Service

Repair
Operation
Manual
Supplement
To be used with TR7
Repair Operation Manual AKM3079 B

Publication Part No. AKM3079/1

Published by BL Cars--Service
© BL CARSLIMITED 1980
G
 This supplement is intended for use with the TR7 Repair Operation Manual AKM 3079 B and pro-
vides additional information, changesto vehicle specifications and revisions to repair procedures.

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

MANUALGEARBOX-- 5 SPEED
Gear-change remote control assembly
--overhaul 37.16.20 ........................................................... 13

WIPERS AND WASHERS

Wiper delay unit
-- remove and refit 84.25.31 ..................................................... 13

ELECTRICAL
Ignition distributor
--data 86.35.00 .................................................... ~ .......... 19
Wiring diagrams
-- UKand Europe ............................................................. 14
--USA ...................................................................... 16

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GENERAL FITTING INSTRUCTIONS GENERAL SPECIFICATION DATA
GEARBOX -- 5 speed from VIN 402027
Vehicle Identification Number Ratios
Fifth (top) ......................... 0.792: 1
Location Fourth ............................ 1.00: 1
The vehicle identification number(V.I.N.) is stampedon a plate on the R.H. front suspension tower Third ............................. 1.40:1
and should be quoted in full.
A sample V.I.N. is shownbelow: Second ............................ 2.09: 1
First .............................. 3.32: 1
Reverse ........................... 3.43: 1
TP A D V 7 A A 402027 Overall ratios UK:
Fifth (top) ......................... 3.09: 1
Marque/Model range Fourth ............................ 3.90: 1
Third ............................. 5.46: 1
Class Second ............................ 8.15: 1
First .............................. 12.96: 1
Body Reverse ........................... 13.38: 1
Engine Overall ratios Europe, USAand Canada:
Fifth (top) ......................... 2.73: 1
Steering/Transmission Fourth ............................ 3.45: !
Third ............................. 4.83: 1
Model Year/Change Second ....... ..................... 7.21: 1
First .............................. 11.45: 1
Assembly Plant Reverse ........................... 11.83: 1
Serial Number
GEARBOX--AUTOMATIC -- from VIN 402027
Type ................................ Borg Warner 66

3rd 2nd 1st Rev.

Overallratios to 1 3.08-5.88 4.47-8.53 7.36-14.05 6.44-12.30
Roadspeed corresponding to 1000 r.p.m.
m.p.h ................... 21.9-11.47
km.p.h ................... 35.2-18.43
AUTOMATIC TRANSMISSION SHIFT SPEEDS WEIGHTS (APPROXIMATE) -- Coup~. From VIN 402027
Manual gearbox Automatic gearbox
Throttle Zero Light Part *Showroom: Minimum ................... 2258 lb (1024 kg) 2251 lb (1021 kg)
position throttle throttle throttle Maximum ................... 2335 lb (1059 kg) 2328 lb (1056 kg)
Selector 1 D D D D *Unladen: Minimum..................... 2348 lb (1065 kg) 2341 lb (1062 kg)
Maximum..................... 2425 lb (1100 kg) 2418 lb (1097 kg)
Shift 2-1 1-2 2-3 3-2 2-1 *Gross vehicle weight ..................... 2954 lb (1340 kg) 2954 lb (1340 kg)
*Maximumaxle load: Front ............... 1576 lb (715 kg) 1576lb (715 kg)
Road speed Rear ................ 1466 lb (665 kg) 1466lb (665 kg)
m.p.h. 28-39 7-13 12-19 27-43 12-22 *Towingcapacity -- braked trailer .......... 2240 lb (1016 kg) 2240 lb (1016 kg)
km.p.h. 45-63 11-21 19-31 43-69 19-35

Throttle WEIGHTS
(APPROXIMATE)
-- Convertible. From VIN 402027
position : Kickdown Manualgearbox Automatic gearbox
*Showroom: Minimum ................... 2249 lb (1020 kg) 2240 lb (1016 kg)
Selector D D D 1 D Maximum ................... 2326 lb (1055 kg) 2317 lb (1051 kg)
Shift 1-2 2-3 3-2 2-1 3-1 *Unladen: Minimum..................... 2339 lb (1061 kg) 2330 lb (1057 kg)
*Gross vehicle weight ..................... 2954 lb (1340 kg) 2954 lb (1340 kg)
Road speed * Maximum axle load: Front ............... 1576 lb (715 kg) 1576lb (715 kg)
m.p.h. 38-48 70-80 60-72 39-50 25-38 Rear ................ 1466 lb (665 kg) 1466lb (665 kg)
km.p.h. 61-77 112-128 96 116 63-81 40-61 *Towingcapacity -- braked trailer .......... 2240 lb (1016 kg) 2240 lb (1016 kg)

FINALDRIVE-- from VIN 402027

Ratios: Usedwith 5 speed gearbox * These figures must be taken as a guide only and vary according tomarket, modelyear and equip-
U.K .............................. 3.90: 1 mentfitted.
Europe, USAand Canada ........... 3.45: 1
Used with Automatic gearbox
Ratio .............................. 3,08: 1

TYRES
Size:
Automatic Transmission (from VIN
402027) ........................... 185,/70 SR 13
5 Speed Transmission
This information supersedes that which is given in the Repair Operation Manual.
UKand Europe .................. 185/70 HR 13
USAand Canada ................. 185,/70 SR 13

CAPACITIES (NOMINAL)
This informauonsupersedes that which is given in the Repair Operation Manual.
USA Imperial Metric
Fuel tank ............................ 14.4 gals 12 gals 54.5litres
Rear axle from dry ................... 2 pts 1,6 pts 0,9 [itres
Windscreen washer reservoir ........... 3.3 pts 2.75 pts 1.6 litres
Air conditioning system ................ 2.5 lbs 1.1 kg. of refigerant 12
./ .......... ..........

ENGINE TUNING DATA -- CANADA from VIN 402027 ENGINE TUNING DATA -- Low Compression Engine

WARNING: Before commencing workon an ignition system, all high tension terminals, adaptors and
diagnostic equipmentfor testing should be inspectedto ensure that they are adequatelyinsulated and
shielded, to preventaccidental personalcontact andminimizethe risk of shock.
Wearers of surgically implantedpacemaker
or diagnostic equipment.
ENGINE
Type .. ........ ......................
Capacity .............................
Compression ratio .....................
Firing order ..........................
Numberone cylinder ...................
Idle speed ............................
Ignition timing:
Static .............................
Dynamicat idle ....................
Location of ignition timing marks . .......
Valve clearance (engine cold):
Inlet ..............................
Exhaust ...........................
Valve clearance adjustment
IGNITION DISTRIBUTOR...............
SPARK PLUGS
Make/type ...........................
Gap .................................
IGNITION COIL
Make/type ...........................
Primary resistance at 20°C (68°F) .......
CARBURETTERS
Make ...............................
Type ................................
Needle ..............................
WARNING: Before commencing workon an ignition system, all high tension terminals, adaptors and
diagnostic equipment for testing shouldbe inspectedto ensurethat they are adequatelyinsulated and
shielded, to preventaccidental personalcontact andminimizethe risk of shock.
devices shouldnot be in close proximityto ignition circuits Wearers of surgically implantedpacemaker devices shouldnot be in close proximityto ignition circuits
or diagnostic equipment.
ENGINE
O.h~c.in line 4 cylinder Type ................................ O.h.c. in line 4 cylinder
122 in ~ 8(1998 cm Capacity ............................. 122 in 3 3)
(1998 cm
8.0:1 Compression ratio ................ i .... 8.0:1
1-3-4-2 Firing order .......................... 1-3-4-2
Front Number one cylinder ................... Front
800 _ 100 rev/min Idle speed ............................ 650 to 850 rev/min
Ignition timing:
10° B.T.D.C. Static ... .......................... 10o B.T.D.C.
2° A.T.D.C. Dynamic .......................... 10° B.T.D.C. at 650 to 850 rev/min
Scale on front cover -- notch on pulley Location of ignition timing marks ......... Scale on front cover -- notch on pulley
Valve clearance (engine cold):
0.008 in (0.2 mm) Inlet .............................. 0.008 in (0.2 ram)
0.018 in (0.5 mm) Exhaust ........................... 0.0!8 in (0.5 mm)
Pallets between valve and camfollower Valve clearance adjustment ............. Pallets betweenvalve and camfollower
Inlet opens 16° B.T.D.C. Valve timing ..........................
Inlet closes 56° A.B.D.C. Inlet opens 16° B.T.D.C.
Exhaust opens 56° B.B.D.C. Inlet closes 56° A.B.D.C.
Exhaust closes 16.0 A.T.D.C. Exhaust opens 56° B.B.D.C.
Exhaust closes 16° A.T.D.C.
See 86.35.00
IGNITION DISTRIBUTOR............... See 86.35.00
Champion N 12Y or Unipart GSP 131 SPARK PLUGS
0.024 to 0.026 in (0.61 to 0.66 ram). Make/type ............................ Champion N 12Y
Gap ................................. 0.024 to 0.026 in (0.61 to 0.66 mm).
Lucas 15C6 or A.C. Delco 3474214 IGNITION COIL
1.3 to 1.5 ohms Make/type ........................... Lucas 15C6
Primary resistance at 20°C (68°F) ....... 1.3 to 1.5 ohms
Twin Zenith Stromberg CARBURETTERS
175 CD SEVX Make/type ........................... Twin SU HS6
B1DH Needle .............................. BBF

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TORQUE WRENCH SETTINGS ANTI-FREEZE SOLUTIONS -- ALL MARKETS
These instructions supersede those given in the Repair Operation Manual. These instructions supersede those given in the Repair Operation Manual.
AIR CONDITIONING The overall anti-freeze concentration should not fall below 30%by volumeto ensure that the anti-
Operation Description Specified torque corrosion properties of the coolant are maintained.
Nm Ibf ft kgfm
Use U N 1 PARTUniversal anti- freeze to protect the cooling system.
Hoses Flare Type
Compressor to Condenser 3A" Crimp Back Nut 40 30 4,0 If this is not available, use an ethylene glycol based anti-freeze (containing no methanol)with non-
Condenser to Receiver Drier %" Crimp Back Nut 28 21 2,9 phosphatecorrosion inhibitors suitable for use in mixedmetal engines to ensure the protection of the
Evaporator to Compressor 7/8" Crimp Back Nut 50 37 5,1 cooling system against frost and corrosion.
Evaporator to Receiver Drier %" Crimp Back Nut 28 21 2,9
Ranco Valve to Receiver Drier ~6" Flare Nut 12 9 1.2 CAUTION:
No other universal anti-freeze should be used with UNIPART
Universal Anti-freeze.
Rotaloek Valve to Compressor 1" UNS 50 37 5,1
Hoses -- ’O’ Ring Type
Compressor to Condenser
Compressor end 1" UNSGasket Nut 27 20 2.7
Condenser end 3~,, Gasket Nut 27 20 2.7
Evaporator to Compressor
Compressor end 1" UNSGasket Nut 27 20 2.7
Evaporator end 7/8" UNFNut 37 27 3.7
Condenser to Receiver Drier %" UNFGasket Nut 18 13 1.8
Receiver Drier to Evaporator %" UNF Nut 18 13 1.8
Ranco Valve to Receiver Drier ~6" UNFGasket Nut 9 7 0.9
 RECOMMENDED
LUBRICANTS& ANTI-FREEZESOLUTIONS-- BRITISH ISLES -- ALL SEASONS
This informationsupersedes that given in the RepairOperationManual
(THE PRODUCTSRECOMMENDED
ARE NOT LISTED IN ORDER OF PREFERENCE)

PER-
FORMANCE
COMPONENT LEVEL UNIPART BP CASTROL DUCKHAMS ESSO MOBIL PETROFINA TEXACO SHELL

Engine BL Cars Ltd Unipart BP Super C~strol Duckhams Ess0 Uniflo Mobil Super Fina Havoline Shell Super
Carburetter " specification Super Visco-Static GTX Q Motor 15W/50 or Motor Oil Supergrade Motor Oil Motor Oil
and Oil Can BLS Motor Oil 20/50 2ow/5o Oil Esso Super- 15W/40 Motor Oil 15W/40 15W/40
22.01.02 15w/50 2ow/5o lube 10W/40 15W/40

Manual Gearbox ATF meeting BP Castrol Duckhams Essoglide Mobil Fina Texamatic Shell
specification AutranG TQF Q-matic Type G ATF 210 Purfimatic Type G Donex TF
M2C 33G 33G

Automatic ATF meeting BP Castrol Duckhams Essoglide Mobil Fina Texamatic Shell
Gearbox Specification Autran G TQF Q-matic Type G ATF 210 Purfimatic Type G Donax TF
M2C 33G 33G

Final Drive MIL-L- BP Gear Castrol Duckhams Esso Gear Mobilube Fina Texaco Shell
Unit* 2105 Oil 90 EP Hypoy Hypoid 90 Oil GX HD 90 Pontonic MP Multigear Spirax 90 EP
API GL4 90 EP 85W/140 80w/90 Lubricant
90 EP

Grease Points NLGI-2 BP Castrol Duckhams Esso Mobil Fina Marson Marfak Shell
Brake Cables Multi-purpose Energrease LMGrease LB 1D Multi- MP HIL2 All Purpose Retinax A
Steering Rack Lithium L2 purpose Grease Grease
and Rear Hubs1" based grease

Brake and Clutch Unipart Universal Brake Fluid

Reservoirs or other Brake Fluids having a minimumboiling point of 260 ° C (500 ° F) and complying with FMVSS
116 DOT

Cooling system Unipart Universal Anti-Freeze

Windscreen Unipart All-Seasons Washer Fluid

Washers

* If final drive unit is completely drained refill with oil meetingBL Cars specification BLS22.OL.03or MIL-L-2105B.
t Front Hubs. Mobilgrease Super.

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RECOMMENDED
LUBRICANTSAND ANTI-FREEZESOLUTIONS-- OVERSEASMARKETS
This informationsupersedesthat given in the Repair OperationManual

SERVICE CLASSIFICATION AMBIENT TEMPERATURE o C

PERFORMANCE LEVEL S.A.E. -30 -20 -10 0 +10 +20

VISCOSITY

ENGINE Use UNIPARTSuper 5w/2o

CARBURETTER Multigrade Motor Oil OR 5w/3o
DASH POTS other oils meeting BLCars 5W/40 <
OIL CAN specification BL 22.OL.02 OR lOW/3O
the requirements of the CCMC >
10W/40
OR API-SE lOW/5O
15W/40
15w/5o
20W/40
2ow/5o
FINAl_ DRIVE UNIT* MIL-L-2105 Hypoid 90
TOP UP ONLY API GL4 Hypoid 80W l

MANUAL ATFmeeting specification

GEARBOX M2C 33G

AUTOMATIC ATFmeeting specification

>
GEARBOX- M2C 33G

REAR HUBS NLGI-2Multi-purpose lithium based grease Front hubs NLGI-2High Melting Point Grease
GREASE GUN
BRAKE CABLES
STEERING RACK

BRAKE AND CLUTCH UNIPARTUNIVERSAL BRAKEFLUID or other Brake Fluids having a minimumboiling point of 260°C (500°F)
RESERVOIRS and complying with FMVSS116 DOT3

COOLING SYSTEM UNIPART UNIVERSAL ANTI-FREEZE

WINDSCREEN UNIPART ALL-SEASONS SCREEN WASHER FLUID

WASHER

* Final Drive Unit if drained MUST

be filled with an oil meeting BL Cars specification BLS22.OL.03 or having a minimumperformance level of MIL-L-2105B
MAINTENANCE SUMMARY, UK & EUROPE
This informationsupersedesthat given in the RepairOperationManual. After Sales
Service
After Sales Service= 1,000 miles/1500km
IntermediateService= Every6 monthsor 6,000 miles/10 000 km Intermediate
Main¯Service= Every12 monthsor 12,000miles/20 000 km
MainSerHce(24 denotes every 24 months,24,000 miles (40 000)
AfterSales
Service
Intermediate Check/top-uprear axle oil
Service .. Checkvisually brake hoses, pipes and unions for chafing, cracks, leaks
and corrosion
MainService (24 denotesevery 24 months,24,000 miles (40 000) kin) Checkvisually fuel and clutch pipes and unions for chafing, leaks and
corrosion
¯ ACTION XOPERATION Checkexhaust system for condition, leakage and security
Fit car protection kit Adjust handbrake cable (where accessible from below)
Checkcondition and security of seats and seat belts Checksecurity of accessible engine mountings
Drive on lift. Stop engine Checksecurity and condition of suspension joints and fixings
Checkoperation of lamps Renewengine oil filter element (where accessible from below
Checkoperation of horns Cleanand refit drain plug
Checkoperation of warning indicators Checkfor oil leaks from engine and transmission
Check/adjust operation of screen washers Lubricate headlampfitting mechanismpivots
Checkoperation of screen wipers Lowerlift
Checksecurity/operation of foot and hand brake: release fully after Fit exhaust extractor pipe
checking Check/adjust torque of cylinder head nuts/bolts
Openbonnet: fit wing covers Renewengine oil filter element (where accessible from above)
Disconnect battery Fill enginewith oil
Raise lift to convenient workingheight with wheelsfree to rotate Lubricate all pedal pivots and control linkages
Removehub/wheel nut caps Top-up carburetter piston dampers
Markstud to wheel relationship front wheels Renewair cleaner element(s)
Markstud to wheel relationship rear wheels Checksecurity of accessible engine mountings
Removefront wheels Checkdriving belts, adjust or renew
Removerear wheels Renewspark plugs
Inspect road wheels for damage Check/top-up battery electrolyte
Check tyre tread depth Clean and grease battery connections
Checktyres visually for external cuts in fabric, exposureof ply or cord Checkbattery condition
structure, lumps or bulges Reconnect battery
Checktyres for uneven wear Check/top-upclutch fluid reservoir
Check/adjust tyre pressures Check/top-upbrake fluid reservoir
Inspect brake pads for wear and discs for condition. Renewpads if Checkoperation of brake fluid level warninglight switch (wherefitted)
necessary Checkbrake servo hose for security and condition
Adjust front hub bearing end-float Check/top-up screen washer reservoir
Removebrake drums, wash out dust, inspect shoes for wear and drums Check/top-up cooling system
for Pressure test cooling and heater system for leaks
s condition. Renewshoes if necessary. Refit drum Renewfuel line filter (wherefitted)
Inspect for fluid leaks from dampers
Checkcondition and security of steering unit, joints and gaiters Checkvisually crankcase breathing system for leaks and hoses for
Refit road wheelsin original position security and condition
Checktightness of road wheel fastenings Renewengine breather filter (where fitted)
Refit hub/wheel nut caps Start engine and checksealing of oil filter
Raise lift to convenient workingheight Stop engine
Drain engine oil Checkvisually distributor contact points, adjust or renew
Check/top-up gearbox oil Checkthrottle and choke operation
MAINTENANCE SUMMARY, UK & EUROPE After Sales
This informationsupersedesthat given in the Repair OperationManual.
After Sales Service = 1,000 miles/1500 km Service
IntermediateService= Every6 monthsor 6,000 miles/10 000 km Intermediate
MainService= Every 12 monthsor 12,000miles~20000 km Service

After Sales MainService (24 denotes every 24 months,24,000 miles (40 000) kin)
Service
Intermediate ¯ ACTION XOPERATION
Service

MainService (24 denotesevery 24 months,24,000 miles (40 000) kin) Road Test
¯ ACTION XOPERATION Fit trade plates to vehicle
Start engine Check starter operation and inhibitor switch--Automatic
Checkignition distributor characteristics and timing, using electronic Checkoperation of lights, horns, indicators, wipers and washers
equipment. Adjust as necessary Checkindicators self-cancel
Stop engine Checkoperation of all warning indicators
Set to fast idle; leave engine running Check foot and hand brakes
Lubricate all locks, hinges and door check mechanisms(not steering Checkengine noise levels, performanceand throttle operation
lock) Checkclutch for free play, slipping and judder
Checkoperation of all door, bonnet and boot locks Checkgear selection and noise level in all gears. Checkengagementof
Checkoperation of windowcontrols auto box parking pawl
Check/adjust carburetter for engine idle speed and emissions settings Checksteering for noise, effort required, free play, wanderand self-
Stop engine, disconnect instruments centring
Start engine (auto only) Checkalignment of steering wheel spokes
Check/top-up automatic gearbox fluid Checksuspension for noise, irregularity in ride (e.g. dampers)and wheel
Stop engine imbalance
Re-checktension if alternator driving belt has been renewed Checkfoot brake pedal effort, travel, braking efficiency, pulling and
Removewing covers binding
Fill in details and fix appropriate Unipart underbonnetstickers Checkspeedometer for steady operation, noise and operation of mileage
Close bonnet recorder
Removeexhaust extractor pipe Checkoperation of all instruments
Removespare wheel Check for abnormal body noises
Inspect wheel for damage Checkoperation of seat belts, including operation of inertia reels
Checktyre tread depth Check handbrake ratchet and hold
Checktyre visually for external cuts in fabric, exposureof ply or cord Adjust engine idle speed while engine is hot
structure, lumps or bulges .... . Position car on lift
Check tyre for uneven wear ’ Raiselift
Check/adjust tyre pressure Inspect engine and transmission for oil leaks
Refit spare wheel Checkexhaust system for condition, leakage and security
Driveoff lift Lowerlift and drive vehicle off
Check headlamp alignment Report on road test findings
Check/adjust front wheel alignment ..... Removecar protection kit
Check front wheel alignment Ensurecleanliness of controls, door handles, etc.
Report additional work required Removetrade plates
Removecar protection kit
Ensurecleanliness of controls, door handles, etc.
Carry out road or roller test This MaintenanceSummary was produced from Leycare SupplementaryJob Sheet SMD2553.
Job Sheets used by BLCars’ Dealers operatingLeycareService are updatedas modifications
affecting routine maintenanceare introduced, and the content of this maintenancesummary
may
differ fromthat currentlyused by LeycareService operatives.
I I I I I i
 ............. ~ ................................................................................................................................................... ~--~ ...........................

BRAKE PREVENTATIVE MAINTENANCE

In addition to the recommended periodical inspection of brake componentsit is advisable as the

car ages and as a precaution against the effects of wear and deterioration, tc makea moresearching
inspection and renewparts as necessary.

It is recommended that:
Disc brake pads, drumbrake linings, hoses and pipes should be exa minedat intervals no greater
than those laid downin the Maintenance Summary.
2 Under normal operating conditions brake fluid should be changedcompletely every 18 months or
18.000 miles (30 000 km) whichever is the sooner. If the vehicle is frequently subjected
severe driving or operating conditions, it maybe necessary to change the brake fluid at shorter
mtervals.
3 All fluid seals in the hydraulic systemand all flexible hoses should be examinedand renewedif
necessary every three years or 60 000 kmwhichever is sooner. At the same time theworkingsur-
face of the pistons and of the bores of the master cylinder, wheel cylinders and other slave cylin-
ders should be examinedand newparts fitted where necessary.
Care must be taken always to observe the following points:
a At all times use the recommendedbrake fluid.
b Never leave the fluid in unsealed containers; it absorbs moisture quickly and can be dangerousif
used in your braking systemin 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 REMOTE
CONTROL ASSEMBLY
Overhaul 37.16.20
These instructions supersede those given in the
Repair Operation Manual.
Dismantling
Remove the remote control assembly
from the gearbox.
2 Removethe two bolts and two counter-
sunk screws securing the bias spring
bridge plates.
3 Removethe two bridge plates, bridge
plate liners and the bias spring.
4 Removethe bias spring adjusting bolts
and locknuts.
5 Removethe two bolts and washers secur-
ing the reverse baulk plate assembly and
withdrawthe reverse baulk plate, springs
and spacers.
6 Removethe four bolts and washers secur-
ing the bottomcover plate.
7 Removethe bottom cover plate.
8 Removethe reverse light switch and
locknut.
9 Remove the square-headed pinchbolt
securing the selector shaft elbow.
10 Removethe selector shaft elbow.
11, Withdrawthe 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 elbows
and press out the bushes and pivot balls.
Assembling
14 Press in newselector shaft bushes in the
remote control casing.
15 Fit newbushes, 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 bottomcover 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 the 36 Apply a light load to gear lever in L.H. WINDSCREEN WIPERS AND
gearbox. direction taking up play. Adjust R.H. WASHERS
Operations to be carried out following the screw downward until R.H. spring leg just
fitting of the remote control assembly to makescontact with crosspin. WINDSCREEN WIPER DELAY
the gearbox. 37 Repeat instruction 36 on the other side. UNIT
24 Fit the gear lever. Play will still be present but at extremesof
gear lever travel the crosspin should make
Adjustingthe reverse baulkplate contact with the spring legs. Remove
and refit 84.25.31
Adjustmentof the reverse baulk plate must be 38 Return lever to neutral and rock across
carried out on a complete gearbox assembly. gate several times. Lever should return to Removing
1 Disconnect both multi-pin plugs from the
25 Removethe bottom cover plate of the gear 3rd/4th gate.
lever remote control assembly. 39 Tighten the locknuts. delay unit.
26 Locate the gear lever in neutral in a ver- 2 Removethe mounting screws and nuts,
40 Adjust the reverse switch, see 86.65.20.
tical position. and withdrawthe delay unit and insulat-
27 Slacken the baulk plate adjusting bolts ing plate.
and locknuts until the baulk plate is in
contact with the backing plate. Refitting
28 Tighten the adjusting bolts equally until 3 Reverse instructions 1 and 2, ensuring
they just start to movethe baulk plate out that the earth lead is fitted to one of the
of contact with the backing plate. mounting screws.
29 Adjustmentshould be such that an effort
of 30 to 35 lbf (13.6 to 15.9 kgf)
required to overcomethe resistance of the
baulk plate. This maybe checked using a
spring balance attached to the threaded
end of the gear lever (gear knob end).
Adjust by tightening or slackening the
two adjacent bolts and locknuts located on
the right-hand side of the reverse baulk
plate.
NOTE:A minimumclearance of 0.010 in
(0.254 mm)must exist between the upper
face of the baulk plate and the lower edge
of the gear lever bush.
Adjustmentof lst/2nd gate stop
This operation must be carried out following
the adjustment of the reverse baulk plate.
30 Engage 1st gear.
31 Checkthe clearance between the side of
the gear lever and the edge of the baulk
plate. This should be 0.010 to 0.049 in
(0.25 to 1.25 ram). Adjust by adding
removingshims as necessary.
32 Engage 2nd gear and repeat the above
operation.
33 Fit bottom cover plate
Adjustmentof gear lever bias spring
34 Unit completely assembled, engage 3rd
gear. ¯
35 Adjust the screws to position both legs of
spring 0.5 mmclear of lever crosspin.
68
i 88~--~

II
1 Battery 29 Heater control illumination
2 Alternator 57 Wiper delay unit 86 Ignition warning light
30 Selector panel illumination (automatic 58 Windscreen wiper motor
3 Ignition/starter switch transmission only) 87 Ballast resistor wire
4 Start inhibit switch (automatic transmis- 59 Windscreen washer motor 88 Ignition coil 6volt
31 Cigarettelighter illumination 60 Map/courtesy lamp
sion only) 32 Panel illumination 89 Ignition distributor
5 Starter relay 61 Doorswitch 90 Heated rear screen switch
33 Switch panel illumination 62 Clock
6 Starter motor 34 Clutch relay 63 91 Heated rear screen
7 Headlampmotor circuit breaker Luggage boot lamp 1 92 Heated rear screen warning light
35 Air conditioning cut-out switch 64 Luggage boot lamp switch~ R.H. steering
8 Headlamp relay L.H. 36 Full throttle cut-out switch 93 Seat belt warning light
9 Headlamp relay R.H 37 Thermostat 65 Luggage boot lamp 94 Passenger seat switch
10 Headlamp motor L.H. 38 Blower motor switch 66 Luggage boot lamp switchj / L.H. steering 95 Passenger belt switch
I 1 Headlamp motor R.H. 39 Blower motor 67 Coolant low indicator unit 96 Driver belt switch
12 Radio 40 Pressure cut in switch 68 Coolant low sensor 97 Reverse lamp switch
13 Speaker 41 Clutch 69 Coolant low warning light 98 Reverse lamp
14 Masterlight switch 42 Throttle jack 70 Choke switch 99 Stop lamp switch
15 Main/dip/flashswitch 43 Condenser fan relay L.H. 71 Chokewarning light 100 Stop lamp
16 Main beam warnmglight 44 Condenser fan relay R.H. 72 Voltmeter 101 Direction indicator flasher unit
17 Main beam 45 73 102 Direction indicator switch
Condenser fan L.H. Temperature gauge
18 Dip beam 46 Condenser fan R.H. 74 Temperature transmitter 103 Indicator warning light L.H.
19 Headlampflash unit 47 75 104 Indicator warning light R.H.
Radiator thermostat Tachometer 105 Front flasher lamp L.H.
20 Headlampflash relay 48 Diode 76 Fuel gauge
21 Front parking lamp 49 Hazardflasher unit 77 106 Front flasher repeater lamp connection
Tank unit
22 Front fog lamp 50 Hazard switch 78 Lowfuel delay unit L.H
23 Rear fog guard lamp 51 Hazard warning light 79 107 Rear flasher lamp L.H.
Lowfuel warning light 108 Front flasher lamp-- R.H.
24 Tail lamp 52 Cigarette lighter 80 Brake warning light
25 Numberplate illumination lamp 53 Horn-push 81 Brake pressure differentialswitch 109 Front flasher repeater lamp connection
26 Fog switch 54 Hornrelay 82 Handbrakewarning light R.H.
27 Rear fog guard lamp warning light 55 Horn 83 110 Rear flasher lamp R.H.
Handbrake switch
28 Panel rheostat 56 Windscreen wash/wipe switch 84 Oil pressure warning light
85 Oil pressure switch

WIRE COLOUR CODES OF FLASHER LAMP CIRCUIT

Right-hand steering Left-hand steering

Wire
identity Item
Heater vehicles Air conditioning Heater vehicles Air conditioning
vehicles vehicles
*1 L.H. supply G/LG GR LG/G - GR
*2 L.H. front lamp G/LG GR LG/G GR COLOUR CODE
*3 L.H. rear lamp GW GR GR and LG GR and LG
*4 R.H. supply LG/G GW G/LG B
*5 R.H. front lamp GW Black N Brown S Slate
LGIG GW G/LG GW G Green O Orange
*6 R.H. rear lamp GR and LG GWand LG U Blue
GW GW K Pink P Purple W White
LG Light green R Red Y Yellow
 WIRING DIAGRAM~ 1981 USA MARKET
FUEL INJECTION VEHICLES

"ll ’ 115 II

¯ ~LG

---Salz.----~114r~l~.
. E
11 14~
!
19

15

If
31 61
NY-

P N62
51

-W.-- -~
6~

GR-

96
 (

1 Battery 29 Ignition warn i

2 Alternator 30 Headlamp ~ot~
3 Starter motor 31 Headlamp trio t ~-~.
4 Headlamp relay R.H. 32 Master light svv-i_
5 Headlamp relay L.H. 33 Speaker
6 Headlampmotor circuit breaker 34 Radio
7 Starter relay 35 Seat belt tirraer//~zl - . ..................................................................................................................................................................................................................................................
8 Starter inhibitor switch (automatic trans- 36 Seat belt warning I ~- ............. ,...............
.,,,..,,....,,,,.....,,,,,,,,..,.,,~..,,,,,
...............
, ..................
,.,,....................
, .........................
.,,,..,.................
~.......................
,,-,...................................................
===,,,..~-~.................:....,,.:
..............
~,,..,.;
.....................................................
=.............
mission only) 37 Belt switch
9 Ignition/starter switch 38 Door switch
10 Condenser fan relay L.H. 39 Audible warning sw
11 Condenser fan relay R.H, 40 Hazard flasher un it
12 Condenser fan L.H. 41 Cigarette lighter
13 Condenser fan R.H. 42 Horn-push
14 Diode 43 Horn relay
15 Pressure cut in switch 44 Clutch relay
16 Air conditioning cut-out switch 45 Clutch
17 Full throttle cut-out switch 46 Engine air solenoidr va
18 Thermostat 47 Windscreen washer rn-.
19 Radiator thermostat 48 Horn
20 Temperature transmitter 49 Windscreen
wash/wipo.~
........................................................................................................................................................................................................................................................................................................................
21 Voltmeter 50 Wiper delay unit
22 Temperature gauge 51 Windscreen wiper rnotczz I1,t
ttNml,,rlTTTHIIII
,
23 Tachometer 52 Low fuel warning light
24 Fuel gauge 53 Low fuel delay unit
25 Coolant low warning light 54 Tank unit
26 Brake warning light 55 Ignition coil
27 Handbrake warning light 56 Amplifier
28 Oil pressure warninglight 57 Ignition distributor

B BI~--.-
G Gro
K Pin a_
S~ LG Lig
/

1 Electronic control unit E.C.U.

2 Test facility feedback monitor plug
3 Fuel pump
4 Injector and E.C.U. relay
5 Diode resistor pack
6 Fuel pumprelay
7 Inertia switch
8 Water temperature sensor
9 Throttle switch
10 Extra air valve
11 Lambda sensor
12 Air flow meter
13 Thermotime switch
14 Cold start injector
15 No. 1 injector
16 No. 2 injector
17 No. 3 injector
18 No. 4 injector

@
 .E
(

1 Battery
2 29 Ignition warn i r-J j,
Alternator 30 Headlarnp
3 Starter motor rnoto--~ .
4 Headlamp relay -- R.H. 31 Headlarnp rrlot ol
5 Headlamp relay L.H. 32 Master light s~it ......
6 Headlampmotor circuit breaker 33 Speaker
7 Starter relay 34 Radio
8 35 Seat belt tirnerJ2~tlz--
Starter. . inhibitor switch (automatic trans- 36 Seat belt warning li~--
mlsslon only)
Ignition/starter switch 37 Belt switch
10 38 Door switch
Condenser fan relay L.H. 39 Audible warning swi -
11 Condenser fan relay-- R.H. - .,
12 40 Hazard flasher unit
Condenser fan -- L.H. 41 Cigarette lighter
13 Condenser fan -- R.H
14 42 Horn-push
Diode 43 Horn relay
15 Pressure cut in switch
16 Air conditioning cut-out switch 44 Clutch relay
17 Full throttle cut-out switch 45 Clutch
18 46 Engine air solenoid val
Thermostat 47 Windscreen
19 Radiator thermostat washer mo .,~-
20 Temperature transmitter 48 Horn
21 Voltmeter 49 Windscreen wash/wipe
22 Temperature gauge 50 Wiper delay unit
23 51 Windscreen wiper rnoto,
Tachometer 52 Low fuel warning light
24 Fuel gauge
25 Coolant low warning light 53 Lowfuel delay unit
26 Brake warning light 54 Tank unit
27 Handbrake warning light 55 Ignition coil
28 Oil pressure warning light 56 Amplifier
57 Ignition distributor

B Blac_
G Gree -
K Pink
kG Ligh~
 -8- lJ’

o
-OG-
o -OW
-G
o -YG-
-YN-
c
-YG----
o
, -@S
o
i -SN-
-$U---

~
--B
o
--YO

1 Electronic control unit E.C.U.

2 Test facility feedback monitor plug
3 Fuel pump
4 Injector and E.C.U.relay
5 Dioderesistor pack
6 Fuelpumprelay
7 Inertia switch
8 Watertemperaturesensor
9 Throttle switch
10 Extraair valve
11 Lambdasensor
12 Air flow meter
13 Thermotimeswitch
14 Coldstart injector
15 No. 1 injector
16 No. 2 injector
17 No. 3 injector
18 No. 4 injector
 58 Oil pressure switch 86 Clock
Battery 29 Ignition warning light 87 Rear fog guard warning light
Headlamp motor L.H. 59 Handbrake switch
2 Alternator 30 88 Fog switch
31 Headlampmotor--R.H. 60 Brake pressure differential switch
3 Starter motor 61 Heated back-light warning light 89 Panel rheostat
4 Headlamp relay R.H. 32 Master light switch 90 Luggage boot lamp
Speaker 62 Heated back-light switch
5 Headlamp relay L.H. 33 Heated back-light 91 Luggage boot lampswitch
34 Radio 63
6 Headlampmotor circuit breaker 64 Main beam warning light 92 Heater control illumination
7 Starter relay 35 Seat belt timer/buzzer unit 93 Map/courtesy lamp
36 Seat belt warning light 65 Main beam R.H.
8 Starter inhibitor switch (automatic trans- 66 Main beam--L.H. 94 Door switch
mission only) 37 Belt switch 95 Service interval counter
38 Door switch 67 Dip beam--R.H.
9 Ignition/starter switch 68 Dip beam L.H. 96 Coolant low indicator unit
39 Audible warning switch 97 Coolant low sensor
10 Condenser fan relay -- L.H. Hazard flasher unit 69 Front marker lamp-- R.H.
11 Condenser fan relay -- R.H. 40 98 Oxygensensor warning light
4l Cigarettelighter 70 Front parking lamp-- R.H.
12 Condenser fan L.H. 71 Front marker lamp-- L.H. 99 Turn signal switch
42 Horn-push 100 Reverse lamp switch
13 Condenser fan R.H. Horn relay 72 Front parkinglamp L.H.
14 Diode 43 Front fog lamp 101 Stop lamp switch
44 Clutch relay 73
15 Pressure cut in switch 74 Rear fog guard lamp 102 Turn signal warning light-- L.H.
16 Air conditioning cut-out switch 45 Clutch Tail lamp -- L.H. 103 Turn signal warning light R.H.
Engineair solenoid valve 75
17 Full throttle cut-out switch 76 Rear marker lamp L.H. 104 Reverse lamp R.H.
18 Thermostat 47 Windscreen washer motor 77 Numberplate illumination lamp 105 Reverse lamp-- L.H.
19 Radiator thermostat 48 Horn 78 Rear marker lamp R.H. 106 Stop lamp R.H.
Temperature transmitter 49 Windscreen wash/wipe switch 107 Stop lamp L.H.
20 Wiper delay unit 79 Tail lamp -- R.H.
21 Voltmeter 50 80 Selector panel illumination (automatic 108 Front flasher lamp R.H.
Temperature gauge 51 Windscreen wiper motor transmission only) 109 Front flasher lamp-- L.H.
22
23 Tachometer 52 Lowfuel warning light 81 Cigarettelighter illumination 110 Rear flasher lamp R.H.
24 Fuel gauge 53 Lowfuel delay unit 111 Rear flasher lamp -- L.H.
82 Main/dip/flash switch
25 Coolant low warning light 54 Tank unit 83 Hazard warning light 112 Instrument illumination
26 Brake warning light 55 Ignition coil I 13 Switch panel illumination
Amplifier 84 Hazard switch
27 Handbrake warning light 56 85 Turn signal flasher unit 114 Blower motor switch
28 Oil pressure warning light 57 Ignition distributor I 15 Blower motor

A Toinjector and ECUrelay

B Todiode resistor pack
C To fuel pumprelay Fuel Injectton
D Todiode resistor pack Wiring Diagram
E Fuel injection timing signal l Seealso

COLOUR CODE

B Black N Brown S Slate

G Green O Orange U Blue,
K Pink P Purple W White
LG Light green R Red Y Yellow
 gl

-~-~~-’ _
T

,,,,,,,,
,,

iiiii
, ,,, ,
I I

i i

-t- II

, ,,, , , , :7

II
--]
i-i-

:Z

i I"11
 ( \

/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~atrifugal Advance
VacmumAdvance
/
Retard Unit
/

7z
 f

IGNITION DISTRIBUTOR APPLICABILITY, IGNITION TIMING AND

FEATURES CHART 1981 IGNITION DISTRIBUTOR
-- DELCO REMY

Data
LOW Manufacturer
Series ........................ ". ¯. AC Delco
COMPRESSION CANADA Delco l~emy’part’no, ...................... D308
ENGINE " ...................... 9977370
Stan part No.
Contact gap ..... ........................ RKC 5525
Carburetter Carburetter 0.014 to 0.016 in
Rotation viewed on rotor ................
1981 Firing angles ........................... Anti-clockwise
1981 Dwell angle ........................... 90 _ 1 degree
Triumph Part No. 39 + 1 degree
RKC 5525 RKC 4722 Open angle
Mov ing
.............................
contact spring tension 51 _ I degree
kucas Part No.
X Condenser capacity ......... 19 to 24 ozf
X iiiiiiiiiiiiii 0.18 to 0.23 mfd
Delco RemyPart No. Enginefiring order
9977370 9977254 ....................... 1-3-4-2
Ignition timing static
10° B.T.D.C. 10 degrees B.T.D.C.
Ignition timing at idle
10° B.T.D.C 2 degrees A.T.D.C.
Retard pipe connected
Idle speed
800 rev/min Centrifnl al advance
800 rev/min
Conventional points ignition Degs. distributor advance
It
X Distributor Degrees crankshaft advance
Electron ic Ignition r.p.m. Crankshaft
X Minimum ] Maximum r.p.m.
It Minimum~
Centrifugal Advance 300 Noadvance to occur
I.,,t 550 600 No advance to occur
5 6.5 lI00
Vacuum Advance 1000 9.5 11 lO I 13
It
X 1500 2000 19 I 22
12 14 3000
Retard Unit 1
X

Vacuumadvance
Ins. of Degs. distributor advance Degs. crankshaft advance
mercury
vacuum Minimum Maximum Minimum Maximum

No advance to occur
0 4.5 0 9
4 7.5 8
6.5 15
7.5 13 15