o

LEYLAND MOTOR CORPORATION OF

AUSTRALIA LIMITED
A SUBSIDIARY OF
B.L. LIMITED
53A HEATHCOTE RD., MOOREBANK, NSW 2170
P.O. BOX 59, LIVERPOOL, N.S.W. 2170 AUSTRALIA

OWNERS/DRIVERS
INSTRUCTION AND
EMISSION CONTROL
HANDBOOK

A TECHNICAL SERVICES PUBLICATION

PART No. TP973

KE
FOREWORD

This handbook provides an introduction to your vehicle together with information on the care and periodic
maintenance required to combine troubleJree motoring with minimal running costs. Your vehicle has
been designed to comply with Transpod Authority safety and emiss¡on regulations current at the date of
manufacture. lt is recommended that you, the owner of this vehicle, ensure that the maintenance
inspect¡ons and procedures specified in this book are carried out at the nominated ¡ntervals. lt is prefened
that this work be entrusted to an authorised Service Centre having qualified personnel with a full
knowledge of Leyland vehicles and having the necessary equ¡pment to carry out the required work.
Your Leyland Distributor/Dealer is provided with the latest information on servicing techniques, tools and
workshop practices enabling him to service and repair your vehicle in a most efficient and economical
manner.
ln addition to this book, you have been provided with a Passport to Service Book containing facilities to
record the date and odometer reading when each service is carried out. This should be completed by your
servicing dealer at the appropriate time. These books should be passed to any subsequent owner at the
time of sale so as to enable the maintenance record to continue.

lmportant
Your attention is drawn to the following:
Maintenance and service charges applicable to the emission control system are not covered by
warranty and are not re-imbursable, unless shown to have been caused by defects in materials and
workmanship covered by the warranty.
References to right or left hand are made as if the car is being viewed from the rear.
The vehicle specification may vary according to market requirements and from model to model. The
manufacturers reserve the right to alter specifications with or without notice at any time. The policy of
constant production improvement by the manufacturers may involve major or m¡nor changes to the
vehicle specification. Whilst every effort is made to ensure accuracy of the particulars conta¡ned in this
Handbook, no liability for inaccuracies or the consequences thereof can be accepted by the manufacturer
or the Dealer or Distributor who supplied the Handbook.

Energy Conservat¡on
It is essential that owners wishing to achieve the best poss¡ble degree of fuel economy ensure, as a first
priority, that their vehicle is tuned to ¡ts optimum level of performance by regular maintenance in
accordance with Leyland recommendations.
Apart from regular maintenance, there are a number of areas where deliberate and consc¡ous actions on
the part of the owner can achieve further and quite marked improvements. The following are recom-
mended:
¡ After starting from cold return the manual choke control to its normal position as soon as the engine
will continue running.
o Switch off the ignition if the vehicle is expected to be stationary for an extended time.
o Avoid short stop-start journeys.
r Anticipate obstructions, junctions and sharp corners and adjust speed as necessary. Do not
generate unnecessary speed.
r Accelerate gently through the gears.
o De-celerate gently wherever possible and avoid heavy braking.
o Stay in top gear as long as possible at the lowest sensible engine speed, but without labouring the
engine.
¡ Ensure tyres are conectly inflated.

2
AMENDMENTS CONTENTS

Page

FOREWORD ... ....2

VEHICLE IDENTIFICATION 4

VEHICLE OPERATING INSTRUCTIONS

CONTROLS 3
INSTRUMENTS & SWITCHES ................... 6
HEATTNG & DEMtSTtNG ................. o

SEATS & SEAT BELTS 11

RUNN tNG TNSTRUCTTONS ....................... 12

BODY ......... 14
HOOD & CURTAINS 15
EMISSION CONTROL 16

MAINTENANCE OPERATIONS ...,... 18

ENGINE 19
IGNITION SYSTEM 20
FUEL SYSTEM .......................... 22
COOLING SYSTEM 26
DRIVE BELTS 28
BRAKES & CLUTCH 29
WHEELS & TYRES 33
ELECTRICAL 35
1U8R|CATtON ........................... 48
RECOMMENDED LUBRICANTS 50
MAINTENANCE SUMMARY ..... 51

GENERAL DATA .. 53
METRICATION ...... 56
AMENDMENTS..... 58

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Kilometres into Miles km/h mph =

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km 0 2 3 4t 5 ¡ 6 7 8 9
0 0
Ð
m iles m¡les miles m iles
miles m iles
m ites I
m iles m ites I
milês õ
0 0.621 1.864 2.4661 3.10 t
1.?43 3. t2ó 4.35U 4.9 /1 5.592 Þ
10 6.214 6.835 7.457 8.078 I 6991 9.321 9.942 10.563 11 .185 11 .806
20 12 o
20
30
12.427 13.049 13.670 14.292 r+ orsl 15.534 16.1 56 17.í198 18.020
18.641 'r 9.263 19.884 20.505 21 1271 21 .748 22.369 22.991 23.612 24.234
=
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40 24.855 25.476 26.098 26.719 zt s+ol 27.962 28.583 29.204 29.826 30.447
I 40 25
50 31 .069 .690 3.1 32.311 32.933 se.ss¿ I 34.175 34.797 35.418 36.040 36.661
60 37.282 37.904 38.525 39.1 46 sc zasl 40.389 41 .011 41.632 42.253 42.875
43.496 44.117 44.739 45.360 ¿s.sazl 46.603 47.224 47.846 48.467 49.088
60
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37
80 49.710 50.331 50.952 51 .574 se.l gsl 52.817 53.438 54.059 54.681 55.302
90 55.923 s6 545 57.166 57.784 ss.¿osl 59.030 59.652 60.273 60.894 61 .516
I

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oo 62 137 62 759 63 380 64 001 ao aral 65 244 6s 865 66 487 67 108 67.730 80 50

Miles into Kilometres

100 62
miles 0 ? 3 4 5 6 7 I I
km km km km km km km km km km 120 75
0 1.609 3.219 4.828 6.437 L047 9.656 11 .265 12.875 14.484
10 tu.o* 17.703 19.3 12 20.922 22.531 24.1 4A 25.7 5A 27.359 28.968 30.578
20 32.187 33.796 35.406 38.624 40.234 41 .843 43.452 45.062 46.671
140
30 48.280 49.890 51 .499 53.108 54.718 56.327 57.936 59.54€ 61 .155 62.764
87
40 64.37 4 65.983 67.592 69.202 70.811 72.421 74.03C 75.63ç 77.245 78.858

50 80.467 82.O77 83.686 85.295 86.905 88.51 4 90.1 23 91 .73: 93.342 94.951 160 100
60 96.561 98.170 99.779 t01 .39 103.00 104.61 106.22 107.83 109.44 111.05
70 1 12.65 I'14.26 1 15.87 117.48 1 19.09 120.70 122.31 123.92 125.53 127.14
80 128.75 130.36 131 .97 t33.58 135.19 136.79 138.40 140.01 14't.62 143.23
.159.33
180 112
90 144 .84 146.45 148.06 149.67 151 .28 152.89 154.50 156.11 157.72

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162.54 165.76 167.37 168.98 170.59 172.20 73.81 175.42
100 160.93 1 64.1 5
200 124
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Metric Units and Symbols ¡
Quantity Melric Unit Symbol Approx. conversion factor õ
Length millimetre mm 25.4 1in
centimetre 1Ít o
=
metre
cm
m
30.5
0.914 1vd z
kilometre km 1.61 1 mile
Mass grams s 28.3 1oz
kilogram kg 1 2.20 tb
Area square centimetres cm2 6.45 1in2
Volume cubic centimetre cm3 16.4 'l in3
cubic metre m3 0.765 yd3
Volume (fluids) millilitre ml 28.4 tl oz
ml 586 pt
litre I 1 76 pt
I 4.55 gal
Volume (flow) litre/ second lls 4.546 gal /s ec
'1
Force Newton N 4.45 tbf
Moment of force Newtonmetre Nm 0.1 1 298 1 lbf/in
(Torque) 1.35582 1 lbf/ft
Pressure kilopascal kPa 6.89 1 lbf /in2
Velocity kilometres per hour km /h 1.61 1 mph

Temperalure Celsius Temperature 5iI ('F-32)

Power kilowatt KW 0.746 thp
282.481
Fuel consumption litre/100 kilometers l/'100 km
X
X mpg

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INSTRUMENTS & SWITCHES GENERAL DATA
Keys (Fig. 4) Standard Californian
Capacities
Duplicate keys are provided with the vehicle. ln order to avoid the possibility of theft, locks and keys 39 litres 39 litres
Fuel tank usable 36.25 litres approx.
are not marked. On receipt of your vehicle, record the number and letters of the key tag and remove -
Engine & transmission
the tag. Consult your D¡stributor/Dealer regarding key replacements. 4.8 litres 4.8 litres
Oil including filter
Cooling system 3.3 litres 3.3 litres
lgnitiodStarter Switch and Steering Lock(Fig. 5)
The Steering column lock, will greatly reduce the possib¡lity of the car being stolen provided the key Approx¡mate Dimensions
is removed. Refer'Lock' below. A Seat Cusion to roof 1054 mm
Unlock
B Seat cusion to floor 330 mm
To unlock the steering, inserl the key and turn it to position 'l'. lf the steering-wheel has been turned
C Windscreen height to ground unladen 1428 mm
D Overall height 1600 mm
to engage the lock, slight movement of the steering-wheel will assist disengagement of the lock Overall width 1448 mm
plunger. The key must be in the 'l' position when towing the vehicle for recovery.
E Height to centre of bumper bar (rear) 546 mm
lgnition and start
F Height to centre of bumper bar (front) 457 mm
G Squab to steering wheel min. 381 mm
To switch on the ignition, turn the key to position 'll'. Further movement against spring resistance to max' 432 mm
position 'lll' operates the starter motor. Release the key immediately the engine starts. H wheel base 2095 mm
Lock
J Overall length 3232 mm
K Wheel centre to bumper bar (front) 584 mm
To lock the steering, turn the key anti-clockw¡se to position 'O' and withdraw it. The lock will engage L Wheel centre to bumper bar (rear) 476 mm
when the steering-wheel is turned. M Approach angle (front) 42"
WARNING. The Steering lock/ignition/starter switch and its electrical circuits are designed to N Departure angle (rear) 55'
prevent the ignition system and starter from being energized while the steering lock is engaged. P Loading length 1156 mm
Serious consequences could result from alterations to or substitut¡on of the steerring lock/ignition S Bumper Bar to end of towbar bracket 76 mm
switch or its wiring. ln no circumstances must the ignition switch be separated from the steering lock. T Top of steering wheel to ground 1054 mm
U Base of back seat to centre of rear hub 940 mm
COLUMN SWITCH W Loading width 1041 mm
Windscreen washer and wiper control (Fig. 6) X Depth of tray 279 mm
Ground clearance 203 mm
Windscreen washer Front track 1245 mm 1441 mm
Press the end of lever inwards ('A') to operate the washer jets. Rear track 264 mm 1460 mm
The washer reservoir should be filled with a mixture of water and UNIPART Screen Wash. ln Turning circle (between kerbs) 10.0 m
freezing conditions use UNIPART Screen Wash. To avoid possible damage to paintwork do not use Front wheel alignment (toe out) 1.6 mm
radiator anti-freeze in the windscreen washer. Rear wheel alignment (toe in) 3.2 mm
Overall width 1448 mm

F¡9. 67
F¡9. 4 F¡9.5

l c D

M -TN
E

U
K H S

J
5NO2ô48

6 55
GENERAL DATA INSTRUMENTS & SW¡TCHES

Windscreen wiper
Standard 1275 Moke Movethe leverdownwards ('B') formanualcontrol. On releaseof lever, itwill automaticallyswitch off
Moke Californian wiper.
Wheels & Tyres To operate the wipers at normal speed move the lever up to the first position ('C') and to the second
Wheel size Std. 4.50 J x 13 550 JJ x 13 position ('D') when a higher wiping speed is required.
Californian 5.50 JJ x 13
NOTE: The wipers and washer will only operate when the ignition is switched 'on'.
Tyre size Std. 5.60-L-13 4 ply
Californian 175.R.13 75.R.1 3
Direction indicators, main beam and horn control (Fig 6)
1

Tyre pressures
All conditions Front 1 50 kPa Direction indicators
Rear 140 kPa The switch operates the indicators only when the ignition is switched on.
Move the lever to position 'E' when turning left and to position 'F when turning right.

Load After making a turn the signal is self cancelled when the steering-wheel ¡s returned to the straight-
Max. Tyre loadings at 220 kPa Tyre size
5.60 x 13 399 Kg ahead position.
600 x 13 458 Kg
155.SR.13 431 Kg Headlamp dipper
165.sR.13 458 Kg W¡tn'tfre'näa¿lamps switched on at the lighting switch, move the lever forward ('G') to use the main
beams;the warning lightwill glow (BLUE). Return the leverto the mid-way position to dipthe beams.
Electrical
Battery Lucas 12V.7P.40 AH 12V.9P.46 A.H. Headlamp flasher
@ 20 hour rate @ 20 hour rate Lift tñe lever towards the steering-wheel ('H') to flash the headlamps irrespective of whether they
Dimensions 228.5 x 134 x 1 96 mm (9.0 x 5.3 x 7.7 ins) have been switched on at the lighting switch or not'
Alternator Lucas 15 ACR Lucas 17ACR
Normal output 28 amps 36 amPs Horns
Press the end of the lever inwards ('J') to sound the horn
We¡ghts
Kerb mass (full fuel, oil and water
but no occupants or luggage) 640 kg 686 kg
Front axle at kerb mass 430 kg 450 kg
Rear axle at kerb mass 210 kg 236 kg
Registration mass (9 litres fuel, full
oil and water but no occupants or luggage) 626 kg 672 kg
Gross vehicle weight (full fuel, oil and
water, plus two occupants and luggage 1000 kg 1 000 kg
Gross combination mass 1200 kg 1200 kg
Maximum towing mass 400 kg 400 kg
Trailer Hitch load 30-50 kg 30-50 kg

Mass Distribution Data

Condition Front Rear Total F¡9.6

h
Standard vehicle kerbside mass with
spare wheel, tools, oils, water and
-
full fuel tank no load (kg) 430 210 640
-
Specification variations
Californian spec. - 14 26 40
Tray top 0 82 82 D E

tcl
1275 cc engine 6 0 o
Rear seats J 13 16 * c J
Hard top 20 30 50 B
Loading data F
-
Each front seat occupant 38 30 68
Each rear seat occupant 13 55 68
Each kg luggage in load area two seater +0.10 +0.90 1.00 B
- four seater -0.06 +1.06 1.00
tray top -0.10 + 1.10 1.00
Each litre of fuel in tank 0.30 0.48 0.78
7
54
INSTRUMENTS & SWITCHES GENERAL DATA

ReÍer Fig. 7 Denotes common to model l¡sted in preceeding column

-
1. L¡ghting Switch. Press in the lower edge of the switch fully for the headlamps. Press in the upper
' edge for the "otf" position. A midway position operates the park and rear lamps. The panel ligni is 998 cc Standard 1275 cc
automatically switched "on" and "off" through this switch.
Engine Californian Californian
Type 99H 12H
2.' Heater Fan Switch (Type A Heatefl
Bore 64.58 mm 70.61 mm
3. lgnition Warning Light (red). The light will glow with the ignition switched "on" or at a slow idling Stroke 76.2 mm 82.28 mm
speed. lt should go out and stay out while the engine is running above normal idling speed. No. cylinders 4
4' Headlight main-beam Warn¡ng L¡ght (blue). The light glows when the headlights are switched on Compression ratio 8.3:1 8.8:1
and the beams are in the raised position. rhe light goes out when the beam is dipped. Max. gross power 29 kw @ 5200 rpm 40 kw @ 5250 rpm
Torque
5. Brake fail Warning Light. The light will glow when the brake pedal is depressed if a loss of pressure Firing order
68 Nm @ 2500 rpm
1,3,4,2,
91 Nm @ 2500 rpm
has occurred in either front or rear braking systems. This c.ircuit is checked forfunction, (i.e.ìhe tamp
will glow) each iime the ignition key is turned to the start position ',lll", Fig. 5. Valve Rocker Clearance (Hot) 0.30 mm
(Cold) 0.31 mm
6. Fuel gauge. When the ignition is switched "on" the fuel gauge indicates APPROXIMATELy the Engine Oil Pressure approx. ldle .103
kPa
amount of fuel in the tank. normal 414 kPa
7. Speedometer. The instrument is graduated in km/h. This will aid the driver to comply with speed
regulations while driving. For certain countries, a speed warning buzzer may also be fitted. The lgnition
instrument also includes an odometer which records the total distance the vehicle has travelled. Contact breaker gap 0.36-0.40 mm
Dwell angle 51" +
8. Oil pressure warning light (green). Will glow when the ignition is switched on and will switch off Condenser capacity
5"
0"18-O.24 microfared
shortly after the engine has started. lf the warning light remains on, or should it come on when the
Spark plugs Champion N-9-Y
engine is running, stop the engine and check the engine transmission oil level. lf the oil level is not
Spark plug gap 0.60 mm
below the low mark on the dipstick, consult your nearest Leyland dealer.
Stroboscoplc timing 8'B.T.D.C. @ 13'B.T.D.C. @
9' Direction turn indicator lamps (amber). The light will flash when either left hand or right hand 1500 rpm 1000 rpm vacuum
¡ndicator is operating. pipe disconnected
10. Park Brake. With the ignition key in the I & ll position the light glows when the handbrake is applied. Coil output 16-22 kv
ldle speed 750-950 rpm
11 . Mixture control (choke) warning lamp (when fitted) will glow when the control is pulled out and is
Fast idle speed 1150-1350 rpm
extinguished when the control is pushed fully in.
Primary resistance 3.2-3.4 ohms
12. Catalyst temperature warning lamp (when fitted) will glow if the operating temperature of the Consumption 3.94
converter becomes excessive.
Fuel System
Fuel pump type SU mechanical
Suction (min) 152 mm Hg
Pressure (max) 27.5 kPa
Carburetter SU: HS4
Needle ADF ABB
Jet size 2.28 mm
Spring Red Red
ldle CO% 3+1% 5% + 1% with
Fig. 7 air & disconected
Japan only
Recommended octane ratings min 90 RON 97 RON

2 Transmission 4 speed synchromesh

Gear ratios
1st 3.526:1
1
5 2nd 2.218'.1
3rd 1.433:1
12 10 4th 1.00:1
Reverse 3.545:1
7 Final drive ratio 4.267:1
11 Road speed kn/V1000rpm
9
1st 7.6
4 Znd 12.1
3rd 18.8
6 3 4th 26.9
Reverse 7.6
I 53
MAINTENANCE SUMMARY HEATING & DEMISTING
ABCD
lgnition System
¡ Check ignition wiring for fraying, chafing and
Two types of heater/demister are used in the Moke range.
deter¡oration, rectify if necessary
o Check/adjust ign¡tion timing and dwell angle, using
electronic equipment Type A (Fis 8)
r Check distributor cap, check for cracks and tracking The Heater
o Lubricate distributor The supply of heat is taken from the engine coolant and therefore full heat is not available until the
r Renew contact breaker points engine has reached normal operating temperature. Two controls operate temperature and fan
r Clean and adjust spark plugs speed. Distribution of air is automatically supplied to both the windscreen and ¡nterior vents.
o Renew spark plugs
¡ Check coil performance on oscilloscope Heat Control
Fuel System The heat control (1) regulates the heat level. The maximum amount of heat is available when the
¡ Check fuel system for leaks knob is fully pushed in. lntermediate positions of the control provide variations to meet changing
conditions.
o Top up carburetter piston damper
¡ Check condition of fuel filler cap seal Pull out the control to the required position and 'lock' by turning clockwise one-quarter of a turn. To
¡ Renew fuel line filter reposition the control, turn the knob anti-clockwise one-quarter of a turn and push inwards.
o Renew carburetter air filter element DO NOT MOVE THE CONTROL IN OR OUT WHILST IT IS IN THE 'LOCK' POSIT¡ON,
¡ Check air intake temperature control system
¡ Renew adsorption canister 40 Air Distribution
r Check/adjust carburetter idle settings lnterior direótion is adlusted by rotating interior vents (2) to the desired position. Fan speed is
r Check/adjust choke settings adjusted by a switch on the instrument panel (3). The switch provides'off', 'low' and 'high' speed
o Checl</adjust CO at idle posit¡ons" Demist facility functions automatically whilst the heater/demister is in operation.
Safety
Check all fluid reservoirs; clutch, battery and windscreen
washer
Check visually hydraulic pipes and unions for chafing,
leaks and corrosion
Check brake linings for wear and drums for conditions,
rectify/renew if necessary
Check/adjust foot and hand brake
Check condition and security of steering unit, joints
and gaiters
Check suspension dampers and steering rack for oil leaks
Check/adjust t¡ghtness of steering-column clamp bolt
Check/adjust security of suspension fixings
Checlladjust tyre pressures, including spare
Check/adjust front wheel alignment
Check tightness of road wheel fastenings
Check tyres comply with manufacturer's specification
Check tyres for tread depth, visually for cuts in tyre fabric F¡9.8
exposure of ply or cord structure, lumps or bulges
Check output of charging system
3
Check function of original equipment, i.e. interior and
exterior lamps, horns, warning indicators,
wipers & washers
Check instrumentation
@ /5-
Check, if necessary renew, wiper blades
Check/adjust headlamp alignment
Check operation of all door locks and window controls @o
Check condition and security of seats, seat belts, and
2
seat belt warning sysiem 1
Test
Road/roller test and check operation of all
instrumentation, report additional work required

52 o
HEATING & DEMISTING MAINTENANCE SUMMARY
Type B (Fig 9) The maintenance summary on this and the following pages is the minimum service required to maintain
The heater your vehicle under normal driving conditions. For other than normal dr¡ving conditions, and those caused
The supply of coolant tothe heater is controlled by a valve and may be shut off when not required. by seasonal changes, we recommend that you consult your Dealer.
Two controls and a booster fan enable the volume, distribution and temperature of the air to be Note: The service intervals are based on an annual mileage of approximately 20,000 km and should the
varied to suit changes in requirements. Full heat output of the heater unit is not available until the vehicle complete substantially less miles than this per annum it is recommended that a 'G' service is
engine has reached normal operating temperature. completed at s¡x monthly intervals, and a'D' service at twelve-monthly intervals.
Heat Control ln addition to the periodic maintenance, the following checks should be made weekly:
The heat control (1) on the switch panel controls the water valve and regulates the amount of hot Check/top up engine oil.
water circulating the heating system. The maximum amount of heat is available when the knob is Chect</top up brake fluid reservoir
fully pushed in. lntermediate pos¡tions of the control provide variations ¡n temperature to meet Checl</top up battery electrolyte
changing conditions. Check/top up cooling system
Pull out the control to the required position and 'lock' it by turning clockwise one-quarter of a turn. To Chect</top up washer reservoir
reposition the control or return it to the maximum heat position, turn the knob anti-clockwise Check function of orig¡nal equipment, i.e. exterior lamps, wipers and warning indicators. Check tyres for
one-quarter of a turn and push inwards. tread depth, visually for external cuts in fabric, exposure of ply or cord structure, lumps and bulges.
Check/adjust tyre pressures, including spare
DO NOT MOVE THE CONTROL IN OR OUT WHILST IT ¡S IN THE 'LOCK' POSITION
Check tightness of wheel fastenings.
Air Distribution
Air distribution is controlled by a shutter lever (2) which can be set to the following positions. Maintenance ¡ntervals
Car: Service km x 1000 Monthly lntervals
Air is directed mainly to the vehicle interior, with some to the windscreen. A 1.6 After Sales Service
B 5-1 5-25-35-45-55-65-75 Three
Screen: c 10-30-50-70 Six
Air is directed onto the windscreen, with some to the vehicle ¡nterior. D 20-40-60-80 Twelve
Note: The demist facility operates whenever air is being distributed to the windscreen. E 40-80 Twenty four
Offr
Distributor shutters closed. Maintenance Operations
Switch (3) operates the heater fan motor. All items marked . in the 'MAINTENANCE SCHEDULE' are emission control related

ABCD
Lubrication
Lubricate all grease points, including hand brake mechanical
linkage and cable guides
¡ Renew engine oil filter
o Renew engine oil
Check/top up engine oil
Fjg. s Lubricate all locks and hinges except steering lock
Lubricate accelerator control linkage and pedal pivot
Check Operation
Engine
Check/top up cooling system
Check cooling and heater systems for leaks, hoses and
@ pipes for security and condition
2 ¡ Check all driving belts, adjust or renew
3 o Check exhaust system for leaks and security
Check security of engine bolts and mount¡ngs
1
o Check/adjust torque of cylinder head nuts
r Check/adjust valve clearances
o Check crankcase breathing and evaporative loss systems
check hoseVpipes and restrictors for security, condition
and blockage, rectify if necessary
Check/adjust clutch return stop clearance

'10 51
RECOMMENDED LUBRICANTS SEATS & SEAT BELTS
Hand Brake Cables (Fig. 6aE) Seats lFlg. 70,)
Smear grease around the cable and channels (4). All seats have a squab fold foruvard feature (1 ) for improved access within the vehicle.
Lubricate the swivel sector pivots with oil (5). Fore and aft adjustment for front seats is ach¡eved by use of a lever (2) located in front of the cushion
on the right hand side. To adjust, move the lever to the r¡ght and hold until the seat is repositioned
Smear grease around the operating lever clevis pin and the cable (6) adjacent to the spring anchor
then release.
brackets.
Head restraints are fitted to the front seats and are pre-set requiring no further adjustment.

Location Specification Seat Belts (Figs. 11 & 12)

Engine/Transmission Use a well known brand of oil to Leyland Specification B.L.S. 01 .02 or MIL The wearing of seat belts is a legal requirement in Australia.
L'2 1 048 or to A. P. l. SE Quality with a viscosity band spanning the tempera- WARNING:
ture range of your F¡9. Seat belts are designed to bear upon the bony structure of the body and should be worn low across
the front of the pelvis, chest and shoulders, as applicable; wear¡ng the belt across the abdominal
Suspension & Steering
area must be avoided.
Grease Points Multi purpose grease. Lithium base N.L.G. 1 Consistency No. 2
Steering Rack Fluid grease. 100cm" maximum Dry Rack BP Energrease FGL or Castrol Seat belts should be adjusted as firmly as possible, consistent with comfort, to provide the protection
EP.LD. forwhich the belts have been designed. A slack belt will greatly reduce the protection afforded tothe
wearer.
Brakes
& Clutch Hydraulic brake fluid to Layland Specification H.8.F.6. Where not available Care should be taken to avoid contamination of the webbing w¡th polishes, oils and chemicals and
particularly battery acid. Cleaning may safely be canied out using mild soap and water. The belt
use fluid to S.A.E. specification J 1703F.
should be replaced if the webbing becomes frayed, contaminated or damaged.
Carburetter Piston
Damper, Distributor It is essential to replace the entire assembly after it has been worn in a severe impact even if damage
and oil pivots oil
to the assembly is not obvious. Belts should not be worn with straps twisted. Each Seat belt
assembly must only be used by one occupant; it is dangerous to put a belt around a child being
Drive shaft constant carried on the occupant's lap.
velocity joints Extreme pressure multi rease to specification G.L. 2-EP
Lap type seat belts are provided for all seating positions. However, la/sash inertia reel belts may be
Cooling System 1. lnhibitor
- Leyland approved lnhibitor SQ. 36 fitted for the front seats when a roll over bar is installed. All belts are fastened by inserting the tongue
2. Anti{reeze
- Solution to specification 853151 , 8S3152 or 452108 into the buckle until a positive click is heard. 1o release, press the button in the centre of the buckle.
3. lnhibited/antiJreeze
- lllLeyland Australia year round coolant additive A retaining strap is provided on the outside edge of each seat for stowage of non-retracting seat
containing lCl formula belts.
Lap Belts front and rear. To adjust, slide the adjuster along the belt in the required direction.
Windscreen Washer
Antifreeze 33% so¡ution of lsopropenol or lndustrial methylated spirits. Retracting lnertaa Front Seat Belts. The inertia seat belts allow the wearers to move the upper
portion of their bodies to reach various controls, etc. The belts will lock automatically with acceler-
ated body movement or in the event of emergency braking. No adjustment is required as the
automatic retract¡on of the reel retains the harness at the correct tens¡on.
Fig- 66
WARNING:
oF -2oo oo 2oo 4c." 60o Boo looo No modifications or additions should be made by the user which will either prevent the seat belt
adjusting devices from operating to remove slack, or prevent the seat belt assembly from being
adjusted to remove slack.

s.A.E. 20d50
I

Fis. 10 Fig. 11
Viscositv ' 2owl4o
Fig. 12

4
row/so
1
10w40
10w/30
5W4o 1

5W30
5w120 I 3

oC -3oo -2o" -loo oo loo 2oo 3oo 4oo 2

11
RUNNING INSTRUCTIONS LUBRICATION
The new vehicle Engine Oil Filter (Fig. 6a)
Care taken in driving a vehicle in its early life will be repaid in greater efficiency later. The engine has Change each 10,000 km as follows:
been carefully assembled and tested before leaving the factory, following which the selling dealer Remove the six screws (4) and detach the front grill panel, unscrew the filter can¡ster (5) from the
has carefully prepared and rechecked the entire veh¡cle before delivery. lt is suggested that for the filter head (6) anti-clockwise and discard the used canister and seal (7).
first 800 km the speed should not exceed 80 km.p.h. except for short periods. The car may then be
driven normally, but the best performance must not be expected until a free running condition has Lubricate the seal on the new canister with engine oil and screw the canister onto the filter head.
been reached. TIGHTEN BY HAND FORCE ONLY. DO NOT OVERTIGHTEN.

Driving Carburetter damper and distributor lubrication

Gear positions are clearly shown on the top of the gear lever knob. All four forward gears are See Emission Control System lgnition
equipped with synchromesh action to ensure smooth, easy gear changes. -
Thè floor mounted gear lever is centrally situated;first and second gears are selected by moving the Steering Rack
lever to the left, and engaged by moving it forward for first gear or backwards for second gear. Third The steering rack is charged with 100 cm3 of fluid grease when assembled in dry state and unless
and fourth gears are selected by moving the lever to the right through the neutral position until leakage occurs from damaged boots, additional lubrication should not be necessary.
resistance is felt, then forward for third gear and backwards for fourth gear.
Steering Lock DO NOT LUBRICATE (Fig. 65A)
To engage the reverse gear move the lever to the right through the neutral position until resistance is -
felt, continue further movement to the right. Move the lever rearwards to fully engage the gear. Location of Greasing Points (Fþ. 65 B,C,D)
Reverse gear must be engaged only when the vehicle is stationary. There are B grease points which require regular attention 6 on the front suspension (3 each side)
and 2 on the rear suspension (1 per side). Refer illustration.-
Starting the engine. To ensure full penetration on the swivel hub joints, it may be necessary to take the load off the joint
Ensure that the gear lever is in the neutral position and that the handbrake is applied. lf the engine is being greased by jacking the suspens¡on to a netural pos¡tion. Grease the nipples until excess
cold, pull out the mixture choke control, turn the ignition key clockwise and release it as soon as the grease appears from the inner bush.
engine starts, immediately reposition the choke control to give smooth running and enough power to
drive the vehicle while cold. Do not use the choke while the engine is hot. Check that oil pressure
The rear radius arm nipple is easily accessible from the outside of the vehicle.
and all the warning lights are functioning normally before driving away.
Do Not under any circumstances run the engine in a closed garage or similar atmosphere. Exhaust
Fig. 65 1
fumes are highly poisonous and, if inhaled, could quickly produce grave, if not fatal results. lt is not
necessary to warm the engine for a prolonged period before driving away.
WARNING: ln countries where a catalytic converter ¡s fitted in the exhaust system, the following
precautions should be taken?
1 . ln order to maintain the efficiency of the emission control system it is essential to use unleaded
gasoline only.
2. Do not tamper with the engine settings;they have been established to ensure that the vehicle
will comply with stringent exhaust emission regulations. lncorrect engine setting could cause
unusually high catalytic converter temperatures and thus result in damage to the converter and
vehicle. lf adjustment to the settings is considered necessary, this should be performed by a

3.
Dealer or other qualified service facility.
A correctly tuned engine optimises exhaust emissions performance and fuel economy and it is
recommended that the vehicle is maintained as outlined under the maintenance schedules of
@ 'l
this handbook. A B c
4. Do not continue to operate the vehicle if any engine malfunction is evident; malfunctions should
3
be rectified immediately. For instance, misfire, loss of engine performance or engine run-on
may lead to unusually high catalytic converter temperatures and may result in damage to the
converters and car.
5. Never leave the vehicle unattended with the engine running.
6. lt is important that the choke is returned to its off position as soon as thê veh¡cle will accelerate
without hesitation. Excessive use of the choke will cause plug fouling, high fuel consumption
and deterioration of the catalytic converter.
7. ïhe use of a catalytic converter increases exhaust system temperatures (particularly under
engine malfunction);therefore do not operate or park the vehicle in areas where combustible
materials such as dry grass or leaves may come in contact with the exhaust system.

D E

12 49
LUBRICATION RUNNING INSTRUCTIONS
Engine Lubr¡cation System
The lubrication syôtem consists of a single oil supply for the engine transmission and final drive
assembly. Oil is pressure fed to the engine lhrough a full flow filter.
Engine/Transmission oil levels. (Fig. 64)
Oil recommendat¡ons are listed in the'recommended lubricants'section. Maintaining the correct oil
level is very important. Too much oil can cause frothirg and excessive splash which the piston rings
cannot control, as well as inducing the risk of oil leaks from seals. Low oil level can cause high oil
temperatures, excessive sludge concenlration and loss of oil pressure while negotiatìng sharp
corners at speed.
Correct readings cannot be assumed immediately after stopping the vehicle, such as when purchas-
ing petrol at a service station. ln these circumstances oil will still be suspended in the upper regions
of the hot engine. Dipstick readings must be taken on level ground'
The Dipstick (1)
The dipstick is located at the front of the engine between the two centre spark plugs.
Engine oil filler (2)
- Apply downward pressure against the sealing ring and turn in an anti-clockwise direction to release.
Oil Changing.
Theéngìne oil should be changed every 10,000 km or 6 months, whichever is the earlier under
normal conditions. For more arduous operat¡on such as stop start running, slow heavy traffic or
dusty conditions, 5000 km or 3 monthly changes a'e recommended. Trailer hauling.
Draining the Oil
The plug (3) on the iight hand side of the transmission drains the engine and transmission oil. A
magnetised section pressed into the plug will collect small metallic particles over the period between
oil changes. These particles must be removed.
F¡9.64
8. The vehicle is designed for normal and light off road use. Below are exanlples of abuse which
could damage the catalytic converter and car, and may lead to a dangerous condition due to
excessively high catalyt¡c converter temperatures'
a. Competition use
b. Severe off-roadway use
c. Excessive engine revolutions
d. Overloading the vehicle
e. Excessive towing loads
f. Switching off the engine while in gear.
o Do not run the engine with either a spark plug lead disconnected or a spark plug removed.
Do not use any device that requires an insert into a spark plug hole in order to generate air
pressure (e.g. tyre pump, paint spray attachment, etc.), as this could also result in catalytic
converter damage.
10. Heavy impact on the converter casing must be avoided as it contains ceramic material which is
easily damaged.
11. lf the engine misfires, the cause must be immediately rectified to prevenl catalytic converter
damage.
12. ln order that exhaust emissions are kept within the legislated limits an idle exhaust emission
test must be carried out after any unscheduled service operations which might affect the
emission control system.
The recommended downward load on the trailor hitch is 30 to 50 kg. This load may be increased or
decreased at the discretion of the driver to obtain a better hauling characteristic under certain
operating conditions. However, the maximum vehicle loading must not be exceeded.
The towing mass 4OO kg, page 54, is the maximum permissable. While this fþure must not be
exceeded, it may be necessary to adjust the weightto complywith localconditions and regulations.
On tow (vehicle recovery), ignition starter switch and steer¡ng lock. With the key in the position
;l', the ignition is switched off and the steering lock disengaged. This position must be used
marked
when towing the vehicle for recovery.

Vehicle loading,
2
\j Due consideration must be given to the overall weight canied when fully loading the vehicle.
Maximum loading will depend on vehicle specification (see page 54 for details-).'
General maximum figure is 216 kg for standard model
'
1 and 176 kg for Californian
Equivalent of 4 passengers and luggage.
Tyre loads and pressures must comply with regulations where such exist.

:-¿
6
3 7

13
48
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COMPONENT GRID REF COMPONENT GRlD REF. COMPONENT GRID REF

m
1. Alternator
2. Battery
82 28. Reverse Lamp R1?J7 51 .
Alternator No-charge t-
B4 29. Stop Lamps L. R11 Warning Lamp Q3 m
3. Starter
4. Starter
Solenoid D4 30. Tail Lamp R.H. R11 52. Direction lndicator Warning o
{
Motor E4 31 .
Tail Lamp L.H. R8 Lamp R.H. P2
5. lgnition/Start Switch E2 32. Number Plate Lamps R9 53. lgnition Coil m1 Ð
6.
7.
Fuse Box G4 33. Trailer Plug R10 54. lgnition Distributor NP1 õ
Radio Line Fuse c5 34. Direction lndicator 55. Side Lamp L.H. 812 Þ
8. Radio (when fitted) B5 Flasher Unit M9 56. Front Direction lndicator t-
9. Heater Motor D5 35. Trailer Direction Flasher Lamp L.H. 812
10. Heater Switch (Type B Unit M9 57. Rear Direction lndicator
Heater) F5 (5 pin flasher unit) Lamp L.H. R7
11. Heater Motor Type iB' 36. Reverse Lamp Switch L7 58. Fog Lamps (front)
Heater c6 37. Stop Lamp Switch 59. Driving Lamps
12. Windscreen Wiper Motor B6 Hydraulic/Mechanical M7 60. Driving Lamp Relay
13. Resistor Unit Low Speed E6 38. Brake fail warning lamp M6 61 . Driving Lamp Fuse
14. Heater Switch Type 'B' 39. Brake fail pressure diff. 62. Driving Lamp Switch
Heater F7 switch N6 63. Headlamp Dip Beam Cutout
15. Combined Windscreen Wiper/ 40. Diode (Brake Fail Lamp 64. Fog Lamp Switch
Washer E7 Test) P6 65. Fog Lamp Fuse
16. Windscreen Washer Motor F8 41 . Engine Oil Pressure Warning 66. Rear Fog Guard Lamp
17. Front Direction lndicator Lamp N5 67. Fog Guard relay
Lamp R.H. B9 42. Engine Oil Pressure Switch o6 68. Rear Fog Guard Switch
18. Side Lamp R.H.
19. Headlamp Main Beam
B9
B9
43. Voltage Stabilizer
44. Fuel Level lndicator
M5 69. Rear Fog Guard Fuse
70. Side Marker Lamp Front
xm
N5
20. Headlamp Dip Beam 810 45. Fuel Level lndicator Tank 71 . Hazard Warn¡ng Switch
21. Horn G11 Unit P4 72. Hazard Warning Flasher {
22.
23.
Horn push
Direction lndicator Switch
G9
H9
46. Handbrake Warning Lamp
47. Brake Switch Hand Brake
N4 Unit
73. Hazard Lamp Fuse
o
24. Dip Switch H10 Warning P4 74. Choke Warning Lamp N2
25. Lighting Switch K1 48. Trailer Direction lndicator 75. Choke Warning Lamp Switch P2 Ð
26. Side Tail & Panel Lamp
1

Repeater Lamp Q4 79. Direction lndicator Lamp =

z
Fuse 49. Panel lllumination Lamp
27. Rea( Direction lndicator
K1 1

50. Main Beam Warning Lamp

Q3
Q3 .
L.H,
Refer Supplementary Diagrams
P2 o
Lamp R.H. R12 0
Þ
CABLE COLOUR CODE o
B.Black; K.Pink; N.Brown;P.Purple; u.Blue;Y.Yellow; G.Green;LG.LightGreen;o.orange; R.Red; w.white; s.slate. 7t
À
.{ When a cable has wvo colour code letters, the first denotes the main colour and the second denotes the tracer colour. Þ
=
 ELECTRICAL WIRING D¡AGRAM HOOD & CURTAINS
F¡9.63 Hood
C\t (f)
s rn o È.. (D G Erecting the hood. (Figs. 15 & 16)
Briñg the front ends of the webbing straps forward to the top of the windshield frame. This will
É. I automatically carry the hood bows forward and upward. Fit the snap-on fasteners to their respective
long studs on the edge of the screen frame.
Pull hood forward and attach to windshield frame by means of the press fasteners, making sure that
each fastener snaps into position correctly. Gripping the rear hood bowysupports as shown in fig.
a o 16 snap the support hinges over centre on each side to tension hood.
@
I
l- rt Caution: Keep hands clear of the pivot area when performing this operation.
r
ö r >c
o- 1 I
@
o- Lowering the hood. .1
Reverse above procedure folding hood as shown. Fig. 8.
J
z
rt
r
0 s
ç { (r- z Side Curtains
(, These are attached to each other and the hood with zip fasteners. Attachment to the body sides is by
É (,
J -F
= 'lift dot' fasteners.
o
+
Curtains can be rolled up and secured with straps provided. Fig. 17. When lowering the hood,
remove and stow the side curtains in the bag provided.
6
o On Californian models, a roll up rear panel is provided.
J J

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--) F¡9. 15 F¡g- 16

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46 15
EMISSION CONTROL ELECTRICAL
Vehicle Emission Control Supplementary Wiring Diagrams
General Description The wiring diagrams below should be used in conjunction with the main diagram, Fig. 59
This section gives a general description of the crankcase, exhaust and fuel evaporative emission Fig. 60 This diagram covers the c¡rcuits recommended for installation of accessory driving and
control systems f¡tted to this vehicle and the function of the¡r individual components. lt must be - fog lamps for Australian conditions
emphasised that correct carburetter adjustment and ignition timing which have been pre-set at the Fig. 61 Covers the supplementary.wiring for vehicles fitted with rear fog guard lamps, side
factory are essential for the efficient functioning of the exhaust emission controls. Shoi..¡ld it become - marker lamps and hazard warning systems.
necessary to check or adjust these settings, this work should be canied out by an authorised dealer Fig. 62 Shows the switcVwarning lamp symbols which could be on control panels.
who has the specialist equipment and training to undertake these adjustments. -
Crankcase Em¡ssion Control
The crankcase emission control system prevents leakage of combustion blow-by gases from the
F¡9. 60
crankcase by maintaining a depression in the crankcase under all operating conditions. The source
of the depression is the 'Constant' depression zone of the carburettor. This depression rises with
increasing engine load and speed, as does the quantity of crankcase emissions to be handled.
Gases from the crankcase are ducted to the carburettor through the combined oil separators and
flame arrestors mounted on the engine flywheel housing and timing cover. The crankcase depres- T---- ---1 SoLENOtD
sion ¡s used to draw evaporative emissions from the adsorption canister into the rocker cover via a
restrictor.
60 -_-___l
62
Fuel Evaporative Loss Control ó5 r--
To prevent air pollution by vapours from the fuel tank and float chamber, the control equipment
stores the vapour in a charcoal-filled canister while the engine is stopped and disposes of it via the
engine crankcase emission control system when the engine is running. The fuel tank venting is L----------l IGN
designed to ensure that no liquid fuel is canied to the storage canister with the vapours and that
64 FUSE

vapours are vented through the control system.

The tank capacity is limited for thermal expansion by extension of the filler tube into the tank and 25
59
venting is initially via the filler and then via the tvvo vapour separator lines to the canister. The dual
separator/breathing system ensures adequate venting and separation cons¡stent with the gradient
capabilities of the vehicle. F¡g 61

The tank filler is sealed with a non-vented cap. 27

Constant Depression SU Type Carburetter

¡¡¡------;ù*-
"t7
The carburetter is manufactured to a special exhaust emission specification and is tuned to give the 70 I
a7
maximum emission control consistent with retaining vehicle performance and driveability. The N
metering needle is arranged in such a manner that it is always light spring loaded against the side of 67
the jet to ensure consistency of fuel metering. A throttle disc by-pass valve limits the inlet manifold 3o
depression and ensures that during conditions of engine overrun the airlfuel mixture enters the t8 25 LR_
LF 26
engine cylinders in a burnable condition consistent with low emission levels. An enriched mixture for
55 R
cold starting is obtained by mechanically lowering the jet assembly. An additional feature on some -
é-B
model carburetters, ¡s a temperature compensating unit fitted to the jet holder from the underside of R
the carburetter. This unit compensates for fuel viscosity variations with fuel temperature and also air LG
density with temperature. lt operates by means of a wax pellet which expands with increasing 72
temperature thus raising the height of the jet and hence weakening the mixture.
tlF----*[*o
'5ó 7t
lntake Air Temperature Control System
The temperature of the air drawn into the engine is controlled by a Bi-metal operated two-way valve.
Fig. 62
The Bi-metal blade is mounted ¡n the air stream to the air cleaner and senses the temperature of the
intake air. The Bi-metal blade controls the position of the two-way valve and admits either cool air
from the engine compadment or hot air via the hot air duct from the shroud around part of the
exhaust manifold, or a mixture of the two.
At intake temperatures below 18FC, only hot air from the exhaust manifold shroud is drawn, into the
air cleaner; at intake temperatures above 33"C, only cool air from the engine compartment is drawn
Æ A =Ð
into the air cleaner.
Front fog Hazard Driving

16 45
ELECTRICAL EMISSION CONTROL

Replacement Bulbs
Location Volts Watts Part No.
Headlamp L.H.D. (except Europe-dip right) 12 50/ 40 BFS41 5
Headlamp, Europe (except France-dip vertical) 12 50/ 45 UP41 O
Key to Fig 19
Headlamp, France (dip vertical) yellow 12 50/ 45 GLB41 1

Pilot lamp 12 5 GL8989

Pilot lamp (capless bulb) 12 5 GLB501 1. O¡l Separator Purge L¡ne
Combined lamp 2. Carburettor 9. Crankcase purge pipe
(festoon type) UP273
3. Adsorption Canister 10. Fuel pump
Direction lndicator front 12 21 4.
Side lamp -
(festoon type) 12 Ã UP254 5.
Oil Filter Cap
Restr¡ctor
11.
12.
Fuel filter
Carburettor Vapour lìne
-
Combined lamp 6. Fuel tank 13. Carburettor air ¡ntake f¡lter
-
Direction lndicator/Reverse lamp 12 21/21 uP1 005
7. Vapour Separator L¡nes 14. Air intake temperature control unit

Stop & tail lamp 12 21/ 5 UP380

Number plate lamp 12 5 UP989
Panel & warning lamp (except brakes) 12 2.2 UP987
Brake warning 12 2
Head lamp light units
Sealed beam with pilot, dip left (UK) 12 60/45 GLU104
Sealed beam less pilot, dip left no UK 12 60/45 GLUl O1
Sealed beam less pilot, dip left not UK 12 75/50 uP701 9
Sealed beam L.H.D., dip right 12 50/40 GLU133
Alternative lamps
Side lamp (Festoon tyoe)
combined type 12 51 UP254
Direction lndicator frorl"'
Side marker lamps 12 21 UP382
Combined lamp rear 12 4 UP233
Stop lamp 12 21 UP382
Direction indicator 12 21 UP382 Fig. 19
Tail lamp 12 5 UP2O7
q
Number plate 12 UP2O7
Reverse lamp 12 21 UP382
Rear fog lamp 12 21 UP382

14

13

11
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12 7
3 9
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44 17
MAINTAINANCE OPERATIONS ELECTRICAL
Location of Maintainance & Lubrication Po¡nts
WIRING OF ACCESSORY LAMPS
Fog Lamps
15 4 Should be wired so that they cannot be illuminated at the same time as the vehicle head lamps.
6
This can be accomplished by wiring as shown in the daigram, using a switch incorporating a pilot
lamp and a relay to switch the head lamps as shown. Operation is as follows:
17 1. Turn ignition key to I or ll and operate the head lamp switch.
2 2. Turn on the fog lamp switch. The pilot lamp will indicate the fog lamps are in use and the head
\ ( Iamps are extinguished.
Should the fog lamp switch be left "on" with the hêad lamps turned "off", the pilot lamp will illuminate
1A 16 when the ignition switch is operated indicating the fog lamps are on standby.

Driving Lamp
7 7 High power driving lamps should be wired as shown in the diagram using power relay(s) and
individual fusing. The switch should be of the pilot lamp type and wired to trip the relay from the
headlamp high beam circuit. This will ensure the lamps are extinguished when head lamps are
switched to "low" beam and pilot will indicate lights are on stand by.

Trailer plug
Trailer plugs should be wired as shown in the main wiring diagram.
1 Note:
A heavy duty flasher unit w¡ll be required to compensate for the additional electrical load. The
direction indicator warning lamps may serve the additional purpose when certain types of heavy
duty flasher units are fitted, but it is usually necessary to fit an additional lamp to meet the
requirement that indication be provided to inform the driver when any one indicator lamp fails.

18

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F¡9.20

18 43
ELECTRICAL ENGINE
Reversing Lamps (Flg. 56)
The reverse lamp is fitted to the passenger's side on both left and right hand steering models. To Key to Fig. 20
gain access to the single 21 watt bulb, remove the lens screws and withdraw the lens. When refitt¡ng
the lens assembly, check conditions of seals and do not over tighten the screws. 1. Qool¡ng System Expans¡on Tank & Pressure Cap 10. Steer¡ng rack
14. Rad¡ator and sealed cap 11. Brake master cyl¡nder
Rear Fog Guard Lamp (Fig. 56)
2. Eng¡ney'transm¡ss¡on oil filler cap 12. Clutch master cylinder
3. Eng¡ney'transm¡ss¡or/oilfilter 13. Battery
This lamp dr¡ver's side on vehicles which have reversing lamp fitted to the passenger's
is fitted to the 4. Carburetter and a¡r f¡lter '14. Fuel f¡lter
side of the vehicle. The lamp is identicaltothat of the reversing lampwith the exception that it is fitted 5. Accelerator l¡nkage 15. Engine/transmission oil dipst¡ck
with a special red lens.
6. D¡str¡butor 16. E.L.C. Can¡ster
7. Steering jo¡nts 17. W¡ndscreen washer reseruoir
The fog guard lamp can only be operated when the side or head lamps are switched on and are L Rear suspens¡on radius arms 18. Fuel tank
activated by an independent facia mounted switch coupled to a warning lamp. The switch symbol for
9. Handbrake linkage 19. Catalytic Converter
fog lamps is as shown in Fig. 62. The schematic for the rear lamp is coloured Red as against White
for front fog lamps.

Number Plate lamp (Fig. 56)

On completion of any of the following equipment service operations, a CO% check should be carried out
One or two lamps of this style may be fitted. Detach the cover assembly for access to bulb.
to ensure the vehicle is in compliance with the relevant regulations.
Bulb Replacement Warning & Panel Lighls (Fig. 57)
Valve Rocker Clearance Adjustment (Fig. 21)
Access to the speedometer illuminator and the warning lamp bulbs it will be necessary to remove
-
the dash panel assembly by unscrewing the nine screws retaining the windshield wiper driver Adjustment must be made with the tappet on the back of the cam, therefore the crankshaft must be
covers demister duct hoses and the six screws holding the panel assembly. Move the panel rotated to bring each valve in turn to its check¡ng position.
outwards. Unscrew the rocker cover retaining nuts remove the rocker covèr and insert a .305mm feeler gauge
Note: lt may be necessary to disconnect the speeCometer cable for ease of access. between the valve rocker arm and valve stems. The gauge should be a sliding f¡t when the engine ¡s
cold. To rotate the crankshaft remove the sparking plugs, engage topgear and push the carforward.
Windscreen wiper arms (Fig. 59) Check each clearance in the following order:
To reposition a wiper arm on the spindle, the arm can be withdrawn when the small spring clip (1 ) is
Check No. 1 valve with No. 8 fully open. Check No. 8 valve with No. 1 fully open.
held clear of the retaining groove. Replace the arm in the required position and push it hard down
Check No. 3 valve with No. 6 fully open. Check No. 6 valve with No. 3 fully open.
onto the spindle (2) until it is secured in position by the retaining clip.
Check No. 5 valve with No. 4 fully open. Check No. 4 valve with No. S fully open.
Check No. 2 valve with No. 7 fully open. Check No. 7 valve with No. 2 fully open.
Blade replacement Us¡ng a suitable open ended spanner betvveen the wheel boss nut and arm,
-
lever off the arm as shown and at the same time, lift the arm assembly just clear of the screen. Adjusting
Slacken the adjusting screw locknut on the opposite end of the rocker arm and rotate the screw
Windscreen washer jets. clockwise to reduce the clearance or anti-clockwise to increase it. Retighten the locknut when the
The jets should be adjusted to spray towards the :op edge of the windscreen. clearance ¡s correct, holding the screw against rotation with a screwdiiver.

F¡9. 56 Fig 57 Fig 21 Fig.22

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42 19
IGNITION SYSTEM ELECTRICAL
ALTERNATE LAMPS
' Plugs (Fig 22)
Spark
The following lamps may be fitted for certain market requirements.
The sþark plugs should be cleaned, preferably with an air-blast service unit, and the gaps reset to
0.6gmm. Use ã special spark plug gauge and setting tool and move the side electrode on the plug,
never the centre one. When fitting new spark plugs ensure that only the recommended type (see Side & Direction lndicator Lamp (Fig. 54)
GENERAL DATA) is used and that they are set to the correct gap before installat¡on. Vertical combined type
To replace bulbs, remove the screws (1) securing the lens assembly. The lower compartment
Distributor (Fig. 23) houses a festoon type bulb (2) for side lights, while the upper compartment houses the direction
Contact breaker indicator bulb (3).
Release the retaining clips and remove the distributor cover. Remove the rotor arm (1 ) and turn the When refitting the lens, ensure seals are correctly fitted to prevent water entry and do not over
crankshaft until the contacts are fully open. tighten the screws.
Cleaning contacts
lnspect tñe contact points (2) and if burned, clean with fine emery cloth or a fine carborundum stone' Side Marker Lamps front (Fig. 54)
Wipe the contacts ciean with a fuel-moistened cloth. Renew the contact set if the points are pitted or Remove screw (4) and withdraw lens (5) to gain access to bulb (6).
worn.
Stop and Direction lndicator Lamp (Fig. 55)
Lubrication Combined type without reverse lamps.
Verylightlysmearthecam(3)andpivotpost(4)withgrease.Addafewdropsofoil to:thefeltpad(5)
To gain access to the bulbs, remove the two lens securing screws (1) noting the location of the
in tne iopbt tne cam spindlé and ihrough the gap between the contact pìate and the cam spindle sealing washers. Remove the lens assembly (2), the lower compartment houses the tail lamp bulb
to lrbri"äte the centrifúgd weights. DO NOT Olt- fng FELT PAD which contacts the cam tace. (3) anã stop lamp bulb (4). The upþer compartment houses the diiection indicator bulb (5).
Every 40,000 km in addition to the routine maintenance, lubricate the contact breaker assembly Note: the base fittings for all three bulbs are the same, making them inter-changeable. However,
centie bearing with a drop of oil in each of the two holes (7) in the base plate. Carefully wipe away all only a low wattage (5-10 watt) should be used ¡n the tail light.
surplus lubricãnt and see that the contact breaker points are perfectly clean and dry.
When refitting lens, ensure the seal (6) is in good condition and conectly fitted. Do not over tighten
Contact gap the screws.
Turn the crankshaft until the points are fully open. Check the contact gap (2) with a feeler gauge (see
GENERAL DATA), the gauge should be a sliding fit. lf a gap varies appreciably from the gauge
thickness, slacken the cðntict set securing screw (8) and adjust the gap by inserting a screwdriver
betvveen the slot at the end of the plate andihe pipe turn anti-clockwise (9) to increase and clockwise
(10) to decrease the gap. Retighten the securing screw'
Refit the rotor arm, engage the slot in the spindle and push down firmly. Wipe the inside and outside
of the distributor cover clean, particularly between the electrodes, and refit the cover.

F¡9. 54 F¡9. 55
F¡9.23
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41
20
ELECTRICAL
Remember that the setting of the beams is affected by the load on the car and the consequent
deflection. The beams should therefore always be setwith the normal load on the car. Checking and
resetting should be entrusted to your Distributor or Dealer, who will have special equ¡pment
available for this purpose.
Side and direction indicator lamps, combined type (Fig. 52)
To replace bulbs in the combined side/direction indicator, remove the two screws (1) retaining the
front rim (2) and detach the rim complete with lenses. The direction indicator, festoon type bulb (3) in
the outer compartment can now be removed from its clips. The inner compadment clips hold the
side lamp bulb (4).
lgn¡tion Tim¡ng
Stop tail direction indicator and reverse lamps, combined type (Fig. 53)
To replace bulbs remove the two Phillip typescrews (1) and withdraw the lamp lens. The direction
indicator/reverse lamp bulb (2), in the top compartment, a double filament bayonet type with offset
locating pins. The stop/tail lamp bulb (3) fitted to the lower compartment is of the same type as the
upper bulb, but having a lower wattage filament for the tail lamp. Do not interchange the two bulbs.
Number plate lamp (Fig. 53)
Access to the bulbs (4)
is obtained by unscrewing the one slotted screw (5) and removing the domed
cover (6) and glass (7).
IGNITION SYSTEM
Contact set renewing
Remove the securing screw (1 1 ) with its spring and flat washer, lift the contact set (12) press the
spring and release the terminal plate (13) from the end of the spring. Before fitting the new contact
set, w¡pe the points clean with fuel or methylated spir¡t and very lightly grease the pivot post (4).
Reconnect the terminal plate to the end of the contact breaker spring, position the contact set on the
distributor base plate and lightly tighten securing screw (1 1 ). Ensure that the contact breaker spring
is firmly in its register on the insulator and set the contact gap.
Whenever a new contact set has been fitted, re-check the gap cam angle after the first 800 km.
During this period, the heel of the contact will have bedded-in and reduced the gap.
The ignition timing is set dynamically to give optimum engine performance with efficient emission
control.
Ensure that the distributor cam angle is within specification prior to adjust¡ng the timing.
Connect an accurate tachometer and timing light in accordance with the manufacturers instructions.
Uncover the timing aperture in the flywheel housing cover. Fi1.24.1
Timing marks (Fig. 24)
Four marks are provided on the flywheel face, 1/4 which is the T.D.C. pos¡tion for numbers 1 or 4
cylinders, the three furlher marks give 5', 10", and 15' B.T.D.C.
Alternate Timing Marks (Fig. 25)
These will be found as a series of pointers on the t¡ming cover which align with a notch on the
crankshaft pulley rim.
The large pointers being T. D.C. 1 and 4, the other points being 4' ,8 ,12' ,1 6'and 20' respectively.
Start the engine and adjust the speed to the specified rpm figure quoted in General Data. With the
aid of a mirror check the timing in accordance with the figures quoted in the General Data.
To adjust the timing, slacken the distributor clamp and turn the distr¡butor in the appropriate
direction. Clockwise advances the timing.
Having moved the distributor check that the engine rpm (see General Data). Adjust accordingly and
recheck the timing when timing is correct at specified rpm reset idle speed to figure quoted in
General Data. -

F¡9. 52 F¡9. 53 Fig.24 F¡9. 25

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40 21
FUEL SYSTEM ELECTRICAL
Fuel System Bulb type light unit- remove the light unit and detach the pilot lamp bulb holder from the reflector.
The efficient operation of the engine and exhaust emission control equ¡pment depends not only on Remove the bayonet fixing type bulb (9) from the holder.
the correct carburetter setting, but also on the correct ignition timing, contact breaker (cam angle),
spark plug and rocker clearance. Also the correct operation of the evaporative loss, engine HEADLAMPS
breathing and exhaust systems. lt is essential that all these systems are checked before adjusting Light unit
.the carburetter. Removing pull the bottom of the outer rim (1) forward and lift it off the lug at the top of the lamp.
Tuning of the carburetter is confined to setting the idle and fast idle speeds and the mixture setting at
-
Pull the three adjusting screws (2) one at a time, out of their locations. Withdraw the lamp unit from
idle speeds. the back-shell, pullthe connector (3) off the main bulb and withdraw the pilot bulb holder (4) from the
Adjustments should only be undertaken on cars required to conform with exhaust emission control lamp un¡t.
regulations if a reliable tachometer and an approved exhaust gas analyser (CO meter) is available.
Pilot lamp bulb
Your Leyland dealer has the necessary equipment and the expertise to carry out these adjustments. Removing press the bulb into its holder (4) and turn it anti-clockwise to remove it. Engage the
pins of the -
new bulb in the grooves of the holder, press the bulb in and turn it clockwise.
Fuel and Engine Oil Filter Caps (Figs. 26 & 27)
Both the fuel tank filler cap (1) and the engine oil filler cap (2) are non-venting and form the seal on Headlamp bulb
the fìlling apertures. IT lS ESSENTIAL TO THE SATISFACTORY OPERATION OF THE Removing spring the clips (5) outwards and lift the bulb out of the lamp unit.
EVAPORATIVE LOSS SYSTEM THAT BOTH CAPS ARE ALWAYS REFITTED CORRECTLY -
AND TIGHTENED FULLY. A DEFECTIVE CAP OR CAP SEAL MUST BE REPLACED.
CAUTION: Before fitting a headlamp bulb it is essential that the adiustable bulb locator (6) is
correctly positioned as follows:
Adsorption Canister (Fig. 28)
The air for engine breathing is drawn through the adsorption canister and into the engine valve
(7) for countries where tratfic travels on the left-hand side of the road;
(B) for countries where traffic travels on the right hand side of the road.
rocker cover.
Fit the bulb, ensuring that the prolection (9) fits into the locating slot. Spring the clips (5) into position.
The adsorption canister must be renewed every 40,000 km or 24 months.
Refitting fit the pilot bulb holder (4) into the lamp unit. Fit the connector (3) with its flat side
ïo renew the canister, disconnectthe air vent pipe (1 ) vapour pipes (2) and purge p¡pe (3) from their -
towards the bulb. Press each adjusting screw (2) into its location. Refit the rim ensur¡ng the holes are
connections o¡ the canister. Remove the retaining screw (4), open the bracket clamp sutficiently to
at the bottom.
withdraw the cânister.
When fitting, ensure that all connections to the canister are secure. Beam setting
Remove the headlamp rim. Turn the screw (10) to adjust the horizontal setting and screw (1 1) to
Purge Line Restrictor (Fig. 29) adjust the vertical setting
To check disconnect the purge line (3) from the rocker cover elbow (4). Examine the orifice of the
restriction formed in the elbow for obstruction. Clear any dirt or deposits Írom the restrictor orif¡ce, F¡9.51
using a length of soft wire.
10

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22 39
ELECTRICAL FUEL SYSTEM
HEADLAMPS Air Temperature Control (Fig. 30)
Light Units (Figs. 50 & 51) An air temperature control is fitted to the air cleaner intake. When the engine is cold, air is drawn from
Either sealed beam with and wlthout park lamp, pilot lamp facility or renewable-bulb l¡ght units are the shrouded area of the exhaust manifold. As the temperature of the air entering the air cleaner
fitted. rises, the control valve (1) will open and admit cooler air to maintain a constant temperature.

Sealed Beam Light Un¡t lnspecting

Removing remove the lamp rim retaining screw (1), ease the bottom of the rim (2) forward and lift Every 20,000 km or 12 months, note the position of the valve when the engine is cold, depress the
-
it off the retaining lugs at the top of the lamp. Unscrew the three screws (3) retaining the inner rim (4) valve indicated and release it. The valve should return to its original position, inspect the valve seat
and withdraw the light unit (5). for signs of damage or deterioration.
Withdraw the three pin connector (6) from the back of the light unit. Air Cleaner Element Renewal (Fig. 31)
A new air cleaner element must be fitted every 20,000 km or 12 months, or earlier in dusty operating
Bulb type light unit conditions.
Removing follow the same procedure as detailed above to remove the light unit.
- Unscrew the two wing nuts (1) securing the air cleaner to the carburetter a¡r manifold, pull the
Headlamp bulb replacement release the spring clip from the reflector lugs and withdraw the bulb connector off the air temperature control flange and lift off the air cleaner assembly.
-
(7). Fit the new bulb into the reflector with the bulb flange locating the slot in the reflector (arrowed).
Refit the spring clip with its coils resting in the base of the bulb flange and the legs of the clip engaged Remove the top cover (3) by prising it off with a screwdriver placed beneath the slots on the
under the reflector lugs. underside of the cover. Discard the old element (4) thoroughly clean the container and fit the new
element. Ensure that the rubber 'O' ring is conectly positioned in the groove on the underside of the
Refitting connect the three-pin plug and place the unit in the back-shell with the three lugs on the top cover. Ref¡t the top cover (3) align the arrow on lhe cover with the location lug (5) of the conta¡ner'
light unit-located in the slots formed in the back-shell. Refit the retaining plate and lamp rim. Refit the air cleaner assemb¡y and t¡ghten the wing nuts. Do not d¡sturb the element at any other
t¡me.
Beam Setting
Two adjusting screws are provided on each headlamp for setting the main beams. The screw 0) is (1
for adjusting the beam in the vertical plane, and the screw (11) is for horizontal adjustment. The
beams should be set parallel to each other in the straight-ahead position and /2" + 7¿o below Fig.28 Fig. 30
horizontal or be set in accordance with local regulations.
1
P¡lot lamp bulb
The different types of holders and bulbs which may be fitted are shown ¡llustrated.
Sealed beam light unit remove the light unit and pull off the three-pin connector (6). Withdraw
the capless type bulb (8)- from the connector.
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38 23
FUEL SYSTEM ELECTRICAL
Fuel Line Filter (Fig. 32) Fuses (Fig. 48)
The fuel line filter assembly must be renewed every 20,000 km or 12 months. The fuse box is located on the right hand corner of the bulk head under the bonnet.
Release the hose clips (1), remove the filter (2). Fit a new filter ensuring the flow arrow (3a) is A blown f use is indicated by the failure of all the units protected by ¡t and is confirmed by examination
towards the carburetter. Alternat¡ve type: connect the end marked 'lN' to the inlet hose. of the fuse when withdrawn.
Before renewing a blown fuse inspect the wiring of the circuit which has failed for evidence of shot't
Carburetter circuit or other faults. lf the new fuse immediately blows and a fault cannot be found, have the circuit
LUBRICATION (Fig.3s) checked by your D¡stributor or Dealer.
Unscrew the oil cap at the top of the carburetter suction chamber and w¡thdraw the cap with its
attached plunger. Too up with oil to bring the level 1 3 mm above the top of the hollow piston rod. ln no
To gain access to the fuses, take the plastic cover (1) away from the base.
c¡rcumstances should a heavy-bodied lubricant be used. To ref it, the cover has a central post which locates in the hole provided between the spare fuses (2).
Failure to lubricate the piston damper will cause the piston to flutter and reduce accelerat¡on. Position the cover and push post into hole.
The fuses used are English style, their rating being that current at which the fuse blows is normally
twice the continuous carrying current, (i.e. a 1 7/35 amp will carry 1 7 amps continuously and blows at
35 amps).
CAUTION:
An incorrectly fitted or lubricated carburetter piston damper can cause a marked increase in fuel Fuse (3) connect¡ng terminals 1-2 (17/35 amp\
consumption. Protects the horn circuit and the auxiliary units that operate without the ignition switched on.
Fuse (4) connecting terminals 3-4 (17/35 amp) protects those circuits which are supplied from the
ignition system.
Accelerator mechanism lubrication
1. Lubr¡cate the accelerator control l¡nkage Line Fuses (Fig. a9)
2. Lubricate the accelerator pedal pivots A line fuse is located adjacent to the fuse box. This (8/15 amp) fuse protects the side and tail lights.
3. Check operation of the accelerator and that the throttle opens fully. To renew the fuse hold one end ofthe tube (1 ) push in, twist and pull offthe other end. The fuse (2) is
then accessible for replacement.
Additional line fuses may be used to protect specific circuits such as radio and auxilliary driving/fog
lamps.

Fig. 32 F¡9. 33 F¡9.49

F¡9.48

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31
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24 37
ELECTRICAL
Emergency Start (Battery Boosting) (Fig. a7)
When connecting an additional battery to boost a discharged battery in the vehicle the following
procedure is recommended.
1. Ensure the vehicle's battery terminals are clean and tight.
2. fhe booster battery is to be of the same normal voltage as the vehicle's battery.
3. The interconnecting cables must be of sufficient capac¡ty to carry the stañing current.
4. The cables must be connected one at a time and to the booster battery first.
5. The cables are connected between the terminals in the following order:
(a) Pull back the protective boot coverinq the (+) positive battery cable connect¡on on the
starter solenoid switch under the bonnet (1)
(b) Attach the booster battery (+) posit¡ve cable to the terminal ensuring that ¡t is sufficiently
secure to prevent falling off or touching other components when the engine is started.
(c) Attach the booster battery (-) negative cable to a convenient earth on the engine (2). The
engine speed must be running at fast idle before leads are disconnected.
(d) Refit the terminal protective cap.
F¡9.47
FUEL SYSTEM
Carburetter Adjustments (Figs. 34 & JS)
Réfer General Data for Settings
1. Top up the carburetter piston damper if necessary.
2. Check that the throüle functions correcfly.
3. Ensurethatthemixturecontrol (choke) will returnfully,andthatthecablehas2mm(1/16ins)
free play before it starts to pull on the lever.
4. Check that a small clearance exists between the fast idling screw (4) and the cam.
5. Remove the air cleaner, then raise and lower the piston witñ a finger, (5) checking that it can
move smoothly w¡thout any tendency to stick or bind. Disconnect air injection (where applica-
ble).
6' Connect up a tachometer. Start the engine and run it at a fast idle speed until it attains normal
running temperature, and continue for a further five minutes.
7. Before mak¡ng any adjustments, increase the engine speed to 25OO revlmin and maintain this
speed for 30 seconds to clear the intake manifold of excess fuel. Repeat this procedure at
three-minute intervals ¡f these adjustments cannot be completed within this period of time.
8. Check I!." j9linS speed with the tachometer and adjust as necessary by tuininq the idlinq
screw (8). lf the engine will not run smoothly at the ôorrect idling spe'edjadjust ihe m¡liuré
setting as follows:
M¡xture adjust (CO%)
9' -
Screw the mixture adjusting nut (1 1 ) one flat at a t¡me, up to weaken or oown to enrich the
mixture, until the fastest idling speed (a) is achieved coñsistent with smooth running. Now
screw the nut up slowly (weakening) until the speed just starts to fall (b)
1 0. Re-adjust the idling screw (8) as necessary to obtain the specified idling speed.
1 1. Using the exhaust gas analyser, check that the reading is within the limits given in General
Data. lf the reading falls outside the l¡m¡ts given, reset the mixture adjusting nu[by the minimum
amount necessary to bring the reading just within the limits.
lf more than half a turn of the nut is required to achieve this, the carburetter must be removed
and serviced. Reconnect air ejection (where applicable)
13. Check and adjust the fast idling speed as follows:
Pull out the mixture control knob until the linkage is about to move the jet, and lock the knob in
this position.
'14' Turn the fast idling screw (4) until the correct fast idling speed is obtained. Return the control
knob fully and check that a clearance exists between the fast idling screw and its cam.
15. Stop the engine and disconnect the test equipment.

Fig. 34 F¡9.35

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36
25
COOLING SYSTEM ELECTRICAL
Battery (Refer Fig. 14 Page 14)
Fig 36
of the right hand body side member.
The Cooling system is a pressurised semi sealed system incorporating a coolant expansion tank Location
- the battery is located in the rear compartment the top cover (5) by turning the
(1). The pressure is regulated to 90kPa (13 p.s.i.) by the cap (2) on the expansion tank. The plain To check the battery terminals and the electrolyte level, remove
filler cap (3) fitted to the radiator is fitted with a safety clip to minimise accidental removal. Deutz type fasteners anti-clockwise using a suitable coin or screwdriver.
CAUTION: DO NOT REMOVE THIS CAP WHEN ENGINE lS HOT To gain access to the battery securing components, remove the set screws attaching the compad-
ment side panel (6).
Should it be necessary to check the coolant level when the engine is hot, it is adviseable to take
precaution against the possibility of scalding from escaping coolant.
Polarity
System Pressure must be relieved prior to removing radiator cap. The electrical installation on this car is NEGATIVE ( - ) earth return and the correct polarity must be
Turn the expansion tank pressure cap (2) anti-clockwise until resistance of the safety stops is felt. maintained at all times. Reversed polarity will permanently damage semi-conductor devices con-
Leave the cap in this position until the pressure is released. tained within ceñain electrical equipment.
Press the cap downward against spring pressure to clear the safety stops and continue turning unt¡l Before fitting any other electrical equipment, make certa¡n that it has the correct polarity for
the cap can be lifted off. installation in this car.

To remove the radiator cap (3), lift the safety clip and turn the cap anti-clockwise to remove. To avoid damage to the alternator the following must be observed:
The engine must not be operated with the batteryterminals disconnected. When starting with the aid
The coolant height should be level with the outlet pipe to the expansion tank.
of a battery booster do not disconnect the battery terminals'
Disconnect both battery terminals before using a fast battery charger.
Draining the System
1. Position heat control for maximum heat (1) Figs' I & 9' Disconnect one or both battery terminals before carrying out electric welding, mechanical or
2. Remove the expansion tank pressure cap (2) electrical operat¡ons which could ground or 'short' the alternator or regulator terminals (even
momentarily).
3. Remove the radiator cap (3)
4. Remove the cylinder block drain plug ( ) General Maintenance
5. Remove the drain plug from the radiator lower tank (5). Dirt and moisture should not be allowed to accumulate on the top of the battery.
Should it be necessary to drain the expansion tank, this can be done by syphoning or removing and
inverting. Moisture removed from the top of the battery usually contains acid and should be treated with
caution. Cloths used for cleaning must not come in contact with clothing, fabric, skin or the vehicle's
paintwork.
Do not leave the battery in a discharged state for any length of time. When not in regular use have
the battery fully charged, and every four weeks, give a short refresher trickle charge to prevent
F¡9.36 permanent damage to the battery plates.

1 7 ttootiünn"Nln"cking
6 the electrotyte in the cells do not use a naked light, and do not use tap water for
3 topping up. Ensure that the vehicle is standing on a level surface.
Ø

@ ln hot weather or when long journeys are being made the electrolyte levels may require topping up
more frequently than as recommended in the 'MAINTENANCE SUMMARY'.

00

fr-5
35
26
WHEELS AND TYRES
Wheel fixings
The road wheels are retained by four nuts which shouh be tightened in a diagonal sequence to 4.5
Nm.
Note: The wheelnuts used on the Californian road wheels have special conical facing
surfaces and are not interchangeable with standard models.
Spare Wheel (Fig. 46 D)
The spare wheel is mounted on the rear panel of the body as illustrated. lt is secured in position with
two nuts. Unscrew the nuts with the wheel spanner to detach the wheel.
Jacking (Figs. 46 A,B,C)
Always applythe handbrake and place a chock against one of the wheels to be left in contactwith the
road. Ensure that the base of the jack is on firm ground, use the jacking block where necessary
Front (Fig. 46 B)
To lift a front wheel place the lip of the jack head just forward of the body side panel and behind the
outer lip of the mud guard. This will prevent the jack head from turning and slipping off.
Rear (Fig. 46 C)
To lift a rear wheel, place the lip of the jack between the sub-frame and the lower panel of the side
member ensuring that the weight is taken on the sub{rame between the two bolt heads. This
ensures that the jack will not slip.
Jack Maintenance
Neglect of the jack may lead to a d¡ff¡culty in a roadside emergency. Examine it occasionally, clean
off accumulated dust and lightly grease the thread to prevent corrosion.
COOLING SYSTEM
F¡lling the System
'1
. Refit the drain plug
2. Prepare the appropriate amount of coolant solution
3. Half fill the expansion tank
4. Add only sutficient coolant to the radiator to cover the bottom of the header tank
5. Run the engine until hot and air is displaced.
6. Add sufficient coolant to bring surface to filler neck
7. Refit radiator and expansion tank cap
8. Recheck the coolant level again when the system ¡s cold.
The cooling system should be drained. flushed and the inhibitor/anti-freeze solution replaced eãch
12 monthly period.
lnhibitor and Anti-freeze Solutions
When the vehicle leaves the factory, the cooling system is filled with a solution of clean water and
1 32 ml of SQ36 inhibitor. Should it be necessary to top up the system a solut¡on containing between
20 and 40 mls sq36;/litre of clean water should be used.
For vehicles operat¡ng in conditions where the prevailing temperatures drop below freezing, an
ethylene glycol type anti-freeze conforming to 83.3151, 85.31 52 or ASQ108 should be used.
Year Round Protection for all climates
As an alternative to the above, year round protection is available by the use of Leyland Australia
coolant additive.
This coolant addit¡ve prevents freezing in winter and minimises boiling during summer months and
incorporates the necessary inhibitors for component protection.
Solutions should be maintained between 33 and 50p/o or between 1.050 and 1.074 SG.

Fig. 46
% Solution Approx. Freezing Point Approx. Boiling Point Specific Gravity
at 90kPa 13
Min 33 -19'C 122'C 1,050
50 -34"C 127C 1.O74

\ Where suitable S.G. testing equipment is not available, the solution should be renewed at each 12
monthly period.

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34 27
DRIVE BELTS
Alternator/Water Pump Belt
Drive Belt Tens¡on (Ffg. 37)
When conectly tensioned, a deflection, under moderate hand pressure of 13 mm (72 in.) approxi-
mately should be possible at the midway point of the longest belt run between the pulleys. Should it
be necessaryto fit a new belt, it should be retensioned after 1500 km.
Adjusting
To adjust the belt tens¡on, slacken the securing bolts (1) and the adjusting link nut (2) and move the
alternator to the required position. Apply any leverage necessary to the drive and bracket (3) only,
and not to any other pañ; to avoid damaging the end bracket the lever used should preferably be of
wood orsoftmetal. Tightenthe bolts, and recheckthe belttension. DO NOTOVERTENSION asthis
will impose an excess loading on the drive bearings and stretch the belt.
Removing and Refitt¡ng (Figs. 37 & SS)
Slacken alternator pivot and adjusting link bolts. Push the alternator toward the engine. Detach the
belt from the alternator pulley and the crankshaft pulley. Manoeuvre the belt over the fan blades at
the belt aperture in the fan cowl as shown in Fig. 384-1 . Spread the belt and hold one side against
the cowl aperture 38A-2. Rotate the fan. When the last blade is passed, the complete belt will be
between the fan and radiator core. The belt can then be removed by passing between the blades
Fig. 38-8. To fit a new belt, reverse the above procedure or alternatively the belt can be fitted from
the engine side of the fan as detailed for removal 384.
WHEELS AND TYRES
Tyres are a major factor in road safety. The tyres fitted as original equipment have been selected to
enable normal passenger requirements and adequate loads to be carried.
Owners are reminded that such things as tyre wear, inflation pressures, repairs, retreading and
tread grooving etc. may be subject to legal requirements.
Tyres are vulnerable to abuse; damage by accident or incorrect ma¡ntenance and need to be
inspected regularly. Sharp objects such as broken glass or pointed stones should be removed
before full penetrat¡on is made. Full penetration does not normally result in deflation if the object is
not pulled out, and the tyres should be repaired when convenient. Penetrations by objects of small
diameter can be repaired with the tyre manufacturer's plugging kit.
Note: The insertion of a plug to repair atubeless tyre must be regarded as a temporary measure and
a permanent vulcanized repair must be made as soon as possible.
Road conditions and minor accidents will influence wheel alignment adversely. Adjustment will be
necessary to correct the condition in order to ensure safety and long tyre life. The rate of tyre wear
depends on many factors such as driving speeds, cornering, vehicle loading, road conditions, etc. ln
addition, tyres wear at different rates depending on their posit¡on on the vehicle. Depending on the
observed condition of the tyres, a rotation of the road wheels may be recommended. The spare
wheel may be included in this rotation to ensure that tyre wear is shared by all five tyres. The dealer
will advise of the need for wheel balancing, rotation or an alignment check as a result of his
observations dur¡ng routine servicing. Tyre condition is checked in each maintenance service every
5000 km (3000 miles) or three months.

Tyre pressures
The recommended pressures cover all average load conditions. Pressure checks should be carried
out before the vehicle is driven and the tyres become warm. Do not deflate to correct the pressure
dur¡ng a long run.
lnflation pressures should be checked once a week or pr¡or to a long journey. Do not neglect the
spare. Any unusual pressure loss should be investigated. Remember the appearance of the radial
ply tyres is deceptive, always use a pressure gauge when examining for correct ¡nflation.
Valve caps should be replaced using finger pressure only. The caps ensure a second seal should
the valve core become loose or fail. They also exclude did and mo¡sture.

Radial ply tyres

Should only be fitted in sets of four. Tyres of different make or construction must not be used on the
same axle. Consult your Distributor or Dealer before changing to radial ply tyres.

Note:
Vehicles fitted with Wintertreat tyres should not be driven at high speeds for prolonged
periods, i.e. in excess of 90 km/h.
F¡9. 37 F¡9.38

1
Tyre replacement
A B Removal and refitting can only be carried out over the inner rim of the road wheel.
\

2
3

1 2
5ñOÔSÂ

28 33
BRAKES AND CLUTCH
Preventative Maintenance
ln addition to the recommended periodical inspection of brake components, it is advisable as the car
ages and as a precaution aga¡nst the effects of wear and deterioration, to make a more searching
inspection and renew parts as necessary.
It is recommended that:
(1) Disc brake pads, drum brake linings, hoses and pipes should be examined at intervals no
greater than those laid down in the Maintenance Summary.
(2) Brake fluid should be changed completely every 1 I months or 20,000 km whichever is the
sooner.
(3) All fluid seals in the hydraulic system should be renewed and all flexible hoses should be
examined and renewed if necessary every three years or 60,000 km whichever is the sooner.
At the same time the working surface on the pistons and bores of the master cylinder, wheel
cylinders, and other slave cylinders should be examined and new parts f itted where necessary.
Care must be taken always to observe the following points:
(a) At all times use the recommended brake fluid
(b) Never leave 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 is best discarded.
(d) The necessity for absolute cleanliness throughout cannot be over-emphasised.
Clutch Master Cylinder
lnstructions for checking the fluid level are given wi:h those covering the brake master cylinder.
Release lever clearance (Fig. 45)
It is important that a clearance should exist between the clutch thrust race and the thrust ring. All
vehicles have this clearance carefully set before despatch. Gradually, as wear takes place, how-
ever, this clearance will diminish and, if neglected, clutch slip will result or if clearance becomes
excessive full disengagement of clutch may not occur.
Checking
Remove the return spring, pull the release lever outwards until all free movement is taken up. A
clearance of 0.5 mm (0.020 in) must be maintained between the clutch release lever (1) and its
return stop (2). Use a feeler gauge to check the clearance.
BRAKES AND CLUTCH
Master cylinder fluid levels (Fig. 39)
Maintain the fluid level in the brake and clutch reservoirs up to the bottom of the filler neck or to the
level mark (1) on the brake master cylinder reservoir.
Filler caps
Before refitting the brake (1 ) and clutch (2) reservoir filler caps, check that the breather holes (3) are
clear.
Topping up
Top up if necessary with Leyland Australia Brake Fluid, specification H.B.F.6 or other brake fluids
having a minimum boiling point of 260"C and complying with specification SAEJ1073F. DO NOT
use any other type of brake flu¡d. Frequent topping up is indicative of a leak in the system which must
be detected immediately and the leak rectified.
Note: Brake fluid can have a detrimental effect on paintwork. Ensure that fluid is not allowed to
contact paint-finished surfaces.
Front brakes disc type (Fig. 40)
-
Wear of the discbrake friction pads is automatically aompensated for during braking operations and
no manual adjustment is required. To check the thickness of the pad material, remove the road
wheel and check that sufficient lining material remains to allow the car to run until the next check is
called for without the thickness falling below the minimum of 1.6mm (1/16 ins).
lnspect front brake pads (Fig. 40)
Apply the hand brake, and jack up each front wheel in turn (see 'Jacking procedure'). Remove each
wheel individually and check the thickness of the pad lining material at the front of the disc brake
calliper (2).
lf the wear on one pad is greater than on the other, their operating positions should be changed over.
New pads should be fitted by an authorised Distributor or Dealer. After fitting new pads, avoid heavy
braking for a few days to allow the pads to bed-in.

Adjusting
To adjust the clearance, slacken the locknut (3) and turn the stop (2) to obtain the specified
clearance. Refit return spring.

F¡9.45 Fig.39
Fig.40

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1 TL 1
22

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23 3

a 2
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32 29
BRAKES AND CLUTCH BRAKES AND CLUTCH
Set the hand brake to the 'off' position and see that the two wheels rotate quite freely.
Front Brakes
- drum lype (Fig. 41)
Brake ad¡uslment Adjust the shoes by means of the adjusting screws as previously detailed.
Excessive brake pedal travel is an indication that the brake shoes require ad¡usting to mainta¡n even Check the hand brake act¡on, and if excessive travel is still present wh¡ch prevents proper applica-
and efficient braking. tion of the brakes, it is probable that the brake-shoe linings are worn or, in exceptional cases, the
cables have stretched.
Front
Use the jack provided in the tool kit to raise each wheel in turn, see 'Jacking Procedure'. Examine the brake-shoe linings, and if worn renew or reline them if replacement shoes are not
available.
Using a Brake Adjusting Spanner, turn each of the two adjusters (arrowed) in the same direct¡on as
theforwardrotationof thewheel until thewheel islocked. Backofftheadjustertheminimumamount lfexcessive brake lever travel is still present with new shoes or linings, it is permissible to take up the
necessary to allow the wheel to revolve freely. excess travel atthe hand brake levertrunnion (1) provided the following procedure is strictly adhered
to.
Spin the wheel, apply the foot brake hard to centralise the brake shoe and recheck the adjustment.
Repeat ihis procedure with the other adjuster and repeat the same operation on the other front d First make sure that the shoes are properly adjusted by means of the shoe adjusters as explained.
wheel. This is most important.
ir
Apply the hand brake until the pawl engages with the notch on thé ratchet, and edjust the nuts at the
Rear
- All Models (Fig. 42)
Jack up one wheel, see'Jacking procedure'and release the hand brake.
hand brake lever until it is just possible to rotate thê wheel by hand under heavy pressure" lt ¡s
important that the road wheels offer equal resistance in order to get full braking power.
Turn the single squared adjuster (arrowed) in a clockwise direction (when viewed from the centre of Return the lever to the off' position and check that both wheels are perfectly free.
the ca| until the wheel is locked. Test vehicle for even braking of foot and hand brakes after this adjustment. Fig. 44 shows cable
Back otf the adjuster one notch (quarter turn) and depress the brake pedal firmly and continue this pivots and lubrication points.
procedure until the wheel revolves freely.
Note: Should it be necessary to back offthe adjuster more than 3 notches, check the rear brake lnspecting brake linings
mechanisms (including the hand brake adjustment) for correct operation. Use the jack provided in the tool kit to raise each wheel in turn; see 'Jacking procedure'.
Lower the jack and repeat the operation on the other rear wheel. Release the hand brake when checking the rear linings. Remove the road wheel and slacken the
Warning: brake shoe adjusters, remove the brake drum securing screws and withdraw the brake drum.
Do not work beneath the vehicle with the lifting jack as the only means of suppoÉ. Place lnspect the linings for wear, and wash out any dust from the backplate assembly and drum
suitable suppoÉs under the sub frame(s) of the side or end(s) of the vehicle which have been preferably using methylated spirits (denatured alcohol). Brake lining dust is dangerous to health if
jacked up.
inhaled and therefore should not be blown from the drum.
Make certain that sufficient lining material remains to allow the car to run until the next check is called
Handbrake (Figs. 43 & 44) for without the thickness falling below the safe limit. Refit the drum and road wheel and adjust the
Should the hand brake not hold the car or the lever show signs of reach¡ng the end of its travel on the brake shoes.
ratchet before the brake comes into operat¡on, re-adjustment is necessary; this will also be indicated
by excessive pedal travel. Replacing brake shoes
Raise the rear of the car until both wheels are clear of the ground. When it becomes necessary to renew the brake shoes, it is essential that only genuine shoes, with
the correct grade of lining, are used. Always fit new shoes as complete axle sets, never individually
or as a s¡ngle wheel set. Serious consequences could result from out of balance brakìng due to
mixing of linings.
F¡9.43 Fig.44

F¡9. 41 F¡9.42
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