Item.

Links.

  1.  Rust proofing: these two guides (links are on the right) are taken from the Tectyl product range.  This unfortunately also means they are in Swedish, but the diagrams are self explanatory...

  2. Autojumble Parts: a few possible alternative parts which may be found (although this is becoming more and more unlikely) at Classic Car show autojumble areas.  

  3. Engine Servicing Information: these vehicles can be used in modern traffic without too many problems, but they do require regular attention.  Modern synthetic and semi-synthetic engine oils should be avoided in favour of e.g. Duckhams Q20/50 Classic, Esso Extra 20/50 or something similar (*).  Brake fluids are glycol-based DOT4 spec. (see item on silicone-based fluids below).  There are 11 greasing points on the Flavia front suspension and steering, 4 on the 2000 front suspension, + 1 on the remote gearshift.   A good quality lithium or molybdenum grease will do fine; just keep the greasing schedule regular.  The Flavia non-power steering box may well leak oil - it is possible to fit a greasing nipple to the filler plug, and then use an appropriate (self-levelling) grease instead.  There should be some anti-freeze or summer coolant mixture (e.g. Comma "Coldstream") in the cooling system at all times.  Powered steering fluid (on the 2000) is not critical, but should be that type specified for older cars (e.g. Ford Hydraulic Fluid F-AT/PS; part # 99SX 19547 AA).  Spark plugs should be modern N7Y equivalents, and can be the "fit and forget" R56 type, if necessary, and if the carburetter/injection system is in good shape.  Petrol is not too critical either - do use an octane additive if this is favoured, but there are many examples of both Flavia and 2000 running quite happily on 95 octane unleaded - modern classic car use is not as intense as when these cars were new, and aluminium heads have alloy steel valve seat inserts anyway.  Don't forget tappet clearances.  These should not require looking at very often, but do take the trouble to get them right, by checking over several (clockwise) revolutions.  The "Rule of 9" doesn't work, by the way.  Clearances should be (cold): (Flavia carb.) inlet 0.20 mm, exhaust 0.30 mm., (Flavia inj.) inlet 0.15 mm., exhaust 0.25 mm., (2000 all) inlet 0.15 mm; exhaust 0.20 mm.  The firing order is 1-3-2-4.  The CB points should be set (all) to 0.45±0.03 mm., ignition timing is (Flavia) 2 to 3° BTDC, (2000) 0 to 2° on carburetted cars, 0 to 2° BTDC on Flavia KF injection cars, 10±1° BTDC on the (2000) Bosch injected cars.  See also the links on the right.

  4. (*) Filling the engine with fresh oil.  This can take some time.  It is not possible to put a funnel into the filler neck and up-end the oil can, which will result in oil all over the engine and your driveway below.  Tip steadily and very slowly, with pauses to allow the filler neck to drain down.  If changing the filter at the same time: the 2000 engine will be OK to prime a new filter (can use the Rover 2000/Jensen Interceptor 3/SP - Fram 2821A - if the OE Fispa FOE 025 is not available).  The Flavia will benefit if you partially fill the filter housing (filter element is as for the Jaguar XK120) before replacing the filter housing top.  This lessens the worrying bearing noises on the first restart.  Do not rev the engine until the oil pressure gauge (see 12 &13 below) shows a significant reading.
  5. Silicone Brake Fluids: this is a copy of a note from Lockheed detailing problems that may well be experienced if this type of product is used.   Consortium members have experienced odd braking behaviour in the past with silicone based fluids: the text is published for information.  Access via the link on the right of this page.  

  6. Battery types: Flavia - type 063; 2000 - type 077.

  7. De Carbon shock absorbers: for Flavia -  (both ends) and 2000 (rear only) may be obtained via: Scorpion Racing, Unit D, The Coppetts Centre, North Circular Road, London N12 0SH.  Telephone 020 8211 4888.  These were fitted as original equipment.  References: V37 1111 23 (front); V37 1112 23 (rear).  Please note that de Carbon are rumoured not to be making any more of these units, as of 12/2007. 

  8. Bosch D Jetronic fuel injection: the link on the right (The ECU) links to a very technical article, which tells you all you might ever need to know... 

  9. Kugelfischer Injection petrol pump: The original Schäfer PLF-5A pump is becoming difficult to source, if the original is not repairable.  The American fuel pump manufacturer Weldon make the JC8150 pump, rated at 30-50 gal/hr., with a pressure range of 5-25 psi (https://www.weldonpumps.com/weldon-jc-pumps).  This should be obtainable from Interex Motorsport Products (01449 721700). 

  10. Wheel bearings: the OE bearing used by Lancia was designed for and exclusively made by FAG and SKF for the Fulvia and Flavia vehicles.  Although it still might just be possible to find some old stock in a small town bearing stockist, this is more and more unlikely as time passes.  The Dutch Lancia Club have developed a replacement equivalent - using an FAG 3210B.2RSR bearing and an adaptor kit.  Details from: http://www.viva-lancia.com.  Members of the Consortium may obtain both bearing and kit from their usual contact, as always if stock permitting.  This bearing and adaptor kit has been trialled by the Consortium, and works just fine.  Update: new OE bearings are available again.

  11. All Lancia technical literature relating to Flavia 815, 819, 820, + 2000 820 vehicles has been gathered by the Dutch Lancia Club onto a series of CD-ROMs.  Details are available on the same website as for item 9 above.  All the documents are filed in Adobe Acrobat format, and each CD-ROM includes an Acrobat reader software download, just in case this software isn't on your PC or laptop.

  12. Starting from cold.  Please be advised: Lancia & C recognised that the original (removable element) oil filter and cooler arrangement on the Flavia did not always prime as fast as was needed from a cold start (or when hot on a very hot day) and published technical circular DICO/SAT-6013/73-RL/cm which said as much.  It is good practice to allow the starter motor to spin the engine for a good 5 seconds before applying choke at a cold start, and resisting the temptation to kick the accelerator to "catch" the engine too soon at a hot start.  The cartridge filter arrangement on Flavia 2000 and 2000 vehicles has no such published limitation.

  13. Low tick-over oil pressure.  - or indeed low oil pressure generally should be confirmed with a proper direct- reading gauge.  The pressure sensor on the oil filter pedestal isn't always accurate (after 40+ years use!) and it may be giving the wrong idea entirely.  Worn bearings will reveal themselves by noise in the usual way...

  14. Changing from 1st to 2nd gear with a stone-cold box can be impossible - particularly the 5 speed boxes - until the oil has warmed and circulated a bit.  Do not force the gear in.  Either start in 2nd gear, if the lie of the land is downhill, or rev it a little more and change direct from 1st to 3rd.  Previous owners may not have been too sympathetic, in which case the synchromesh will not work properly now, and dropping from 2nd to 1st, even double de-clutching with a warm box, will be noisy.  The 1st to 2nd change problem usually goes away after a mile or two.  See note 17 below regarding suitable oils.  A high engagement point at the clutch pedal is normal.

  15. Using the jack.  Unless you have had the cills repaired, and know for absolutely certain that the car body structure is totally sound in this area, do not jack (or let anyone else) under the corners of the cills.  For the same reasons, do not let a garage use a 4 point vehicle hoist on the car.  These vehicles are heavy for their size , and were not designed for continuous suspension at the corners of the cills, even if totally sound.  Each front wheel may be raised by using the scissor jack supplied under the knuckle at the outer end of the lower wishbone - just inboard of the swivel joint.  Tyre centres will lift the front with a trolley jack under the centre cross member, which is beneath the bell housing.  This is OK, but will eventually bend the lower surface of the cross member somewhat. The rear wheels can be raised under each end of the axle, or in the centre of the axle to get both rear wheels in the air at once.  Remember - Safety Assessment At All Times.  In gear, handbrake on, level ground, chocked wheels.      

  16. Wheel alignment.  ALL.  Front: 1 to 2 mm. toe-out, measured on the rims with the car under static load.  Rear: 2 to 3.5 mm. toe-in, measured under the same conditions; which must have been somehow set at the rear axle by the factory, as there is no apparent way to carry out further adjustment!

  17. Gearbox.  ALL.  (except those vehicles fitted with the big 4-speed gearbox; e.g. the Flavia 2000LX berlina and the the Flavia 2000 coupé - see note 21 below)  If you check in the owner's handbook, then you will see that Lancia & C specified oils such as Esso GX90 and Mobilube HD90.  These are your good old-fashioned  90 grade "light" hypoid oils (service grade GL4 or less), not these thin 75/90EP GL5 oils that are used today.  Do not use a synthetic gear oil, but obtain a similar SAE90 oil from a classic car oil specialist such as Morris's of Shrewsbury, or Millers, or Penrite for example.  These may be expensive, but do last a very long time.  Synthetic oils will cause damage.

Sedan RP

Coupe RP

Autojumble Parts

Servicing.

Electrical

Silicone Brake Fluid

The ECU

External Trim

Flavia Handbrake Adjustment

Currency Conversion

Track Rod Ends

Rebuilt water pump front housings.

Torque Values

Rear spring shackle blocks

Replacement air filters

Shock Absorbers

WD40

Distributors

Brake Seals and Pads

Common Parts

Compulsory equipment when travelling on the Continent

Fuels containing bio-ethanol

Replace spring-to-wishbone buffers.

2000 sedan driver's seat cushion repair

Label on big 4 speed gearboxes that only use one grade of oil.


  1.  Kerb weights (for MOT, in kg.).   Flavia sedan: 1190; PF coupé: 1160; Vignale: 1150; Zagato: 1060;   2000 LX: 1240; Flavia 2000 coupé: 1190; 2000 sedan: 1235; 2000 coupé: 1200 
  2. Brake discs - 2000 - re-facing.   Front - original thickness 12.565 to 12.835 mm.  Minimum allowed 11.5 mm.  
  3. Rear 2000 - original thickness 9.390 to 9.610 mm.  No allowed minimum, although allegedly competition Lancia Fulvias were allowed to re-face rears down to 8.5 mm.
  4. Fuels containing bio-ethanol.  It is said that these are on sale now at some supermarket petrol stations, and on the continent to some extent.  In the latter case you will see the designation E5 (5% bio-ethanol) on the pump, although at an English supermarket this is only a partial mix and not we think identified as such, as British Standard EN 228 sneakily allows for blending.  This stuff is causing concern even to those who run vehicles made since the late 1980s, with good reason and especially with carburetter engines.  The link above to the right is to a DfT report which is very thorough and fairly worrying.  You will need the Adobe Acrobat reader (free download from www.adobe.com) to view it.
  5. Those vehicles (see above) using the big 4-speed gearbox have the differential and the gearshafts in separate compartments, each with their own filler and drain plugs.  The comments above apply to the gear train compartment (2.4 litres).  The differential compartment should be separately filled with an EP140 oil, as specified in the owner's handbook (2.2 litres). NB Late 819 2 litre, Flavia 2000 coupé and early 2000 sedan with this box may only use 90 grade hypoid (approx. 4.5 litres) as Lancia revised the lubrication requirement.  These transaxles should have a label (see link on the right) and probably only one filler hole.