The Mk 1 Consul, Zephyr and Zodiac Owners Club Technical Manual Originally created in 1991 by Neil Tee, with contributions from John Blythe, Phil Downer, Dave Hardwick, Mick Johnson, Rowland Oliver, Alan Sim, Neil Tee, Andy Tutt, John Wiles. Retyped and Reformatted by Gaz Leaver, 2017. 1 Contents Bodywork ................................................................................................................................................ 6 Initial examination - bolt on parts and sills ......................................................................................... 6 Door Sill Replacement ......................................................................................................................... 8 Structurally important areas ............................................................................................................... 9 Non-Structural Rot ............................................................................................................................ 11 Doors ................................................................................................................................................. 11 Bonnets ............................................................................................................................................. 12 Rear Panel ......................................................................................................................................... 12 Boot Guttering .................................................................................................................................. 12 Boot Lid ............................................................................................................................................. 13 Wings ................................................................................................................................................ 14 Brakes .................................................................................................................................................... 15 If you can’t get the brakes to pull straight ........................................................................................ 21 Where to get the parts...................................................................................................................... 21 Brake Hoses and Bleeding ................................................................................................................. 21 Breaking a Mk1 and Saving Useful Parts ............................................................................................... 22 Clutch and Gearbox ............................................................................................................................... 24 Symptoms and Problems .................................................................................................................. 24 Clutch ............................................................................................................................................ 24 Clutch drag .................................................................................................................................... 25 Gearbox ............................................................................................................................................. 27 Removal of the gearbox ................................................................................................................ 28 Getting things out of the way ....................................................................................................... 28 Beginning the dismantling ............................................................................................................ 29 Removal of the gearbox cross member ........................................................................................ 29 Removing the bolts around the bell housing ................................................................................ 30 Removing the handbrake front cable ........................................................................................... 30 Removal of the gearbox itself ....................................................................................................... 30 Removal of the clutch ................................................................................................................... 30 Repair and Replacement of Parts ..................................................................................................... 30 Clutch ............................................................................................................................................ 30 Gearbox ......................................................................................................................................... 31 Replacement of the gearbox and clutch ....................................................................................... 31 Cooling System ...................................................................................................................................... 32 2 Overheating and Cooling Problems .................................................................................................. 32 Stuck Thermostat .............................................................................................................................. 32 Fan Belt Loose ................................................................................................................................... 32 Clogged Radiator ............................................................................................................................... 33 Leaking Radiator ............................................................................................................................... 33 Head Gasket ...................................................................................................................................... 33 Collapsed or Leaking Hoses ............................................................................................................... 33 Ignition too far Advanced ................................................................................................................. 34 Cracks or Leaks in the Block .............................................................................................................. 34 Badly Fitting or Wrong Radiator Cap ................................................................................................ 34 Brakes Binding ................................................................................................................................... 34 Electrics ................................................................................................................................................. 35 The ignition warning light ................................................................................................................. 35 Ignition Switch .................................................................................................................................. 36 The Battery ........................................................................................................................................ 36 Dynamo and Control Box .................................................................................................................. 42 Bad Earths and other wiring faults ................................................................................................... 42 Joins in the Loom .............................................................................................................................. 42 Bullet Connectors .............................................................................................................................. 43 Construction of the Loom ................................................................................................................. 43 Why fit a new Loom? ........................................................................................................................ 43 Indicator Switch ................................................................................................................................ 44 Getting the indicators to cancel .................................................................................................... 44 Ignition Warning Light ................................................................................................................... 46 Fitting New Ignition Points ............................................................................................................ 46 Distributors ................................................................................................................................... 46 Engine.................................................................................................................................................... 47 Problems with Starting ..................................................................................................................... 47 Engine Repair .................................................................................................................................... 51 The Mk1 Unit................................................................................................................................. 51 Preparing 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