Haynes Hillman Minx Series I to VI, Husky Series I to III Owners Handbook Maintenance Manual 0856961744, 9780856961748

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

https://archive.org/details/hillmanminxserieOQ0O00ward

m2: Min se x ries |toVI Husky series |to II! Covers all models

from1956 to 1967

Owners Handbook /Maintenance

by P. Ward

HAYNES

Manual

460012150 Acknowledgements Special thanks are due to Chrysler (UK) Limited for their co-operation with information and illustrations; and to Castrol Limited A handbook in the Haynes Owners Handbook and Maintenance Manual series Edited

©

by Stanley

Randolph

JH Haynes and Company

Limited 1974

Published by J H Haynes and Company Sparkford, Yeovil, Somerset Set in 10 point IBM Univers Medium

Printed in England

ISBN

08 5696

174 4

Limited

Contents Introduction

Model history and identification

Specifications, weights, dimensions, capacities

Road test data Tools Spares and touring pack

General information Automatic transmission Lubrication chart Routine maintenance

Other maintenance Bodywork - maintenance, cleaning, minor repairs

Preparing your car for the MOT test

Buying and selling a used Minx Wiring diagrams

Fault finding Metric conversion tables

105

Index

108

Hillman Minx Series |! Convertible

Hillman Minx Series 111C Saloon

Introduction This handbook is intended for the owner who wishes to find out more about his car and wants to keep it serviced fully, but with the minimum of effort, so that it provides economical, reliable transport. In this handbook are all the routine maintenance tasks required to keep the car running well, and the tools and other things needed to do them. All cars covered by this handbook are subject to the MoT roadworthiness test. Details of what the tester will be looking for, and how to check them yourself are in this book. Guidance in looking at secondhand cars is given. Cars are not perfect, and diagnosing faults can be a great problem. Therefore a methodical guide to fault finding is given. Much time and trouble can be saved if reference is made straight to this book instead of hopping from one thing to another. If success in tackling the jobs on your car, given in this book, encourages you to take on more complicated work, a very useful Owner’s Workshop Manual is available from the publishers, or through all good accessory shops and booksellers.

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Model

history and identification

The Minx Series | Saloon DeLuxe, Convertible and Special Saloon were introduced in May 1956 and provided a new concept in body design after the somewhat rectangular lines of the previous Minx range. A new sloping bonnet was fitted together with a narrower and larger grille with the sidelights located at the end of the horizontal bar. The headlamps were hooded and a wrap around rear window used. In this instance the chassis numbers started at A1600001. In September 1957 the Series || models were introduced and remained basically the same as the previous model except for the radiator grille, which was slightly redesigned, the horizontal bar disappearing and the word ‘Hillman’ appearing in script. A different camshaft was also fitted which resulted in the engine developing maximum power (51 b.h.p.) at 4400 r.p.m. instead of 4600 r.p.m. ‘‘Manumatic’’ transmission was an optional extra on this model. In January 1958 the Husky Estate car was introduced and used the same 1390 cc engine as the Minx Series 11. The wheelbase of the Husky was 7 ft 2 in. as opposed to the 8 ft of the Minx. September 1958 saw the introduction of the Series Il, the main difference being the replacement of the 1390 cc engine with a bored out 1494 cc unit. Production started with chassis number A1900001. A restyled one piece grille was fitted with “HILLMAN” in capitals above it. The facia panel was also restyled. In October 1959 the Series IIIA made its appearance with chassis number for the DeLuxe version starting at B1000001 and for the Special saloon BO0000001. The main mechanical change was the introduction of a remote control floor gear change, with the column change optional, except on Special models. The

power of the engine was increased to 56.5 b.h.p. at 4600 r.p.m. and a new close ratio gearbox fitted. The mesh radiator grille was divided by five central horizontal bars and the sidelights were made rectangular instead of circular as previously. The rear lights were also altered to oval shaped units and combined the stop, tail and indicator lights. Small curved tail fins were adopted and larger brakes fitted. A - Smith’s ‘Easidrive’ Automatic transmission was

available as an optional extra. In October 1960 the most important change was the fitting of a hypoid rear axle, and with modifications to the gearbox was known as the Series IIIB. Production commenced at chassis number B1100001. At the same time the Special saloon was replaced by the Minx Saloon, which had a new aluminium grille similar to the DeLuxe model. A better air filter and a larger oil pump were also fitted. Finally in August 1961 the last of the III Series models - the IIIC made its appearance from chassis number BO200001. This made use of a larger 1592 cc engine. Alterations to the suspension comprised the fitting of greaseless nylon inserts on the outer track rod ball joints. The popular centre floor gearchange was standardised on all models. The previous Hillman Minx Series was discontinued and the models were known as the DeLuxe Saloon with a ‘°1600” motif on the front doors. Meanwhile the Husky had continued in production virtually unaltered. In March 1962 the Series 11 model had been introduced. This had a lower roof line and a new radiator grille. In August 1963 the Series V was introduced as a DeLuxe

Saloon

only and was completely

restyled with a redesigned grille and a lower bonnet line. Various improvements were made to the gearbox and suspension and all greasing points were dispensed with. The facia panel was redesigned, separate front seats were added, and disc brakes on the front wheels were fitted as standard equipment. At the same time, a restyled Husky (the Series Ill) appeared with a lower bonnet line and an improved gearbox and greaseless suspension.

The model designations were not changed for the Motor Show in October 1964, but a new all synchromesh gearbox and 7% in. diameter diaphragm clutch were introduced together with a dished steering wheel and redesigned front seats. In September 1965 the Series VI superseded the Series V and although outwardly similar, the new Rootes 1725 cc five bearing crankshaft engine was used. This model can be identified by the Rootes motif low down on the front wings to the rear of the wheel.

Hillman Husky Series II!

Specifications, dimensions, weights, capacities Engine

Type Bore: 1390 cc 1494 cc 1592 cc 1725 cc Stroke: 1390 cc 1494 cc 1592 cc 1725 cc Cubic capacity:

Four cylinder, in-line, overhead valve

3 in. (76.2 mm) 3.11 in. (79 mm) 3.21 in. (81.54 mm)

3.21 in. (81.54 mm) 3 in. (76.2 mm) 3 in. (76.2 mm) 3 in. (76.2 mm)

3.25 in. (82.55 mm) 1390 1494 1592 1724

cc cc cc cc

(84.82 cu (91.17 cu (97.1 cu. (105.1 cu

in.) in.) in.) in.)

Compression ratio: High: 1390 cc 1494 cc 1592 cc 1725 cc Medium: 1494 cc Low: 1390 cc 1494 cc 1725 cc Maximum bhp:

1390 cc (HC) (LC) 1494 cc (HC)

(HC) (LC) (EG) 1592 cc (HC) 1725 cc (HC) early models 1725 cc (HC) later models Maximum torque:

1390 cc (HC) (LC) 1494 cc (HC) (HC)

(LC)

47.5 (net) at 4600 rpm 43 (net) at 4400 rpm 49.2 (net) at 4400 rpm 46.5 (net) at 4400 rpm 46.0 (net) at 4200 rpm 42.0 (net) at 4100 rpm 52.8 (net) at 4100 rpm 65 (net) at 4800 rpm 58.5 (net) at 4200 rpm

with with with with

25 22 25 22

mm mm mm mm ;

choke choke choke choke

69.75 |b ft. at 2400 rpm 66.3 Ib ft. at 2200 rpm 78.3 |b ft. at 2100 rpm with 25 mm choke 73.5 Ib ft. at 1800 rpm with 22 mm choke 73.7 |b ft. at 2000 rpm with 25 mm choke

Specifications, weights, dimensions, capacities

10

i

(EG) 1592 cc (HC) 1725 cc (HC) early models 1725 cc (HC) later models Firing order Valve clearances (hot or cold): All models:

71 |b ft. at 2000 rpm with 22 mm choke 86.8 Ib ft. at 2100 rpm 91.4 ib ft. at 2400 rpm 92.2 |b ft. at 2200 rpm Widen 2

0.012 in. (0.3 mm) 0.014 in. (0.35 mm)

Inlet

Exhaust

Lubrication system (engine) Type Pump type Intake filter Oil pressure, hot Filter type

Sump capacity (total) Refill capacity (approximate)

Wet sump Eccentric lobe

Gauze type 30 to 50 psi at 50 mph Full flow; throwaway type or renewable element - according to model 8 pints (4.5 litres) 7 pints (4 litres)

Ignition system

Type

Coil and distributor

Ignition control: Early Series | models All other models Spark plugs: Minx | and Il; Husky | Later models Series VI models Spark plug gap Static ignition timing (degrees before top dead centre):

Series | and I (HC) (LC) Series !11 (HC)

(LC) Series V and VI (HC) Contact breaker points gap Fuel system: Pump type Pump pressure

Carburettor type: Series | and II! Special from Chassis number A 1986736 Series I! and II! De luxe and Special Up to chassis number A 1986735 Series 111A Series I1I1C and V (manual gearbox) Series V (automatic) Husky | early models Husky | from chassis number

Centrifugal Centrifugal and vacuum KLG FE 50 KLG FE 70A Champion N5 0.025 in. (0.63 mm)

4 to 6° BTDC 4° BTDC

9 to 119 BTDC 10 to 12° BTDC

6 to 89 BTDC

0.015 in. (0.38 mm) Mechanical; lever operated from eccentric on camshaft

1.5 to 2.5 Ib sq in. (0.11 to 0.18 kg/sq cm)

Zenith 30VI or 30VM8 Zenith 30VM8 Zenith 30VIG Zenith 30VN Solex 33PSE 1 Zenith 30VM8

|

Specifications, weights, dimensions, capacities ee TTC A 2824858 and early Series || models Husky II, later models Husky III Minx, Series VI

11

Zenith 30VIG

Zenith 26VME Zenith 30VNN Zenith 341V

Air cleaner type: Minx | to IIIA Minx IIIB, IIIC and V Husky | and II Husky II Minx VI

Gauze Gauze Gauze Gauze Paper

Fuel tank capacity: Series | to I1IC Series V and VI Husky

7% gallons (33 litres) 10 gallons (45.4 litres) 6% gallons (28.4 litres)

or oil bath or paper element or oil bath or paper element element

Cooling system

Type

Pressurized by centrifugal pump; fan assisted

Fan: number of blades diameter drive Radiator type Pressure cap setting (except Series VI) (Series VI) Thermostat setting: Bellows type

4 14.5 in. (368 mm) Vee belt from crankshaft 3 row gilled tube

7 psi (0.49 kg/cm2) 9 psi (0.63 kg/cm2) Opens Fully Opens Fully

Wax type Cooling system capacity: Minx | to I11C; Husky | and III Minx V and VI; Husky II]

at 170° F (76.79 C) open at 185° F (85° C) at 185° F (85° C) open at 200° F (93.3° C)

13% pints (7.5 litres) with heater 12% pints (7.1 litres) with heater

Clutch Single dry plate, hydraulically operated

Type Diameter: Series | and II Series VI and late Series V Other models Pedal free movement (where adjustable)

7% in. (18.4 cm)

7% in. (19.05 cm) 8 in. (20.3 cm) 3/32 in. (2.4 mm)

Gearbox (manual)

Four speed and reverse

Type Synchromesh: Series VI and late Series V Other models Gear ratios:

All forward gears Second, third and top

Top Minx | & Il; Husky | (early models) 1.000:1 1.000: 1 Husky | (later models)

Third 1.491:1 1.516:1

Second 2.471:1 PASS MIEN

First 3.567:1 3.644:1

Reverse 4.757:1 4.615:1

Minx IIIA & 111B; Husky II (early models)

1.392:1

2a

3.346: 1

4.239: 1

Minx I11C; Minx V (early models);

1.000: 1

Specifications, weights, dimensions, capacities ei in

12 a

Ratio: Minx | & Il Saloon & convertible, Minx II, II! & IITA estate cars from chassis number A 1820115, and Husky

| up to chassis number A 2817457 Minx | & Il estate car Minx II; IITA saloon & convertible, Husky | and early II Minx 111B (high compression), Husky 11 (with hypoid axle) Minx !IIB (low compression) Minx IIIC Minx V & VI Husky II (with Zenith 26 VME carb), Husky III

B= NONO Pa TE agg

A221

Steering gear Make

Burman type “’P” or “’F’’, or cam gear Worm and nut or recirculating ball

Type Turns (lock-to-lock):

25 TS

“P” type > eo type Ratio (straight ahead):

“P” ty pe oP type oe type

15.7 14.5 16.4 from chassis number B 0310448

Adjustment: “P” ty pe

Adjusting screw Shims

“F’ type Husky II (later models) and Husky III Minx V (later models) and V1

1.000: 1 1.000:1

Oil capacity: All synchromesh gearbox Earlier gearboxes

3% pints (1.85 litres) 2% pints (1.56 litres)

Automatic transmission (optional on Series V and VI

Type

Torque converter ratio Gearbox ratios

Lubricant capacity (total)

Borg Warner Model 35; hydrokinetic torque converter and planetary gearbox

Infinitely variable between 2:1 and 1:1 High InterLow Reverse mediate 1.000: 1 1.45:1 2.393: 1 2.094: 1 11 pints (6.25 litres)

Rear axle

Type Final drive:

Series | to IIIA Series 111B onwards Oil capacity

Semi-floating Spiral bevel Hypoid 1% pints (1 litre)

Specifications, weights, dimensions, capacities Front suspension

Type

Independent; coil spring, with unequal length wishbones

Castor angle: Series | and early Series I| Later Minx Il onwards Minx estate cars Husky Wheel camber angle King pin inclination Wheel lock angle Toe-in Shock absorbers Hub end float

2° 16° + 15’ 0° 30’+ 15’ 19 40'+ 15’ 20+ 15’ 0° 30’+ 15’ 5° 15’+ 15’ 25° on each outer lock 1/8 in. (3 mm) Telescopic, direct acting 0.002 to 0.007 in. (0.05 to 0.18 mm)

Rear suspension

Type

Live axle with semi-elliptic springs

Shock absorbers: Minx models Husky

Telescopic, direct acting Armstrong hydraulic, double piston type

Braking system

Type Handbrake Front brakes: Minx V and VI Other models Rear brakes (all models)

Wheels and_ tyres Wheel type Size: Minx V and VI Other models Tyres:

Type Size: Husky Minx saloons and Husky from chassis number F 68197 Minx estate cars Minx V and VI Tyre pressures: Series V and VI, front and rear, all conditions Other saioons: Front and rear Rear, fully laden Estate cars and Husky, front and rear

Electrical system Type (except Series VI)

(Series V1) Battery

Lockheed hydraulic Mechanical; to rear wheels only

Disc Two leading shoes Leading and trailing shoe; self adjusting on late models Pressed steel, four stud fixing

4%J5 x 13 45x 15 4 ply ratio, tubeless, cross-ply

5.00 x 15 5.90 x 15

5.60 x 15 6.00x 13

25 Ib/in2 (1.75 kg/cm2)

24 Ib/in2 (1.7 kg/cm2)

26 Ib/in2 (1.8 kg/cm2)

28 Ib/in2 (2.0 kg/cm2) 12 volt, positive terminal earthed 12 volt, negative terminal earthed 38 amp hr

13

Specifications, weights, dimensions, capacities

14

Generator: Minx | to 111, Husky | Later models Drive Control box (except Series V1) (Series VI) Starter motor Lamp bulbs: Headlamps Minx 1; 11; Husky | Minx II! onwards; Husky II Later Minx IIIC; Husky 11 onwards Side and flasher Stop and tail Rear flasher Warning lamps: Ignition Oil pressure Flashing indicators

Beam indicator (where fitted) Rear number plate (except Minx V1) Interior Panel illumination Side (Minx V; Husky III; Minx V1) Front flasher (Minx V; Husky II!) Rear number plate (Minx VI) Reversing lamp (where fitted) Fuses: Dimensions Wheelbase: Minx Husky

Track (tread): Front

Front (Minx Series V and V1) Rear Overall length: Minx Series | Minx Series Il to IIIC Minx Series V and VI Husky

Overall height: Saloon (Minx | to I11C) Saloon (Minx V and V1) Estate car Convertible Husky Series | Series II, III Overall width: Minx Series | to IIIB Minx Series IIIC, V and VI

C39 PV -2 C40 - 1 Vee belt from crankshaft Lucas RB 106/1 or RB 106/2 Lucas RB 340

Lucas M35G/1

Lucas Lucas Sealed Lucas Lucas Lucas

354 12V 42/36 w 414 12V 50/40 w beam unit 50/40 w 380 12V 21/6 w 380 12V 21/6 w 382 12V 21 w

Philips 12829 12V 2w Philips 12829 12V 2w Philips 12829 12V 2 w Philips 12829 12V 2 w Lucas 989 12V 6w , Lucas 254 12V 6 w (festoon) Lucas 987 12V 2.2 w Lucas 222 12V 4w Lucas 382 12V 21 w Lucas 501 12V 5w Lucas 382 12V 21 w 1 or 2 35 amp fuses. (Some models also have 1 10 amp heater blower fuse)

8 ft 0 in. (243.8 cm) 7 ft 2 in. (218.5 cm) 4 ft 1 in. (124.4 cm)

4 ft 3% in. (131.4 cm) 4 ft 0% in. (123.2 cm)

13 ft 4% in. (407.7 cm) 13 ft 6.7 in. (413.2 cm) 13 ft 5% in. (410.2 cm) 12 ft 5% in. (379.8 cm)

4 4 5 4

ft 11% in. (151 cm) ft 10 in. (147.3 cm)

ft 1 in. (155 cm) ft 10 in. (147.3 cm)

5 ft 2 in. (157.5 cm) 4 ft 11% in. (151.1 cm)

5 ft 0% in. (154.3 cm) 5 ft 1 in. (155 cm)

Specifications, weights, dimensions, capacities Husky Ground clearance (unladen): Saloon Estate car Convertible Husky Turning circle: Minx I, early I Minx later Il onwards Husky with Burman ‘’P” type steering Husky with Burman ‘‘F”’ type steering

Weights Weight (approx.) with fuel and water: Minx t (Saloon) Minx I, Il (Estate car) Minx I (Saloon)

5 ft 0% in. (153.7 cm) 7 in. (17.8 cm) 7 in. (17.8 cm) 5% in. (13.9 cm) 6% in. (16.5 cm)

34 36 31 33

ft ft ft ft

3 in. (10.43 m) (10.97 m) 6 in. (9.59 m) 6 in. (10.2 m)

2200 Ibs (998 kgs) 2335 Ibs (1059 kgs) 2142 Ibs (971 kgs)

Minx III, IIIA, HIB (Saloon)

2230 Ibs (1011 kgs)

Minx I, IIIA, IIIB (Estate car) Minx I11C (Saloon) Minx V and VI Minx I11C (Estate car) Husky I, Il Husky III Minx V and VI (Automatic)

2353 Ibs (1067 kgs)

Towing capacity Minx | to 111B, Husky Minx IIIC to VI

2225 Ibs (1009 kgs) 2200 Ibs (998 kgs) 2329 Ibs (1056 kgs) 2080 Ibs (943 kgs)

2061 Ibs (935 kgs) 2240 Ibs (1016 kgs) 15 cwt (762 kgs) max 17 cwt (863 kgs) max

15

Road test data Series |

Series !1

Maximum speed

(mph)

Series I11

Series V

Series V

Series VI

Automatic

82

76

80

80

el

76

87

60 to 65

60 to 70

65 to 75

65 to 75

70

70

70

240 approx.

200 approx.

200 approx.

200

270

240

250

Cruising speed

(mph)

Series IIIA Automatic

Normal cruising

range (miles) approx.

Maximum speed — manual transmis-

sion (mph): First Second Third Top (fourth)

30

27.5 36 60 82

40

38 63 76

87

23

24

22

27

24

25

Acceleration

through gears

(seconds): 0 to 0 to 0 to 0 to Oto

30 40 50 60 70

0 to 80

6.2 11.2 16.8 28.6 =

~

Time for standing

quarter mile (seconds):

23.0

Fuel consumption

- overall (mpg):

31 to a2

Mph at 1000 rpm in top gear:

1622

30

Zt 16.1

17.2

17.45

Tools Having made up your mind that you wish to carry out the maintenance work on the car, a reasonable set of tools will be needed. Broadly speaking, tools can be divided into

two categories - good ones and bad ones; the latter being more of a liability than an asset. Most large towns have at least one factor specialising in tools, so proprietor. He should be what is value for money you will be able to buy

have a talk with the able to advise you on and with a bit of luck something reasonable

without getting the most expensive items he has

got. You may well be worried about the cost, so, if necessary, spread the load over a period of time. The list below should be adequate for the maintenance tasks listed in this handbook:

Set of combination spanners (ring one end, open ended the other) 5/16 to 7/8 in. AF (late models) Set of combination spanners 3/16 to 3/8 in. Whitworth (early models) Set of BA spanners, 2BA - 6BA Adjustable spanner, 10 inch parrot jaw Spark plug spanner Pair of 6 inch pliers Screwdriver - medium 8 inch Screwdriver - crosshead 8 inch Screwdriver - small electrical Brake adjusting spanner Brake bleed nipple spanner Set of feeler gauges File, medium cross cut, with handle

Hand cleanser (eg Swarfega) Overalls Clean, non-fluffy rag

In addition it is also important to keep an adequate supply of the oils, greases, etc, listed in the ‘Recommended lubricants’ Section of this handbook.

Spares and touring pack Before undertaking any long journey, whether in this country or abroad, it is advisable to thoroughly check your car and its contents. It is better to service the car early, before the exact required time if necessary, rather than put it off until your return. Breakdown services, accredited dealers and spare part availability 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 should always be carried in the car and the other suggesting those which it is advisable to carry if undertaking a journey abroad. Some dealers are able to supply manufacturers recommended touring packs on an hire/buy-ifyou-use basis. Always carry This handbook First aid kit and manual Spare set of keys (not in the car) Gallon can of fuel List of car main agents Breakdown triangle (compulsory Continent) Torch, with red flashing dome Fan belt Finilec puncture sealer Roll of PVC insulating tape Temporary plastic windscreen Length of heavy duty lighting cabie

on

the

Spark plug Tyre pressure gauge Tyre pump Jack and handle Wheel brace Distributor rotor, condenser and contact set The tools listed on the previous page Always ensure that the spare wheel is carried and inflated to the maximum pressure which is likely to be needed.

When travelling abroad also carry Tow rope Set of light bulbs Set of spark plugs Set of Schrader tyre valves Set of radiator hoses Radiator sealer (eg Radweld) Set of fuses Length of ignition HT cable Fire extinguisher Tube of gasket cement Tin of Castrol Girling Universal Brake and Clutch Fluid Quart tin of Castrol GTX Cylinder head gasket set Adequate set of maps List of car main agents abroad Any other tools or equipment you think you may need

General information instruments and controls The layout of the facia instruments controls has altered considerably over

Wow

20

2

and the

production run of this series of cars. In general, they are self explanatory, with the accompanying illustrations depicting the various layouts.

22

yp: ee i aw « ames 5

Instruments and controls on Series | and II models (Except Special)

Choke Fuel gauge

Oil pressure gauge (optional) Light switch Speedometer

Clock (optional) Temperature gauge (De-luxe models) Ammeter (optional) Gear lever OONDOARWNH—

Oil pressure warning light (green) Left direction indicator warning light Main beam warning light Right direction indicator warning light

Ignition warning light (red)

15 16 17

Horn ring (central button fitted on Special) Ventilation control lever Gear pattern

Ignition/starter switch Ashtray

Radio (optional) Windscreen wiper switch Instrument light switch Dipswitch Clutch pedal

Steering wheel Brake pedal Accelerator pedal Handbrake

20 Instruments and controls on Series I! Special and Husky models

Steering wheel Horn button Starter switch

Ignition/light switch Windscreen wiper switch Speedometer Direction indicator warning light

Fog light switch (optional) Clock (optional) OODNONDORWN— 10 Choke 11 Interior ventilation contro! 12 Handbrake 13 Dipswitch

14 Clutch 15 Brake 16 Accelerator 17 Direction indicator switch

18 Oil pressure warning light (green) 19 Gear lever

20 Fuel gauge 21 Ignition warning light 22 Gear pattern

Instruments and controls on Series !i1, 1A, 1B and IIIC models

Choke Speedometer Direction indicator warning light Oil pressure warning light Fuel gauge Ignition warning light Main beam warning light ONOOLWNAmmeter and

oil pressure gauge

(optional) 9

Temperature gauge

10 Ignition/starter switch 11 Horn control ring 12 Steering wheel 13 Gear pattern 14 Light switch

15 Clock (optional) 16 Dipswitch 17 Gear lever 18 Ashtray

3

14

1b)

16

18

9

2

19 20 21 22

Clutch Brake Accelerator Windscreen wiper switch

23 Panel light switch 24 Ventilator control 25 Bonnet release

26 Handbrake (beside seat)

Instruments and controls on Series V models

Glove box lock

Ignition/starter switch Choke control Panel lamp switch

Heater control (optional) Clock (optional) Lamps switch Windscreen washer (optional) Windscreen wiper ODNOORWN-

10 Heater blower switch (optional) 11 Headlamp main beam warning lamp 12 Speedometer and trip control

13 Ignition warning lamp 14 Fuel gauge 15 Oil pressure warning lamp

16 Temperature gauge 17 18 19 20 21 22 23

Flasher warning lamp Flasher switch Accelerator Ventilator control Brake Clutch Dipswitch

24 Horn ring 25 Steering wheel 26 Gear lever * 27 Ashtray

* Late Series V models have a gear pattern similar to Series VI models

Instruments and controls on Series V1 models

Glove box lock

Ignition/starter switch 5

——)

6

9

8

7

bY ONNR2BUWS

Choke Pane! light switch

Heater control (optional) Clock (optional) —\

|}

~

Three position light switch

en fra! (soos! jam jos

Heater blower (optional) Windscreen wiper/washer control OMNOOARWNH—

——= Q Sa

Column change

Dire

22

10 Left direction indicator warning light 11 Temperature gauge 12 Ignition warning light 13 Speedometer

14 Main beam warning light 15 Oil pressure warning light 16 Right direction indicator warning light 17 Fuel gauge 18 Horn ring 19 Dipswitch

20 Oil pressure gauge (optional) 21 Ammeter (optional) 22 Ventilator control 23 Direction indicator switch

22

General information

Bonnet lock A bonnet lock is fitted to all models, and comprises either, an external lever which can be moved to one side to release the bonnet on to the safety catch or a pull control beneath the parcel shelf. Once released, the bonnet will lift a little to permit the fingers to enter and release the safety catch.

General running instructions When starting an engine from cold, ensure that the gear lever is in neutral and the handbrake is on, then pull out the choke control to its maximum position. Once the engine has fired and started to run it may be possible to push the choke in a little; this will give a smoother tickover and economise on petrol. As soon as possible after starting, the choke should be pushed fully home in stages. A warm engine will not require the use of the choke, although the accelerator pedal should be depressed slightly until the engine fires, then released. If a very hot engine is difficult to start, do not pump the accelerator pedal, but depress it fully until the engine fires; it can then be released. When ‘running-in’ a new or reconditioned engine it is important not to allow the engine to be overloaded or to be revved excessively

during the first 500 miles (800 km). After this period the engine speed can be increased progressively over the next 500 miles. The maximum recommended speeds during the first

il

cee

500 miles (800 km) are:

First gear

10 mph (15 km/h)

Second gear Third gear Top (fourth) gear

15 mph (25 km/h) 25 mph (40 km/h) 40 mph (65 km/h)

Jacking up the car and changing a wheel Unless completely impracticable, always jack up with the car on level ground, with the handbrake applied and if possible chock the wheels which are to remain on the ground. Whenever it is required to remove a wheel, initially, prise off the hub cap, then slacken the wheel nuts slightly before jacking up. Next, position the jack in the appropriate square section recess at the front or rear of the vehicle and lift the car as necessary. The wheel nuts can be fully removed once the car is raised and the wheel then removed. When refitting the wheel, initially pinch the wheel nuts up with the car raised then lower the car, and finally, tighten the nuts with the car on the ground. Note that

The front jacking position

on some models, the wheels will have to be positioned to align the brake adjustment holes with those on the drums. If the car is to be raised to gain access to the underside of the car it is important to use ramps, axle stands or a chassis jack for your own safety.

Heating and ventilating Although many cars in this range were not fitted with heating and ventilating controls as standard equipment, those which were so equipped had a layout similar in style to the one illustrated. In addition to these controls, a booster fan can be incorporated to provide — airflow when the car is stationary. Refer to the illustration captions for the key to the control positions.

General information

23

SCREEN

el ==> OFF

A AAMAN

LORE

ie

SWE he SEW

SCREEN

HEAT

SCREEN

& CAR

Typical heater controls Heater and ventilation off

Ventilation (unheated air) QwpD> Warm

D E

Hot air Windscreen de-icing

air

Vehicle identification Whenever spare parts or accessories are required, it is important that certain information is given to the dealer in order that the correct parts can be supplied. This information is normally limited to the full chassis number and the engine number.

The chassis number, including the suffix and

prefix letters are on a plate fixed to the engine

side of the scuttle or to the bonnet lock platform; the plate is visible from inside the bonnet. The engine number is stamped on the lefthand side of the cylinder block.

Automatic transmission With the Borg-Warner model 35 automatic transmission, driving is considerably simplified. Since the normal clutch peda! and gear lever are eliminated there remain only the accelerator and brake pedals to operate. After starting, gear changing is automatic in accordance with road speed and the drivers requirements. The transmission is operated from a floor or steering column mounted lever. A small window adjacent to the lever depicts the layout of the various selections, and is marked “L’’, “DD, “nj iis “R oo and

Dee

R-Reverse — This is used to reverse the vehicle.

PPark —In this position the transmission is locked and must only, therefore, be engaged when the car is stationary and the handbrake applied. This position should also be used when making adjustments which involve running the engine.

=

=

S

ae

L-Lock up — This position is used to hold low or intermediate gear which may be advantageous when travelling over rough or wet ground, icy roads or when descending steep hills using the engine as a brake.

D-Drive — This is the position used for all normal driving. Gear changing is automatic according to the position of the accelerator pedal and the demands made by the driver. N-Neutral — No power is transmitted rear wheels in this position.

to the

lever

ALTERNATIVE POSITION FOR LEVER IN N

TLOWRP \ ere

on

Coiumn mounted automatic transmission selector lever

Later floor mounted automatic transmission selector lever

Automatic transmission Operation (later types) To engage L, R, or P the safety button in the end of the T lever handle must first be depressed although the lever can be readily moved between D or N. The button must also be depressed before the lever can be shifted from P.

Operation (earlier types) The column mounted selector levers or early floor mounted selector levers are spring biased and require to be moved as shown in the illustrations for the appropriate selection.

Starting the engine Starting is carried out in the normal manner with the brake applied firmly. The starter switch will operate with the selector lever at either N or P. If the engine stops, the selector lever must be returned to N or P before attempting to start it again.

Selecting L- D-N-RorP P or R must not be selected whilst the car is in motion. When at rest do not select D, Lor R unless the engine is running at idling speed. Always ensure the brake is on before moving

the selector lever if the engine is running. Excessive ‘creep’ will occur when the brakes are released, if D, L or R are selected above idling speed.

Driver controlled change-down (kickdown) As long as the car speed is below the maximum attainable in low or intermediate

can be change down gears, an immediate obtained by fully depressing the accelerator pedal. This method of changing down provides more pulling power or acceleration and gives up-changes at higher road speeds.

Lock up This position is used to hold the transmission in low gear, for maximum engine braking, providing that it is selected before moving from rest or at road speeds of less than 5 mph (8 kph). If L is selected when in high gear an immed-

iate change down to intermediate will occur at

road speeds over 5 mph (8 kph). The transmission will then remain in intermediate to provide moderate engine braking and when the

25

speed is reduced below approx. 5 mph (8 kph) will automatically change down to low gear. If low gear is required at higher speeds, it may be obtained at speeds below 20 mph (32 kph) by momentarily fully depressing the accelerator with the selector lever in L. Intermediate can be obtained by selecting L (without resorting to ‘kickdown’) but this should not be done above 50 mph (80 kph) except in extreme emergency.

Driving on an upgrade Under prolonged heavy load conditions on an upgrade, L should be selected to engage the indirect gears, thereby increasing the engine cooling fan speed when at reduced road speed. Too high an engine speed in the indirect gears should be avoided wherever possible. Towing - caravans or trailers For towing, the automatic transmission fluid cooler and the fluid temperature gauge must be fitted, as it is important that the transmission fluid does not overheat. The temperature gauge

covers the range from 70° C to 180° C. 1 Temperatures up to 120° C are

quite

normal. 2 Provided that the temperature does not exceed 135° C it is safe to drive for short periods. The vehicle should be stopped and

checked if the temperature determine

the

cause

reaches 135° C to

(eg misuse,

lack of fluid

etc). 3 Never allow the temperature to exceed 140° C as damage to the transmission will result. Emergency starting An emergency tow-start may be obtained by initially selecting N, then, when at speed of approximately 25 mph (40 kph) with the ignition ‘on’ and choke control set, selecting L.

Driving out of mud, sand or snow if D and R are selected alternately, with a moderate throttle opening, thus rocking the car backwards and forwards, a good rear wheel grip can be obtained.

Towing - by another vehicle Unless the transmission is defective the car can be towed with N selected, provided that the fluid level is correct. If the transmission is defective the propeller shaft must be removed and the rear end of the transmission sealed to prevent ingress of dirt or water.

26

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27

Lubrication

KEN \ | oat, LAS

Chart

Biprn , ———_e--

SUSPENSION LINK BUSHES SUSPENSION BALL JOINTS

iS

TRACK ROD AND LINK

STEERING UNIT REAR AXLE

FRONT WHEEL HUB

Routine

maintenance

In this section the various points which require attention are listed. They are presented as an initial summary list with the procedure and any special instructions immediately following. Wherever reference is made to draining oil, it is always beneficial to give the car a warming-up run immediately before commencing. This allows the oil to thin down, and is therefore more easily drained. Before removing any filler caps or drain plugs, the surrounding area should first be cleaned to prevent ingress of dirt. Do not forget that any containers used for collecting oil must be of adequate capacity for the particular purpose. Don’t forget that whenever the car is to be jacked up for any reason at all, it should be on a level surface, the handbrake should be on, the road wheels which will remain on the ground should be chocked and adequate supports should be placed beneath the car. Refer also to ‘jacking up and changing a wheel’ in the ‘General information’ Section of this handbook.

Maintenance summary

1 Weekly, or before a long journey Check Check Check Check Check

the the the the the

engine oil level radiator coolant level battery electrolyte level windscreen washer reservoir level tyre pressures

NO OhWNH— Every 1,000

1 Check levels

miles (1600 km) or monthly

the brake and clutch

2 Lubricate suspension

the

steering

reservoir fluid

linkage

and

front

(early models only, where grease

nipples are fitted) 3

Lubricate the propeller shaft universal joints (early models only where grease nipples are

fitted)

3 Every

3,000

miles

(4800

km)

or

three

months

1 Change the engine oil and renew the filter (applicable to cars using monograde oil or where the car is being used for very short journeys and does not warm up properly) 2 Adjust the brakes/check the pads (as applicable) 3 Check the tyres for unequal wear and general condition, and the wheel nuts for tightness Check the level of oil in the steering gearbox Check the level of oil in the gearbox (manual and automatic) Check the level of oil in the rear axle Lubricate the distributor OD own at Lubricate the pedal pivots, door hinges, boot and bonnet hinges, steering column, gear change mechanism (where fitted), carburettor linkage and pivots, handbrake cable, etc. 9 Check the clutch pedal adjustment (where applicable) 10 Inspect the hydraulic pipes for deterioration 11 Inspect the fuel pipes for deterioration 12 Inspect the cooling system hoses for deterioration 13 Check the operation of all controls, warning lights, windscreen wipers and washers, etc. 14 Road test the car a

Every 6,000 miles (9600 km) or six months

1 Change the engine oil and renew the filter 2 Change the oil in the gearbox (manual gearbox only) 3 Change the oil in the rear axle 4 Inspect the condition of the brake linings 5 Clean and tighten the battery terminals 6 Clean the spark plugs 7 Clean the contact breaker points 8 Check the ignition timing

9 Check the valve/rocker clearances 10Clean

the

fuel

pump

filter

and

sediment

Routine maintenance bowl 11 Clean/renew the air cleaner element 12 Adjust the engine idling speed 13 Lubricate the dynamo rear bearing 14 Check the fan belt tension 15Check the seat belts and their anchorage points 16 Check the exhaust system for leaks 17 Check the suspension/steering nuts for tightness 18 Check for wear in the balljoints and swivel pins of the steering and front suspension 19Clean all dirt, oil and mud from the ventilation slots, grille and sump on the automatic transmission (where applicable) 20Check that the door drain holes are unobstructed 21 Check the fluid level in the rear shock absorbers (Husky models)

5 Every months

12,000

miles

(19200 km) or twelve

1 Fit new spark plugs 2 Fit new contact breaker points 3 Check the end-float of the front hub bearings and re-lubricate 4 Check the tightness of the propeller shaft universal joint flange bolts, rear spring attachment bolts and shock absorber mounting bolts 5 Check the handbrake adjustment 6 Check the headlamp alignment

6 Every 24,000 miles (38400 km) or two years 1 Clean the commutators

of the dynamo and

starter motor 2 Renew the rubber parts in the braking system and renew the hydraulic fluid.

Using dipstick to check engine oil level

29

Procedure 1 Weekly, or before a long journey

1 Check the engine oil level, which should be maintained at, or near, the “MAX” indication on the dipstick. Top up as necessary using

Castrol

GTX

or monograde

oil if this is nor-

mally used. The dipstick is located on the spark plug side of the engine, between the distributor and the oil filter. 2 When the engine is cold check that the coolant level is approximately % inch below the radiator filler neck. If possible use rain water for topping up. If the level is to be checked when hot, use a large piece of rag and turn the cap slowly anti-clockwise to the stop. Once the steam has stopped escaping, press the cap slightly then continue turning and pull it off. In this instance the coolant should be up to the level of the filler neck. 3 Check the battery electrolyte level and, if necessary, add distilled water only to bring the electrolyte just above the tops of the separators. 4 Top up the windscreen washer reservoir as necessary, then check that the operation is satisfactory. 5 Check that the tyre pressures are in accordance with those given in the Specifications Section. Whenever possible use your own gauge and periodically check its accuracy with that of somebody else; garage tyre pressure gauges are not noted for their accuracy.

2 Every 1,000 miles (1600 km) or monthly 1 Check the fluid level in the brake and clutch master cylinder reservoirs and top up if neces-

sary, to within

half an inch of the top using

Adding oil to restore correct level

30

Routine maintenance

Castrol Girling Universal Brake and Clutch Fluid. The reservoirs are situated on the bulkhead of the engine compartment on the same side of the car as the brake and clutch pedals. Note: If the fluid level has fallen considerably

since

the

last

check,

carefully

inspect the system for leakage. 2 On early cars, where grease nipples are fitted to the suspension link bushes (five nipples), suspension balljoints (two nipples), track-rod (three nipples) and track link (three nipples), give three or four strokes of a grease gun charged with Castrol LM Grease to each nipple (Castrol Hi-press gear oil may be used as an alternative). 3 On early cars, where grease nipples are fitted to the propeller shaft universal joints, give three or four strokes of a grease gun charged with Castrol LM Grease to each nipple (Castrol Hi-press gear oil may be used as an alternative).

3

Every

3,000

miles

(4800

km)

ENGLAN’

IF

Hydraulic fluid reservoirs/master cylinders

Plan view of the steering linkage

1

Steering unit

2

Drop arm

3

Relay lever

three

1 Where a monograde engine oil is being used, or where a car is being used on short and stop/ start journeys, drain the engine oil into a suitable container. When all the oi! has ceased to flow out, clean the drain plug and around the sealing face of the sump, renew the sealing washer if its condition warrants it then refit the plug firmly. Next, unscrew the oil filter but be prepared for some oil spillage. If the element can be renewed, clean out the canister and fit the new element. Whichever type of filter is in use, lightly smear the sealing faces with engine oil then fit a new sealing washer and then the new item to the car. 2 Where front disc brakes are fitted, check the thickness of lining material remaining on the pads. If this is down to 1/16 in. (1.6 mm), or is likely to be down to this thickness before the next 3,000 miles (4800 km) check, the pads should be renewed either by a Chrysler agent or by reference to the Haynes Owner’s Workshop

LocKHEey€0

MADE

or

months

4 5 6

Track rod (cross tube) Outer track rod Steering arm

Routine maintenance

31

Manual for the Minx. Where drum brakes are fitted (except for the self-adjusting rear brakes fitted to some later models), the adjustment is Carried out from the outboard side of the drum by inserting a screwdriver through the holes in the brake drum (one hole per drum for rear brakes). In some cases this can be done without ‘removing the road wheel. Raise the appropriate front road wheel and if necessary remove it. Turn the drum or wheel to align the holes with the adjusters then insert a screwdriver and turn each adjuster clockwise until solid resistance is felt. Next turn each adjuster back one notch or

until

the

wheel/drum

can

just

be

rotated

without the shoes rubbing. The procedure for the rear brakes is similar, except that only one

adjuster is fitted. 3 Raise each road wheel in turn and check the tyre for bulges, cracks, cuts and evenness of wear. At the same time, remove any stones from the tread before they can work their way through the cover and cause a puncture. Even if the tread wear is apparently satisfactory it is a good idea to interchange the wheels (not if fabric belted radials are fitted), to even up the

Sump drain plug (A) and gearbox drain plug (B)

Brake adjustment through the wheel

32

rad .

©

Rll:

;

ote

oe

6.

1

ak

Baer h

Si Ns: eas Peas

saat

Heavy

tread wear in centre of tyre: inflation

Caused by over

Heavy

tread wear on outer edge of tyre: Caused by § under inflation

Each of the drawings in this page illustrates wear which is symptomatic of incorrect tyre pressures or mechanical

steering/suspension faults. All three are dangerously worn beyond the legal limit. It is unnecessary and uneconomical for this type of wear to take place. The causes of this type of wear can be rectified before damage takes place if the tyres are checked regularly. If in doubt about the condition of your tyres consult a garage or tyre specialist. .

Uneven caused

tread wear: The drawing above illustrates wear by excessive wheel toe-in/toe-out (usually

accompanied

by ‘feathering’ of tread edges),

or by

excessive wheel camber

Patches

of tread wear

(not illustrated)

in seemingly

random positions around the tyre circumference are caused by one, or more, of the following — Wheel imbalance; Worn shock-absorbers; Faulty brake drums or disc.

Routine maintenance i overall wear using one of the methods shown in the illustration. Where any serious wear is occurring it is important to consult your Chrysler dealer without delay since a chassis frame or suspension alignment problem is indicated. On completion, check that the wheel nuts are tight. 4 Check the oil level in the type F (see Specifications) steering box and top up if necessary to the level of bottom of the filler plug orifice. The rubber filler plug must be wiped clean when removed and firmly fitted after topping up. The recommended lubricant is Castrol Hypoy oil. Where a type P (see Specifications) steering unit is fitted, apply several strokes of an oil gun

33 t———C—C®W

(charged with Castrol Hi-press) at each of the nipples.

5 Manual gearbox: Where a steering column gear change is fitted there is a combined dipstick/filler plug on the top of the gearbox. On floor change models, there is a filler/level plug on the right-hand side of the gearbox. Each type is accessible via, a rubber plug in the raised section of the floor. Top-up as necessary, either to the full mark on the dipstick or to the filler/level plug height. For floor change models, apply a few drops of engine oil to the points indicated by arrows in the illustration. For steering column change models refer to paragraph 8. Use the same grade of oil as is being used in the engine for topping-up purposes. Rubber filler plug 7?

“SAS | Ss

% ’ QW LLL LLLLL

Suggested alternative methods of interchanging the wheels to equalize tyre wear

The type “F’’ steering unit

OIL

FILLER/LEVEL

PLUG

OIL NIPPLE OIL NIPPLE

The type “’P”’ steering unit

Floor change gearbox lubrication points

Routine maintenance

34

Automatic gearbox: In order to check the fluid level in the automatic transmission, first run the car for about 5 miles (8 km) then select P and allow the engine to idle for approximately 2 minutes. With the engine still running remove and wipe clean the dipstick. Refit and check fluid level with the engine still running at idling speed. Top up to “HIGH” level if necessary, but do not overfill. If frequent topping up is required, the advice of a Chrysler agent should be sought. 6 Check the level of oil in the rear axle and top up if necessary with Castrol Hypoy. 7 Apply two or three drops of engine oil to the top of the distributor contact breaker cam after removing the cap and rotor. Apply two or three drops of oil to the advance and retard mechanism through the lubrication hole in the baseplate, and a light smear of Castrol LM Grease or petroleum jelly to the cam profile. Refit the rotor and cap on completion.

8 Using engine oil or Castrol

Underside of automatic transmission unit showing

cooling ducts (arrowed)

Everyman Oil,

apply a few drops to all the door, hood, boot and bonnet hinges and catches, the seat adjusters, pedal pivots, carburettor linkage and pivots, and the handbrake cable pivots and adjusters. Where a steering column gear change is fitted, apply a few drops of engine oil at the points indicated by arrows in the illustration. Where lubricator nipples are provided on the handbrake cables apply two or three strokes of a grease gun charged with Castrol LM Grease. 9 Where an adjustable type clutch is fitted it should be adjusted to provide approximately

3/32 in. (2.4 mm)

of free movement

at the

outer end of the withdrawal lever. This can be carried out by slackening the locknut at the back of the fork on the outer end of the withdrawal lever and turning the piston rod. Tighten the locknut when the adjustment is satisfactory.

10Carefully examine all the rigid hydraulic pipes for corrosion and dents, and the flexible hoses for bulges, cracks and chafing. If any defective or suspect pipes are found they must be renewed without delay either by a Chrysler dealer or by reference to the Haynes Owner's Workshop Manual for the Minx. 11 Examine the pipes in the fuel system as described for the hydraulic system previously. 12 Inspect all the hoses of the cooling system for cracks and general deterioration, renewing any which are defective or suspect. 13Check the operation of all lights, controls,

Rear axle lubrication

Routine maintenance warning lights, windscreen wipers and washers, horn, dashboard instruments, direction indicators, accessories, etc. to ensure that everything is functioning satisfactorily. This will need to be carried out in conjunction with the Road Test in the next paragraph. 14The purpose of the Road Test is to ensure that the car is in a thoroughly roadworthy condition. Find a deserted stretch of road and brake sharply to check that the brakes pull evenly. Listen for any squeaks and rattles, and check that those controls which have not previously been checked, are operating correctly. When you have finished your run bring the -———

car to rest using the handbrake only, checking that it does not have to be pulled up to its mechanical stop. Now have a last look round in the engine compartment and underneath for any signs of oil or water leaks. If possible leave the car standing for a few hours as any leakage will then be more prominent. 4

Every 6,000 miles (9600 km) or six months

1 Drain the engine oil and renew the oil filter. The procedure for this is given in Section 3, Paragraph 1. 2 Where a manual gearbox is fitted drain the

CAP CARBON BRUSH (RADIO SUPPRESSION) ROTOR ARM MOVING

ft-hand rear lamp Adjacent to right-hand rear lamp

6 7 8 9 10 11

Left-hand wing valance Right-hand wing valance

Under facia near steering column Under facia on right-hand side

Adjacent to wiper motor Adjacent to left-hand horn

72

STantTeR

STOP LAurs FLASHER RH

TAIL LAMPS LH.

FLASHER

BaTTery {[-a

C2

Fa ae]

SovenciO.

§Y

ees)

N

pas)

STOP LAme Swircr

2)

DOoR

IH SCREENWIPER

Pucar

T

Switch

on

[ev

ae

oO

wae

5

9

Pane Rw

SswitcH

IGNITION STARTER

8 Sw

wR

SCREENWIPER

OisTRIBUTOR

cow

SIDELAMP

RA,

HEAOL AMP

RH

HEAOLAMP

FLASH

SwiTcr.

HEADLAMP

WIRING

OF

RH,

HEADLAMP

HEADLAMP

FLASH

LH.

SW.FOR

L.HO.

Wiring diagram, Minx Series V (early models)

Locations of snap connectors

Upper left-hand corner of luggage compartment Beneath facia at left-hand side Adjacent to control box At rear of left-hand tail lamp moowWw > At rear of right-hand tail lamp

E G H 4 K

On left-hand wing valance (front) On right-hand wing valance (front) Beneath facia at right-hand side Adjacent to rear of speedometer Beneath facia adjacent to steering column

73

|

jy| Ga iN ta i| A Oo 8]

Co Henao

i

e

Or

:

;

SG

.

aa

HeaoLame LH

SIDELAMPL-H

Wiring diagram, Husky Series III (early models)

Locations of snap connectors At rear of left-hand tail lamp cluster A At rear of right-hand tail lamp cluster B Beneath facia of left-hand side Cc On front wing valance at right-hand side D

G) a im

Beneath facia adjacent to steering column On front wing valance at left-hand side Under bonnet adjacent to control box Adjacent to instrument at rear

74

SToP Lames FLsBHER

RH./

STARTER

Tak Lamps.

FLASHER

SOLENOID.

un

zl

| GNITION

&

STARTERS

~v.

wR

x oN

Ko)

SPEECOMeETER:

©) nN

a

bere ey

Sioce

1

SS

|

SIOELAMP RH.

HEAGLAMO RH

HOPNC

HEACLAMPLH.

sice.

SIDELAMPL.H.

Wiring diagram, Husky Series I!1 (later models) Locations of snap connectors At rear of left-hand tail lamp cluster At rear of right-hand tail lamp cluster

Beneath facia at left-hand side OOBWyOn front wing valance at right-hand side

E F G H

Beneath facia adjacent to steering column

On front wing valance at left-hand side Under bonnet adjacent to contro! box Adjacent to instrument at rear

75 STOP

FLASHER

Léurs

TAIL

;

RH

FLASHER

mi

arta

SsvTaeteR

LAMPS

—

LH.

.-

ae

ics nebo

SOLENDIO

ATTER

°

Ream we [I] i,

et

STOP

|

-\~¥ \

Nn

we

Lame

Switcre

ScREeNWwIPER SwmitTce

W/UIGHT

(GAZELLE Ont)

IGNITION

9

STARTER

Sw

9-

2] |nTEROR

ScCame

&

switcr

HEADLAMP

FLASH

Seg

8 FLASHER

}

vf if

ip ee

Boh

NG

OYuAMoe

a

sic ;

&

\

:

&

SiICEL AMP RH

.

aE

inelialSa

HEAOLAMP RH

swirce

russe Switers

HEAL AMP LH

HEaOr

WARMING

SiOecame LH

Ame

LIGHT

o.r

HEADLAMP

WIRING

OF

AH

HEADLAMPS,

Wiring diagram, Minx Series V (later models) Locations of snap connectors Upper left-hand corner of luggage compartA ment

B Cc

Beneath facia at left-hand side On front wing valance at left-hand side

D E F

G

On front wing valance at right-hand side Beneath facia at right-hand side Adjacent to instruments at rear

Beneath facia adjacent to steering column

76 STOP Lamps FLASHER

RH

ps

FLASHER

LH

STARTER

tela

SOLENOID

/

O'L PRESSURE SwitcCH ©) wr

STOP

LAMP

pet

DooR PILLAR Switch LH

R

eS

ONy

Tes

tes

IGNITION

STARTER

SIDELAMP RH.

-HEADLAMP RH

HEADLAMP

FLASH SWITCH.

ae ciade iy

HORN

LH

HEADL AMP LH.

SIOELAMP LH.

Swircn HEACL

WARRING

HEADLAMP

WIRING

B

Sw

RH

HEADLAMP

OF HEADLAMPS,

AMP

LIGHT

LH,

Y/LIGHT & FLASHSW FOR

L.H.O

Wiring diagram, Minx Series V1 (floor gearchange)

Locations of snap connectors A Top left-hand corner of luggage compartment B Left-hand side of facia (6 Left-hand side front wing valance B R

Black Red

G U

Green Blue

N Ww

D E F

G

Cable colour code Brown White

Right-hand side front wing valance Right-hand side of facia Behind facia near speedometer

Steering column cowl P Ye

Purple Yellow

77 TAR LAMPS

STOP Laws

Flagver RH

FLASHER

SrartTem

SoLEncio

LH

Wiring diagram, Minx Ser ies VI (column gearchange) see previous page) (For location of snap connectors and Cable colour code

Fault

finding

charts

How to use the fault finding section The fault finding section has been compiled to help the owner deal with two very different sets of circumstances. The most annoying and frustrating type of fault is when the car will not start or when it breaks down on a journey. For this there is an elimination chart that goes methodically through various tests. The other type of fault is the worrying kind: odd noises, or the car not going properly. These have been tabulated under the heading of the symptom. Even if you cannot rectify one of these latter faults, you must at least be able to find whether it is safe to continue. The following main groups have been used to separate the information:

The Chart Engine stoppage

The Tables General engine faults Electrical failures Clutch defects Brake defects Running problems

Engine stoppage: the road

It will not start, or stops on

1 There are many possible defects, so finding the cause will be difficult, and nigh impossible,

unless a logical course is followed. 2 From statistical surveys of causes of a large number of breakdowns, it is apparent that the ignition system is more often to blame than the petrol system. The fault finding sequence therefore aims to eliminate the fuel system at an early stage. 3 Failure to start from cold is usually a combination of damp and dirt on the ignition system, and that system anyway giving a weak spark because of overdue maintenance, all aggravated by a weak battery. 4 Therefore it may be misleading to treat a car’s failure to start as a definite defect. On a cold damp day it is often best to try a push Start before going into the fault finding sequence. The slightest lack of verve in the way the starter spins the engine should therefore be

interpreted in the chart as ‘starter cranks sluggishly’. 5 In the stoppage chart reference is made to various tests. These are listed after the chart.

Engine stoppages: with chart

tests for use in conjunction

TESTS OF THE IGNITION SYSTEM Test 1.1 Check ignition HT at a plug

a) Switch on ignition b) Take an HT lead off a plug c) Hold metal contact of the fitting on the end of the lead 1/8 inch from a bright metal ‘earth’ such as the cylinder head. If the plug lead fitting has a shroud to cover the plug, stick a % inch bolt into the contact asa probe. d) Operate the starter e) There should be an easily noticeable spark

Fault finding SS

a

a

Test 1.2

f) Continuous sparks mean there is current flow to somewhere; thus a faulty rotor arm

Ignition HT at source a) If possible take the central ‘King’ lead from the distributor cap and hold it 1/8 inch from earth and repeat as for test 1. b) If the king lead is not readily detachable from the distributor cap, remove it from the coil and rig up a temporary lead. Test 1.3

a) Remove distributor cap b) Ignition switch on

contact

breaker

points with

a thin

screwdriver or if the engine has stopped so that they are already open, short them with the screwdriver. d) There should be a small but definite spark. Test 1.4 Check the rotor arm

a) This test is to see if there is a short through the body beneath

of

the

rotor

arm

to

TESTS OF THE PETROL SYSTEM Test P.1 Fuel flow into carburettor

a) Remove the fuel pipe where it enters the carburettor. b) Crank engine with ignition switched off c) Fuel should gush out of the pipe.

Check ignition LT at contact breaker

c) Open

79

a

the

spindle

b) Rig up the ‘king’ lead as for test 1.2, or a substitute lead c) But hold the lead, not to the block, but near the centre of the metal contact on the top of the rotor arm d) Operate the starter e) There should be only one small spark as the metallic mass of the rotor arm contact is electrically charged and then no further sparks

Test P.2 Check fuel flow into the pump a) This is difficult to check as the pump draws fuel up by suction b) Remove the pipe into the pump from the tank c) Suck on the end of the pipe and find if petrol can be drawn up, but ensure petrol does not get into the mouth. Ideally lengthen the pipe with some clear plastic tubing so that the flow of petrol can be seen coming. If by mischance fuel gets into the mouth spit it out at once then rinse the mouth with cold water. d) If petrol cannot be drawn up by sucking try blowing. Having an assistant listen at the tank for the bubbling of the blowing. If there is resistance at first, and then it eases, it could be that the blowing has pushed out a blockage e) Also, whilst the pipe is off the pump inlet, crank the engine using the starter motor and feel for suction at the pump inlet using a finger.

Engine wil

a

Starter

does NOT turn

Starter

cranks sluggishly or will not

engage Ignition warning light goes dim

Ignition warning light stays bright

Or Out, Or never came on

Starter or wiring

Flat battery Get push start Recharge battery

fault

Loose battery terminal.

Clean and tighten

———— ' SPARK Fuel checks Check flow into float

chamber:

FLOW

(Test P.1)

NO FLOW

Clean carburettor

Remove pipe at pump outlet and switch on ignition

NO FLOW

aoe eae

Check at pump

Inlet (Test P.2)

SUCTION ry but NO

-

“FLOW

i

FLOW

i

but no suction

Check filler cap breather

to tank

Piosae

carburettor blocked:

clear

Check pipes back

FLOW

Remove

Check pump

and clean

Starter cranks

engine well

Engine stops On the road

Recheck controls: Ignition on?

Choke?

Foolish faults:

Fuel in tank? Engine soused by floods? Ignition leads fallen off? Parts left off on assembly? Carburettor flooding: float stuck?

Ignition on, use starter:

Check HT spark at plug lead

ee

(Test 1.1)

ee

ae NO SPARK I

Check HT spark at king

]

lead from coil (Test !.2)

Check ignition timing

NO SPARK

SPARK Check distributor cap for

visual check of all leads

cracks, dirt, moisture Check

Check rotor arm

LT flash at c.b.

(Test 1.3)

(Test 1.4)

FLASH

NO FLASH

Visual check of c.b. components and cleanliness of points

Trace back down wiring to eliminate wiring fault or

|

Check points actually open and close as

engine turns

Change condenser

coil failure

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Metric conversion

tables

Millimetres

0.0254 0.0508 0.0762 0.1016 0.1270 0.1524 0.1778 0.2032 0.2286 0.254 0.508 0.762 1.016 1.270 1.524 1.778 2.032 2.286

Inches

( : : : 4 t P H : é d ‘ ‘ ; . : 1 .

Millimetres

2.54 5.08 7.62 10.16 12.70 15.24 17.78 20.32 22.96 25.4 50.8 76.2 101.6 127.0 152.4 177.8 203.2 228.6 254.0

Torque Wrench Settings Kgm

WN OANOAOHKWN OOOO —

0.138 0.276 0.414 0.553 0.691 0.829 0.967 1.106 1.244 1.382 2.765 4.147

Kgm

— OOAONMNOAHRWNH

Metric Conversion Tables

Distance Kilometres

Kilometres

1.61 3.22 4.83 6.44 8.05 9.66 11.27 12.88 14.48 OONODOFPWNH— 16.09 32:49 48.28 64.37 80.47 96.56 112.65 128.75 144.84 160.93

— OONOORPWNH

Capacities au 3 a

Litres

Pints

1.76

0.57 1.14 1.70 2.27 2.84

OMANOORWN—

OMNOOPWNH— —_oO — —s

_ NO

Gallons

Litres

Litres

Gallons

4.55 0.22 0.44 0.09 13.64 0.66 18.18 0.88 22.73 1.10 1.32 27.28 31.82 1.54 36.37 1.76 40.91 OOnNOOPWN— 1.98 45.46 2.20 50.01 4.40 54.56 WN QDOOCOOONOOPW 6.60

Metric Conversion Tables

Tyre Pressures Ib/sq in

Kg/sq cm

Ib/sq in

0.07 0.14 0.21 0.28 0.35 0.42 0.49 0.56 — OAONODOARWNH 0.63 0.70 1.41 2.11

14.22 28.50 42.67 56.89 Fiasi2 85.34 99.56 113.79 128.00 142.23 284.47 WN OCOOOCOOONOOAWNH— 426.70

Inches

Decimals

Millimetres

1/64

0.0156 0.0313

0.3969 0.7937

0.0625

1.5875

3.1750 4.7625 6.3500 7.9375 9.5250 11.1125 12.7000 14.2875 15.8750 17.4625 19.0500 20.6375 22.2250 23.8125

Index A Air cleaner - maintenance - 40 renewal - 40 Anti-freeze - 47 Automatic transmission - data - 12 fluid level - 34

general description - 24

B Battery - electrolyte level check - 29 maintenance - 37 Bodywork - cleaning - 51 hood repairs - 58 lubrication - 34 minor repairs - 53, 54 MOT test check - 60 paint spraying - 55 paint touch-up - 52 rust holes repair - 53 rust prevention - 52 steam cleaning underside - 51 Bonnet lock - 22 Braking system - adjustment - 31, 45 bleeding - 46 data- 13 defects - 96 drum inspection - 37 hydraulic fluid renewal - 45 hydraulic fluid topping-up - 29 hydraulic pipes check - 34 juddering - 99 maintenance - 30, 37 MOT test check - 59 pads check - 30 pedal feels spongy - 96 poor stopping ability - 96

Bulb - renewal - 47, 50 Buying - 61

C Carburettor - adjustment - 42 faults - 83 Carpets - cleaning - 51 Chromium plating - cleaning - 52 Clutch - adjustment - 34 data - 11 defects - 94 fails to disengage - 94 hydraulic fluid topping-up - 29 hydraulic pipes check - 34 slips - 94 squeal - 94 Compression ratio - 9 Contact breaker points - renewal - 44 Controls - 19 Cooling system - coolant level check - 29 data - 11 draining - 46 filling - 47 flushing - 47 hoses check - 34 loss of coolant - 85

D Dimensions - 15

Distributor - contact gap adjustment - 37 faults - 85 lubrication - 34 maintenance - 34, 37 Dynamo - lubrication - 43 maintenance - 45

a

Sa

E Electrical system - data - 13 fault finding - 91 Engine - data - 9 excessive mechanical noise - 89 excessive oil consumption - 89 fails to warm-up - 88

Index

109

et

| Ignition - timing - 38 Ignition system - data - 10 fault finding - 78 wiring diagram - 82 Instruments - 19

fault finding - 83 lack of power - 83 low oil pressure - 90 lubrication system - 10 misfires - 85

oil changing - 30, 35 oil level check - 29 overheats - 85 ‘pinks’ - 88 stalls - 83 starting - 22 stoppage - 78

Jacking-up - 22

L Lights - bulb renewal - 47, 50

fault finding - 91 MOT test check - 59 Lubricants - recommended - 26 Lubrication chart - 27

F Fan belt - adjustment - 43 Fault finding - brakes - 96 clutch - 94

M Model identification - 7 MOT test - 59

chart - 80/81 electrical system - 91 engine - 83 fuel system - 79 ignition system - 78 steering - 100 Front hubs - maintenance - 44 Fuel pump - maintenance - 39 Fuel system - data - 10 fault finding - 79 pipes check - 34

G Gearbox (manual) - data - 11 oil changing - 35 oil topping-up - 33 Gearshift mechanism (column change) adjustment - 50

H Handbrake - adjustment - 45 lubrication - 34 Headlamp - beam alignment - 45 bulb renewal - 47 Heater controls - 23

History of marque/models - 7 Hood repairs - 48

O Oil changing - engine - 30, 35 gearbox - 35 rear axle - 37 Oil filter - renewal - 30, 35 Oil leaks - 89 Oil pressure - low - 90

Pedal rubbers - 51 Performance data - 16 Petrol system - fault finding - 79 Propellor shaft - lubrication - 30

R Radiator - coolant level check - 29 Rear axle - data- 12 oil changing - 37 oil topping-up - 34 Road test - after maintenance - 35 data - 16 MOT test - 60 Routine maintenance - summary - 28 Rust prevention - 52

110

Index S

Transmission judder - 100 Tyre pressures - 13, 29 Tyres - check - 31

Seat belts - 43, 59 Selling - 63

Shock absorbers (Husky) - lubrication - 44 Spares - ordering - 23 to carry - 18 Spark plugs - faults - 36 maintenance - 37 renewal - 44 Starter motor - maintenance - 45 Steering - fault finding - 100, 104 lubrication - 30, 33 maintenance - 43, 44 MOT test check - 59 Steering gear - data - 12 Suspension - data - 12 lubrication - 30 maintenance - 43, 44 T

Thermostat - faults - 88 Tools - 17 Touring pack - 18

type - 13 :

U Upholstery - cleaning - 51

Vv Valve/rocker clearances - adjustment - 38 Vehicle identification - 23 Ventilating controls - 23 Vibration - 100

Ww Weights - 15 Wheel changing - 22 Wheels - type - 13 Windscreen washer - MOT test check - 59 topping-up - 29 Wiring diagrams - 65 - 77

111

Castiol 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 API MS requirements and manufacturers’ specifications. Castrol GTX with liquid tungstent generously protects engines at the extreme limits of performance, and combines both good cold starting with oil consumption control. Approved by leading car makers.

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 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 Castro! 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. Castrol Grand Prix

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

A premium SAE 30 motor oil possessing good detergency characteristics and corrosion inhibitors, coupled with low ash forming tendency and excellent anti-scuff properties. it is suitable for all two-stroke motor-cycles, and for two-stroke and small four-stroke horticultural machines.

Castrol Hypoy B (90 EP)

Castrol Medium

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

A medium consistency calcium based grease.

gearboxes and rear axles.

A heavy consistency calcium based grease.

Castrol 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 Heavy

Castrol Graphited Grease

Castrol D (140)

A graphited grease for the lubrication of

A heavy full-bodied gear oil with fortifying additives.

transmission chains.

Castrol Thio-Hypoy FD (90 EP)

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

A light-bodied powerful extreme pressure gear oil. This is a special oil for running-in certain hypoid gears.

Castro! Under-Water Grease

Anti-Freeze Castrol Anti-Freeze Automatic Transmission Fluids

Castrol TOF

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

(Automatic Transmission Fluid)

Castrol CR (Multi-grade) A high quality engine oil of the SAE-20W /30 multi-grade type, suited to mixed fleet operations.

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

Castrol TO Dexron®)

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.

(Automatic Transmission Fluid) Complies with the requirements of Dexron(®) Automatic Transmission Fluids as laid down by General Motors Corporation.

Speciality Products

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

Castro! CRB 20, 30 Primarily for diesel engines, heavily fortified, fully detergent oils, covering the requirements of MIL-L-2104B.

Castrol Penetrating Oil Castrol Greases

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

Castro! R 40

Castrol LM

Primarily designed and developed for highly stressed racing engines, Castrol ‘R’ should not

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

A light-bodied solvent oil, designed for

applications including chassis and wheel bearing lubrication.

gearcasings.

be mixed with any other oil nor with any grade of Castrol. +Ligquid Tungsten is an oil soluble long chain tertiary alkyl primary amine tungstate

covered by British Patent No. 882,295.

Castro! Gear Oils

flushing engines, rear axles, gearboxes and

Castrol MS3

Castrollo

A high melting point lithium based grease containing molybdenum disulphide.

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

Castrol BNS

Castrol Hypoy (90 EP)

A high melting point grease for use where

A light-bodied powerful extreme pressure gear oil for use in hypoid rear axles and in some

recommended by certain manufacturers in front wheel bearings when disc brakes are

gearboxes.

Castrol Solvent Flushing Oil

fitted.

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

Titles in the Haynes Owners Handbook/Maintenance Manuals Series

Austin Austin Austin Austin BLMC

A35 and A40 (101) A60 (172) Allegro (142) Maxi (075) 1100/1300 (042)

BLMC 1800 (105) BLMC Mini (041) Fiat 850 (168) Fiat 128 (176) Ford Anglia 105E/123E

(045)

Ford Capri 1300/1600 (063) Ford Corsair 1500 (065) Ford Ford Ford Ford Ford Ford

Corsair Cortina Cortina Cortina Escort Transit

V4 (100) Mk 1 (046) Mk 2 (056) Mk 3 (099) (057) (144)

MGB (146) MG Magnette IV (173) Morris Marina (O66) Morris Minor 1000 (058) Morris Oxford V1 (173) Sprite/Midget (143) Reliant Regal (147) Renault 12 (177) Renault 16 (175) Riley 4/72 (172)

Rover 2000 (151) Triumph Herald (O60) Triumph Spitfire (148) Triumph 1300/1500 (077) Triumph 2000, 2.5 PI (102) Vauxhall Viva HA (059)

Vauxhall Viva HB (043) Vauxhall Viva HC (064)

Ford Zephyr Mk IV (103)

Vauxhall Victor FB (061) ©

Hillman Hillman Hillman Hillman Hillman

Vauxhall Victor 101 (FC) (149) Vauxhall FD (076) Vauxhall Victor FE (104) VW Beetle (106) Wolseley 16/60 (173)

Avenger (062) Hunter/Minx - (1966 on) (145) Husky Series | to II! (174) Imp (044) Minx Series ! to 1V (174)

More titles are in preparation

A full range of Owner’s Workshop Manuals also is available from the publishers

Although every care has been taken to ensure the correctness of data used, it must be berne in mind that alterations and design changes can occur within the production run of a model without specific reclassification. No liability can be accepted for damage, loss or injury caused by errors or omissions in the information given.

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SERVICE

APPROVED AND dance

%

Ail Hillman Minx Series | to V! and Husky Series | to III models from 1956 This

Maintenance

Manual/Owners

Handbook

is for all Minax/Husky

owners

who want to reduce their motoring costs, enjoy reliable trouble free motoring, extend their car's life and maintain its resale value. Written specifically for the

Minx/Husky owner the contents show you how to maintain and service all models correctly to help give safer, more enjoyable motoring. A further advantage is that by doing your own maintenance you will dramatically reduce your motoring bills and not waste time while your car is in the garage. Minor repairs are carefully explained -even inexperienced amateurs can follow everything clearly. Extensive fault finding charts pinpoint troubles and will-help-get-—— you moving if you cannot start, or break down. There. is also a complete section showing how to check and prepare your Minx/Husky for ithe MoT test. Specifications, road test data, production history, model identification and ‘how to buy a good used Minx/Husky ‘are also included. 28 Carry this book in your car and it should save you its modest ConRmeny times over.

0 ac 174. 4