Haynes Simca 1100-1204 Owners Handbook Maintenance Manual 0856961701, 9780856961700

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

https://archive.org/details/simca110012040wn0000ward

Simca lOO/1I204. Covers all Simca 1100 and

1204 models from 1967 on

Owners Handbook /Maintenance Manual

by P. Ward

HAYNES

46001384x Acknowledgements Thanks are due to many people for their help and enthusiasm in the production of this handbook. Special thanks are extended to Castrol Limited for advice on lubrication.

A Handbook in the Haynes Owners Handbook and Maintenance Manual Series Edited by Stanley Randolph (c) J H 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

O 85696

170 1

Limited,

Contents Introduction

Model identification

Specifications, dimensions, weights, capacities Road test data Spares and touring pack Lubrication chart Automatic transmission General information Tools

Routine maintenance Other maintenance Bodywork - maintenance, cleaning,

minor repairs Preparing your car for the MoT test

Buying and selling a used Simca 1100 Wiring diagrams Fault finding Metric conversion tables

105

Index

108

Sa

OOLL

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 gives economical, reliable performance. 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 this. 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 in this book. Guidance in looking at secondhand models 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 Owners Workshop Manual is available from the publishers, or through all good accessory shops or booksellers.

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Model

identification

It seems strange in this day and age that we still consider the front wheel drive car as something of a novelty. It is true that there are few types with a tranversely mounted engine and gearbox, but one model now familar to most of us is the Simca 1100. This rather angular car was announced in

France early in 1967 and became available on the United Kingdom market in October of the same year. It had received very good press reports both for its brisk performance and outstanding aim has

roadholding, and the manufacturer’s since been to keep it abreast of the

more popular models in the 1100/1300cc car range through periodic engine modifications. The original Saloon car appeared in two and four door forms (“LS and “‘GLS” respectively) and were supplemented by a two door Estate car which was lengthened at the rear to provide a welcome increase in load space; avan also appeared with the same basic body dimensions as the Estate car but fitted with a low compression engine. In October 1968 a tailgate was added to the Saloon versions along with other detail modifications, and twelve months later an improved cylinder head provided an increase in engine power. In 1974 we see that the range has continued with a run of minor production modifications behind it to keep abreast of contemporary trends. Meanwhile, a long-stroke version of the engine was introduced in September 1970 in what became the Simca 1204. This had twin carburettors and consequently improved performance,

fication.

together

However,

with

a better

this model

general

was

speci-

not to re-

main and twelve months later a Simca 1100 Special appeared with a 1294 cc engine. This model is currently being produced as a two or four door Saloon along with the smaller engined Saloon, Estate cars and vans. On all versions the engine and gearbox/final drive unit are transversely mounted and inclined 41° rearwards from the vertical. The engine is a conventional water cooled, pushrod operated, overhead valve unit with a light alloy cylinder head and a thermostatically controlled electric cooling fan. The standard gearbox has four forward speeds (an optional Ferodo semiautomatic three speed gearbox can be supplied). Drive to the front wheels is by twin double-jointed shafts, with steering by a direct acting rack and pinion unit. Suspension is all independent with unequal length wishbone and torsion bars at the front, and trailing arms and torsion bars at the rear. Suspension control is by telescopic shock absorbers, and anti-roll bars front and rear.

The

braking

system

is disc/drum

with

a

brake pressure limiter acting on the rear brakes. According to the particular model, a servo is available as an option or fitted as standard equipment. The body and underframe form a unitary, all steel, welded structure with bolt-on wings which can readily be removed. From the safety, comfort, roadholding and performance aspects there is little that can be faulted. In fact the only really adverse criticism which can be levelled at the complete range is a lack of accessibility to some of the maintenance points.

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Specifications, dimensions, weights, capacities Engine Type

Four

cylinder,

overhead

valve, water

transversely mounted

Type designation:

Bore (1118 cc and 1204 cc) Bore (1294 cc) Stroke (1118 cc) Stroke (1204 cc and 1294 cc) Cubic capacity

Compression ratio: 350 350S 353 353S 366 366TT Firing order Maximum brake horse power: 350 350S 353 3538S

366

350 (1100, low compression) 350S (1100, high compression) 353 (1204, low compression) 353S (1204, high compression) 366 (1100 Special, low compression) 366TT (1100 Special, high compression) 2.9134in. (74 mm) 3.0156 in. (76.7 mm) 2.559 in. (65 mm) 2.7559 in. (70 mm) 1118 cc (1100 models) 1204 cc (1204 models) 1294 cc (1100 Special models) (ej) 9.6: 1 sil 2 | 9.5: 1 9.6: 1 1On2 1 i 3-42 54 60 70 75

(DIN) (DIN) (DIN) (DIN)

at at at at

6,000 6,000 6,000 6,000

rpm rpm rpm rom

75 (DIN) at 5,800 rpm

cooled,

10

Specifications, dimensions, weights, capacities Maximum torque (Ib ft): 350 350S 353 353S 366 Valve/rocker clearance: Inlet Exhaust

Lubrication system Oil pump type Oil pressure at 70° C Oil filter type Sump capacity

Ignition system Type

60 62 67 70 72

(DIN) (DIN) (DIN) (DIN) (DIN)

0.012 0.014 0.014 0.016

in. in. in. in.

at at at at at

3,200 3,200 3,600 3,600 3,400

(0.30 (0.35 (0.35 (0.40

rpm rpm rpm rpm rpm

mm) mm) mm) mm)

Cold Hot Cold Hot

Gear, externally mounted, driven from camshaft 56 to 80 psi at 3,000 rom Full flow, disposable cartridge 5.25 pints (3 litres)

Coil and distributor with centrifugal and vacuum advance and retard

Coil: Type Primary resistance Secondary resistance Distributor: Type

Contact gap Direction of rotation Ignition timing (static): Type 350 to engine No. 6002416 Type 350S to engine No. 6566462 Type 350S from engine No. 6566463 Type 350 from engine No. 6002417 Type 353S (manual) from engine No. 7310021 Type 353S (auto.) from engine No. 7310021 All other UK imported models

Spark plug type: Type 350 engines Others Spark plug gap

Fuel system Air cleaner type Carburettor type

Ducellier or SEV, oil filled 3.0 to 3.5 ohms 5000 to 5500 ohms

Ducellier or SEV 0.017 in. (0.43 mm) Clockwise, viewed from top

9° BTDC 99 BTDC 10° BTDC 129 BTDC 0° BTDC

4°BTDC 120 BTDC

Champion N6Y Champion N7Y 0.024 in. (0.6 mm)

Disposable paper element Solex 32 BISA, 32 BISA3 or 32 BISA4 (350, 350S and 353 engines) Weber twin 36 DCNF (353S engine)

Weber single 36 DCNF Fuel pump Fuel tank capacity

15 (Series 366 engines)

SEV, AC or Sofabex, mechanical 9.2 gallons i

Specifications, dimensions, weights, capacities ee ee

ee

Se

11

Cooling system Type

Semi-sealed, thermo-syphon, water pump assisted with electric fan

Electric fan: Switches on at Switches off at

95° C (2030 F) 860 C (1870 F)

Thermostat:

Opens at Fully open at Clutch Type

Driven plate diameter Facing material Free movement at release fork arm end

Transmission (manual) Type Gear ratios:

1st 2nd 3rd 4th Reverse

Final drive: Type

Ratio Ratio

(1100 cc engine) (1204 cc engine)

729C (1619 F) or 839 C (1810 F) for late 1100 Special models 890 C (1920 F) Single dry plate, hydraulically phragm spring 7.13 in. (181.1 mm) Ferodo 180D 0.04 to 0.06 in. (1.0 to 1.5 mm)

operated,

dia-

Four forward speecs (with synchromesh) reverse. Final drive attached to gearbox SOLA

and

Helical gears 3.94: 1 Sh7/ 3

Lubricant capacity:

1.25 pint (0.71 litres) 1.0 pint (0.57 litres)

Gearbox Final drive

Transmission (automatic) Type Gear ratios:

1st 2nd 3rd Reverse

Ferodo three speed semi-automatic with torque convertor and sealed unit single plate clutch 2.47: 1

3.17%

Final drive

Similar to manual transmission

Oil capacity of torque converter, cooler and reservoir tank

7.5 pints (4.275 litres)

Steering gear Type Turning circle (approximate) Toe-in/toe-out

Rack 35 ft 37 ft 0.019 0.059

and pinion (clockwise) (anticlockwise) in. (0.5 mm) toe-in to in. (1.5 mm) toe-out

12

Specifications, dimensions, weights, capacities

SS ——————————————————————————————————— ——._—_.000 rr

Front suspension Type

Independent with unequal length wishbones, anti-roll bar and torsion bars. Hydraulic, telescopic shock absorbers

Camber angle: Up to vehicle From vehicle Up to vehicle From vehicle Castor angle

No. No. No. No.

E E E E

21110563 21110564 21110563 21110564

(Car) (Car) (Estate) (Estate)

Rear suspension Type

0° 15’ + 30’ positive 0° 15’ + 30’ negative 0°+ 30° negative 19° 0’ — 30’ negative 2ONS + 3Os

Independent

and

transverse

with

trailing

torsion

arms,

anti-roll

bar

bars. Thermostatically

controlled, hydraulic, telescopic shock absorbers

Braking system Type

Hydraulic, front disc and rear drum. Brake servo and rear brake pressure limiter fitted on some models booster

Front brakes: Type Disc diameter Minimum permissible pad thickness Rear brakes: Type

Teves disc and caliper

9.173 in. (233 mm) 3/32 in. (2.4 mm)

Bendix drum, single cylinder, leading and trail-

Drum inside diameter Handbrake

ing shoe 8.275 in. (210.2 mm) Cable operated to rear wheels

Wheels and tyres Tyres:

Saloon Estate and Van Tyre pressures:

Saloon (1100 cc) Saloon (other engines) Estate and Van

145 x 13 165 x. 13 24 psi front, 26 psi rear 26 psi front, 26 psi rear 23 psi front, 26 psi rear

Electrical system

Type Alternator: Type Maximum

12 volt, negative earth

output

Control unit Battery

Starter motor Type Windscreen wiper motor

Ducellier or Paris Rhone 23 amps (1100 and 1204 Special) 30 amps (1100 Special) Ducellier or Paris Rhone 40 amp hour Ducellier or Paris Rhone Pre-engaged Bosch, Marchal or Siem

Specifications, dimensions, weights, capacities Bulb chart Front parking lights Front flashers

13

5 watt spherical 21 watt spherical

Headlamp, main/dipped Additional lights

40/45 watt spherical 55 watt halogen

Interior lights, festoon

4 watt festoon 5 watt spherical 21 watt spherical 5 watt spherical 21 watt spherical

instrument panel Brake stop light Rear lamps Rear flashers Rear lamps/flashers (Estate)

21/5 watt spherical

Fuses No. 1

Protects the front side lights, rear lamps, index plate lamp, instrument cluster lamp and the side

and rear lamp warning light Protects the electric clock

No. 2

(if fitted)

and the

interior lamps

No. 3 No. 4

Protects the heater and the flasher circuit Protects the windscreen wiper motor Additional 10 amp fuses protect the cigar lighter and the heated rear window, where fitted

Dimensions (approximate) Overall length (Saloon) Overall Overall Height Height

12.94 ft (3944 mm) 12.89 ft (3929 mm) 12.87 ft (3920 mm) 4.78 ft (1458 mm) 4.83 ft (1472 mm)

length (Estate) length (Van) (Saloon) (Estate and Van)

Overall width

5.21 ft (1588 mm) 4.485 ft (1367 mm) 4.298 ft (1310 mm) 5.5 in. (140 mm)

Track (Front) Track (Rear) Ground clearance

Weights (kerb) Manual

Automatic

Fully laden

Simca 1100:

Saloon

2-door 4-door

2006 |b (910 kg) 2050 Ib (930 kg)

2028 |b (920 kg) 2072 |b (940 kg)

2932 |b (1330 kg) 2932 Ib (1330 kg)

Estate

2-door 4-door

2039 Ib (925 kg) 2072 |b (940 kg)

2061 Ib (935 kg) 2094 |b (950 kg)

3087 |b (1400 kg) 3087 |b (1400 kg)

1962 |b (890 kg)

1962 Ib (890 kg)

3087 |b (1400 kg)

4-door

2028 |b (920 kg) 2072 |b (940 kg)

2050 Ib (930 kg) 2094 |b (950 kg)

2976 |b (1350 kg) 2976 |b (1350 kg)

4-door

2072 |b (940 kg)

2094 Ib (950 kg)

3087 |b (1400 kg)

Van

Simca 1100 Special: 2-door Saloon

Estate

nat

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

Acceleration through gears (secs): 0— 30 0-40

0—50 0—60

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

1100 GLS 85 75 250

1204 Special 95 85 225

68 45.5 27

68 45.5 27

5.0 8.5 12.0 18.0

3.9 6.2 9.1 13.5

30 40.5

27.8 35

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 if 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 shouid 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 -if-you-use basis.

Jack Wheelbrace Distributor rotor, contact set and condenser The tools listed on the previous page Always ensure that a spare wheel is carried, and that it is inflated to the maximum pressure which might be required (see Specifications).

Going abroad: The items in the ‘Always carry’ list Tow rope Spare set of light bulbs Full set of spark plugs Spare schrader valves Set of radiator hoses

Radiator sealer (eg Radweld) Always Carry: This handbook First aid kit and manual Spare set of keys Gallon petrol can (full) List of Simca main agents Breakdown triangle (compulsory on the 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 Spark plug (see ‘Specifications’ for type and

gap) Tyre pressure gauge Tyre pump

Set of fuses Length of ignition HT cable Fire extinguisher Cylinder head gasket set Gasket cement Tin of Castrol Girling Universal brake and clutch fluid 1 quart of GTX engine oil Any other tools you think you may need Adequate set of maps List of Simca main agents abroad If you should have the misfortune to break down abroad, and you are unable to get the car moving again, always produce the handbook. A foreign mechanic may not be able to fully understand the handbook, but the illustrations and certain terminology should give him some assistance.

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(linkages) cable Handbrake hubs Rear 5 6

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Front hubs Final drive

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filters) (including Engine 1 2Gearbox

Automatic

transmission

Where automatic transmission is fitted, no clutch pedal is required. There are four selector positions (see illustration) and they are used as follows: Exceptional (exceptionelle): Used for fast starting and exceptionally steep hills.

Town/Mountain (Ville/Montagne):

Used

for

town and mountain driving, for slow running and for good open road acceleration. Road (Route): Used for normal road driving. Reverse (AR): Used as a conventional reverse gear. The vehicle is started in the normal way but as a safety precaution the selector lever must be at neutral for the starter motor to operate. Select the appropriate gear range with the brakes applied. Slight movement of the car may be felt but this is quite normal. When ready to move off release the brakes and depress the

throttle pedal as required. Whilst driving, another gear may be selected if required (except for reverse which must only be selected when stationary), but when selecting release the throttle pedal pressure slightly. Do not rest your hand on the selector lever once a gear has been engaged ort the gearbox will disengage again. In the same way, all selections should be positive and precise, and made without undue hesitation. When stopping at traffic lights, there is no need to select neutral; the foot or handbrake should however, be applied. When parking, always apply the handbrake. , The car may

be tow started, if necessary, at

approximately 12 mph with “exceptional” selected or 15 mph with ‘“Town/Mountain” selected.

EXCEPTIONNELLE ROUTE

MONTAGNE VIELE

AR

Alternative arrangements of the gearshift pattern where Automatic transmission is fitted

General information The purpose of this section of the handbook is to familiarise the owner with certain aspects of his car which may not be obvious at first glance. Instrument panel

1 Electric clock: The electric clock is electrically energised at all times. The position of the hands may be adjusted, if necessary, by turning the central knob on the glass. 2 Windscreen wiper switch: The two special windscreen wipers are of the self-parking type. The knob is rotated to the first clockwise position for slow speed wiping and rotated further still for high speed wiping. 3 Windscreen washers: On early models a floor

mounted pedal)

button operates

(to the the

left of the

windscreen

clutch

washers.

On later models a switch to the right of the steering column, just below the facia, is a combined electric washer/wiper switch. 4 Fuel gauge and warning light: The scale of the gauge is marked “Red” (empty), “White” (half full), ““Green’’ (full). When the level of fuel has fallen to approximately 1 gallon the warning light will illuminate continuously. 5 Direction indicator warning light: A repeater light operates when the indicators are operated. If this repeater fails to operate when the indicators are in use, a faulty indicator bulb is the

likely cause. 6 Water temperature gauge: The scale is marked ‘White’ (cold), “‘Green’’ (normal) operating temperature, ‘“Red’’ (overheating). If the needle reaches the Red area during normal engine running, stop the car immediately and investigate. Where no gauge is provided a combined oil pressure/water temperature light is fitted. 7 Oil pressure warning light: This lamp may illuminate at idling speeds when the engine is hot. If it fails to extinguish at speeds above idling, stop the car immediately and investigate.

8 Tachometer

(where fitted): Where a tacho-

meter is fitted it is important that the engine speed indicated is not allowed to enter the red sector on the scale under any driving conditions. Intermittent engine speeds within the orange sector are permitted, for example when maximum acceleration is required. 9 Lighting switch: The switch knob is pulled out to illuminate headlamps, sidelamps and instrument panel. The lower of the two steering column mounted switch stalks operates as follows: Up (sidelights only), Mid position (dipped beam), Down (main beam). The headlamp beam is flashed by pulling the lever towards the steering wheel. 10 Horn: The horn is operated by pushing the end of the lighting beam lever (see previous paragraph) towards the steering column.

Water temperature indicator Tratficator control lamp

Electric clock

Oil pressure control lamp

Speedometer

Revolution indicator Trip recorder Main beam warning lamp

Charge

contall Gap

Reset control for tripmeter

Parking lights warning lamp Fuel gauge

Minimum fuel level contro! lamp

The facia layout on some left-hand drive cars

20

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Rae

14

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16

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Sa a

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Instruments and controls on right-hand drive 1100 and 1100 Special models Electric clock

10

Headlamp beam warning light

Electric clock Low fuel warning light Fuel gauge

11

Water temperature

12

Lighting switch

13. 14 15

Air vent Heater unit Ashtray

16 17

Cigar lighter Choke

Direction indicator warning light Oil pressure warning light Side light indicator Speedometer and mileage recorder Ignition warning light OOMNONOPWN—

gauge

Hand and foot controls

18 19 20 21 22 23

Floor mounted windscreen Clutch pedal Brake pedal Accelerator pedal Direction indicator switch

Lighting selector switch

washer button

General information Ignition/steering column lock A combined ignition/steering column lock is ' fitted on models from September 1969 onwards. Position “A’’ (see illustration) locks the steering and switches off the ignition; the key may be withdrawn. At position ‘’B”, the ignition is off but the steering is unlocked; this position enables the car to be towed or pushed. The ignition circuit is energised at ‘’C’’, but the key cannot be withdrawn. Further turning of the key to ‘’‘D”, operates the starter motor. Once the engine has fired, the key should be released and allowed to return to “C”. The positions “A”, “B”, “C” and “D” correspond to Stop, Garage, Marche (On) and Start on the switch. Note: It may be necessary to turn the steering wheel a little when engaging or disengaging the lock. Doors and windows Doors can be opened from inside the car by pulling the lever “A” with the locking button “B” raised. Front doors are locked from the outside by key; and from the inside by pressing the locking button; rear doors are locked from the inside or outside by pressing the locking button. Where childproof rear door locks are fitted, the door cannot be opened from the inside when the lever ““C” is raised. A handle “D" is provided for windows except for the rear windows of two-door versions - here a latch is pulled and the window glass pushed open. Seat adjustment Longitudinal adjustment of the front seats is effected by pulling lever ‘“A’ upwards and sliding the seat. Raising lever ‘‘B” permits the slope of the backrest to be altered. On twodoor models the seat backrest can be tilted forwards when the lever “‘C” is depressed. The rear seat backrest can be lowered by unhooking the ends of the rear inner canopy flexible ties with the tailgate open. The levers on the retainers are then depressed to allow the squab to be folded forward or tilted. The rear inner canopy and seat (LS model) can now be removed if required. On later models the parcel tray can be pulled out when the tailgate is opened.

Seat belts Seat belts are provided

for your safety and

even during the shortest should be worn belts are not fitted at the Although journeys.

21 _

be)

iL The gear lever positions

cD vy

The ignition/steering lock switch positions Refer to the text for the captions

The interior light is operated by sliding the lamp lens in direction A

22

The door and window catches

A Opening lever B_ Locking button

C D

Childproof lock lever Window winder handle

E

Latch on rear window of two-door models

Seat position adjusters Refer to the text for the captions

joor

:

pele A

Flexible

B

Retainer lever

Alternative arrangements for the seating

Sliding out the parcel tray

24

General information

rear of the car, attachment points “B”, “C”, ““D” are provided to permit their fitment. Driving mirror On some models a tilting driving mirror is fitted. By pressing tab A, the mirror can readily be tilted to prevent glare from the headlights of following cars at night. Bonnet release catch To release the bonnet, pull on the catch at the side of the steering column. Raise the bonnet and support it on its stay (early models only) - on models from 1971 onwards, a semi automatic stay is fitted.

Heating and ventilating controls The heater unit is mounted in the vehicle below the facia panel. The unit combines the facilities of fresh air ventilation (air being drawn in through the grille just below the base of the windscreen) and warmed air which is heated by the engine cooling system. A booster fan is incorporated to increase the air flow to the vehicle interior when the vehicle . is moving slowly or is stationary. The heater unit controls are of the sliding type and provide settings for every heating, demisting or defrosting requirement. A flap “E™ at the base of the heater, controls the air flow to the rear compartment.

Attachment points (B, C and D) for fitting rear seat belts

The interior mirror

A

Tilting tab

Releasing the bonnet A

Release catch

B

Support stay

General Information

25

The heater controls Refer to the text for captions

To defrost and demist, shut the flap ““E”, place the levers “A” and “D” in the ‘maximum’ position. Push lever ‘“’C” fully to the left to deflect all air stream to the screen and move blower speed lever “’B” as required. To heat the interior of the vehicle, move lever “’C” fully to the right of its slot, regulate lever ‘‘B” to obtain the desired blower speed, place lever “‘D” centrally in its slot (to provide

a reduced demisting airflow) and open flap “’E” if required.

General running hints When starting from cold, use the choke control as necessary; there is no need to depress the accelerator pedal. As soon as possible, return the choke knob to the normal position, this not only economises on petrol but prolongs

engine life. When starting a hot engine, depress the accelerator pedal a little if necessary. Do not pump the pedal as this will make starting difficult. When running in a new or rebored engine, observe the maximum recommended gear speeds in the following table to prevent undue wear and the possibility of engine seizure. T

|

Mileage

First

=

|

Second

Third

mph

mph

|

Top

| mph

|

0 - 650 miles

15

| 20

650 - 950 miles

18

28

950 - 2500 miles

20

35

mph

30

38

45

|

55

* Progressive increase to maximum speed

Saloons and Estate cars should be operated using 97 octane fuel (4 star). A slightly lower octane fuel can be used with vans. On completion of the first 300 to 600 miles (500 to 1000 km) with a new car, you are recommended to take advantage of the free service inspection. This inspection covers renewal of lubricants and a check of all the major mechanical

components.

Winter/summer settings on air cleaner The winter setting is indicated by the arrow

Air cleaner - winter/summer settings All air cleaners are fitted with a flap valve which enables warm air to be drawn into the carburettor if necessary. At temperatures in

excess of 5°C (41°F) the valve should be set so that cool air is drawn Summer setting.

in; this is known

as the

26

General Information

ES

Jacking up and changing a wheel Before attempting to raise the car, apply the handbrake and select bottom gear. Prise off the hub cap (embellisher) using the screwdriver end of the wheelbrace then slacken each road wheel bolt about a quarter of a turn. Position the jack beam into the square socket nearest to the appropriate road wheel and set the jack in the rear-vertical position. The wheelbrace can now be used to lift the car and the wheel removed.

When fitting the wheel initially pinch the bolts up with the car raised, then finally tighten them with the car lowered to the ground. The spare wheel is fitted below the boot and can be lowered by using the wheelbrace on the carrier bolt working from inside the boot itself. The wheel carrier lowers as the bolt is unscrewed. The jack and wheelbrace are stowed in the engine compartment on the right-hand wing valance.

Prising off the hub embellisher

Spare wheel removal Loosening the carrier bolt The carrier should be turned to release the wheel

Ordering spare

parts

Always buy genuine SIMCA spares from a Chrysler/Simca dealer. Most parts are immediately available and components not in stock at a dealership can usually be supplied within a day or two. When ordering spare parts, it is essential to give full details of your vehicle to the storeman. He will need to know the type, the serial number and where the engine or gearbox is concerned, the serial numbers of these units as well. The vehicle serial number, body number, paint code and other details will be found either on a single plate (early models) located within the engine compartment (photo) or on separate index strips. The engine number is found on the side of the engine block. The gearbox number is stamped on a plate adjacent to the drain plug. It is always helpful to take along the component which is to be renewed as an additional safeguard against modifications which may have taken place to the particular component since the vehicle was built. Many of the vehicle manufacturers original parts can no longer be exchanged on a factory reconditioned basis. New components can only be purchased outright. Experience has shown that new parts are not always available ‘off the shelf’. If you know beforehand that new parts will be required, contact your dealer in advance to ensure that he has got the parts or alternatively can order them for you.

Data plate, later models

A B

Type number Body number

C

estell Nr -N°di Serie total en charge - Wax ©

Single plate serial numbers

Gearbox number

Paint code

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

Set

of combination

end, open ended the range 8 to 18 mm AF

spanners other)

(ie ring one to cover

Set of BA spanners (open ended) the range 2BA to 6BA

the

to cover

Adjustable spanner, 10 in parrot jaw Spark plug spanner Pair of pliers, 6 in Allen key, 12 mm AF Screwdriver, medium 8 in Screwdriver, crosshead 8 in

Screwdriver, small electrical Brake adjusting spanner Brake bleed nipple spanner Set of feeler gauges File, medium crosscut, with handle Hand cleanser (eg Swarfega) Overalls Clean, non-fluffy rag It is important also to keep an adequate supply of the greases and oils listed in the ‘lubrication’ section of this handbook.

The wrong way to jack up your Simca 1100

Routine

maintenance

No matter how well you look after your Simca 1100 various components inevitably are going to wear out and need replacement but by regular maintenance you will be able to get above average mileage from your car before replacement becomes a necessity. A great many of the maintenance tasks are purely a visual examination of components; many are vital to the roadworthiness of the car and safety of its occupants. The whole business of routine maintenance may become a bit tedious at times but do not neglect anything. Your life, or that of an innocent party, could depend on it.

slowly if you are trapped underneath. 8 Always use the correct size of spanner, otherwise it might fly off causing great damage to yourself or the car. 9 Do not allow battery acid to come into contact with the skin or clothes; should this occur, immediately wash off with a copious supply of cold water. 10Do not rush a job; before starting work make sure you have ample time to finish. General tips

1 Whenever engine

Safety Accidents will happen but they can often be prevented. A little thought can save a considerable amount of heartbreak as well as inconvenience. Read through the following points and always put them into practice: 1 Do not run the engine of the car in the garage with the garage doors closed. 2 Do not work in a garage pit with the engine running. 3 Do not wear a tie or have long sleeves when working on the engine with it running. They can easily get caught in the fan or the alternator drive belt. (This applies to hair also - tie it

back). 4 When jacking up the front or rear of the car always chock the remaining two wheels. Where possible also apply the handbrake. 5 Do not rely on the jack to support the full weight of the car. Always supplement with axle stands or thick wooden blocks beneath the front suspension lower crossmember or wheels. 6 Immediately wipe up any grease or oil spilled on the floor. 7 If you are working under the car for any length of time ask someone to check every half an hour to make sure all is well. Time passes

or

oil

is to

transmission,

be drained take

the

from car

the for

a warming up run beforehand. This allows the oil to thin down a little and facilitates the draining. 2 Before filler and drain plugs are removed, and again before they are refitted, wipe around the proximity of the plug and the plug itself, to prevent ingress of dirt to the particular system. 3 When draining oil into a container, due consideration must be given to the amount of oil to be drained with regard to the size of the container.

Plan ahead Before starting work always read through what work is involved and make sure you have all the parts and lubricants that will be required. Most do-it-yourself motorists do their work during the evenings or weekends when the parts department of garages are closed. Nothing is more annoying than starting a job and being unable to complete it due to lack of spares. Also refer to ‘Ordering Spare Parts’ in the “General Information’ Chapter of this handbook. A list of the Routine Maintenance requirements is set out below, followed by detailed instructions and precautions which should be heeded at all times.

Routine Maintenance

30

EEE

nnn

Maintenance summary 1 a 1 2 3 4 5 6 7

Weekly, every 250 miles (400 km) or before long journey Check the engine oil level. Check the engine coolant level. Check the tyre pressures. Check the battery electrolyte level. Check the windscreen washer fluid level. Check the brake and clutch fluid level. Check the automatic transmission fluid level

(where applicable). 2 Every 3000 miles (5000 km) or 3 months: 1 Renew the engine oil. 2 Lubricate the distributor. 3 Check the alternator drive belt tension. 4 Check the oil level in the gearbox and final drive. 5 Check the free travel of the clutch pedal. 6 Tighten the cylinder head and manifold front pipe bolts on the 1100 Special Saloon and Estate (first 3000 miles only). 7 Check the front brake pads for wear. 8 Check the condition of the tyres, and the tightness of the wheel bolts. 9 Give the car a ‘once-over’ check for water and oil leaks, and for the correct operation of all lights, instruments, accessories, etc. 10 Road test the car.

Every 6000 miles (10000 km) or 6 months: Renew the engine oil filter. Renew the oil in the gearbox and final drive. Clean the air cleaner element. Clean the spark plugs and ignition HT leads. Clean the distributor contacts. Check the ignition timing. Clean the fuel pump and carburettor filters. Clean the battery terminals. Clean and adjust the — ODNMUHARWNY

rear brakes. 10 Check the handbrake adjustment. 11 Check the condition of the seat belts and their anchorage points. 12 Lubricate the pedal pivots, carburettor linkage, door, boot and bonnet hinges and catches, seat adjusters, etc. 13 Check the condition of the brake pipes and hoses. 14 Check the condition of the fuel system pipes and hoses. 15 Check the condition of the cooling system

hoses. 16Check the exhaust security of attachment.

system

for

leaks

and

17 Check for wear in the front suspension, drive

the condition

shafts and steering, and rubber gaiters. 18 Road test the car.

4 Every

12000

miles

(20000

km)

of the

or

12

months:

Renew the air cleaner element.

Check the valve/rocker clearances. Clean the crankcase breather valve. Renew the distributor contacts. Renew the spark plugs. Renew the brake and clutch system fluid. Check the operation of the rear brake NOOPWN— pressure limiter. 8 Regrease and adjust the rear hubs. 9 Adjust the steering. 10 Check the headlamp alignment. 11 Road test the car. ;

5

Every 24000 miles (40000 km) or 2 years:

1 Renew all the rubber seals and pipes in the braking system.

Maintenance procedure 1 Weekly, every 250 miles (400 km) or before a long journey 1 With the car on level ground, remove the dipstick, wipe it clean, replace it then withdraw it again. Check the oil level which should be at or near the ‘’“maximum” marking on the dipstick, topping up if necessary with Castrol GTX. If the engine has just been running, or when topping up, allow about two minutes for all the oil to drain into the sump. Never overfili or allow the oil level to fall below the ‘“minimum” marking. The dipstick is located near the distributor, the oil filler cap is on top of the rocker housing at the alternator end. 2 When the engine is cool, check that the coolant level is between the “maxi” and “min” levels on the expansion chamber wall. If necessary, any topping up should be carried out using an antifreeze/water mixture in the same proportions as currently being used in the cooling system. If the level’requires frequent topping up, carefully inspect the system for leaks.

Routine Maintenance 3 When the tyres are cold (ie before a long run where the pressure will increase due to the heat) check their pressures. It is always preferable to use your own gauge because those at garages tend to be treated with a certain amount of disrespect and are very often inaccurate. It is a good idea to check the accuracy of your own gauge periodically with one belonging to a friend or neighbour. When checking the tyre pressures, always check the spare and inflate it to the maximum that is

likely to be required then adjust if necessary when it is used. The tyre pressures are given in the Specifications Section of this handbook. 4 Check the battery electrolyte level and if necessary top up with distilled water only until the level is just above the tops of the plate separators. 5 Top up the fluid level in the windscreen washer reservoir using water and one of the proprietary cleaning agents. This helps to prevent haze on the windscreen and freezing of the

Filling the engine with oil Note - for clarity the air filter has been removed

The cooling system expansion chamber

31

The battery The arrow indicates the filler plugs

32

Routine Maintenance

The early type windscreen washer reservoir

solution. 6 Check the level of fluid in the brake and clutch system reservoir tank. The level should be maintained between the markings “A” and “B” (see Figure) using Castrol Girling Universal Brake and Clutch Fluid. If frequent topping up is required, inspect the systems carefully for leaks. Experience shows that brake system leakage is the more likely to occur, particularly at the wheel cylinders. Aiso refer to item 3.14. 7 Where automatic transmission is fitted, check that the fluid level is between the ‘‘maximum” and “minimum” markings on the dipstick attached to the filler cap. Any topping up that is required may be carried out using Castrol TQF automatic transmission fluid. The oil may remain in the filler tube after topping up, but will fall once the cap has been replaced.

2

Every 3000 miles (5000 km) or 3 months:

1 Using a 12 mm allen key or hexagonal socket wrench to remove the drain plug, drain the engine oil into a suitable container. After allowing for the last drops to drain out, wipe the drain plug clean, renew its sealing washer if the condition warrants it and refit it firmly. Replenish the system with Castrol GTX, run the engine at a fast idle until the oil pressure warning light extinguishes then switch off again. Allow the oil to drain back into the sump and top up again if necessary. 2 Spring back the distributor cap retaining clips, remove the cap and pull off the rotor. Apply two or three drops of engine oil to the The later type windscreen washer reservoir

The brake and clutch system fluid reservoir

The automatic transmission fluid reservoir

Exploded view of Ducellier type distributor Cap Rotor Moveable breaker arm Vacuum advance link OPWNFixed contact breaker

6

Own

Contact breaker baseplate Cam assembly

10 11 12

Centrifugal advance 13 weight control springs 14 Drive shaft and plate

Body

a

LT insulator Condenser Vacuum capsule Cap retaining spring

Thrust washer Sealing ring Spacer washer Driving dog Retaining pin Felt pad

34

Routine Maintenance

absorbent pad on the top of the cam spindle, one drop (only) to the contact pivot and a trace of Castrol LM grease or petroleum jelly to the cam profile. Replace the rotor, cap and spring clips on completion. 3 To tension the alternator drive belt properly first remove the cover then slacken the alternator upper securing bolt followed by the adjusting link bolt. Slacken the belt slightly then use a soft pencil to mark two lines 3.93 in (100 mm). Now move the alternator outwards so that the belt is under tension and tighten it in the position where the distance between the two pencilled lines has increased to 4.008 in (102 mm). If the belt adjustment is fully taken up at the adjusting link, renew it at the first opportunity. 4 With the car on level ground, or alternatively evenly jacked up, remove the level plugs from the transmission (gearbox and final drive) and check the oil level. When fully topped up, the level should be up to the filler plug hole. If any additional

lubricant is required it is preferable to use a plastic dispenser to avoid spillage. The correct lubricant is. SAE 90 EP gear oil (eg; Castrol Hypoy). When refitting the level plugs ensure that they are clean and that the sealing washers are intact. 5 Check the free play of the clutch pedal by measuring at the end of the release fork arm; the correct amount of free movement is 0.04 to 0.06 in (1.0 to 1.5 mm). If adjustment is required, refer to the relevant illustration and slacken the locknut. Detach the spring clip which secures the pushrod to the release fork then screw the adjuster nut down the pushrod until there is no free play between the nut and

Alternator adjusting and attachment bolts

_ fork. Now screw the adjuster nut back 1 to 1% turns. Fit the spring clip and tighten the locknut. The free movement will now be correct. 6 After the first 3000 miles (5000 km) it is necessary for the cylinder head bolts and manifold front pipe bolts to be tightened on 1100 Special models. This calls for. the use of a torque wrench and should be entrusted to your Simca dealer. 7 Jack up the front end of the car, one side at a time, remove

each front road wheel in turn then prise off the cover plate on the caliper to inspect the thickness of pad material remaining.

If this is down to 3/32 in (2.4 mm), or is likely to be down to this level before the next 3000 mile (5000 km) check, they should be renewed. This should be entrusted to your local Simca

Topping up the gearbox

35

Ciutch free movement 1

Push rod locknut

2

Spring clip

3 A

Adjuster nut Free movement

Front caliper unit - exploded view od

Cover plate

Spring Friction pad Friction pad

Snap ring Dust cover Piston = SOON OORWN Seal

36

Routine Maintenance

Neen ee eee

ee ee

dealer or carried out in accordance with the procedure laid down in the Haynes Workshop Manual for the Simca 1100, 8 Raise each road wheel in turn and inspect the tyre for cuts and bulges in the tread and both the inner and outer walls. Any stones that are embedded in the tread should be removed before they have a chance to work their way through the cover and cause a puncture. Examine the tread for signs of uneven and excessive wear. It is illegal for tyres with less than 1 mm of tread to be used; this amount of wear is evident from the transversely set markers in the tread pattern being flush with the tread on most types of tyre. If uneven tyre wear is found, it may be indicative of a suspension, wheel

balance

ES

eee

or body

frame

alignment

problem and should be investigated by a Simca dealer without delay. In order to equalise tyre wear, if considered desirable, the wheel positions can be interchanged as shown in illustration (this is not advisable if fabric belted radials are fitted). After inspecting the tyres, use the wheelbrace to check that the wheel bolts are tight. 9 Give the car a ‘once-over’ check, looking for oil, fuel and water leaks, checking that all the instrument lights and controls function correctly, that the doors shut without undue effort and that the seat adjustments are satisfactory. If necessary, some of these items may be carried out in conjunction with the following road test. 10When you have completed the maintenance tasks listed take the car out on a test run. Listen for any squeaks and rattles that may

eee

have developed and for general engine and transmission noise which might be indicative of something nearing the end of its life. When the road conditions permit, check that the brakes will bring the car to rest evenly, and without effort. When you have satisfied yourself that everything appears to be satisfactory, bring the car to rest using the handbrake only, checking that it does not need to be pulled to the extreme limit of its travel. After the run, leave the car standing for a few hours to check for any drips of oil, fuel or water on the ground.

3 Every 6000 miles (10000 km) or 6 months: 1 Whilst draining the engine oil (item 2.1), unscrew the engine oil filter. Be prepared for a certain

amount

of oil spillage as it is removed,

by placing newspapers beneath. The filter is not particularly accessible, but is positioned on the bulkhead side of the engine, low down, vertically below the oil filter cap. If you are unable

to turn the filter by hand,-wrap a strip of emery cloth around it for a better grip. When refitting the new item, lightly smear the seal with engine oil and fit it firmly, tightening by hand only. 2 Remove the drain and filler plugs from the transmission (gearbox and final drive) and allow the oil to drain into suitable containers. When all the oil has drained, which may take fifteen minutes or more depending on its temperature, clean the plugs renew the sealing washers if the condition warrants it, then replace the drain plugs firmly. Replenish both gearbox and final drive with a gear oil of SAE 90 EP viscosity (eg Castrol Hypoy) and refit the filler plugs.

Suggested order for interchanging wheels to equalize tyre wear

37

Veryay AS

‘

aeats-

=

pcan Sigs

sie)

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 imcorrect 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.

Exploded view of cylindrical type air cleaner

1. 2

Air intake (single carburettor) Air intake (twin carburettor)

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Key to additional wiring diagram for automatic transmission

becomes becomes becomes becomes becomes becomes becomes becomes becomes

models

Coil Battery Neutral switch Clutch electro-magnet

Stop light switch Starter relay Selector lever switch Fuse unit

Ignition switch/steering lock

Fault

finding

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 The chart

Engine stoppages

Engine stoppage: it will not start, or stops on the road 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

type of fault is the worrying kind; odd noise, 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 groups ation:

to

have

continue.

been

The

following

main

used to separate the inform-

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

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

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.

Fault Finding Engine stoppages : tests for use in conjunction with the chart

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

a) Switch on ignition

81

b) Rig up the King lead as for test 1.2, or a substitute lead c) 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 f) Continuous sparks mean there is current flow to somewhere;

thus a faulty rotor arm

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 Y’inch bolt into the contact as a probe. d) Operate the starter e) There should be an easily noticeable spark

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

a) Remove the fuel carburettor

pipe where

it enters the

b) Operate the starter to work the mechanical

Test 1.2

petrol pump. Take care the pipe is not pointed at ignition leads or a hot exhaust pipe

ignition HT at source

‘c) Fuel should gush out of the pipe

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

SYSTEM

it from the

coil and rig up a temporary lead Test 1.3 Check ignition LT at contact breaker

a) Remove distributor cap b) Ignition switch on c) Open 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 definite spark Test 1.4

Check the rotor arm

a) This test is to see if there is a short through the body of the rotor arm to the spindle beneath

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 beware petrol does not get into 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 d) If petrol cannot be drawn up by sucking try blowing. Have 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 block-

age e) Also whilst the pipe is off the pump inlet, work the starter with a finger over the inlet union. The suction of the pump should be felt.

82

a

Engine will

Starter

Starter

does NOT turn

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 fault

Flat battery Get push start Recharge battery

Loose battery terminal. Clean and tighten

—— SPARK Fuel checks Check flow into float chamber: (Test P.1)

NO FLOW

FLOW

Remove pipe at pump outlet and Operate starter

Check carburettors |

: Clean inlet filter

|

Clean carburettor

a SUCTION

but NO “FLOW” |

NO FLOW Check at pump

Inlet (Test P.2)

“ELOW"

but no suction

Check filler cap breather clear

Check pipes back to tank

Check pump

FLOW

;

Pipe to carburettor blocked: Remove and clean

Starter cranks

engine well g

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

(Test 1.1)

NO SPARK !

Check HT spark at king

lead from coil (Test |.2)

Check ignition timing and orientation of H.T. leads

SPARK

NO SPARK

Check distributor cap for cracks, dirt, moisture

visual check of all leads Check LT flash at c.b.

Check rotor arm

(Test (.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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tables

Inches

Millimetres

0.001 0.002 0.003 0.004 0.005 0.006

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

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Torque Wrench Settings ov

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Distance Kilometres

Kilometres

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— OONDOPWNH

Capacities Litres

Litres

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OMANODOHWN—

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Gallons

Litres

Litres

Gallons

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Metric Conversion Tables

Tyre Pressures Ib/sq in

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Inches

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Decimals

Millimetres

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; :

Index A Air cleaner - element cleaning - 39 element renewal - 47

winter/summer settings - 25 Alternator - drive belt tension adjustment - 34 Antifreeze - 53 Automatic transmission - fluid level check - 32

general information - 18 specifications - 11

B Battery - electrolyte level check - 31 faults - 96 maintenance - 41

Bodywork - cleaning - 56 minor repairs - 59 MoT check - 64 paint touch-up - 57 repair of dents - 58

repair of rust holes - 58 rust prevention - 57

steam cleaning underside - 56 Bonnet release catch - 24 Braking system - bleeding - 50 checking - 67 drum brakes maintenance - 44 fault finding - 99 hydraulic fluid level check - 32 hydraulic fluid renewal - 49 pad thickness check - 34 pipes and hoses inspection - 44 rear brake pressure limiter checking - 49 rubber seals and hoses renewal - 50 specifications - 12 Bulbs - renewal - 53, 55 specifications - 13

Buying - 69

C Carburettors - idle speed adjustment - 51 Carpets - cleaning - 56 Clutch - adjustment - 34 fault finding - 97 hydraulic fluid level check - 32 specifications - 11 Compression ratio - 9 Contact breaker - gap adjustment - 41 maintenance - 39

renewal - 48 Coolant level check - 30 Cooling system - draining - 52 fault finding - 87 filling - 53 flushing - 53 hoses inspection - 46 specifications - 11 Crankcase breather valve - cleaning - 48

D Dimensions - 13 Direction indicator - warning light - 19 Distributor - lubrication - 32, 41 maintenance - 39 Doors - 21 5 Drive shafts - checking for wear - 46 Driving mirror - 24

& Electrical system - fault finding - 95 specifications - 12 Electric clock - 19 Engine - excessive noise - 92 fault finding - 82 idling speed adjustment - 51 lack of power - 85 misfires - 87 oil change - 32 oil level check - 30 overheats - 87 ‘pinks’ - 91 running-in - 25 specifications - 9 stalls - 85 starting - 25 stoppages - 81 Exhaust system - checking - 46

F Fault finding - braking system - 99 clutch - 97 cooling system - 87 electrical system - 95 engine - 85 fuel system - 81 ignition system - 81

Index steering - 101, 104 Final drive - oil change - 36 oil level check - 34 Front suspension - checking for wear - 46

specifications -12

109 P Performance data - 14 R

Rear hubs - greasing and adjustment - 49

Fuel - octane rating - 25

Rear suspension - specifications - 12

Fuel gauge - 19

Road test - after maintenance - 36

Fuel pump - maintenance - 41 Fuel system - fault finding - 81

data - 14 MoT test - 68

pipes and hoses inspection - 46

Routine maintenance - general information - 29

specifications - 10

summary - 30 Rust prevention - 57

G

Gearbox (manual) - oil change - 36 oil level check - 34 specifications - 11

H Handbrake - adjustment - 44 Headlamps - alignment - 50 bulb renewal - 53

Heating controls - 24 History of marque/models - 7

Horn - 19

S Seat adjustment - 21 Seat belts - 21, 44 Selling - 74 Spare parts - ordering - 27 to carry - 15 Spark plugs - maintenance - 39 renewal - 48 Steering - adjustment - 49 checking for wear - 46, 64

fault finding - 101, 104 Steering gear - specifications - 11

I

Suspension - checking for wear - 64

Ignition - timing check - 41, 52

Ignition/steering column lock - 21 Ignition system fault finding specifications Instrument panel

circuit - 84 81 - 10 - 19

J

data - 12 maintenance - 36 pressures - 12

Jacking-up - 26, 28

Lamps - bulb

T Tachometer - 19 Tools - 28 Touring pack - 15 Transmission judder - 101 Tyres - checking pressures - 31

L renewal - 53, 55

U Upholstery - cleaning - 56

Lighting switch - 19

Lights -.checking - 68 faults - 95

V

Lubricants - recommended Lubrication - engine - 93 general - 44 Lubrication chart - 17

- 16

Valve/rocker - clearance adjustment - 47 Ventilating controls - 24 Vibration - 101

Lubrication system - specifications - 10

W Water pump - 90

M

Water temperature gauge - 19 Weights - 13 Wheel changing

Model identification - 7

O Oil consumption excessive - 92 Oil filter - renewal ’-36 Oil pressure - low - 94 warning light - 19

- 26

Windows - 21 Windscreen washers - fluid level top up - 31 general information - 19 Windscreen wiper - switch - 19 Wiring diagrams - 76

110

Castel 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

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.

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.

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 XL 20/50

Contains liquid tungstent; well suited to the majority of conditions giving good oil consumption control in both new and old cars. Castrolite (Multi-grade) This is the lightest multi-grade oil of the Castrol motor oil family containing liquid tungstent. It is best suited to ensure easy winter starting and for those car models whose manufacturers specify lighter weight oils. Castrol Grand Prix

An SAE 50 engine oil for use where a heavy, full-bodied lubricant is required. Castrol Two-Stroke-Four A premium SAE 30 motor oil possessing good detergency characteristics and corrosion inhibitors, coupled with low ash forming 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 Heavy 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 D (140) A heavy full-bodied gear oil with fortifying additives.

Castrol Thio-Hypoy FD (90 EP) A light-bodied powerful extreme pressure gear

Castrol Graphited Grease

A graphited grease for the lubrication of transmission chains. Castrol Under-Water Grease A grease for the under-water gears of outboard motors.

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)

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

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 Dexron® Automatic Transmission Fluids

as laid down by General Motors Corporation.

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

Speciality Products

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

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

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

A leaf spring lubricant possessing a high degree of penetration and providing protection against rust. 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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Titles in the Haynes Owners Handbook/Maintenance Manuals Series

Austin Austin Austin Austin BLMC BLMC BLMC

MGB

A35 and A40 (101) A6O (172) Allegro (142) Maxi (075) 1100/1300 (042) 1800 (105) Mini (041)

(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)

Fiat 850 (168) Fiat 128 (176)

Riley 4/72 (172)

Ford Anglia 105E€/123E (045) Ford Capri 1300/1600 (063) Ford Corsair 1500 (065) Ford Corsair V4 (100) Ford Cortina Mk 1 (046) Ford Cortina Mk 2 (056) Ford Cortina Mk 3 (099) Ford Escort (057) Ford Transit (144) Ford Zephyr Mk IV (103) Hillman Avenger (062) Hillman Hunter/Minx - (1966 on) (145)

Rover 2000 (151)

Triumph Herald (060) Triumph Spitfire (148)

Triumph 1300/1500 (077)

Triumph 2000, 2.5 Pl (102) Vauxhall Vauxhall Vauxhall Vauxhall Vauxhall

Viva HA (059) Viva HB (043) Viva HC (064) Victor FB (061) Victor 101 (FC) (149)

Vauxhall FD (076)

=.

Hillman Husky Series | to II! (174)

Vauxhall Victor FE (104)

Hillman Imp (044)

VW Beetle (106) Wolseley 16/60 (173)

Hillman Minx Series | to |V (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

must be borne the production can

be accepted

the information

to ensure the correctness ot data used, it in mind that alterations and design changes can occur within run of a model without specific reclassification. No liability for damage,

given.

loss or injury caused

by errors or omissions

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