Haynes Rover 2000 Owners Handbook/Maintenance Manual 0856961515, 9780856961519

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Owners Handbook/Maintenance

D.I.Y.

Manual

SERVICE

APPROVED AND RECOMMENDED

VER

Fioutine Maintenance 0 MOT Preparationo Fauit Finding

Repairs

by P. Ward

~9 MAY 1977 25, Ju. 1977

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BOOK No.

46000188

must be returned on or before the date shown to the Library from which it was borrowed

LANCASHIRE COUNTY LIBRARY CORPORATION STREET, PRESTON,

UU EU

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above

aan ms

9

4

Rover 2000 Covers all models 1963 onwards Owners

Handbook

Maintenance

Manual

by P Ward

HAYNES

7Op

N6000188 Acknowledgements Special thanks are due to BLMC (Rover) 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 ©s H Haynes and Company

Limited 1973

Published by J H Haynes and Company

Sparkford, Yeovil, Somerset “Set in 10 point IBM Univers Medium Printed in England

SBN

O 85696

151

5

Limited

Contents Introduction Model Identification

Specifications, Dimensions, Weights,

Capacities

Road Test Data Tools Spares and Touring Pack Lubrication What you need to know about your car Routine Maintenance

Other Maintenance

Bodywork - Maintenance, Cleaning and minor repairs

45

Preparing your Car for the MOT Test

51

Sane and Selling a used Rover 2000

53

Wiring Diagrams

58

Fault Finding

71

Metric Conversion Tables

103

Index

106

Aemejng Buimesp 40 943

4aA0y 000Z

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 over three years old are subject to the official roadworthiness test. Details of what the tester will be looking for, and how to check them yourself are given, along with guidance in looking at secondhand cars. 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

Workshop

work,

Manual

a very useful Owners

is available

from

the

publishers, or through all good accessory shops

or booksellers.

42004 000ZDS

Model

Identification

The Rover 2000 was introduced in October 1963. It has a 1978 cc chain driven single overhead camshaft engine with a five main bearing crankshaft, which drives the rear wheels via a remotely controlled four-speed all synchromesh gearbox and hypoid geared final drive unit. September 1966 saw the introduction for the UK market, of a more powerful version designated TC and an Automatic model embodying the proven Borg-Warner model 35 transmission system. Minor changes to various components have been introduced throughout the production run but the first body restyling was carried out in September 1970. The car is a four seater luxury saloon, with all wing panels and mechanical components bolted to a chassis skeleton. Hide upholstery, protective bodywork undersealing, radial tyres and hydraulically operated disc brakes on all four wheels are standard equipment. Suspension is independant at the front and semi-independent at the rear, with unsprung weight being kept to a minimum by mounting the final drive unit to the base frame. A De Dion tube is used.

IL 0007 42004

Specifications, Dimensions, Weights and Capacities Engine Bore Stroke Number of cylinders Cylinder capacity Compression ratio BHP (gross) Firing order Spark plugs

8.57 crn (3.375 in.) 8.57 cm (3.375 in.) Four 1978 cc (120.8 cu. in.) 9.0: 1 (TC: - 10.0: 1)

99 (TC: - 124) at 5500 rev/min Sythe &

Spark plug gap Ignition timing (static and dynamic at 550 to 600 rev/min) Ignition timing (static and dynamic at 700 to 750 rev/min) Fuel octane rating Tappet clearance, cold (inlet) (exhaust)

Champion Champion Champion 0.60 mm

N9Y N6Y N7Y (0.025

(SC and Automatic) (TC before Sept. 1970) (TC after Sept. 1970) in.)

4° BTDC (SC and Automatic) 6° BTDC (TC) 95 - 97, 4star (TC:- 100, 5 star) 0.20 mm (0.008 in) 0.30 mm (0.013 in)

Oil pressure (warm engine)

3.5 to 4.2 kg/cm2 (50 to 60 Ib/sq in) at 30 mph

Lubrication Oil filter, internal Oil filter, external

in top gear Full pressure Gauze pump intake filter in sump Full flow, replaceable canister

Clutch Type

Gearbox Type

Automatic transmission (where applicable) Type Torque converter

Gearbox

Hydraulically operated diaphragm spring, single dry plate, 215 mm (8.5 in) diameter

4 speed and reverse, with synchromesh forward speeds

on all

Borg-Warner model 35 Three element, hydrokinetic with infinitely variable torque multiplication between 2:1 and 1:1 Torque-speed responsive, hydraulically operated planetary gear set with three forward speeds

and reverse

Specifications, Dimensions, Weights and Capacities

10 Gear ratios Top Third Second First Reverse

4 speed 1.0: 1 iesoeat Pies Wein 3.62: 1 3.43: 1

Overall ratios Top Third Second First Reverse

3.54: 4.92: 7.55: 12.83: 12.14:

1 1 1 1 1

High Intermediate Low Reverse

Automatic 1.0:1 1.45: 1 2.39: 1 2:09 "1

High Intermediate Low Reverse

3.54: 1 5.13: 1 8.46 :1 Teal

Final drive unit

Type Ratio

Hypoid crownwheel and bevel pinion 3.54: 1

Propeller shaft

Type Fuel system Fuel pump Carburettor

Air cleaner

Cooling system Type Pressure cap setting Early models Later models Fan belt adjustment Electrical system Type

Battery voltage Battery capacity Dynamo* Type Current voltage regulator

Type Alternator* Type Output control unit Type Field isolating relay Type Alternator warning light control Type

Open, Hardy Spicer with one lubrication point

AC mechanical Single SU type Twin SU type Twin SU type Paper element

HS6 or HD8 or HS8 (late models) type

Pressurised, with pump, fan and thermostat

5 Ib/in2 (0.35 kg/cm2) 7 Ib/in2 (0.5 kg/cm2) 8 to 11 mm

(0.312 to 0.437 in) free movement

Positive earth (cars prior to suffix letter D) Negative earth (cars with suffix letter D onwards, and TC) 12 volt 60 AH at 20 hour rate

Lucas C42—22910

Lucas RB340—37517 Lucas 11AC Lucas 4TR

Lucas 6RA Lucas 3AW

Specifications, Dimensions, Weights and Capacities SL I ga a

11

ee

Alternator *

Type

Lucas 18 ACR

*denotes alternative charging systems Starter motor

Inertia type

M418G—25521D (SC) or M45G—26164A (TC) LU M418G (Automatics)

Pre-engaged type Windscreen wiper Type

Lucas 6W wards)

Screen washer Type

Lucas

Mixture control thermostatic Makes contact at Breaks contact at

type

Distributor

contact

breaker

Front suspension Type

from

suffix letter D on-

4SJ

switch

51 to 55°C (124 to 131°F) 410. 63°C: (47-10. 127°°)

Ignition system Coil type Distributor

(or DL3A

gap

Lucas HA12 (SC and TC) Lucas BA7 or 16C6 (Automatics) Lucas 25D4 41085, vacuum advance unit 54411462 (TC) Lucas 25D4 41119, vacuum advance unit 54411589 (SC and Automatic) 0.014 to 0.016 in (0.35 to 0.40 mm)

Independent

leading

link with

horizontal

coil

spring

Rear suspension Type

Semi-independent coil tube and Watts linkage

spring

with

De

Dion

Suspension dampers Type

Hydraulic, telescopic, non-adjustable

Steering Type Ratio Front wheel alignment

Adamant hour-glass worm and roller followers 20.3: 1, 3.75 turns lock to lock

Braking system Type Front brakes Rear brakes Handbrake

3.0 mm (0.125 in) toe-in

+ 1.6 mm (0.062 in)

Hydraulically operated with vacuum servo, selfadjusting Dunlop or Girling outboard discs Dunlop or Girling inboard discs Mechanical linkage, self-adjusting, with separate pads on Dunlop system or integral with rear footbrake on Girling system

12 a

ee

Specifications, Dimensions, Weights and Capacities NE NH SHELTER alas Se Neer ee anne ae

Wheels Type

Sm

5J x 14 in, steel disc. (Wire spoke wheels have

been available as an option) Tyres

Size Pressure, normal loads fully loaded

165 x 14 radial ply only

26 Ib/in2 (1.8 kg/cm2), front 28 Ib/in2 (1.9 kg/cm2), rear 26 Ib/in2 (1.8 kg/cm2), front 32 Ib/in2 (2.2 kg/cm2), rear

Bulbs Inner headlamp Inner headlamp (after Sept. 1970) Outer headlamp Side lamp Side lamp (after Sept. 1970) Stop/tail lamp Direction indicator lamp Rear number plate lamp Rear number plate lamp (after Sept. 1970) Instrument panel light Instrument panel lights (SC, after Sept. 1970) Instrument panel lights (TC, after Sept. 1970) Warning lights Warning lights (suffix D onwards) Warning lights (SC, after Sept. 1970) Warning lights (TC, after Sept. 1970) Interior lights, festoon bulb Interior light (after Sept. 1970) Map reading lamp Map reading lamp (after Sept. 1970) Clock Reverse lamps

Rear luggage boot lamp Tachometer Switch panel, festoon bulb Selector light (automatic transmission) Selector light (after Sept. 1970) Hazard warning light Heated rear window switch light

LU54522973, 37.5W sealed beam unit Lucas 12V 75W sealed beam unit

LU54521806, 50/37.5W sealed beam unit Lucas No.989, 6W Lucas No.233, 4W Lucas No.380, 6/21W Lucas No.382, 21W Lucas No.989, 6W Lucas 233, 4W Lucas No.987, 2.2W Lucas No.984, 3.6W 12V , 2.2W capless Lucas No.643, 2.2W Lucas No.984, 3.6W Lucas No.643, 2.2W 12V, 3W capless Lucas No.254, 6W Lucas No.272, 10W Lucas No.254, 6W Lucas No.233, 4W Lucas No.281, 2W Lucas No.382, 21W Lucas No.209, 6W Lucas No.987, 2.2W Lucas No.254, 6W Lucas Lucas Lucas Lucas

No.254, 6W

No.256, 3W No.281, 2W No.281, 2W

Dimensions

Overall length

4.55m).(14 ft 1123 in) SGC 4.59 m (15 ft 0.5 in), TC

Overall width Overall height Wheelbase Track, front Track, rear Ground clearance Turning circle

1.68m (5 ft 6 in)

1.4 m (4 ft 7.25 in) 2.63 m (8 ft 7.38 in) 1.35 m (4 ft 5.38 in) 1.33m (4 ft 4.5 in) 21.6 cm (8.5 in) 9.6 m (31.5 ft)

Specifications, Dimensions, Weights and Capacities Weights With water, oil and 22.5 litres (5 gallons) of ) fuel

Roof rack load, maximum Towing weight, maximum Capacities Engine sump (including filter) Extra for oil cooler (where fitted) Gearbox (manual)

) )

1245 kg (2774 Ib), SC 1282 kg (2827 Ib), TC 1267 kg (2793 |b.), Automatic Transmission

50 kg (112 Ib) 1250 kg (2800 Ib)

Reserve supply

9 pints (4.5 litres) 1 pint (0.5 litres) 1.75 pints (1.0 litre) 11.25 pints (6.4 litres) 2.25 pints (1.25 litres) 12 gallons (55 litres) 1.25 gallons (6 litres) early models

Cooling system

2.5 gallons (12 litres) later. models 14 pints (8 litres)

Gearbox (automatic) including oil cooler Final drive unit Fuel tank (including reserve)

13

42A0y4 00029S

auibua

14

Road test data Maximum speed (mph) Cruising speed (mph) Cruising range (miles) Maximum speed in gears: 3rd 2nd 1st

Rover 2000 SC 99 85 285 83 55 31

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

mph mph mph mph mph

Standing % mile (seconds) Average fuel consumption (mpg) Consumption at 50 mph (mpg)

4.3 6.7 9.7 13.6 19.6 19:35 22.9 36

Rover 2000 TC 109 95 260 88 60 34

Tools To carry out the routine maintenance tasks

in this book you will obviously need a reasonable set of tools. A really comprehensive tool kit will be expensive to purchase at one go most home mechanics have built up a kit over the years as they have tackled new and more complicated maintenance and repair work. This way the cost is spread out. Remember though, it does not pay to buy cheap tools; they may break and damage yourself and the car. Tool factors are to be found in most towns, so talk things over with the proprietor. Tell him you are not interested in buying rubbish and he will think more of you and tell you what is value for money. The following list suggests the tools required to undertake the work detailed in this book, so when you've got them, keep them together where you know they can be found (preferably in the car); you sometimes need them at the most inconvenient times:— Set of combination spanners (ring one end,

open ended the other) to cover the range 5/16 to % inch AF Open ended spanners 2 to 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 bleed nipple spanner Set of feeler gauges File, medium cross-cut, with handle Hand cleanser (Swarfega) Overalls Clean, non-fluffy rag Besides this list, always keep an adequate supply of the oils, greases, etc, which are listed in the 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 for your Rover 2000 are not always there when you need them, particularly abroad and in outlying districts of Great Britain. The following lists of spares and touring packs indicate firstly those which should always be carried in the car, and secondly those which it is advisable to carry if undertaking a journey abroad. Some dealers are able to supply manufacturers recommended touring packs on a hire/buy-if-you-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 Rover 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 cable

on

the

Spark plug (at least one) Tyre pressure gauge

Tyre pump Jack and handle Wheelbrace Distributor rotor, condenser and contact set The tools listed on the previous page. Additionally, always ensure that the spare wheel is in the car, inflated to the maximum pressure you are likely to need (see specifications). Also carry, when going abroad:The items listed under ‘Always carry’ Tow rope Spare set of light bulbs Set of spark plugs Spare schrader valves Set of radiator hoses Radiator sealer Set of fuses Length of ignition HT cable Fire extinguisher Tube of gasket cement Tin of Castrol Girling Universal Clutch and Brake Fluid 1 quart of GTX oil Cylinder head gasket set Any additional tools you think you need Adequate set of maps List of Rover main agents abroad.

may

18

Lubrication chart

EVERY 750 MILES ENGINE Check level and, if necessary, add

sufficient Castrol GTX to bring level up to “H” mark on dipstick.

EVERY 5,000 MILES ENGINE After the first 1,000 miles, and thereafter every 6.000 miles. or four months, _ whichever occurs first. drain the old oil while warm and refill with fresh Castrol GTX in summer and winter. NOTE :—At engine oil change also drain the oil cooler. (neve 2000 TC only.) Owners are reminded that in the car

maker's handbook more frequent sump

EVERY 10,000 MILES Including 5,000 mile service FRONT

WHEEL

draining periods are recommended if the operation of the-car involves :-— (1) Frequent stop/start driving. (2) Operation during cold weather, especially when appreciable engine idling is involved. (3) Where much driving is done under dusty conditions. Capacity—9 points + 1 pint for filter—

2000 TC

8 pints +1 pint for filter—2000 SC and Automatic models.

HUBS

Check front hubs for leakage.

This may

be seen at disc shield or inside wheel rim. Should any leakage be apparent your Rover Distributor or Dealer should

be notified immediately. Cestrol LM Grease should be used for repacking.

MANUAL GEAR BOX (if fitted) Cneck level and replenish if necessary. with Castrol GTX to the bottom of the filler plug hole. The filler and level plug is accessible through an inspection hole on the side of the gearbox cover.

STEERING BOX: Check level and, if necessary, add sufficient Cestro!l Hypoy Gear Oli to bring level

After the first 1 miles, and thereafter every 20,000 miles, drain off the old oil while it is warm and refill with fresh Castrol GTX. Capacity :—1# pints.

up to the bottom of the filler plug hole

PROPELLER

SHAPT

With the grease gun apply Castrol

LM Grease to lubricate the sliding spline.

DE DION TUBE Check level and, if necessary, add pews GTX to the bottom of filler plug hole

FINAL DRIVE UNIT Check level. preferably after a run when the oil is warm and. if necessary, replenish to the bottom of the filler plug hole with

REAR

WHEEL

HUBS

Check hubs for signs of leakage at flange adjacer | to drive shafts at rim of wheel flange. Should any leakage be apparent your Rover Distributor or Dealer should be notified immediately. Castrol LM Grease should be used for replenishing

Castrol Hypoy Gear Oil. After the first 1,000 miles, and thereafter every 20,000 miles drain the old oil while it is warm, and refill with fresh Cestrol Hypoy Gear Oll. Capacity—approximately 24 pints.

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What you need to know about your car The main instruments and controls are of the conventional form and are laid out in either of two basic ways. All models manufactured up to September 1970 and subsequent SC’s and Automatics have a rectangular instrument cluster mounted on the facia above the steering column. TC models manufactured after September 1970 have similarly positioned circular controls which include additionally an ammeter, tachometer and oil pressure gauge. It is not considered necessary to detail all the controls, instruments and warning lights since the majority are self explanatory. Those, however, which do require some explanation, together with certain other features, are listed in the following paragraphs. Front seat adjustment Front seat adjustment is effected by lifting the locking bar for fore and aft movement, and by depressing the locking lever to permit repositioning of the reclining back-rest.

Automatic transmission

controls (where applic-

able) General description The Borg Warner type 35 automatic transmission unit may be fitted as a factory production optional extra to models covered by this handbook. Cars produced before October 1966 did not have automatic transmission offered as an optional extra. The system comprises

two

main

placed between the two front seats and controls the operation of the automatic transmission. There are six positions marked on the quadrant and these are:- ‘P’, ’R’, ‘N’, ‘D2’, ‘D1’ and ‘L’. As a safety factor to prevent accidental engagement it is necessary to depress the button in the centre of the selector lever to engage all positions, except between ‘D2’ and ‘D1’. Also the lever can be moved from ‘L’ to ‘D1’ or ‘D2’ and from ‘R’ to ‘N’ ~ without depressing the button. ‘P’ This is the park position, whereby no engine torque is transmitted to the driving wheels and the transmission is locked by mechanical means. For safety reasons it is recommended that this position be used for tuning or adjustment. Serious damage will result if this position is selected whilst the car is moving. ‘R’ Reverse position, whereby the car can be driven in reverse. To assist control, full engine braking is available. As with the ‘P’ position it is important not to select ‘R’ whilst the car is moving forwards. ‘N’ This is the neutral position, whereby no engine torque is transmitted to the driving wheels. Always apply the handbrake when the selector lever is in the ‘N’ position and the car is stationary.

‘D2’

com-

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Three quarter front view of Base Unit Note: Shaded panels are non-serviceable

Three quarter rear view of Base Unit Note: Shaded panels are non-serviceable

101

Layout of ‘Three Can’ Exhaust System (3rd type) SC models

102

Layout of ‘Three Can’ Exhaust System

(4th type)

Layout of ‘Two Can’ Exhaust System (5th type) SC, TC and Automatic models

Metric Conversion Tables

Inches

Millimetres

0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09

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

Torque Wrench Settings

Kgm

— AWN SCOMOOANOO

885

=SSCBYHFHMAWA

88s

Metric Conversion Table

Distance Kilometres

Kilometres

1.61 3.22 4.83 6.44 8.05 9.66 11.27 12.88 14.48 16.09 32.19 48.28 64.37 80.47 96.56 112.65 128.75 144.84 160.93

80 90 100

— OONOOARWN

Capacities

Litres

0.57 1.14 1.70 aH 2.84 3.41 3.98 4.55 5.11 QO = OMAN OA2WDND 5.58 6.25 6.82

Litres

Pints

1.76 3.52 5.28 7.04 8.80 10.56 12.32 14.08 — OOONOOfhWN

—

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4.55 0.09 13.64 18.18 22.73 27.28 31.82 36.37 40.91 — WNH OS OMNOA 45.46 50.01 54.56

Gallons

0.22 0.44 0.66 0.88 1.10 12s2 1.54 1.76 OMDONONAPWN 1.98 2.20 4.40 6.60

105 Metric Conversion Table

Tyre Pressures Ib/sq in

nN —

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Kg/sq cm

Kg/sq cm

Ib/sq in

14.22 28.50 42.67 56.89 FAA 85.34 99.56 113.79 OANDOAWN128.00 142.23 284.47 426.70

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

Decimals

Millimetres

0.3969 0.7937 1.5875 BsH750 4.7625 6.3500 7.9375 9.5250 LAA25 12.7000 14.2875 15.8750 17.4625 19.0500 20.6375 22.2250 23:02 5

Index A Air cleaner - replacement - 34, 39 Anti-freeze - 27 Automatic transmission - controls - 21 data - 9

downshift cable setting - 34 driving technique - 21, 24 fluid level check - 31 normal driving conditions - 23 special driving conditions - 23 starting the engine - 23

B Battery - faults - 84 - maintenance - 37 Bodywork - cleaning - 45, 46 - lubrication - 38 - minor repairs - 47 - paint touch-up - 46 - rust prevention - 47 - steam cleaning underside - 45 Braking system - bleeding - 41 - checking for wear - 37, 38, 51 - data- 11 - fault finding - 89 - fluid level warning switch - 31 - fluid reservoir topping up - 31

-

front caliper (Girling) - 92 general information - 27 layout (Dunlop) - 90 layout (Girling) - 91

Bulbs - 12, 42 Buying - 53

Cc Capacities - 13 Carburettor -

adjustment - 34 air intake (TC) - 27 damper dashpot lubrication - 34 faults - 76 general lubrication - 38 SC models - 77

Carpets - cleaning - 45 Choke control - 25 Chromium plating - cleaning - 46 Cigar lighter - 25 Clutch - data - 9 - fault finding - 87 - fluid reservoir topping up - 31 Compression ratio - 9 Controls - 20, 25 Coolingsystem ~- data- 10 - draining -'42 - filling - 42 - flushing - 42 - loss of water - 79 Crankcase breather filter - maintenance - 39

D De Dion tube - lubrication - 38 Dimensions - car - 12 Direction indicators - 25 Distributor - contact points servicing - 35 - faults - 80 - lubrication - 37

Dynamo - lubrication - 34 - Lucas C42 - 85

E Electrical system - data - 10

Engine

-data-9 - excessive mechanical noise - 81 - excessive oil consumption - 80 - fault finding - 72, 73 - lack of power - 76 - misfires - 78 - overheating - 78 - pinking - 80 - stalling - 76 - stoppages - 71 Exhaust system - checking - 38

Index F

O

Facia- 20 Fan belt - adjustment Fault finding - brakes - clutch - engine

Oil changing

- 39 - 89 - 87 - 72, 73 - fuel system - 74 - ignition system - 71 - steering - 98 Final drive - lubrication - 31 - oil changing - 40 Flame trap - replacement - 39 Flasher light - 42 Fuel pump - maintenance - 40 Fuel reserve - 25 Fuel system - data - 10

G Gearbox - data - 10 - lubrication - 31 - oil changing - 40

H Handbrake - checking - 37 - lubrication - 38 Hazard switch - 25 Headlamps - alignment - 40 - dipper - 25 - flasher - 25 - removal - 42 Heating syste, - 26

History of marque/models - 7 Horn - 25

| - 44 - data - 11 - fault finding - 71 - wiring diagram - 75 Instruments - 20, 22 Interior light switch - 25 Ignition - timing Iynition system

J Jacking points - 27

Lights - bulb replacement - 42 - checking - 51 - failure - 84 Lubrication chart - 18

M Model identification - 7 MOT test - 51

Oil leaks - 80 Oil pressure - low - 81

Pp Panel light switch - 25 Performance data - 15 Propeller shaft - lubrication - 34

R Rear light - 42 Road test - after maintenance - 38 - data- 15 - MOT test - 52 Routine maintenance - safety - 29 - weekly - 29 Rust prevention - 47

S Seat belts - 26, 38, 52 Seats (front) - adjustment - 21, 22 Selling - 55 Side light - 42 Spares - ordering - 28 - to carry - 17 Spark plugs - faults - 78 - maintenance - 35 - replacement - 39 Steering - checking for wear - 51 - column adjustment - 22 - column lock - 24 - data - 11, 97 - fault finding - 98 - lubrication - 39 - maintenance - 37, 39 Suspension - data- 11 - front - 95 - rear - 94

T

L

Lubricants - recommended

- engine - 30 - final drive - 40 - gearbox - 40

- 19

Tachometer - 25 Thermostat - faults - 79, 80 Tools - 16 Touring pack - 17 Transmission - judder - 96 Tyres - checking for wear - 38 - data- 12 - pressures - 12 - wear - 99

108

Index

U Upholstery - cleaning - 45

V Vehicle identification - 28 Ventilating syste, - 26 Vibration - 96

WwW Warning lights - 25 Weights - car - 13 Wheels -changing - 27 - type- 12 Windows - heated rear - 25 Windscreen washers - 25, 52 Windscreen wipers - 25, 44, 52 Wiring diagrams - 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70

109

Castfol craves Castrol Engine Oils

Castrol Gear Oils (continued)

Castrol GTX

Castro! Hypoy Light (80 EP)

Castrol CL

An ultra high performance SAE 20W/50 motor

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.

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 cald starting with oil consumption control. Approved by leading car makers. Castrol XL 20/50 Contains liquid tungstent; well suited to the majority of conditions giving good oil consumption control in bath new and old cars.

Castrolite (Multi-grade)

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 gearboxes and rear axles,

A medium consistency calcium based grease.

Castrol Hi-Press (140 EP)

Castrol PH 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)

Castro] motor oil family containing liquid tungstent. It is best suited ta ensure easy winter starting and for thase car models whose manufacturers specify lighter weight oils.

A light-bodied gear oil with fortifying additives

An SAE 50 engine oil for use where a heavy, full-bodied lubricant is required. Castrol Two-Stroke-Four A premium SAE 30 motor oil possessing good detergency characteristics and corrosion

inhibitors, coupled with low ash forming tendency and excellent anti-scuff properties. It is suitable for all two-strake motor-cycles, and for two-stroke and small four-stroke horticultural machines.

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

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

Castrol Graphited Grease

Castrol D (140)

Castrol R 40 Primarily designed and developed for highly stressed racing engines. Castrol ‘R’ should not be mixed with any other oil nor with any grade of Castrol. tLiquid Tungsten is an oil soluble long chain tertiary alky/ primary amine tungstate covered by British Patent No. 882,295.

Castrol Gear Oils Castrol Hypoy (90 EP)

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

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.

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

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

(Automatic Transmission Fluid) Complies with the requirements of

Speciality Products

Castrol Girling Damper Oil Thin

The oil for Girling piston type hydraulic dampers.

Castrol Shockol

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

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.

Castrol Greases

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

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

Castrol Heavy A heavy consistency calcium based grease,

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

This is the lightest multi-grade oil of the

Castro! Grand Prix

Castrol Greases (continued)

Castrol Penetrating Oil

Castrol LM A multi-purpose high melting point lithium based grease approved for most automotive applications including chassis and wheel bearing lubrication.

Castrol Solvent Flushing Oil

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

Castrol MS3

Castrollo

A high melting point lithium based grease containing molybdenum disulphide.

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

Castrol BNS A high melting point grease for use where recommended by certain manufacturers in

front wheel bearings when disc brakes are fitted.

Everyman Oil

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

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