ECO mode FORD CAPRI 1974 User Guide

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.00 Chapter 9 Braking system
PR IMARY CUP
SeCONDARY J CUP _ RETA INER SCREW
INTERMEDIATE RING
SECONDAR Y CUP)
STOP WASHEP. WASHE R
PRIMARY ~ (''''')
CUP PISTON ~lJ ~
SPRIN\G SEAT T 1 WAStE:~L~\C Q I~
PRl~lARY CUP ./
SPRING OISC I -1 '" "'~'f" SPRING i SEAT L ,:-\,/(.'.~·, J ' '
RETAINER • \ . '0 I)J-'0'.'.)'. ',:.,' "'f
I -, " ,O"'j')'" I' . I r -h" .
l J i\\"\" ,jl;
~G«1N w: 1 vl";';':' ~ .. '
" r • • {l"t:';" ,: .• ,-; \{. . ' SNAP . \J, ~;'. PISTON RING
--
1\-\1 ijM:\'.' ,J , ~1.1"9 _ ·S TOP SCREW .....
--
SEAL ','
-'---
WASHEA
---, ,

/ /
SECONDARY CUP
Fig. 9 .9 EKplodcd view of tho Teves (ATE) master cylinder (Sec 11)
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- --
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'-- ----
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- . ' , ..... (
F ig 9.10 The Tavos (ATE) maste r cylinder pisto ns as sembled ready fo r reliUing (Sec 11)
12 Pressure di Herent;al switch -desctilHion. removal and refitting
E,lrly mOdels were filled with a pre ssure diHerent ial switch to illurnin~to ~ wolfning l igh t on the in stru men t pilnel in the event 01 a drop in preSsure in eithe/the Iron t 0/ rear hydraul ic circui ts . The switch ir- "'rporates 1I piSton which is kept 'in b alanco' if the pres sures in tho I. and roar ci,cui ts are equal. Howeve/, rl there is a pressure drop in
one circuit. t he pisto n is displaced and the switc h con tacts close .
2 The switc h is loca ted on tha lowe, left .hand side of the eng ine comp,Htrnent and a lthough it was once possible \0 obtain new in ternal
seals these are no longer available. Th e switch may be renewed alone (without Iho hyd,au lic body) by disconnecting the wiring and unsc rewing it .
3 To rernovo the hydraulic body. first tigh t
en a piece 01 polythene shoetinu bene ath th e brako Iluid reservoir fillor cap 10 reduce th a loss 01 fluid .
4 D isconnec t the swit ch wiring.
5 Unscrew the fi
ve union nuts thon disconnec t and plug the pipes.
6 UnSCfew the mouming bolt and romove the unit.
7 Relillin g is a reversa l of removal. but on comple tion bleed the hydraulic system as described in Section 15 .
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Chapter 9 Braking syste'm 153
3
Fig, 9 .13 Foothr<lke pedal cOlllponents for automatic transmission models (Sec 16)
1
Spring clips 7 Clip 2 Washer 8 Bushes 3 Shafl 9 Clevis " in , Spacer 10 Rdl/fn sp,illY
5 Bushes /I Rub/u."r P,lI/
6 Pl1d;1I
172 Stop lilOlP switch iHld witi:lg plug
18 Handbrake -adjustment
)Jack up the ,e<lf 01 the CM ,HJd suppOrt on axle stands. Chock the hont wheels. Fully mleJse the Iwndb'Jke level .
6
11
Early (1974/1975) models 2 loosen the locknul on the end 01 the primMY c<lble then tum the <ldJustment nut unt,1 the levC! 'S Just clem 01 the slap on the feaf axle
b,acket. Tighten the Jocknut.
3 Loosen the locknul on the IIgill·hnnd end 01 the secondnry cable then IUfn the adjustment le"ule until <III cahle slack is Illst eliminated M<lke SUIC Ih<l the ope"ltlng levefs on the b<lckplatcs remain on their stopS (ie lully ,eleased).
Fig. 9.14 Handbrake primary cable adjustment nut an d locknut (arrowed) on early models (Sec 18)
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procarmanuals.com

)4 Chapter 9 Braking system
Fig 9 .16 H an dbrak8 cable adjusting nul (A) on later models (Sec 18) ~&#39;9. 9 .15 Handbrako secondary cable adjustment fonu le and lockn u t (arrowed ) on early models (Soc 18)
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Fig. 9 .17 Hnndhrnke operating lover n n d (llwtment (ldjuSlment gn p ·A' on later models (Sec 18)
'-iller mode!!s 4 LO(:,'I" trw r.al,lo .1dlUS1Cf lust forWi1f(1 01 the 10." axle dillCrcntinl , ;;.~.IIl!J (,.holn). then Sflp,l'ate Ihe ndjus\ing nul and sio eve usinIJ II se.ewtl""cr ["n,'IIO lhe keyed sleove in the bracket.
5 T 11m Ihe lldlu sling nul unlot all c.,l>lo slilc k is eliminated and a cleiuallr.e of I 0 '0 1 5 mill (0.039 to 0.059 in) exists at tho handb'Jke ope.aling 10l'm .. butment points (Fig. 9.17) Temporarily apply the holn(i!),,,kc 10 cnUage t he ilujus\ing nut with the sleeve then recheCk the ildJuSlmcnt.
All models 6 Lower Ihe r.'lr In the ground.
1 9 H ,1"dbrako lover -removal and refilling
Chock till) front whecls then lack l'P thO tcat 01 t he Cllt and SUllport on ilxlc swnds . Rclc~!se the halldbmko . 2 Whete applicahle remove the centre console with reference to Chapter 11.
3 Disc;onnecl the l>fiOlilJy cable from the lower end of t he h andbrilke
lever beneath the etlr . On early mooels baek all the cable adjustmen t
and unhook the c lev is (photo). On lale r m odels remove the splil pin and withdtaw the clevis pin (photo). <1 Remove the SCHlWS and withdraw the gaiter over the top 0 1 th e lever.
S Unbol t the hanrlhtake lever Irom the lIoot. 6 Relinin g is a revetsal 01 removal, but check the handbHlke
ildjustment as desClibed in Section 18 .
19 .
3A Prim ary cable connection to
handbtake lever (early models) 19.39 p.ima.y cable connection 10 handbrake leve r (Iale. models)
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,
156 Chapter 9 Brakin g syste m
Secondary cc1ble (early models) 5 Loosen 1I1c lock.nut ~nd unscrew the adju stment ferrule from the right-hand rear clevis.
6 Remove the split pin and clevis pin securing the secanda.v caulo \0 the left-hand Icar operating le ve l. 7 htrac the clip, remove the clovis pin. and withdraw the pullcy wheel from the lever on the Ical a~le. 8 Remove Ihe cable from the lever.
Transverse rod (later models) 9 Disconne ct the cable from the righi-hand rear opCfating Icvcr by
removing the split pin and clovis pin. to Uncl.p the cable hom the 'Hlnsvcrse rod . 11 Remove Iho spli, pin and clevis pin securing the fod 10 the Icft·h~nd le;!1 operating lever . 12 Slide the transverse rod Irom the guide on the rOM axle . 13 Check thO {luide bush lor wear and dama ge and renew It il necessary by prising il oul and pressing a new bush irllo POSilioll.
All models 14 Refining is a r e versa' of removal. but lubr icllto the lin kage as )scflhed in Section 2, and atljl' stthe cable as (fescri bed in Section 18.
21 VilCUUrll sorvo unit -dosCrilHion
A vacuum servo unit is linod Into the lir,lk e hydrallirc cil cu il. 111 series with I he 111,1S ler cylinde f. to provide assiswnco to the dllver whlln Ihe brake pedal is depressed . Thi s reduces the eHolI le{luired try the driller to oper,lIe the brakes, under all brak ing condi tions .
This unit operates by vacuum, obtained from Ihe indu ction mnni rold and comprises basicall y iI booster diilphragnl and check lIallle . The servo unit and hydraulic master cylinder are connected
t o gether so that th e serllO unit piston rod acts as the master cylrnder pUShrod. The driller's b rilking ellon is trilnsmitted through allot her PIi ShlOd 10 the serllO unit piston and ils built-in COmrol system . The scrllo unll pislon docs not fit tightly inro the cylinder. but has a strong ,lltl flhril!Jlllto ke el) liS edges in COllst ilnt COntaCI with I he cylinder Willi_
23 rilult diagnosis -hrilking system
~ylllptom
-'ceSSllle ped,,1 u;tllel
nrakcs pull 10 ono Side
Or;tke ludder
E~cessive eHor l to stop car
so ensuring an i1inigh t seal between the two parts, The fo rward
chamber is held undelllaCUUm condi tions cleilted in the inle t manifold of the engine and during periods when the brake pedill is not in use, the controls open a passtlge 10 the rear ch ambe ., so placing it under lIacuum conditions as well. When the b.ake pedal is dep.essed. the lIacuum pass.Jge to the rear chamber is CUI oH and the chamber expos ed to atmospheric pressure. The consequent rush 01 ail pushes
the servo piston lorward in tile lIacuum chamber and operates the main push rod to the m.Jster cylindcl. The controls are designed so that assistance is given under all condllions. When the brakes are 1'101 requ ired, vacuum in the rear chamuer i s .e -es tabl ished when the br.Jke ped.J1 is released . All air Irom the atmosphe.e entering tho rear ch.Jmbe. is passed through II sma ll air trlter. Und er normal opcr.Jting cond itions tho IIflC(IUm serllO unit is lIery relraule and does not require ollerhaul e~cepl at IIcry high mile,1geS. In this case it is far bcner 1 0 o bta in a serllice e~hange uni l. r,1the, than rcp;ti . the o,igi'lo11 unit . Although inlernal components we,e once .Jv'lIlaule 10 ' ovcrhauling purposes this service has no w been
d,scont,nue(t .
22 Vacuulll servo unit _ remOlla l MId re filtillg
I RemOIlO the master cylinder as desc.ihed In Section 10. 2 D,scolllwc l thc vacuum hose from the non·return lIalve on the serllo \lI1it. 3 Work i,,!) insido thc cal. remOlle th e lower l;t cia panel below the stccring column. 4 E~tractlhc clip and l)ul1 outlho clellis pin attaching Ihe push.od to the l ootu .ake ped;t!. 5 Unsc.ew the nuts securing thc mount ing b.ack.et to the bulkhead.
then withdraw thc serllo unit and bracket from the engine COlllp,lJtlnen t, 6 UnSClew th e nuts ar1(1 serlar,lle the braket 110m the SCIIIO uni, . 7 netrning IS;t rell e.sal 0 1 remOllal w ith leference .Jlso 10 Section 1 0 when retrumg Ihe master cylrnder.
Renson(s)
RC.Jr blake self adju sting mechanism faulty All i n hydrilulic system
WOIll or cont,llllina led /rnin{Js Seized Caliper or wheel cy linde r
E~cessille run-out or distortion of discs o. drums
Worn Of cont aminated linings Brake backplate or caliper l oose WOIll suspensio n bailloints
SerllO unit faulty
Worn or conwmin.Jted linings
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)76 Chapter 11 Bodywork and fitting
General description
The body is of all-s teel welded construction with impact ilbsorbing hont Dnd rear sections . Anli-burSllocks nrc lilted 10 the doors, ilnd the
t ailgDte is supponcd by \J<ls- filled d ,lmp crs. All window glass is of toughened safety type. The front seots Me 01 reclining bucket type. whde the '(Jill sealS mJy be of individufli bucket type or bench type. The level of lIim both ;IHellor ,H1(1 exterior vanes accordll1lJ 10 the Pill!lCular model.
2 Routine nwintenancc
AI the in1erVills speCIfIed in the Routine M"IIl\cnilnCe section in the front 0 1 the nl<lnual c,my out the lullowlI1!J procedures.
Check seal bellS 1 ThorouUh1y check nil sent hellS 101 frayu10 . cu\s, <I,unage Or dctCHnrmion and If ncccssnry Ii"new thell) . Check lor sccu"ty
iheck and lubricafe bonnet and door locks 2 011 the bonnet lock ilnd sillety c~tch ilnt! check thilt they oper~lle correctly. 3 011 illl the (Ioor check strilps ilrld lock hilrwls 4 011 the luel 1IIIer CilP hlnw:! ilnd lock
Check underbody protective coatiog 5 W,th the CM supponed on i1xle stilnds. check the cond,tlon 01 the un(lelbody protcctivc coating. i1nd wherc neceSSilry clean <lny dilll1ilged i1rCilS ilnd ~pply il ncw coming. It the car is 51111 wrlhlll the corrosion w~rranty period check the terll1s illld conditions 01 the
w<lrrilnty lirs t.
3
M,,;ntcll<lI1Ce ~ bodywork ilnd underfrilme
The gorH)!<l1 condlt<on 01 iI vehicle' s hodywor k IS the one thin\) that SluruhC<lntiy Mlects ,ts v<lllle Maintenililce is easy but needs to he leu"lilr. Ne!)lcct. p;lItlctllilrly <liter mU10r dama\}e. C,)I lead qUIckly to hllther delCIIor<ltlon and costly !Cpolir hIlls It IS <"'ponant ;rlso to keep watch on those palts 01 the vehlde not lIl)lllcdr;'tllly vl~lblc. lor IIlstance the undersIde. Inside "II the wheel ~II(;h(ls ,l"d th(l lower pillt ')1 th e engine COlllP'IIt"'Cnt. The bnSlc 1l1&#34;inlen~IIl{;c rOutlile lor the hodywork is wilshlllU -')rder"hly WIth <l lot 01 wnlCr. !rom" hose . T1l1s WIll rcmove 1111 the
ose solids which lIl.1y have stllt:k to the vehIcle. It is i",portant 10 Ilush these oU in such a way ilS 10 prevent \}lIt 110m scratching Ih(l Irni sh . T11e wheel arches o1I1(f unded'nrne need w~lshln9 in the s;rrne
Wily to remove any aCCUIllUI,lted mud whIch WIll retillll mOlslu re <llld tend to encournge rust. P&#39;:lIado~ically cnough, the besl timc to clC.1n Ihe urrderl,arne and wheel ilrches is in wet weill her when the mud is Ihoroughly wei and 5011. In very wet weilther the undcrfrarne is usuilily cleaned 01 large ~ccumuliltions Jutorl,"l1cllly amf this is a good lim(l
f or inspection. Periodically, except on vehicles w'lh iI wax· bnsed underbody protec tive cO<lling. it is 11 good ideil to have Ihe whole 01 the underframe 01 the vehicle steam cleaned. engine compartment included. so Ihat a thorouuh Insp(lction C<1l1 be ca"ie(l out to see Wh,lt minor repilirs ,lnd renoviltions are neceSSilry . Steam cleaning is available at many g<1lage5 and is neceSSilry for removal 01 the accumul<ltion 01 oily g,ime which sometimes is allowed 10 become thick In cer t<lin areas . If steJm cleaning f<lcilities are not i1va;!aole. there nre one or two excellent grease solvents aVilililble which can be brUSh <lpptied. The (Iir( can then be simply hosed off. Note thaI these methods should not be uS(ld on vehicles wilh wax·based underbody proteclive coating or the coaling w ill be removed. Such vehicles should he inspected i1nnualiy, preferably just prior \0 winter. wh(ln the underbody should be washed down and any damage to the wax coaling rep aired. Ideally, a completely fresh coat should b(l applied. It would illso be worth conSidering the lise of such wax·hased jotection lor injectio n into door panels, srlls, box sections. etc. as i1n i1dditional saleguard a\Jilinst rust damage where such protection is not provided by Ihe vehicle manufacturer.
After w<lshing paintwork, wipe 011 with <l chillllois lemher to give an unspoiled clear finiS h. A coat of clear protective wa~ polish will gIve added p rotection i1gilins t chemiCill pollutants in Ihe ilir. II the pilintwork sheen hilS dulled or oxidised. use a cleilner/poli5h(lr comhinntion \0 restore the brilliilnce 01 the shine. This lequires il l'llIe eHort . but such dulling is usually caused b(lcause rcgulilr washing has been neglected. C<lIe needs t o be Inken WIth mewl1ic paintwork, as speciill non·"brasive cleilner/polisher is required 10 lIvold dllmaue to the fInish. Alw<lys check thM Ihe door and ventililtor opening drilin holes and pipes <lre completely cle<lr so Ihilt wilter Ciln be drained oul. Bright work should be tre<lted in the Silme wily ilS pllint work W indscreens and windows Ciln be kcpt clear 01 the smeary film whrch oftcn appenrs by the lise 01 iI proprielilry gl1l5S cleaner. Neve, use any lorm of wax or other bOdy or chromium polish on glass.
4 Mnintenllnce -upholstery MId eMpets
Mats and C<lrpets should he h,ushed or VilCULU!! deill1ed rngulJ' Iy to keep them free of gilt. II they <lre badly stilrned remove Ihem hom thc vehicle for scruhbing o r sponging Jntl m<lke ql,ite sur e thr:y art) <f,V before re!rlling. Scms and mtcroOI tlim p,lnels clln he kept clean by wiplll!J WIth <l damp cloth. II they do hecome still ned (which '-:<111 he more <lpp<lrelll 011 IIgll1 coloured upholstery) use <l illlie ilq",d deter\Jent ilnd ,1 soil nllli brush 10 scour lhe \}rime out 01 the ()lalll 01 the rnnlerinl . Do nOI 10r!Jetto keep the he,ldlining clenn in the same w,1y as lhe upholstery. When using liquI{1 cle,1ners mSlde Ihe vehie.l e do not over-wet the surf!lces beinu cle<lned . Exces~lve damp could !Jet inlO the 5e,IIns nnd padded in1erior C.1USil1n sWins. offensive odours or evell rot II the IIlside of the vehicle gets wet accidenl.1lly it is worthwhrle t;lking some I,ouble 10 dry il out properly. par ticularly where cMpet5 i1re involved Do rlo/lc,we oil or clec/,ic helllClS illsiclc Ihc vchicll) lor tllis l!Urposc.
5 Minor body dnnl<lge -repair
rhe phOlo{Jr.1phic SCl/rICIICCS 011 P,IflcS 174 ilfld 175111051'.11" Ihe OIWfil/iofl$ d"lo1Ifcd ill Ih" 101i0willY suh·SCC(IOII$. Note: Fo, mon' (il-1,1iIL'd ili/OlilialiOIl 01/)01/1 I}odywork fCfwir. Ihe U"ylll:s P"hlislllilY Group pu/)/ish II book by Lilli/say POller c!llIed The C,If lJodywork H"II,11f Mill",al flII:~ lIIeorpor"ll!s ;lIlo,,,,,l(ioll on sllcli <Is/wets as rIIsl (rcallllc,rl. Ih1!IJlin!/ <Ifill 9',15S frb'l) ((!p,1irs, ,1S well ,15 rlvlilffs olr 11/011) <1fll/JllioIlS rcpai,s IIIvofvirry weldlllY i",d p,lltel belrlillg.
Repair of minor scratches it) bodywork II the scratch is very superllclill, MId docs not penetrilte 10 the Illelill 01 the hodywork, repnir is very simple. LIghtly rub the area 01 the scratch with a pilintwork renoviltor, or il vcry line CUtlll'\} p<lSle, to relllOVe loose paint frOI11 thc scratch and 10 clear the surrOlllldlll\J hodywork 01 Wil X polish. Rinse the alca woth cleMI wilte,. Apply lOuch·up pnint to Ihe scrntch using iI IrIle p~1I11 brush, continue 10 apply fi ne faye rs of point until the surlilce 01 the pamt ,nthe scril lch is level with the surrounding p<liIllWork. Allow the new p<linl nt le<lst two weeks 10 hMden: then blend it into the surrOUlld in\}
pa il11work by rubbing Ihe sC/Dtch men w ith iI pilintwork renovator or a
very line culling pils te. Finally, opply wax polish. WhNe the scrotch has penctrDt(ld right through to the metill of the bodywork. causing the mowl \0 rust. iI d ifferent repa ir lechnique is
required. Remove any loosc rus t fronl the bottom 01 the scra tch with a penknile. then apply rUSI inhibiting paint 10 prevent the lormation 01 rust in Ihe future. Using n rubber or nylon appliCiltor fill the scratch with bodystopper paste. II requ ired. this paste Ciln be mixed with cellulose thinners to provide a very thin paste which is ideal for filling narrow scratches. Before t he stopper·paSI(l in the scratch hardens. wrilp il piece 01 smooth COllon rJg i1round the lOp 01 J linger. Dip the finger in cellulose thinners and then quickly sweep it i1CIOSS the surlace of the 5topper-pJste in the scratCh: this will ensure tha t the surfilce 01 the stopper,pilste is slightly hollowed. The scratch can now be p<linted over as described eMlier in this Section.
Repair o f dents ill bodywork When deep denting 01 the vehicle's bodywork hilS taken plilce. the
first wsk is to pull the dent out, untrl t he affected bodywork almost
procarmanuals.com

17 8 Chapter 11 B odywork and fitting
If the owner is renewing ~ complete component himself. he will be left with the problem of IlIldmg a sUI1<Jble p;linl for finishing which is compJliblc with the type of pl,lSt;C used. Alone lIme the use of il uniVCfsat pil int was not possIbl e QWII10 [0 the complex '<loge of plastics encountered in body componelll applicillions. Standa,d paints. generally spc1Jking. will 1101 hond 10 pl<Js!ic Of rubber satis factorily. However. IllS now possible to Obtain a plastic body parts finishing kit whIch consists 01 a prc ·primer treatment. il prime, ilnd coloured top COD!. Full II1S1rUC1,ons alc nO"ll"liy supplied with a kit. but bnsicaliy the method of use is to f"st apply the pre -primer 10 the component concerned [lnd nllow It to dry 10' up 10 30 minules. Then Ihe prime, is ~pplred ~Ild left 10 dry for all'.Hrl iH1 hal" uelo,e finnlly npplying Ihe special colowed top coal The result rs a co"eclly coloured campanellI whera the paUlI wrll fle x wrth the plaslic a. r ubUer. a property Ih';l standard parnl docs not normally possess .
6
Major u o d y damage - repair
Where serious danHlge has or.cur",d or la,ue aW<lS rllJed reneW;ll due 10 neglect. rl means cerlirrnly th.n r.o'''plC:tely new ~cr.trons or parlels wrll need welding Ul <lnti th,S rs hest tdt 10 profcs~ronals. 11 the d<llll<lge is due 10 imp<lCI rl wdl ,llso he necesS<l'y !O conlplctely ched the <llignmenl of the hodyshell ~Ifl,ct&#34;re Due 10 the prrnciple of ~nlslruclion Ihe st.englh <lnr! ~h.;p(! of Ihe whole can fJC "ifeclCd by dnma(le 10 01 p<lrl In such rnstance~ Ih" s".vrc(!s of <l Ford o1W"H with speci<llrst check'n(J JilJS ilre essc:nllal If a Ir;u11O rS Ic:fl mrSirlr!lned it 'so li.st 01 illi. d,lnUerolis as tlw velur.le Will nOI h.lrnlln l>roperly and. secondly. nneven slresses w,1I be Impos".r nil tli,! S1o:"rmu. (!n\l&#39;n(~ nnrt
Ir<lrlsmission. Cillrsing nbuon",,1 W"i" or r.ompl"l" l;rrl"", lyre w,~ar mily illso he excessive.
7 Door r<lttles -trllcing and reClificatior
The most common C<llrSe of door rallle~ rs ir nHs'rhuned. loose or worn striker pl:ue. Other c(luses Ill<ly be
(,1)
Loose door or window winde, ",,,,dft,!; (Ii) Loose 0' lIIiS.lliUned d(Jo, lock c(lillj/olJC!lJl~ (c) Loose or worn relllOle con/iol ""."/."";",i$III
2 It IS quite possrule 10' r,rllies 10 he the ",suit of" [O,,,lrrllirl,Orl 01 111<.1 atrove laullS. so a c;,r(:/ul <.1xanrrrr;riron should he rn",h, 10 ilCIl'UllU1e III<, exact CillrSf:! 3 If <l 's Imrnd Ilec&#34;,;~.rry to ,rdl',:;t lit(' sl"\..'" pl"I" (phOIO). t:1osr: til" door 10 the llr~t 01 Ill<: Iwo locking P()~lt&#39;ons. Vrsu;rlly check the <l;laliVe ntlrlude of the strrker Olrts,de ed\Je to Ih,) lod suppo,t pl"le edUe. The
cd\Jes A and B (FIIJ . 11 1) should I", p,Hirl l,,) ,md "an he d1ecked by slrrnm\J a torch tlrrou\jh Ihe dOllr \Jap lrom "iJovo 'Irld Irelow the strrker • Cheek the <l1110Unl I,y wh'cll the door Slarrds p'oud 01 the adlaCerll ,,~nel. AdJustlhe strrke' pl;rte as IWCE;s~,lry to olJt<lrll a d&#34;l1en~rOr1 01 6 0 111m (024 rn) .
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7 .3 Door striker plate
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(.'----+"<, --'-1 ------<0
00>-----1\.. -~--.
F i!J.1l.1 A lignin!J the s triker 10 lock support plnte (Sec 7)
Edyes A and lJ shoold be 1'.1(.lllel
A
'0- - -- . ,
,'---I.::i.I I ,
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F ig 11.2 Lock claw·to·striker cleiHance (Sec 7)
A -70,11111 (028111)
5 Wrlh t he lock in the open positron. check the lock cl<Jw strrke< cleoll""ca (drmensron A in Frg 11.2). This should ha 7 0 mm (0 28 in) and can Ire checked uy plilCIt1(1 <l sm<J1I hall of pinstrcrne. or simllJr
milterral on Ihe siroker POSI ,lnd cheding Its hergllt n!tar gently closll1g the doo •. The striker plale call be reposnroned verlrC<llly to Obtilrll thiS
d lmensron. bw t~ke Colle 10 not to dislurb any prevrous milral se1\lI1gs 01 Ihe pl,lte.
8 Bumper s -removal nnd refitlin g
FrOIll bumpN 1 D,sconnect the u<.rttery earth lend. Also where necessary dis connect the IIldrC<Jtor wrrrng. 2 Remove the r<Jdrator grdle (Section 9).
3 Renlove the fOI" bumper rewining screws (pholo) nnd hit away the bumper. On Imer models drser1!lage the bumper corner sectiOns f,om the body side clips as the I)umper IS wnhdrJwn. <1 Refrl1ing r$ the reverse 01 the removal p.ocedure. but do nOI fully truhlCn Ihe uolts unlrl tire bumper is correclly aliUned .
Rear bUll/pel 5 Open the lJ.tgate. Ihen rernOve the mal ilnd the sub·floor. G Remove the Jack ilnd washer water reservOIr (where applrcable) . 7 Remove the two nuts. Sp",l(J wilsher and 11m wilshers. <Jt each end and lilt away the bumper (photo).
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inlet manifold - 83
main system components remova l and refilling -80 m~intenilnce, routine -79
specificiltions -67 to rque wrench settings -67 Fuel pump carburettor system cleaning - 68 re moval and refilling - 68
testing -68
fuel inject ion system removal and refining -80 Fuel system (carbureUor) accelera tor cable -74
accelerator shah and pedal - 75 air cleaner - 68
carburetlor -66, 68 to 73
description -67 e~ haust manifold - 76 lault diagnosis -85 luel pump -68 fu el wnk -73, 74 fu el lan k fille r pipe -74 fuel tank sender unit -74 inle l manifold -75 mainte nance, routine -67 specifiCiltions -66 torque wrench senings - 67 Fue l tank cleaning and repai r -74
filler pipe removal and re fi\ling .-74 remova l and refilling -73
sender uni t removal and ref il\in g -74 Fuel tank sender unit (fuel injection models) -83 Fuses
G
general -220 specifica tio ns - 199
Gearbo~ see Manual gearbO K Gudgeon pins - 37. 52
pdbrake adjus tment -153 cable(s} and rod removal and refilling 155 lever removal and refitting -154
warnin g hght switc h -225 Headlights alignment - 212 assembl y: removal and refilling ~ 211 bulbs renewal-2 13 Heater assembly: diSI11(lntting and reassembly 8ehr - 19 4 Smiths standard and heavy duty -196 assembly: removal and ret.tting -193 contlols
adjustmen t -192 removal and refilling ~ 1 93 water valve (heavy dUly heater)
removal and re fitting - 193 History o f tho nlodal-5 Horn faul t tra cing . remova l and refilling -220 Hubs, front
bearings renewal -162 removal. ret lu in g and bearing adjustment -16 1 Iraulic systam (brakes) bleed ing - 152 pipes and hoses removal and refilling -151
Index
Ignition switch and lock -224 Ignition system -87 el seq Ignition sys tem amplrlier module (2 .8 l i\(e mode ls)
r emova l and refilling - 94
condenser (3. 0 litre models) -90 COntact bre aker points (3.0 litre models) - 89
description -88
dis tributo r -
90. 92. 93 fau lt diagnosis -96
firing order -87 mainteMnce. routine -88
spare plugs - 91. 95 speci fications -87
t im ing -94
torque wrench settings -87 In strument cluster ill umina tion switch -224 removal and refitting _ 221 Instrument voltage regulator removal and refilling -226 Interior lamp and bulb
removal and refilling -217
J
Jacking -7
L
lubricants and fluids recommended - 17 lubrication chart - 17 lubrication system
M
2.8 litre engine -39 3.0 litre engi ne -53
Main and big·eOld bO(lrings e~amination and renovation -37, 52 Main bearings (3.0 litro engine) removal - 51 Maintenanco , routine bodywork and fillings d oor ch ec k straps security check - 16 locks, door chec k Straps. tuellilte r C<lll flap lubricalion -16 locks operat ion chec k - 16 seat belts wear/damage /security check -16 underbody protective coati no chec k -16, 176
upholstery and carpets - 17 6 windsCtee n illld windows cleilning - 16 braking system
h andbrake linkage lubricat ion -16, 144
h ydraulic fluid levul check /lap up - 16 . 143 hydraulic flu id renewal -16. 144
line s and hoses check -16
pads ilnd shoes we." check -16 , 14 3 servo check -16 . 144 vacuum hose check -16 Clutch adjustment chock -16, 98 cooling syslem
coolan l leve l chec k/top up -16, 59 coolant renewal -16, 59 drivebelt condl tion/wnsion check -16, 59 leaks check - 59 electrical system
ballery elec tro lyt e leve l cheek /top up - 16. 200 equ ipmen t opera tio n check -16. 200 headlamps cleaning -16
253
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