Service

Repair

Operation

Manual

SupplementTo be used with TR7Repair Operation Manual AKM 3079 B

Publication Part No. AKM 3079/1

Published by BL Cars--Service

© BL CARS LIMITED 1980

G

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This supplement is intended for use with the TR7 Repair Operation Manual AKM 3079 B and pro-vides additional information, changes to vehicle specifications and revisions to repair procedures.

CONTENTSPage

General Specification Data ........................................................ 4Engine Tuning Data ............................................................. 6Torque Wrench Settings .......................................................... 7Anti-Freeze Solutions ............................................................ 7Lubricants ..................................................................... 8Maintenance Summary ............................................................ 10

MANUAL GEARBOX -- 5 SPEEDGear-change remote control assembly

--overhaul 37.16.20 ........................................................... 13

WIPERS AND WASHERSWiper delay unit

-- remove and refit 84.25.31 ..................................................... 13

ELECTRICALIgnition distributor

--data 86.35.00 .................................................... ~ .......... 19Wiring diagrams

-- UK and Europe ............................................................. 14--USA ...................................................................... 16

GENERAL FITTING INSTRUCTIONS

Vehicle Identification Number

LocationThe vehicle identification number (V.I.N.) is stamped on a plate on the R.H. front suspension towerand should be quoted in full.A sample V.I.N. is shown below:

Marque/Model range

Class

Body

Engine

Steering/Transmission

Model Year/Change

Assembly Plant

Serial Number

TP A D V 7 A A 402027

GENERAL SPECIFICATION DATA

GEARBOX -- 5 speed from VIN 402027

RatiosFifth (top) .........................Fourth ............................Third .............................Second ............................First ..............................Reverse ...........................

Overall ratios UK:Fifth (top) .........................Fourth ............................Third .............................Second ............................First ..............................Reverse ...........................

Overall ratios Europe, USA and Canada:Fifth (top) .........................Fourth ............................Third .............................Second ....... .....................First ..............................Reverse ...........................

GEARBOX--AUTOMATIC -- from VIN 402027Type ................................

0.792 : 11.00 : 11.40:12.09 : 13.32 : 13.43 : 1

3.09 : 13.90 : 15.46 : 18.15 : 1

12.96 : 113.38 : 1

2.73 : 13.45 : !4.83 : 17.21 : 1

11.45 : 111.83 : 1

Borg Warner 66

3rdOverall ratios to 1 3.08-5.88

Road speed corresponding to 1000 r.p.m.m.p.h ................... 21.9-11.47km.p.h ................... 35.2-18.43

2nd 1st Rev.4.47-8.53 7.36-14.05 6.44-12.30

AUTOMATIC TRANSMISSION SHIFT SPEEDS

Throttle Zero Light Partposition throttle throttle throttle

Selector 1 D D D D

Shift 2-1 1-2 2-3 3-2 2-1

Road speedm.p.h. 28-39 7-13 12-19 27-43 12-22km.p.h. 45-63 11-21 19-31 43-69 19-35

Throttleposition : Kickdown

Selector D D D 1 D

Shift 1-2 2-3 3-2 2-1 3-1

Road speedm.p.h. 38-48 70-80 60-72 39-50 25-38km.p.h. 61-77 112-128 96 116 63-81 40-61

FINAL DRIVE -- from VIN 402027Ratios: Used with 5 speed gearbox

U.K .............................. 3.90 : 1Europe, USA and Canada ........... 3.45 : 1

Used with Automatic gearboxRatio .............................. 3,08 : 1

TYRESSize:

Automatic Transmission (from VIN402027) ........................... 185,/70 SR 135 Speed Transmission

This information supersedes that which is given in the Repair Operation Manual.UK and Europe .................. 185/70 HR 13USA and Canada ................. 185,/70 SR 13

CAPACITIES (NOMINAL)This informauon supersedes that which is given in the Repair Operation Manual.

USA Imperial MetricFuel tank ............................ 14.4 gals 12 gals 54.5 litresRear axle from dry ................... 2 pts 1,6 pts 0,9 [itresWindscreen washer reservoir ........... 3.3 pts 2.75 pts 1.6 litresAir conditioning system ................ 2.5 lbs 1.1 kg. of refigerant 12

WEIGHTS (APPROXIMATE) -- Coup~. From VIN 402027Manual gearbox

*Showroom: Minimum ...................Maximum ...................

*Unladen: Minimum .....................Maximum .....................

*Gross vehicle weight .....................*Maximum axle load: Front ...............

Rear ................*Towing capacity -- braked trailer ..........

2258 lb (1024 kg)2335 lb (1059 kg)2348 lb (1065 kg)2425 lb (1100 kg)2954 lb (1340 kg)1576 lb (715 kg)1466 lb (665 kg)2240 lb (1016 kg)

Automatic gearbox2251 lb (1021 kg)2328 lb (1056 kg)2341 lb (1062 kg)2418 lb (1097 kg)2954 lb (1340 kg)1576 lb (715 kg)1466 lb (665 kg)2240 lb (1016 kg)

WEIGHTS (APPROXIMATE) -- Convertible. From VIN 402027Manual gearbox

*Showroom: Minimum ...................Maximum ...................

*Unladen: Minimum .....................*Gross vehicle weight .....................* Maximum axle load: Front ...............

Rear ................*Towing capacity -- braked trailer ..........

2249 lb (1020 kg)2326 lb (1055 kg)2339 lb (1061 kg)2954 lb (1340 kg)1576 lb (715 kg)1466 lb (665 kg)2240 lb (1016 kg)

Automatic gearbox2240 lb (1016 kg)2317 lb (1051 kg)2330 lb (1057 kg)2954 lb (1340 kg)1576 lb (715 kg)1466 lb (665 kg)2240 lb (1016 kg)

* These figures must be taken as a guide only and vary according tomarket, model year and equip-ment fitted.

./ .......... ..........

ENGINE TUNING DATA -- CANADA from VIN 402027

WARNING: Before commencing work on an ignition system, all high tension terminals, adaptors anddiagnostic equipment for testing should be inspected to ensure that they are adequately insulated andshielded, to prevent accidental personal contact and minimize the risk of shock.Wearers of surgically implanted pacemaker devices should not be in close proximity to ignition circuitsor diagnostic equipment.

ENGINEType .. ........ ......................Capacity .............................Compression ratio .....................Firing order ..........................Number one cylinder ...................Idle speed ............................Ignition timing:

Static .............................Dynamic at idle ....................

Location of ignition timing marks . .......Valve clearance (engine cold):

Inlet ..............................Exhaust ...........................

Valve clearance adjustment

O.h~c. in line 4 cylinder122 in~ (1998 cm88.0:11-3-4-2Front800 _ 100 rev/min

10° B.T.D.C.2° A.T.D.C.

Scale on front cover -- notch on pulley

0.008 in (0.2 mm)0.018 in (0.5 mm)Pallets between valve and cam followerInlet opens 16° B.T.D.C.Inlet closes 56° A.B.D.C.Exhaust opens 56° B.B.D.C.Exhaust closes 16.0 A.T.D.C.

IGNITION DISTRIBUTOR ............... See 86.35.00

SPARK PLUGSMake/type ...........................Gap .................................

Champion N 12Y or Unipart GSP 1310.024 to 0.026 in (0.61 to 0.66 ram).

IGNITION COILMake/type ...........................Primary resistance at 20°C (68°F) .......

Lucas 15C6 or A.C. Delco 34742141.3 to 1.5 ohms

CARBURETTERSMake ...............................Type ................................Needle ..............................

Twin Zenith Stromberg175 CD SEVXB1DH

ENGINE TUNING DATA -- Low Compression Engine

WARNING: Before commencing work on an ignition system, all high tension terminals, adaptors anddiagnostic equipment for testing should be inspected to ensure that they are adequately insulated andshielded, to prevent accidental personal contact and minimize the risk of shock.Wearers of surgically implanted pacemaker devices should not be in close proximity to ignition circuitsor diagnostic equipment.

ENGINEType ................................

Capacity .............................Compression ratio ................ i ....Firing order ..........................Number one cylinder ...................Idle speed ............................Ignition timing:

Static ... ..........................Dynamic ..........................

Location of ignition timing marks .........Valve clearance (engine cold):

Inlet ..............................Exhaust ...........................

Valve clearance adjustment .............Valve timing ..........................

Inlet opens 16° B.T.D.C.Inlet closes 56° A.B.D.C.Exhaust opens 56° B.B.D.C.Exhaust closes 16° A.T.D.C.

O.h.c. in line 4 cylinder122 in3 (1998 cm3)8.0:11-3-4-2Front650 to 850 rev/min

10o B.T.D.C.10° B.T.D.C. at 650 to 850 rev/minScale on front cover -- notch on pulley

0.008 in (0.2 ram)0.0!8 in (0.5 mm)Pallets between valve and cam follower

IGNITION DISTRIBUTOR ............... See 86.35.00

SPARK PLUGSMake/type ............................Gap .................................

Champion N 12Y0.024 to 0.026 in (0.61 to 0.66 mm).

IGNITION COILMake/type ...........................Primary resistance at 20°C (68°F) .......

Lucas 15C61.3 to 1.5 ohms

CARBURETTERSMake/type ...........................Needle ..............................

Twin SU HS6BBF

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TORQUE WRENCH SETTINGSThese instructions supersede those given in the Repair Operation Manual.

AIR CONDITIONINGOperation Description

Hoses Flare TypeCompressor to CondenserCondenser to Receiver DrierEvaporator to CompressorEvaporator to Receiver DrierRanco Valve to Receiver DrierRotaloek Valve to Compressor

Hoses -- ’O’ Ring TypeCompressor to CondenserCompressor endCondenser end

Evaporator to CompressorCompressor endEvaporator endCondenser to Receiver DrierReceiver Drier to EvaporatorRanco Valve to Receiver Drier

Nm

Specified torqueIbf ft kgf

3A" Crimp Back Nut 40 30 4,0%" Crimp Back Nut 28 21 2,97/8" Crimp Back Nut 50 37 5,1%" Crimp Back Nut 28 21 2,9~6" Flare Nut 12 9 1.21" UNS 50 37 5,1

1" UNS Gasket Nut 27 20 2.73~,, Gasket Nut 27 20 2.7

1" UNS Gasket Nut 27 20 2.77/8" UNF Nut 37 27 3.7%" UNF Gasket Nut 18 13 1.8%" UNF Nut 18 13 1.8~6" UNF Gasket Nut 9 7 0.9

m

ANTI-FREEZE SOLUTIONS -- ALL MARKETS

These instructions supersede those given in the Repair Operation Manual.

The overall anti-freeze concentration should not fall below 30% by volume to ensure that the anti-corrosion properties of the coolant are maintained.

Use U N 1 PART Universal anti- freeze to protect the cooling system.

If this is not available, use an ethylene glycol based anti-freeze (containing no methanol) with non-phosphate corrosion inhibitors suitable for use in mixed metal engines to ensure the protection of thecooling system against frost and corrosion.

CAUTION: No other universal anti-freeze should be used with UNIPART Universal Anti-freeze.

COMPONENT

EngineCarburetterand Oil Can

Manual Gearbox

AutomaticGearbox

Final DriveUnit*

Grease PointsBrake CablesSteering Rackand Rear Hubs1"

Brake and ClutchReservoirs

Cooling system

WindscreenWashers

RECOMMENDED LUBRICANTS & ANTI-FREEZE SOLUTIONS -- BRITISH ISLES -- ALL SEASONS

PER-FORMANCE

LEVEL

BL Cars Ltd" specification

BLS22.01.02

ATF meetingspecificationM2C 33G

ATF meetingSpecificationM2C 33G

MIL-L-2105

API GL4

NLGI-2Multi-purpose

Lithiumbased grease

This information supersedes that given in the Repair Operation Manual

(THE PRODUCTS RECOMMENDED ARE NOT LISTED IN ORDER OF PREFERENCE)

UNIPART

UnipartSuper

Motor Oil15w/50

BP

BP SuperVisco-Static

20/50

CASTROL

C~strolGTX

2ow/5o

BP CastrolAutranG TQF

BPAutran G

BP GearOil 90 EP

BPEnergrease

L2

CastrolTQF

CastrolHypoy90 EP

CastrolLMGrease

DUCKHAMS

DuckhamsQ Motor

Oil2ow/5o

DuckhamsQ-matic

DuckhamsQ-matic

DuckhamsHypoid 90

DuckhamsLB 1D

ESSO

Ess0 Uniflo15W/50 orEsso Super-

lube 10W/40

EssoglideType G

EssoglideType G

Esso GearOil GX

85W/140

EssoMulti-

purpose

MOBIL

Mobil SuperMotor Oil15W/40

MobilATF 210

MobilATF 210

MobilubeHD 90

MobilMP

PETROFINA

FinaSupergradeMotor Oil15W/40

FinaPurfimatic

33G

FinaPurfimatic

33G

FinaPontonic MP

80w/90

Fina MarsonHIL2Grease

Unipart Universal Brake Fluidor other Brake Fluids having a minimum boiling point of 260 ° C (500 ° F) and complying with FMVSS 116 DOT

Unipart Universal Anti-Freeze

Unipart All-Seasons Washer Fluid

TEXACO

HavolineMotor Oil15W/40

TexamaticType G

TexamaticType G

TexacoMultigearLubricant

90 EP

MarfakAll Purpose

Grease

SHELL

Shell SuperMotor Oil15W/40

ShellDonex TF

ShellDonax TF

ShellSpirax 90 EP

ShellRetinax A

* If final drive unit is completely drained refill with oil meeting BL Cars specification BLS 22.OL.03 or MIL-L-2105B.t Front Hubs. Mobilgrease Super.

O / ¯

ENGINECARBURETTERDASH POTSOIL CAN

FINAl_ DRIVE UNIT*TOP UP ONLY

MANUALGEARBOX

AUTOMATICGEARBOX-

REAR HUBSGREASE GUNBRAKE CABLESSTEERING RACK

BRAKE AND CLUTCHRESERVOIRS

COOLING SYSTEM

WINDSCREENWASHER

RECOMMENDED LUBRICANTS AND ANTI-FREEZE SOLUTIONS -- OVERSEAS MARKETSThis information supersedes that given in the Repair Operation Manual

SERVICE CLASSIFICATION AMBIENT TEMPERATURE o C

PERFORMANCE LEVEL

Use UNIPART SuperMultigrade Motor Oil ORother oils meeting BL Carsspecification BL 22.OL.02 ORthe requirements of the CCMCOR API-SE

MIL-L-2105API GL4

ATF meeting specificationM2C 33G

ATF meeting specificationM2C 33G

S.A.E.VISCOSITY

5w/2o5w/3o5W/40

lOW/3O10W/40lOW/5O15W/4015w/5o20W/402ow/5oHypoid 90Hypoid 80W

-30 -20 -10 0 +10

<>

l

+20

>

NLGI-2 Multi-purpose lithium based grease Front hubs NLGI-2 High Melting Point Grease

UNIPART UNIVERSAL BRAKE FLUID or other Brake Fluids having a minimum boiling point of 260°C (500°F)and complying with FMVSS 116 DOT 3

UNIPART UNIVERSAL ANTI-FREEZE

UNIPART ALL-SEASONS SCREEN WASHER FLUID

* Final Drive Unit if drained MUST be filled with an oil meeting BL Cars specification BLS 22.OL.03 or having a minimum performance level of MIL-L-2 105B

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MAINTENANCE SUMMARY, UK & EUROPEThis information supersedes that given in the Repair Operation Manual.After Sales Service = 1,000 miles/1500 kmIntermediate Service = Every 6 months or 6,000 miles/10 000 kmMain ̄ Service = Every 12 months or 12,000 miles/20 000 km

AfterSalesService

IntermediateService ..

Main Service (24 denotes every 24 months, 24,000 miles (40 000) kin)

¯ ACTION XOPERATIONFit car protection kitCheck condition and security of seats and seat beltsDrive on lift. Stop engineCheck operation of lampsCheck operation of hornsCheck operation of warning indicatorsCheck/adjust operation of screen washersCheck operation of screen wipersCheck security/operation of foot and hand brake: release fully aftercheckingOpen bonnet: fit wing coversDisconnect batteryRaise lift to convenient working height with wheels free to rotateRemove hub/wheel nut capsMark stud to wheel relationship front wheelsMark stud to wheel relationship rear wheelsRemove front wheelsRemove rear wheelsInspect road wheels for damageCheck tyre tread depthCheck tyres visually for external cuts in fabric, exposure of ply or cordstructure, lumps or bulgesCheck tyres for uneven wearCheck/adjust tyre pressuresInspect brake pads for wear and discs for condition. Renew pads ifnecessaryAdjust front hub bearing end-floatRemove brake drums, wash out dust, inspect shoes for wear and drumsfor condition. Renew shoes if necessary. Refit drumsInspect for fluid leaks from dampersCheck condition and security of steering unit, joints and gaitersRefit road wheels in original positionCheck tightness of road wheel fasteningsRefit hub/wheel nut capsRaise lift to convenient working heightDrain engine oilCheck/top-up gearbox oil

After SalesService

Intermediate

Main SerHce (24 denotes every 24 months, 24,000 miles (40 000)

Check/top-uprear axle oilCheck visually brake hoses, pipes and unions for chafing, cracks, leaksand corrosionCheck visually fuel and clutch pipes and unions for chafing, leaks andcorrosionCheck exhaust system for condition, leakage and securityAdjust handbrake cable (where accessible from below)Check security of accessible engine mountingsCheck security and condition of suspension joints and fixingsRenew engine oil filter element (where accessible from belowClean and refit drain plugCheck for oil leaks from engine and transmissionLubricate headlamp fitting mechanism pivotsLower liftFit exhaust extractor pipeCheck/adjust torque of cylinder head nuts/boltsRenew engine oil filter element (where accessible from above)Fill engine with oilLubricate all pedal pivots and control linkagesTop-up carburetter piston dampersRenew air cleaner element(s)Check security of accessible engine mountingsCheck driving belts, adjust or renewRenew spark plugsCheck/top-up battery electrolyteClean and grease battery connectionsCheck battery conditionReconnect batteryCheck/top-up clutch fluid reservoirCheck/top-up brake fluid reservoirCheck operation of brake fluid level warning light switch (where fitted)Check brake servo hose for security and conditionCheck/top-up screen washer reservoirCheck/top-up cooling systemPressure test cooling and heater system for leaksRenew fuel line filter (where fitted)Check visually crankcase breathing system for leaks and hoses forsecurity and conditionRenew engine breather filter (where fitted)Start engine and check sealing of oil filterStop engineCheck visually distributor contact points, adjust or renewCheck throttle and choke operation

MAINTENANCE SUMMARY, UK & EUROPEThis information supersedes that given in the Repair Operation Manual.After Sales Service = 1,000 miles/1500 kmIntermediate Service = Every 6 months or 6,000 miles/10 000 kmMain Service = Every 12 months or 12,000 miles~20 000 km

After SalesService

IntermediateService

Main Service (24 denotes every 24 months, 24,000 miles (40 000) kin)

¯ ACTION XOPERATIONStart engineCheck ignition distributor characteristics and timing, using electronicequipment. Adjust as necessaryStop engineSet to fast idle; leave engine runningLubricate all locks, hinges and door check mechanisms (not steeringlock)Check operation of all door, bonnet and boot locksCheck operation of window controlsCheck/adjust carburetter for engine idle speed and emissions settingsStop engine, disconnect instrumentsStart engine (auto only)Check/top-up automatic gearbox fluidStop engineRe-check tension if alternator driving belt has been renewedRemove wing coversFill in details and fix appropriate Unipart underbonnet stickersClose bonnetRemove exhaust extractor pipeRemove spare wheelInspect wheel for damageCheck tyre tread depthCheck tyre visually for external cuts in fabric, exposure of ply or cordstructure, lumps or bulges .... .Check tyre for uneven wear ’Check/adjust tyre pressureRefit spare wheelDrive off liftCheck headlamp alignmentCheck/adjust front wheel alignment .....Check front wheel alignmentReport additional work requiredRemove car protection kitEnsure cleanliness of controls, door handles, etc.Carry out road or roller test

After SalesService

IntermediateService

Main Service (24 denotes every 24 months, 24,000 miles (40 000) kin)

¯ ACTION XOPERATION

Road TestFit trade plates to vehicleCheck starter operation and inhibitor switch--AutomaticCheck operation of lights, horns, indicators, wipers and washersCheck indicators self-cancelCheck operation of all warning indicatorsCheck foot and hand brakesCheck engine noise levels, performance and throttle operationCheck clutch for free play, slipping and judderCheck gear selection and noise level in all gears. Check engagement ofauto box parking pawlCheck steering for noise, effort required, free play, wander and self-centringCheck alignment of steering wheel spokesCheck suspension for noise, irregularity in ride (e.g. dampers) and wheelimbalanceCheck foot brake pedal effort, travel, braking efficiency, pulling andbindingCheck speedometer for steady operation, noise and operation of mileagerecorderCheck operation of all instrumentsCheck for abnormal body noisesCheck operation of seat belts, including operation of inertia reelsCheck handbrake ratchet and holdAdjust engine idle speed while engine is hotPosition car on liftRaise liftInspect engine and transmission for oil leaksCheck exhaust system for condition, leakage and securityLower lift and drive vehicle offReport on road test findingsRemove car protection kitEnsure cleanliness of controls, door handles, etc.Remove trade plates

This Maintenance Summary was produced from Leycare Supplementary Job Sheet SMD 2553.Job Sheets used by BL Cars’ Dealers operating Leycare Service are updated as modificationsaffecting routine maintenance are introduced, and the content of this maintenance summary maydiffer from that currently used by Leycare Service operatives.

I I I I I i

............. ~ ................................................................................................................................................... ~--~ ...........................

BRAKE PREVENTATIVE MAINTENANCE

In addition to the recommended periodical inspection of brake components it is advisable as thecar ages and as a precaution against the effects of wear and deterioration, tc make a more searchinginspection and renew parts as necessary.

It is recommended that:Disc brake pads, drum brake linings, hoses and pipes should be exa mined at intervals no greaterthan those laid down in the Maintenance Summary.

2 Under normal operating conditions brake fluid should be changed completely every 18 months or18.000 miles (30 000 km) whichever is the sooner. If the vehicle is frequently subjected severe driving or operating conditions, it may be necessary to change the brake fluid at shortermtervals.

3 All fluid seals in the hydraulic system and all flexible hoses should be examined and renewed ifnecessary every three years or 60 000 km whichever is sooner. At the same time theworking sur-face of the pistons and of the bores of the master cylinder, wheel cylinders and other slave cylin-ders should be examined and new parts fitted where necessary.

Care must be taken always to observe the following points:a At all times use the recommended brake fluid.b Never leave the fluid in unsealed containers; it absorbs moisture quickly and can be dangerous if

used in your braking system in this condition.c Fluid drained from the system or used for bleeding should be discarded.d The necessity for absolute cleanliness throughout cannot be over-emphasized.

/ .

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MANUAL GEARBOX -- 5 SPEED

GEAR-CHANGE REMOTECONTROL ASSEMBLY

Overhaul 37.16.20

These instructions supersede those given in theRepair Operation Manual.

DismantlingRemove the remote control assemblyfrom the gearbox.

2 Remove the two bolts and two counter-sunk screws securing the bias springbridge plates.

3 Remove the two bridge plates, bridgeplate liners and the bias spring.

4 Remove the bias spring adjusting boltsand locknuts.

5 Remove the two bolts and washers secur-ing the reverse baulk plate assembly andwithdraw the reverse baulk plate, springsand spacers.

6 Remove the four bolts and washers secur-ing the bottom cover plate.

7 Remove the bottom cover plate.8 Remove the reverse light switch and

locknut.9 Remove the square-headed pinchbolt

securing the selector shaft elbow.10 Remove the selector shaft elbow.11, Withdraw the selector shaft.12 Press out the two selector shaft bushes in

the remote control casing.13 Remove the circlips securing thepivot ball

and bushes in the selector shaft elbowsand press out the bushes and pivot balls.

Assembling14 Press in new selector shaft bushes in the

remote control casing.15 Fit new bushes, pivot balls and circlips to

the selector shaft elbow.16 Fit the selector shaft to the casing.17 Fit the rear elbow and secure with the

square-headed pinchbolt.18 Fit the baulk plate assembly.19 Fitthe reverse switch and locknut.20 Fit the bottom cover plate.21 Fit the bias spring adjusting bolts and

locknuts.22 Fit the bias spring, bridge plate liners and

bridge plates.

23 Fit the remote control assembly to thegearbox.Operations to be carried out following thefitting of the remote control assembly tothe gearbox.

24 Fit the gear lever.

Adjusting the reverse baulk plateAdjustment of the reverse baulk plate must becarried out on a complete gearbox assembly.25 Remove the bottom cover plate of the gear

lever remote control assembly.26 Locate the gear lever in neutral in a ver-

tical position.27 Slacken the baulk plate adjusting bolts

and locknuts until the baulk plate is incontact with the backing plate.

28 Tighten the adjusting bolts equally untilthey just start to move the baulk plate outof contact with the backing plate.

29 Adjustment should be such that an effortof 30 to 35 lbf (13.6 to 15.9 kgf) required to overcome the resistance of thebaulk plate. This may be checked using aspring balance attached to the threadedend of the gear lever (gear knob end).Adjust by tightening or slackening thetwo adjacent bolts and locknuts located onthe right-hand side of the reverse baulkplate.NOTE: A minimum clearance of 0.010 in(0.254 mm) must exist between the upperface of the baulk plate and the lower edgeof the gear lever bush.

Adjustment of lst/2nd gate stopThis operation must be carried out followingthe adjustment of the reverse baulk plate.30 Engage 1st gear.31 Check the clearance between the side of

the gear lever and the edge of the baulkplate. This should be 0.010 to 0.049 in(0.25 to 1.25 ram). Adjust by adding removing shims as necessary.

32 Engage 2nd gear and repeat the aboveoperation.

33 Fit bottom cover plate

Adjustment of gear lever bias spring34 Unit completely assembled, engage 3rd

gear. ¯35 Adjust the screws to position both legs of

spring 0.5 mm clear of lever crosspin.

36

37

38

3940

(

Apply a light load to gear lever in L.H.direction taking up play. Adjust R.H.screw downward until R.H. spring leg justmakes contact with crosspin.Repeat instruction 36 on the other side.Play will still be present but at extremes ofgear lever travel the crosspin should makecontact with the spring legs.Return lever to neutral and rock acrossgate several times. Lever should return to3rd/4th gate.Tighten the locknuts.Adjust the reverse switch, see 86.65.20.

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WINDSCREENWASHERS

WINDSCREENUNIT

WIPERS AND

WIPER DELAY

Remove and refit 84.25.31

Removing1 Disconnect both multi-pin plugs from the

delay unit.2 Remove the mounting screws and nuts,

and withdraw the delay unit and insulat-ing plate.

Refitting3 Reverse instructions 1 and 2, ensuring

that the earth lead is fitted to one of themounting screws.

68 88~--~i

I I

1 Battery2 Alternator3 Ignition/starter switch4 Start inhibit switch (automatic transmis-

sion only)5 Starter relay6 Starter motor7 Headlamp motor circuit breaker8 Headlamp relay L.H.9 Headlamp relay R.H10 Headlamp motor L.H.I 1 Headlamp motor R.H.12 Radio13 Speaker14 Masterlight switch15 Main/dip/flashswitch16 Main beam warnmglight17 Main beam18 Dip beam19 Headlampflash unit20 Headlamp flash relay21 Front parking lamp22 Front fog lamp23 Rear fog guard lamp24 Tail lamp25 Number plate illumination lamp26 Fog switch27 Rear fog guard lamp warning light28 Panel rheostat

29 Heater control illumination30 Selector panel illumination

transmission only)31 Cigarettelighter illumination32 Panel illumination33 Switch panel illumination34 Clutch relay35 Air conditioning cut-out switch36 Full throttle cut-out switch37 Thermostat38 Blower motor switch39 Blower motor40 Pressure cut in switch41 Clutch42 Throttle jack43 Condenser fan relay L.H.44 Condenser fan relay R.H.45 Condenser fan L.H.46 Condenser fan R.H.47 Radiator thermostat48 Diode49 Hazard flasher unit50 Hazard switch51 Hazard warning light52 Cigarette lighter53 Horn-push54 Hornrelay55 Horn56 Windscreen wash/wipe switch

(automatic57 Wiper delay unit58 Windscreen wiper motor59 Windscreen washer motor60 Map/courtesy lamp61 Doorswitch62 Clock63 Luggage boot lamp 164 Luggage boot lamp switch~ R.H. steering

65 Luggage boot lamp/66 Luggage boot lamp switchj L.H. steering

67 Coolant low indicator unit68 Coolant low sensor69 Coolant low warning light70 Choke switch71 Choke warning light72 Voltmeter73 Temperature gauge74 Temperature transmitter75 Tachometer76 Fuel gauge77 Tank unit78 Low fuel delay unit79 Low fuel warning light80 Brake warning light81 Brake pressure differentialswitch82 Handbrakewarning light83 Handbrake switch84 Oil pressure warning light85 Oil pressure switch

86 Ignition warning light87 Ballast resistor wire88 Ignition coil 6volt89 Ignition distributor90 Heated rear screen switch91 Heated rear screen92 Heated rear screen warning light93 Seat belt warning light94 Passenger seat switch95 Passenger belt switch96 Driver belt switch97 Reverse lamp switch98 Reverse lamp99 Stop lamp switch100 Stop lamp101 Direction indicator flasher unit102 Direction indicator switch103 Indicator warning light L.H.104 Indicator warning light R.H.105 Front flasher lamp L.H.106 Front flasher repeater lamp connection

L.H107 Rear flasher lamp L.H.108 Front flasher lamp-- R.H.109 Front flasher repeater lamp connection

R.H.110 Rear flasher lamp R.H.

WIRE COLOUR CODES OF FLASHER LAMP CIRCUIT

Wireidentity

*1*2*3*4*5*6

Item

L.H. supplyL.H. front lampL.H. rear lampR.H. supplyR.H. front lampR.H. rear lamp

Right-hand steering

Heater vehicles Air conditioning

G/LGG/LGGWLG/GLGIGGR and LG

vehicles

GRGRGRGWGWGW and LG

Left-hand steering

Heater vehicles Air conditioning

LG/G -LG/GGR and LGG/LGG/LGGW

vehicles

GRGRGR and LGGWGWGW

COLOUR CODE

B Black N Brown S SlateG Green O Orange U BlueK Pink P Purple W WhiteLG Light green R Red Y Yellow

WIRING DIAGRAM ~ 1981 USA MARKETFUEL INJECTION VEHICLES

"ll ’

---Salz.----~114r~l~.

115 II

¯ ~LG

14~ . E11

!19

If

31

NY-

15

61

51

GR-

96

P N 62

-W.-- 6~-~

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1 Battery 292 Alternator 303 Starter motor 314 Headlamp relay R.H. 325 Headlamp relay L.H. 336 Headlamp motor circuit breaker 347 Starter relay 358 Starter inhibitor switch (automatic trans- 36

mission only) 379 Ignition/starter switch 3810 Condenser fan relay L.H. 3911 Condenser fan relay R.H, 4012 Condenser fan L.H. 4113 Condenser fan R.H. 4214 Diode 4315 Pressure cut in switch 4416 Air conditioning cut-out switch 4517 Full throttle cut-out switch 4618 Thermostat 4719 Radiator thermostat 4820 Temperature transmitter 4921 Voltmeter 5022 Temperature gauge 5123 Tachometer 5224 Fuel gauge 5325 Coolant low warning light 5426 Brake warning light 5527 Handbrake warning light 5628 Oil pressure warning light 57

Ignition warn iHeadlamp ~ot~Headlamp trio t ~-~.Master light svv-i_SpeakerRadioSeat belt tirraer//~zl - . .............................................................................................................................................................................................................................................................................................................................................Seat belt warning I ~- ............. , ................,,,..,,....,,,,.....,,,,,,,,..,.,,~..,,,,, ..............., ..................,.,, ...................., ..........................,,,.., .................~ .......................,,-, ...................................................===,,,..~-~ .................:....,,.: ..............~,,..,.; ............................................................= ...............Belt switchDoor switchAudible warning swHazard flasher un itCigarette lighterHorn-pushHorn relayClutch relayClutchEngine air solenoidr vaWindscreen washer rn-.HornWindscreen wash/wipo.~ ........................................................................................................................................................................................................................................................................................................................................................................................................Wiper delay unitWindscreen wiper rnotczz I1,t ttNml,, rl TTTHIIII ,Low fuel warning lightLow fuel delay unitTank unitIgnition coilAmplifierIgnition distributor

S~

B BI~--.-G GroK Pin a_LG Lig

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1 Electronic control unit E.C.U.2 Test facility feedback monitor plug3 Fuel pump4 Injector and E.C.U. relay5 Diode resistor pack6 Fuel pump relay7 Inertia switch8 Water temperature sensor9 Throttle switch10 Extra air valve11 Lambda sensor12 Air flow meter13 Thermotime switch14 Cold start injector15 No. 1 injector16 No. 2 injector17 No. 3 injector18 No. 4 injector

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12345678

1011121314151617181920212223

2425262728

BatteryAlternatorStarter motorHeadlamp relay -- R.H.Headlamp relay L.H.Headlamp motor circuit breakerStarter relayStarter. . inhibitor switch (automatic trans-mlsslon only)Ignition/starter switchCondenser fan relay L.H.Condenser fan relay-- R.H.Condenser fan -- L.H.Condenser fan -- R.HDiodePressure cut in switchAir conditioning cut-out switchFull throttle cut-out switchThermostatRadiator thermostatTemperature transmitterVoltmeterTemperature gaugeTachometerFuel gaugeCoolant low warning lightBrake warning lightHandbrake warning lightOil pressure warning light

2930313233343536373839404142434445464748495051525354555657

Ignition warn i r-J j,Headlarnp rnoto--~ .Headlarnp rrlot olMaster light s~it ......SpeakerRadioSeat belt tirnerJ2~tlz--Seat belt warning li~--Belt switchDoor switchAudible warning swi - - .,Hazard flasher unitCigarette lighterHorn-pushHorn relayClutch relayClutchEngine air solenoid valWindscreen washer mo .,~-HornWindscreen wash/wipeWiper delay unitWindscreen wiper rnoto,Low fuel warning lightLow fuel delay unitTank unitIgnition coilAmplifierIgnition distributor

B Blac_G Gree -K PinkkG Ligh~

-8- lJ’

o

o

o

o

o

-OG-

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o -YG--YN-

c-YG----

, -@S

i -SN--$U---

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1 Electronic control unit E.C.U.2 Test facility feedback monitor plug3 Fuel pump4 Injector and E.C.U.relay5 Diode resistor pack6 Fuelpump relay7 Inertia switch8 Water temperature sensor9 Throttle switch10 Extra air valve11 Lambda sensor12 Air flow meter13 Thermotime switch14 Cold start injector15 No. 1 injector16 No. 2 injector17 No. 3 injector18 No. 4 injector

Battery2 Alternator3 Starter motor4 Headlamp relay R.H.5 Headlamp relay L.H.6 Headlamp motor circuit breaker7 Starter relay8 Starter inhibitor switch (automatic trans-

mission only)9 Ignition/starter switch10 Condenser fan relay -- L.H.11 Condenser fan relay -- R.H.12 Condenser fan L.H.13 Condenser fan R.H.14 Diode15 Pressure cut in switch16 Air conditioning cut-out switch17 Full throttle cut-out switch18 Thermostat19 Radiator thermostat20 Temperature transmitter21 Voltmeter22 Temperature gauge23 Tachometer24 Fuel gauge25 Coolant low warning light26 Brake warning light27 Handbrake warning light28 Oil pressure warning light

29 Ignition warning light30 Headlamp motor L.H.31 Headlampmotor--R.H.32 Master light switch33 Speaker34 Radio35 Seat belt timer/buzzer unit36 Seat belt warning light37 Belt switch38 Door switch39 Audible warning switch40 Hazard flasher unit4l Cigarettelighter42 Horn-push43 Horn relay44 Clutch relay45 Clutch

Engine air solenoid valve47 Windscreen washer motor48 Horn49 Windscreen wash/wipe switch50 Wiper delay unit51 Windscreen wiper motor52 Low fuel warning light53 Low fuel delay unit54 Tank unit55 Ignition coil56 Amplifier57 Ignition distributor

58 Oil pressure switch59 Handbrake switch60 Brake pressure differential switch61 Heated back-light warning light62 Heated back-light switch63 Heated back-light64 Main beam warning light65 Main beam R.H.66 Main beam--L.H.67 Dip beam--R.H.68 Dip beam L.H.69 Front marker lamp-- R.H.70 Front parking lamp-- R.H.71 Front marker lamp-- L.H.72 Front parkinglamp L.H.73 Front fog lamp74 Rear fog guard lamp75 Tail lamp -- L.H.76 Rear marker lamp L.H.77 Number plate illumination lamp78 Rear marker lamp R.H.79 Tail lamp -- R.H.80 Selector panel illumination (automatic

transmission only)81 Cigarettelighter illumination82 Main/dip/flash switch83 Hazard warning light84 Hazard switch85 Turn signal flasher unit

COLOUR CODE

B BlackG GreenK PinkLG Light green

N BrownO OrangeP PurpleR Red

SUWY

SlateBlue,WhiteYellow

86 Clock87 Rear fog guard warning light88 Fog switch89 Panel rheostat90 Luggage boot lamp91 Luggage boot lampswitch92 Heater control illumination93 Map/courtesy lamp94 Door switch95 Service interval counter96 Coolant low indicator unit97 Coolant low sensor98 Oxygen sensor warning light99 Turn signal switch100 Reverse lamp switch101 Stop lamp switch102 Turn signal warning light-- L.H.103 Turn signal warning light R.H.104 Reverse lamp R.H.105 Reverse lamp-- L.H.106 Stop lamp R.H.107 Stop lamp L.H.108 Front flasher lamp R.H.109 Front flasher lamp-- L.H.110 Rear flasher lamp R.H.111 Rear flasher lamp -- L.H.112 Instrument illuminationI 13 Switch panel illumination114 Blower motor switchI 15 Blower motor

A Toinjector and ECU relayB Todiode resistor pack

l See also

C To fuel pump relayD Todiode resistor packE Fuel injection timing signal

Fuel InjecttonWiring Diagram

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/I~ITION DIST’I~I/~

riumph Part No.

tmcas Part No.

~lco l~emy Part No.

ltr~ition timing -- static

IImition timing at idle

idle speed

Gnventional points ignition

Ellctronic Ignition

C~a trifugal Advance

Vacmum Advance

Retard Unit

/

/

7z

f

IGNITION DISTRIBUTOR APPLICABILITY, IGNITION TIMING ANDFEATURES CHART 1981 IGNITION DISTRIBUTOR

Triumph Part No.

kucas Part No.

Delco Remy Part No.

Ignition timing static

Ignition timing at idle

Idle speed

LOWCOMPRESSION

ENGINE

Carburetter

1981

RKC 5525

X

9977370

10° B.T.D.C.

10° B.T.D.C

800 rev/minConvention al points ignition

Electron ic Ignition

Centrifugal Advance

Vacuum Advance

Retard Unit

It

X

I.,,t

It

X

CANADA

Carburetter

1981

RKC 4722

X

9977254

10 degrees B.T.D.C.

2 degrees A.T.D.C.Retard pipe connected

800 rev/min

X

It

X

-- DELCO REMY

DataManufacturerSeries ........................ ". ̄ . AC DelcoDelco l~emy’part’no, ...................... D308Stan part No. " ...................... 9977370Contact gap ..... ........................ RKC 5525

0.014 to 0.016 inRotation viewed on rotor ................Anti-clockwiseFiring angles ...........................

Dwell angle ........................... 90 _ 1 degreeOpen angle 39 + 1 degreeMov ............................. 51 _ I degreeing contact spring tension

19 to 24 ozfCondenser capacity ......... iiiiiiiiiiiiii 0.18 to 0.23 mfdEngine firing order....................... 1-3-4-2

Distributorr.p.m.

300550

10001500

Centrifnl al advance

Degs. distributor advance

Minimum ] Maximum

No advance to occur5 6.59.5

1

1112 14

Crankshaftr.p.m.

600lI0020003000

Degrees crankshaft advance

Minimum~

No advance to occurlO I 1319 I 22

Ins. ofmercuryvacuum

Vacuum advance

Degs. distributor advance Degs. crankshaft advance

Minimum Maximum Minimum Maximum

046.5

No advanceto occur4.5 07.5 87.5 13

91515