oil FORD CAPRI 1974 Workshop Manual

Chapter 11 B odywork an d fitting 1 93
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Fig . 11 .2 6 Heilter control cil blc 1Hljus tm ent
on SlHn (IMd heilter (S ec 40)
A (),.\·/"UlI/Ot flajl COII/ro//aVllr 8 I/Cgll/;I/O( Il.7p con/fo/h'vt'f
"'!ovy dilly IIfHltOf Chl.-r.k thilt Ihe d'Slflhutor 1I"p levc. ,HId WilIC, cont.ollcve. (FlU 11 28) we 011 Ihc cnd ollhl)" Ir,"vel ilnd clamp Ihe oulC, cablcs "I \IllS lIon.
AlllwMCfS 5 On complct ion. reconrWC I Ihe ulove comp;lr llllent liUhtinU leads.
Ihen lelil Ihe Ulove COllll)nltrllell1 nnd reconnet;1 Ihe hnllelY emlh len {1
41 H OMe r controls - removal and refittinu
1 Disconnect Ihe ballery eimh lend. 2 Rcmove Ihe s teer ing column shroud (2 screws D tthe bOliO",. then pull oul .lIlhe lOp). Lo wer thc stee.ing column (lel\Ving Ihe twO bOltS in position) sufficiently to ullow t he inst.umenl cluster I rim to be remOve d. 3 DIsconnect Ihc switch 10MIs ;lnd remove the instruments cluSIO' t"m. COllll)lot e with cowl "im (11 screws). Rcmovc the instrumont clusle r l!clOI (3 scrcws). 4 Pull oil Ihe hOiltor control knobs. II t his IS 1I0t possIble I><cilk thcm wllh ,1 larue pili. 01 pllors then rCl110vcthc conllols (4 scrcws). 00 not d'SCOIlI1CCt the control ci lhles ilt the heiller. 5 l1uI1Iove t he hCilIC' control PiHlCI ( 2 scrcws). ilenlove the b lowcr
sWItch illI(1 light i"'1 leild5 . D,sconncct the cilhles 110111 tho hCiller COl1lrols Rcll1tlllU IS the .evcrse 01 Ihe rcmovi,l p.ocoduro. du"ng whIch It
.. hc neccssmy 10 adjust th e callies. as dl.'SCfllled III the p.evlous ::. .on Also it w,1I be necessary to obtall1 new hCille. control knobs where npphcable.
42 HCHte r
water villve (hellvy duty heater) -IC lll oval an( 1
refittin g
Drilin
the engine coolant ilnd dlsconncct tho lowe. hosc !rom th c ,aulato. (,efe. to Chapter 2. II necessary). 2 Disconnect Ihe th.ee water hoses f,olll tho Wille. valve. 3 Removo the OUWr cilble from the clip on the WilWr v~lve bracket.
Ihen lenlOve the assembly from the bulkhead (2 screws). 4 Twis t the wate r valve. to disconnect the cable IrOI11 the operilt ing
l ever .
S Relilling is Ihe reve'so of the removal p.occdure. during which ~dJustl\lcnt should be m~do. as described in Section 40 fOf the heavy duty healCf On completion. re li t the rudiutor hose and fililhe cooling SYSt(:rll . us described in Chapler 2 .
43 Heater assembly -re mova l and re fillin u
1 DlsconnOCl lhc tJiltH:ry ea.th ICild. 2 -,,,in the COOIIlI1l. rei!;fliny 10 Chllpte. 2. II neCCSSilry. 3 sconnect th e Wiltcr hoscs from the hoale. he;!t e.chanuc. (phOtO). II I><il':ticable. hlow th.ough Ihe heat e.chunger WIth
2111111
- ' = 1 --·-~··&#34;&#34;I c,
'1,:-1
F ig .
11 .27 Heale r COl\trol cilhle ncJju stm ont on heilvy cJllty hl"latot (Sec 40)
A /),., ·{n/w/III If,}!, CQII/lo/ft'vct
Il"'·I·"1>.1 VU[ CO""'OL U·OL(
".."Tt"CO""'OL -NIL\[
Fig. 11.28 Willer varv e o n heavy duty heilter (Sec 40)
43.3 H eiltel water hoses
i , , . ,,
"
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~&#39;l4 Chilpter 11 Bodywork and fitting
~I-----------------------------------------------------------
complessnd ~&#34; to IcmOVI! ,OIly I.nolar ,,,",,,"1111)11 Alh,,,)attv,,lv pl;)c" clothS JII,l/or I1CW~I)ilP&#39;&#39;&#39;S 1)(!I\!;o1th In ,11",,, 1, al'V SI"lld!!" 11 Remov" thc (.over pan,,1. tn!I"lh," wllh II", lw,'t nxch'''''Ie! 10 watel cOI&#34;&#39;~~(:IIOIl \J,;~k...r. f,om th,~ IlLII~I&#34;&#39;,1,J (2 ~r:tI~WS) 5 SlackclI till! !1&#34;o1ll~N&#39;&#34; l(l(.k"(li. 111,·" ""''''Vl) Ihl) !)&#34;oI,I,~vf)f The locknut IClIlIlICS a 5p,,(;'al p"!J Sp""""'. ,IV,HI.lhl" hOIll Foul. hllt It IS lIot
d,fficult to 1;)10'11:;\1" ,1 10,, 1 wh'<.-II which wIll do Ih" 1010 6 Rcmove til.., I'n,r,d I';IV (1 ~&#39;:II!WS) WI""" til",,, IS a celli'" fOI1S<)t.i. this must hc ICmOVl!ri "Iso (lcfcl to SC,.t'Oll 32 ) 7 Remove Ihe strJ(!IIllli coll,"m sl"olld (2 ~n&#34;ws al tl", hOllUm. th(!n
pull out <H the lOp) Low,", Ih" ~&#34;&#34;~&#34;&#34;!I coh'''''' (1&#39;~&#34;VI&#34;~llh&#34; two holts in pOSlllon). slIfflCICllllV 10 "lIow tI", &#34;&#39;~I&#34;&#39;&#39;&#39;&#39;&#39;&#39;&#39;&#39;I Llllsl,,' till,,, 1l'Il\()v"d S RenlOV<l th"lowl" r"cla p.1II,·1. "'''''1'10'1'' wllh, IIV," 1'.111,,1 R"nHl"" the nsln,;,y ;",,1 O:I!I,H"lt" II!II)I," ,,,,,I ,I,'., '"""'0:1 II" , ,.w&#39;h.I,,·~ II&#39;IIOIO~) 9 RI!IlH"''' tl", !llovo: "'''''p.''t''',,''1 I,V ""," "'W"'!I 1110: ~ &#34;,&#34;&#39;w~ oIt Ih" top ,mrl 2 Illns al th" I,olt'"'' AI~o d,'" ,HII)'" 1 II", !11"vII ,.<1'"1',,,111":111 h(JIHlIl!) I&#34;ad~ 1 0 D ,sco'lIH:CI tto,· d&#34;m&#39;~lo:&#39; ,,,,11 1, , ho&#39;,,,~. 1<J!l'"lh", w,lir II .. ,,,
CO'lneCI'Olls (1 '01""W ",II.h) 11 D'SI:OII'H,,:t 110" I,ll.'" ""IIt h&#34;~&#34;,, h",,, 110" 1"'011," TI"·,,, ,',,:") '''' tI'" 'lilnrt;)ld lHloll<;r .",<1.1 "" II", 1 .. ,,,vV d"IV 1,,·.110" ? Rel\\o"" tlo" IIIw,,, d.l~h 1'.,"0:1 ~&#34;I&#39;I&#34;&#34;t ~I&#34;y (1 ~&#34;&#34;w) 13 O,s",,,,,,,,,,t II", C,,,,I,,,I (""1,1,,,, (,'"'' 11,,· 1",.,1", .",,1 11", 10",,10"
J.se Rel\\ov,n\! lire il~ht&#34;)V
hlowef If!a<l,; 11 Removr: IIHI d"""st',, nOl.lles (Ieff)( to Sect,on 1\6, II necessary). 15 Remo"" the wmdsc'ecn WIPCf 1\\ r h'ilcket 1,0m liS mOUlllrnu 16 Rel110Vl! Ih" 1 he,;!!)1 ~eCWUl!J screws, (photo) Ihen pllilihe hemct 1M enOIl!lir ":;HW,ll1l 101 the wme, COllllectlon p&#39;pc~ 10 CICM the hulkhend TIlt the top of Ihe IrC,lIN IIpwa,d and IOIWilld, ,1n<l w llhdlaW .1 sldewilV~, Ihcn 'e'nove thf! fn.1m !FISkel also. 17 Ref'II"'!) IS the ,e&#34;I~&#39;~u 01 Ihe ,emnvill procedure, dlllln(J wh,ch II w,1I he nIlCIl&#39;;~i\&#39;V to ,1dlliSt Ihe h";)I<)! conllols ,1S d(l~cllhed In Sect,on 40. Do not IOlli et 10 I'\lhll)n thl! \lllartl)Vel locknut. On completion, hll Ihe cool"l!1 ~V~I&#34;rlI. as d&#34;~r:,,hed Irl Ch.lpl<~&#39; 2
1111 Heatcr ass(l'lIhlv (Behr) dismantling <Inti rC<lssemhly
Runl""" Ih" d",\I,I",IOI 1I&#34;I&#39;~hol(1 (1 clop) NOI" th,lt Ihe fl.1p ""ll;)UlS II) Ihe 1"""'1 SI,,:tl"') "f the IU)lISI"!! ? R"",ov" tlw ,: I.IInps ~&#34;r.&#34;&#34;n!1 Ih,~ IWO h"lv"s 01 the IIm,s,n!j, "srn!) c"ciop pi"",. Iklll"'" 11\" "I'P'" ~&#34;r:I&#34;&#34;&#39;, ~&#39;Ol&#34;pl&#34;jll w llh tilt, m01o,.from tlw low"" ~&#34;&#34;trOI\ 3 Rem,,,,,, tI,!! 1",.11 !!~d&#39;.&#34;HJ&#39;&#34; ""tI I",m Ih" I"rn,,, Ihe low!!' SCCllnn
43.16 He,ltcI tnounilng holt (a,rowed)
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)96 Chapter 11 Bodywork an d fittings
of the housing, then remOlle the heal exchanger from the 1ramc and lake ott the fOilm pilcking. 4 To remove the distributor flap from the housing. remove the clip and withdraw the conlrollcvcr sideways. 5 Remove the rcgul<110r flap from the lower section of the housing, Bend bJck the 2 claillping straps sulticicnlly \0 enable the conlrollCIICI 10 be withdrawn (liter i, hilS been turned tow;1rds the side, then remove the regulating flilp. 6 Remove the retaining straps for the blower mOlor cap. by pressing outwards from the inside uSing 11 screwdriver. 7 Deweh the mOlOr from the upper sectioll. Disconnect the motor leads, remove til(! <1 rewining clumps and remove the motor and filiI inw,uds. a When reassembling. positIon thc blower mOlOr so that the clectric<ll connections face IOwards the c<lble fastening iI! the upper section Secllw the n10tOl nnd connect the lea(ls. then 111 the mOlor cap. 9 POSItion thc legul<ltlng tI<lP in the lower section nrul inse, the conl!ollcver by tll,nlllg it IrOlllthc side as necessary and SWIllU It roulld 11110 tilc stral)S . Close the straps usinu pliers . 10 POSItion the dIstribu tor tlap in the lower section and IIlsell the
control lever from the si(lc.
11
11 The remainder 01 the reassembl y procedure is the reverse 01 the
r emova l procedure.
45 Heate r nssenlbly (Smiths standard and heavy duty) -dismantl ing and reassem bly
Standard he,1ler I Remove clips A and B (Fig. 11.32) ilnd remove lhe heater housing
sidc cover complete with flaps (15 screws) .
Heavy duty healer 2 Remove clip A (FIg . 11.32) olnd remove thc hcater housing SIde cover complete WIth flaps (15 screws)
All he,lIers 3 Remove thc heat e~chnnger nnd 10,1111 sen I. <1 Prise off the c"clip nnd remove the Ian I.om the blower motor shall. 5 Detach the blowe r motor from the support (3 nuts and holts). 6 Reassemhly is the reverse of the dismantl ing procedure.
Fig .
11.30 Stilndllrd Smiths h eater (Sec 4 5 )
1 M%r assembly
2 COVt·( and black!:t assembly 3 Control valve operatillg le vel
4 Righr·hand housing cover 5 Dis/ributor flap 6 Fan
7 Control v<llve 8 Housing 9 Demis/e r hose connection
10 Heal eXChanger seal 11 Plenum cflambe! cover
-------------------------------~ 灲潣慲浡湵慬献捯m

)
Index
A
Accelerator cilble removal ilnd refining -14 shnft ilnd pedal removal and refining -75 Air cleaner removill Jnd ref,nrng cal buren or mod cis -68 fuel injecllon models -80
P rnator .,rushes inspecllon. removal and refilling Bosch -202 Femsa -203 Lucas - 202
dismantling and rcassembly -203
removal and refining -201 Antifreeze mixture -60 Automatic transmission descrip tion -122
B
downshift cable removal. refi11ing and adjustment -121 extension housing oil seal renewal -121 faull diagnosis -127
maintenance. routine -123
removal and refOlting -123
selector mechanism ildjustment - 126 rcmovill. overhaul ilnd refl11lng -125 speclflf:iltions -103 SI.1r1er IIlh'bilm/reVerse lamp switch remov<ll <lnd refIlling - 127 lorque wrench senings -103 'iliary (driving) light ,oIigrllnell t 212
Bilttery clrilrgmg _ 201 description and testing -200 removal and rcfll\lng -201 Big-end bearings -37. 52 Bleeding the hydr<lulic system brakes -152 power steering -168 Bodywork IJnd fittings -173 el seq Bodywork and fittings bonnet -186 bumpers -1 78
centre console -189
demister
noules reOlov<l1 and refi11ing -197
description _ 174
doms-178.180. 18210 185 face level vents removal and refItting -197 facia panel -188 fuel filler flap -188 heater -192 to 194. 196 10<ld space trim panel removal and refitting -186 -'alnlenance
) bodywork and under/rame _ 176 routine _ 116
uphOISlCry
and carpets -176 mirrors
-
192 open rem quarter glass assembly
removal and refitting -186
re~r qllMlcr trim panel removal and refitting -185 repi'lir millor damaue -178 minor damage -176 sent belts -191 seats -192 sunroof-189la 191 lailgate -180. 187. 188 torque wrench scuings -173 windscreen -180 Bodywork repair sequence (colour) -174, 175 Bonnet release c<Jble removal ilncl refitting -186 removill. reflt1ing and adjustment -186 Bml<ing systll'm -14201 seq Braking system deseriPlion -142 lilUl1 di<lgnosis -156 fOOlbrake ped .. 1 removal ')nd rel ining -152 fronl disc brakes -144,145 handtHake -153 \0 155 hydraulic system bleeding -152
p ipes <lnd hoses -151 n1<lintcnance. routine -143 n1<lSler cylinder -148. 149 presslilc uIHe&#34;~llIial switch removal and relitting -150 pressure reducing v~lve rernov~llInd refining -151 rear drum brakes -146 10148 specif'Cil!ions -142 stop IJmp swilCh removal. refi11ing ilnd adjuSlmeJl1 -152 lorque wrench se11ings -142 vacuum servo unil -156 Bulbs. lamp 'Tenewnl -213 to 217 spcclflcntions -199 Bumpers removal and refIlling -178
c
Camshaft (3.0 litre engine) retitting -54 removal -50 Camshaft and camshaf t bearings examination and renovation 2 _8 litre engine -35
3 .0 litre engine -51 Camshah and front intermediate plate (2.8 litre engine) refilling -41 Capacities. general -6 Carburetlor (Weber) aulomat ic choke
adjustment -71 removal. overhaul and retitting -71
dismantling and reassembly -69 general -68 idling adjustment -73
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)
rernoy .. ' and refl Uing -69 spcc,'iC<ltions -66 Carpets maimcnancc -1 76 Centre console removal .. nd refluing -189 Choke . au tomatic _ 71 Cigar 'ighter romoval ;lIld . e 'ru in g -225 C lock (console mounted) .emoval ilnd 'clming 223 el,/tef, -97 cl seq Clutch assemhly ",speclion 99 relluing 99 remov;]1 99 calli e renewal 100 dcsc.illllon 97 laul l d'''[jnos.s 10 nMlllIon,wec. foulorU) 98 pcd,,' rCIllOVill ,mel fcllUII1\) 10 1 release bca"ng .emoval ;mll wl,ulIIU 100 Speclflc,uions 9 7 Condenser (3.0 lilre models ) lCSI,nu. 'CIllO"'o1' MId refllli,,!) 90 Connecting rods (3.0 l itre engine) 5 1.52.54 Connectin g rods amI gudgeon pins examina tion ilnd ICnov;'Jlion 37, 52 Connecting rods ;lnd pisto ns refi Hing ~ 42. 54 Contact breaker points (3.0 litre models) i1djuslOlCm -89 remov1)1 nnd refiuing -89 Conversion fac tors -18 Coofing system 57 CI SCII Coo ling systcm nnhl.cew ",ixltlle GO desC.i,l liOn 58
d'ilUlinU 59
(IlIvchells
G3 e~p:mSloll I nnk 6<1 Ian hub l)()nllllH (30 hilI] 1110<1111,;) 64 f~ull (II;)Ul1osl~ 65
flll".U -
60 lIush"'9 59
",nmlen,lncc. roullllC 59
'ild,nlOr
GO speclficn llon5 57 lem,)er;!lurc unuuc Sf:n(Ie. unil -134 IhcrmOSl<11 -61 10Htlle wrench selll ngs 57 VISCOUS drlv\! 11'111 -63 W1)ler IWIllP 61 Crankca se ventiln tion system 2.8 tol'c engine -39 3.0 rillC engine 53 Cranksh1)ft 2.8 li l.e engine examinat ion nnd rcnoviuion -37 refilling -<10
3 .0 til.e cn gine examination lind renOV1'l110n -52 Crankshilft and main bearings (3.0 litr o engino) removal -51 Crankshllft pulley refitting (2.8 hIre engine) -44
removal ( 3 .0 litre engine) -50 Crankshaft r ear oil seal (3.0 litre engine) .efllling - 55 .emova l -51 Cylinder bores ~xaminalion and .enovation -36. 51 Indo r heads 2.8 titre engine dismanll ing .• cnova lion and .eassembl y -35
Index
D
refining - 45
3.0 litre engin e
. eassembly -55 refining -55 .emoval wilh engIne -49
removal wil h engine in car -49
Decarhonising -52 Dimensions. vehicle _ 6 Dim-dip lighting system _ 226 Disc br1lke s scc Front disc brakes Distributor overhaul 2.8 hlle engIne -93 3 a !r1l0 cng,ne -92 rcmoval and r efIlling _ 90 Doors eXle.io. hllndle ,emoval and refilling - 183 lock 1Issernbly removal and .efilling -184 pillar swi lc h -224
priVill e lock ,ernovill and ref'lIing -185 fnllics tracing nnd feCllik al ion -178 remOle conlroi hnndle removal and refilling -180 Hlmoval and rell\1l11g _ 185 Irim j>ilnel removal and ,efi ning _ 182 window Irnm c
moul(II ng nnd door wealhcrSlrips
removal and refining -185 rcmoval and relining -185 wmdow glass removal and retilling - 184 window regulnlor nssembly
r emoval and relilling -183 Drivebelt s .emov,,1 ilnd refil ling -63 Drum brakes sce Renl drum brakes
E
Eloc triclIl.system -198 e/ seq Electrical systcm altell11110, -201 10 203
ilu xiha.y driving "ghl -212 bmlery -200. 201 bulbs -199.21310217 ciga. IighlOf -225
clock -223
d escrip llon -200 dim-dip ligh ling syslem -226 laull diilgnOSIS -19. 233 ""sher unils and rel1lys -225
fuse s -199. 220
headligllls -211 10213 horn -220
inSI.ument clUSler -22 1 inSI.ument vollage .egula lor - 226 Inmp5 -21410217 mninlenance. fOUline w 200 mobite r"dio equIpment - 226
precautions - 200
rildio /casse tte player -226 specif ications - 198
speedomeler cab le -226 Slmte . mOlOr -207 swi tches -223 10 22 5 lailgall) wash er -217 laHgme wipef -217 to.que wrench sell ings -199
w indscree n washer -219 windscreen wiper -21810 220 wi.ing diagrams -235 10 249
25'
Ii
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" .... Index
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Engine -23 cl $cq Engine (2 .8 litro) lmcillllries -29. 36 camshaft -35, 41 components e~aminlltion for wear -34 connecting rods -37. 42 crankcase ventilation system -39 crankshllft -37, 40 crankshaft pulley -44 cylinder bores -36 cylinder heads -35. 45 description -26 dismantling -29 fault dingnOSlS -20. 56 flywheel -38. 42 front interm!.lt hate plme -41 gudgeon pins -37 lubriClllion system·-39 main Il!ld big·end bellrings -37 rll(lintenance, routine -26 OIl pump -38. 42 operations possible with eng :ne in car -22 op(!r;lIions rC'quiring engine remov,,' -22 iSlOn rings -36 pistons -36. 42 rC(lssembly -40 refining -46 removal -22 removal methods -22
rocker asscmbly -34. 45 spec ifications -23 start· up after overhau l-4 6 sump -34, 44 lappets ;:and pushrods -35 timing covcr -43 timing gears - 38. 43
l orque wrench senings -24 valvcs -46 Engino (3.0 litro) ilO)cill:lr ies • 49. 55 camshalt •. 50. 51. 54 componcnlS e~.-.minlllion lor WC:lr -34. 51 connecting rods -37. 42. 51. 52. 54 cr.-.nkshMt ventoilltion system --53 Crank~hllh -52. 54 Crtlnkshllh pulley -50
c .t1nkshaft rear oil seal -51. 55 cylillde. bores -36. 51 ylinde. hoad s -49. 55 decarbonising -52 descrif)1ion _ 47 dism.-.ntling -29. 49 faull dingnosis -20. 56 lIywhecl/d.ivepl(lte -50. 52 . 55 Iront covc. -50 hOn! plate -54 gudgeon pins -37. 52 IUbricntion system -53 main and big·end bcarings -37, 52 mainten(lnce. routine -48 oil pump -50. 52. 54 operations possible with engine in ca. -48 operations requiring engine .emov,)1 _ 48
piston rings -36. 51 pistons -36. 42. 51, 54 push.ods -35. 51 reassembly -40. 54
refining -56
removal _ 48
removn! methods -48
rocker arms - 49. 51. 55
specifications -25
sump -
50. 55 pppels -35. 50. 51 !lming gears -38. 50. 52. 54 torquo wrcnch sellings -25
.
villvcs -46. 49. 52. 55 Exhaus t syste m remova l and refining -76 EMpnfls ion tank ( coolin g sys tem) removal and refilling -64
F
Facia pilnel t(!mov,)1 and rcfining -188 Fan hub bearing (3.0 lit r e models) .encwal -64
Fan. viscous d rive remov,,1 and refinmg -63 Fnllli (Jingnosis -19 et seq Fault di,)gnosis
lIulOtl1allC lrnnsmrssion -127 tJ,nkmg system -156 Clutch -101 coolmg system -65 clectf1clll system -19. 233 cnlline -20. 56 fuel system cilrbure uor - 85 lucl inlCCho n -85 IHn,hon system -96 mllnu .. 1 !Je.l,hox 122 p.npeller shaft -131 1f!.1f <lxlc· 1111 ~u$penslon nlld stcering -172 Firing ordcr -87 Flnsher unit -225 Flywhccl/d rivepla te 28 htre engine CMamin,),ion ;md renovlll ion -38 retItling -42 3 a Inre enginc c~amin.-.tiOIl .-.nd .enovatlon - 52 .efllling -55 mrnov.ll -50
FrOIl! cover (3.0 l i lre engino) reftlovnl 50 FrOllt dir oc tion indicator l<lfllp ;lIld bulb 't"'I()vnl and rdIU '"u . 214 Front disc brnkes
c; ,hper
oved'lIul -
145 remov<ll and refntinu -144 d,scs inspection. remov<ll and retltung -145 p<lds remov<ll -144 Front driving j')mp <lnd bulb
r emoval and retnung -215 F ront log lamp ')nd bu lb
rcmoval ilnd rcfilling -2 I 5 Front suspen sio n COIl sprinU removal and refIning -162 duscnp tlon -158 fault dIagnosis -172 h\,bs-161.162 milintenance. routine -161 stabiliscr bar removal and rcfming -163 Strut removal and refilling -162 lorque wrench sellings - 158 track control arm removal and .elilling -164 Fuel (/lid exhaust systems -66 el $eq Fuel filler cap .cmoval and refining -188 Fuo l injection syste m ')CCclcflltor cable -74. 83
air Cleilller -80 deSCri ption - 77 exhaust manifold - 85 fault diagnosis -85 fuel lank. s&nder unit and filler pipe -83 idle mixture ,)djustment -82
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2"4 Index
",-----------------------------------------------------------------1 -
ligh\s operation check -16 w~she( fluid levels check/lop up - 16, 217, 219
engine
crankcase emission valve renewal -16, 27
fluid leaks check -16 oil i1nd filter change -16, 26 oil filler cap clClIning -16. 26 oil level check/lop up -16 1I;llvo clearances check/adjust -16. 46
exhaust system condition check -16
fuel sySlCm <lir cleaner temperature control check · 16. 67 air filte, element renewal 16, 67. 79 fu el fIller renewnl (fuel injection models) --16, 80 fuel hoses condition check · 67 idhng speed/mixture check/ad)llSl -16, 73, 79 inlet tllllniioid nuts/holts UUll1cn -16, 27, 83 vilcuum hoses check -16 ignition system contact brC<lkcr points renew"j (3.0 hire eng1l1e) -16, 89 dlS1riiJulor Cilp, (olor, HT le<lds [111(1 co,1 c!e ,ln/cileck - 1 G. 88 (hst"hlltor lubrication -1 G dwell angle check/~diIlSt (30 hue elllJ'ne) -16. 89 sp,lrk pillns cle"n/re-UJp Hi, 95 sp~rk phl\)s renew· 1 G, 95 limin\) check -16 . 94 real axle 01 1 level check/top lip 16, 133 s~fely prec,HltiollS -12 sC(vice schedules -13 suspension Jnd steellfl!) power steerlllg drivebel1 cond,tlon/tenslon Check 16, 161 power steering fluid level Jlld hoses check 161 steering components condition check -16. 161 suspension condition check --16.161 transmission ~utom~tic tr~nsmission brake b,l lld ~dJuSlmenl -16. 123 i1(,tOlmllic transmission Ionk,lge luhricmion -16, 123 oil/fluid leve l check/IOI) up -16, 104. 123 lyres IH(!SSUres chcck/~dJllst -16. 158 we<lr/d~m~gc check -16. 171 whllels comlilion I:llCck 171 Manifolds (cnrburettor nlodels) Icnlov,,1 and 'Cf'tl"'!) exhnust 76 inlet 75 'nnifolds (fuel injection models) relllov~1 and rell!1Ul(J
exhaust -85 Inlet 83 M ,lIlua l g e<Hb ox (iescriptlon -104 fault di~gllosis 122 f,ve -speed disenIJil!)emcnt o f 5th \jeM - 121 dlSnl~ntlmg -111 exallHnat ion Jnd renovation -119 "'put shaft dlsmantlln\j ami rNlsscmbly -109, 119 mainshalt (lismalllllllg and le,l ssc"li}ly -115 reassembly -119 four-speed (lismantllng -106 examination lind renovation -109 input shah dismantling and reassembly -109 I~ygcar dosillanlhng ilnd reilssellli)ly -109 reilsscrnhly -110 gcarchilnge lever (lour-speed) modlflcmions -111 ma intenance, routine -104 removal and reflu;ng -104 speclficmions -102 IOrque wrench SCHings -103 Manual g ea rb o x ./Ild lIutol1w tic trMlsmissioll -102 c( scq M aster cylinder (brllking s y stem) ovcrhaul _ 149 ~ernoval and relltlin\) -148 tvr'rror
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removlll and relltting lldjustllble exter ior -192 interior -192
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28 Iotre engine dismantling. examination and re~sselllhly -38 ref in in 9 -42 3 0 li tre englllc dismantling. eX~lllinmion ilnd reass embly .-52 [elit\lng -54 removill 50
Pedal ,1cceler,ltOr 75 bra k e · 152 clutch -101 Pisto n an d connec ting rods ref,nin\j -42. 51 Pistons and pisto n rin\js exanllna\lon ,1nd rcoova\lon 36,51 Pi sto ns. connecting rod s il11d bearin\js (3.0 litre cngine) [lmlov,11 51 Propeller shaft 128 d s, .'r/ Prop elle r shaft cenlre bcarln!J r()&#34;l]w~1 12!J
descrip1l011 28 I"ul l (i iaunosis - 131 removat and rel,UlI1U -128 10rque wrench seHlIlgs -128 univers~1 10lllts inspection 130 Pushrods 35< 51
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Rndi,lto r rel11ov~I, Inspcctoon, cie<ln'll!l ilnd ",fIIlIlIO GO Rildiator grille removal and refll\lng 179 Radio/cassette pl,ryer
<emovill ilnd reflttln\J 226 Radio equipment. mobile Iflterlerence- free IIlst;lllat,on ,-226 Rcar ,1Xle -132 e/ seq Rear axle ,1xle reilr cover rClllov,, 1 and rellttln\J -135 axleshah beoliing rcnewill 135 removal ilnd relilling 134 descllpt,on -132 fauit (/lilgnosis - 141 limited slip (hiferentoill -140 rnainterlilllCe, routine -133 overhllul -136 pinion oil seal renewal -135 removal ilnd refltling - 133 specifoCiltions -132 IOrQue wrench sellings -132 wheel stud fenewal -140 Rear drum brilk e s
rear hilckpl~te removal and rclluin(J -148 shoes renewal - 14 6 wheel cylinder removal, overhilul ~nd ref'lllllg - 14 7
Rear lamp and b ulb removal and refttling - 216 Rear number plilte lamp and bulb removal ilnd relilling -216 R ear su spension description - 158
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