engine FORD CAPRI 1974 User Guide
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26 Chapter 1 Engine
PART A, 2.8 LITRE ENGINE
General dcscril>liOIl
The 2.8 !lIte cnnlne IS of GC,Il1;l1l V(l Qve.hctld v<llvc type. The (OI,llsh;,l l .s loe;lIed centrally In the tylimler block ;lnd IS (Iliven by hchcill \JC~ars from the 0,'nk5ho1h, The vtllvc$ mil opcrillcd hy !:lppCIS. pusluods ill'\(1 rocker 'UIllS. The cylinder hCilds ate of the cross flow (lcsl\J1l With the mlC1 11\,111,lold IOCiltfld on lOp 01 the cylinder hlock between the twO cyhmle. hCilds .111(1 the exhnust m.1nofolds on the outside of the heads Tho r.omhincil c,ankcaso ;1I1d CylUldc. hlock IS madc 01 ens! "011 AllilChcd 10 Ih .... 1>01l0'11 ollhe clankcl'ISC IS a pressed steel sump whIch ,lets ns a "'~"\lOIl fa. the cnWllc 011 I\hlll1l1l1lll11 ,1110y p'Sl0ns illC conl1CClcd 10 lhe Clanksho1l' hy ~I !.1·C"OII 10lucd s'l~1 COllnCChng lods ,1n(l glld\Joon pillS Two I:Olllp'f'SSIOII 111'\)5 a/HI onc 0.1 (:onllol Illig, ,,11 101:;111,,1 al,ov(! lhe !llulgtJon 1)111. alo Io110d. Till) la'lIed c."nksh"'1 ""'s in lOll' ilia", iJca'lI1gs. and en(lIioal 's (:Olll.ollcll hy II110M w;lshc.s 00 No 3 1I1;lIn bO~'IIl!J. The dllv(! 00'" IOf
the d'SI"hutOf ,m(t 0,1 pump is located in flont 01 the 'Oil! Cilm bC;1rIog lub"cation IS by means of a bi-rotor 011 pump
2 Routine lll;lintelHlnco
I\llho inlo.vals sj)ecilio( in 1110 Routine M~"'lcn,1ncc $CCllon II from 01 Ihe m~nll;ll carry 0111 the 'ollowlng p.ocedu.es.
Change engine oil. renew otl tiller olld clean oil filler c. 1 Apply Ihe hil"clb.~kc Ihon jack III) Ihe lrolll 0 1 Ihe Cill and Sil l on ilKlc Sliln(\s. Alle'nnlively pOSll10n Ihe Cill ovc. ,111 ",~pcCtl(ln I 2 rlace a SUlliluh:1 cont~Ule. beneillh Ihn sum1) Ihen tlns.;."w dHun ph.!) (photos) ~nd (If""' the 001 3 Wh.le the o,l.s cI.,}lninu unserew Ih" 0,11.110. '-:;111,,<190 USII'H a' wl()nch ., Clean Ihe d.;IIn plug and Sltllllllhen ,elll Ihe pili!) and IIUhl"!! 5 CtCill1lhc IllIer COlllil(:1 mea 01 11i(, CXlenSIOII blackc. 6 Sme:1f a fIlm 01 enUlnc 011 011 Ihe now 0111.1Ir,. ",hhe. u,'~k(" I screw lion IImoi " JlISI CO(l\;1CIS the t"n~k"l 1 ,1(:(, (photo) 1'",111
Fig. 1.1 EKptoded v iow of tho 2 .8 titro engine Illain c0I11I)ononl5 (Sec 1 )
I T!,ellliostnl hUl/slII!) 5 U y poss /Just! /l,J/Jyc
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Cr;III.sllllll gear 13 Od pump dflVOS/l,l/l
2 'h':III.ostn/ 6 Ifl/.:1 " ... ",ilold 10 Flywheel 14 M{J;n b e{Jflng CilP
3 W,J/er PUJllP , C{J/lJS/",/I/llfI/SI/J/OJ//! /I Cr{Jnbh<J/1 splgol bO<Jring 15 Od pl/mp 1/ I mllllg "over 8 COJmsfwl1 gem 12 Od seM
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) Chapter 1 Engine 27
oint t ighten II ~ further 3/4 l urn ~ Remove the t,l ler C,ll> all the left· hand side of the engine and I,ll the g ine with th e correct quantity and grade 01 od (photo), ;n RemOve the OIllcllcl dipstIc k and wipe it clenn. th en fe -insert'! and emove it Jg<llll The all level should b e up 10 the Ill,UimlJlll llliHk ;phOIO). but nolC thnt Ihls check is only nCCUJiltc ,/ the C<1I IS on level
grourod. 9 If neCeSSary. lOp up the level nOI1l19 thaI the diSlnncc between the minimum and 1l1.1X"mHll level marks rep rescms ,1pprox imil\cly 1.0 hIre
(1.76 p int). 10 CICJfl the 0,11,1101 CilP then refit il .
Check and adjust valve cle<lmnces
11 Refe r 10 SeClian 35
hgMel) inlet manifold bolts 12 Remove the ,111 chamiler and \'oh\on the Inlet 111.11"lold hnlls ({J the spec ified lOrque WIth Icfcll!IlCe t o Ch~ptl!r 3 On compl"I")1I ,(:111 Ihe
JII chnmbcI
R enew (fie crankcase ellli,~sion valve 13 pulithe v(1lvl.' (1Pl(I'hose 1'0111 tlw leM 0 1 Ihe "ohl·l1(1nll locker caver
(photo). 14 [1.clc;lse tile cl'll ill1<1 ",movc the v(1lve foorn the h ose 15 Fit the new valve.n levr:rse ordel
3 Major operations possible with eng inc in car
Thc fol lowrng ma lo r operat,ons Cilrl he C;1<ned out WIthout removing Ihe CIl\IIIIC from the CM.
(,1) Removal al>d rufilliny ollfl~' cyh,,(h,r heiufs (h) Removal ami rehlllilg 01 rocker shall aml/lllslliods (e) Rcmov,11 ,m(/ ,elilllilg of {'Or!( elwine mOllnlings (rf) R/,fIIov,rI ,11[(/ reliltirry 01 (lie flywlleel (geillbo>< lI:muved) (t') Remov,ll amI rufl/liny olille Slimp 011(1 oil f)(!fIIP (I) Re/IJov,)1 ,11111 rehltiny of Ilw liming yl."ilf$ (y) RCIlIOvo1l ,mil relilliny ollhe biy-crlflln',llinys
,
(It) Rl.'tttOV,ll ollnf ,ellllmg of IIII.' 1".'·(Ofls ilfld cOrlfleelmy rods (,) Rcnewal 01 tI", c ,i/nkslliplt 11(1,,1 Sl'it! rtI IIIIII"y C(lVCI
4 Major operalions requirillg erlgirlo rO!lloval
T he followlllg IHaJOI opernl'OIlS ,,,.IV I", Cill!ICli out ilfl'" 1t'l\1o,",ll of tir e englllC:
(<1) Rcmuvi" iJllr! Id,lllIIY 01 If." ,.,.ttt~Sfti"l .,11(1 II>,1ftl 11,-,tlIIIYS (IJ) !1ellclV,11 ollfw o,wksft,dl II'." .~,.",
5 Methods of engine removal
Althol!OIr It ,~; flo~~lllle to .. ,1)1,,\·,· tI .. , "WIlli': .:Illd U"iU!'vX <IS ,111 ils~c,)lhly ,t IS 1"':OIlHllellllc1l th,'t th" "II!I"I<, ,S "'1\10v(,1! ,,~ ,I ,;OP<I ',) k Uil il If t))(, ell!)"'!! '·'1111 ~lendlOx ille II·"'"v,.d .,~ ,ill ,hSI:mhly 01 11ilS to I,,) hft,.,d Oll l ;, 1 n '"'''v ~t"l;p o1<l(Jle ;111(1 I", iI"~ .1 '.()n~ ilcl.1hl(, Irlt."\) he'oll! IS rcqu"cd 2 If the wo,k 1>')IIlg \IIldCllilkcn 'C'I"''''~ Ih ... 1(,IIIl ),,)1 of tl .. , \i,),IIbo~ ,IS well as the (:1l!1" 1" ,t 's l ecomnH:lld,'pJ 11\,11 tip,) O",Hho x 'S ,,,,OlI<.)v()(1 fr'~l (nil"r to Chap('" 0)
o Ellgino rcmovill
II IS t',,-,,.'IIII.-,1 If! h,v" <1 fl<wd "'!I_'1. ,,,,,I lI\1i 'IAf" sl,mds rI "" IIISI)I."(;/io" fill IS 1101 itvad,11!1e lltu $1!i("""':L' 01 OIIL'I,111utJS I'SI,'d m II,,~ Sec/lull'S !lol ",llcal ,H Ilic 1)(I$,liOIl 0111"." fWf~()1I "n(/",I:'''III!J II".' Ivork . 01 lite /001 III IllS Iwnd. Will (/1."lcr/mllt' 10 a ccrlaill CXlt'lII Ilic ut(lv, ill ,vlllcil the IICCCSS,lIV OPI!l,11wIIS illC /let/ortt/cd ObvlolislV /lw '."tI{f1ll1.' C,lllllOI Iw ,ctt/ol'cd 1fI1111 cvcrylf""fJ IS dl~cotllrccl"'/I 11I1tt1 II i,,,d tlw lollow"'fi $"(fIl,'IIl'V Will el/~(tll.! IIt. ·It rlOI/""{J IS 10I901l<:fI 1 Removc the bOlll1c t "s descllb"d '" Ch,lpw, 11 2 Disconnect thl! llilth)IY ncg;rtlvl.' le.,,1 ,IIHI Ih e ealth l.ill,IL' frun , lh,)
,. '~ , I\; , .,
28 E[lO"lc 011 levI;[ d'pstlck ma,kll1gs 2 13 Removing the Cfankc<1se cnHSSIOIl v<1lve
62 Ea'th cable Oil the alte'''''lOl adl"slIllt:l1t u,,,ckel (<H,owl.!d)
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28 Chapter 1 Engine
al1crn;1IOf ,1d,ustmcnl braCket (phot,,)
3 Dr,un the coohnO SY~'cm <'1nd ,emoll" IIw 1,1<1'.1101 ,1S (InSCribed "' ChnplC' 2 <I Remove t he cxp;ms,on !i1nk and h'dd", ,15 dcscullcd III Chnptcr 2 (1Ih010S) 5 D'sconncct the hoses from lilt, i".x.hnrV ,ll! villI/c . 1helnl ost,ll hOllsm\j. nil!! the heater lulles on the hulkhnnd.
6 DisconneCt the h'nkc SCrllO vacuu", h 050 Irom the "" chamber 7 Disconnect t he IIllel duci hom the ""onlc hOusln\) and nH~tUlc control 111111 8 DIsconneCt the IIl.on'e cilhle w.lh ",1.·",,,c(1 to Cha,l le. 3 n Pull the CC"I"~ itT ICil\, lmm the <1",,,1,,",,, C.11> ,l oll PO~I1,on (Oou" s,dn
1 0 D'sc:onnCCl ,hc mirth plUH I.um th., ,1"""'''''01 11 DISCOIllH:CI the W""lO hum th" 1""'I~".ll",e IFllI!)U scnd...,f 111'" (phOlo). lhc.mo!"1111 SWlh:h. Wi"'" "I' "~I"','IOf. i!uxlh;uy ;111 ,r.'VIC' ~ ,1nd coli! Sl.1.1 Vil!VO
12 UIIS, ;I"W Ihc '''11 011 ,,"1 and dl~r.",,,,,', I Ih" O,! lI,eSs,"!! !F'U!JIJ h"" (phQlo) 13 D,sr.UIII'ccllhe IW"h "d,le hOOIlII,,'II,,· h"lkh(:, 1d (I,hnlo) 1'1 rO~lllon ,I ~\lII;IIII" 1:01\1,,,,,,,, 1'''''''.,11, th" I,owe. ske""!1 '''''''I' Ihen <11~(:ollll'~':llhe ilu'd ho~es (CII<IIII"1 III) "nd d 'il lll Ihe (1",,1 1'1,1':1' II,,~ htlses 011 0111) ~uln 15 R,:m()v.: Ihe ,111,,,";oIOl;lS d"sn'I~',I"1 C":h.llllnr I'} 1 G fl,,,,u,v,: Ilw 1",wI'1 ~h"'II"!1 1"""1' ,101\·,·1,,·11 ;'S d"sl:fII'c,1 III eh"llI"1 >0 17 fl,mIDv" Ih" <III dl",,,,I,,·, 11":11 ,"'II",V<: II,,: 1I11",: IIlIS. 1",'VIf'!1 111<:11, l'li,,,, I,,,1I III 11m I"d I,w,s .• 11"'1111 .... "". II,,· I,,,,'" III '''''. ",I.· lid", hi Ct.""I". 3 III, Ih" 1I:1I1l",,,1 1"'".".1",,,
1 8 AIIl'ly Ih" h,~"dlJ,,'ke tlll '"I, ••. k "II Ihe 110111 0 1 the c", alld s"PI' 011 il~lc ~1,II,ds 19 A .m'ovo: Ih" s.,~llcr mow, ;,~ d,.:, ... ,hcd III Ch"",c, 1 '} 20 R","ov" Ih.] clu lC h c"t,le 1"JlI' Ih,~ \I";"b()~ wllh ,.,1'''I'I'CI; ChnplC' 5 2 1 U .. 0>1 .... w , .. , d ",'novc Ih" 0,1 r,h,·, <;."!II,I!lc ($1:(:11011 21 22 OI~,"("'''''':1 II", hoses "011 II,,· " .. ,,,,,Ic. 23 U~"I!I .1 '/7 ",," sll;mn,,, "" .... I .. W II,,: ~,occI.11 nul "",:"IIn(1 1 IlxIClls"'" h',II.k',1 II) Ihe 0,1 c(,,,I"1 H","m'c thc h",o,:kcl. 101Io.:!I"" w III<! w"~h,,," "",1 0 ''''u (phOI'" '}' 1 Un" "·W 110" "uiS I,olll III,· I.'," ""'1''''' 1I""JI' I,IlHS {p""I": 7() l!nl",IIII", ,,,h.1U~1 P'PI!S I""" 11,,·1, ·1( .",01 II!II" C~h.IU" II"."H!()I, I", Ih"11 III "n" ~It'll ;'If> UIII,ull th,· !w;"I)O~ !1Il'" 11"" "!I"'" "d,'I,T(JI 1'10110: '}7 Lm'''' 110,· ,;," 10 Ihc WOlIn"~ 78 51'1'1''''1 II." !I,·,uhOx willi" 1",11,,\' I." I 29 All."" " 1.""'1 10 II", "n!I"'" , .. "I i"',1 I "~,, ",. W"''1J'1 I" ''',11101, ';I'!I"'" ".,1 .. ", "." ~",t.1hlc "I.~ ,. I", "II,,,·, I ,I~: hlll si cll., , ... '" .""UI th" h""1 " I II,,· ,:.h,'"~1 ",.",,1..',,·, :I() T" P"""'" d, .. II.tUC 10 II" , ,~., h,I" .. ,,, "'I' ,"" . ,hI", .""'. "'m" 110<:111 ""I" :,.1,·,,,,,,:,, '0 Ch,'pl'" I
: n li,,~, "'w 110" !JI',)lhO~ III .. n" ",. I,,,t ...
:17 n." .... · II ... ""~I"": wh,'" ~I"': '''I I ... • ""'1"'" """,nl""I', It",,, It :.II)lh·1I I",,,~, ... 11'1,,,10) Ii "',' I,.. I .. Iplo" III "'''''I.I",,· ly ''''''OVI: I I
"!II'I h,""I""""'I"", W,lh II,,·, '"I''''' ',lI~"'" I,·,,, ','I I,,, I", .. ~, .... . P' ,I I"'W,IId·,! .. ol""'II""! IC ,I 1«,,, . tl,,· '1··,,,1,,,, ,,,,01 (,,,',"1(,,, dll""'''' :C! Wh,'11 110.· , Io,t, 10 IS ,I",,, "I II,.. '1,·.lIIH" "'p,,1 "Io"! 1 loll tho: "'''111
III"" Ih,' ""'1,1", """I~~'I"'''''I '\',,1,· ."",toll" ,I " .. ~I II", '.""("",,",, , '" "I" "', ''''', i pl" .. o 1
" " ,
" )
....... '.
"
G 4A fl"nlovlI'g Ihe QXP,IIlS IOlt t.1l1k "'O[l"III' U b,.1Ct..CI ujlpc, ""
,1nd lowc. Sr.ICWS 6 11 TCI""c",t".c U'lUge stJOdCf U<II. wlllfl lJ (iII.owetll
6 12 0,1 P'~SS'"C gauge IInc (llo0wcd)
.--~--. ...-,~ .. - -.-... -"',
6.13 Rcmo~'ng Ihc ea,lh Cllb le I.om Ihe bu!khe"d 623 IlcIlIOI"'!)lhc C~I~ns,on b,ac~.et (,'lfowedl trO'1i Ihl' 0<1 COOle,
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Chapter 1 Engine 29
624 Left-hJnd cI1!I'"c i)lO(lI1I"'(ll1l1l 6:12 LIIllll!l Iii\! ''''!)Ull: deal 01 Ihu rnOlllllln!) hr,lCkel~ G 33 L,Illll\) thr, ('''!JI''e hom the engine c()nlp~rtrnr!lll
7 Engine d isl1lil"tling -(Jenerill
\'Vhcn Ihe cn!I"'o I~ lelllovud ['0'" the ':'H. 'I. n"d p;olllc"bdy ,IS aCCCSSOllIJS. are v"llle"IlJle 10 d.lm;I!IC If 1")~~d)lo, 111(""11 the ('''Hill') Ull il stand. or fnlhng thiS. Illnke sUle II IS SUPI!'.)II,,, I In ~(Ich it "'oll'l",r th.ll rt W ill nOI bc dillllJocd whdsl "ndOll'!I t 'jlhl nub ;rrHI hollS . 2 Cleanliness,s ""pollanl wh..,n d, s"""'II,"!) tl,(~ cn!)"H~ to prcvllnt e xposed PMIS from contnm,nnt ,on B(dore ~1:llt'"0 Ih\! (hSIll;lnt lll'(j operJtions. cle;:!n Ihe oulsldc 01 Ihe ell!J1IlC wllh 1';H"Um. 0' a !.food greilSe solvent II 11 IS vcry diriy. Carry outlll1s clc;lIu"\I ,Iway frolll the area in which Ihe [lismilnliino IS to ta ke place_ 3 If an eng ine S1<lnd is Ilot IIv;"lllalJlu callY OUI Ih e wo,k on ;, hurrch o r wooden pimfolll,_ Avoid work"'U with thc Cfl\)lIlC (illcctly Oil " concrete Iloor. as Wit preSelllS ,1 re,ll ~olllce 01 troulJle <1 As pilrts o1Ie )cn'ovcd. cl~'o1n lh(:11 '" .1 p"I<,II", 11.1111 Never ",,,,,u,se l''''ts woth Inlelll.l1 Ollw.1ys III po1r,lll", lo"t w'pe dowII c",d"lly w,th iI pCllol·damponcd I;'~) Clean OllWilys w,lh w,'" 5 It '5 advlSilhlu to I"we ~;"'Iahh! co"la"u,,~; to hold ~."'all ItelIIs III lhcII O'OIiPS as tlus woll help wl\(~11 ",assn",hlll'!) Ihu CII!I"'e ;)1,,1 a lso p,ev(:nl posS,I>I" los~
G Always Ohtalll (;oolll'lele s"ts 01 (la~knls wll,,,, Ihu C"!l'"U 'S IoU'"!! (I,sll'''"tled It IS a !Jood poll(:y to always j,t Ilew \l"skeb III v'ew 01 thc rCI"I'vely 5,,,,,11 CO~t IIwolv!!d l\et.1'" the old !F"knts when (lisIllilllllo"!J the en\J"'e With .1 v,ew to \lSII,\! them as .1 patlCln to ,""ke a rCpl,lcemellt !Ja~ket ,t a new olle 'S 1101 "vallable_ 7 \'\,hun pO%Ihle. "d,t "lOiS. holts illld washe,s III Ih e", loc,ltloll5 liS nu s helps to p,otcct the IlIru,ld5 flom d;u""IJe ""d Will ~Iso b e helpful wh~" t.he enO'"~ 1S to"",\! reilsse"'hled. ;os II uSl<llllishes lhell locilt'o( 8 flew", IHlSUrVlco,lble lIems unt,1 the new pails ;HC obl<lllH!d. 50 Ihilt Ihe ,,~w P,III C.ll' 1m chcr-ked ,1\)<IIIISt the old pill I 10 e"~",e that the r.o"e~, ' tem hilS 1"'011 supplied
8 Engine ilnciffMies -relllovnl
AlthoUIJh the Ilems listed Ill;"ly 1m ,,,moved separ~(o)ly wllh the ''''O",e installed (as tI"scliheci '" III(J ,eh:Volnt Chapters) II IS more ,1pP'Opfiaie 10 lake thclI' oil illter the cnOlllc has hcen removed Irom lhr, f.;11 wh(", e xtensive d iSlllil'l1hllO IS hell'!1 cilifieri 0111. The items .11(1'
Friel init1c/I(Jri svs/I.'II> cOlllponellls (Clmplcr 3) DlS/fibulOf (CII,1/>IN 4) Filn ilnd w.llcr IJUIIIP (Cilill'lL'r 2) Power slccring PUm/' (CII,lp/N 10) IlIkl MI(J cX/)<lUSII!I.lndold.~ (CI!.1f!/er 3) C/uld, (C/,.lplef 5) Sl,m" 1,IIIgs (Cfwplcr 4 )
9 Engine -disIlHlIltli,,\)
1 fh,nH)V( ' tloo Oil lev,,1 (hp~t'ck_ 2 UnSClcw the cellire ~Iecve a",1 "!1II0ve tile 011 coolel ilnd g,lske t (pholo) 3 II lIot done prCV'Oll sly. u nscrew tile ~wnp drollll pili\) ;"Inri drJ11l the oll IIlto a Sllolahle conl,,,"c' <1 Unholt the engine mounlings (photos).
5 Unhol t the power steeling pUIllP Idler pulley illld h rilCkel (photo).
6 D,scollncct thc bYPil5S huse 1 '0111 till) tll"ill\) cover ,eill elbow (photo).
1 Hernovc t he rocker covcr secll""\) boilS "nd hit off the covels (photo). DlscGlllle(;t the b,e.llher hose where ,1pplocJble. 8 Undo the rocket shah seClIring holts and remove the ,ocker s hahs Jild 011 splash stllelds (photos). Notc wh,ch Wily the splas h shIelds "re
920,1 cooler show"'!J centre ~Ieeve 9.4A Left·h~nd Side enUlne 1II0Ullt '"0 948 RI\)hl·hand Side enU11le moul11lng
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30 Ch[lptc r 1 Engin e
!l 5 Pow." ~1o'''''n!J JUIIlljl,dlolr rlUlley :111(1 I,,;ldi:;t! ' (."",,,, ... 1 96 D'$l:IIUII,·,:I"'(1 til" hy !l;ISS I,n~fl hum the ,"nUl1l U,II", w;u dhow
9.SA Unsc .. ;w lil., bolts 9.8H .. ,,,,,I '(:I\1OY') ( h " roc ke r ~1,;,11S 9 8e . . lrlli oil ~pl,l~h slll!:lds
'-'.
,-:~~q!~"
, " . i.
99 Remove the push,otls 9 .1 0 RcmovlrI!) the cylinder he"d boils 9.11 RCmOVUln the "Ohl himd sIde c,(hud". head
tilled. M,uk the locke. Sh,llI S so (h,ll they C<ln he ref,und U JIHN o,i9il1(11 POSltlun s 9 Lift OUI Jhe 11\lshlOds imd keep ChClIl1ll Ihelf respective POSItIons on relation 10 the 'oc~c, sh .. lts 10 cnsu.e 1I",e Ihey arc .cloned ,n (heu ollOil1;:11 IOCill10n~ (photo) 1 0 Unscrew the cylnull :" head bolts 1),og,cssl\lcly and "' the reverse order 10 the "uhtcnmH sequence shown '" F.U 1.7 (phOIO) 11 E<lch hC<ld (<Ill now lJe lolled from Ihc hlock (photo) II thc hC<ld blOCks \0 the cylon!!.;:r hlock t.y to u,c<lk Ihe se,ll by r oc kinU'1 II Ih.s docs nOI !rcc'I.1 ~oh I;lced hanunc. C(1Il he lIwd to slroke " Sh,1'p1y <111,1 brC<lk the Cyloll,i!,' hU;I( )onH sc,.1 Ncvcr use ,1 mewl h<lmmcr dllcctty on the he;ld as tillS nr,.ylr'lct"rc Ihc C.l~IU\!J Also Ilev(!r Iry 10 l)flSlllhe
head free by fo'CUltl <I SCU;W(hIV(;r or chls(:1 hr.:lweell Ihe cylinder head nnd Cylrn(iur IJllI'-~ .Ib this w.1I (\;lnl;l\JO th ... Ill<l l.ng sur laces 12 Remove Ihe t ,1""10,, hcad gaskels 13 Unsc,,;w lire <.11"e~!>u.c sWllth 14 USIII\) <I P'\:I ." ull,,,,,, wile. p"se lire V,IIVI; l;lppetS Irom the 1,lock
(l)ho\O~) f>1;lc(! Ih(! tappe ts with thell r espec tive pushrods to cnsu")
coneCI rcllltlllU 15 Inv(;.t Ihe engine "nd unbOlt the sump (photo). Remove Ih(l
Uas kets 1 G Unholt the plck·up p'pe from Ihe OIl pump. Dnd !CllIove the \.Iaskel (photos) 17 Unb011 the ort PVIl1P and w,thd,aw the (
lveshalt. notlnlJ whIch wny fOun(1 II IS lIlted (I)hotos). 18 R(;l11o\(! lhe crankshaft pulley S{-cIIIUI!1 boll and lake the pulley ot! the cranksh;l ft (photOs) Reslr,"11 the c,ank~hnfl I.orn lurnlllfj I,y
ch ockrn\) thc II~whccl 19 Indc>l mark lh(; pOSItIon 01 III<! flywheCI In .(;laIIOn to Ihe Cfllllksh:Jit so th;.t It c~n be retilled 111 the sam~ 1)I)~Itlon 20 Chock the Ilywheeito festram " 110m lurllln\). then remove the SI. bolts S(;C .... roI1\) Ihe fiyvd'ce 10 th(; Clankshaft .Ind hit 011 the flywh(;i:I (photo) 2 1 R«r"ove th e «n\lone adaptOf rlaw (photo)
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ClliIpter' Engine
22 Unholt the thcrmOSlilt INlr Woller eillow R()llloVC the ~Jo1~kCl 23 Unboillhe 1II11Ing cover "ml relllove the UaSkCl (photos) 24 Ullscrew Ihe bolt securing the r..~m~h;'lh {le.1. 10 the Cillll$ho1h ;mll pull oHlhl! nCill (photos). 25 Unscrew the fronl ontctnlcrh,lle plil!C {IHllch'llg boilS ':'IIld rel110VI) tllO rn(crnlClhnl C pinto . Remove the \p$kct ,HId ~pnccl (photo~) 26 If the crDr1kshil ft gO;!' nco(ts 10 be removed usc a stand.lld (1UIle. 10 d 'ilW 11 all the CI;mkshilh (phOlO) 27 Unscrew th e camshah thrust pl,lle 50CU''''0 boilS, rcmo"" Ih, ) thrust 1)I.Jle ilnd wi\hdrilw the Cil!l\shatl (ph010S) , 28 Check th,1 tho l)ig-ol1(1 hC.1roll!1 caps Hlld connCCllllU ,ods loll"', ,denl,lic,ltion 11\;1Iks. This IS 10 "n"",,) (h,1I the CUllect CilpS au! [,II,-d (" the COllcc t connecting rods aod nl "',I"""lIlhly 1l1l~ flBed IIl1h"u ~:O"'''.1 cyllndcr hOles NOie thol11 he I)'~IOII'; h,we 1'111 olllOW (0' r\ou;1I1 ma,~"d on Ihe Clown 10 rUdrC,lle Ihe Inrw,r,,1 1",:OIl!1 s ,de (pholOs) 29 flelllove Ihe No 1 cyllnde, I,,!! ,'r,,1 ""IS. Ihen l.1p of! Ih" I,,!! ':Old
cnp I<",.p I"'~ ~h"11 ''''.1fOllgS w'lh Ihe C,1p .1nd COllneCling 'od I, wh,ch lh~,y Me ,eOllIJved . To remove the shell hearings. p,ess "eolllnu on Ihe s,d,) opposilc Ihe g,oovn on hOlh Ihe connCC IUlg ~0(1, Ihe C"I) .• md Ihe h("lllnu w,1I slide 0"1 (photos) 30 W'lhrh.1w Ih" il'~I(ln and co,m(,r:llI1!1 'od "pwards out 0 1 cylind", I,ow hv 1.lpp,ng w'lh lin, h,,,,dl< , 01 " hnmmcr I, 1I,,,le""',1Ih 31 Rtpc:1 II", poo f.·,lwc gIVen ,11 11;'I'''!I',11'105 2!l.1nd 30 10 remove 'C011.1HlH1!1 ,"~IO"~ an, 1 ,:onneclIl1\j fo.b 32 M,,~,) ~II'" Ih,1 II", ,denul'C<liloll O1101r~~ :Iff! vlsrble on 11m no 1""""'0 ':"I'~ ~o lh.l 1 Illcy cnn b e 1(",II"d 111 IlniU o r'Ulllol l pOSl\lon· ,,,as~eH1I,ly 1 he ""1" ."0: Ilumberr.d .llld oll1 ,UIOW IIldIC<lICS Ihc lIon Ill" CI1!I"U, (phoW) Null) lhal as 1.0111 fdMU.~'y 1982 Nos 2 olml 3 f.
."" ",I, "I1I:d wl,h "'11'10 " holls Ulf.'''II(".l\u'!I l' domed head (phot K",'p Ih.· ,.! 101""11,,,,01 ,,,' poslilon.
:13 U"",, Ih" ""a"'"~lllolts ~mllih 011111" Ill.llt' iJ(!.1tltJU f.nps '''I(I
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9 .2 1 Removinu Ihe enu ine oldaplo, pl.rlC 9 23A Unholr Ihe 11111111\1 cover 923B tll1( retllOV(! lhe {JJskel
9 7.IIA Removc l11e secunnu holl 97.110 ,1rHf ~I"I" "II Ihe t:;1I11~h,"1 un,II [) 25A UI1~Clew Ihe Ilults
;Itld .{!tllOVC the UlICltfled'JIC 925C tlml !JiI!.kt:l
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34 Chapter 1 Engine
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9 .33A flerllovlllU n m,l'" /)(:,lrrl1g h011 934 flemovinu Iho crnl1kshah 9 35A n"movino In upper rnolill henrillO 5oh(:11
935U flernovrllU the llppe. hil!f 01 No 3 mJrl1 bCilrrng shell
liu(iom half of ench i>CIIIIIlU shr,lI. Iilk"'11 I:"rr) 10 kccp Ihe hea"ll<j sh(:11 Ifl Ihe "!)hl ,nps (phOlo) Whell remov",!) Ihe 'car ""lrl1 IWolrrllIJ c;'P nOIp. Ih'" th,s illso .etams lire cr<lllkshili l mar orl seal. Whcn rClllovrrlU Ihe No 3 "'nu, hca"nu C,1p. no Ie the !los'tlon 01 Ihe two half IhruSI wn~;hc.s ,l"d mark lire", 50 Ihal thllY can he refilled or, Ihll S,IIll!l position On h'le' motl!!ls the thrusl w,lshers ;no ,nlcgral with Ihe nlarrl
sheU II "'i'y he nm:; ess,lry to Io1p the mol'" bearing caps with" solt·lacell hnml1lor to releaso Ihem 34 L,lt Ihe C 'Jnk shah oul of thO crankcase and remove Ihe renr 011 seill (pholo).
35 Removc Ihe upper hnlvos 01 the m,un Iw.nrtrlg shells ;lIlt! thll upper hillf 01 tho No 3 hc:um!j Ih,ust wilshers (whe.e illlphcnlJle) "am lire crilnkcnso ilnll Illacc them wI,h the lespectlve m,lln h en""ll C.lpS (photos )
1 0 SUnIl) -rClllovl.1 and refitting with enuine in c;or
1 Disconnect thO hillhlry neU ,lIlve leJd.
2 RomOve the d,Slrrhuto. enl) (Chilpte. 4) Jnd the rad'ilIO' silloud (Chapte. 2).
3
App'y Ihe hil'l('h.ake Ihen l ilCk u', Ihe fronl 01 I he C,1' ilnd suppori on axlo Slo1nds.
<l Unsc.ew Ihe sump tlrillfl P'U!j ilnd drarn Ihe oil inlO a sUItahle
COll lalfler. When completed relll Ihe plug 'lnd lighlen. 5 Remove the SIMIOr mOIOI as descrlhed In ChilplCr 12 (j Unscrew Ihe nutS 110m hOlh engine mountings 7 Reillovo Ihe i,dilplor plilte 'Jo11 f,oll1 Ihe geilr[}ox. 8 Unscrew Iho sump holts ilnd prise the sump frO"l Ihe cr,lnkCil5o. 9 R<lise the onll,ne as lilr ilS posslhle USIll\) a hoist or trolley Jilck. and SUPIJor! wilh swnds hCllCalh the gearbox "nd front of tile enUIfle 10 Lower I he sump I,olll Ihe en<jllle 11 Scrape off all Iho !folskets anrJ cleiln Ihe matlfl9 fa ces 12 Rdmlll!j IS il 'I;Vl;rs,oI of lemoval. hut III Ihe new !jaske!s wllh refcrence 10 SOCllon 33 F",ally 1111 the enU'ne wllh 011.
12. 1 The rOCker shJh h,1s a relillning pin at
I;ilc h end (arrowed)
11 EnUino eOlllpollent:; -(!x ,1Il1i nation fo r WCilr
Whcn Ihe enUIIlc hil~ heen siripped down ilnd all Ihe pilrts h 'mr~n cleilned. Illey should be exarllinc(t fo r w car. In cases where delrllile we", hn1l1 IS !IIv,~n. II ",ust be a mailer of ,udgmenl on whe: or IIOt J PM I IS 10 be ICllcwe(1 o. relilled. Iilklng inlO conSIdClatlon 'urthel "'e expeCled hom Ihe engine. Ihe degree 01 reliabllily reqlJl' Iho COSI ollhe new pilrt ilntl Iho:! nmount of diSfllillltlrng which wII, necess.1fy 10 renew Ihe pilrt lat e •.
12 Rocker ilssemlJly -dismantling. examination ilnd reassembly
Tilp o u, 'he rotl pin !rom one end 0' ' he rocker shall and removo spllng w,'she. (phO IO) . 2 Shde the rocker amlS. rocker Suppor,s and springs 011 Ihe '0(, Shill!. Keep Ihem in Ihe COllecl Older so thaI they can be reassemble r the same pOSition It il rocker support sticks it can be removed 'ilpping " with a solt·lilced hal11mer.
ID ~~t:, rL'O'~COO' f0 .: . . , -111'" . . , . II . ,.: , -' /')')')')-" . .
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f iU· 1.2 Exploded view 01 rocker shafl ilsselllhly (Sec 12)
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Chapter 1 Engine 35
3 Examine the rocker shah ,md ,oc ker il,ms for we~r, II the rod", alill rl tha t conwcts the valve stem IS conSiderably worn. n,new the " ."'"nl I f it is worn shqhlly step-shnped it may be cleaned up wIth rOc e r ". . a fi ne oil stone. . , commencing Jalluary 1984. modolled ,oc ker shah sp"nOs have ~een fi n ed. Where wppet no,se IS evident 011 e~rlier models hl'lw",en e n g ine speeds of 1500 ,111d 2000 'p'll. the later type 01 SP,,,llIS nl.1Y he
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5 Od t he parts and reas~r)!llhle them on therr shahs III thO) n"lI,n;.1 or der With both rockel shafts f,tled the 001 holes must face downw.l,ds to th e cylindel heads Th.s po~"tlon IS lIl(hcated by a notch 011 Oil" "nd
lace of th e rocker shaft
13 Tappets and pushrod s - eXill11inalion 1It HI renova tion
I Examine the v<llve 1;11'1"'1'> 101 wr:<lI "nd (lan1.11Ie. r",new II ~I,·,t"'Lt 2 Check the pusluods for ~"I"S 01 hendiPl\l or we"l Co",,<;t '" 'o:11O".\'
JS ncceSSary .
14 Can,shaft ilnd ciln ls h Hft b earings -cxmninatio n "" d
rCll ovntion
II there is excessIve WO),11 III lhe camsh;lft thp.y will h,lVl! t" lJ" lunc wed. As the 1'1lI1'11 ul '''"1'11 Iwarrll\lS w!(lI"es speel,lI [(",I, thl~ ~houtd be left 10 your 10c,, 1 FOI(! dealer. 2 The camshaft n1;IY show SI\II1S of wear Of) tlH! I)(:''''''!I 1""""'1s 00 C;In lobes. The main d(:elsloll to lake IS what de!)",,, "I I'll"," n ec e ssitaleS renewIng the camshaft. which IS e xpensIve S<:'H"'!IOI da",~ge to t he bearIng 10",()"ls cannO I he ren'OVNI hy ''''I,,,,,I'''!I. runew,)1 0 1 the camshnft IS the only so lutioll J The CJm lobes mny show SlUns of ridgIng or piltmg on Ill" I"U" poin ts . II ridging IS sllghl then It may be pOSSIble 10 rel\\OVC It woth "
lonc oil stone or emery clOlh. The cnm lobes. however. ;"" ~urf;It:e hau Jencd nnd once the h<l,d skill 's penetr;lled wem Will he v,,,y '''pld
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15 Cylinde r heads -dismantling . renova tion and rCils sembly
Clenn the d "t nnd oil off the cylinder he<lds. Renlove lhe carbon deposits Irom tlie combusl10n C I\11'11be,s <lnd vnlve heads with il scraper 01 ,olary wire brush.
2 Remove lilt! valves by comp,ess>llg the valve springs WIth a suiwble v"lve spPlng compressor and loft,ng out the col lets, Relense the v<1lve sprin\j compreSSOI nnd remove the v<1lve sp"ng retainer. spril~,) ami valve (photos). M;llk each valve so that Ihey can be fltled u, the S<1me 10CfltIOn 3 WIth th" v,llves removed. clenn out thC Ci1,lJon Ir{)m the POltS l EXnlllUH! the hearts of the valves nn<lthe v"lve SC,lts for pIt lIng and l1urn ll1\1. If thE' p'tton\l on vall'c and sent IS 511\:)111 II CJll be removed by Uflnclong the v"lve~ and sents togelh(" WIth coalse, ana !hen fIne. valve ~1"ndon!1 P"~h~ Ilihe jll!1lnu IS deep l1lo vnlves will h~ve to be leground on" v;,lv" O""dlnUl\1iJchinc Jnd t h(: S(:ilts WIll have to be reCli t WIll' iJ v;Ilve So,It CUlh" rloth these op(:ratlons .lre n loh 10' your 10(";,11 Ford
d ..,;II(:, or nlUll>l fJngmeerini) speCIalist. 5 Check IhE' valves guides lor wear hy "'s(:'II"U the valve on tho (J",de. the valve stem shovkl move eJslly '11 tho gUide withoul SIde
pl<ly R()newa l 01 wOln gui(lcs requires speelnllOols <111(1 should be left
t o yOl H 101:,,1 Fo, d de"ler G When !J"ndlnU sllgh11y pIned vnlvcs ,'11d '· .llve se"ts w ,th ca,ho,uIHI"ll) pas1e pro1:eed as fOllows Apply ,I Illtio coalse I) "ndon>! p;,S1C !O tlo" valve seal <Ind "S"I~1 ,1 SuctIon lype valve fJ"lHlrn\j tool. UIIl1d th" v"lv" ,nto I1S scat w'th n scnll-IOWry 1\10"':~1ll0'11. IIftu'\I the vil lve fro"" Hm o to li"lO. A light sp rmi) under the valvc head WIl l ass,s l '" 11"5 ope,,,tl"" When a dull mati even surface firnsh ,'jlpeJ,s on bOlh the v"lve ,,,,, I the v;llve seat. clean off the con,se paste .lnd repe"t Ihe \1,ond,nU OP,,,;IlOOI' w,th n I, ne grindln(J paste unli! n contInuous rlnn 01 trUIH U 'ey l1I.1tl I"llsh appears on both vnlve nnc! vollve seat C.1refully
clean off ,III lr;lC()S of 9,in donu paste . Blow Ihrough the gas pass<1ges With comp",ssed air 7 Check the valve springs for dn!1ln\le and .1lso check the free len\jth. rcler to the Spceo/ lcntions at the beginnong of this ChJpter, Renew II defeclive .
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t5 2A Comp' ess the SP'Ii") woth II valvlJ
! ' Il "nU comp,esso, . 1
5 .2£1 thu" """ove the collets (n'il\l'lellC 15 2C. followe(1 by the ,elnmer
1520 ... an d valve SP"Il\!
p,ohe show,,)
t;. "" &' '
'('ii" " 18 ... ,,,
'" ' .
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15 2E RlInlov,nU nil 'nlel valve 15 2F Inltl valve (top) and cxhnust v<1lvU {bot 10m) COlllpo"ents
.. ----------------------------~, 灲潣慲浡湵慬献捯m
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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
,
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
2 CO
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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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.
,
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.
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