Austin Metro 1980-1991 Workshop Service Manual for Repair
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🏷️ Basic Information Identification Make: Austin Model: Metro Model Code: AHH (various derivatives) Body Style: 3-door hatchback, 5-door hatchback Generation Generation Designation: First Generation Codes Platform: ADO 82 (shared with MG Metro, Rover Metro) 👋 Introduction Market Position Segment: Subcompact car Primary Market: UK and European markets Competitive Analysis Key Competitors: Ford Fiesta, Vauxhall/Opel Nova, Volkswagen Polo, Peugeot 205 Key Features Design Philosophy: Designed to be a modern, efficient, and affordable small car, replacing the aging Mini. Innovation: Innovative Hydrolastic/Hydragas suspension system for ride comfort. 📋 Manual Details Coverage Areas Applicable Years: 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991 Page Count Page Count: 190 Manual Type Manual Type: Workshop Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: 1.0L (A-Series), 1.3L (A-Series), 1.4L (Rover K-Series - later models) Fuel System: Carburetor (SU, Zenith-Stromberg), Fuel Injection (later K-Series) Ignition System: Distributor-based, Electronic Ignition Cooling System: Radiator, Fan, Thermostat, Hoses, Water Pump Transmission: 4-speed manual, 5-speed manual (Leyland/VW based), Automatic (less common) Clutch: Hydraulic, Cable Suspension: Hydrolastic (early), Hydragas (later), Front (MacPherson strut), Rear (trailing arm) Steering: Rack and pinion, Manual, Power assisted (optional/later) Brakes: Front Disc, Rear Drum, Hydraulic system, Handbrake Electrical System: 12V system, Battery, Alternator, Starter Motor, Lighting, Wiring Harnesses, Fuses Bodywork: Chassis, Panels, Doors, Hood, Trunk, Interior Trim, Bumpers Heating And Ventilation: Heater Matrix, Blower Motor, Vents Procedures Included Maintenance: Oil changes, filter replacements, spark plug checks, brake adjustments, fluid level checks Troubleshooting: Diagnosis of common faults, electrical system issues, engine running problems Repair: Engine overhaul, transmission rebuild, brake caliper replacement, suspension component renewal Disassembly And Assembly: Step-by-step instructions for component removal and installation Adjustments: Carburetor tuning, ignition timing, brake adjustments, clutch free play Tightening Torques: Specifications for critical fasteners across all systems Special Tool Usage: Identification and usage of specialized tools for specific repair tasks Technical Depth Depth: Comprehensive, covering routine maintenance to major component overhaul and rebuilding. Detail Level: Detailed step-by-step procedures with pictorial diagrams, exploded views, and schematic illustrations. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable (high resolution for clarity) Binding Type Binding Type: Digital Download (N/A for physical binding) Paper Type Paper Type: N/A (Digital) Software Requirement Software Requirement: Adobe Reader Compatibility Compatibility: Windows, Mac, Linux OS ⚙️ Engine Specifications Primary Engine Engine Type 1: BMC/Rover A-Series (OHV) Engine Displacement 1: 998 cc (1.0 Litre) Engine Bore X Stroke 1: 64.59 mm x 76.2 mm Engine Compression Ratio 1: 8.4:1 (typical) Engine Horsepower 1: Approx. 45-50 bhp @ 5500 rpm (depending on tune) Engine Torque 1: Approx. 55-60 lb-ft @ 3000 rpm (depending on tune) Engine Fuel System 1: Single SU HJF or Zenith-Stromberg CD175 Carburetor Performance Engine Type 2: BMC/Rover A-Series (OHV) Engine Displacement 2: 1275 cc (1.3 Litre) Engine Bore X Stroke 2: 70.61 mm x 81.28 mm Engine Compression Ratio 2: 8.8:1 (typical) Engine Horsepower 2: Approx. 60-65 bhp @ 5500 rpm (depending on tune) Engine Torque 2: Approx. 70-75 lb-ft @ 3000 rpm (depending on tune) Engine Fuel System 2: Twin SU HS2 Carburetors (Metro GT/GTI), Single SU HJF or Zenith-Stromberg CD175 (standard 1.3) Fuel System Fuel Type: Unleaded Petrol (from 1989 introduction of unleaded fuel capability), Leaded Petrol (earlier models) Fuel Tank Capacity: Approx. 35 Litres (8 Gallons) 🔧 Transmission Standard Transmission Type Standard: 4-speed manual Optional Transmission Type Optional: 5-speed manual (available from mid-1980s), 3-speed Automatic (rare) Features Gearbox Layout: Front-wheel drive, transverse engine layout 📐 Dimensions Exterior Length: 3410 mm (134.3 inches) Width: 1590 mm (62.6 inches) Height: 1360 mm (53.5 inches) Wheelbase: 2286 mm (90 inches) Weights Kerb Weight: Approx. 740-800 kg (depending on specification) 💡 Technology Features Infotainment Radio System: Optional factory-fitted or dealer-installed radios, often with basic AM/FM and cassette players. Driver Assistance Driver Assistance Features: None in modern context; basic safety features like seatbelts and hazard warning lights. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 6,000 miles or 12 months (refer to manual for precise intervals) Oil Specifications Engine Oil Type: 20W/50 or 10W/40 API SF or SG (refer to manual for specific grades and capacities) Gearbox Oil Type: GL4 Hypoid Gear Oil SAE 90 Fluid Specifications Brake Fluid Type: DOT 3 or DOT 4 Coolant Type: Ethylene Glycol based antifreeze (50/50 mix with water) Known Issues Suspension: Hydrolastic/Hydragas spheres can fail, requiring replacement or re-pressurisation. Fluid leaks from spheres. Rust: Prone to rust, particularly around wheel arches, sills, and suspension mounting points. Electrical Gremlins: Older wiring harnesses can degrade, leading to intermittent electrical faults. Engine A-Series: Can suffer from oil leaks from the crankshaft seals and gearbox. Carburetor: SU or Zenith-Stromberg carburetors can require frequent tuning and rebuilds. Spark Plug Type Spark Plug 1 0L: NGK BP6ES or equivalent Spark Plug 1 3L: NGK BP5ES or equivalent 📚 Vehicle History Brand Heritage Manufacturer Origin: British...