check engine FORD CAPRI 1974 User Guide
Page 43 of 205
42 Chapter 1 Engine
28 G TempO'i1'y holl 101 IOC;l1inO the mlc""t:thiUo: plale 29 5 0'1111(1 the )l'~10n linUS 29 7 0,11I1{J the cyllnde. hOlo
";; '. '''' . :~ .,
.. : .
..-2 9 8 US'''H (I plSl0n "l1g compressor when uiSerhn!llhc p,ston "110 the hore 30 2 Chet;kln~1 the Sial) washer I)OS'['OIl on the 0,1 pump d""csh"fl 31.3 O,llhe tlywheel holls bel o re ',",ng
(j 1,1 II", two f.t:"11'~ holts ItI1!jl.:r·"!lhl then 101 ;Hlorlm' two holls t'''''IHH""ly 1o. IIU:"I"'!I purposes T'!Jhtcli the CCIllle sec"""!J hails th.·" It''''"Yll the '"ml""'''Y Io,u "d 1000,umU bulh (photo)
29 P istons Hnd COIH1(!cli"g rods -refitting
WI, ... , ('.101,1" the COIU1I;:(.I,n\l ,ad h"U of tll c !l0U·end bO il'lIlll 1111d rh e IInde,sulu ollh(l ~hcll h .... "l1y ;lnd IIIIhe sh ell hc"rlllU "' pO$IIIOn WIth It S Im :, IIUI!llonuuc OIl!"'!I'!!! with the COH CSpo tUhnU CU[-OU1 ",the lad :1 If II", old hC.l.II'!)S 'lrllnea.ly n.;w nlld nrc hell'U re!ltu:d Ih en ensure Ihey inn ,dlll"d III Ih"" cO"I.'Cr 1000.UioilS on the COUOCI ,ods :1 The 1%lOn5 , c:;()n ll'l",,~ With c:;onm;c:;t"'u ,ods. mo f,tted 10 the" IH,::es from th(l lOP 01 Ih'! block
'1 luc ilte the p'stoll ""u Hap s III th e 101i0w inU rllilnnCI .
TOil 1['0' fr Olll Ollt· sir/e of /l,e Oil conl,o l 'IllY "ehc.1/ t'xf/8mle. y,l!) Cellt", 150 /tom lire O/Jilosi/e SI(/e of fire Oil cOII(101 ""Y l,el,cM cx,r.lnr/<!l ya{J
Bo/lom or! cOll/,,,1 ""9 HeI,cal eXI',lIIdel' 01l 110s,/ e I/IC /II,lfAed {J,S/OII "on / side
ad cOIl/,OI ''''y, III/':"llrHI',J/c lings 25 film (1 0 ill) c.,,1/ sie/e of tllC /Jchcall;xl1amh'l 9,7/'
5 Well lulJllc~le Ihe pl~lon iln d ring s w il h e ngine oil (phOlo).
6 Fit n unlve.salring compressor Imd I>'epalc 10 insell Ihe fllsl p'Slo n IIItO IIw ho,e. Mnke sure 11 is Ihe corrcct piSlon·conneClinu lod ilSse'l.hly 101 Ihill par',culil' boro. Ihillthe c onnecting lad is Iho COII(.'(:I Wily .ound and th3tthe fron t of Ihe piston (mmkcd with an arro w 01 11 notch) ,s 10 Ihe fronl ollhe engine. 7 Lul )l'Ciltc Ihe Cylmd,:r \)o,e (photo) and inserllhe conncCllIlU ro d a"d p, ston nsse ",!;ly ,nlO Ihe cylinder !loro up 10 Ihe botlom of the pislon IIIllJ com plessor 8 Genlly hUI f,,"'ly Illp Ih~ l/ls!On Ihrough Ihe piston "ng compressor nllu "'I u Ihe cyhnd er 1)(.1'''' uSlI'g Iho shah 01 a hammer (phOtO) 9 G".""nu~ly luh",c"I" 11,,, ,,"ank,),,) 10U"",ls with engllle 0,1 JII{ltu.n Ille ClI,nbh;,lt so 11\1,1 III" e'<lnkpin 's If) Ihe mOSI advanlageous
POSIIUHl 10' Ihe CO'"1(JI:I"'(I .ods 10 il(! dr l.w n \)lIto" 10 WOlle !:In,l n rhe cOIl''''CIi''U ,ad heillOflU Cilp ilild hack 01 the 5 1 he<lIlIl\J. ,IIId f'llhe Sh<..'11 henllng III pos'1I 0n ellSI""'U Ihilt lho local '
10llHue ill lh e b<lck olthe hClII"'U cIlU"ges w'lh the locating groove
Ihe cO""OClmg rod Cill) 11 Gcn e.ouSly lulmc,lI e Ihe shell h,)IHIlIU ,lIld oller up lhe conncct' .od bCil''''U cal> 10 Ihe connect,n n rod 12 Ret,n,nu the cU'U1eCtlf'H lod lillIS, 13 Tluhten the nulS w.lh a 10f(lue wrench 10 the sllCc,hed SClling 14 When "II Ihe p'Slons i1nd conneCI",u ,uds h,we b(lcn filled. rO I,' the Cf.1l1ks hillt 10 check Ih"l eve'yl""'u 'S Ilec. :Ind Ihill Ihere are' hiUh SI.>OIS cauSi ng bUl(llIIg
30 Oil pump -re fitting
Ensure the l1lillmg lilces 01 Ihe 0,1 pump ;Jnd Ihe clankcase n cle'lIl . 2 Inse.1 the hexilgo nal 0.1 pum p drivesh"fl wilh Ihe pointed en lowil,ds the <1ist"bulor localion. The SlOP washer (photo) must IJ posil ioned 127.5 mm (5.020 in) foom the lounded end 01 t h driveshilll 3 FII th o od pump 10 tho cfankcose and secure wilh t wO boll "9hle llcd to Ihe spec,f,ed 1 0'(lUe N ote: When a flew or overhaoled 0 pump is bl!illY IiI/cd. II should be /illed wilh enyine Olll1l1d lurned . b hand 101 om: comple/e ,evolution before being fil/ed. I his will po"" /he plm.p
3 1 F lywheel and clutch _ refilling
1 Fir Ihe engino IIdap lol pla le on Ihe twO localing dowels 2 Ensure Ihe milling faces of Ihe lIywhc(;1 and crank shaft arc cleal
,lnd fit t he flywh eel 10 tho Cliln kshnll. aliUn",U Ihe nla,ks made ii' (hsrn;Jnthny. unless n ew l>arlS a.e being lilted
procarmanuals.com
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46 Chapter 1 Engine
35 Vnlvo clearances -checking lind adjustment
Adll'S 1 the inle t Jnd c~h"ust villvc clcnrnnce s when lho engine is cold, he lween 20 <Inc! 40'C (68 i1rl<l104'Fj. Clear,1nces ille impor tant II the CIC;)IilIlCC is 100 !J,eil1 the v,1lycs will 1101 open as fully as they should. They will ;lIsa open 'ille 1111(1 close early. Ihis will alfcel the engine perform,mec. IIlhe ch!"'anccs arc 100 smalilhe valves mlly not close COnl l)lelely which could resull in lack 01 compression and ve,y soon. hurnt out valves .md valve SOillS 2 When tummy the cngmc dUflng valvo clearilllce adrustments ,llways 1l11111ho cnuulC ulthe duoel'0n 01 norlll;")1 10\<lI;on hy means 01 a ~1)illlllCl on the puliey nul 3 Tt"" tht! cnyulC imd <JlIgn the C!llnksh<1ft pulley 111;l,k With tho O'I11",k on the 111111111) cove. 1 If Ihe c.,lnksh.111 pullev IS 10t.1ted Unckwn.ds ,lilt! IO.W,l.ds sl'ghtIV.
th e valves 01 N o 1 or 5 cy lll1(le l Will he seen to be rocking (the two lOCker .1.ms movlI1(J '" oppOS'to tlireCt,ons). If thc vlllvcs 0 1 N o 1 cylinde • .1IC lockll1~J. ,Ol:lhl the CI:lllksllol ft th.ough 360' so thl1l those 011 No 5 cylinde. ,lie ,ock"'!J 5 W hen the vlllves oj No 5 cVhnd':I :lre In thiS position. check the v:llve cle.1 .. lOlces 01 No 1 cyhndc, by IIlseillng a leder gnugc 01 the
S llcclfled thickness hetween Ihe lock e ' ,'1111 :lnri the vnlve stem. ArlluSt the cl("II:lncc. It necess,"Y. hy hlmong the lOCkCf null ndJushn!,l screw 1011111 the speCified cfenlnnce IS obtained (1Ih010) Inle t nnd edlo1u~t v;,lv'~ cle;IIances a.e rh(/.!.ell\. 6 II the engine IS now IOt,~tcrl '/301 II hun the v.1lv .... s 01 N o 3 cvlll"l!":r w,1I he rockul~J ,111<1 the v;olv"s 01 No ,I CVlll,!s,!r r..1I' he checked ,lnd I1dJus t()d .
7 Proceed to ;"Idlust Ihe cf":II:II'CCS .1I:COrdrn\1 1 0 th" '''rnO o!(ler ;"IS lollows. F,U 1 .8 shows the cvlOildel IHHllhe.s "nd valves Irsl .... d OIl tllell eou eer o.rlcr. wo,k",U Ilorn Ihe llOlIt 01 the engone .
Valves rocking No 5 Cldimler No 3 cylm(lcr No 6 cylmticr No 1 cylll/tier Nu 4 CylllltilH Nil 2 cylll/tie,
Villves to ndjust No 1 cyltll(lef (ill. ,'x) No" cyllmler (III. ,'x) No 2 cylm(lcr (ill. ex) No 5 cylilltier (cx. ill) No 3 cylmdcr (ex. IiI) No 6 cylimft'r (ex, ;n)
8 r-11 the rock er COV~!' U,1skcIS ;IIHI rockc. covers (photo). T 'Uh ten the S(!C'''rI1 !) holts to Ihe speCi fied twqllc
~:j?0
ex-0
(;\G-in
~G-E'X
r:\G-in
0G-E'X
ex---{) 8 4 G-in
. n 1
in--v FRONT "'""
of
Engine
Fig. 1.8localio n of inlet <HId exhaust valves (Sec 35)
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I
36 Engine anciIiMies·· ref itting
Rcle' 10 SCClrOIl 8 "ud rul,t the Irsted COllllJor""'t~ \Vllh rele,erlce to Ihe Chaple,s mtl'C,lh)(!
37 Engino -refitting
Rcf,wn!) the cngrne '$ D reve,sDI 01 the ,emoval procedure given or Section 6 . hili III Ddd,uon note Ihe lol/owing pOin ls
(,l) (b) ,oj (II)
(c)
Llyfuly (frc,lSC fhc yembox illfml shaft Ch~'ck 111,11 /h,· clulch rcle,'se ,11m IS correctly loca/cd AdIIlS/ Ihe CfffU;h C,l"'C as (Iescfibed til Chilpler 5
Ad,US/ Ifle tcnSfo n of Ihe powef sleell;IY pump ilnd ,,1/emilIO ' "nvd1ell(s) ,IS (/eSt'nlwtilll CII,lplefS 10 alld 2 respcc/ively Fill Ille COQIIIUI sySlem (Ch.lp/er 2) "1/(1 powcr stecling SYS/VIII (ell"!!I,.:, 1 0). Illen I,II/lic Cflgine w,III 011 (Scc/ioil 2)
38 Engine -in,t;"l stMt 'lIl) ,,/ter major overhaul or rcpnir
M"ke su,e thai th.:: h:l1tc1y ,$ fuliV cha,u.::O '!IId Ib,"" alliub rrcafl tS coolant and lucl ,lie '''III''''',sl,..,,,
.... ~ __________ .................................. r
procarmanuals.com
Page 48 of 205
Chapter 1 Engin e 47
--;; ble chec k ~II littings nnd elcct"cill connections. Ensu,e thnt the 2 .,",or is correctly lilted ilnd Ihil t Ihe IUnil,on tlmmg StJtlC Selllll\) 's distrlU
I CI , t II in doubt Ie el 10 1npler . eorr~~ ~10VO 1110 SPJlk plugs nnd the '- ' conneC lion from Ihe 1\)111110n 3 '1 Turn Ihe engine over on Ihe st~rler motor unlil Ihe 011 pres~!II{! co'· . light is e~til1gu,shed or unlIt 01' pres sure IS .ccorded on IIl{!
warnu"lg . d I This witt ensure Ihill Ihe engme ,s no l Slarve 0 0,1 dU"I1!11he g~~ge,. I,w minules running alte. IflIlJ.1t SI.:lrl·Up. The l uel syslulll W Ill ,,,toea . I· • be p!"iOled dunng IllS ope.atlon.
: SOReconne<:llhe '_ ' conneclion on the 'IIn'tlon co,1 and ,elll th e sp.:llk
lugs and loads .
Stilrl .Ihe ~ngme .. ~ AS soon as Ihe engme Ilfes and .uns. keel) ,t gOll1g ill il lilst \lckov(;.
nl (no las te,) and bring it up 10 nOlll1nl wo.kong ICmpernturc ~ ~s the engine WilflllS up there WIll lie (){I(I smelts nnd SOfll~ "mol Il
hom pariS getting hOI and uUI.l1Ing olf all (leposIl5. The Signs IU luok
10' arc l eilks 01 w<l!er or Ol!. which WIll hll uhvlOus If SllrlOus Che(:k ,d~u he exhauSII)ipe llnd I1lJI111old connections as lhese do nOl ,lIwilY s Iond :he
i•
exact gos liUht position unlil lhe w:1I1l11h ;oml vlh!al'On hiwU ;I(;t,," on Ihem, and il is almos t CllrWU1 th.11 th(ly WIlt ncrHI I'Hhw1l1l1H hllth". Tills should be done. of course. wllh Ihe C"( ,,nc slopped 7 When nOrmal running lefllJ}Coallll e hilS hecn .cnch",<I. "dl,,~t th" l"'OiflC ,die speed as desoil}Cd In Ch.1ptc. 3. 1 S lOP Ihe engine and wnll a lew ""11,,1,,,5 10 sec ,I any I"l",cam or tool')flt os dflJlP lng out when t he ",nuone oS ~tallona.y 9 Alief the enuinc has run 10. 20 ""lltltIlS .(!move lhe en!Jllu: .oc~e, cove's ~nd rocke r shafts .1nd rllCh(,c.k Ihe tluhtncss 01 lhe cylondc . Ioc.111 boilS (photo). Also check the tiuhlness 01 lhll sums) bolts. In hOlh taSCs usc iI torque wrench. 10 Road teSllhe tar 10 chcck Ih.11 thC Im"nU IS correCI ~n<l Ih"t Ih" enOine is giving the necllss~ry Sl1100tllllr.SS <ind power. Do 1101 .ace Ihe
(lnuine -il new bemings and/or pistons "nve hcen lIlted II shollid he
I' !.tilled as a new engine and run IIl.1t.1 .cducc(1 spcud tor Ih~ IUS I 1000 miles (1600 km).
PART B: 3.0 LITRE ENG INE
39 Gener;!1 description
ThC !lcne'il' conl,uu'illion 0 1 the 3 0 hue enuine is sil11l'nr 10 the 2 8
( \:\.~ ,..d r •• -~~ .. ; ~
389 Recloeck,,'u Ihe Iluhlness 0 1 Ihe cyhnder head bolts afte. ,,,,,.loIlU lhe enu")e fOf 20 'I1In ul('"5
hire nllu""1 d(:~c"hed III Sec(,on 1. Thc Slunillcan t dltferences iI.e .1S follows
(i') FI,'I •. yllll(/vr ht',1(/$ ",'III the combustion cl.,1mba,s itl lila I".~I()IIS (b) Imhvr(/",llly IIIOUlIlCd rOC~t'f ,Jrms illstead of a lockct sitaft (c) W"lvr pump 10C,11cd 011 Ihe ,i!llu of the allgine ((f) DiSlfllmto' ,WI/ orf ,,"1/11' (I,ivell f,om thc front of thc c,lrmllllft (e) ML'ch,mic.1llllcl,Jl/flfP ollcfMed by ,1f1 ccccntric on tllC frolll vllhc c,lmshMt (f) /rr.';" (Ill sC;llloCMCII '" ,1 S':l'olfall: c,ltric, (y) OJ! trltvr IOt';llvl/ on tlw "I}fI1 lef(-h,mrf sidc (If tlw clI{Jlln'
Fig. 1.9 Sectional view o f tho 3.0 litre engine ( Sec 39)
i
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~ .... ------------------------------.. ~; 灲潣慲浡湵慬献捯m
Page 49 of 205
:as::.w.'q
48 Chapter 1 Engine
110 Routine '!lain!cnanc!!
At the 1I11Clv"ts specifIed III Ihl! ROutlll!! M"inlcni'lnce sectIon in thO !rom althe mil"l).11 cnlfy out the followmg procedures.
ClwlIgc ollgiflO oil. reflew oi/Ii/fer t/lld clean oil filler cap 1 Rdo, 10 S()C\'OIl 2
Check illld <1r/jllsl vMvc c/c,7f<1nccs 2 Rcfe. 10 Scellon 89
TigMt'lI mll;( IlliIlldold hollS 3 RP.1110VU Ihe ;", Llr:"llcr ;unl lI!Jh1cn the Inlet rlIi'1ll,fotd holts 10 Ill" spccll",d ,ollluO wIlh .oleumc!! to Chapter 3. On comple\lon re lu the au deane.
R(JIII.'w Ihe cmllkc'ISf! l.'mission v,Jlve " Ad", In SIl<:\lUIl 7
41 Major operations \lOssi!>lo with (lilgine in car
T 10" lollow,n!) ""'1111 Ot",,;otlOIlS Illay he r.'If.icd Ollt wlthou, ""''''VIII!lllw';!)!luH!
(.,) /r,·", .. vmy .1",1 "'/'/flll!! III!! ,:ylmd ... , "1.'01(1", (II) {,"'IIIIJVIlIf/ tllld "d'I/IIIO (/1<: /ltmll!l 1I,·.ItS (i:) 11,:IIIIIVIII.'I.IIItI,dll/III!/ /IIt] I!II{/IIIL' 11II1I/11!""I1/III!I~ (II) III'II"'~IIIY .",,1 "-'''/lilly/he Im!lIll~'I!It];,,""" ",;" "'111"'/"'.'1 (,') /{"/IIIIVHI!I .mlf ,,-,"II"'II,IIt] (;;/II'S/l."1
42 M" jot Ollcra lio ns requiring engine removnl
The followll1~lll1alm ope"II'OIiS may be c,lIIlI~d OUI allC! ,cmoval of Ih" !!II!I"W
(01' /r,''''''''''''! ,mlf ,,:III/my llit] fly"'/md (b) 1,'I;"""'III!I ;lIId 1I:"lIiII!! lIlt] II.'''' "';1111 '''.·;IIIIIY vII sl~.ll (,;) f,',:/lWVIII!1 11",1 ,,:hl/myllll" ,:,.mAr:;,.w stlll'p· (,I) 11,·wIIV"'!1 .md It"/tflmyl/t,) 1.-"/II,,.t:I"'!1 tOri 1t~·;"'''!1 (,.) /1,.",,,,.,,,.'1 .md II-,!t/lmylll,) ,,,sl,"'.~ .1111/ ,;ullltL'd"'!1 IUds II) ".,.""",,,,.'1 .lIId tdll/myll"-' "II /lllillfl (.'/) f'"'·"'''V''''f ,11101 td'IIIII,,'''t] (I.mAsh .. ", ;/lul",;,,,, ht];mllYS fli) J,',·IIU1V'It!l .1111111.'1t1/1II!I fl,t, C,lll/.f/"dl 1141.<111."5
A lth""!lh 'I'~ 1)(,·.~d,le 10 1(~II1()~clhe SUI"P W'lh lhc C"gllHlII' the ca'. I! IS 1(":o""",·,,~I,,d thai 101 ,Illy ope"u,olls wh'ch .elt""e Ihe .emov,d 01 IIH: ~""'P. ~,,<:h ;,~ the ,eOllov,ll nf Ihe CI,'nksh;lfl alllll"o c!l(II)c<I''''Us.
tl,,: ""!)"'" ,~ '''''''IV'·!!
43 Mctho(ls of engine removal
The ""!I""~ 'n"V he hfWd oul e'the. 0'1 us own u. III u."t wuh Ihe I""'~""!>~'{)" On I1lo.I\lIS l'I1t.'<I w'th ,1UlOm"toc 1'''"S''Hss.on 1 . s ",co"""""d,;d Ih;,1 Illc ellUlile he hfled out on 'IS OW". unless <I ~III'~IiIl'tJ;" <':I;'''£, or o~ .... ,hll"d hO'SI 's <lvn,lnhle, hecolu~e 01 the wc'ght f, ,<:IO' II Ih" ''''u'"e ;lIu t 1"I"S""S5'O" <I.e .emoYcil as a uIHllhey have W hI! hf!Loti o.n at " Yery Ml'Cp il"UIC. so mako sure Ihill the.e ,s stllI,cuml hrl"'~1 "'-"0111 nvndalJlc.
44 Engi"e -rcmoval
Open imd p.O)) up Ihe bonnet lhen covel Ihe w'ngs w'lh CIOlhs. o~ <:n.(l11O.1,d. 10 Il,olecl Ihcm hom scr<ltches (luling Ihe subsC(IIHlrH O)le(,ll'O"S '1 Millk til" outline of Ihe hOllllel 1""IlCS and 1hen w,th the help 01 an "ss,stim l. ""nove tl'l! 1o". lK.ln'll! se'l:Ws . ,t;l lIilse the bonnet stily and e.udtlllv hl l tl'l: lmnnet cre", 3 [)'~CO""l:<:t Ih(: l'il1I .... 'y lends. tIllT10ve Ihe hnlln'y clilmp bOlt <lnd hfl
II", IJ.,U",v oul <1 fle,l/oyu lhv ,II' cle<ln(!/.
5 flc"'ovu 111,· ~pl.'~h ~h,(;ld hy "''''<1VU'H II", hlllt~ ,1,,<1 cI'p~ 6 PI,lce ... ~:Il"I.I·nf" of 10 lot", 11"16 JI"'I) r:,'I),II·, tv ,,,,,Iu.,,, !,
'iI(I'<lIO'. ""novc Ih/"! ""h:OIO' hun",,, h"", .1,,,1 ,h"", th" r.Il"I.l,, · 7 RcmfJv,~ Ih,' "1'1)1" hll~" I,n'" Ih" ",";,1", I''''''P n'·'I1"~" Ih, 110m Ihl) all d,,1I,·I.I,,, pa" .. 1 ""d I""" lh" ,;"""t,,, ~h"",,1 ;'"d ,.
Ihem
8 flc"'"~,, Ih., I",,, hllll~ ...... · '"II'!I th", """.11',, til Ih" '''UII Ila" hfl Ihc "1(10,,10, ""t
\) D,sc""''',,:1 Ih,· ',,11 w",.·, hm,,, 1"111' Ih" w"tt·, 1"""11 ;",.t a"I, cho~e
10 fle"",,,,, tht! -l.lI"·' ""'10' h,·;11 ~h,,'ld .11,,1 II"·,, ,I,,, '''''''·'·1 tho I,om Ih" ,,11"""'\0 " t'·IIIt"·'."'"'' '.""d,·, 111"1. "1"'''"11 1./,,1 ;111,* mOIO'
II R"IIl'l"" Ih,· ...... " huh ... "''' ~""'!I th.· 11""nl,· h"k"!IU I,
aSS(lmhly to Ih" .1\1<'1 ",.",,1,,101 .lIlfl "·"If"·,, It Ipl'Il.IIt 1 2 fl'''''<l~'' Ih,· '" .. I .. Il'· ... ""101 II,,· 10,,·1 1''''''1' (plo(II"). Ihe,
vnCll"Ill hn,." I",,,, Ih,· ,"1,·1 " .. ",,1,,101 .",,1,1,,· "oJ )."· ... ~II"· I",,, fll. conn,-ct", .11111 , .. I.· ... t I""" tl,,· .,,1 IW""";'" '" .... ,,,,, 13 R""",,,,, tl", •...• , 1",l b ""·"""'!I Ih" '.1.",,·, "",r,,, .""t ",,,,(,,. 14 flell1""" Ih,· I.\() """ 10, 01 ..... ·"'''''·''1 II,., ,,,hi,,·, """I.'I"'~ III, en(Jllh1 """,,'I"'!I' 15 RII"'(J~" tt,,· I.'." ~"'I~ f""" '·.11 h ,·~h.""t n.",,),· ,11,,1 ,II".,,,,,,, e~h,'"~1 il'l"'S ),'"'' III" ,·~I,.".,t ",.""f',lel
114 12 Fuel j)1""p ". d 1,,0;1 I,"t;
I;" ,
1:-,
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Page 52 of 205
t
,
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f
)
-• the twO boilS sccurong Ihe 0,1 pump 10 the crankcase and 3 R emov
',.,' . the pump assembly nnd ,ts (roves la I-wllh
drilw
59 P istons, c o nnecting rods and bCilr ings -removal
1/ lhe crankcase sump and the cylinder hC<I(ls ,Ire ,elll~)Yc~1. the ' . .od connecting rods can be .em ovcd with the engulCl In the P '$tOn5 . The bearing shctls
C,IIl he removed wIthout 'CIllOVlllg the cylInder ca l. tle-ads. 2 B efore removing any COllncCllrIg rod cnp, make sure Ihal the r del number IS mn.kcd all hoth Il<lr\s. II no mark'119 IS \'I5lhle, pul " """9 marks on Ihe )0111 he folc IcmovillU 11m buils. mil'n ' " . 3 Tu rn , he CI(lllkS Il<,h lHl\,llhe connect Ill\) 10! )('11\\1 Icmovcr! IS;Jt itS
lowest position . . ., Remove the COI1l1CCIIl1\1 ,ud nuts ilnd pull (lit the [)(lalln!) Cilp 5 Rotate ,he crnllkshafl \liH,llhe connCCllrl!l rod 1)"'11(1 removed IS 111 it s h ighes t positio n thon u~() Ihe h,lndle of ~ hanHller to plr~h \Il"
~ssemblv Ollt of the top of thu cyhnder . 6 W,thdrllw Ihe assemhly frorn the cyhntler ,lIld ptace Ihe hCillrnO C,IP
~ck on the connecllrt{J 10(1. 1 If Ihe be.:uinos rue l>CrllO ",newetl. lelnove the uld 1)("""'!15 hy ),,1I1n9 Ihem lound unlrl Ihe nOl ch on Ihe !J(,,,,rnO ~h.,tl rs tlrsenH<10cd
f rom Ihe lecess on Ihe l)e,1r1"U Se,llrnn 'lIlll Ihen hft the IJofI<1rrtlH oul If tho beJrin{Js <11e lemovell ,,,,d the S,lnm ones ,l.e 1":111111 nsctl a!F"n. illS viMlthat Ihey ale .elillcd III Ihe s.lmc scahnH a ... Ihe Olle I.om whIch
thf.'Y WC.C lemoveli.
60 Crankshaft reM oil seal - rellloll,,1
To !emove Ihe 011 sei\1 wllh Ihe ell!J",e In Ihe ca,. Iusl remove Ihe U<lJlhox. or aUIOIllJItC IransmlSSlon .. S de1;Jlted In Ch<lpler 6 On r"anual 1f(lf"Isml~Slon madelS. II is Ihen ncceSS<11y 10 lemove Ihe clllll:h uscmllly ilS descrrllcd In Chllpler 5
2 Releilse Ihe SIX holts S"",,"IO Ihe tlywheel lI11d remOlle I,ve 01 Ihem Wh ,l o holding Ihe flywheel. fCmove thc slxlh bolt and hll ,Iway Ihc lIywheel. 3 n emove the lour hOlts SCI;""IIU Ihe Orl se;rl C<rllle, <rnd 11ft ott Ihu COrlle, Jnd sell l assemb ly . 0 D rive Ihe seal OUI of Ille ca,.,c,. t;rk"'~1 I:;IIC 'H)I In danl;l\l' : I he I""" 0 1 Ihe Col" ICf.
Fig.l.1 2 R ernovinu the rear oil se al from Ihe carrier
(Sec 60)
~ Crank sh aft llnd main
henri nUs -re rnov.r1
, Relnovc" 2 n Ie CIIIl"I" 1'011 Ihe car . 'J, 3 n emovc the ClelC h HSSI~olhly 011 Illllllual transm,ss,on madels ·1 ernove lir", , , ,
L'
·
.... yw lI.le ;lIld Ihe leal 01 sual cal"er. "/-·H. $'i;:.
5 1
<I Mnke SUfe Ihm Ihe c.ankcasc Slimp has bcen d,amed. Ihen turn Ihe eno,nc III>Sld e d own. chock It sccu<el y and .elllove the sump. 5 Remove Ihe Cfnnkshalt pulley (m(l the engIne Ioonl cover. 6 Remove Ihe OIII)Ump anll Slr,uner. 7 Check thm "lIlho rna", and connechnll fod t ..... a"n!l calIS hnlle theu Ide.u,ly,no numbers SlampCll on. so Ih,1t Ihey c.ln h'l ret,tled III Ihell O "Oll1al pOSlllons . 8 Remove Ihe Cf;rnksh,,1t gea •. n Renlove Ihe two nuts ~nd Ihe healing Cal) 01 eac h connecllng rod
"' 111111 ,1n(1 Illy I")ul Ihe he.1""\) cnps In ord~r. 10 nemove the IWO boilS Irom eadl ollhe malll b(:;IIIIIIJ c"ps. hit lilt)
CilP S all .111(1 lay 1111:111 out'" order NOlll Ihm Ih" c~nlle 111:1111 hcn"ng f.':IP has Ihrll~1 wa~hcfs M;l,k Ihetr POSIIIOIIS hili",,, <ornOIlIIlO Ihem. 10 ellsure thaI Ihey :IIe 'el'lled exactly as lemOved 11 Can:itrlly hit Iht) f.lill1k sh;111 0111. I:Ikln~1 eMe 10 ~o"p 01 p;II.1I1(;1 w,th til,) e .. ,nke;rsc. so Ih:'1 Ihe \I""st hC,l"lI\l $urlar.es of lilc upper hea""\) h.1II11:5 iI,e onl rI"mn\jcd 12 HelllOVC tllo I,,,,"'II!I ",sr, IS ['0111 the cyirml", I,iol:k. her"U cnlolul \() IlUIl: Ihe POSItIon hOIl1 whu;" "nl:h 01 the 10\11 !>..,<IImos "nd e.l(.1> 01 lire IWO th,us t wi\~hels We'e ""Hovod
62 Ellgiflo Carl\l)Ollelll~ -e~iHllil\1ltiol1 far we"r
nc:lm 10 Soctll)" I 1
63 noct.e r arillS -examination ;ond nmovalion
llll) siuds 011 whIch Ihe locke, arm~ p,vot arc a pless 101 Into the cyhllder he,1I1. ,111(1 II .1 51'<1'0101 cdUO IS Inld aCfOSS all s'x. II cnn be seell whelhtlf ;"'y h,ll1e 1>f:\Jull II) pull oul. II Ihl5 IS Ihu case. Ihe stud w,1I have 10 h e I..,1ll0vt:d. Ihe hole re,lllll!'\! 0111 ,IIId ,Ill overSlie Stud hllll(1 2 Check Ihal Iht.: Itucuds on the sluds a,e!ll Uood conti'IIOI1 anll that ~ \IJ'(juc 01 nllc.1S1 59 N", (<I 0 Ihl It) 'S fcqlJllnd 10 111111 ,,;Jell .1dJllsh lr 1111 orl..,d 1111..,:1\) ... IIlhls IrHUH) IS nOl "chlcved. III ,I r,,;w ':Idluslcr ,In.) ,I
Silil dl:lrCIUIlI. hi a locknul to Ihe mlluslef 3 EX;IIWlln 1hll Illeke. <1111l~ ;IIH) IUit;IUIlI snalS 10' S'~lns 1.11 rrdH'nU. 1.1< I:XCtJSS we,ll 1111 Ih'l Ilc;o,'nu $IIII"I:<.'S II Cllher p.lll shows excessIve W"'II. 1".111 Ihe ,",.k.)! ;",n a"ti ti,e 1\lle'IliH sent '''u~1 IlIl .enowcd If When I;hcr:klll\l lilt"! rI)C~,)lS ;UIIlS. 'C"IOVI) Ih,;", one .11 a l"no \0 ,,"mlll(llo: allY POS).Ihllrly 01 ,urllS ,Iud seals Ilct:lJn l,tlH ullerchan\)cti. or Ilelll(l 1.,!I1Il:d III Ihe W'OIl(j ~IIIrI
GIf Tappets ,HId pushra()s -elWlllin alion ;lIld renoviltian
ncle. 10 Sm;trr)ll I 3
65 CamslHlIt ,\lid ca!l1sh':llt bC(H inos -c~arl\il\"tion and
renovation
UlllhHSI~C camshaft beaflflf)S ;1fC ayml.,tJle. so II IS poss,hlo \0 SOlly,IUIl , I waul c amsh31t by rCtJtlIl(lrnO Ihe 10uII1als. II the call1s . or skew gllar. atll wOln stOllllocallll y. Of arc d':II11.10,,(I. a ncw call1Sh.1h
IllUSt be I'lled and thc tJcallngs should Ihen also be renewed. 2 WOlll or dalllaUed c;m,sha1t bearings can be replaced by ncw ones. hullh,s re'lullt;:s spI)Clal tOOls and should llc om,usted 10 il FOld dC<1lel. 0 ' 10 (1 wa.kshol) wh,ch undertakes carnshafl reclalnl'nu
G G Cylinder horus _ eXHl11irHltio n and re nov(ltion
Reier
til S(:Cllon 1 G
67 P is tons and t)isto n rillUs -ellamilwlioll ,lIld renov(ltion
R e
lcf 10 Sectlo" 11.
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Page 53 of 205
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52 Chapter 1 Engin e
68 Connecting rods and gudgeon pins -Il~nmination a nd renovation
Refer 10 Sccuo n 18.
69 Cr,lIlkshnft -e~(lrl1in<ltion and renOV;ltion
E~amUle the four 'lIil;" l>e .. "n9 Journals and the s,~ Cfanlq>nls. whIch should illl be smooth Iln(1 IHlJhly polIshed II there arc any dllCP Ulooves. 01 deep scratches ;mo lhe.e ,s a sirn,l,lr <loI0"ola 1,on in the corrc5pon(fulH Iwaring sh(:ils. 1ho crallksh<l h should he reU'Ound. 2 II the JOUr1l<lts <I,e ,n noml conditIOn and 11 IS slIspec!(1d lhnl th e cI,Hlkshnh mily he suH,eocmly worn 10 fL'(IUIiO ,cYllndrng. II IS wa. 1h SCClo.II;t! the advice of ,) "'11111 Ford ,1\jCIlt. 0' cWllkshaf1 regllndlng servIce. 3 If ,he C1ank sh"f( IS '!](IIouml. till) wOlks w,1I ,1lso sUIW1y rhe new hC,lIIl1US wt\lt.;h WIll he rCII"'''!!! 10 Jl\atch Ihe lournal d,nmOlf"S.
" Check the spiuol bu,1"n!) III Ihe .ea. 0 1 the Cfankshall on manual l.ans.mSSlon m()(lels :mllil necess;uy .enew II
70 Mail' and biu·end heafinUs -olwillinmion and H)!1ovation
Ilelo,r to Seo.:lIOIl 20
71 TilninU oellrs -e~i1miniltion find renOVlltio n
Re f
el to Sec t,on 21.
72 Flywhee l/ d riveplale -Okamitliltiotl lind ronovtttion
Inspf:CI lhu ffywhf)l)I 0 ' ([ttvl'pl,,": fOI (!;U";'\lC ilnd 1:I".1I:k Ih;'1 Ihe ""!I H".u docs uol have .IIlY \)Iok"n o. l);Idly wOtn teeth. :1 On ''''''''';11 I'''"''''US~IO'' mnd"b ,I IS pOSSII.Il) 10 'CHew the I"'!l \]C,II .'S Ilesl:<Ihe(] ttl SeCtlim 22. IHlt on olllt()I\IHIIC IlilllSn"SSlon ,,, o(lels It IS nOl tlOss,bl" 10 le",OVf) 110" ""!I 11"01. hom Ihe dllVel)lttlc
73 Valves (",d v"lvo sO,,1S -tJkiu"illHtion lind renovation
[xallutle Ihl} v,tlves 101 IlIls "lid !l,ooves lind the valve SIems to. e~c,'SslV') we,l' III d'~loIIIOII' 2 Ek,""l1ltJ Ihe v,oIVil hf)"d 10' SI!.!"S 01 hu",u,U of the vOllvo seillS lind ch .. !ck Ihe ht 01 Ihl) villves III Iho v,llve UUldes . 10 SCl) II Ihe villve uu,des il,e WO!ll
3 We"" valve U",dcs c;'" be r l),lIned O\It lind vlIlves w'th overs.~e Siems lilted II iI v<llve !lulClt: h<ls h(."Cn ,eamed oUI. Ih(l eOllespon(fing vlllv(l sent must he rdOlCe(1
" Villves illld v~Ivo se .. ts whlc" show JollIe s,on 01 wear. call he lilpped in.
S To 1,1P the valves. In tt s u ction Iype gnmlonu 1001 to Ihe villvc hettd. smeil' a lu tle COil.se c;ubo.unllulll urmdmu pOIste on to I he sealing I~c e 01 Ihe vnlve ond inserllhe valve 11110 the cyJonder he"d. Rub Ihe stern of the v al ve gundlng 1001 hetween the palms 0 1 the hands. so Ihal Ihe valve,s ,otllle(l hHckwards 1I11d lo.wa.ds When II IS lelt lhOlI culling has
ceased. loft Ihe villvc. rotate It th.ough 90·, lowe. 1 and fepCill the u"n(llnu o.:.e.atlon . • e dlslllbulill9 the g"nd,ng pas!O on Ihe seal if necessilry. Conlinue Ihe process unlll a mllll gwy bOlnd IS pfoduced OIloun d the complete pe"phclY of hoth the vlllvc and t he valve seil l G RepoiJl Ihe opcrilllO" US" 'U fine o""d,nU I).Jsle. 10 ohtil'" <I I,ne.
IInlsh. then clean lJoth Ihe valvcs and Ille v alve seals 10 ,emove IIU \llIces 01 u"ndlno pash:! 7 II 'I IS convenl,,1lI 10 liIke Ihe eyhndc. he<ld and the valves 10 a wo.kshojl wllh the necosstt.y cquipment. II is In. h ellef to have illi Ihe va lves <lod Ih,,,, seJts ",f"ced. so IhOlI alilhe villves and sellts OIle lit the co""Ct ''''Ule and h ;lve Ihe COllect w,dlh o f conlllC1.
74 Dccarbonising -go notal
When Ihe cyllnde. heilds (li e removed. eilhe. in Ihe Course ovelhJul Of for inspection 01 bows 0. villve condllion when the e IS in Ihe CM . il IS nO'''1<I1 to remove 1111 CMhon deposits from the I Cfowns and heild
2 Th is is hesl done wilh 0 cup shilped wire hruSh ilnd iln elect." and is laorly slriliuhlforw,!,d when Ihe engine IS d'S<llilnlled an,
p,slOns removed Somel,,"es h.l. d SPOIS 01 ca.bon iI.e nOI , .emoved exc e)) t by iI SCf,'pCI . When cleanln!) Ihe p'Slons wllh a SCI IiIke care nOllO dam.lge Ihe sudace 01 the ,)iSlolI.,n (lilY WlJy . 3 When Ihe en!l",e IS in Ihe car. ceria", prCCau tlons mUSt be t whe", dcca.OOrllSIno the pistons' c.owns in o.del 10 p.evenl dislo, pieces 01 carbon 1.111;110 into Ihe inlerior 0 1 the ellgme which c cause dillllilgC to Cylindcr hores. pis Ion .10d lings 01. 01 allowed the Woller jl.1sSolues. llilrllilOC 10 'he Willer pun.,). Turn the engine so Ihe p'S lOn lleinU Wal ked on IS Mlhe top 01 lIS slIoke and then mas l Ihe a(llttcen l cy'",der bores ilnd ilil sU!roundl",g wttt(" l"cket alii wllh papel and .1!!hes,ve 1ape Press !lwasf) ,nto Ihe gil(l illI .ound pislon 10 keep Cilrbon pa,lIcles alit ,,"d Ih(ln SClilpe 1111 c,lfllon awa hand Do not usc iI power thin and wile hntsh when Ihc enguI(lls II, ettr as II WIt! virlUillly be 1Il1posslhie 10 kcop alf the cal ball dUSI clc, the engine. When compleled. c.1wlully c'ear OUI the OH,,,se moun(I ",II 01 Ihe (liS lon With ,1 mlllc h SlIck or somelhl"U Sllm 'iI • . bringing ciI.bon palhcles wllh It. R c,lellt the p(()r,e~s onlho o the. p,slon C'OIol II IS nOllecormllended Ih.lll1 "'ljJ 01 "uhon IS leit .ound Ihe edge 01 p,slon on I h(l Iheory Ih"t ,I Will ,11(1 all consumplion. ThiS WilS valli
Ihe eiliite. dilys 01 10nU stroke low .eVYlnO en!)lIles tJUllllodern enUil fuels ilnd Itrb"canlS C,1use less cOIIOOn deposils OInyway and any. b ehind lend merely 10 cause h O I .SpO IS.
75 Oil PU"',) -disnwntlino. eknmin"liOil ,,"d reOlssembly
The Oil pump mm"Itt;"S a I)ressure 0 1 ilbout 2 8 kgl/cm' (3 Ihf/in') lInd unless Ihere is ,1 sIo",IIcanl (hop In 001 P'(lSsuro willel ,)loved to he due 10 the Pllln,). rillhn. Ih;", 10 wo", heil'm!)s. 11 IS be .
t o le"ve Ihe 011 pump und'S hilhed. 2 To d'smanlle Ihe pump. fll:.1 ,emove II hOln the en!l'ne ns desc,,1 III SUClion 58 3 Remove Ihe IWO bolts seCulII1!J Ihe en d cover 10 the body 1 'emove the covel ilnd 1he .ehel v;" ve "sscmhly. Ihen Ihe Iwo P"
fOIOI assembly.
" Remove ,he IWO bolts lind ,,,ke Ihe p,ck·up w he lind SCIl' lIssembly oft Ihe pump housin!1 S Wilsh all lhe pilrlS In petlo'. usc iI hlllsh 10 cleol" Ihe Inside 01 1 pump ho usinu ilnd lhe p.cssu,.., .elle' vil've eh'!lnbel. ilnd milke 5' Ihilt ,111 p,tltlClcs 01 dill ilnd mewl n,e ,emoved Allow the pttrlS 10'~ n;IIUf,lllyor blow them d.y G Check Ihe Illslde ollho Puml) houSII'9. Ihe OilIer .;w:e ilnd Ihe 101 101 dilfllilUe and e~cesSIve weill 7 E~ll'''Ule the I111lling su.lace 01 lhe I)Ump cove. 101 we,lr It Ihe CO' IS sco,ed. o rooved. a. shows ilny s'g ns o f wea •. a new covef must I hlled 8 W,lh the ,otor assembly filted in the hOuSing. place a straighl·ed!. over Ihe end 0 1 the housing <lnd measure the .o tor end play. If 111 exceeds 0.1 04 mm (0004 in). Ihe ouler race. Shilfl and ,Olor must t renewed olS an assembly. 9 M eOlsllle the rOlor·IO·houslng clea'ilnce. which should not exce e 0304 mm (0
.012 in) OInd Ihe Inner 10 oute. rOlor gap. which should b 'oss IhOln 0.020 mOl (0008 i n ) II oulside these dimenSions. a ne" pun,,) Should be fitled 10 Check that Ihe leroel vollve and its sea Illig ,Ire Iree of dan'ilge all' thaI the .elief vOl've sp.ing ha s nOt collapsed. 01 is damaged. and 1 new paIlS ,f necessil rv. 11 Reassemble Ihe pump by IUSI lilting the lillie. IJnd outer rOIOr) Ihen lubric.11inU them wllh enUOne OIl. '2 Apply e ngine 011 to Iho rehcl vlllve plunuer <lnd sp""g ilnd Inse l Ihem inlO thei
r hOUSing Relll the Sjll1llU cal) and Ihe pump covel '3 Refit t he cov e. allolchrnenl sc.ews 1111d IlghlenIhelll1 0 the to.qu' wrench sen ing giv<m In ,he Spec,flcalions Altel t1uhtemng the screws
chec k thOlI Ihe 1010r moves freely 14 Refil the PlCk·up lUhe <lnd stralnel as semhly 10 the puntp body usi nU a new gOlskcl OInd then insert and hUhten the IWO IIxHlO screwS
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Page 55 of 205
) 54 Chapter 1 Engine
,n the "Oill hand ror;ke. covc. ~nd mlO Ihl) en!IHlC Ih'ouUh .111 .1(1,1pl0' bene,.!!> the (.1,hl"l)ll01 The sys\cm '!nSlI.ct; 11\.11 !lIlhurnl lIilSCS ille .ChunNt to Ihe enU'"e fOI fUllher (:orlllJ\'~I'OIl
78 Engine reassernbly - gcner<l l
Rolli' [0 Se(IIOn 20
79 C,lInsllllll -re';II'I1I)
SI"h, Illc SpM.,<1 "",th li S ChitrllfCI1'" "ml [""I onin Ill" r:;HlI:.hall ;oml ,, the kr,y 2 LlIb",':"I" lh" c"m~h,111 lo",.,als w,lh <:Ill)"") nd ,llld ~I,d" Ihe ' ·.IIlI~hah "' hOln\h" hOIl!. 1.II-IItH C;UI~ 10 ~""P ,1 ~1',IO!lhl. SO ,I', nvt III rl.mlil!1" II", /:.III1,h,,11 I)","'IIO~ 3 rr! th., (.l", ~h"h 11""~1 ,)1",,, wuhou! ;, !1.'~"('1 fIt lI,e two (,(lInl\I:!,,,nk hr',lei rr,!,'"lll'!! serews ;1I,d 11\lhl"" III"",
80 Cranksh .. ft reblti,,!!
~V'lh lilt: "II\IIIH' "p',ul" ,low". I. 'v ";I, h "I II", "1'1"'11"',""'0 h.,I,,",s ''''10 Ih" "1'1""1''''''1: u.",ll .• '~" wI·h. 111,'''''''1 ~,,,,, Ih." Ih" 1<" ""'!II.IIIO 0" II", I""""'!I '~P"'I""IV ""!!,,!!,,,I '" ,II" ':C"":~I"""h"!I ~I{)I '" II,,: 1; • • u'"c;I~" WI'!> Illh., "Id I""""'!I~ .,," I"""!I ",!tW:Il. ItI.lk" .;",1.111,,10:01 e.lch I .. """,!! hill! IS '''Iud • III III.., 1'1.,, ;11 h"ll wh";h,, W.IS ",mo"..,d Fn Iht:: Ih'u~1 w.lsh".s 10 <1;lcl. ~,,11l 01 11", CI:'II • .., I...,a''''!I. Ih" 0''''''''''([ l;lI;"s 01 Ihe wa~I'e.s IJelll!! Oulw;!lds (1"11 1 16) n"I.""II,c II"tI~1 w.l~I""s 11 1)lar.r. w,lh UH}.1SC 2 FII Ihe low ll anO "!1 halv",s 10 the app,op""h: I>";'''''!I ,;nps 1"1 Ihl1 IllIuSI wM,h.."s on ellll(!' S,dCl "r Ihe <""'"11 I>e;"'I1!l ':"1', Wllh Iho 1.," 01 Ihe w" she. Iitied "1i0 Ihe slOI It' IluI be''''''!1 <;;'1' Rel<lll' Ih" rh"'~1 w" she,s '" 1)I"ce ""'Ih !IIIMSo! :I LIII" '<:<111) Ihe c:o.lnk<:<,:.c l,e;IIln!! h.,I""s Will, '"'0''''' ,"I .11,,1 I .• l.o;I"IIV low,,, Ihe ':'''Ill~hilh unlO 111,,111 'I r"k" <:;,d, I>o:.1""!1 e:il!> '" hlln. lulll'G'h, 11<; hl'''''''!1 h;,u W'III ""II""! ",I AI'I,IV ""!I""] ".1 III IhH ('I,,,,ksh.lr, 1001lll,,1 ,,,,eI III 1111' !"'''''''H':''P W,III Ih" ""ow 11('''I1'''!llO"".''d~ IIH' ''''''1 01 II,n ""!lIII" L.e:h I""II"'H ""1' '''''~I I", ,"',1I.·d '"~ IIHi 1l('S""'" 100'" whll.h II W.IS II,IIl1lvod ~ I"'.",, II,,: 1""0 ,,,I."""'!, holts ;",d 1'!IIII"1 Ih,,,,, It) 11"1 10",IIe w",",.h ~('I''''H 11''''''' '" Ih.., SI,..:(' . .r,,:,,'I("'~ r,u" II,,· e:I,llIhh,,11 Ii) "II'",,: Ih.'1 II 11I1"Il!S 1"".jV. III'lorn I'IL"'!! Ihe "oxl hei""'11 1:011'_ II lh,' .:"lI1l~h.,h ,I""" ""I 1<1",10: III:<.:IV. Icn'o",! Ih'l l'l"""'\1 r.iljl Hnll check 11>.lllhll I>";""I!I ~hl!!l~ l1.w<I sc.,h,ld p,npedv ilmllhal IllI! hcall"H cap '5 Ihc CO"'''.I 0110) 10' Ih.'1 l'I/Slllon ij r'l Ihe oall~~h.ll1 ~,·V PI''':e Ihl! o.l,,"~hilll !lCil' 011 Ihe en,l ollh.., , .•• lIIl~II.,h .11101 1)0','111111 II hV 1,·lllpO •• ",ly "iII"!! II", e:'.111bh.o1l p"II"V .11 .. 1 II,,, OI'UIl1,,1 wil~II" •• ",,1 holl T'!I" I,·" Iho ""II. Ih(:" 1l!"'0"(! Ihe 1,,,11. w;o~he. ;11,11 ,-,,,,,ls","1 pulh:V 7 M""slI'" Ihll (l alll~h"'1 "",lIIo;lI ("'~I! Secholl 27) ..... h,ch sho"ld he .-IS Sll(!c,f'ell II "(;Ce~S;"V. hlmll .1 belwecn lior:s" hlll'l.~ bv IlIseltll1!J 11"U51 w.lsh",s of Ihe .11 }I)lOp".IIe 11nck"css
8 1 Pi~tons a"d COl1l1ectin g rods ~ re fitting
RclC' 10 $CCI'O" ;:t!)
82 Oil pump -refillin U
P"lTle
Ihe oilllUlllp L>V 1IIIol1g Ihe IlIlel 1101l wnh Cl1g,"e 0,1 and Ihen flJlat,ng Iho dllvcshilh 10 d,sl"L>ule Ihe 011 wllh," the I'lI"'P hodv 2 Inselllhp. pOll1led end ollhe dliveshMI "'to Ihe PWIlP hodv and III Ihe clop 10 .etain II 3 Place Ih o pUIliP U1 I)051110n . cngnU!! Ihe d""e~h;JII and Iheo inseH Ihe ' .... 0 llitallung IJolls r'\lhlet1ll1.., holts to thC lo.que w'lInch SCII,ng
\I,,,(:n III Ihc SpClcol,c,lIIons < Rell lihu boll SClCU.IIlU Ihe 0,1 pick up luhe 10 IhCl ",nln I)C;UU1U cap ",,(I "U"l"" II 10 Ihe ~j}ec"H,d 10'ljue. F
ig. 1
.16 Cr.1J1 kshilft Ihru st wash ers ~ ;orrowed (Sec 80)
83 T illl i,,!! !I ClH'S illid I rOll 1 pla to rclillill!!
Apply 1""'III'!1 1:1>"'1","11<1 In Ih " (11,1,,1 ""!I" nllh" 1"'''1 "n,loI Ih. <,yin""" hl(1{.k ;"HI l<J Ihp 111.11 I •• co: I,f III" 110111 allilj1I(/I IAilh) ;:t 1'''~llIf1nlllll !1.J~k('1 'lilt! "d"plm pl;Il". ",),;""11\I,,·,,, w"h Iwo holl
'''~"I\'''' flll!!", II!III 3 r,l II", ada •• lm 1,lille f(,,,,IUICelllunl ( F,\! 1 17). IIlS"' lIS IllIC(j b olt· ;""j II!)I>I'''' tI":",, 111,," II,IllIJV(l Ihl) IWO PI(,v'(lu sIV III~I),wd local"'!
1o"lh < no:l,1 the e:"nlsl1.1 lt ge".. Sf> Ih.ll Iho kP.VW.1VS "I I>ulh Ihl} CI.lnkshall ill1Illlol: e:.1t11sh"'1 "H) In lone ;11111 Ih,: ",,,,ks on Ihe tW,lIS .1,Q on 11m Silllll
I",,, II", <.I:'l1ksllo1ft \1";11 hilS IWO "';IIks Oil 'I alII I " " mipOIWnl Ih;n 111"V iIIe l'OSI\loncd as ~hown ,,' f.U I!; [) M""~,,,e Ir." I:lldllo.1l 01 II", <:.1I1l~hall ;,ft,,, '"~"'IIIIII Ihe t:alllsh;oIl "''''''''''!I hull ami lI\1hl"IIIlI\1 , 10 Iho: 111"1'''' wII,I1I:h ~I:H"'!I U,,,e,, III 1111, SI'"",I,,;;llll)lIS 11", cillll:;h:.11 1;"dllu"l e:"" I", ;111",'01"01 lIy f,ItIl'lI .'
Ilelf'·I,".1 1''''lIlh ~I'.".'·I G M""~,,,e'II": 1"".ll.l~h ul II,,, 1:O",,,h.111 !I",,, ill 1"lIl ··'IIl.,lly ~1'.1(:",1 PIII"i'. .",,,,,,,1 "s I""'I"""V lh.~ ~hull"ll", 0 7.2 In 0 32 """ (000910 001:l "I) 7 AIII,IV 1"'''h''!1 (:O"'P(111,,<1 II! Ihe cII(:uII11r:"",ce ollhe 1",uIIU CO"..,, 101111 I.",,~ .IIHI It) l hl) 100111 01 Ille ;"I.'pIO' pl.'le JI,d oil." up Ihe 1I1l11r'>{'
co"el 8 1l,,1'1 Ih" ",,"'kshall j)l11l!:V to pO~'I'IHI Ih.., IIIIIIII!} '.0"'1<. rhcll mSCIl III" 1""'''11 CO"", hOlls alld t'H"I"" Ih..,111 10 Ihll 10'<1"(: .·"~IIe:h Sr:l1Illg
11''' 1)'' UI Ihe SI'I1t:o/'C;l\'OllS
9 Apply ,0"lIuIII C0111llOll11d In 01111 f.,.:c 01 Ihl! e:,.,,,1 ~11i,11 llullllV w;o~I"", pl.lcc Ihls s,de 10w",US 111(; I'tlilev . ItISC.I Ihl! pull,;V SCCUH"!I holl ,,"(1 ilUhlCIl II 10 Ihc SP':Cllll1d tOlqllC
Fi
U.1 .17 Adap te r plato reinlo lcclllcnt (Sec 83)
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7
Chapter 1 Engine
Fig . 1.1 8 R ear oil sen I ilnd ildaptcr pliltc (Sec 84)
84 Renr oil se;1i ,,,,(I lIywheel - rc fitti"u
1 I'll the ()n!J"I(~ .r,," ,,(1"1'10' pla1<:1 and s(:clIre ,I wllh 'I S IIv(: holls. 2 Smenr en\J1ne (ld OlltO the CI,mkshah '''". Smear 0,1 on the lip 01 the sea l tlnd pos(( lon tlon ';".11 on th e cran hha ll. 3 Align the seil l c;""er holos wllh Ihose 011 the cylrnd(:, hlock . Insell the loul bolts and 11!lhlCll Ihem 10 the SpeCifIed 10lqUfl 4 F it the flywher.:l . or dllveplalc on au lOlllallC lwnsrnis sion Illodels.
InSerll h e six holl S ;",d u\llole rllhem 10 Ihe 10 lque w rench sell"'U Uiven in lhe Speclllcm'olls
8 5 Sump -rciiuill!)
En~",,, lh;ol Ill" ru,rI "'!) ',u.l,u :e s 01 hoth IllI.! Slimp a"d t h e c(,1nkcilsc ,lie cl ea" ,mol IIi,1I n", '.""I",!) SlIrJ ,u;e 01 the Sli mp IS not d'S lo lte d. 2 Apply IO" ,I,,,!! c"'''pollnd 1 0 the pOUltS wllel(~ Ihe l"llllll) cover ablilS lhu ,;yir r"lr" 1,Io ck .lIId where Ihe rea' 001 $u,,1 carr.(:r "dIOIllS II 3 Pln ce tloo \J,,~k"l '" fJo~.t.on, lIt tlo" SlIm l} ,'Ild IIlS(). 1 lhe r0Io1111il1l)
bolts ImUO I tl!lhl 4 PrO!lres~lvely 1I!llIt,," llw sump holt s 011 opposIte I'ilr ts lIllt,1 all 0 1
t
hem ,H" il l tl", ~ 1"":lllI"d IOlllUU , 5 FII ,1 now w;,~h", 10 Ihe ~Ul1lp II"'UI pili!) , IIlscrl lhe dl,lIll pllll) and
t ,uhlen ,t
8 6 Cylinder h e"ds re;rssernbly
L~y the cylrnd" r h",.\! on .IS s Ide. luhrrcnt e cvcry valve Uu ide with eng;l1(! oil. ,lilt! ,"~,,"t the valves 11110 the \Ju, dc Irom whIch lh ey wele remov(:d 2 To ,WOld d<l(11;U)III\) lhe II p 01 the stern 0,1 sonl , with consequent rncreJsed 0.1 con~UI1'ptIUIl. wrnp <I p.cce 0 1 ndheslvc wpe. or fo il. fOund the \JrOove o f cvery v,llve SWill Sh( le lhe scn ls over t he valve sIems and push th clll over th.: lupS of the vnlve u",des 3 Remove Ihe "dh"~lve wpc. or fOIl. horn Ih e vnlve S1(~I1IS. 4 F,t the valve sp"nl) ovc, the valvc. Wi lh thc close cOllcd end 10wnrtis the Cylrnd er head. lhen fll thc sprin\J relarne r on top 01 lhe
sprlll\). 5 US1ll\J a vnlve ~prul!) compresso r. com press lhe splln\) lus t enou\)h 10 inse,t the IWO Splil COIl,,15 If lhe vnlvc spml(j is compressed 100 filr.
lhero.s dilnlJC' oltl1<.: ~I""IU rcW""C' dillllil\)IIlU tllC villve SHlm 011 sen l
G Ahcr "lsert")!J tit" ~pllt collets. r eleilSo the spllny compressor (111(1
rcmove II 7 C hcc k th"t lh..: ~pl'l cull":IS hilve seilled properly and t<lp the top o f
t he v"lve S1C1lI hUhl1y w llh a plJstrc headed hJmrne, to ensure 1I11S,
Fi g. 1.1 9 Tightening sequenc e for cylinde r head bolts on the 3.0 litre enuine (Sec 8 7)
a Repe"l liln pruccdwn orven III p;ua!Jrnphs 1 to 7 o n the (CmJlnlllU
v,llv"s
87 Cylinder heads - re fitt;nu
11 the tappels w ere rcmoved. luiJricnle lhe lilppets nnd I heu hores wnh enoine orl nnd insor t thOlll wilh lhc;, d Ished cnds uppermost Ensule lha l every tappet ,s rclltlcd Into lhe hore hom whIch II wns
t nkcl1
2 Mak e sure tha t Ihe rna t"'!1 surlaccs o f lhe cylinder block. cyl lndor henrJs ;Uld 1111,,1 Ill,lIlIlold ;lIe de;"l. then plnce new cyhndcr head \Ja~kets ove, the Wildes un thn cylrmh" block. Tho cyirnder head \I,,~k ~IS beilr thO malkln\! TOP f:nON T ilnd nced to h e pOSII,oned
cOII(:ct ly .
3 Low ul Ille cyl ""lcr he,1ds ov"r the" posl tlonrngst u(!s, Although t he cyhlld\~r headS ,"0 Id entlc;,I, they should h,lVe been Illtlrke d when remuved ilnd should be lehllUd III thcrr ()IIUinal positions t1 Inse rt the cyirndcf 11I)"d boilS f"'!I(:r t.!Jh l then tIghten lhelll prUglC SSlv(: ty OIl the olde, shown III r,U I l!J and III llle stnucs",s U iven
m the SpcelirC;lt'OnS
88 Rocker arms and cover
s -refiUing
Ensure Ihm "II Ihe puslllOlls ,lie ,nselwd I!ltO the" p'llpor placos ;II1<J lh at thc" lowcr ends nle on\J"gcd in the ClipS o f the t"ppelS 2 Place the roc ker arms over tho jlllshrods. fIt the fulcrlllll seMS and ;ldllJS 1o r nulS. an d liuhten the ntl)usting nulS !"'ger light 3 Se t No 1 cyllllder at TO C <Jnd reh t the dis tllbu tor (see ChilP1C' 4) 4 I\dlust the vil tve clea ra n ces as descrohed in the foll o w rng Section 5 FIt the roc ke' covers , uSlIl g Ilew \Jilskc IS . ens uring tho t the gilskets arc senlOd e venly n il round l ho cylinder hend. Fit the cover altilchlllont
l
)olt S nntl lighten them t o the spec ,f led torque.
89 Valve clearnnees -checking nnd adjustment
R eier
to SeC!lon 3 5
90 Engine ancillaries -refitting
R eier 10 Sec tIon 46 and ref, t lhe I. ste d componenlS w,th refercnce
to th e Chaptels ind,cilte(f
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56 Chapter 1 Engine
91 Engine -refilting
Rcf'tlIng the engine is a rCllcrsnl alth e removJI procedure given In Section 44. bUI in addrhon note the following 1)O;I1IS:
(,,) Ugh/I)' 9(0"50 Ihe ycar/)QIC ;npu{ Sh,ll{ (m,lI/v.,1 transmission) (b) Check tlMllhe dlileh fc/c,He .7Im is cOIf(!clly loentcd (m,lllu,)1 (fiJn$miSS;OIl) (e) Adiusl (he clutch cClbfll ,15 (/(!sCllbcri ill Clwp/fN 5 (m,mu,,1 flilMmission) (d) BelOfc COfl/weliny the engine /0 {I!(! ,W{omMIC {MOSl/tllSion check 111M /he /O((/lle con vet/or is fully 01l9,19N/ wilh lite /f,lfI smiSSI()II pump by reh'/(!IICa to CIWp/Of 6 (e) Refll' file ,)II/QIII,llie ("'''lllltHiOIl WillI 1141/11 ,15 dcsCfI/)t'd III Ch,lpWI 6 (/) Ad/usllhe lellsioll 01 the IJowor steeling IIlIfIIll MId .11/emMa. !lnvalid/(s) ,15 d(!scfI/)ml in Ch,?pICIS 10 i/lld 2 f(!SpcC/lv(!/y (!I) Fill Ihc cooJillfl sys/cm (el,.l/'/C' 2) ,md /lOW,!' Slcc/IIIY
SVS/l:tII (ella,'/Cf 10), 1111:11 fIIlllle mlylllc Willi od (SeC/lOll ti~) ("ho/Q)
92 E n £line -initial start-u p after major overlwul or re pair
Hel",
10 Sect Ion 38
PART C, FAULT D IAGNOSIS
93 Faull diagnosis -engine
Sympto m
(n!Jlne f.111s to tllm OVCI whim ~t;llt", IS Opc,;) lcd
Enll"n) lUIIIS ill no.",al ~pced. hili dous not 51,IIt
E"u'ne SlOp s ilnd Will not 'estill t
Enll'Ile
.",slucs, O. lUll S unevenly
L~ck of powc. illlt! poo, comp.esslo ll
91 1 T OPPln! 1 lIl) tile ""'II"") wIth od
ReilSOn(S)
DI~ch.1'Hed 01 delec tlv" 1o:,lle.y
Dilly 01 lI)os" lI.11tc.y le.,ds
O"f '!I:llve sl; IIt", soL"",,,, I. ,II SW'II: " Odl'ctlvl' s lillte. "UIIOf
Dilly 0 ' III"ken e"!I"IC "'''1111''11 SIt;IP
1\I1'"111 ':Ol1lpOlu",ts Will (If ,1;""1) DefectIve low te nSIOIi le"d Detective o. InCOllec,ly :,,, 1 ,:"III"C I h,e;oke. (,I "PI.I,,:a"fe)
Oe f"ctlve condense. (If '11'lllIo,;.,"lc) O'st"hulor cal) defec tIve. or celltral h,ush HI (irs l,,"uto ' cap Ilot m,,~, COfltilf.t w'th th e .otor a"n Ifls.ulhc,em petrol "' tilllk V.1pOOf Iud '11 luel hlle (," hut cOl1{lIuolls)
Fuet pump I:uhlfe E~O:Hs51ve c hoke, caus,,,u spillk pluUs 10 hccolllt) wet
IU"I1I(HI 1,,,IUle result Ill!.! 110111 b.cakdown. or prescncc o t w;'1ler \,Inti w(: 1 cOnthllOIlS l:n:k 1.11 tud. at luel IJlock, l!Je
loose 19111tlon Icads F(luIIV s J)n. k 1)Iuli T'(1ckin£l on d,slllbuto. cnjl IIlsuliltion
InCOIICCll11lxtu'e 'Ullilion 100 telilldcd Dilly con[,lCI blcakc. POlll1S (,I ajlplPcablc). or loose connection'
<I'SI""\,IIO'
Faully Of loose condense' ( II ~)JpIPcilblc) Lea kin U ca.hu.eItOJ. o. lII.lll1fold JOlllt
D"lectlve v.,lves Blown cyIP"de . head £lasket
WOlll bo.es OJ dilm ilye<l ,,,slon
Wo.n cylinder bOles Do::tt)cllve v~Tve Stenl seals Le<lks
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Page 60 of 205
)
'tz
Chapter 2 Cooting system 59
1 I VISCOUS (IPlVC I,m coupling (I,~mpc,alu,e sensitIve 1VIle shown) 2.5 Tuppill\l -lIplhc COlllilll1 h,vel in the c~J)alls,on \;lI\k 27 Checkin U the drive-belt IClls,on (28 hire CIlUulC)
2 Routino Illaintcnanco
Altho ,n1C, ... "ls SPOC""]!! utlhe Rouhnc M .. "UcnanCf! SOChOr! on Ihe 110111 01 the m;uu,a1 c;lrIy oul the lol1oWl!ljl p.occduoes
Check cnoling syslcm lor /c,1k.~ 1 In spe cl Iht! coolin!! sysh),l) hose s 'llcludlll!) the ,adIOiIO' :,"<1 Iwate. hoses for damage. detcriOlllll0n i1nd sccullly If Ihelt) is I'Irly IOulle;1I'01] of swelling 01 p<lflshinu ,en ew the hoses . 2 Chock the ,a<li;uo . fa . dilmaUc ;lUd leaks, ,llld clean ;lny dchlls from Ihe coolmg fillS.
Check coo/tint level 3 Whe r(l Ilrl expanSIon 11lnk 's hlte d (I"te. Illodels) lhc I;oolnnl ICv!:1 can tJC check ed without .enlov,nu the pr<lssu.e C;'f};1S the lank ,s made of t.anslucent f}I"st'c. The t(lnk should he ;1PP'OX"l1;1tdy hllil lull wuh the cool.,,, t lust cove.in\J the pillst'c lev<l l ,"d'CH tO '. W,th i1 h ot CI1U"'c the level 1"',11 he ShUlllly hiuher 4 On ciuhc •• nodfJIs not f'U e(1 w,th 1111 exp lln:;'(l1I wnk the level "'''~t be Checked with the .. muine cold . Unsc.ew Ihe .ad,alO' p.essu.e cap and check Ih,\( the cool,u'l leve l IS hetween 25 0 111111 (1.0 In) ~II(I 35 0 111m (1.'1 In) helow the base of the filler ne ck . 5 Top·up the flurd level USing the COllect sohl\lon of wa!IJ' and ;mtilreele with the enuino cold (photo) 11 the c"Ulne is wal"'. the P'<lss,,"e Cilpmust be remov<ld slowly to illiow Ihe PICSSUfC 10 e sc ape U'llduilily. otherWise the pres su.e d'OI) fllily c~use thc coulllni to hod over cllusi,,!) I)Clsolla l Injury.
Check drivebelt conditioll and tensioll 6 Inspect the complete lenlJth 01 th e tJrovehell(s) for dClello.,llIon which WIIIIlI)f)e,lf ,lS h1lyll1U 0' UlilZinU to the 1)Ulley cUl1t ilC t su.fi\Ccs. 7 Check th(lt the deflec tion 01 the d.ivebclt{s) midway hetween the wate. pump i1nd (litelnntor pulleys is i1pp.ox,,11i1tely 100 111111 (O 4 OIl) under 1ll0de'i1 le thumh p.essule (photo). 8 Whe.e ~Idiustillent is neceSS(I'y. loosen Ihe Ililefllilto. p,vot and adjustment bolts. re l)OSlloon the alternilto. then tighten the b olts. A leve. mill' be used at the pulley end o f the IIlterna tor 10 o b1;lIn Ihe
COf/ec t tension If .equir e d .
9 Run the enuine f o r severlll minutes Ihen rec hec k t he lension.
Renew,1/Jtilreeze 10 O.am i1nd flush Ihe CO(lhng System as descrlhed in Sections 3 and 4 . 11 F,II the coollllg system With Ihe correct solullon of watel and amlf,ccle as desc"hed in SeClions 5 and 6 .
3
Cooling sysl e m -drai"inU
If pOSSIble. ensu,e thilt the engine IS cold belo.t! d.al"i"lJ Ihe cool ant. 10 aVOid the fisk of scalding.
2 Remove Ihe .adlatOf or expanSIon tank IIlIe. cap. If the eflUlnc IS hot. Ih ls must be done vl;lry caul,ously, because a sudden release 0 1
Fig. 2.3 Clltawa y view o f Iho expan sio n tlln k showin g tho plastic lovel indicator -tH rowed (Sec 2)
P'".'·S5U'0 CilIl ,esull II. the cool(lnl !.>oIling i1nd blOWing Oul. On ,1 hot enUlIle. plilce iI cluth ove, the caf} and lurn il ve. y uently. '0 release tim p,ess\lIe slowly. 3 flel110ve the SplilSh shield frOI11 b enomh the ra(II;IIOf. of i1pplrcilble
" Unless !he coolilnt IS beinu discarded and thc ca. 's over (I slilt illJle
d'illl1. ,,'"ce a deiln IWO i1nd a half gallon Conl;1ine. underneath the ,adlaIOl. !) Rel110ve the radlatOl bOllom hose lind allow the coo'al11 10 drili" . 6 If the SyStel1'IS to be completely d,ained. rcmove the cyhnde. block d.;1I1' pluU and draIn oul Iho .emainlng coolant hom tho engine . ThiS d'illf' plug IS locilted all the s,de of the cyl inder block to Ihe rear of the oiliolicr. 7 On 1I10deis wilh all eXJ}ilnSlon tank 'emove the rad.alO' cap as well
4 Cooling systom -ftushing
In IUlIe. !he cooling syStel11 Will lose ils efficiency because o f a bu,ld'lIp 01 .uSI and sedunen t in the radiator. To clean the .adliltol. .emove thc IllIer Cill) i1nd 'he bOllom hose ilnd !lush Ihe radialo" by inse.llng a hose in Iho f,lle. car> neck i1nd funninu Wille. th.ough fOf about tr.m I11mules . 2 If Ihere is a Ilea vy aCCUmuliltlOn 01 sediment. it is betler to .eve.se
flu sh Ihe .adl~tor. by connecting the water supply 10 Ih o boltom of the rilclmof alld allowinu II 10 flow oul of the tOIl. Speclnl hose adapters arc avai lable to enahle thIS to be done w ith the rild.ator In I)OSllion. but It is p,efe.able '0 removc the lad,ato. and tum il upside down.
3 Remove t he thernlos,a, (Section 8) then .eve.se lIush Ihe engine wi,h a W1l1e. hose u n lll clean waler flows from the .ndlat Of bottom h ose connectIon.
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