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DRIVER'S HANDBOOK
Notes
<h2>Handbuch London Taxi und Hire Car FX4</h2>
.~
<h1>London TAXI AND HIRE CAR</h1>
<h2>Driver's Handbook FX4s and Hirecar</h2>
This handbook contains information on FX4S models fitted with Land Rover Diesel and Petrol engines
Dieses Handbuch beinhaltet Informationen für das London Taxi FX4s und generell auch für FX4
Contents Page
Maintenance
Replacement & Data
Publication Part No I. TISS3400986
Published by London Taxi International Limited
Holyhead Road, Coventry CV5 8J J
LONDON Taxi Nat LIMITED 1986
Foreword
Controls & Operation
This handbook introduces you to the various Information and Driving information
Instructions to facilitate the Getting to know your vehicle e
Controls, switches and components of the
Speedy replacement of consumable items is
London Taxis International Taxi and Hire Car and Automatic transmission 1 2
Given with useful general forecourt data in the Controls
Explains their function and the procedure by the final section of the handbook. 7
Which they are designed to operate Accelerator
7 Brake s The following meanings are ascribed to the Brake pedal
Care and regular maintenance during usage will Clutch pedal
Words in bold type which precede notices Fi~id Ir, vol warning_ ', hot
Prolong the useful life of the vehicle and it is Gear lever - manual gearbox 8
12 Val t~r,~kes
Strongly recommended that the maintenance WARNING: The procedure must be followed Gear lever - automatic gearbox
7
Scheduled at regular intervals in the centre precisely to avoid the possibility of personal Handbrake Fuel consumption 1 2
Injury. Mixture control (choke) 7
Section of this handbook is never overlooked and
Is carried out by qualified personnel in a suitably Steering lock/starter switch 9
CAUTION: Follow this procedure to avoid 9 Heating and ventilating g
Equipped garage or workshop. Care and planned Steering lock/starter switch keys 1 1
Damage to components. Air intake
Maintenance will be rewarded by continued 1 1
Reliability and economy and locks Air distribution
Note: This method makes the job easier. Doors 1
Bonnet 18 Air temperature
Blower switch 1
Front door 16
Passenger's heater 1
Keys 16
Luggage compartment 18
Mirrors 1 4
Rear doors 17
Rear door security locking 1 7
17 No-charge warning 1 0
Windows
4 Oil pressure 1 0
Instruments
Switches Seats
Seat adjustment 1 4
Fascia switches 5 1
6 Seat belts 5
Column switch 16
Direction indicator 6 Rear seat belts
Headlamp dips 6
H 6 Starting
Headlamp flash Starting - diesel engine 1 0
Horn 6 1
Starting - petrol engine 0
Interior lamps 6
Warming-up 10
Warning lights 4
2
3
Controls & Operation n I Controls & Operation
Fig 1 Left-hand drive e
~is 7 Right -hand drive
INSTRUMENTS - Figs 1 and 2 7. No-charge warning. Glows red when the . Hazard warning switch. Press the switch
FASCIA SWITCHES - Figs. 1 and 2 18
Auxiliary c rcu ts are switched on the light marked HAZARD downwards to operate the
1. Speedometer. Indicates the road speed in should go out as the engine is started and its
13. Lighting switch. When the switch is direction indicator lamps as a hazard warning
Mp/h or in km/h and also records the trip and
Speed increases pressed downwards to the first position the side the lamps on both sides of the vehicle and the
Total distance the vehicle has travelled. The trip
And tail lamps are switched on, and when warning lamp in the switch will operate in unison
Recorder enables the distance of a pa reticular 8. Direction indicator warning. Flashes green
Presses to the next position the headlamps are irrespective of whether the auxiliary circuits are
Journey to be recorded and is reset to zero by when the direction indicators are flashing. The
31so switched on switched on or off
Turning the knurled knob on the fascia light goes out when the indicator switch is
Anti-clockwise until the figures return to zero. Returned to the 'OFF' position n . Driver's blower switch. 19. Heated rear window.
14
2. Oil pressure gauge 9. Door warning. Press the switch X Press the switch raja
. Indicates the pressures the left-hand light glows rear window.
( Downwards to operate the blower motor and downwards to operate the heated
In Ibf2i of oil being delivered by the pump the orange when the left-hand rear door is not
Increase the circulation of air in the rl~ivtrf ~ the switch will illuminate as a warning light for
Gauge should register within 30 seconds of closed and the right-hand light glows orange
Compartment details of the are to be taken of the heated rear
Starting the engine when the right hand rear door is not closed
Window sees CLEANING
3. Fuel gauge 15. Passenger's blower switch.
. Indicates the approximate 10. Door locks warning. While the ignition is
Amount of The switch 29 NB: Scotches 14. 15 & 19 can only he operated
fuel in the tank, 'E' indicating empty switched on this red light will glow if the rear
Can be used to switch the passenger's when the auxiliary circuits are switched on
And 'F' full the gauge operates only when the doors are not locked and can be opened from
Compartment blower on or off irrespective of
Auxiliary circuits are switched on inside by a passenger. I see also page 171.
Whether the push-button type switch in the
4. Temperature gauge. Indicates the 12. Brake failure warning. (See also page 8) passenger's compartment is on or of f
Temperature of the coolant in the engine when
The auxiliary rye circuits are switched on 'C' indicates NB: On later modest the 3, n I and speedometer 16. Panel lamp switch.
Cold, 'N' indicates normal, a nod 'H' nod have changed positions Press the switch Q
Indicates hot
Downwards to () position the panel; rend switch
5. Ammeter. Ideates the r.3tt, .,t voice the illurninations 1 h . ;~,
WARNING LIGHTS - Figs .1 and 2 17. Passenger's interior lamp switch .
1 hrsw~th o
6 . Main beam warning . r ;iov, it,
Controls & Operation Controls & Operation
COLUMN SWITCH - Fig. 3 CONTROLS - Figs . 6 and 7
Direction indicator. The selfcnncellinq sw,tcr.
1 . Handbrake. Pull the Irror ~,p,vards to,rpply
operates the rndreators when the auxiliary crrcwts
the re,ir hrakes To reledse the brakes pull thc
are switched on Move the switch to position ( 1 I
lever ulw,rard,, tilrghtly, depress the buttonon the
to operate the right-hand indicators and to position
end of the lever and push downwards
(2) to operate the left-hand indicators ; the
warning light will flas h 2. Accelerator pedal.
Headlamp flasher. Lift the lever towards the 3. Brake pedal.
steerrnq-wheel 13) to flash the headlamps The
lever will return to its normal position when 4. Clutch pedal.
released
5. Gear lever . Lift and move the lever to the lett
Headlamp main beam. Push left hand lever before engaging reverse gear For operation with
forward - blue warning light will illuminate in autornatrc transmissron see page 1 2
speedometer To cancel lift lever towards
Fig 3 6. Cigar lighter ( if fitted). Press the knob in to
steering wheel returning to original positio n Fig 6 Right-hand drive - diesel - manu a
operate When heated and ready for use the
Horn. Press the end of the lever inwards (4) to element will partly elect and can then be
sound the horn withdrawn for use
Windscreen washer . Push button at end of Petrol engine mixture control (choke) - Fig . 8
right-hand leve, When startrng the engine from cold . pull out the
control and turn it clockwise to lock it in position
Windscreen wiper switch . Move right-hand The further out the control is pulled, the richer
lever upwards; for tvvo speed wipe as required will be the fuel mixture to assist starting a cold
Move right-hand lever down for flick wip e engine
DRIVERS INTERIOR LAMP - Fig. 4
Press ae~tin -, s. tch adlacent tr, ~re lamp or,
the partt:on be,rnd the driver to switch o n I I / '/I
3 2 5 1 6-
PASSENGER'S COMPARTMENT
LAMP - Fig . 5 Fig 4 Fig 7 Left-hand drive - petrol - auto
Press the push-button type switch in the
passenger's compartment adjacent to the
right-hand interior lamp to switch on or off .
The operation of the passengers interior light can
be overridden by the switch a on the fascia
panel
Fig 5
6
Controls & Operation - 1
Controls & Operatio n
Steering lock and sta rter switch - Fig . 11
The switch has four positions marked'0','I','II'
BRAKE S and 'lll' The switch key can only be withdrawn
or inserted when the key is at the'0' position
The brakes on your new vehicle will increase
their efficiency as they are used during the first Diesel switch
few days of driving During this bedding-in Insert the key and turn it towards position '1' to
period, the pedal pressure required will dimmish unlock the steering If the steering lock remains
,is the hf ;3kPS irnprove engaged, slight movement of the steering wheel
will release it . Further movement of the key to
WARNING: As a safety precaution against position 'I' will switch on the auxiliary circuits
total brake failure, the four wheel brakes Turn the key against spring pressure to the'II'
operate as two separatepairs. If the hydraulic position to switch on. Turn the key further to the
circuit to one pair of brakes fails, the other 'III' position to operate the starter motor The key
pair of brakes will operate normally if the will return to the 'I' position when it is released .
pedal is pushed to the full extent of its travel.
Push the pedal beyond the area of no Petrol switch Fig. 11
resistance until the second pair of brakes Insert key as diesel and turn towards position'I' .
operate. Do not pump the pedal in an attempt Further movement of the key towards position
to restore pressure. Do not allowextra thick 'II' is required before auxiliary circuits operate,
matting on the floor to limit pedal travel. then turn the key towards position'111' to operate
- Figs. 9 and 10 the starter motor. The key when released will
Brake fluid level warning light
return to position 'II' .
Warning light (2) will operate only when the
ignition is switched on and the fluid in the To lock the steering and withdraw the key. Turn
reservoir is below a safe level. the key to the '0' position and withdraw the key.
To test the warning lamp and circuit, switch on Never turn the key to the'0' position while the
the auxiliary circuits and press the switch (1) vehicle is in motio n
below the lamp. If the bulb and circuit are
functioning the lamp (2) will piow And go out as WARNING: The steering-column kock/starter
the switch is released switch and its electrical circuits are designed
to prevent the engine being started while the
WARNING: If the warning lamp glows at any
steering lock is engaged. Serious
time except when the bulb is being tested the
. consequences could result from alteration or
cause must be investigated immediately substitution
of the steering-column
Unless as a result of vour ~nvestioating you are Fig 10 Left-hand drive lock/stanter switch or its wiring. In no
satisfied that it is safe to proceed . you should circumstances must the starterswitch be
leave the vehicle where it is and call for separated from the anti-theft device.
assistance Even if you are satisfied that it is safe
CAUTION: Do not lubricate the steering tock.
to proceed. the vehicle should only be driven in
cases of real emergency, extreme care should Keys
be taken and heavy braking avoided. In deciding To reduce the possibility of theft, locks are not
whether it is safe to proceed you should consider marked with a number It is important that
~% hether YOU will be infringing any Government owners MAKE A NOTE OF
THE KEY
Rr~tulations NUMBERS IMMEDIATELY on taking delivery of
Wet brakes the vehicle The number of the steering-column
been washed, dr lock and starter switch key is stamped on the
If the vehicle has iven through
water, or over wet roads for prolonged label attached to the key ring . It is advisable for
perrods,
may not beavailable owners to consult their Dealer regarding steering
full braking power . As soon
as it is safe to do so dry the brakes by apply lock and starter switch key replacements
ing
the iootbrake lightly several t mes while the
v~h~cle is in motion Keep the handbrake applied
while us ng pressure wash nq equipment
9
IQ I
Controls & Operation Controls & Operation I l
STARTING - DIESEL ENGIN E OiI pressure
If the oil pressure gauge fails to show any HEATING AND VENTILATING - Fig . 12
Check that the handbrake is on and that the gear pressure while the engine is running, stop the -
lever is in the neutral position (manual gearboxl engine, check the oil level is not excessively low, I he system will provic7e fresh w for 'i+a,itnrl or
or the selector lever is in'P' or'N' (Automatic consult your Dealer before re-starting the engine venlilating the driver's cornpartment and for -
=f~
gearbox) Switch on the auxiliary circuits and demisting or defrosting the windscreen The air
check that the no-charge warning light glows . Warming-up ! will be heated by the engine water system
A DPS fuel pump is fitted to the 2 5 litre engine Do riot allow the engine to idle slowly while according to the position of the air tpef-Iture
THE ACCELERATOR PEDAL MUST NOT BE warming-up The vehicle can be driven on the -
contro l I
DEPRESSED WHEN STARTING . Operate the road immediately after starting-up, in which case 7 ~
starter, releasing the key as soon as the englne is hard acceleration or allowing the engine to Air intake control
running labour must be avoided until normal working Push the lever (1 j in the cectre ,f thc tu a lI ~ I
temperature is obtained the right, and then downwards to open the
scuttle ventilator and allow fresh air on to the
STARTING - PETROL ENGINE Running-in windscreen via the heater uni t
Check that the handbrake ison and that the gear The following instructions must be strictly
Air distribution control
lever is in neutral or at'P' or'N' . adhered to with a new vehicle or engine during
Open the door (21 which is below the centre of
the first 500 miles (800km) .
If the engine is cold, pull out the mixture control, the fascia over the gearbox cover to allow air to
turn it clockwise to lock Do not exceed 40 m.p h . (65 km/h) on a light enter the driver's compartment at foot level
throttle . Close the door completely to direct the maximum 3
J /
Insert and turn the starter switch key to position amount of air to the windscree n
'III' to operate the starter and as soon as the Do not operate at full throttle in any gear . 2
Air temperature control
engine starts release the key The RED no charge Do not allow the engine to labour in any gear .
To increase the temperature of the air entering
warning light will go out when the engine is
running Progressively increase the maximum speed and the driver's compartment move the lever (3)
throttle opening of vehicles over the first 1,500 sideways from the 'MIN' pos tUon towards the
If the mixture control has been used to assist miles (2,500km) . 'MAX' position If cool air is required, leave the c 5
starting, unlock the control by turning it lever at the'MIN' positio n
anti-clockwise and push it in until about 13mm Filling with fuel
Blower switch ~~
(y2 in) of travel remains and re-lock . Do not fill the fuel tank to the extent that fuel is
visible in the filler neck To increase the amount of air entering the
. If this happens, and the
Approximately one minute after the engine has vehicle is parked in the sun, expansion will cause driver's compartment press the switch (4) to
started, unlock and push the mixture control operate the blower moto r
both loss of fuel and dangerof fire from exposed
right in Fig 12 Right-hand drive panel shown
fuel Park the vehicle in the shade with the filler Passenger's heater
cap in as high a position as possible . The system heats and recirculates the air in the
Starter
Operate the starter for up to five or six seconds WARNING : The fuel tank is fitted with a vented passenger's compartment The temperature of
at a time. If the engine fails to startthe first time, filler cap. It is essential thata replacement cap the air, heated by the engine coolrng system, is
do not use the starter again until the engine has is of the correct type. controlled by the lever (3) in the driver's
stopped turning Release the key immediately compartment The heater blower motor is
the engine fires and run . Do not use oxygenated fuels such as blends controlled by a push-button type switch (5)
of inethano!/gasoline or ethanot/gasoline located at the top of the right-hand rear door
Note: The starter motor may have to be operated (e.g. GASHOL). pillar in the passenger's compartmen t
tor more than five or six seconds in cold weather
condition s Empty fuel tank - diesel The operation of the passenger's heater blower
In the event of the diesel fuel tank becoming motor can be overriden by switch (6) o r the
No-charge warning completely empty, before the engine will start l
fascia pane
If the no-charge uvaming light fails to go out, stop the fuel tank must be replenished and the fuel
the engine, check the alternator driving belt, and system must be primed to exclude all air (see Rear fog guard switch
adlust if necessary If the adjustment is correct page 33) With the headlamps switched on, prr-,,, t'
or adjustment fails to correct the fault, consult switch (7) to operate the rear fog lamp tne
your Dealer or Agent as soon as possible Use of warning lamp will illuminate the switch Piess
the starter and%or lamps in these circumstances the switch aqain to switch off the foq drnt ,
w ll exh,iust the battery quickly
AIR CONDITIONING (if fitted )
R('ff " t, l - ., ,~I , I'.Ir , infUl "nlll"tl { '., , 1, Ir
10
Controls & Operation
Controls & Operation p
FUEL CONSUMPTIO N
This information is taken from the officially approved tests as required by the Passenger Car Fue AUTOMATIC TRANSMISSION
l
Consumption Order 1977.S 1 1601 WARNING: When selecting any gear with the
Simulated Urban Constarlt Speed vehicle stationary the brakes must be applied
Driving 56 mp.h . (90km/h ) until gear selection has taken place.
FX4'S'Model rnp.g. litre/100krrm mpg Irtre/100km Selector positions - Fig. 13
P
Manual transmission 27 .4 103 37.3 7 .4 The selector lever and accelerator pedal control R
Automatic transmission 286 99 31 .5 9 0 the operation of the automatic gearbox . N
D
Important note 7- Park. When the vehicle is parked, apply the
L
The results given here do not expressor imply any guarantee of the fuel consumption of the particular handbrake and select'P' to lock the transmission
vehicle with which this information is supplied . The vehicle itself has not been tested and there are mechanically. No power is transmitted to the
inevitably differences between vehicles of the same model . In addition this vehicle may incorporate rear wheels .
particular modifications . Furthermore the driver's style and road and traffic conditions, as well as the
extent to which the vehicle has been driven and the standard of maintenance, will all affect the fuel 'R' - Reverse. Select only when the vehicle is
consumption . stationary. If a reversing light is fitted it will
operate while the ignition is switched on . Fig. 13 Right-hand drive
AUTOMATIC TRANSMISSION
'N' - Neutral . Apply the brake and select 'N'
Startin g when the vehicle comes to rest . No power is
Always apply the brakes before starting the transmitted to the rear wheels .
engine. The starter can only be operated when 'D' - Drive. Select this position for normal
the selector lever is in the'P' or'N' position . For driving. Gears will change automatically both
details of the starting procedure see page 10 upwards and downwards through the three
Note: Vehicles with an automatic gearbox ratios according to the vehicle road speed and
cannot be push- or tow-started . accelerator pedal position .
Driving 'L' - Lock-up . Automatic changes are confined
After starting the engine and, with the hand to the first and second ratios . Select when rapid
brake and foot brake applied, lift the selector lock acceleration or engine braking is required, also
and move the selector lever to the required when :
position . Release the brakes and press the a) descending a steep hill.
accelerator.
b) driving up a long hill to prevent frequent
CAUTION: Do not run the engine above rd/e changes of ratio .
speed with a drive position selected while the c) negotiating bends or gradients, particularly
car rs slahonary Selecr N" or'P tor prolonged when heavily laden .
penods of idlin g
When selected while stationa ry, the transmission
Increased acceleration will remain in the first ratio during driving .
To change down quickly for overtaking or hill
climing, press the accelerator beyond its normal If selected while driving in third ratio, the gearbox
travel The down-change cannot take place will change down to second ratio and give
above40mph (65km/h) . engine braking should the road speed fall
between 16-27 m p .h. (26-43 km/h) or when the
Engine braking
accelerator is pressed quickly to the floor below
Reduce the road speed to below 45m .ph 35-43m.p.h . (56-70km/h). First ratiowill be
(72 km/hl by use of the foot brake and select 'L' selected automatically when the road speed falls
To give maximum engine braking, further reduce below 5 to 11 m p .h. (8 to 17 km/h) and will give
the road speed to below 5 to 11 mp h . (810 maximum engine braking .
17km/h )
DO NOT
Soft surfaces
Select 'P when the vehicle is moving _
When thc ,0heels f.ill to qrip, rock the vehicle
b,ickwan f~ , ind lorwards by alternately selecbng Select 'R' when the vehicle is moving forwards
R' and ' P ~n,iih,i small throttle openrng Select 'L' above 45m .p h i70km/hl
12
Controls & Operation Controls & Operation I
DRIVER'S SEAT - Fig .1 4 AUTOMATIC SEAT BELTS - Fig. 17
4
Move the i,ver 11 I it the front of the se,rt'rame Wearing
to the right to adlust the location of the seat on The k>elt fasthner or buckle musl be,il the side of
the floor Lift the forward lever (2) at the side to the h p. never at the front The lap section of the
raise the seat against spring pressure with the belt rnust always lie across the hip bones . never
lever lifted to lower the front of the seat Ensure across the soft parts of the abdomen Wear the
that the catch has engaged when the lever is belt as tightly across the body as possible
released Press down the rear lever (3) to adjust without undue discomfort Ensure that the belt 6
the angle and height of the rear of the sea t webbing is lying flat and is not twisted
Fastening
DRIVER'S SEAT - Fig. 15 Pull the locking tongue 11) and belt across the
body gently, and insert the tongue into the
Lift the Inv.er rail i1 I at the front of the, seat and
locking unit (2) Press the tongue into the unit
slide the seat to the preferred poslt on . Release
until the locking mechanism is heard to click into
the rail and move the seat until it lock s
Fig 14 Right-handdriv e position Do not pull the belt across the body
With the body weight raised from the seat, lift quickly, or the locking device in the automatic
the upper rail (2) to raise or lower the sea t reel will operat e
Pull upwards on the lever (3) to the left of the Releasing
seat to incline the back rest in the most Lean forwards against the belt and press the
comfortable position release catch (3) of the locking unit marked
'PRESS' until the tongue is detached from the
MIRROR S unrt . Allow the return spring of the belt reel (4) to
assert itself and return the belt to its parked
Exterior position It may be necessary to feed the last few
The door-mounted mirror may be adjusted from inches of belt onto the reel by han d
the seat position when the window is opened .
Care of seat belts
To adjust a wing mirror, slacken the retaining nut Inspect the belt webbing periodically forsigns of
and adjust the mirror head to the desired position abrasion or wear, paying particular attention to 1 r,
Tighten the retaining nut the fixing points and adjusters Do not attempt to
make any alterations or additions to the seat
Interior - Fig . 1 6 Fig . 15 Left-hand drive as could impair
belts or their fixings this their 3 2
The rnirror sterr witf- antdaz :le head is efficiency Renew a seat belt that has withstood
designed to break away from the mounting the strain of a severe impact or shows signs of
bracket on impact The stem may be refitted in severe fraying or has been cut
the mounting bracket as follows. Align the stem
ball (1) with the bracket cup (2), ensuring that the Before cleaning the seat belts see page 20
small protrusion (31 on the stem aligns with the
Testing
indent of the mounting bracket Give them a
smart tap with a soft instrument to join the two WARNING: This test must be carried out
components undersafe road conditions, i.e. level, dryroad
with no following or oncoming vehicles.
Anti-dazzle
l o reduce w,ror dazzle, press the lever (4) Wrth the be'ts ,,i ~,se d,we the vehide at 5m p h
.c).1-arci~ the r: indscreen l8km hiand br,ike sharpiy The ,iutomat,c
locking device should operate and lock the belt
It is essential that the driver and passenger are
sittinq in a normal relaxed position when making
Fig 16 IhetF!st The ret,arding ef fect of brakmg must not
ht,nUC~pated
II i I n . lt fxk tn liirk .
frq 17
Controls & Operatio n
Rear seat belts - Fig . 1 8
Provlslon I; rrnrule for the rrttachment of two Rear door - Fig. 20
belts for ~e.3r soat passenger s
Door lock
The anchorage point for the short locking strap Depress the button 111 on the exterior door
for each belt, which should lay on the centre of handle to open Pull the interior handle 121
the rear seat cushion, is reached from the upwards towards the grab handle to open No
luggage compartment Remove the lack and provision is made for locking the door from the
spare wheel, pass the end of each strap between inside To lock the door from the outside turn the
the seat cushion and back rest and secure to the key (3) towards the front of the vehicle, to
tapped holes in the spare wheel well with the unlock, turn towards the rear of the vehicl e
special seat belt bolts Window lock
The long belt on each side is secured at the top The window may be locked in the closed position
by the reel which is bolted to the rear parcel shelf by moving the lever (4) rearward s
after removing the sealing plug
Window opening -
T he tab at the lower end of each long belt is Flg 18 To open or close the window, move the locking
Fig . 20
bolted to the fixing point in the wheel arch and lever forwards and slide the glass up or down ;o
this too is easily accessible when the seat the desired posit on
cushion is lifted forward Rear door security locking - Fig. 21
Each belt is intended for use by an adult occupant When the electronic rear door security svstern is
only and is fastened by pulling the tongue over fitted the rear door locks are made to operate by
the shoulder from the reel until it crosses the the motion of the vehicle or the driver applying
chest and can be pushed into the lock nearest the footbrake
the wearer A click will nd cate that the belt is
If the ignition is switched on while the vehicle is
locked
stationary the red warning light ( 1) on the
instrument panel will glow and the rear doors
DOORS AND LOCKS can be opened.
Keys As soon as the footbrake is applied the locks will
Three keys with dupllcates, are provided The operate automatically, the warning light will be
lurge key is for the steering lock .:,d starter switched off and the doors will remain locked
switch, and of the two small keys one is for the from the inside until the footbrake is released.
front and rear door locks and the other is for the Fig 2 1
luggage compartment lid lock As soon as the vehicle moves the rear doors will
lock automatically, the warning light will go off
To reduce the possibility of theft the locks are and the doors will remain locked until the vehicle
rtot marked with a number Make a note of the comes to rest. If the vehicle comes to rest
key numbers immediately on taking delivery of without the footbrake being applied there will be
the vehicle a delay of two seconds before the locks release
Front door - Fig. 19 If the vehicle comes to rest with the footbrake
applied the locks will not release until a few
Door lock seconds after the handbrake is applied and the
f q) 19
~f,ress the button (1) on the exterior door footbrake is released The locks will release
lr° tcr or,en Pull the rntenor handle (2) Quarter-light immediately the ignition is sw itched-off
:pwards to open the door, push the handle Ir) opon tIly duarter-hght, press in the plunger(5 )
downwards to lock the door To lock the door When the automatic locks are applied, the rear
thecatchandplvotthecatch
from the outside turn the key(3) towards the rear doors can be opened only from the outside This
e~ve~!ow-3d: the rear of Ihequ,irterllght
if the vehicle, to unlock turn towards the front safety feature enables occupants to be released
of the vehicl e in case of accident either by someone outside
the vehi~_ ~-, nr by the occupant themselve, ;
Window lock lowenn(Ithrw~ndow,mdpressinqthc hul!r~~<~n
~ . . ~, D. ~.^ . 1, Ue Irlcked it, the ClOsed p09UOn 11'F' ; ara11 1) i' aniil i
When tht~ rerl li~lht n)ountedun thedtx~r rtn~~~s ~ifl
the rlrlnr I~ r~'k ~~-. tr~~Ir, ;rsC~d
1F -~ I
17
Controls & Operatio n Maintenance
Luggage compa rtment - Fig. 22 Automatic gearbox Lubricant specifications 2
5
Turn the handle (1) in either direction to open the Parking pawl check 28
luggage compartment, To lock, insert the key (2) 42 Lubricants - service 26
Oil filter
and turn it anti-clockwise ; to unlock turn
clockwis e ery top-up Lubrication procedure s
Batt 41
Bonnet - Figs. 23 and 24 Automatic gearbox 28
To open the bonnet, move the bonnet lock Brakes Distributor 36
release lever (1) to the left to release the bonnet Adjustment 38 Engine oil change 27
lock and then move the safety-catch lever (2) to Fluid reservoir 36 Engine oil check 27
the left to release the safety-catch Lift the Lining inspection 37 Engine oil filter change 27
bonnet until the bonnet prop (3) locates in the Replacing brake shoes 37 Handbrake linkage 37
suppo slot (4) in the bonnet prop channel To Locks, hinges and catches 31
rt
close the bonnet, raise it slightly, pull the prop Cleaning Manual gearbox 28
forwards out of the slot and lower it Make sure Exterior 20 Power steering 30
the lock has engaged Interior 20 Propeller shaft 30
Materials 21 Rear axle 29
Fig 22
On later export models the bonnet lock is Steering connections 30
released from inside the vehicle Clutch fluid reservoir 36 Steering idler 29
Cooling system Preventive maintenance 2 1
Frost precautions 40 Brakes 23
Topping up 40 First 1,000 miles 22
First 6,000 miles 22
Engine Every 3,000 miles 22
34 Every 6,000 miles 22
Air cleaner element
Belt tension : Every 18,000 miles 23
Every 24,000 miles 24
- alternator 41
- power steering 30 Every 36,000 miles 24
33 Weekly 21
Diesel fuel - bleeding air
Diesel fuel filter 34 Tyres 39
Diesel fuel injection 32
Diesel heater plugs 32 Windscreen
Fig 2 Fuel sediment bowl - petrol 34 Washer reservoir check 42
3
Sparking plugs 36 Wiper arm 42
Valve rocker clearance 31 Wiper blade 42
Fig 24 Right-hand drive
18 1. 19
1 I
Maintenance 1 Maintenance
CLEANING - DO's AND DON'Ts Exterior CAB CARE
use of the following products selected from the UNIPART range will ensure maximum effectiveness
Interior Do :
in maintaining the appearance and condrtion of your vehicle .
;^J ,h Ihw brulyworF In,aurmtly with,i suf l
Do nrt plentv ul W,Jter cont'+inmg r :' u Carpets . . . .
. GAC 214 UNIPART Nylon Upholstery Cleaner
rin pl,r;lir. f u .rrrl ,it hhrrlt,tr! ry w ith dilutrrrl
Seats and trim (vinyl and leather cloth) . . . . . . . . . GAC 109 UNIPART Upholstery Cleaner
lnls;tery rar;nnr .,r
Seats (nylon) and headlining . . . . . . GAC 214 UNIPART Nylon Upholstery Cleaner
I1sc chrrmr> elr;aner t o r,~ntuve tarnish from
(,Ican nylrin far.r,r1 uphr~Islr,ry with st hrush or Washing . . . . . . . . . . . GAC 198 UNIPART Luxury Car Shampoo
tmqhl tnF't,tl
vacuunr r;lui mer . .inti n--rnovr; stainti with nylon GAC 112 UNIPART Car Sponge - celulose
cleaner, using a p,ttting ar,tion U;e (Ilas~; cleaner tI ) removu wrndscreen smeiars GAC 283/4 UNIPART Car Sponge - synthetic
GAC 232 UNIPART Chamois-leather - large
C.le m se<tt belts by sponging with warm w,tter, lltie petrol or wh~tc- spint In remove spots of (GAC 233 - standard)
using a non detergent 5o ;rp and allowing them to grease or tar from the pa+ntwork and bright tnrri Glass . . . . . . . . . . . . . . . GAC 102 UNIPART Glass Cleaner
dry naturall y Bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . GAC 106 Hi-Shine Car Polish
Use car polish to retain the new appearance of Chrome and bright trim
GAC 108 UNIPART Chrome Cleaner
Clean c arpeis with a brush or vacuum cleaner your vehicle Engine grime and grease . . . . . . . .
. GAC 176 UNIPART Engine Degreasant
Occasionally clean carpets with diluted
Don't (Aerosol)
upholstery cleaner
" +h,,asrves or met,tl pol sh on bright metal
Winter aids
Use only a clean soft cloth or chamois leather to Washer reservoir . . . . . . . . . . . . . . . . . . GAC 313 UNIPART 'All Seasons' Screenwas h
clean the interior of the rear w ndow and the
direction of cleaning should be in I ne w tn the A UNIPART Tool Kit is obtainable in a waterproof roll and contains the following tools .
heating elements and ~ ot across them
8 combination spanners 2 screwdriver s
Don't 1 adjustable spanner 1 feeler gauge
r, i rubbing action when remowng stains from 2 pairs of pliers
Iov ; f,,ced upholsten
This kit can he supplemented from a comprehens ive range of UNIPARTquality hand tools which are
Use upholstery cleaner on painted surfaces also available-
Bleach or re-dye seat belt s
Preventive maintenanc e Every WEEK or before a long journey
Clean seat belts by us-q ;:,jusuc soap chem cal Preventive maintenance, together with the use Check/top-up engine oil.
cleaners or deterge-t s of Genuine London Taxi International pa rts is the Check/top-up power steering fluid .
key to economy, safety and reliability for your Check/top-up automatic transmission fluid .
Dry seat belts with artltic ai heat or direct
vehicle. It is in your interest to have maintenance Check/top-up brake and clutch fluid reservoirs .
exposure to stml ght 3fter cle,ar.ing
carried out regularly by a specialist Taxi Dealeror Check/top-up cooling system .
Dry-clean' carpet s Agent . He has qualified personnel and the Check/adjust operation of windscreen washer,
required facilities. He can offer a maintenance and top-up reservoir .
Damage the he:,iting element ar. the re,irwindow serv ice scheme to cover systematic maintenance Check/top-up battery electrolyte .
by scratching, wipng ~ % th ;t rnged hand in accordance with our recommendations and Check function of exterior lamps, wipers and
,~towing h,trd objects ,o air ;t the glass, o r standards . The following pages include a warning indicators .
cli mninq ~n-rth <tn%th,irt `,.ir ;h summary of the various checks, lubrication and Check tyres for tread depth, visually for external
ma intenance procedures which should be cuts in fabric, exposure of ply or cord structure,
completed at the prescribed intervals on a lumps and bulges.
regular basis . Check/adjust tyre pressures, including spare.
Check tightness of wheel fastenings .
Take the advice of your Dealer or Agent on the
need for more frequent oil changes and
additional brake maintenance or special servicing
which may be desirable if the vehicle is operating
in dusty conditions or driven hard in arduous
conditions and subjected to high levels of tyre
and hrake wear
" ; ? 1
Maintenance Maintenance 11
Steering Body .
First 1,000 miles (1500km) Windscreen washer Check/top-up steering idler od. Lubricate all locks and hinges (not steering lock ).
Free Service - adlusrments anr1 checks Check/adjust operation of windscreen washer , Check/top-up power steering reservoir . Check condition and security of seats and seat
and top-up reservoir. Lubricate all grease points, excluding hubs . belts
First 6,000 miles (10000km) Electrical Check condition and security of steering unit, Check operation of seat belt ine rtia reel
Check/renew w loints and gaiters. mechanism .
Automatic gearbox indscreen wiper blades g
Check function of interior and exterior lamps Check/adjust steering box Check rear-view mirrors for cracks and crazin
Renew external od filter Iwhere f ttedl .
horns, windscreen wipers and warning Check/adjust front wheel alignment .
indicators . Check/adjust front hub bearing end-float. Every 12,000 miles (20000km )
Every 3,000 miles (5 000km) Check/top-up battery electrolyte or 6 months whichever occurs first
. Rear axle
Engine - petrol and diesel Clean and grease battery connections
Check/top-up rear axle Engine - petrol or diese l
Renew engine oil Wheels and tyres Check/adjust valve clearances,
Renew engine oil filter Brakes Renew engine oil.
Check/adjust tyre pressures, including spare. Grease handbrake mechanical linkage .
Check alternator driving belt, adjust or renew. Check tightness of wheel fastenings . Renew engine oil filter .
Check power steering pump driving belt ; adjust Check security and operation of handbrake.
Renew air cleaner element .
or renew Body Check/adjust brakes. Check alternator driving belt
Check/top-up brake fluid reservoir . ; adjust or renew.
Check condition and security of seats and seat Check power steering pump driving belt; adjust
Gearbox belts. Check brake servo hose for security and
Check/top-up gearbox oil or renew.
Check operation of seat belt inertia reel condition. Clean engine breather filter.
Automatic gearbox mechanism . Check operation of footbrake with engine Check exhaust for leakage and security.
running .
Check/top-up gearbox flu d-
Every 6,000 miles ( 10 000km) Inspect brake linings for wear and drums for Diesel engine
Propeller shaft condition. Renew fuel filter element .
or 3 months, whichever occurs first Check visually hydraulic pipes and unions for Check injectors for burst pressure and test for
Lubricate all grease points- .
Engine - petrol and diesel chafing, cracks, leaks and corrosion spray
Steering Check/adjust valve clearance s Check heater plug wiring for condition .
Cooling system .
Check/top-up steering idler oil . Renew engine oil . Decarbonise heater plug holes
Check/top-up power steering rese rvoir Check cooling and heater system for leaks and Petrol engine
Renew engine oil filter hoses for security and condition .
Lubricate all grease points excluding hubs. Clean/rotate air cleaner element . Clean fuel pump sediment bowl .
Check/top-up cooling system .
Check alternator driving belt, adjust or renew . Renew sparking plugs .
Rear axle Renew distributor points.
Check power steering pumpdriving belt ; adjust Clutch
Check/top-up rear axle. Lubricate and clean distributo r
or renew Check/top-up clutch fluid reservoir
Brakes Check exhaust for leakage and securit y Check ignition wiring and H .T. leads for fraying,
Windscreen washe r chafing and deterioration.
Grease handbrake mechanical linkage . Petrol engine
Check security and operation Check/adjust operation of windscreen washer, Check voltage drop between coil CB and earth .
of handbrake .
Clean/adlust sparking pluos and top-up reservoir Check/adjust ignition timing and distributor
Check/adjust brakes.
Check/adlust distributor point s characteristics using electronic equipment .
Check/top-up brake fluid reservoi r Lubricate and clean distr r Electrical
buto
Check operation of footbrake with engine Check/renew windscreen wiper blades. Gearbox
running. Check voltage drop between coil CB and earthi .
Check function of interior and exterior lamps, Check/top-up gearbox oil.
Check/adjust ignition timing and distributor
Inspect brake linings for wear and drums for horns, windscreen wipers and warning
condition characteristics using electronic equipment Automatic gearbo x
indicator s
Check visually hydraulic pipes and unions for Gearbox Check/top-up battery electrolyte . Check/top-up automatic gearbox fluid .
chafing, cracks, leaks and corrosion Check/top-up gearbox oil Clean and grease battery connections . Check parking pawl engagement .
Check/adjust headlamp alignment
Cooling system Automatic gearbox Propeller shaft
Chec:k/ top-up automatic gearbox flui d Wheels and tyres Lubricate all grease points.
Check cooling and heater system for leaks and
Check p,+rking pawl engagemen t Check tyres for tread depth, visually for extelhal
hoses for security and conditio n
cuts in fabric, exposure of ply or cord structure,
Chec:k/top-up cooling system Propeller shaft
lumps and bulge s
Clutch Lubncrjle all grease point s including spare
Check/adjust tyre pressures,
('I wrf t,I p clulch fluid reservoir Check tightness of wheel fastenrngs
Maintenance Maintenance
Steering Check operation of seal belt inertia reel
F 20' 0 20 40 e0 90 1o0 LUBRICATION
Check/top-up steering idler orl rnechanism
Check/top-up power steering reservoir Check rear-view mirrors for cracks and craz n q 2ow5o ,
!` r r ~ ,v,~ r n r ; i n , ~ , s 1 illei with specrat oil to protect it
Lubricate all grease points, excluding hubs 20w40 -
15w60 . durrng this running in period The engine must be
Check condition and security of steering unit, Every 18,000 miles (30,000km) or
15w 40 rlrainedafter 1000mdes ( 1500km)andrefilled
loints and gaiters l0w 5
9 months whichever occurs first 0 with a Service Lubricant before driving at high
Check/adjust steering box 1ow 40 . speed
Check/adjust front wheel alignment In addition to the 6,000 mile (10000km) service ° 10w30 -
Check/adjust front hub bearing end-floa t it is recommended that the brake and clutch 5w .40 .~ . -- - . Other lubricating systems are filled with high
fluids are changed due to deterioration under 5- 10 ~+ . performance oil giving prolonged Iife-
Rear axle 5- 20 rw -
normal operating conditions .
Cf-?ck/rop-up rear axle oil You should always use a high quality oil of the
C 30 20 10 010" 20 30' 4 0 correct viscosrty range in the engine, gearbox
Brakes Every 24,000 miles (40,000km ) Multigrade engine oil viscosity/ambient and rear axle during maintenance and when
Grease handbrake mechanical linkage . or 12 months whichever occurs first temperature ranges topping-up. The use of oil not to the correct
Check security and operation of handbrake. specification can lead to high oil and fuel
Check/adjust brakes In addition to the 12,000 miles (20 000 kml
IF 20° o' 20' 40' 60' 90- 100 ' consumption and ultimately to damaged
Check/top-up brake fluid reservoir servlCe. ~---- . -
components .
Check brake servo hose for security and Automatic gearbox
condition 30 r - - F Oil to the correct specrf cat on contains additives
Adjust front and rear brake bands
Check operation of footbrake with engine which disperse the corrosive acids formed by
running . Wheels and tyres ?01 I combustion and prevent the formation of sludge
Inspect brake linings for wear and drums for Repack front wheel bearings with grease . 20w20- which can block the orlways . Additional oil
condition . Check visually hydraulic pipes and additives should not be used . Always adhere to
unions for chaf ng, cracks . leaks and corrosion Corrective maintenance 10 ?hCt rr`r()m.rnended ;ervicmy rnleNals
Take the advice of our Dealer on the need for
Cooling system additional brake maintenance - see page 3 9 WARNING: Many liquids and other substances
Check cooling and heater system for leaks and used in motor vehicles are poisonous and
hoses for security and condition C 30` 20 10" 0` 10` 20" 30' 40 ' should under no
Every 36,000 miles (60 000km) or circumstances be consumed
Check/top-up cooling system M onograde engine oil viscosity/ambient and should so far as possible be kept away
18 months whichever occurs firs t temperature ranges from open wounds
. These substances among
Clutch others include anti-freeze,
In addition to the 18,000 mile 130000km1 service brake fluid, fuel,
Check/top-up clutch fluid reservoir
windscreen washer additiv4s, lubricants and
it is recommended that all fluid seals in the Engine
Windscreen washe r various adhesives.
hydraulic system and all flexible hoses should be l lse a well-known brand of oil to B L S OL 02 or
Check/adust operat on of windscreen washer renewed At the same time the working M I! L -46152 or A P I SE/CC quality, with a Idler
and top-up reservoi r surfaces of the pistons and bores of the master viscosity band spanning the temperature range
1 op-up with H D 90 IMIL-L-2105B1 above
cylinders, wheel cylinders and other slave of your locality 10 C 115"Fi or H D 80 IMIL-L-210501 below
Electrical
cylinders should be examined and new parts 10Ct15 F l
Check/renew windscreen wiper blades Automatic gearbox and power steering
fitted where necessary
Check function of interior and exterior lamps, Use Autom,3tic T r;rnsmi>sion Fluid Tvpe t.
Grease points
horns, windscreen wipers and warning WARNING: Timing belt must be replacedat
Manual gearbox Isr Multiparpose Lithium Grease N.L.G I
indicators 60,000 miles maximum .
No rnuUrle change r5 reqwred If ll ` ~~nsr ;lrnsv No 2
Check/top up battery electrolyte a complete ref i
Clean and grease batte ry connections- s r~c~ce,sary Shell L3766 gearbox oil should be Monograde oi l
C he.ck/ ~.dust h e.adlamp alignment used ana this rs avarlable under part number RTC 1 ho ur;e (-,f n monoqr ;ide oil is permissible,
1896 When the recommended oil is not ;,)v ri nq t hrl ; it is of the correct viscosity for the
Wheels and tyres obtainable iri SAE 71W hypoid oil may be used
is temperature It should also be of the same
C'leck tyres `or t'r'<id depth, visually for external An SAE 80W hypoid o l may be used for topp ng
quaiity IMIL-L-461 521 as the preferred
r:uts in fahnc. e,unsure of ply or cord structure up but SAE 80W hvpoid oil must NOT be used Inr l
multigrade oi s
lumps and bulges a complete re.fill
Check/adust tyre pessures inr_lud Ing spare For t :u~t,imed h iqh tipee r1 opr`r,ltron or operation
Check t,qhtness of wheel fastenrnq s Rear axle f"r Irmr{ ; ornlds rn , .tn ~.i~`v,lir(i ,nrtemperature,
IlwithH ')t)i%~11L I ?111r,1~r tf,r~ utir of ,i rnulhqr,n h`,~~i ~,r the correct vrscosit~ ,
Body ~I!,fli,rl~!1ri11P,'111 1 ~~lrl'it=~
rll Irw h 111d hrnqe~ rnnt sterr Ing lockl I . . ,i( 115fr
iiit Ir`i , ~ , Isrtrurrt~;r ,r`,rtti .rndse.lt
>l
Maintenance Maintenance
Engine oil level check - Fig . 1
a> Withdraw the dipstick (1 ) from the left hand side
U) of the engine and wipe the blade Clean .
x a~ 0 a~
~ a) C a ~
N Q
o Y N 2 7 = N Re insert the dipstick fully ihen wrthdraw it and
Yaa~
¢ Q L (J NM check the oil level indication . The level should
U O O ~ a7 C
m O m = register between the 'H and 'L' marks .
C O d
0 m J u O Q
~ J
~ m If the oil level is below the 'H' mark, remove the
W f dler cap (2), pour m new od and repeat the
procedure until the level is correct Do not overfill .
Replace and secure the filler cap
~
U CO 0
~O
N N - O ~ O Engine oil drain and refill
~ C p N
Q ~
a C Em O N Q X Dra n the oil while the engine s warm and
x 7 N 0 C
r U 4% a change the oil filter element wh le the oil s
r1~ N ~ ~ LL Q W ~ m draining Place under the engine a container that
0 C 0 Fig. 1
~ has at least 8 litres (14 pints) capacty and
unscrew the drain plug from the nght hand side
of the sump to allow the oil to dra~n Clean the
drain plug, use a new sealing washer ~f necessary
_ x
~~ and refit the drain plug .
M Fill the engine with the correct quality of new oil
2 ~ W
and check that the level ~s at the 'H' on the
dipstick
Oil filter replacement - Fig . 2
0 ~ The oil filter element must be renewed at the
0 0) m
U U O same time that the eng~ne o~l is changed
X ~ N O .
L ~ )
X d O ~ ~
O W
Q'C a7 J Clean the area around the filter head and place a
Y o N rY 7 a W
m T ao mo t7 ~n receptacle beneath the engin e
a~ > U n
U O ~ W roQ. O ~ S O
L ~0
a> a
LL ~ w m Cartridge type -
7 Fig . 2
Element Part No. GFE 175/ETC 6599
Unscrew the oil fdter 14) and discard it Smear the
c
0 0 seal i5) of the new element with od and screw
00 0 0
o rn v 0 into position by hand only. Do not tighten . Start
-°c 0 0 0 l o o ~
Na c~, ~ oo ~ the engine after filling withnew oil and check for
N O a ~ o ~ a a
leaks Finally, top-up the od to the'H' mark on the
o o~_
` ~. - 0 O Q 4 J O O > `0 dipstick
O ~ X O N M ~ O 6
a~ ~ ni m ~ 7 ~ a X m ~
o ~ a `o o ~ n p
7 ?x o > > Engine breather filter - Fig. 3
J J 0~ E O c a o
" ~ m Q a~ E XCXL N O O O ~ To clean the filter first detach the hose (1) and Irft
a U a~ N C M
N C7 `p O U ~ O 7 rO 7 ? p O U
Q N ~ LL ~ V) O the fdter 12) from the rocker cove r
T N 7 S(Q/) O U U U~
O N ~ N 7
SlL O O . 2 N
~ N Wash the gauze, dip in clean oil and, after
lN W
C
shaking off the surplus oil, refrt the filter to the
rockercover
Reconnectlhe hose
V1
~c E
O c
O
O. L O
E O 0
0 X ~
~ 0 a> ar 0 y a
U U a w m
Maintenance Maintenance
Manual gearbox - Fig. 4 Rear axle oil level - Fig . 6
With the vehicle st.rndinq on level ground With the vehicle standing on level ground, clean
r(,rn, ~vr- the oil level plug 12-)wed) and, using a all d rt from around the oil filter and level plug (1)
suitablr : dispenser such as a pump-type oil can and remove the plug Top up the o l until it is level
with flexible nozzle, top-up the gearbox until the with the bottom of the filler hole threads Allow
oil is level with the bottom of the filler plug surplus oil to drain before refitting the plug and
threads wiping clean I
Allow 5urplus od todr,rin,,wi,-fittUnq
the I,v-l t>I;ig ,nd wip,nr1 cle-vr
Automatic gearbox - Fig . 5
Check the fluid level as follow;
Stand the vehicle on level grouno and apply the
handbrake firmly Start the eng ne from cold and,
with the footbrake firmly appl ied, run the engine
at idle speed for 2 to 3 minutes, passing selector Fig 4 Fig 6
lever through the complete range of positions Steering idler - Fig . 7
two or three times and pausing for about 10
Wipe away all din from around the oil filler plug
seconds in each, to ensure that the transmission
(1) and inject oil to bring the level up to the filler
is primed
plug aperture
Select the'P' (Park) position and keep the
handbrake appl ed. Leave the engine running at
idle speed Remove the transm ission dipstick
and wipe it with a clean, non-fluffy cloth Replace
the dipstick, ensuring that it is pushed fully into
the tube and withdraw it immedrately for reading
Check the fluid level on the dipstick and if
necessary, add fluid through the filler tube
SEE SERVICE LUBRICANTS
/
Repeat instructions until the fluid level is correct
Do not overfill the gearbox The difference Fg. 7
between the MAX and MIN marks on the Power steering fluid level - Fig . 8
dipstick is approximately 1 pint (1,2 U S . prnts. The power steering unit is lubricated by the
0 6 litre ) operating flui d
Parking pawl engagement check
Remove the cap/dipstick from the fluid reservoir
Stand the car on a level surface Switch off the
on the pump and top-up the fluid if necessary to
or lo 'c r,>iease the handbrake 3rd move the
the MAX. level shown on the dipstick if the fluid
lever tc ' P' IParkl Attempt to push th e . '/, in
is hot. If cold the level should be approx
carwards and forwards, the car should not
below the MAX level.
1nrwr, x,sult v our Dealer if the car does move
DO NOT OVERFILL.
Fig 8
L
it.
Maintenance
Maintenance .
Valve rocker clearance - Fig. 12
. 9 To check and adjust the clearance f irst remove
Power steering pump belt - Fig
the air cleaner, engine breather filter and rocker
Slacken the pivot bolt ( 1) and the bolt (2) securing
cove r
the slotted quadrant to the mount ing bracket to
allow the pump belt tension to be adjusted . If the clearance is correct a 0 010in (025mm)
feeler gauge (1) should be a sliding fit between
CAUTION: Use hand pressure to rotate the
the rocker arm and each inlet or exhaust valve
pump assembly clockwise and tension the belt stem while the engine is hd
t
Never apply a lever between the pump body
and the mounting bracket Check each clearance in the following order :
When belt tension is correct first tighten bolt (2) Check No. 1 valve with Na 8 fully ope n
and then bolt (1) The belt can be deflected 3 .. " .. 6 ., ..
10cm (0 5in) by thumb pressure between the 5 . 4 .. ..
two pulleys when the tension is correct 2 7 " . ,
" 8 . . 1 ..
6 ., .. , . 3 .. ,. Fig. 12
4 5 ..
7 . . .. . . 2 . .
Adjusting.
Slacken the adjusting screw locknut (2) on the
F ig. end of the rocker shaft and rotate the screw (3)
9
clockwise to decrease the clearance or
Steering connections - Fig. 10 anti-clockwise to increase the clearance
.
Grease nipples are provided at the top and
bottom of each swivel pin (1), at either end of the Re-tighten the locknut when the clearance is
lower link fulcrum pin (2) and on the steering correct, holding the screw aga inst rotation with a
tie-rods (3). Wipe away all dirt from the nipples screwdriver. Re-check the clearance Clean the
and inject grease giving three or four strokes of rocker cover gasket sealing face and renew the
the gun to each nipple . gasket if it is damaged .
Refit the rocker cover, breather fifter and a ir
cleaner .
Locks, hinges and catches
To ensure trouble-free operation, it is essential
that the door locks, hinges, and catches are
adequately lubricated.
Propeller shaft - Fig. 1 1 Locks
There are three grease nipples, one on each of Inject a small quantity of thin oil, preferably
the universal joints (1) and one on the sliding UNIPART Lockspray,
thrpugh key slots, around
sleeve (2) . Wipe away all dirt from the nipples the push-buttons.
Do not oil the steering lock.
and inject grease, giving three or four strokes of
the gun to each nipple. Hinges. Apply grease or oil to the moving joints
of the h nges .
Bonnet catches. Apply grease to the moving
surfaces of the bonnet release mechanism and
od to the release lever and safety catch pivot
points
Ful 11
Maintenance
Maintenance
Bleeding air from the diesel fuel system -
Figs. 15 and 1 6
Diesel fuel injectors - Fig . 13
iiilurrl lu st,rrt or errntic accoleration may he the
Injector cleaning and testing requires spec ialised
result of a r entering the fuel system If the fuel
high pressure equipment and must be entrusted
tank becomes completely empty or there is a
to your Dealer or Agent or C A V agent
leaking ioint . or a new fuel filter element or
TO,dentify a faulty inleclor and make an iniector has been fitted, the system must be
emergency roadside sub5trtution . see primed as follows to exclude all air
'Replacement and Data' .
(a) Ensure that the fuel cut-off tap (1) is turned
Starting Aid - Fig. 1 4 on and slacken the blanking plug (2) and the
Take care not to twist the centre termrnal and union screw (3) on the hlter-head
remove the electric leads ( 1) and unscrew each (b) Release air vent screw on distributor body (4)
plug (2) from the cylinder head Inse rt atwstdrll Fig 1 6
(3) of 6mm (15/64 in) diameter into the screwed
holes (4) in the head and turn the drill by hand to (c) Operate the fuel pump hand priming lever
remove the carbon build-up Withdraw the dr ill until fuel free of air emerge s Fig 1 5
and remove any pa rticles of carbon from the
conical seatings in the cylinder head Do not use (d) Retighten the air vent screw .
a w/ re brush Refit the starting aid and electrical
(e) Operate the starter motor and when the fuel
leads
issuing from at least two of the high pressure
pipes is free from air bubbles tighten all four
union nuts
(f) Start the engine and allow it to run until it is
firing on all cylinders, checking for leaks
After renewing the main fuel filter element .
providing the engine is not cranked during this
operation, it is only necessary to bleed the fuel
filter at points (2), (3) and (4) by operating the lift
pump before starting the engine.
Procedure when distributor pump has been Fig 17
drained
~, ;try,)!lt instructions Ibl to ifl ir'Clusw R
CAUTION: Lubrrcation of the injection pump
n~ed,anr ;m rs effected by fuelorl under
pressurc : therefore no attempt should be made
to bleed the fuel system by towrng the vehicle in
gear as this may result in serious damage to the
injection pump
Maintenance Maintenance
Main diesel fuel filter - Fig . 1 8 Air cleaner element (Petrol) - Fig. 21
To release water which may have accumulated Release the hose from the air cleaner and
in the filtercup, remove the plug (6)anddrain off remove the air cleaner from the engine Remove
the water Refit the plu g the end cover (1), undo the wing nut (2) and
carefully withdraw the element . Note that the
To renew the element (1), support the filter cup vane unit is attached to the element and cannot
(2) and unscrew the retaining bolt (3) located in
be removed
the centre of the head casting (4) Detach the
filter cup and, using a twisting movement, Wipe all dust from the cover and cleaner body
separate the element from the filter head . and ensure the valve (3) is clear Blow dust from
Remove the three sealing rings (5) from the head the element, or fit a new one, and reassemble
and base . Clean the filter base, and reassemble before replacing it on the engine
the filter unit using a filter element and sealing
rings . Adjusting distributor points (Petrol) - Fig. 22
Release the retaining clips and remove the
The fuel system must be bled of air after distributor cap. Remove the dust shield and rotor
dismantling and reassembling the filter un t . Fig . 18 arm
Fig. 2 1
Fuel sediment bowl - petrol - Fig . 19
If the points are burnt or worn, new ones should
The bowl next to the fuel pump on the right hand be fitted by your Dealer who has the electronic
side of the petrol engine provides filtration for equipment necessary to set the points correctly .
the fuel and requires cleaning . To remove the In an emergency, to adjust the gap between the
bowl, first slacken the thumb screw and swing contacts, turn the engine until the contact points
the retainer to one side while supporting the are wide open .
bowl .
The clearance should be 0.014 to 0 .016in
Remove and clean the gauze filter in fuel or
(0.35 to 0.40mm) with a feeler gauge . The gauge
renew it if damaged
should be a sliding fit between the contacts (1)
Renew the sealing washer if necessary and If necessary, slacken screw (2) which secures
replace the gauze and bowl Operate the hand the adjustable contact, adlust the gap and
lever to prime the pump tighten the screw.
Air cleaner element (Diesel) - Fig. 20
Replace the dust shield, rotor arm, d str bulor
Remove the bolt (1 1 at the centre of the air can and retaining clip s
cleaner top cover and detach the cover (2) Lift Fig 1 9 Fig. 22
out and discard the element (3), clean out the Distributor lubrication - Fig. 2 3
container and fit a new element Refit the top Remove the distributor cover and lift off the rotor
cover. fibre washer (4) and bolt arm (1) and anti-dust shield
Inspect the contact breaker points (2) ; if burnt or
worn they should be renewed by your Dealer .
Very lightly smear the cam (3) with grease and
lubricate the pressure pad (4) with grease also .
Add a few drops of oil to the felt pad (5) in the top
of the cam spindle
Turn the crankshaft until the distributor
centrifugal weight pivot post is v s ble through
the cut-out in the base plate (6) and lubricate the
Pivot post with a drop of oil Repeat for the
opposite pivot post Fig 23
Carefully wipe away all surplus lubricant and Refit the rotor arm, engage the slot in the spindle
ensure that the contact breaker points are clean and push down firmly
and dry
Wipe clean the inside and outside of the
Refit the,jn(rdust shield distributor cover, particularly between the
Fiq 20 electrodes, refit the d str butor cover and secure
it with the clip s
34 35
~,lr
Maintenance
Maintenance
Sparking plugs (Petrol)
To clean and adjust the plugs, pull the plug cover Lining inspection - Fig. 26
and lead from each plug and clean the immediate Jack-up each wheel in tur n
area
Jacking instructions and precautions are detailed
Remove the plugs with a Unipart Sleevlok plug on page 44 . Remove the road wheel and slacken
spanner to avoid damaging the hexagon or the brake adjuster(s) fully Remove the two
fracturing the plug insulator . countersunk screws (1) and withdraw the brake
drum (2) . Inspect the linings (3) for wear and
Clean the plug with an air blast unit and set the
carefully wipe the dust from the backplate
gap to 0.029 to 0.032 in (0-75 to 0 80mm) by
assembly and drum, preferably using methylated
moving the side electrode . A Champion spark
spirits (denatured alcoho p
plug setting tool is available
WARNING: Brake lining dust is dangerous to
Clean the plug seat, insert the plug finger tight, health if inhaled.
ensuring the washer is in good condition, and
tighten about a quarter of a turn only . If the lining thickness is less than !/e in Omm) it
Fg 24 is not sufficient to allow the vehicle to be driven
Wipe the plug insulator and lead and press the Fig, 26
safely until the next inspection and new linings
cover over the plug terminal .
must be fitted Refit the drum and road wheel
Only use the recommended plugs as and adjust the brakes
replacements (see page 56 ) Replacing brake shoe s
When it becomes necessarv to renew the brake
Clutch fluid reservoir - Fig. 24 shoes, it is essential that only the correct grade
Unscrew the cap and top-up the fluid level in the of I n ng is used Always fit new shoes as
reservoir to the MAX mark on the body. complete axle sets, never individually or as a
single wheel set. Serious consequences could
Ensure the air vent in the can is clear before result from out-of-balance b-aknq due to a
replacing the cap. mixture of Iining s
Brake fluid reservoir - Fig. 25 Handbrake linkage - Fig. 27
Wipe the reservoir body clean and check the Grease the pivot pins (1 )
fluid level . If the brake fluid is below the
'maximum' mark, hold the centre terminal block Wipe dirt from the nipple (2) on the brake rod
Fig. 25 compensator on the rear axle and give three or
stationary and unscrew the outer rim of the cap
four strokes with a grease gun _ Fig 27
to remove it .
Fluiddrained from the system or used for
Top-up the fluid and ensure the breathervalve bleeding is best discarded
area is clean before replacing the ca p
The necessity for absolute cleanliness CLUTCH AND BRAKE HYDRAULIC
Brake and clutch fluids If the vehicle is frequently subjected to
throughout cannot be over-emphasized SYSTEMS
Use Unipart Universal Brake Fluid or other brake severe driving or operating conditions, it may
Corrective maintenance be necessary to change the brake fluid at
fluid having a minimum boiling point of 260°C
in addit ion to the recommended periodical shorter intervals.
(500°F) and complying with specification FMVSS
inspection of brake components it is advisable as
116, DOT 3 or SAE J 1703cc specification . 3 . All
the vehicle ages, and as a precaution against the fluid seals in the hydraulic system and all
Do not use any other type of fluid . effects of wear and deteriorat on, to make a flexible hoses should be renewed every
more searching inspection and renew parts as 18 months or 36,000 miles (60 000km)
CAUTION: Brake tiu~d wiit damage paintwork necessary whichever is sooner At the same time the
working surfaces of the pistons and of the
Care must be taken always to observe the It is recommended tha t bores of the master cylinder, wheel cylinders,
following points and other slave cylinders should be examined
Brake I n ngs. hoses and pipes should be
At alltimes use the recommended brake fluid and new parts fitted where necessary
examined at intervals no greater than those
laid down in the Prevent ve Maintenance
N,,ver leave fluid rn unsealed contarners It
summary in the Handbook
,ihsorbs moisture cluicklv and can be
A{nilrrous if used in your hr,jkrng system in Under normal operating conditions, hydraulic
this cornlil on fluid should be changed cornpletely every
9 months or 18.000 miles (30000kn0 .
wh~chever is the sooner
Maintenance Maintenanc
e
BRAKE ADJUSTMENT
The handbrake s automatically adjusted with the TYRES
rear brakes WARNING: Driving with under-inflated tyres
Excessive brake pedal travel is an indication that can be hazardous and causes rapid tyre wear
the brakes require adjusting . and possible permanent damage to the cords
of the tyre casing.
Front brakes - Fig. 28
Apply the handbrake and place blocks against Owners are reminded that tyre wear and inflation
the rear tyres to prevent the vehicle rolling . pressures are subject to legal requirements,
Check the tyre pressure weekly, including the
Jack up the vehicle until a front wheel is free to spare, and adjust if necessary to the
rotate and place suitable additional supports recommendations given at the back of this
beneath the chassis near the jack. Handbook. The spare tyre should be maintained
at the highest recommended pressure and
Turn one adjuster (1) clockwise, viewed from the
adjusted before use.
centre of the vehicle, until the wheel locks then Fig. 28
turn the adjuster anti-clockwise until the wheel Pressures should be checked with a UNIPART
is just free to rotate . Tyre Pressure Gauge when the tyres are cold,
and should not be reduced in warm tyres where
Repeat for the other adjuster . Repeat for the the increases above normal pressure is due to
other wheel, remove safety supports, fack and temperature. Tyres are permeable and a natural
safety blocks. pressure loss will occur with time : any unusual
Rear brakes - Fig . 29 pressure loss should be investigated. If
Place blocks against the front tyres to prevent necessary, use a UNIPART Foot Pump to
rolling and release the handbrake . increase the pressure.
Jack up until a wheel is free to rotate and position Valves and caps
safety supports beneath the chassis near the Screw the valve caps down firmly by hand . Do
jack. not use tools as too much force will damage the
cap. The cap prevents the entry of dirt into the
Turn the adjuster (1) clockwise, viewed from the valve mechanism and forms an additional seal on
centre of the vehicle, until the wheel locks . Turn the valve .
the adjuster anti-clockwise until the wheel will
rotate just free of brake lining friction . Fig . 29 Tyre care
The tyres should be inspected at frequent
Apply the footbrake to centralise the brake intervals for damage and wear . Excessive local
shoes and check that the wheel remains free to distortion as a result of striking a kerb, a loose
rotate brick, a deep pot-hole, etc ., may cause the
casing cords to fracture . Every effort should be
Lubricate the adjuster stem, repeat for the other made to avoid such obstacles .
wheel, remove the safety supports and jack .
Apply the handbrake and remove the safety Any oil or grease which may get onto the tyres
blocks should be cleaned off by using petrol (gasoline)
sparingly . Do not use paraffin (kerosene), which
has a detrimental effect on rubber
Flints and other sharp objects should be
removed with a penknife or similar tool If
neglected . they may work through the tyre .
Tubeless tyres
Normally a tubeless tyre will not leak as a result
of penetration by a nail or other puncturing
object. provided it is left in the tyre At a
convenient time have the tyre removed for
vulcanizing
Maintenance Maintenance
COOLING SYSTEM Use UNIPART Universal Ant i-freeze If this is not BATTERY
available, use an ethylene glycol based
WARNING: To avoid injury from escaping anti-freeze (containing no methanol) with non- Topping-up the electrolyte - Fig. 31
steam, the radiator cap and the pressure relief phosphate corrosion infubitors suitable for use in f)o n0f uSe .3 n,ikf ;d liqht when rfl"r .king th['
cap on the expansion tank must not be engines to ensure the protection of the cooling re(.lr!dyte levr- l
removed while the system is hot. ,;ystem agai nst frost and corrosion
Remove the sealing plugs and check that the
Topping-up - Fig. 30 CAUTION : No other,unrversal ' antrfreeze electrolyte covers the plate dividers in each cell
To check that the cool,r g sysu,m is ful, . remove ~nou d be usedwith UNIPART Universal Antr-
If necessa ry pour drstrlled water i
the pressure relief cap 12) from the expans on `reeze nto each cell
until the plates are covered.
tank Squeeze the top radiator hose and observe
Every two years the cooling system shoutd be
the movement of the coolant within the th the correct Ensure the sealing plug vents are clear and
drained, flushed and refilled wi
expansion tank replace the plugs
amount of anti-freeze solution
If necessary. add coolant to bring the level up to Note: ~, ,i71emp1 must be made in ton, ;r_-
p Do not use anti-freeze solution in the screen
the mark indicated Refit the pressure relief ca -a1ec1 r1r hle baNenes RAler Io m-,. e,.s
washing equipment.
~s7, ucr;ons on batrer,,
If the level has fallen appreciably, suspect
The recommended quantities of anti-freeze Alternator drive belt tension
leakage or overheat ng . . - Fig. 32
solution are given below
The pulley should slip when a torque 11 Ibf f t
Radiator filler cap 11 5kgf m) is applied to the pultey nut and should
The radiator cap 111 can be removed while the deflect 0.25 in (6mm) si
deways under a load of
engine is cold and after the expansion tank cap 7 51bf (3 3 kgf)
mrdway between the pulleys
has been removed to release pressure in the
system . Failure to set the belt tension correctly will
allow
the alternator pulley to slip when driving and the
The radiator should always be completely filled battery will become discharged
with coolant and is fitted with a plain ca p
To increase the belt tension slacken the pivot
Do not fit the radiator cap to the exoansion tank securing bolts 11) and the tens
ion adjusting
bracket pivot bolt 121 Slacken the adjusting
Frost precaution s
bracket bolt (3)
We recommend that the cooling system always
contains anti-freeze to protect the radiator, Pivot the alternator away from the
engine to
cylinder block and heater against damage during increase the belt tension
and tighten the
freezing weather cond t ons Have the specific adlustrng bracket bolt (3 ) Tighten the Fig 32
pivot bolts
gravity of the coolant (water mixed with and recheck the drive belt tension
anti-freeze solution) checked by your Distributor
or Dealer at the beginning of autumn . When Fig 30 If leverage is necessary
use wood or soft metal
only against the
topping-up the cooling system use an drive-end bracket.
anti-freeze solutio n
The overall anti-freeze concentration should not
fall below 30°i° by volume, to ensure that the
antr-corrosron properties of the coolant are
maintained
of anti-freeze Commences freezing Frozen solid
Solution Amount
'F
Maintenance Replacement & Data
Battery Recovery
Boosting 46 Being towed 4
5
Charging 46 Towing 45
Polarity 47
Replacement bulbs 53
Cooling syste m
Draining 46 Warning lamps
Filling 46 Brake failure 1
5
Direction indicator and door 5 1
Data 56 Hazard warning 52
Heated rear window 52
Distributor points 45 Warning and panel
52
Fuel injectors 45 Wheels and tyres
Changing a wheel 44
Fuses 4s' Jack 44
Fig. 33
Jacking 44
Windscreen wiper blade - Fig. 33 Identification 58 Radial-ply tyres 44
To renew a wiper blade, pull the wiper arm away Spare wheel 44
from the windscreen, press the arm (5) against Lamps
the spring (3) and withdraw the blade (4) from Direction indicators - front 49 Wiring diagram
54
Direction indicator repeater 49
the arm. Headlamps
48
Secure the new blade on the arm by pushing the Interior - driver's 50
arm into the fastener on the blade Interior - passenger's 50
Number plate 50
Windscreen wiper arm - Fig. 33 Rear fog guard
53
To reposition a wiper arm, hold the reta n ng clip Sidelamps 49
(1) clear of the spindle (2), and withdraw the arm Stop, tail, indicator - rear 49
Fit the arm on the spindle in the required position Taxi sign/roof lamp 51
and press it down until it is retained by the cl p .
Windscreen washer - Fig. 33
Use in conjunction with the windscreen wiper in Fig 34
dusty and muddy conditions Replenish the fluid Automatic gearbox external oil filter
through the filler (6) in the top of the plastic (when fitted) - Fig. 34
container (7) The washer reservoir should be
The oil fdter must be changed after the first
filled with a mixture of water and UNIPART
6,000 miles 110000km) and subsequently only
Screenwash In freezing conditions use after a major gearbox failure or overhaul
UNIPART'AII Seasons' Screenwash Do not use
radiator anti-freez e Thoroughly clean the area around the filter and
its pipe connections . Unscrew the tube nuts (1)
To adjust the washer jets (8), insert a thin needle
at either end of the filter and remove the nut and
in the orifice of the jet and swivel the jet ball to
bolt (2) securing the filter mounting bracket to
the required pos t on Thewaterjet should strike
the chassis . Detach the mounting bracket from
the windscreen at the centre and highest point
the filter and discard the filter . Fit the mounting
of the windscreen wiper blade arc Take care not
bracket to the new filter and attach the bracket to
to damage the )et or f ce when carrying out
the chassis, tightening the nut and bolt (2) finger-
adlustments
tight Connect the pipes to the filter, holding the
hexagons (3) on the filter body securely while
Uqhtening the tube nuts (1) Finally, tighten the
mounUnq bracket nut rnd bolt 12 1
iop-up the gearbo~ f!uid level fsee page 281nn f
rheck the lilter connectinns for leaks
Replacement & Data ; Replacement & Data
Spare wheel and jack - Fig. 1 BEING TOWED FOR RECOVERY Diesel fuel injectors - Fig . 4
ThE -;p.u- wheel and );u.k are retained in the WARNING : To ensure that the steering does Do not attempt to dismantle any of the injectors
.nrnpartment bya pl:jte 11) and nut The or the in)ection pump at the roadside . The only
Intlq,ryir i not lock up when the vehicle is being towed, it
wheelbr;rce is secured by clips to the underside is essential that the steering lock starter key is servicing which is possible at the roadside is the
of the rear parcel shel f turned to position 'I' and remains there whilst replacement of a faulty fuel injecto r
the vehicle is moving. To locate a faulty injector, slacken the feed pipe
Neglecting the lack may lead to difficulty in a
Examine it occasionally WARNING: When the vehicle is being towed union nut (1) on the first injector and run the
road-side emergency
without the engine running, g reater pedal engine slowly_ Repeat this on each injector in
and clean and lightly oil the thread to prevent
eftoR than normal will be necessary to apply turn. If there is no change in the engine
rust
the footbrake. performance or if a faulty condition, such as a
Jacking - Fig. 2 smoky exhaust, has disappeared, it can be
Apply Ihe rindbrake and place blocks at one of Being towed - manual gearbox assumed that the rnjector was faulty
tne wheels to stop it rolling when the vehicle is CAUTION : ? r ~ ehrcle must not be towed wrth
being lacked up. the rear .afier-rs on the road unless the propeller
shalt is drsconnected or the engine is running to
There are two jacking sockets (1), one on each operate the gearbox orl pump and lubncate the
side of the vehicle below the running-board and marnshalt bearin g
the front door Ensure that the spigot of the lack
Is pushed well into the socket before screwing Being towed - automatic gearbo x
;t; ?hP vr , %r; th the handle p,o% ;Jr-- Before being towed add an extra 3 pints (3 .6 U S
pints, 1 7 litres) to the transmission and move
WARNlNG : Do not work beneath the vehicle the selector lever to'N '
with the jack as the sole means of support.
supports beneath A vehicle fitted with automatic transmission
Place suitable additional
to the jack. must not be towed at speeds higher than 30
the chassis at a point near m p.h. (48 kmlh) or for a distance greater than 30
miles (48km)
Changing a wheel - Fig. 3 If the transmission is faulty, remove the
Apply the handbrake and block one of the propeller shaft or tow wrth the rear wheels lifted
wheeis Prse off the hub cover, using the Frg . 5
flattened end of the wheelbrace Do not lever CAUTION: When the vehicle is being
the wheel cenire but g ive a rr:insported 'P' must be selected : except it the
the cover from Changing a diesel fuel injector - Fig . 4
sideways twist with the tool provided vehicle is being carried as rail lreight . when 'N'
To remove an injector, disconnect the high
must be selected The handbrake must alwa ys
Slacken the wheel nuts half a turn . i e turn anti- Fig 2 be pressure pipe from the individual in)ector 11) and
applied
to loosen Jack up the vehicle the pump 121 and the leak-off pipe unions (3)
clockwise
to enable a wheel with a fully inflated Towing - automatic gearbo x from all the injectors . Never bend the pipes to
sufficiently
Remove the wheel nuts and When towing another vehicle, always select 'L' release a union or banjo from the injector . Note
tyre to be removed
l before ascending or descending steep gradients the seal washer either side each banjo .
lift off the whee
Driving in these conditions wrth 'D' selected can
the wheel, first lightly screw Remove the two injector retaining nuts (4) and
When replacing give rise to dangerous overheating of the
their conical faces seat withdraw the injector Extract the corrugated
on the nuts ensuring that transmission flunri
the recesses of the wheel stud holes sealing washer (5) from inside the nozzle heat
correctly in
and fully trghten the wheel nuts in shield - Fig 5 .
Lower the lack
the order shown
Before refitting an injector fit a new sealing
A torque wrench set to 65Ibf it (9 0 kgf m) should washer (5) as illustrated, and inspect the injector
be used to t ighten the wheel nuts whenever copper seal (6) for servrceability .
possible Place the rim of the hub cover over Iwo
the wheel centre and give the Tighten the two rnlector retaining nuts evenly
of the studs on
outer f,ice of its sharp blow with the fist over the and to the correct torque tightness of 6 to 81bf it
third slud Remove the lar-k ;rnd blrlck s Fict 3 10 8 to 1 0 kgf ml Reht the high pressure feed
e , 1 the pine .inrf Ir .,il.nff hq)r"
the rear wh c h w th convenlronal lyres 1
Cross-ply tyres fiont
n F,
Replacement & Data ~ Replacement & Dat
a
COOLING SYSTEM When charginq a battery in the
vehicle from an
Draining - Fig. 6 outside source such as a trickle charger, ensure
Remove the expansion tank filler cap (protect ng tha t
hands against escaping steam if the system is
the charger output voltage is the same as the
hot) to release pressure from the syste m
nominal voltage of the batte ry;
(See page 42)
the charger+ (positive) lead is connected to
Place a container in position to collect the the
+ (positive) terminal of the batte ry ;
coolant .
the charger- (negative) lead is connected to
Remove the radiator filler cap and detach the the - (negative) terminal of the batte
ry
hose from the bottom of the radiator .
Polarity
Remove the cylinder block plug (1 ) from the The electrical
installation on the vehicle is
left-hand side to the rear of the alternator . NEGATIVE (-)
ea rth return and the correct
Filling Fig . 6 polarity must be maintained at all times
Refit the radiator hose and cylinder block drain Reversed polarity will permanently damage
plug- the cables are connected between the semi-conductor devices in the alternator and
. radio (when fitted )
battery terminals in the following order
Fill the system with anti-freeze solution through + (positive) to + (positive) and the n
the top of the radiator and replace the plain cap Before fitting a radio or any other electrical
- (negative) to - (negative) ; equipment, make certain that it has
on the radiator . the correct
the engine speed is reduced to 1,000 rev/min earth-return polarity for rnstallation in this vehicle
Fill the expansion tank to the level marked on the or below before disconnecting the boost
Alternator
tank and replace the pressure release valve cap battery - The vehicle battery must never be
The following precautions must be observed to
on the tank. disconnected while the engine is running .
avoid damage to the alternator and its ancillary
Run the engine until the top of the radiator Battery charging components.
becomes warm and check that the coolant in the A high-speed charger may only be used if the
Ensure that the correct batte ry polarity is
expansion tank has remained at the correct level battery has been completely disconnected from
maintained at all trmes; reversed battery or
If necessary, protect the hands, release the cap the vehicle electrical system . Certain types of
slowly and add coolant to bring,t up to the level charger connections will damage the alternator
maintenance-free batteries, for example the rectifiers-
mark Replace the cap . lead-calcium type, can be damaged by
high-speed chargers If in doubt, consult your The battery must never be disconnected while
Dealer or Agent . the engine is running .
BATTERY BOOST STARTING AND Never use an ohmmeter of the type incorporat ng
CHARGING a hand-driven generator for checking the
rectifiers of the transistor s
Ba ttery boosting - Fig . 7
A high-speed battery charger must not be used It is important that the belt tension is set
correctly; if the correct tools are not available
as a starting aid .
consult your Dealer or Agen t
CAUTION: The followrng precautions must be
Fit a new belt with a moderate degree of tension,
observed to avoid the possibility of serious
damage to the charging system or electrical run the engine for five minutes at 1,000 rev/mrn
stop the engine, then set the belt to the correct
components of the vehicl e tension
When connecting an additional battery to boost a
discharged battery in the vehicle, ensure that
the booster battery is of the same nominal
voltage as the vehicle battery ,
the interconnecting cables are of sufficient
Capacity to carry sl,irtnlg current,
the cables areinterconnecte.d one at a time to
the booster h,tttery first .
Replacement & Data
Replacement & Data
FUSES - Fig. 8
Sidelamps
The fuse box is located under the bonnet on the Th~ ,irl~~limtr, in~ rnr,orporatrrr! ~n rli r
right-hand side .
The circuits protected by each fuse are Remove the headlantp nm anrl rirtar.:h
the tighl
Interior Lights unit
V/'1 NG (Brown and Green) -
~ NW (Bown and Wh ite) - Hazard Pull off the plug at the back of the light un t
~(Red) Left Hand Side and Number Plate
~ Lamps Pull (h" -~idr'l hulh ni,r nf :t't h"l, ;r,
? . RU (Red and Blue) Right HarldO de Lamp plUo
i f ~. UK (Blue and Pink) Left Hand Headtamp Dip
Front direction indicator lamps - Fig. 1 1
Beam
TO rFrt)l"ct~~ .i tnilf, rr,r, , ,r .' . . . .,nn 11 rew;
f 6 UR (Blue and Red) Right Hand Headlamp
Dip Beam
7. US (Bltie ltnd Slate) Left Hand Headlamp withdrawn
Main Beam Fnsuro th;, , , , , -r ; ,
. , .
8. -UW (Blue and White) R ight Hand Headlamp ,E{ t r, Fig 11
. Main Beam Frg . 8
,/9. G (Green cr Passenger Heater, Direction indicator repeater lamps - Fig . 12
PDWA, Indicators To re.nrrw ~, hr, t~ rF~-~ the lens retairnnq
-""1 0. WBJ'1Nhite and Black) Heated Rear Window screw 1 1 I and Iift out the lens (21 The bavr nr '
./'I 1 . GY (Green and Yellow) Drivers Heater, cap type bulb (3) can then be removed
Instruments. Brake Light Switch
When replacing the lens. ensure the moulded
? 12. K (Pink) Drivers Radio
recess in the end of the lens enq :jn~ti ,rr;rler the
Spare fuses tag on the lamt ~ has e
Spare fuses are provided in the fusebox covers
and it is important to use only the correct Stop, tail and direction indicator lamps -
replacement fuse . The fusing value is marked on Fig . 1 3
a coloured paper slip inside the glass tube of the To rei~ w a bulb, rP;move the two -,crews (1)
fuse . If the new fuse blows immediatelyand the re+,:! y the lens The bayonet-cap type bulbs
cause of the trouble cannot be found, have the (2) and ( 3) can then be removed
equipment examined by a Dealer
' Note : '-1 dor,ble-fdament srop ta,' bu!b f31
LAMPS ;ocahnq prns 10 ensure : Orrect
~(~nr in the bum hnIhPr
Headlamps - RH steering - Fig . 9
The headlamps are of the sealed-beam type, and
incorporate the s delamps
To renevy a~light unit remove the headlamp rim
(1), remove the three screws (2) retaining the
light unit plate (3) . detach the plate and lift out the
unit (4). Detach the plug (5) from the rear of the
light unit Pilot bulb (8)
When refitting a light unit, ensure that the lugs
moulded on the back of the unit engage in the
slots in the lamp back-shell before refitting the
headlamp ri m
Headlamps - LH steering - Fig. 1 0 Frg 1 0
To renew a headlamp bulb remove the headlarnp new bulb with the location tabs and retaining
rim (1) and the three screws (2) retaining the light spring correctly engaged with the reflector unit
unit plate (3) Detach the plateand hft out the unrt
(4) Pull the socket Ihl fmm the back of the unit RH and LH Steerin g
and release the bulb t81 by disengaging the hionzonLil and verUcal 3dlusirnent of the light
rf>ttanunq spring (9) from the reflector Fit th e beam is controlled by screws (6) arid (7)
dR
Replacement & Data ~ Replacement & Data
Taxi-sign roof lamp - Fig. 1 7
Number-plate lamp - Fig . 14
To renew a bulb, prise out the centre disc I1 I of
The number-plate lamp only operates when the the lamp and remove the bayonet-cap type bulb
sidelamps and tail lamps are switched on Twin- (2) from its holde r
bayonet-f ixing bulbs (1) are fitted and the cover
(2) and glass (3) may be removed after slackening Entiure that the spring retainers (3)on the centre
the small retaining screw M . disc engage correctly when refittin g
Driver's interior lamp - Fig . 15 Direction indicator and door warning lamps
A double-f ilament bayonet-fixing bulb (1) is fitted - Fig. 18
and the glass and bezel (2) may be removed after To renew a bulb, unscrew the lens and front of
screwing the small retaining screw (3) out of the the lamp body (1) Withdraw the bulb and
bezel. unscrew the collar (2) from the bulb (3) .
Passenger's interior lamp - Fig . 16 Ensure that the flange of the collar is at the end
Adouble-filament bayonet-fixrng bulb (1) is fitted of the bulb when refitting
and the glass and bezel (2) may be removed after
Brake failure warning lamp - Fig . 19
screwing the small retaining screw (3) out of the
Remove the assembly from the pane~ by
bezel
depressing the four retaining tongues (1)
Through the two pivot holes in the holder (2)
depress the pivot legs (3) and remove the switch
from its holder Unscrew and rernove the bulb
(4) .
Fig . 15 Fig 18 .
Fig 16 Fig 19
Replacement & Data Replacement & Data
Rear-fog guard lamp - Fig . 23
Warning and panel lamps - Fig. 20 To gam access to the twlt), release the two
To renew a bulb, remove the push-fit bulb holder screws (1) and remove the lamp lens (2) Press rn
(1) from the back of the speedometer or (2) from and turn the bulb (3) to remove it
the hack of the speedometer or instrument
cluster and unscrew the bulb i3 i Fit a new bulb, then fit the lens and tighten the
retaining screws
Switch illumination and warning light -
Fig. 2 1
To renew a bulb remove cover (1 ) f rom switch
body (2) This is achieved by using a small flat
screwdriver placed at point A and then prise
cover away from the main body unscrew bulb to
remove. To replace cover press into switch
Fig 20 Fig 23
Replacement bulbs
Unlpart
Watts Part No.
Sealed beam unit (RH Stg .) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60/45 GLU 131
Headlamp(LH Stg.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45/40 GLB 410
Pilot lamp (RH Stg .) 5 GLB 501
Pilot lamp (LH Stg.) 5 GLB501
Tail and stop lamps . . . 21/5 GLB 380
Rear number-plate lamp . . . . . . . . . . . . . . . . . . . . . . . . 5 GLB989
Taxi-sign roof lamp . , 36 -
Interior lamps 21/5 GLB380
Direction indicator and door warning lamps 14v 0.56 GLB 921
Direction indicator lamps 21 GLB 382
Direction indicator repeater lamps 4 GLB 233
Brake failure warning lamp 1 .5 GLB 280
Warning and panel lamps . . 2.2 GLB 987
Fig 21 Switch dlumnation 14v 0,56 GLB 92
1
Replacement fuses
Urnpart
Circuits (as Fig 8 Page 48) Part No
1, 8 . 9, 10, 11 - 17 amp (White)
2, 3, 4 GFS 35
. 5. 6. 7 - 8 amp (Light Browni GFS 15
Replacement & Data
WIRING DIAGRA M
. 1 Front Flasher RH 59 Windscreen Washer Switch
2 Side Light RH 60 Windscreen Wiper Switch
3 Dipped Beam - Headlamp RH 61 Head/Side Lamp Switch
4 Main Beam - Headlamp RH 62 Main/Dip Beam & Flash Switc h
5 Main Beam - Headlamp LH 63 Horn Switch
6 Dipped Beam - Headlamp LH 64 Direction Indicator Switch
7 Side Light LH 65 Control Box (Electronic Door Locking )
8 Front Flasher LH 66 Proximity Sensor
9 Horn 67 Ignition Switc h
10 Side Repeater RH 68 Auto Gear Selector Illumination
11 Side Repeater LH 69 Hire Sign
12 Alternator 70 Fog Guard Switch
13 Distributor 71 Drivers Interior Ligh t
14 Carburettor (Cut-Off) Solenoid 72 Taximeter Junction Bo x
15 Engine Temperature Transmitter 73 Interior Light Switc h
16 Battery 74 Front Door Light Switch
17 Pre-Engaged Starter 75 Door Locking Solenoid
18 Diesel Heater Plugs 76 Rear Door Light Switch WIRING DIAGRAM
20 Spark Plugs 77 Rear Interior Light Switch
21 Ignition Coil 78 Passenger Interior Light Switch
22 Flasher Unit 8f1 79 Taximeter Switch
23 Brake Switch 80 Passenger Heater Switch
24 Flasher Unit 9f1 81 Passenger Heate r
25 Drivers Heater 82 Tail Lamp Assembly
26 Fluid Level 83 Rear Fog Guard
27 Neutral Interlock Switch (auto only) 84 Number Plate Illumination
28 Wrndscreen Wiper Motor 85 Heated Backlight
29 Electric Windscreen Washer 86 Fuel Tank Unit
30 Electronic Door Locking Warning Light 87 Speedometer Illuminatio n
31 Temperature Gauge 88 CAV Control Unit
32 FuelGauge 89 Solenoid Micro Switch
33 Oil Pressure Gauge 90 Door Locking Warning Light
34 3 in 1 Instrument Illuminatio n
35 Ammete r
36 Ammeter Illumination
37 Door Indicator Warning Light
38 RH Door Warning Light
39 Ignition Warning Light COLOUR KEY
40 Speedometer LG Light Green
41 Main Beam Indicator Light K Pin k
42 Voltage Stabilizer P Purple
43 LH Door Warning U Blue
44 Heated Backlight Switch N Brown
45 Fiu~d Level Warning/Test Light B Black
46 2 INay Heater Switch R Red
47 Heater Switch W Whte
48 H"rwd Sw 1ch Y Yellow
49 I,~terior Light Switch 0 Orange
50 P,inel Light Switch G ee~ n
51 Fuse Box S
52 9 1Nav Column Switch Termnjl Bloc k
VVhen two i ulour5 .wpear logether Ihe b rst
54-58 - le-tter represents the ili,lin colOUr,lnd the ~
r eIhP trrce
rA
Replacement & Data
Replacement & Data - Replacement & Data
Steering
GENERAL SPECIFICATION DATA Ratio . . . . . . . . . . 24 1
Turning circle (kerb to kerb) . . . . . . . . . . . . . . . . . 25 ft (7 .62m)
The vehicle specification may vary according to Front wheel toe-in : Cross-ply tyres . . . . . . . . . . . . . . . . . . . . 1 /16 in (1
market requirements and from model to model. .6mm )
Radial tyres . . . . . . . . . . . . . . . . . . . . . . . . 1 /16 in (1
The manufacturers reserve the right to alter .6mm) - 1 /8in (3 .2mm)
Front hub bearing end-float . . . . . .
. . 002-.004in ( .05-. tOmm)
specifications with or without notice at any time
The policy of constant product improvement by Tyres
the manufacturers may involve major or minor Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5.75 - 16 cross-ply (6 ply)
changes to the vehicle specification . Whilst or 175 - 16 radia l
every effort is made to ensure accuracy of the Recommended pressures:
particulars contained in this Handbook, no Cross-ply tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 bar, 321bf/in2, 2 2
Radial tyres: 175 - 16 . . . .3 kgf/cm
liabilities for inaccuracies or the consequences . . . . . . . . . . . Front 2.6bar 381bf/inz2
.6kgf/crn2
thereof can be accepted by the manufacturer or Rear 2.4bar 341bf/in2 2.4 kgf/cmZ
the Dealer who supplied the Handbook . During Principal dimension s
running-in from new, certain adjustments vary Length overall
from the specification figures detailed. They will .14ft 117/16in (4.558m)
Width overall . . . . . . . . . . . . .
be set to specification by your Dealer at the . 5ft 85/8in (1 .743m)
Height overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After-Sales Free Service and should thereafter . . . . . . . 5ft 9%z in (1/765m)
be maintained throughout the vehicle's life . Capacities
E e(incl . ding filter) . . . . . . . . . . . . . .
Engine . ~ . . . . . . . . 112% pints (7.1 litres)
Engine oil filt ur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- .
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Petrol . . . . % pints (0. .8 litre)
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel . . . . . . . . . . . . . . . 12 gal (54.5 litres)
Cooling system (with heaters) :
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dry system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.562 in (90 .57mm) . . . . . 14%, pints (8 .25 litres)
Refill after draining (from drain plug only) . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.819 in . . 13 pints (7.4 litres)
Heater . . . . . . . . . . . . . . .
Capacity . . . . . . . . . . . . . . . . . . . . 2495cc . 1 %, pints (0 .9 litre)
Expansion tank . . . . . . . . . . . . . .
Valve/rocker clearance (hot or cold) . . . . . . . . . . . . . . . . . . . . . . 0.010 in (0.25mm) Kerb Weight (Manual gearbox) . 1 pint (0-6litre)
. . . . . . . . . . . . . . . . . . . . . . . Petrol8.0 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 3,541 Ib (1606 kg)
Compression ratio . . . . . . . . . . . . . (Automatic gearbox) . . . .
Diesel 21 :1 . . . . . . . . . . . . . . . . . . . 3548 lb (1609 kg)
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 3, 4, 2
Petrol ignition system
. . . . . . . Champion N12Y, Unipart GSP 121. . . . . . .
Sparking plug
Sparking plug gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.029 to 0.032 in (0 .75 to 0.80mm)
Distributor . Ducellier 525232 A
Distributor gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ . 0.014 to 0.022 in (0.35 to 0.55mm)
I 1i- 3 - 1 3 c
Diesel fuel system 3
Fuel filter . . . . . . . . . . . 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAV FAS 583
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAV DPS with mechanical governor 3v
Fuel injection pump
Fuel injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAV Pintaux BDN OSPC 6209
Fuel injector nozzle holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAV BKB 35S 5283
Nozzle opening pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 atmospheres ---
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAV MICRONOVA starting Aid ~
Heater plugs .
Injector nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 to 8 1bf ft (0.8 to 1 .0 kgf m) I j~ )Ji c~,~
Replacement & Data Notes
SERVICE PARTS AND IDENTIFICATION
ACCESSORIES
Whencnw iniuniC3trngwithvrrur[)eaerrxlly
Genuine London Taxis International parts and the chassis, car Ibodyl . and enqin,always quote
accessories are designed and tested for your rnumbers When the cqmmunication concerns
vehicle and have full backing of the Vehicle transmission unit it is also necessa ry to quote
Service Statement Only when genuine London the unit casing numbe r
Taxis International parts are used can
Chassis number. Stamped on a plate fixed to
responsibility be considered under the terms of
the chassi,, side-member adlacent to the rrght-
the statement
hard front rnudw,ng valance
Car (Body) number. Stamped on a plate fixed tc
Safety features embodied in the vehicle may be
the scuttle drain channel
impaired if other than genuine parts are fitted In
certain territories, legislation prohibits the fitting Engine number . Stamped on the right-hand sid,
of parts not to the vehicle manufacturer's of the cyiinder block
specification Owners purchasing accessories
while travelling abroad should ensure that the Gearbox number. ~=~nt~rri in;he side face of
accessory and its fitted location on the vehicle the gearbox Case
conform to mandatory requirements existing in
Automatic gearbox number. Stamped on a
their country of origin
plate fixed to the left-hand side of the gearbox
Vehicle identification number . Stamped on a
plate attached to the left-hand valance panel
adjacent to the cooling system header tank.
London Taxis International Limited
Holyhead Road
Coventry CV5 8JJ
Telephone Coventry (0203) 595001
Notes
60
Notes Notes
Notes Notes
-A
Notelt Notes
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