as drill, sander, bench grinder etc, and when working under the vehicle. DO use a barrier cream on your hands prior to undertaking dirty jobs — it will protect your skin from infection as well as making the dirt easier to remove afterwards; but make sure your hands aren't left slippery. Note that long-term contact with used engine oil can be a health hazard.

DO keep loose clothing (cuffs, tie etc) and long hair well out of the way of moving mechanical

parts.

DO remove rings, wristwatch etc, before working on the vehicle — especially the electrical system. DO ensure that any lifting tackle used has a safe working load rating adequate for the job. DO keep your work area tidy — it is only too easy to fall over articles left lying around. DO get someone to check periodically that all is well, when working alone on the vehicle. DO carry out work in a logical sequence and check that everything is correctly assembled and tightened afterwards. DO remember that your vehicle's safety affects that of yourself and others. If in doubt on any point, get specialist advice. IF, in spite of following these precautions, you are unfortunate enough to injure yourself, seek medical attention as soon as possible.

Asbestos Certain friction, insulating, sealing, and other products — such as brake linings, brake bands, clutch linings, torque converters, gaskets, etc — contain asbestos. Extreme care must be taken to avoid inhalation of dust from such products since it is hazardous to health. \f in doubt, assume that they do contain asbestos.

Never cause a spark, or allow a naked light, near the vehicle's battery. It will normally be giving off a certain amount of hydrogen gas, which is highly explosive. Always disconnect the battery earth (ground) terminal before working on the fuel or electrical systems. If possible, loosen the filler plugs or cover when charging the battery from an external source. Do not charge at an excessive rate or the battery may burst. Take care when topping up and when carrying the battery. The acid electrolyte, even when diluted, is very corrosive and should not be allowed to contact the eyes or skin. If you ever need to prepare electrolyte yourself, always add the acid slowly to the water, and never the other way round. Protect against splashes by wearing rubber gloves and goggles. When jump starting a car using a booster battery, for negative earth (ground) vehicles, connect the jump leads in the following sequence: First connect one jump lead between the positive (+) terminals of the two batteries. Then connect the other jump lead first to the negative (—) terminal of the booster battery, and then to a good earthing (ground) point on the vehicle to be started, at least 18 in (45 cm) from the battery if possible. Ensure that hands and jump leads are clear of any moving parts, and that the two vehicles do not touch. Disconnect the leads in the reverse order.

Mains electricity When using an electric power tool, inspection light etc, which works from the mains, always ensure that the appliance is correctly connected to its plug and that, where necessary, it is properly earthed (grounded). Do not use such appliances in damp conditions and, again, beware of creating a spark or applying excessive heat in the vicinity of fuel or fuel vapour.

Ignition HT

voltage

A severe electric shock can result from touching certain parts of the ignition system, such as the HT leads, when the engine is running or being cranked, particularly if components are damp or the insulation is defective. Where an electronic ignition system is fitted, the HT voltage is much higher and could prove fatal.

Contents Page

Acknowledgements

2

About this manual

2

Introduction to the Vauxhall Viva HC

2

Safety first!

4

Routine maintenance I ERIE OTE ON VEE eee

eee

6

eee

Buying spare parts and vehicle identification numbers

10

Chapter 1 Engine

|

Chapter 2 Cooling system

46

Chapter 3 Fuel system and carburation

53

Chapter 4 Ignition system

74

Chapter 5 Clutch and actuating mechanism

83

Chapter 6 Gearbox

89

Chapter 7 Propeller shaft and universal joints

113

Chapter 8 Rear axle

116

Chapter 9 Braking system

124

Chapter 10 Electrical system

141

Chapter 11 Suspension, dampers and steering

173

Chapter 12 Bodywork and underframe

193

Chapter 13 Supplement: Revisions and information on later models

212

Tools and working facilities

258

a a Conversion factors cp Index

;

260

a 261

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 vehicles 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 Illustration

ENGINE OIL LEVEL WITH THE DIPSTICK Level must be above ‘Add oil’ mark. Quantity required from ‘Add oil’ to ‘Full’ is 2 pints

of the

servicing

cycle

which

includes

gr ek

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 level 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

checks

under

the ‘S’ service covering all safety requirements for the DOE Test

Topping- up engine oil level

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 Fan belt adjustment

SUSPENSION Grease upper and lower arm ball joints

AUTOMATIC

TRANSMISSION

Clean all ventilation holes and slots around the torque converter cover. Scrape all accumulations of dirt from surrounding areas also.

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 Renew

fluid

TRANSMISSION

NO gh

GenByr kh

Recommended Component

or system

1

Engine

2

Front suspension

balljoints

6

lubricants and fluids

Lubricant type/specification

Duckhams

recommendation

Multigrade engine oil, viscosity SAE 20W/50

Duckhams

Hypergrade

Lithium based molybdenum disulphide

Duckhams

LBM

Duckhams

Universal Brake and

10

grease 3

Braking system

Hydraulic fluid to SAE J1703

Clutch Fluid 4 Air cleaner (wire gauze filter element)

Multigrade engine oil

Duckhams

Hypergrade

5

Rear axle

Hypoid gear oil, viscosity SAE 90EP

Duckhams

Hypoid 90S

6

Manual gearbox

Multigrade engine oil, viscosity SAE 9OEP

Duckhams Hypoid 90

6

Automatic

Dexron type ATF

Duckhams

D-Matic

8

Distributor

Multigrade engine oil or light oil

Duckhams

Hypergrade or Home Oil

Multi-purpose lithium based grease

Duckhams

LB 10

11.

transmission

Front wheel bearings

Routine Maintenance SS

1 Engine Oil Weekly

Sp

A

ES

SSA

4

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

Service ‘A’ 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 oil. 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 lithium based molybdenum disulphide 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 Aijir cleaner Service ’B’ With a wire gauze type filter element, remove, wash in paraffin, oil, drain and replace. 5 Rear axle oil Service ‘A’ Remove filler plug and, if necessary, replenish to the bottom of

AS

AR

eA

RS SS

RSE

RS

aS

the filler plug orifice with SAE 90EP gear oil. Examine casing for signs of leakage.

6 Gearbox oil Service ‘A’ Remove the filler plug and, if necessary, replenish to the bottom of the filler plug orifice with SAE 9OEP gear oil. If for any reason the gearbox has been drained, or a new gearbox fitted, refill with fresh oil. Examine casing for signs of leakage. Capacity:- 0.9 pint

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 engine oil or light oil and put a few drops also through the indicated faces sparingly with petroleum jelly.

9

hole. Smear the spindle cam

Engine oil filter — see Item 1.

10 As for 2.

11 Front wheel bearings Service ‘C’ Remove bearings, flush with paraffin and repack with lithium based grease.

Buying

spare parts

and vehicle

identification

numbers

Buying spare parts

ance of your car (eg spark plugs, bulbs, fanbelts, oils and greases,

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

touch-up paint, filler paste, etc). They also sel! 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 import-

of parts which are peculiar to your car and are otherwise not generally available (eg; complete cylinder heads, internal gearbox

ant components which wear out relatively quickly (eg cylinders/ pipes/hoses/seals/shoes and pads etc). Motor factors will often provide new or reconditioned components on a part exchange basis - this can save a considerable amount of money.

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-

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

Car Identification

Engine serial number

numbers,

is fitted

to the right

hand wheel arch panel in front of the battery. The engine number is stamped on the block just underneath the front two spark plugs.

Number

Chapter 1 Engine For modifications, and information applicable to later models, see Supplement at end of manual Contents

General description ee Major operations with engine in1 place... : Major operations for which the engine must be removed Methods of engine removal Engine removal - with gearbox ... Engine removal - without gearbox Engine dismantling - general pee Engine dismantling - ancillary components Cylinder head removal - engine out of car Cylinder head removal - engine in car ... Valve rocker arms - removal Valves - removal ... RS Valve guides- reconditioning Sump - removal as

and renovation on Valve rocker arms and Bubh odes axanination and renovation = Tappets -examination and renovation’ Connecting rods -examination and renovation Flywheel starter ring - examination and renovation ... Oil pump - examination and renovation Decarbonisation ... Pe Valves- valve seats and springs -exantnauey and ONDNOOTABRWN—

renovation : Cylinder head- examination Engine reassembly- general

Crankshaft replacement... ES Pistons and connecting rods - renssemibly

Crankshaft pulley- timing cover,Peoroc ies eid chai removal Sec Pistons, connecting as ee bigland pearingee- cerneval

Piston ring replacement.. Piston replacement in colinders Connecting rod to crankshaft- Peanaehabiie

Gudgeon pins

Tappet/Camshaft - replacement

Piston rings - removal Flywheel - removal Oil pump - removal

Timing sprockets, timing chain, cover and ronsicnsel replacement Crankshaft pulley oheel® - Weniacerient Oil pump - replacement .. Sump - replacement Engine mounting brackets- venlacemiene Flywheel - replacement.. = Valves and valve springs-redssembly & apie head Cylinder head - replacement ne Valve rocker arms and pushrods - replacerven® Valve clearances -adjustment ... Inlet manifold - replacement Exhaust manifold - replacement Crankcase breather valve Final engine reassembly ... Engine replacement

Camshaft - removal Tappets - removal

Crankshaft and main bearings-Gorhovall Engine lubrication system- description

Oil filter -renewal of element ... Engine examination and renovation- general _ Crankshaft -examination and renovation

Big end (connecting rod) bearings and main bearifigs examination and renovation

:

Cylinder bores -examination and ranovadiant Pistons and rings -examination and renovation Camshaft and camshaft bearings - examination and

renovation Se 2 Timing chain, sprockets and tensioner; loamination

:

F

a

Specifications ee

1159 cc (70.7 cu in)

Engine - General Type Bore Stroke... Weight Compression ratios 1159 cc Standard 1159 cc Lowcompression 1159 cc High performance 1256 cc Standard 1256 cc Low compression

77.7 mm (3.062 in)

81 mm (3.188 in)

61.0 mm

61 mm

(2.400 in)

(2.400 in)

227 Ibs (270 Ibs with gearbox) approximately

...

... ...

Firing order

(No 1 cylinder at front of engine) ... Compression pressure

1159 cc and 1256 cc Standard 1159 cc Low compression 1159 cc High performance

1256 cc (76.6 cu in)

4 cylinder in line OHV pushrod operated

... ...

S.5ical ToS 9.0:1 Scorn Pfee hong |

Neopar2

125 Ib/sq in 110 Ib/sq in 135 Ib/sq in

1/Engine Chapter ali he

ee ie i

Brake horse power TUiS9%cciStandardz,.. =

LIVE

CONTROL

GAUGE FUEL/TEMPERATURE

Fig 13.56 Method of suppressing gauges and their control units

KEEP THIS LEAD AS SHORT AS POSSIBLE FUSE

y

bens

> LIVE

IN LINE CHOKE (SEE TEXT)

Fig 13.57 An in-line choke fitted in the radio supply lead can reduce interference sure that all electrical components are well earthed, if necessary by fitting earth leads from the component mounting to sound bare metal. pa ee Sh ne eo

ee

12 Suspension and steering eS

Suspension and steering balljoint rubber boots 1 It is emphasised that long life will only be obtained from the suspension and steering balljoints if the protective rubber boots are in good condition and correctly fitted. Renew a damaged

boot without delay. Avoid over-lubricating as this may split or displace the boot.

(where applicable)

Steering balljoint removal and refitting 2 It is important that whenever a steering balljoint locknut is slackened or tightened, whether for removal of the joint or for

adjusting the wheel alignment, the flats on the balljoint are held with another spanner to prevent the balljoint being twisted.

Failure

to observe

this precaution

can

result in damage

balljoint housing, with potentially disastrous consequences.

a

EY

to the

Fig 13.58 Hold balljoint on flats (arrowed) when slackening or tightening locknut

3 Where a heater water valve is installed, a control panel of modified design is used in which the heat control lever moves upwards to the ‘HOT’ position.

ST

13 Bodywork and underframe

Window support channel (front door)

—_—eaeaerererererereaearooer———————————

4 A new type window support channel was introduced at chassis No FX100001 and it will be noticed that the window regulator guide channel is no longer attached by two bolts, but is now an integral part of the window support channel. The glass dimension remains the same. 5 It is recommended that the window support channel filler strip is glued to the glass using Loctite 312 to Prevent the glass moving in the channel. This recommendation does not apply to the rear doors of four-door models.

Heater water valve 1 In order to ensure a from the engine to the ‘COLD’, a heater water shroud panel and is cable 2 The connecting hoses and from the valve to the

more positive shut-off of hot coolant heater when the controls are set to valve is mounted on the ventilator operated. run from the cylinder head to the valve heater matrix inlet Pipe.

Chapter 13 Supplement

231

Fig 13.60 CLOCK AND TRIP MILEOMETER Fig 13.59 Heater water valve

Fig 13.61

Instrument panel cover removal and refitting 6

Disconnect

the battery earth

(seven-dial lead.

1

Knurled nuts

2

CABLE FIXING

Recessed screws

Exploded view of 7-dial instrument panel surround

instruments)

It is necessary

—

to remove

the steering wheel and to detach the speedometer cable before the instrument panel cover can be removed. The clock and trip mileometer cables can be disconnected after removing the panel filler. 7 Having removed the securing screws, carefully pull the cover

forwards far enough to be able to disconnect the oil pressure gauge pipe. 8 Tilt the cover to gain access to the wiring connectors. Disconnect the wiring and withdraw the cover and panel complete. 9 Refitting is the reverse of the removal procedure. Take care not to accidentally strain or disconnect any wiring or cable connections whilst refitting the assembly.

232 (POS Sy

ee

ee

r] STARTER

BATTERY 12 VOLT

Hi

STARTER MOTOR

ALTERNATOR

LIGHTING SWITCH FUSIBLE

LINK

ALTERNATOR WARNING LAMP

@® HIGH NOTE HORN WINDSHIELO WIPER SWITCH

LOW NOTE HORN

|_____(eg)__

—o o— HORN PUSH

WINDSHIELD

SWITCH

@ LH

DCOR SWITCH

WASH

INTERIOR LAMP & SWITCH

HEATER MOTOR SWITCH

@® RH DOOR swiTcH

VOLTAGE STABILISER TAILGATE

COURTESY

LAMP

SWITCH

TAILGATE COURTESY LAMP

@)

@ TRUNK INTERIOR LAMP SwiTCH.. nS,

LH

MAIN BEAM

FILAMENT

LH MAIN BEAM

FILAMENT

MAIN BEAM

INDICATOR

MAIN

BEAM

FILAMENT

RH MAIN

BEAM

FILAMENT

RH

4

TRUNK INTERIOR LAMP

HEADLAMP = —O

WATER

TEMPERATURE GAUGE

FLASHER

OIL WARNING LAMP

oe

HEAD LAMP THERMAL

OVERLOAD

TURN SIGNAL

LH DIP FILAMENT

UNM

TURN SIGNE

SWITCH RH DIP

FILAMENT

STOP LAMPS

te

LH TAIL FILAMENT

NUMBER

RH

PLATE

SIDE LIGHT

LAMP

FILAMENT

@)

HANDBRAKE /BRAKE FAILURE WARNING

LH

SIDE LIGHT

FILAMENT

INSTRUMENT

INSTRUMENT

S.

LAMP

LAMP.

INSTRUMENT LAMPS SWITCH

D HEATER CONTROL LAMP

Fig 13.62 Theoretical wiring diagram — 1974 models

REAR WinDOW SWITCH

DEMIST

LAMP.

233 2

SS

SS SS

A SD SD ED YG

GD GO

STARTER SOLCNOO & STARTER MOTOR UNIT ®

SPARK PLUGS

STARTER MOTOR

SOLENOID STARTER SWITCH

RESISTANCE WIRE

CIRCUIT BREAKER

WINDSHIELD

WIPER

WINDSHIELD

WASH

MOTOR

WINDSHIELD WIPER SWITCH

WINDSHIELD SWITCH

WASH

on

MOTOR

HEATER MOTOR

HEATER MOTOR SWITCH

VOLTAGE STABILISER

FUEL GAUGE TANK UNIT

WATER TEMPERATURE UNIT WATER

TEMPERATURE GAUGE

OW PRESSURE SWITCH

LH TURN SIGNAL INDICATOR

LH FRONT TURN SIGNAL FILAMENT

LH REAR TURN SIGNAL

TURN SIGNAL

i

FILAMENT

RH FRONT TURN SIGNAL FILAMENT

TURN SIGNAL SWITCH

RH REAR TURN SIGNAL FILAMENT RH

STOP LAMPS SWITCH

:

a.

()

HANDBRAKE / BRAKE FAILURE WARNING LAMP

TURN

INDICATOR

LH STOP LAMP

©)

SS

RH. STOP LAMP

HANOBRAKE

—t—

PRESSURE

@)

SIGNAL

SWITCH

@ ‘noicates Domestic onty DIFFERENTAL

R.wW.D INDICATOR

SWITCH

LAMP

@o REAR WINDOW DEMIST ELEMENT REAR WINDOW SWITCH

@ INDICATES MODELS

9UD15,9UEIS & 9UFIS

®

9UE11, 9UE69 SUF 11, SUF 37 & 9UF69

INDICATES MODELS

@ INOICATES MODELS 9UEA & QUFA @ INDICATES MODELS 9UDA, 9UEA & 9UFA @® INDICATES MODEL 9UFA ONLY

DEMIST

Fig 13.62 Theoretical wiring diagram — 1974 models (continued)

234 WINDSHIELD WASH MOTOR

BATTERY -12VOLT

BATTERY

es

TURN :

big

me

(at

au

spd! oP

7

SIDE

4LF

16 58

70 7 se YI A LT EDF 4 ee 17 59

a

Be ABT LP

!

4

ee

26

INTERNAL CRIMPED JOINT ~2 N&s47-64

3

RH FRONT LAMPS

SSS ee ee a

FUSIBLE LINKS

+ LOW

63—G}—- 2

NOTE

HORN

63-0} 5 TERMINAL

I

SOLENIOD SWITCH

STOP

1 4 51

5

STARTER

BRAKE PRESSURE WARNING SWITCH

BLOCKS

D

:

47

b

47

-

LAMPS

SWITCH

61 nO I

—

é

| {

6

steno

ENGINE TEMPERATURE

H

P

UNIT

ALTERNATOR H

SPARK PLUGS

=

] (} |

CYLINDER BLOCK

an IGNITION aR eTeUT

2

eds

IGNITION COIL

i

Aa

A3

56

a

7 ror

iH

cS

“a ENGINE MOUNT SIDE RAIL

See,

4 OlL PRESSURE SWITCH

5 19

53

i mos

55

(}

57

WINDSHIELD WIPER MOTOR

57 MAN

Lx}

ye

SPEEDOMETER & INSTRUMENTS

DE ET

10

BF ERE BREE

SEP POF |

DG LBP LE

, RE EE

SF LEP LDP

H

(|

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H

a

JY

15

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AS oi

fh ff ie

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pre

55 CD55

29—C1}— 34

SIGNAL

12 VOLT ALTERNATOR

SYSTEM

- NEGATIVE

Ss

RIGHT ORIVE SHOWN LEFT DRIVE SIMILAR

59

ACCESSORY

TO BE USED IN CONJUNCTION WIRING

DIAGRAM

oF 39

GROUND LH FRONT

60

LAMPS

HEATER

33|GREEN/RED 34|GREEN/RED 35|GREEN/PURPLE BROWN/ BLUE BROWN/ YELLOW

36| GREEN| WHITE

PURPLE/BROWN PURPLE| WHITE PURPLE/BLACK

GREEN/ BROWN 32|GREEN/ BLUE

14 /0.30

9 28 14 9 9

42|LIGHTGREEN| BROWN £3) LIGHTGREEN| BROWN

1% 030 9 10.30

£8) WHITE [BROWN

REO/WHITE

1% /0.30 9 10,30 9 /0.30

37|GREEN|WHITE 38|GREEN/ YELLOW 39|GREEN/ YELLOW 40|GREEN/ YELLOW 41|GREEN/ BLACK 64|LIGHTGREEN/BLACK 45|LIGHTGREEN/BLACK 46|WHITE 67 |WHITE

RED/GREEN RED/LIGHTGREEN

5959

GROUND

WITH THE

49|WHITE /BLUE 50|WHITE /RED 51 |WHITE/RED 52 |WHITE,/GREEN

53|WHITE /LIGHTGREEN 56 |WHITE /BL ACK 55 |YELLOW/LIGHTGREEN

56|BLACK 57|BLACK 58|BLACK 59|BLACK 60|BLACK /BLUE 61 |BATTERY CABLE 62|GROUNO CABLE

63 |FUSIBLE LINKS 64 |RESISTANCE WIRE

1030 /0.30 /0.30 /0.30 /a30

1% 10,25 9 1030

35 10,30

14 10.30 9 10.30

28 /0.30 2810.30 14 10.30 14 10.30

14 10.30 7116 /0,10 % 10.30

28/030 14 10.30 %% 10.25 9 1030 14 10,30 3710,90 16/ 16 10.30 1% 6”

Fig 13.63 Physical wiring diagram — 1974 models

MOTOR

J § } ohj s

‘

f

j (

)

57 TURN

|

Y

57

=

INSTRUMENT WIPER SHEATER GROUND

(] ( 11

(] é

arr"

j

235

RW 00OR SWITCH @

RA REAR LAMP

j

}

}

35

ony UIT

y

v

BREAKER

INTERNAL | | CRIMPED W | Jor -2

| H

|

IGNITION, STEERING COLUMN LOCK & STARTER SWITCH

STOP LAMPS SWITCH

} H

LM HAZARD WARN CONN

a

FUEL GAUGE [ANK UNIT

[] HazaRo WARN

Paseo

= ‘

H

2 Je Ht :

33i

stk

21 9

s

Rat” 2341 +2

" 26

F 53 19 15 55

26 29 19 15 55

26+ |} 26

f $ (— ya

JOINT—1

29 19 15 55

HANDBRAKE SNOGRA

CRIMPED

N°s £64664

°

INTERIOR LAMP

TAILGATE COURTESY LAMP & aes

NUMBER PLATE LAMP GROUND

REAR WINDOW DEMIST

|

@¢g

AUTOMATIC TRANSMISSION 20 aaa =)ILLUMINATION CONNECTOR

———

5 8 =i 18

52——o ae

\

17 Soo—17 59—{1}—59

25 59 17

PANEL LAMPS SWITCH

Hl

REAR NUMBER PLATE LAMP

” Fa

46 WINDSHIELD WIPER 4 WASH SWITCH

£6

SSeS

We

INTERNAL

=

HEADLAMP FLASHER & DIPSWITCH 42 BS

agi 42

SoS [+36 Th33

i ‘

TAILGATE COURTESY LAMP SWITCH

HORNPUSH .TURN SIGNAL

JUNCTION 34 34 37 37

}

:N

E8

PLAN

RH HAZARD WARN CONN

43 TD—43+4+-+-4

A

TURN SIGNAL

49

as 3

‘

|!

30

Ss

acta eaeterre Bice Sw

j

352028

37

1717 59

"]

—1——. Al

STOP

TURN SIGNAL UNIT

]

N9s 67-64

35

poate,

Bis

‘ H H ”

35

34 —D—30 LIGHTING

17

a5

CIGARETTE LIGHTER GONNECTOR

20

20 ae

? INSTRUMENT WIPER & HEATER GROUND

ES aE WGAR AGES ERGAGAT ty

nai

REAR WINDOW DEMIST SWITCH

LH

CIGARETTE LIGHTER ILLUMINATION CONN ®

———

TURN SIGNAL

SWITCH

HEATER CONTROL ILLUMINATION ®

@e

HEATER MOTOR SWITCH

@ @ ®@ @

/NOICATES WNOICATES INDICATES INOKATES

DOMESTIC RD ONLY 9U015 9UE15 9UE1! 9UE69 9UE11 9UE69 9UEIS

® INDICATES 9U011 9UD69 QUEN! 9UE69

9U015 9UEIS

LH D00R switcH B

|| kemeamaans:

SYMBOLS >»

8 Cc CONNECTORS

oe BULKHEAD CONNECTOR

a= TES DIREC al CABLE RUN IN HARNESS EXTERNAL JUNCTION

D E— F G

= GROUND

H

PLUG & SOCKET

020. 04020" ©9 ° J © BULKHEAD CONNECTOR DIAGRAM

Fig 13.63 Physical wiring diagram — 1974 models (continued)

17

=

REAR LAMP

@ DENOTES SINGLE STRAND RESISTANCE

WIRE

GIVING A

TOTAL

RESISTANCE

WIRE 1/Q71 OR 22S. WG

OF 2a%:202 ROUTED BETWEEN POINTS A1-A2-A3

RESISTANCE PER 25MM -0312n2 5%

TAIL

STOP

236

\

3 FUSIBLE LINK

ita 12 VOLT AveA BATTERY TURN SIGNAL ‘

ep- osTH

42eS

22 “OMATIC TRANSMISSION JMINATION CONN

a

FOG

REVERSE | AMPS SWITCH

REAR WINDOW DE MIST SWITCH

OENOTES

SINGLE

STRANO

ESISTANCE WIRE GIVING A IOTAL OF

oe

2n #020n ROUTED BETWEEN PSINTS

= 22) RSs

HEATER MOTOR

a

5

Al-A2-A} RESISTANCEAc

L4 poor switcHQ

if

= CRIMPED &INSULATED

JOINT

"7, Fe = Gah cee ore)

)

= INDICATES

DIRECTION

OF

CABLE RUN ‘N HARNESS

A

ws

WokS

Co

fac]

£0 Fo

1a?|

Go

-4A

3] al

| a3

eS rbHOUND )

Ho

P. Ta 1G & SOCKE r

/

Be

Oo

0°00

BULKHEAD CONNECTOR

WIRE 1/0710R 225 WG

RESISTANCE PER 25mmO0312n + 5%

a

SYMBOLS

CONNECTORS

TURN

ae

|

0

GA 0

0

0

0

rT

2

1GN 2 acc

(a2

0

0

BUURNCAD CONNECTOR. dps

“ LIGHT

Fig 13.65 Physical wiring diagram — 1976 de Luxe and SL models (continued)

STOP

YNNYL

YOINZLM DNV7

HILIMS

HILIMS

4-4

ILVIMVL ASILENOD

HILIMS

—=s

10V3HDNV14

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ous

% Y3dIM GTJIHSONIM HSVM HILIMS

ae

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F9NVD ANWL LINN

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3141939713 9079

BP

HILIMS

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HOLIMS 4OOG H7&)

NYOH

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————

HNNYL YOINFLN

a

dW]

‘ dWv7

MOT

oe ee

FL 134V9ID

co

3LON NYOH Ho

dcWV7

ONINYYM YOLVNY ILIV

NIT F78ISN —~——5

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9

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WOD NOILINDI

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243

244 12 VOLT BATTERY 65

BATTERY CARRIER

TURN

WINDSHIEL

0 WASH

— INTERNAL CRIM NoS 4848867

MOTOR

31-39

SIGNAL

INHIBITC

59 6) 6 uw ” 59

oP. PARKING

RW

RH HAZARD WARN

STOP LAMPS

39

SWITCH

ie

FRONT LAMPS

CONN

‘

HAZARD WARNING JUNCTION INTERKAL CRIMPED JOINT 2

SOLENOD SWITC

nos 19867

LOW NOTE HORN

ALTERNATOR

STARTER

LL

SPARK

TEMPERATURE

ENGINE

unt

ZL

MOTOR

oe 6.

PLUGS

% DISTRIBUTOR “9

IGNITION COIL

Sr

rr

wae

eee

Sc eee ee

50

CYLINDER BLOCK

2

T

—

y

6362

Oi

U

PRESSURE

SWITCH

65

H

= ENGINE MOUNT

BRAKE

WARNING

PRESSURE

‘al

SWITCH

i

SIDE RAIL

y

lH

FRONT

LAMPS 2)

MAIN —

>

rs

59

PARKING —

"

7

Evtue

==

55

= 18

HEATER

MOTOR

—

6 —

===55

57 Co

oats

TURN SIGNAL

—

—16 —{O— IEF

59 —

— 57 —— fd

AP

ie

|

6 i

a

|

&' 62 59

eae |

6 INSTRUMENT

GROUND

eal Dee.

No 1

COLOUR

SIZE

|BRLWN

ELC 39

2 |SROWN 3 |BROAN

4L)530 951090

36| GREEN/RED 37| GREEN/PURPLE

< |BROWN

WIL 2.

38)

GREEN /WHITE

% 10,30

5 6 7 8

ISIC IE 91630 35/0 70 28/5 30

39) 40) 41] 42]

GREEN/WHITE GREEN/YELLOW GREEN/YELLOW GREENIYELLOW

910,30 28/0 30 % 1030 91030

| BROWN IHL UE |BROWN/EL OW |BLUE |RLUE

= 35| GREENIRED

% 1030

9 |ALvEIRED

FIG 30

43] GREEN/BL ACK

1 |A. UE FED "2 |BLUEIWHI~E 17 |BLUE rtre

2315 30 12 I9C 3510.70 2510.30

44] 45| 46) 47)

10 |BL VE/RED

| PL UEIWH TE 15) Bu JEW "E 16 |BUEN WsHT

17 |RED. 18 |RED

141056 250 GREEN:

19 |HEDIBLUE

50]

% 10.25 919.30

51) WHITE |8LUE 52| WHITE /RED

916,30

53| WHITE / RED

20] REO/GREEN 21) PEDILIGHT GREEN

7810.30 1610.30

39510 30

24 |PURPLE 25] PURPLE

249.30

26| PURPLE IBROWN

1410.30

27] PURPL EIWHITE 28|

PURPLE /BLACK

48) WHITE 69) WHITE

6/930

23) PURPLE

22| REDIWHITE

LIGHT GREEN/BROWN LIGHT GREEN/BROWN LIGHT GREENIBL ACK LIGHT GREENIBLACK

910.30 91030

910,30

WHITE /BROWN

54 | WHITE /GREEN 55] WHITE [LIGHT GREEN

56 |WHITE /BL ACK

57| YELLOWILIGHT GREEN

58| BLACK 59] BLACK

%.1030 %1630

717161 010

1% 10,30

2810.30

910.30

31) GREEN 32) GREEN

%1025 910.30

63| BLACK/WHITE 64] BATTERY CABLE

65] GROUND CABLE 66] FUSIBLE LINKS 67| RESISTANCE

9/030

%1030

% 10.25

280.30 1410.30

9/030

9/0,30

10,50

60] BLACK

61| BLACK

62] BLACK/BLUE

9/0,30

% 1025

351030 % 10.30

28/030

1610.30

34 |GREEN/BL UE

910,30 % 10,30 910.30

2810.30

29) GREEN 30| GREEN

33) GREENIBROWN

91030 910.30

WIRE

% 1030

910,30 370,75

16 116 |0.30 % 10.30

Fig 13.68 Physical wiring diagram — 1977 onwards 1300 Land E models

AUTOMATIC TRANSMISSION ILLUMINATION CONN

CW a Ne as ma om

A a

ee we

245

RW DOOR SWITCH CONN

* A

AEF ET AOD AF IF a

A AAI A TY Re

allae cas a

ae

INTERNAL CRIMPED JOINT 1 NoS 6848467 Maicien eer tee

pf

Ny

TURN SIGNAL UNIT IGNITION. STEERING COLUMN LOCK & STARTER SWITCH

68-—-—

oe 5) }

RH REAR LAMP

4 TRUNK LAMP

lal

47

STOP

8 =

H H

~TAll

_ TURN

4

SIGNAL

HAZARD

WARN

CONN

lo

39—-——___. 6 — = HAZ AKO WARNING JUNC TION 49

“TCH

d REAR WINDOW DEMST

THERMAL OVERLOAD CIRCUIT BREAKER

JUNCTION

RH

oe

8

8

HASARD

WARN CONN

f) H

36

ra =

=e

H

WORK PUSH. TURN SIGNAL ME ALL AMP Fi ASHER & DIPSWITCH

ey

FUEL GAUGE

| \

ee

TANK UNIT

RH REVERSE | AMP y

|

|

19 Ng PH FOG REAR GUARO

LAMP CONNECTOR

47

rs)

PANEL | AMPS SWITcH 2

REAR NUMBER PLATE LAMP

18

27

18 Ace W rn

UOME

| AMP

—61

NUMBER PLATE LAMP GROUND

LH FOG REAR GUARO

190) AMP CONNECTOR SPEEDOMETER & INSTRUMENTS 20-0

\ H REVERSE LAMP CONN

55 55 tne

30

SF

57.

-16

6

2

—2!

47

30

WINOSHIEL D WIFER

57

& WASH

SWITCH

16 2

46

36 32

46

18

5 pm =

= See ee a

Se

ee ee ee

eee

aT

a

LIGHTING

20-

37

SWITCH

FOGSwiTCH REAR CONNECTOR GUARD LAMPS 19 ——-O "

1

pe

lL H REAR | AMP

HANOBRAKE SWITCH

22

Se

en

a

ee ae ye

;3

a a a ae 5

AUTOMATIC TRANSMISSION ILLUMINATION CONN

-. 2—o 59-——O lame CIGARETTE

ea

ee

om

HEATER

27

aheis ee

61

ey

Se em

aie

+

Ae me ee Ce a

a

ee

32 33

SE

—

40

42

REVERSE

REAR WINDOW

o—o

LIGHTER

CONTROL

hig ILLUMINATION

ee ne ee ee ae

LAMPS

DENOTES SINGLE STRANO SISTANCE WIRE GIVING A TOTAL OF 2n :Q20n ROUTED BETWEEN POINTS Al-A2-A}-Ad RESISTANCE WIRE 1/071 0R 22S5WG RESISTANCE PER 25mm00312n + 5%

SWITCH

DEMIST SWITCH

CONNS

Ne 30 2 oe —ei —=t? =

qT

gegen nome

LM DOOR SWITCH CONN

SYMBOLS 9

CONNECTORS

et

en ee — CRIMPED BINSULATED JOINT

==)

INDICATES DIRECTION OF

CABLE RUN IN HARNESS

vi

r

80

BULKHEAD

+ ni GROUND

| OCKET PLUG & SOGKE

Hares '

co

Oo @

6

ws

Fo

°

°

°

iH 0:

Sows,

fae il

2

°

Do

ay

[ CONNECTOR

LAH 8

bd

oad: BULKHEAD CONNECTOR

2

IGN 3

acc ‘

LIGHT

OUGRAM

Fig 13.68 Physical wiring diagram — 1977 onwards 1300 L and E models (continued)

TAIL

STOP

246 earreay-@ var

ja?)

a2)

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