check oil FORD CAPRI 1974 User Guide
Page 38 of 205
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Chapter 1 Engine 37
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17 8e Tho socond compress,on " 11\1 I~ steppr:d
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cOI"es out 01 I1S groOvO. ;;Ippll' sligllt IIpw;;Ird P":SSlJIU SO tlt"t rt ,,:~ts on tllo 1,lrI d ,1bove , It C;;In thon be e<1sed off the pr~ton. wo1h the I,·der u~uge stopping II Irom sl lppllll) 11110 ,1n I:mpll' ~llnov" II It I S ;1rI1' Itut thu tOil pislOn ring thilt It being removed (phO(OS) !l The piston rings must always I>e remov"d trom Ihe tOp 01 Ih"
pi~10n. 10 C heck that the piston ring grooves and ollwal's ,lie IholOl1uhly d CJn Jml unblocked. Piston rings IllUSt ,1lways be hilI,!! (Jv,n Ihe he;){1 01 II,e pis ton and neve r from the bOllom II Th e eilSiest method 10 use when linin\) ,inUS 'S 10 WIHP <l leo lo, \1''''Ue rOlmo tho top 0 1 Ihe pistoll al1(1 place tho III1US on one "t <l (lillO,
. ',lrl'llg wnh tho bottom 011 contlol IIIlII. ovor th" lee le' \FI1t\le The 1~'o:Iel (jauUe , complete wilh rlllO. can then he sl1d down thl) piston ov1!r Ih<) Olher p .ston linn groovos tullil the COIlf:Ct (l!Dove IS ,e<lcll<;d The II'~IOI\ rin\) is Ihon slul olf Ihe leele, 11<1"Ue ,1110 the W0I)VO 12 An alte'nolt,ve mel hod IS 10 I.t the rnl\l~ hy hold",!) tll"l1l ~;"(Ihtly opI~n w ith the thumbs nnd both 01 Ihe ",ril:x r,nqels ThiS II 'elhod '"C[uorcs n sle~dl' h,,,,d ,lIld Ilre,l( C<1ro ol~ il is ei'~1' h; Dllell the ""!! to<, much nlld lltcak II
lB C onnecting ro d s and gudgeoll pins - exami,wtioll ;;Inri f"novation
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Gudgeon p IllS "ro n sllrlnk fil IIitO the cOl1l1eCllliu wds Netllter 01 lh,,~~ would lIo'1l1~1I1' l1eed .enewal lInl,)ss (he p'stons woro 1J~mq ~h.lnucd. III which case the lIew p'S tOIiS wOlild 0111tol1li\(1(;,1I1y h~ ~lIpp"ed Wllh IIew \)lJ(IUeoll pillS . .2 C OllllcCtlllU lo(ls are nOI subject 10 wear hut 111 extr<:Ille tnCVIlIS1"IICCS such as ellUlIle se.zure Ihey could he dlstoll~d. Such (OO(I"lons Ina I II h 'I' )~ V'SUi' I' ilppiliOlit but whew doubt e XISIS th"y ~ o uld be checked lor o1l1gn1\\onl ,111d II necessa,1' rellewed or W,l'gh(ened TI " . 01 file )",1.lIlg Caps should ~Iso he ex""I1l1ed lot I!uhcauofls (h I tng ?own whiCh may h~ve been <1ltempted in Iho misl<1ken ,deil .11 heanng slackness could be romed1ed III t hiS wal' If Iher e DIe such !I'Ons (hen (he c F d onllect",u tods <1ntl C<1PS should bo rOllewed hy your 0' ')!lent or locill elluinee'lIlg speci<1hst
19 C r<lnk sh aft -eX"mill<ltion {lnd renov"tio n
~c.a ~~~ll1iIlO the malll ho~,illg louillais nne! Cfo1l1kplllS 10' score 1l1.11~S or Oval~ es. Also check thom tor ov,:tltty using <1 micromet"r (pho(o) e,ce~~v~n excess 01 0025 mm (0001 III) should he .c!)<lrded as
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llt.;rv I e.c , 0 nOrmal praCtiCe. For d stipulate that undet no , umSIJnces sho II I exces s' U ( tie cranksllillt be .e\)tUund; so tI d,III'J\)e o. cr~nks~a~t.weJr <s eVldelit it Will be neceSSJrl' to Oil",Ul J !lew
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3 II the old C"ll1bhollt 'i b.."nH rel'lI(:tl. ch"t:k ttl,1I tl'" o,lw~ys ,1I1I cle,lI Th<s Call he done b, pro hlliU w,tll Wile 01 Ilv ulow,n\) thrOll\lh w,th <111 ,111 I, ,,,, '111..,11 111S[·'·. Ille lIoale 0 1 aI' 011 gUll .1110 the leSp,-,\:tlve o,lw,ll's. eaeh IIIIU! 1J1 <llll11U 011 the p"WIOUS lIolp.. <1rl(l ~qll"t od tlllOllUh Ihe ~I",fl II sholl'c ,-"u e'lle th'OIlUh the Iw xt hole Any 011 will' block<1g e n',,~1 <lIN'OUSt. be cie<1ne(1 OUI p"o. 10 rehllIng Ihe
cran kshollt 4 Check the ,PI!JOI be,1''''!J III the reil' 0 1 Ihe crJnkshalt and ,f
necessary .ene w It
(photo ·
20 Main <111(1 hiu' Cl1d bearings -e~<1ll1ilH!tio1\ and renovation
W,lh C<llCllll s.."v'ClIlg ,\lid ,eU\Jlolr 0,1 ,lIltl f, llcr chJnges. bearings Will last lor ~ ve,y 10liU :'UlC, hul th~y C<1n sltll f,1I1 lor unforeseen reaSOliS W ,th blU ·end b~a''''os the 111(1IC<lI<Oll IS ~ ,egullH .ythymic loud knockIng 1'0111 t h e c-ankCilse The irerl'leocl' (lepen(is on en g ine speed <Inti ,5 pJ<tlCllla ,ly nO(Iccal,ll: wl'lIli tile enu,ne IS undc' 10<ld.
TtI 'S sympt orn '5 ,1cc on,p~'II':HI!Jy " 1,,11111 0,1 P'l:SSuro). <1lthough th is IS II0t normolllv not.ce<1lJll: ~nluss all 011 p,,,s su. e U~lI\)e IS hlted. M olin be"r.nu la,luI~ IS usu<1111' "d,e<11l<d bl' sel'OllS v,h"1I10 rl. parl,cul;lrly al h lghe. enU",e .o)vulullon, <1ccolllpa n,ud by a mure SIUn, f'CJrll d.op '0 0,1 p.essu'l< aod a '1lIlll!J 1 ng' 1101~e
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Page 39 of 205
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38 Chapter 1 Engine
20.6A Mil,kIl1H S 011 the reverse 01 ,1 hl!1 ClI,t tlP.ilrnlH sh ell (, .... owed) 20.GEl ·S1.1n<!;u(l' 1l1;J.kinns on Ih.} O(,vmsc 0 1 ., m,un bCil,ong sh(:U (ilrfown(/) 20.7A PI,'~liY<lUo u~ed 10 Check the 'un, clemallco 0 1 m.110 nnd blu-end bea"ngs (imowed)
2 BCilrll1!j shells 111 (lootl condItIon h,IVC 1)C"fU'O surfaces wllh il smooth. (lyen m.m s,tvcr /u,ey coloUI .111 ave._ Wam hCillln!IS wIll show piuches 01 il d,t(clcnt colour when the hctlring mottll h<ls worn nWily nnd exp o~"d lho undcilny O''',,[lo cd bC1'lllIlIJS will be PltI..,!! [)r scored II the 1:,;"'~!>hMl IS III good cOII(1I110n ,t IS n1(:.cly " qUC!ol10n of "hlilllllllU ,1"0Ihl;l SCI 01 hC.111"!Js th;;! SiUllfl s,~e. A new Oilllksh;,h WIll I1C,,<I new hc,,,u'(j shot ts ;ls il II},"!!) , of cour~c 3 The (II'UII,al hOle ill the cyhn(ICr hh;x:k l110ly have hoon !o,wndard 0' lhll rllSI !IIild.: ovcrs,~c ;mel in the taller IIlswncc llus WIll he ,mhCillud by Ihe 1>","II1!I c"ps wh,ch wol l he m",ke(1 wnh while piunl I) The oll!)""ll S'l!} 01 Ihe CI<lnkshMt manl hem Illy 10llln,11s Ill<ly hnve
heen stnnd;ud a. 0 .25 nun (0.010 .n) unde,s'le. II the lournnis were underS'le Ofty.nally. Ih.s w.1I he ind.cale d hy a ween str,!)e o n Ihe lus l halance weigh I 5 The o"wnal size 01 the bly-end IOUll1:l1 W<lS elth!} , s[,lnd<l.d or 0 .25 mm (0010 tn) undersile_ 11 undersrze. Ihe corresponding .0Utll<l' web w.1I he 1l\11.k ed With a urecll ~pOI. 6 II Ihe Ue<lrttlIJ shells <I.e 10 be renewed. lilke the old oues alollY to you. sUPI)"e. and Ih;s Will aC I "5 " check th"l you ,IIC ttel1lllU Ihe co.mCI SI/ .e 1I1:,1"11!15. Undel sil.e hen"IlUs n.e 1ll.1.ked as such on Ihe ..... ve.se I<lc(, (1IhOlos)
- , The ,WII II"1I clea.,l"ce 01 [h" hC"""!lS m,ly he ch"cled U~I"!J PI<lsu!J.1!IC lhn 1,I<lSIIC th,cild IS IKlsllloned o n Ihe lou,nal Ihen tim
l ,e;IIII1() ~IH:II "n(l C,IP IISSOllliJtr,d . ,lilt! 1110 l)Oits/nulS 11!Jlllcncd 10 Ihe speerllod 10'(lul1 W hen Ihe C<ll) IS ,cmoved. Ihe Width 01 Ihe Ih,e<ld IS me<lsul(.~1 wllh <I canl !F1Uue whic h Ill(hcates the ftrrmmU cle<lmrr ce (photns).
21 T iroin g gOMs -oxailliniltion .1nd renovat;OH
I,,~t>(:ct Iho !)(:<I' teeth 10' d'llllilge. o r Siuns 01 e~ccsslVC wea, which Will C;JUse nOI SY Ope'<l tlon 2 The IliIckln sll helween Ihe CHIllSh,111 Hem nlltl Ihe ClllllkSh"h geal
muS I nOI exce ed 027 mm (0011 In) .md Ihe bilckl<l sh should be checked al lou, d,lIe,(: n t POilU S a.ound the pellphc,y 01 Ihe yea. (pholO)
22 Flywheel _ examinntion and renovatio n
hl~l)t";t Ihe lIywheel lor danln!Je and ch"ck Ih(: ling tical 10.
,1nd d.llll,I!IC 2 If th'l .1I1!1 IIC'" IS h,utiy worn Of has IllISSIl1!J It!clh II shaul. ,e!lew,·d Til" old 11111.1 call ho 'emoved Ironl tile lIywhecl by CU1\1 1l0 lc h 1I.·lwc"n two leeth With <I h;lcks<lw <111(1 thell Sl)irmng 1 " 1:01 .. ch,~d 3 Tn III ,I lIeW "nil !Jeill ,eqlllies h!};oIUln Ihe fino 10 2Q4"C {4Q ( ThiS c<ln tH: dOlle hy polish;ng fou, equal spnccd seCI,ons of Ihe · laYing .1 o n <I SUII,lhle heM ,eS'S tm,1 sudace (suc h liS Ille bucks) he,'lIng It evenly wnh n hlow lamp or 10.ch unlolthe polished a,eas <I IIUllt yellow Illll Do not ove,hen, or the hnrd we,lfill\! P,ol)C,lles he lost Till! 'JeM has <I Challlle.cd inne, edge which should go ilg,l Ihe shoulde' when pul on I he lIywheet When hOI ellou!Jh place U<Jilf 111 position qUickly. IIlPPlIlg il hOln e IS ,lecessmy. <lnd let It ' n.1lUr;llIy WIthout Iluench .. l!' III <lny w<ly
23 Oil "ump -distl1;l!llling. cxarninntion nnd reassembly
II 011 [lU'''1> w~," IS slIspecw(l il is pOSSlhle 1 0 OOIJIIl n 'CpJII Check fVI W("" 11151 li S desc!lbed IlIte! in IhlS Sec llon ilnd II conlun vhlain ,III IIVCI "(lui kil O' il new pump_ The twO f O tors <I.e a m<l1C P<ll< <llld 'Ulf\)" smgle ,eplncenlcllt unl\. Whe.e t he ,Olor ilssembly I
he le·l,s~(1 <llId Ihe OU(O •• otor. pOIOr to dISIT1,111tlrng. mUSI oe m<l,ke(".
Its hont f,IC e ,n o,de, to ensu,e cOllecl .e ilssembly 2 Remove Iho u'I"~e PIP(! and 0,1 slfaUle' If flOI ;:rlre<ldy 'emoved 3 Note the IdaHI·e POSIII OII ollhO 011 pump covel nlld body nlld Ii (111(10.11111 lemove the oolls and spung was he,s {,}hO loj Llfl i1wav COVflr. <1 Cn.efuliy .emove the ,0lOrs hom the housmg 5 USlnll <I cem.c lJunch. lOp ~ holo;n Ihe cellt.e 01 t he p.esslHe" v.llve Sl'airUg plug. (rnilko a note W obtain a new one) _ 6 Screw OIl <I sell-tapping screw and. uSIng iln open-ended spanl wilhd,aw Ihe Scillrng plug.
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20.7B Cil.d U<luge 10' checking widlh 0 1 PlilstiU3ge 2 1 2 Ch(ock,ny the timing gea, backlash 23.3 Unbolting Ihe 0, 1 pump cove.
procarmanuals.com
Page 40 of 205
Chapter 1 En gine 39
238 Checkirog the rolor lobe cle<lwnce
1 Thoroughly cle"n nil PDflS ,11 petrol or p<l,nlllll nnd w'pe dry US!Il\J a IIon.lluify ,ago The neceSslHy clemill1ces nwy now be checked USUl(J a ,nJChirocd st.aight·edge {il good steel rule} "nd " SCI of leeler g<luges. Tho cII,ic<l1 clearanceS ",e belween Ihe lolles 01 Ihe cen1rc ,01Or Jnt! ~vllvex faceS 01 the oUler '010'; between Ihe lOlor and the pump hody,
and between bOlh rotors olnd Ihe end cover pl"le. 8 The rotor lobe cle<ll"nce rll"y be chccked lISUI\1 feeler \liluncs alld ~hauld be within the lin1lt5 0.05 to 020 mill (0002 10 0.008 on)
(phOIO). 9 The cleal3nce between tile outer r010r ,lnt! pump body should IJC w,thin Ihe limits 0.1510 0,30 mm (O.006 to 0012 'n) (photo). 10 The endltoal clear"nce n1ay be lllC"SlUCd hy plnc,ng n slecl t. !r.l<gh\.edge across the end ar the pump In(1 rneilsu"IlU the g;lp h"tWCCIl the rotors and the straight-edge (phow), The g<lp ill e'ther lutO' ~hould be w,thin the I"nits 0,03 10 0 .10 mnl (0_0012100,004 rn) 11 II the only excessive clearances arc endllo;l1 rt ,s possrhle 10 reduce
II,em by removing t he rotors and l<lpping the [nee ollhe hody on J II;lt b"d ulll,1 Ihe necessnry cleoll"nces <lIC oi)wulnd 11 must be emphJ' t';~"d. however. thatlhe lace 01 tile hody muSl ,nmnUl perlectly 1I<ll "nd "\IJI1 .e to Ihe "xis of the rotor spindle, otherw,se the cleDr<lnceS wdl nOI h,) equ"lllnd Ihe end cove, Will nOI be n press\ue tighl f'IIO Ihe body II ,~"'Orlh t.ylllg. oj ~ourse. II Ihe pump '$ In need of n:newal unywilY hul unless done propedy. ,t r.ould seriously leOPJrdlse the reSI of Ihe ove.h,'ul. Any V<lrlillions III lhe other twO CleJ'illlces should be
overcome wilh ol new unil. 12 W,lh JII P"I!S scrupulously cle<ln. luSI rehl Ihe tChfll vJlve ,lI1d
!.p.ojl!l ilnd IInhlly luhuCJIC w,lh eng;ne VII. 13 Us,ng a SUltilble dl"nu.:ler d"fl. drove in il new se<lhng plug, IIJt s,de (I"lw",ds unl' ;t is flush with the intJke pipe "1<ltUlg LICO . 14 luh"cnle both rolO<S wllh enwne all oln(1 "tlhellllll Ihe hody FIt
Ihn 0,1 pump cover all(1 secure Wllh Ihe holls t l\Jhtcned In iI (('Juon,,1 .1n<l rllOU.css;ve mililner 10 the lorque w rench set\lIlg given'" Ihe
Spr'Crl,c,1t,ons . 15 f'lthe d"veshilft ",to Ihe !Olor dllvesh<lh ;l1l(1 cnsurc Ih<llthe .olO r h"n~ Ileely 16 Frtlhe "lInke p'pe <lnd all st';llller 10 the pump body to\lClhe. wllh ol II"", O.1s~et
24 Lubric"tion system ~ description
The p'essed steel 0,1 sump is allDched to Ihe underside 01 Ihe C'~~kcase and aCls as a reservoir 10' Ihe engine all. The 0,1 pump d,,,ws ~~ 'o01lhe sump via an oil SlrDiner and inlake p,pe. Ihen passes 'I uno , t6 lull. flow olll,tler The 1,lte,ed oil 1I0ws hom the cenlre of Ihe oil ;,~e, elenlenl and passes tluough a shari drilling. on Ihe right.hJnd , ,", to the 0, p,essu re switch and 10 the main gallery (on the e 1· Mld side of II -
F Ie C1ankCllse) th,ough " ttansverse d"llIng. Md °h'''' d"lhngs conneCI Ihe main galie,y to the lou, maUl bellflngs be I C camShaft bea"ngs in their turn are connected 10,,11 Ihe Illain d"~I':ngs The b,g-end bea'lIlgs D,e supplied w,lh 0,ltl1l0\lgh d,ayonJI ) 'nys Iro01 the ne,uest rllilill bearing b'U~\,h~rolhec,ankShaft is ,0 tJtlllg. oil ,$ Ihrown irOllllhe hole in each and e~ bea"ng and ensures splash lul)ric"tlon 01 Ihe gudgeon pins lu b ,I HuSt s,(le 01 the cylmder$. The ttllling \)ears <He also splilSh
~:.;. ' "cilled Ihrough lln 0,1 d"IIon\) . ,J",'
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2310 Checkillg Ihe endflont
Fig. 1.3 Engine lubricalion system for the 2,8 litre engine (Sec 24)
The c r<lnkshJh third he~.ing lournal interfllillenlly feedS 0", under p ressure, 10 the rocker shafts throuUh ~ drilling in the Cylillder block ~nd cylinder he"d. The oil then passes hack to the engulC sump. v,a
large dllilings in Ihe cylinder block "nd cylinder he"d_
2 5 Cr<lnkcase ventilntion system -description
The closed crilnkc<lSe venlltnt,on sys tem is \Jsed 10 conltol the emiss,on of crankcase vapour. It IS controlled by the ilfllOUf1t 01 ~" drawn in by the engme when ,I is 'unnm;) and the lilrouuhPIJI of Ihe
vent valve_
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Page 42 of 205
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Chapter 1 En Hine 41
27.1 3A Crankshaft cndfl,,"t r:,Ul he ct",cko:d
w
Ith fee ler gauges
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2" I!3A Lrll;,lhl Ihe dow!;1 ~".;lo; WI III" "'.I1n
I)e,',"]!! <;;'1'
n .I50 ... ~nd press lully 111 wllh a ~(."·wdrivcr
28 1 A FII Ihe ch;IIl\lclct! Sjhlcer 28W ,lIld k e y on lhc Cil,,'~hdlt
!l Apply n :;'\\1),11 01 II'"a~rl 10 bolh suh,~; "f Ihl' No 3 1\\"111 bU,lIlIlIJ C;]P ,.0 !IS W lelnll] thu th"", W:ISIII:IS FIt 11"1 llrlllsl w;,~hur~ wrlh lllC 1;llf 10C,'tNI 11 lhu 1J'OUVI] ,,,,,f lire slul S I;'<;"'IJ uulw!llds (u~dy moticls nllly) . 10 FIt lhe 111,'''' hU;""\11 caps wnll thu ,II lOWS Oil Ihe C,lpS pOI1lI<l1\) 10 II,,! frOlll of lhe u"lllO\u (plluw). I l"O!jlfl~s.vcly l'Uhl uIl the !!lilli' bC;"'Il!) ~ucu"nu holts 10 the ~p'("cdlcd to"I\lC . exce,r' No 3 he;I""!! bul,s whIch should only he rU'!JCI"'l]h, Now ples~ lhe cr;lIlkshah lully co lhe lear lhen slowly ,"r~~ I, tully 10'W;1.\I. ho ht " ,,1 tillS P() ~.t,on ;rnd lll)hten Ihe No 3 111i1111 1~""II\!1 c"p seCtll"\!) hole s 10 thu SIXlOf,(:d lo'quc (phOIO) Tius "":,\11(,5 lh", Ihe Ihr\l~l wa~lIcrs ;ue cotru<:lly locilted 12 I''',SS Ihe 'Car ,,,a,,, h"'annIJ 0,1 se,ll I"mly ,1\1'1II'SI the rca. Ill;'lln h"""Il! 1 11 lully ',WIIU ,I. p.oleel Ihe sr!,l! lops wllh adhesiv!, tape /c,holOj
13 US"'!J I<-eter \J;'Iu\1es. check Ihe cr,lnksh!l1t clltllloai by luse'ton\! Ihe t,.utl":< u,luue belwt.'e" Ihe e.,lnkshalt IOtHnal sldc and Ihe IhlUSI ~,'~hCIS The elc;"al)ce musl 110 e xcet'(! Ihe "gUle u,ven Ul the
( O('e",entoons lhe check call nlso he made IISlnU a dIal IJilugc 011(1105). ~: Rot
ale the crankshafr to enswe tll:ll II'S nOI hlndmg or stlekln\!
I,,'ould It he v Ory SI,I! to t"", 01 have I m)h 0;1)015 ,t must be fCrHoved and Oloughly Checked . IS CO;'llhe rea. ilia." hC!lrlllIJ CliP dowd su~ls wilh seallllg compound ,'nd "Ion t)OSIl 0 U
1 II I n. se a 1,Iunt soew(hlvcr or suml,:" 1001\0 press Ihem IU V 'n (phOlo s) They should be tItled WIth Ihe rounded face pomong ow,l,ds th e beann\.] cap
28 Cam!;hld, ( ( ant rOllt inlermedill\e pl,II o -refitting
1 Shde lhe . 41lrJ I I SI);'I<;cr onlO th e camshafJ with Ihe chJmlered sIde II1sl 2 ,II Ie key (photos) 3 ~UIJI;cnle lhe camshah beil"ngs. Ihe camshafl and Ihe tluust plalC illC ullV Inseltlhl.l cilmshah !rom lhe lront and III the IhfU SI plale
;""t sell.I<,,:k"'\1 M,CI,'IIl!J ""'1" TI\jI't\:1l Ilw II<III~ 1<. lh" ~I"·I:"II·,I
[()lillie.
" ~'I lhu 1111""\1 , ;OVUI \JII"k ~,I,'''v,'s and 0 IIn\1 o;.,;lb <Inlll III"
CI"nkc,1$() , lin ,:h;Hll"~lud end 01 11m Ulnde sl(]eve~ muSI k,cl) oulwa,d
I()w;"d~ III" llIlllnU r ;(}ve' 5 [nsulc 111" m"Wl\1 f;lcl.Is Ilf llll! 1: .;",~c;15e ~nd thu hOfllllllenncdlalc plalC an, clean ;"" lhen apply ~""""\I compound 10 holh lac,-,s rO~'lIon lhu nd"kt;1 on Ihe ct""kcase ,mlllhen I.llhe IlIlern,ulh all' plate
(phOlO)
/
/ \.
285 F,urnll Ihe Interllled.ate pl"te
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42 Chapter 1 Engine
28 G TempO'i1'y holl 101 IOC;l1inO the mlc""t:thiUo: plale 29 5 0'1111(1 the )l'~10n linUS 29 7 0,11I1{J the cyllnde. hOlo
";; '. '''' . :~ .,
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..-2 9 8 US'''H (I plSl0n "l1g compressor when uiSerhn!llhc p,ston "110 the hore 30 2 Chet;kln~1 the Sial) washer I)OS'['OIl on the 0,1 pump d""csh"fl 31.3 O,llhe tlywheel holls bel o re ',",ng
(j 1,1 II", two f.t:"11'~ holts ItI1!jl.:r·"!lhl then 101 ;Hlorlm' two holls t'''''IHH""ly 1o. IIU:"I"'!I purposes T'!Jhtcli the CCIllle sec"""!J hails th.·" It''''"Yll the '"ml""'''Y Io,u "d 1000,umU bulh (photo)
29 P istons Hnd COIH1(!cli"g rods -refitting
WI, ... , ('.101,1" the COIU1I;:(.I,n\l ,ad h"U of tll c !l0U·end bO il'lIlll 1111d rh e IInde,sulu ollh(l ~hcll h .... "l1y ;lnd IIIIhe sh ell hc"rlllU "' pO$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
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Page 44 of 205
)
Ch<lpter 1 EnUine 43
---3 Fit Ih e si~ flywheel sec"""\1 11()1I~ (n, t"dl <lnd hghtly t'ghten
(phOto ).
4 Chock the secur ing boilS
flywheel 10 "'~1'.111' ,I fro", tll,nlll\J. <1nd tighlen Ihe in il (li<1110I1ill <111(1 plO!i'''~~''VU l11<1ntJer 10 the speclf,ed
IOf~:iil l he clutch (Iosf: ilnd p"'~"'l"" pl.rle iI~s"mbly 10 Ihe flywheel 5 . ,ure Ihe disc ,s I he co"",:1 w.,y lo"nd (see Ch<1plor 5) rTlJk,ng . 6 Secure the pr~ssum pl"h~ "~~I:mhly Wllh the ,ct.1U1Ing boIlS. enl'Jlise Ille clulch dISC "Sill\) .11' old !i,,,"I>OX ,npul slwh 0' sul\ahle ~1Jnd,el Jnd thel1llghten Ih,~ ",I""'II1(II,,,IIS to Ihe sp~clfl()d tOlque III <l
diagonal Jnd pr09,esS1ve m;II'"<.;1
32 TiOling geMS ilild li,nin(1 COVIH refitting
I Check Ih<llthe keyways '" II", "~lId "I 110" f:I;,nkshilfl arl) cicilil ;,,,,1
Ihe keyS ;110 f,ee I,on' hili'" III II,,, I.,y'> ",(" II,,, k<.;yw;IYs 2 If Ihe c'<lnksh<1h Ueill w.". I('II,,,v,,d H"hl 11 I" Illn "';Hlk~h"fl U~II\\I iI w'IJule diJnlete ' lube 10 (I. ,VI: ,I 1"lly I",m<: 1\11,,,nilllve ly t","pola"ly
u~c 1 M pulley Jnd boll to P""'S ,I "" (pll"I"~)
';
. ,
. -\.
...
I't'
3 hI Ih'~ c,"n~h<lh y(~ ... on Ihe <':<lI1>';h,,1( wIth Ihe punch ""Ilk III
,111(I'"nOIlI with the mark on tho cr,ll1bh.1ft HO<l' (phOIO) NolO Ih<lt r! lh'~"J ,110 IWO punch lIl<lrks all Ihe cr,IIl ksha fl Ile.l •. ensure th,rl the COIled lll.llk IS <lh!JIl!:d (F,\!_ 1_5). .! FII Ihec;II"~h<lh 1I'1nr ret<lIll"'H w,,~III" "nd hall T'Hhlen(he Ilot! to Ihe ~1",cr!,e,IIOIque 5 II .wall,,!>I!) use a dl<ll Y<lu\Je 10 ch(,,;k (he C<ln'shaft elldfll)<lt
(pholo) 6 Oel~'lllllln th" pO~lIlon of Ihe OIl sedllll lI,c l"llIlly C()V('I, Ih'-:II d"vc Oll( Ille old su,,1 (ph010S) . 7 0,·.011 1110 100111 i."rIOO of Ihe 1111"",1("Io;no plate ;",.1 the I.ICe of Ille 111""'0 f:OVI". nll,l IOO<l1 Iloth n1<llll1'1 f;":,,s Willi sIJ<rIn>(1 COlllpOIHH I fI f'''~lt''''\'' IIIJW !!'I,.kl,1 all Ihe Illlr:fIl",(ilil(n plall' "lid Irl lire ,,,,,,n(l ('I)V", 10 lire cyirnd,,, hlock Inserl Ihe I,,,II~ f'II\IOI l'Uln D C.,III,,, Ih" ("'''II!) cover ~rolilid II", nuse of IIw (.,.II,k~h.lft USnl\) v"",,'" C,oI'I"'"s .11 I'JII' dl~mCI!lc pO'"I~. 11",,1 fully 1'\lhIo:II 111" hailS
(1'1",1") 10 1 " 1 11,,, f'''111 n,l ~(, .. I tn the 11111111(j .:ov"r .111tl .haw 01 11,10 lh" 1'()~'IIOI\ ,h.I""))II,,,<I '" P'''''()'''I'II 6 US"l\) a sock"t ,,,,d I,oft Iph"t",.,) 1 1 T""l ;o"y p,,,I,,,d,,,O U<1skel f,olll II,,, ~"'llP ",;'(IIl\1 f.":,, (pilato)
~ ..
:U 'lA Loc"lo the cr,lnksh<1fl U", II 01 111" e ,.",hhilh
322B ,. ,HId uSO Ihc pull"y In pruss It on 323 Alryn"".",t d01S 0" lhu III\lII1~) \le<l'S
lh"l
~ .. ,
..,
, ,
., ' ,
32 .61 Checklllg Ihe pOS,I'Oli of Ihu old 0,1 se<ll in tile IlI\lIIly cov",
32.10A Fi11lllg the c,,,nkshJfl fronl 0,1 se<11 using a sockut ~nd 11011
32 6B OflVII1!j 0111 the ""'lIlg COV(:r 0,1 se<11
32. 10B F,tluU posItion o f Ihe e<aoks!rJIt
f ,ol1l orl ~",~I III Ihe 1Ir1I11ly cove,
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Page 47 of 205
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)
" .
l
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
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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
"
'j
~ .... ------------------------------.. ~; 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.\() """ 10, 01 ..... ·"'''''·''1 II,., ,,,hi,,·, """I.'I"'~ III, en(Jllh1 """,,'I"'!I' 15 RII"'(J~" tt,,· I.'." ~"'I~ f""" '·.11 h ,·~h.""t n.",,),· ,11,,1 ,II".,,,,,,, e~h,'"~1 il'l"'S ),'"'' III" ,·~I,.".,t ",.""f',lel
114 12 Fuel j)1""p ". d 1,,0;1 I,"t;
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Page 52 of 205
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-• the twO boilS sccurong Ihe 0,1 pump 10 the crankcase and 3 R emov
',.,' . the pump assembly nnd ,ts (roves la I-wllh
drilw
59 P istons, c o nnecting rods and bCilr ings -removal
1/ lhe crankcase sump and the cylinder hC<I(ls ,Ire ,elll~)Yc~1. the ' . .od connecting rods can be .em ovcd with the engulCl In the P '$tOn5 . The bearing shctls
C,IIl he removed wIthout 'CIllOVlllg the cylInder ca l. tle-ads. 2 B efore removing any COllncCllrIg rod cnp, make sure Ihal the r del number IS mn.kcd all hoth Il<lr\s. II no mark'119 IS \'I5lhle, pul " """9 marks on Ihe )0111 he folc IcmovillU 11m buils. mil'n ' " . 3 Tu rn , he CI(lllkS Il<,h lHl\,llhe connect Ill\) 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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