TVR Cerbera Workshop Service Manual - Introduction
Contents
1. First fill from factory Super 15W40 6000 mies 10000 km Second fill Mebii 1 0W40 6000 miles 10000 km Regular Service or 12 months Gearbox Mobil SHC ATF Differential Mobil SHC 80W 140 ID Cooling System Mobil Universal Antifreeze Brakes and Clutch Mobil Universal Brake and Clutch Fluid SAE J1703 C V Joints Mobil Grease Special NLGI 2 Power Steering where fitted Mobil ATF 220 NOTE TVR use and recommend Mobil products Failure to use these products could effect vehicle performance and reliability and may also invalidate the warranty Weekly Checks All exterior lights Oil level Coolant level Brake fluid level Power steering fluid Windscreen washer bottle Tyre pressures Visual check for any fluid leaks DO O OM aes ici If for any reason the vehicle is grounded or an object strikes the chassis from below it is advisable to visually inspect the chassis for signs of damage If there is damage the vehicle should be taken to your local dealer for a thorough inspection Service Intervals The following are recommended service intervals for the vehicle 1000 miles 6000 miles 12000 miles 18000 miles 24000 miles 30000 miles and every 6000 miles thereafter or every twelve months which ever is reached first NOTE All service work should be carried outby a TVR factory approved service centre General repair procedures Services by TVR dealers should b2. Service Workshop Information Introduction Hosted ana optimised by WWW TheTVRSLte com a en Q eo og This Workshop Service manual has been compiled for the TVR Engineering model Cerbera Any modifications that do occur to the production car will be reflected in additional pages being sent out The aim of this workshop service manual is assist skilled TVR technicians in the efficient repair and maintenance of any TVR Cerbera TVR do not accept any responsibility for any inaccuracies errors or omissions contained within this manual although every effort has been taken to make it as complete and accurate as possible TVR do not accept any liability for any consequential or other losses howsoever arising as a result of any of the recommendations contained within this manual All repairs to the TVR Cerbera should be carried out by a TVR Dealer Repairs should never be attempted by untrained individuals In this introductory section warnings cautions and notes will appear in boxes to give more helpful information WARNING These procedures must be followed accu rately to avoid the accidents CAUTION To ensure no damage occurs to any components these procedures must be followed NOTE This calls attention to ways which make a job easier or gives helpful information Interpretation of Workshop Manual This manual is divided into sections as shown on the contents page To locate information
3. line of cleaning products Power washing the bodywork is quite acceptable during the manufacture and maintenance of the cars However do not spray the high pressure jet directly at and recommend their range of products the paintwork or the door window seals For a current list of Autosmart products and stockists Automatic car wash contact Hosted ana optimised by Www TheTvVRSite com
4. 169 0170 and has a brake calliper mounting bracket J0162 Later cars will utilise a cast upright and will include integral mounting bosses so there will be no need for the bracket J0162 All of the uprights are dimensionally identical and have helicoil inserts where the steering arms etc bolt on Again the bolt lengths are fairly critical so refer to the drawings The steering arms upper ball joint mountings brake calliper brackets and the lower drag struts are not handed The geometry is adjusted in the same manner as the Griffith and the car seems to be very sensitive to castor The shims are the only current means of adjustment but we are intending using three different lengths of drag strut suitably marked so that the castor adjustment can be performed more easily and more accurately Hosted ana optimised by www TheTvRSite com Wheels Tyres and Steering The wheels are the same front and rear but the tyres are not The 225 45 x 16 front tyres are responsible for some of the sharp steering characteristics but in the main the very light and quick rack is the cause you will get used to it There are a few other details regarding the rack You cannot centralise the steering wheel at the boss It must be done at one of the UJ splines If the rack itself is not central relative to the car ie equal travel in each direction then it is possible for for the tyres to foul the upper wishbone on full lock It is intended to utilise t
5. As per the charger s instructions CAUTION If charging the battery whilst it is still Carpets connected to the car a trickle charger giving out no more than 7 amps must be used as a larger amp charg Carpets should be cleaned regularly with a vacuum er will cause damage to other components cleaner to remove dust and dirt Mild detergents and warm water may be required to remove any difficult 4 Once the battery is charged switch of the charger marks or stains and disconnect the leads CAUTION Over charging the battery may cause per Engine Bay Cleaning manent damage and effect it s reliability Cleaning the engine bay should be done by hand A Power or Jet washer MUST NOT be used It must be ensured that water is not spayed or poured directly on to any electrical equipment or connection If this is allowed to happen damage may be caused to the cars Cleaning Recommendations electrical circuits leading to break downs and expensive repairs This applies particularly to the throttle potentiometers lambda sensors and crank sensors If such connectors become damp spray witha Exterior Cleaning moisture repellent e g Mech oil etc By Hand The body work can be washed using a mild detergent or specialist car shampoo A low pressure hose pipe should TVR Approved Cleaners be used to rinse the vehicle Specialised cleaners should not be used when cleaning the road wheels Using a power wash TVR use the Autosmart
6. TION It is essential that jacks and axle stands the trailer using the correct points on the car are positioned under the chassis to avoid damaging the body e t c Do not position jacks or axle stands CAUTION If the correct fastening points are not used under the fibre glass body structure or floor pan the vehicle will be unsafe during transit and parts of this will cause damage and would also be extreme the Cerbera may also be damaged due to abnormal ly unsafe stresses Jacks or axle stands must be positioned only on the areas shown above and over page CAUTION Work should never be started until suitable axle stands have been positioned in the indicated positions Towing Procedure The TVR Cerbera is not designed to tow other vehi cles and for this reason there is no towing eye on the rear of the car In the case of a break down there is a towing eye on the front of the car fig12 by which it is possible to tow the car to an appropriate place for repair however it is not recommended that this dis tance be too great CAUTION Please noted the brake servos and power steering will not be operative whilst the car is not running thus greater pressure will have to be applied to the brake pedal and greater effort will be needed to turn the steering wheel Hosted ana optimised by www TheTvRSite com 4 Jump Starting Battery Charging It is now possible to jump start the car or place th
7. d having to perform this procedure again it is advised not to turn the engine off until a sufficient charge has been built up in the battery to allow the car to be started under it s own power or until the vehicle is in a position where it is possible to fully charge the battery from a mains charger Charging the battery To charge the battery the procedure for connection of the leads is similar to that of jump starting it is as follows 1 The vehicles must be parked so that the jump leads will reach both batteries alternatively a fully charged booster battery may be placed on the floor adjacent to the vehicle 2 After checking that the ignition and any other elec trical accessories are switched off and that the car is in neutral with the parking brake applied connect the Mains Supply o Or joo ao Positive lead to Positive Terminal of Discharged Battery 12 Volt Battery Charger leads as follows A One end of the first jumper cable connect to the pos Dischargea Cerbera ce i Car Battery itive terminal of the booster battery B The other end of the first jumper cable connect to the Negative Lead to positive terminal of the discharged battery This is a Good Earth the only terminal that is accessible whilst the battery Engine fig19 remains in the Cerbera Hosted ana optimised by www TheTvRSite com CERBERA SERVICE WORKSHOP MANUAL WARNING During the charging process Hydro
8. e bat tery on charge Both of these procedures are explained in the following sections Jump Starting Battery Charging Procedure NOTE When the discharged Cerbera battery is con nected to a slave battery or charger the alarm and immobliser will activate Follow standard alarm deac tivation procedure outlined in the Cerbera Handbook to deactivate the alarm and immobliser Jump starting procedure To jump start the Cerbera the following procedure should be followed Positive lead to Positive Terminal of Discharged Battery Second Car or Fully Charged Discharged Cerbera Slave Battery Car Battery fig18 Negative Lead to a Good Earth Engine C Connect one end of the second cable to the negative terminal of the booster battery D Connect the other end of the second jumper cable to the engine to create the negative connection WARNING The final cable connection could cause arcing at the connection point which if near battery could cause an explosion Continued 3 If the booster battery is connected to another vehicle start the engine and allow it to idle 4 Start the engine of the Cerbera using the normal pro cedure 5 Remove negative jumper cable 6 Finally remove the positive jumper cable from positive terminals of both the booster battery and dis charged battery ensuring that the ends do not touch the negative terminals and create a short circuit NOTE To avoi
9. e carried out at the intervals listed above and everything listed on the ser vice schedules should be checked every 6000 miles or 12 months The following pages give details of some of the things that should be checked and replaced and the recom mended procedures used to perform the service The rest of this manual goes into more depth and will act as a workshop service manual Cooling System Reservoir Battery Engine Oil Filler Cap Windscreen Washer Reservoir Power Steering Fluid Brake Fluid Reservoir Engine Oil Dipstick NOW BWR 1 Cooling System The coolant level is visible through the transparent sides of the expansion tank When the engine is cold the coolant level should be at the MAX mark which is indicated by the seam on the side of the tank When the engine is at its operating temperature it is normal for the coolant level to rise above the MAX level fig 1 Hosted ana optimised by www TheTvRSite com CERBERA SERVICE WORKSHOP MANUAL NOTE Do not remove the blue pressure cap on the expansion tank if the engine is hot Always check the coolant level when the engine is cold If for any reason the cooling system needs the addition of a large quantity of coolant i e after draining or major leak then the system must be carefully bled With the heater control set to hot fill the system through the expansion tank Then full loosen the large brass screw on radiator Air will be expelled tighten th
10. e plug when water without air bubbles is expelled Loosen the bleed screws on both the passenger side and driver side coolant rails These are located between the black air boxes and the camshaft covers Once again air will be expelled Re tighten the bleed screws when water without air bubbles is expelled Start the engine and run run at fast idle 1500 rpm with the blue pressure cap off and continue to add coolant through the expansion tank Rebleed radiator and coolant rails before the engine gets too hot When the thermostat opens more coolant will need to be added When no more coolant can be added replace the blue pressure cap Let the engine run for a few more minutes until the fan cuts in and switch off the engine Should the temperature gauge enter the 100 section before the fan cuts in stop and allow to cool When the engine has cooled and no pressure can be felt in the radiator hoses remove the blue pressure cap and top up to the MAX level indicated on the side of the expansion tank Then rebleed radiator and rails the system is now full Note Check the coolant level every week 2 Battery Located under the bonnet on the passenger side inner wheel arch Should the battery need recharging please follow the instructions given in Charging the Battery fig 2 Hosted ana optimised by Www TheTvRSite com fig 2 3 Engine Oil Filler Cap To remove unscrew the cap in an anti clockwise direction and top up with TVR
11. ers and 306 mm vented discs with integral rear drum handbrake There is no balance valve The front rear split is controlled by the combination of disc piston and pad size The brakes do squeal from time to time the cause of which is being investigated by AP The pad chamfers should be such that they contact the disc first Along with the diff the brakes should be gently run in Only the demo cars have aeroquip hoses the production cars have rubber hoses Hosted ana optimised by www TheTvRSite com CERBERA SERVICE WORKSHOP MANUAL Chassis The plates underneath are very important but for reasons of prop clearance etc they could be better The front sump plate is made from either steel or alloy If it is alloy there should be a pair of additional stainless steel reinforcing sections below the front anti roll bar mounts Note that all the underside mounting bosses are 10 mm threads Kear Suspension The rear suspension is fundamentally similar to the Griffith the main differences being the wheel bearing and hub the upright and driveshaft and the anti roll bar The same methods of adjustment apply If you are removing the bearing pack be careful with the length of the three mounting bolts as if they are even 2mm too long they will interfere with the handbrake shoes See drawings for bolt lenghts Front Suspension The front suspension however is completely different The upright at present is machined from a billet of aluminium C0
12. fts of the diff do have a little play this is quite normal Itis not unusual for the diff breather to vent a little oil at first This is usually a sign of too much abuse too soon Once it has breathed in this way the oil level will have found its own position and it should then be OK It is a good idea to change the diff oil early on the recommended change is at the 1000 mile service and then every 12000 miles Be sure not to overfill the unit as this will exaggerate the breather problems With respect to daily use both diffs should be quieter than the GKN unit although the Hydratrak is a slightly more benign LSD with a less severe action With the Hydratrak there is some free play in the output shafts which is normal The internal end of the shaft is centralised only when there is some torque passing through the unit Dampers The dampers have been designed and built for the Cerbera in conjunction with an outside specialist The springs are Eibach springs which are blue at the front and green at the rear The car will always appear high at the rear when unladen due to the low spring rate and the change in axle loads when laden There are also many varieties of bumpstops This need not be a problem as long as the opposite hand is the same The bushes are the same as the Griffith Brakes These have been developed in conjunction with AP Racing and consist of alloy 4 piston front callipers and 291mm vented discs with 2 piston rear callip
13. gen The use of automatic car washes is not recommended as and Oxygen gases are produced This gas mixture can the door window seals are not designed to withstand explode if flames sparks or lighted tobacco are the direct force of high pressure water jets Also the brought near the battery For this reason it is essential detergents used and the cleaning action of the brushes that the charging area is well ventilated thus avoiding may damage the paintwork the gases to become concentrated NOTE The charger should be switched off during all Interior Cleaning connection and disconnection procedures Vinyl Leather 1 Ensuring that the charger is off connect the posi Vinyl and leather should be cleaned with a damp cloth tive cable normally coloured red to the positive ter However a little mild detergent or proprietary minal of the battery This is the only terminal that is upholstery cleaner may be required to remove ingrained accessible whilst the battery remains in the Cerbera marks Leather upholstery will benefit from a periodical application of Hide Food 2 Connect the negative cable normally coloured black to the engine as indicated in the diagram CAUTION Care should be taken when cleaning the steering wheel gear lever or pedals as most cleaning products will leave a slightly slippery surface layer 3 Switch on the charger and charge until the battery which can be extremely dangerous during driving is fully charged
14. gineering are fitted In certain countries leg islation prohibits the use of parts not to the manufac tures specification Any torque wrench values given in the manual must be strictly adhered to Locking devices where specified must be fitted if any such device is impaired during removal it must be replaced with a new one Certain fasteners must not be re used How to Order In order to avoid delay the following information should be read carefully and the instructions fellowed N carefully to ensure that the factory importer or dealer receives sufficient information in the approved form to enable speedy dispatch of the correct parts Orders for parts should be forwarded separately and not with correspondence dealing with other matters The chassis number vehicle identification number and engine number including all letter prefix and suffixes of the car concerned must be quoted on every order This information is given on the identification plate on the front panel of the vehicle and on the engine cylinder block The full part number and description of the parts must always be given and if any doubt exists a sketch or pat tern should be forwarded with the order For any special parts that are required and specific details such as the part number are not known please give as many details as possible on a separate sheet Special Note As pipe and hose lengths may vary from time to time due to variations in produc
15. he latest Bridgestone tyre the 502 as and when it becomes avaliable The front size remains the same but the rear will become 245 45x16 Do not fit different tyres or sizes on the same axle Due to the coarseness of the splines the ultimate centralisation of the steering wheel may be achieved by shuffling of the rack bar but this should be limited to no more than 1 2 turn of each track rod Some of the racks seem to have a tight spot just to each side of the straight ahead position We suggest leaving the adjustment for a few hundred miles as they do wear in GEOMETRY SETTINGS Parameter CAMBER DEG 0 5 1 25 NEG 0 5 125 NEG 0 25 CASTER DEG 3 5 4 5 POS N A 0 23 TOE MINS 10 20 N 10 20 IN 5 TYRE PRESSURE 24 28 2 NOTE The toe figures are TOTAL for the axle in question i e for a PAIR of wheels The above figures represent acceptable tolerances The maximum discrepancy from to side on the axle in question should be no more than the figures shown in brackets In an ideal world the Cerbera would be aligned at the intended ride height however unless it is always to be used with 4 people it will be acceptable to use a passengerless car with at least half a tank of fuel The greater tyre pressure range is aimed at continued high speed use above 100 mph Service Requirements amp Regular Checks Recommended Lubricants amp Fluids Engine Oil Type Change After Delvac 10W30 1000 miles 1600 km
16. ig 5 raw Vehicle Identification numbers VIN s 1 Locating The Chassis Number 7 Beste Fluid REEN oir The Cerbera chassis number is positioned in the engine bay on either the front cross member early cars or Check that the fluid level is up to the MAX line on the inside the O S front wishbone mount fig 8 reservoir the warning light on the dash will come on if low and with the handbrake on Only top up with TVR recommended fluid Recommended Lubricants and Fluids fig 6 RS J Sy 4m I N B N S Shown Hosted ana optimised by ate ee CERBERA SERVICE WORKSHOP MANUAL 2 Locating The VIN Plate 3 Reading The VIN Plate The VIN plate is produced in a standard format for the To find out or check any of the vehicle identification range of TVR vehicles The diagram opposite shows the numbers the VIN plate must be located plate and the location of specific identification numbers The VIN plate is located in the engine bay of the 3 Cerbera and is only visible when the bonnet is fully Jacking Procedure open resting on it s support The actual position of the VIN plate is at the front of the engine bay on the near side of the car Before commencing with the instructions below the car fig 9 must be raised off the ground 1 To Raise Front Wheels 1 The surface must be a solid ground surface 2 Ensure that the hand brake is on 3 Ensure that the jacking device is positioned only
17. ned and repeated contact with used engine oil 2 Protective clothing including impervious gloves Hosted ana optimised by www TheTvRSite com should be worn when handling used oil 3 Avoid contaminating clothes that are directly in contact with the skin 4 Immediate first aid treatment should be obtained in the event of oil coming in contact with open cuts or wounds 5 Do not wash the skin using gasoline kerosene diesel fuel petrol thinners or solvents 6 Where and when practical degrease components before handling 7 Eye protection should be worm e g goggles or face shields where there is a risk of eye contact An eye wash facility should always be provided Disposing of Used Oils When considering the disposal of used oil give due con sideration to any adverse enviromental effects it will have and dispose of it through authorised waste dispos al contractors as it is illegal to pour used oil into the sewerage system into waterways or onto the ground If in doubt contact your local Enviromential Health office for advice on disposal facilities Repairs amp Replacements When replacement parts are required it is essential that all parts are obtained from TVR Engineering Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories safety features embodied in the vehi cle may be impaired if parts other than those specified by TVR En
18. ould always be close at hand when handling fuel Hosted ana optimised by www TheTvRSite com CERBERA SERVICE WORKSHOP MANUAL WARNING When a car is undergoing any work that involves the fuel system it is very important that the ae battery is disconnected before starting as arcing at the battery terminals may ignite any fuel vapour in the air All forms of ignition should therefore be extinguished before fuel system work commences and it should always be done by a TVR technician with fuel system training Hot Fuel Handling Precautions WARNING The listed procedures must be followed before any operation requiring fuel to be drained from the fuel tank is started 1 Firstly time should be allowed for the fuel to cool avoiding contact with hot fuels 2 The system should be vented during drainage by loosening the fuel filler cap ensuring that a ventilated area is used when this operation is carried out The filler cap should remain on Fuel Tank Repair Under no circumstances should a repair to any fuel tank be attempted Used Engine Oil WARNING After lengthened and repeated contact with used engine oil the natural fats in the skin are eventual ly removed leading to dermatitisand other skin disor ders Adequate means of skin protection and washing facili ties should be provided as engine oil contains potential ly harmful contaminants which may cause skin cancer Handling Precautions 1 Avoid lengthe
19. recommended oil if required tighten completely See Recommended Lubricants and Fluids fig3 4 Windscreen Washer Filler Reservoir Refill with a mixture of clean water and windscreen washer fluid Mixture as per manufactures instructions fig 3B fig 3B Fea 5 Power Steering Reservoir 8 Engine Oil Dipstick Remove the reservoir cap dipstick Check the fluid level when the car is cold The level should be between the The oil should always be checked on level ground with top mark on the dipstick and the bottom of the dipstick the engine switched off Let the oil settle 5 minutes Only top up with TVR recommended fluid then pull the dip stick out and wipe clean to ensure a Recommended Lubricants and Fluids fig 4 true reading Re insert the dip stick and remove once again The level of oil should read between the min and max marks on the dipstick fig 7 Ensure it is fully seated and do not knock off injector plug 6 Clutch Fluid Reservoir Located under the engine bay trim panel on the o s of NOTE Over filling may cause oil wastage Running the bay The clutch fluid reservoir cover will then need the engine with an oil level below the minimum mark to be removed Check that the fluid level is up to the could result in considerable damage being caused MAX line on the reservoir and reseal the cover Only top up with TVR recommended fluid Recommended Lubricants and Fluids f
20. referring to a gen eral area of the vehicle such as suspension brakes instrumentation etc use the main contents page The general sections are split up further into sub sections denoted by a number so for example C3 will describe an individual procedure in the Front Suspension sec tion Each of these individual procedures is listed at the start of each lettered main section Usage will quickly make the user familiar with the workshop manual layout enabling efficient and effec tive use of the manual Dimensions All dimensions stated in this manual are given in metric measurements i e millimetres litres etc unless other wise stated Poisonous Substances Many of the substances used on the Cerbera could cause physical harm and you must ensure they are kept away from open wounds Fuel Handling Precautions The following section outlines information on handling fuel safety that shouldn t be ignored to ensure the upmost safety at all times The vapour that fuel creates is extremely flammable toxic and explosive in confined areas It produces around 150 times its own volume when it evaporates and when mixed with air it beguns very ignitable The vapour will always fall to the lowest level because it is heavier than air This creates a problem because it is very easliy distributed throughout a workshop so even the smallest of spillages could be dangerous A fire extinguisher containing FOAM CO2 GAS or POWDER sh
21. tion build please state length required in addition to the part number in order that we may supply the correct item Always specify the dispatch method required e g Air freight Airmail sea post passenger train etc Confirmation orders must be clearly marked to avoid duplication Crates and packing cases used for dispatch goods will be charged for and credited in full if returned undamaged within one month Damaged and broken parts sent as pat terns will not be returned unless specially requested General Technical Information Differential There are two types of differential The HYDRATRAK is a sophisticated LSD that works basically by forcing fluid through small bleed orifices when one wheel tries to spin relative to the other It does this though a series of small vane pumps in aa similar manner to a vane compressor Because of this it should be run in very carefully The Cone diff is fundamentally similar to a Salisbury plate type diff and the same drawbacks apply One oil will suffice for both types of diff MOBIL SHC 80W 140 ID Any other oil will wreck the Hydratrak unit itself i Running in the diff merely requires a gentle warming up of the unit and progressively more load over the course of about 500 miles The Hydratrak unit will only be operational when there exists a difference in the wheel speed between the two output shafts and so this requires gentle comering loads in order to bed the vanes in The output sha
22. under one of the chassis tubes and not under any part of the floor pan or body The recommended area for positioning the jack is between the two front wheels of the car on either the crossmember that the towing eye is located on or the crossmember behind it 4 Proceed with raising the vehicle fig 9 5 Insert axle stands These should be positioned behind the front wheels fig10 awe ENGINEERING LIMITED BLACKPOOL ENGLAND VEHICLE IDENTIFICATION No gap ABCDEF 1G2HJ3456 3 ENGINE No r fig10 BODY CODE The Body Code gives the car s paint 2 ARI a It begins a a 2 To Raise Rear Wheels letter followed by four numbers e The Engine no is an 11 figure code also consisting of both letters amp num 1 Use a solid level ground surface bers 2 Ensure that the front wheels are securely chocked The VIN no is an 17 figure code con 3 Ensure that the jacking device is positioned only sisting of both letters amp numbers under one of the chassis tubes as close to the main chassis rail as possible and not under any part of the floor pan or body Hosted ana optimised by Www TheTVR SLte com i 4 Proceed with raising the vehicle 5 Insert axle stands These should be positioned in front of the back wheels on the chassis tube fig11 Transporting by Trailer When transporting the Cerbera by trailer or by a flat bed transporter etc it is crucial to secure the Cerbera to CAU
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