ignition FORD CAPRI 1974 User Guide

Chapter 4 Ignition system 93
8 Distributor (2.8 lilre engine) -overhaul
There arc only two overh"ul jol)s possible. these being the fitling of a t"UUcr carl krtllnd the renewal of the vacuum advance uni\. Excessive
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Fig. 4.5 Exploded view 01 the distrihutor fitted to the 2.6 litru cnginc (Scc 6) 13
, DIS/111m/or Cill' 2 HOIQ'lIrm 3 Du,~1 covtJr 4 Rolf I,m , Clrchjls 6 T,iY(Jt'f ,1m! ,lssl.'ml!l y 7 Tii{Jllt'/ coli 8 SWim <lim ,lSsom/)ly
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" Vacuum ullil
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'6 Ch,1 c/.ll11/1
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weM or dllmage to the distri butor body or drivesh"ft wrll I11C<ln Ihe
r enewal of thO complete distributo •. 2 Refer 10 F'g. 4.5 fo r the order of fomov<ll of tho coml)onents and lightly oil the shalt <lnd vacuum unit MOl during rCilsscrnhly (photos).
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94 Chapter 4 Ignition system
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. --8 2A Removill{J the IllnSlre dust COve, (28 hl'c Cllume)
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J 2C W'''I1!j connector i'Uld seCUJlIlg screw (lHOwS)
9 Ignitio n timing -adjustment
Wnh the (.lIs\"OuIO' III!Cd ilS dcscllbed OIl SectIon 6, check Ihilt 1Ill! COHCCt llllllng m;l!ks "'0 ;1119110d. 2 To check the ;1111,,11 (5 t;1I,e) setting, .emovc the (I'51"lIu I0' c;lll [11l\( check IhJllhc rOl0' ;lIm IS PO"1I1119 to the No 1 cylmdc. scgmon!.n the Cill) rndlcmed by the sial on the 11m. 3 On the 3.0 lUre engIne the cont,le l poullS ll\u~1 he ,ust SCI)ilril\U'!J Tho e~ilCt Instant C,1" he checked by connect"'u il 12 vol1 lest lamp between the contilC, brcilke r low tenSIon Iemur),,1 iUl(t O,"lh, W,th the iUnilion Oil, tho d is trlbuto. ShOllld be turn ed nrl\,·clockwisc unlol lho bulb luSlligh(s. " On (he 28 li(re enuule the ("gger arms and stator ;HIllS must bc aligned It not. (um I he (hst"bulOr as necessary . !:i Tighten the (hSI"buto. clamp boll and .ehl the cap 6 Set In thIS way the lUlling WIll be alll)'Olmalely co<rC(:t but a morc ilccurate rne thod IS by using a stroboscopIc tu"ing hghl. 1 HIghlIght the spcclilcd lIming marks on the trrllll1U cover an" cronkshalt pulley WIth wh,le pamt or chalk 8 Connect a timing liijtH to Ihe No 1 spar k pluij le;l d, 9 Disconnect the vacuum mlvance pIpe at tlHl carhure1l0r or au bo~ juel injection) and plug the pipe then .un the engine unt" nOlln,11 ope.ating telllpera tur(!s a.e .eached.
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8 2B UtJlle. vIew 01 the l.imJer Mrn .lrld Call (28 lIt Ie enU"Wj
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8 20 Vacuum un.1 sC(:u"ng screw WIth e')Hh lead termmal
10 W,lh Ihe enij1l1e I(lIrng pornt thc \fmlng hgh( at the cr",lksholl1 pulley The wh,le 1),1mte<l mar ks WIll ;lIme", sliltlonary ,111d If thO tlmlno IS COller. 1 (hey WIll be III ahgnment. 11 To adjust the tllnm9. stop (he engine. sla ck en Ihe cl;'lmp bolt iln(1 turn the (I ,st"l)uto. slIghtly_ TIghten the clamp bolt. star t the engrne ;md .Ct;heck the (umng Repeat tillS 11IocedUie unlll Ihe rIlilrks ,)re In
hne
12 To check the mechanrcat adv.1nce. Increase the engIne speed and note whelher the wh,te malk on the pulley moves away Irom the mark on th e pOInter . 11 It docs the mechanical advance is lunctioning 13 W,th the enOlile Idlmu the vnCU\ Jm advance can be checked by suc kIng the oldv~ncu pIpe that W.1S removed from the carburellOI o r air box ThIS should also c.Juse the while rnark on the pulley to move away horn the mar k on the pointer 14 On completIon remove Ihe timlllU hght and rC(:onnec lthe v.1CUUIll pIpe
10 Ignition illlllllifier module (2.8 l i tre enuine) -removal and rClittinu
Thc Iunitlon illl\J}l lflcr module is locmed on Ihe left· hand SIde of the engIne COnlpar tment. tUSI behind Ihe hOnt suspenSIon strut upper mounting.
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Chapter 4 Ignition sys te m 95
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. 2 1!11"I'On ampllf,er mod&#34;l~ .1m1 mull< .pluu eOllllecto,s
2 With til() l~pll!lOn sw'tehud off rhsconner.1 thO two llIulu·plu!) comW(:I<J&#39;~ (photo) Pull thu WIIP.!i. not thl! plu!) il !iell 3 Unsc".:w Ih., l1'Olll1 ll11H sc.ews ;wr! ,uIII(lve the mOdu le 4 RehW"H's a .evl!.s:d 0 1 .enlowl!. hUI the m!lnlllaclU'c,S .ecll'" mcnd Ih!ltlh,-, m ulu 'lllu!)s ,lie 1.II!"!d wl1h .11'lh'lllll tJ.1~ed !),c .lse
11 Spark 1)lugs -re m oval, servicing and retitling
l' Rem ove the ilir clea ner or inl et duCling ilS rC{luuC tl. 2 Identify Ih c HT leads for posi lion \hen c11Se 0I1I1CCI them from thc sp.,.k I)I!I!J$ hy plllhn!) on the IC'fl,i",11 ends. not Ihc tIIilin leilds (photo) 3 US'''!! a sp;"k pluy Sl)ilnnrlr. unscrew tllf! pluUs 1'0111 the cyhnder
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Ci'ld s (ph&#34;lo~1 4 H Ih'l IIl',,,laIOl no~ of Ilw sp",k pl"H IS dean i'lnd wh,te. wl1h 110 (ICPO$115 tlw;.~ ".dlCo1l1ve of a w,~;,k n&#34;~IUH1. 0' 100 h o t .1 plug (,1 hot plug II;&#39;n~h:ts 1",.11 aWily fWIl' t he I)h.~:I.odc slowly il cold I lhl!1 triHl sle.s ,I ;rw.lY "",dly) <; lhl! IIltl!JS f'l1l:d ilS stimrJi"d a'c ilS hSICd IIllhoJ S pccifleallol1s!lt Ilic <lgrllfulIH u l tl llS Chapte. If thO 111 1 ,l "d I"SUI,llo' n ose Me covercd wllh
ha. d black look",U depos.ls. th..,,, Ih .s .s ,mheilhve Ihilt Ihe m&#39;~I\I.e IS o "eh Should Ihe plllg he h l"ek amI Oily. Ihen II IS lik ely thaI the .I U ine IS fairly W Olfl. (IS well il~ Ihe mixilne benlU 100 Itch 6 If th c lllSuliltor nose '5 cove.ed wnh I I\Jll t Ian 10 glcY ls h blown (ICI>oSIIS. Ihen Ihe mlxllue's CO"I..'CI ,lnd II '5 h kely Ihallhe eng"'e IS ill good condurOll 7 "the.c ilfC illly Iraces of lo"g b.ow n tnpC""1J stilU'S onlhe OUlslde 0 1 Iho wh'le pOl lion ollhe plug. the n th O pl\l\: 1 W ill h,1V(l1O be renewed.
as Ihis shows Ihiltlhere .s il filulty Jom l helween Ihe plug ilnd body and Ihe insulilIO '. and comp. ess.on .s beltlU ilflowed co IC<lk ilWily
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Fig. 4 .6 HT I Cild l)osilion5 o n the 3.0 l i tro C &#34;~Jine (Soc 11)
AllOW III'''(;,lICS ,,,,,,1 ul "'''UtllC
Fig. 4 .7 HT lead posit io ns 011 Iho 2.8 lilro engino (Sec 11)
AllOW imilc,lles I'UII ! 01 ell!}"''''
8 Plugs should be clCilned by.1 So,,,(1 hlilsung n'achme w hich w.lIl.ce thcll' from cil.bon mo.e Iho<ouUhly lhan cleanlf'Y hy hilnd The milch,ne will also tes t the conc1,t lo n o j Ihe pl\JUs untie' COlllpf(~SSlon. AnV plug that lalis 10 spmk il t the 'ccommcn(led prf;"SlIfC s hould be
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enewcd.
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I • I 2 DlSCOllllCC I thO lIT leild . 11.3A ... unsc.ew the spa.k plug I I 38 and remove 11
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,6 Chapter 4 Ignition system
9 The spark plug gaf} is 01 conside rable impor1~e. as. if it is too lilrge or too small. the size of the spark ilnd its efficiency will be seriously impilired. The spilrk plug should be set to the ligure given in thl} Specifications ill the beginning of this Chapter; IOTa sel it, measure the gilp with a/cere, gauge. and then bend open. or close. the outer plug electrode untillhe correct gap is achieved. The centre electrode should never be benl as this may crack the insulation ilnd cause plug fAilure if nothing worse. 11 Relit the plugs, and re/ilthe leads from the distr ibu tor in the correct I"ing order. which is given in the Specifications. Screw the plugs in by hilnd initiilily then tighten them to the specified torque using the plug spilnnel.
12 Fault diagnosis -ignition system
By lar (he nlo1jori (y 01 brCJkdown and running troubles ilre caused by InUits In the igrlOlron system er(her in (he low (enSlon or high tens ion circuns There <ire two mnin symptoms Indlca(lI1g Igni(ion IJults. flthel (he "ngine WIll not Start or lire. or the engine is dIffIcult to SWr( and misfiles If it is a regulnr misflte the fault IS almost sure to he in the Icondary or hIgh tenSion cirCUlI. !f the misfir'"g is intermittenL the "HI lt ~oliid be ;n either the high ur low tension circuits. If (he car stops suddenly. or WIll not stilr( ilt ,111, I( is likely thm the lault is in the low ten sion cncwt. loss of power ,1nd overheating, tlpar t from f,lUlly c,lrl>LJratlon or fuel Injec tion Setlln(Js, ilre normally tllle to faults in the d,strrllulOr Or 10 Incorrect I(Jrlltion tlllllrl!J .
Engine fails 10 staft 1 If the engine falls to StM( and t he cal was IIJnning norll1t1l1y when.t wns IJst used, first check ther e is fuel in the petrol wnk. If (he engille tums ovel normally on (he starter 1I10tor and the bilHery is evidently well chmged. then the lault mny be in either the high or low tension circuits. Firs( check Ihe HT circuit. Note: If lire hal/cry is known 10 hI! {(Illy ch,}lged, Ihe ignilion liglll cOllies on, ,1I)d Ihe s/arler 1II010r {,lils /() tum IIIe ongine check the tightness o f the le'lds on the biltlely terillinilis ,1I)d <1Iso (lte seCUIIHWSS oflhe e,l,th leold (0 irs cOllllec/ion 10 tire body It is qui(e common for tlie le,1(ls /0 Ii,}ve wOlked loose. l.'vc'1I If Ihey look ,1n(/ lecl seclI,e. /I one 01 the boll/my ((:{minM {Josts [11.'1.1' vC'IV liot wi".." (Iyiny (0 wOlk Ihe s/mler 1II0tOl (his is ;/ sUie IIId'C,7/IUI/ 0/ ;/ I;wlty COllllel;('On 1(1 1h.11Ie"lIillal. 2 One of tile commonest rOilsons lor bad stmtln!J IS wet or d;UllP sp,uk plug lead~ and dlstribu(or. Hemove (he distllblltor cap. H "JOdenSil(Ion is v iSIble IIlte!llillly dry the CJp With il rag and also wIpe ;lCf the leads nelu the cap_ 3 If (he enUiue sull fmls 1 0 St.l.t. check that cunent IS reachlllg (he JUS, by dlscounectln!1 ench plug le,l<1 in turn ilt the sp1Hk plllU end, .. ,ld holdlllg Ihe end olthe callie about 5 mm (0.2 Ill) aWilY from the cylillder block. Spin the enu'ne all the sta rter motor. 1 Spa,klllg between the end of the cable ilnd Ihe block should he fa"ly strong With J strong leuulm blue spark_ (Hold (he lead WI(h wbber to ilvold elec(IIc shocks) If Clluelll is reilching (he plugs. then rel110Ve them and clean and reg,lp them. Tho engine should now SWrt 5 If there is no spilrk ilt the plug leilds. wke of! the HT lead from the cenlre of the d'sltibutor C<lP and hold i( (0 the block i1S belore. Spin the engine on Ihe SWrter once more . A Inpid succession of blue sparks hetween the end of the loau and the block ind'cate thilt (he coil is In order and that the distributor cap.s cracked, the rOlOr mm faulty, 01 the carbon brush in the tOp 01 the distributor Ctlp or rotor Mm spr ing is nOt making good contact Poss,bly, (he POintS me in had condition (mechanical contaCI hrOilker) . Renew them ns doscribed in Ih is ChnJ)ter, Sec tion 4_
6 If Ihere me no spmks Irom the end of the lend 110m the coil check the connections atlhe coil end of the lead. If il is in order 5(31 1 checking (he low tension circuit. 7 Use iI 12V voltmeler or a 12V bulb ilnd two leng(hs of w ire. On conventional distributors switch on the ignilion i1nd ensure tha t the points arc open. On breakerless dlstlibulOlS ensure thilt Ihe segments on the rOlor are nOt adJilcenl to (he triggel coil. Make a tes t between the low tension wire to the COil ( + ) terminal nnd eilrth. A leading of 7 (0 8 'lollS should be obtained. N o reJding indiCiites a break in the supply from the ignition swilCh or il f,1UIl in the ballast resiswnce wire. A correct rending indicn(es a faulty cojl or condensel, or n blok en lend between the coil ilnd the distrIbutor. On breokedess ignition systems the (rigger coil and ilmplificr module are suspect . H~ve (hem checked by a Ford dealer. . 8 Take the condenser wire off the points assembly Jnd with the points open test between the moving point ilnd eMth. If there is now a leildrng then the tault is in (he condenser. Fit a new one as dcsclibed in this Chapter, Section 5 9 W,th no reilding from the moving point to eilrth, wke ,1 reildrng between eil/th ,1nd the ell or negiltive ( - ) teminal ot (he COIl. A rendm(J here shows a broken wire which will need to be renewed hetween (he COil ilnd dis(rihutor. No retlding confirms thil1the coil hilS failed ilnd must be renewed, afler which the eno"te wdl run once more Rcmtmher (0 rel,t tho condenser wire 10 the pomt$ ilssemhly.
Engine misfires 10 If the enOlnr. mlsfues re!Julariy. run It ilt a f~st irllrng speed. Pull off eilch 01 the plu(! C,lpS III hUll nnd hsten t o (he note 01 the engrne. Hold the phl(J cnp In il dry cloth or with a rubber g love <IS addition,of protection au"inst il shock frOll1 the HT supply_ 11 No d,ifercnce in eng me running will he noticed when the leild 110m the defective plug is removed. Removing th e lead from one at the good cylinders will accentuilte (h e misfire. 12 Remove the plugleild from the end o f the defective plug ilnd hold il tlbmlt 5 i'lli'll (0.2 in) nwny from the hlock_ SWrt (he enoine. If the sPJ'king is fairly strong and regul"r the I""'t must lie in the spnrk plug 13 Tho plu~J mily be loose, the Insulation mav be crtlcked. or the points may have burnt away g,ving 100 wide tI unp lor the spark to juml). Worse stoll, one of the points may hnve broken off. 11 II there IS no spilrk ilt the end of the plu\J lend, or ,f It is weak ilnd IIlIermiHent, check the Ignition leild from (he distrdwtor to the plug. If the IIlsulJtlon IS cracke( 1 or pCIIshed, renew the lead_ Check the COrlilections Jt the distllbutor CilP_ 15 If (here is s(111 no spark, eX,lmllle the dlstlil)utor CilP cillefully fa, (r"dIllU. ThiS Cilll be recoor1,sed by a very thm black line running between two or more electrodes. 01 between "n elec lrode and some
other Pollt of the dlstllhu(or. These lilles J,e p,lths which now conduct electllcit y Jcross the CJp lhus lewng it run to e,,'th. Tile only answer IS a new distllbutor CilP_ 16 APilit frorn the Ignition tll1l1ng being Incorrect. other Ciluses of rlllsl,,,ng hilve already been denl( w l(h under Ihe section dealrng with the f,lriUre of Ihe enuine to star I. To reCi!p - these 0110 Ih,lt:
(,J) The cOllm.lV be {,lufly giving ,111 iniNmil/elll mislile (b) Thele limy he ,1 (/iJmiJged wile or loose cOrlflee/ioll in till! low (eflsion circuil (c) The condensel /II,lY I;e shOll circuiling (i{ filled) (d) There nwy be a meehanic,lllolUI! IiI Ihe dis/flbll/or (bfOken dliving spindle or eOlllac/bleaker spring. if filled)
17 If the ignition (iming is too far reto1lded, it should be noted thallhe engine will tend to overheat. and there will he a quite no(iceable drop in powel. If the engine is overheating and Ihe power is down, and Ihe ,oni(ion tim in!) is correct. then Ihe carburenor or fuel injection should be checked, i1S ,I is likely that this is where the Iilult lies.
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Chapter 6 Manual gearbox and automatic transmissio n 127
2 Select position O' th en pri$e off the selector level escutcheon nnd. Irom under th e cnr. re move the plug in the side 01 the selector housing. 3 Adjust the inhibito r cnble locknut X to giv e a dimension of 0.1 to 0.2 mm (0.004 to 0 .008 in) (Fig. 6 .36). 4 Refit the plug nnd escutcheon. S With the trnn smission shih lever and the mnnunl selector lever in '0'. ndJust th e selector rod link until it cnll be reconnected without strain .
23 Downshift cable -removal. refitting and adjustment
Support till! front o f th e cm on Jxle Sl<lnds . Remove the spirt pin and d ,sconnect the cable from the cmllurenor Ilnknge . 2 SIJcken the adJust")I} nut hom the upper mount>ng brncke!. pull b~ck the outer sheilth and unhook the c;rble hom the slol. 3 Unsc!Cw the nut at the trnnsrnissiorl rnoun trr\\) hracko::t and unhook the outer she,l th. 4 Unhook the inner callie from the tranSl\\ls s,on lever , 90::1011,n(l ,$ a reversal of the ,lllovc. but the II1Il!.:r nut nt the upper should be screwed on conlp!ctcly. nnd th e OllH:r nu t only il few turns. 6 'p,ess the acceter;-rt{)r \lo::dal hIlly. ,,,,d chcc k thnt the thlOttle plate is ' ... ,y open 7 Us,n\) a screwdrrver. Icvo::r the downsl,,!t cab le lever UPWMt!S. pulling t he mner cahle lully upw,uds 8 Tum th e adjust in\) nut 10 lenuthen or shorten the cnhle to (Jiv e J clearance 01 0.5 to 1.3 mm (0 .02 to 005 Ill) between the downshlf, lever nnd th e accelerator shnl! (Fig. 637) TI\Jhwn the locknut
24
S lnrter inhibitor/reverse Inml) switch -removal and re fitting
1 Pull the cable connector off the switch" 2 Unscrew the slnrter inhihitor swilch and remove the a"int[ 3 To rel'llhe swilCh. fil a new a·ring nnd screw the switch into lhe housing longer. tight. T'gh ten Ihe switch 10 the lorque wrench settin g
given ,n the Specilicntions. I t is imporlnl11 ,hn t thiS torque is not excee dud, 4 Ro::I't the cnhle plug conn ector to the sw,tch,
5 Chuc k th,ll th e en!J"'c will st",t only w,th the lever '" the '1" and "N' posilions and in no other POSlt'on. S TlIIn 0 " the ignition without startll1g th e engine, Check IhM the
r ' ;inU light comes 0 11 in th e "R" po~rtlon, but not in any other.
25 .tension housing o il senl-renew,,1
1 Remove the propeller shnl!. ns do::scrrhed III Chi,pter 7.
2 Jnck t he r enr of Ihe c,u to [1Hn",HSe the loss of 011 from the
transmission . then carefully pr ise out the od seill. being cJrtJIut not to (JamJ,Je the machined recess into which the sc,rI I,ts, 3 E'lslIfe that the recess is cle<ln <Ind undamage d, then press in iI new senl with the lip of the seal inwards. Tnp the senl home fully with n tuhe of suitnule diame ter. or with a hammer nnd ,1 hlock of woorl. being careful that Ihe seal is inserted squnrely. 4 Refit Ihe p ropellur shaft. lower th e car 10 the \)roond Jnd th en check the leve l of Ihe Iran smission fluid as descrrued in Section 19 . F
ig.
6.37 Adjusting the downshift cable (Sec 23)
Depress Ihlollle hJlly (bloken arIOw). Pivol/he downshilllev,·( ,)wuy frum Ihe ,1ccelef,1{Qr sllMI lind UdjllS! Ih e clcarance at Ihe MljllSling nul (solid arrow)
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Fig. 6,38 Inhibito r switc h renewal (Sec 24)
A Wiling connector B Inhibl/Ul swilch C O-riny
26 Fault dingl10sis -nutornatic Ir<lnsmission
FJuit in these units Me most commonly the result of low fiu,d level. Incorrect adJustmen l of the selecto r linkage or downshift cable. or <I I<lldty inh ib itor switch . If the problem st ill exists <liter these points hilve been checked. it w,1I be neceSS<lry to t<lke the car to 11 dealer with equ'pment to diJgnose internal f<lults .
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inlet manifold - 83
main system components remova l and refilling -80 m~intenilnce, routine -79
specificiltions -67 to rque wrench settings -67 Fuel pump carburettor system cleaning - 68 re moval and refilling - 68
testing -68
fuel inject ion system removal and refining -80 Fuel system (carbureUor) accelera tor cable -74
accelerator shah and pedal - 75 air cleaner - 68
carburetlor -66, 68 to 73
description -67 e~ haust manifold - 76 lault diagnosis -85 luel pump -68 fu el wnk -73, 74 fu el lan k fille r pipe -74 fuel tank sender unit -74 inle l manifold -75 mainte nance, routine -67 specifiCiltions -66 torque wrench senings - 67 Fue l tank cleaning and repai r -74
filler pipe removal and re fi\ling .-74 remova l and refilling -73
sender uni t removal and ref il\in g -74 Fuel tank sender unit (fuel injection models) -83 Fuses
G
general -220 specifica tio ns - 199
Gearbo~ see Manual gearbO K Gudgeon pins - 37. 52
pdbrake adjus tment -153 cable(s} and rod removal and refilling 155 lever removal and refitting -154
warnin g hght switc h -225 Headlights alignment - 212 assembl y: removal and refilling ~ 211 bulbs renewal-2 13 Heater assembly: diSI11(lntting and reassembly 8ehr - 19 4 Smiths standard and heavy duty -196 assembly: removal and ret.tting -193 contlols
adjustmen t -192 removal and refilling ~ 1 93 water valve (heavy dUly heater)
removal and re fitting - 193 History o f tho nlodal-5 Horn faul t tra cing . remova l and refilling -220 Hubs, front
bearings renewal -162 removal. ret lu in g and bearing adjustment -16 1 Iraulic systam (brakes) bleed ing - 152 pipes and hoses removal and refilling -151
Index
Ignition switch and lock -224 Ignition system -87 el seq Ignition sys tem amplrlier module (2 .8 l i\(e mode ls)
r emova l and refilling - 94
condenser (3. 0 litre models) -90 COntact bre aker points (3.0 litre models) - 89
description -88
dis tributo r -
90. 92. 93 fau lt diagnosis -96
firing order -87 mainteMnce. routine -88
spare plugs - 91. 95 speci fications -87
t im ing -94
torque wrench settings -87 In strument cluster ill umina tion switch -224 removal and refitting _ 221 Instrument voltage regulator removal and refilling -226 Interior lamp and bulb
removal and refilling -217
J
Jacking -7
L
lubricants and fluids recommended - 17 lubrication chart - 17 lubrication system
M
2.8 litre engine -39 3.0 litre engi ne -53
Main and big·eOld bO(lrings e~amination and renovation -37, 52 Main bearings (3.0 litro engine) removal - 51 Maintenanco , routine bodywork and fillings d oor ch ec k straps security check - 16 locks, door chec k Straps. tuellilte r C<lll flap lubricalion -16 locks operat ion chec k - 16 seat belts wear/damage /security check -16 underbody protective coati no chec k -16, 176
upholstery and carpets - 17 6 windsCtee n illld windows cleilning - 16 braking system
h andbrake linkage lubricat ion -16, 144
h ydraulic fluid levul check /lap up - 16 . 143 hydraulic flu id renewal -16. 144
line s and hoses check -16
pads ilnd shoes we." check -16 , 14 3 servo check -16 . 144 vacuum hose check -16 Clutch adjustment chock -16, 98 cooling syslem
coolan l leve l chec k/top up -16, 59 coolant renewal -16, 59 drivebelt condl tion/wnsion check -16, 59 leaks check - 59 electrical system
ballery elec tro lyt e leve l cheek /top up - 16. 200 equ ipmen t opera tio n check -16. 200 headlamps cleaning -16
253
'i
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•
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2"4 Index
",-----------------------------------------------------------------1 -
ligh\s operation check -16 w~she( fluid levels check/lop up - 16, 217, 219
engine
crankcase emission valve renewal -16, 27
fluid leaks check -16 oil i1nd filter change -16, 26 oil filler cap clClIning -16. 26 oil level check/lop up -16 1I;llvo clearances check/adjust -16. 46
exhaust system condition check -16
fuel sySlCm <lir cleaner temperature control check · 16. 67 air filte, element renewal 16, 67. 79 fu el fIller renewnl (fuel injection models) --16, 80 fuel hoses condition check · 67 idhng speed/mixture check/ad)llSl -16, 73, 79 inlet tllllniioid nuts/holts UUll1cn -16, 27, 83 vilcuum hoses check -16 ignition system contact brC<lkcr points renew"j (3.0 hire eng1l1e) -16, 89 dlS1riiJulor Cilp, (olor, HT le<lds [111(1 co,1 c!e ,ln/cileck - 1 G. 88 (hst"hlltor lubrication -1 G dwell angle check/~diIlSt (30 hue elllJ'ne) -16. 89 sp,lrk pillns cle"n/re-UJp Hi, 95 sp~rk phl\)s renew· 1 G, 95 limin\) check -16 . 94 real axle 01 1 level check/top lip 16, 133 s~fely prec,HltiollS -12 sC(vice schedules -13 suspension Jnd steellfl!) power steerlllg drivebel1 cond,tlon/tenslon Check 16, 161 power steering fluid level Jlld hoses check 161 steering components condition check -16. 161 suspension condition check --16.161 transmission ~utom~tic tr~nsmission brake b,l lld ~dJuSlmenl -16. 123 i1(,tOlmllic transmission Ionk,lge luhricmion -16, 123 oil/fluid leve l check/IOI) up -16, 104. 123 lyres IH(!SSUres chcck/~dJllst -16. 158 we<lr/d~m~gc check -16. 171 whllels comlilion I:llCck 171 Manifolds (cnrburettor nlodels) Icnlov,,1 and 'Cf'tl"'!) exhnust 76 inlet 75 'nnifolds (fuel injection models) relllov~1 and rell!1Ul(J
exhaust -85 Inlet 83 M ,lIlua l g e<Hb ox (iescriptlon -104 fault di~gllosis 122 f,ve -speed disenIJil!)emcnt o f 5th \jeM - 121 dlSnl~ntlmg -111 exallHnat ion Jnd renovation -119 "'put shaft dlsmantlln\j ami rNlsscmbly -109, 119 mainshalt (lismalllllllg and le,l ssc"li}ly -115 reassembly -119 four-speed (lismantllng -106 examination lind renovation -109 input shah dismantling and reassembly -109 I~ygcar dosillanlhng ilnd reilssellli)ly -109 reilsscrnhly -110 gcarchilnge lever (lour-speed) modlflcmions -111 ma intenance, routine -104 removal and reflu;ng -104 speclficmions -102 IOrque wrench SCHings -103 Manual g ea rb o x ./Ild lIutol1w tic trMlsmissioll -102 c( scq M aster cylinder (brllking s y stem) ovcrhaul _ 149 ~ernoval and relltlin\) -148 tvr'rror
o
removlll and relltting lldjustllble exter ior -192 interior -192
Oil pump
p
28 Iotre engine dismantling. examination and re~sselllhly -38 ref in in 9 -42 3 0 li tre englllc dismantling. eX~lllinmion ilnd reass embly .-52 [elit\lng -54 removill 50
Pedal ,1cceler,ltOr 75 bra k e · 152 clutch -101 Pisto n an d connec ting rods ref,nin\j -42. 51 Pistons and pisto n rin\js exanllna\lon ,1nd rcoova\lon 36,51 Pi sto ns. connecting rod s il11d bearin\js (3.0 litre cngine) [lmlov,11 51 Propeller shaft 128 d s, .'r/ Prop elle r shaft cenlre bcarln!J r()&#34;l]w~1 12!J
descrip1l011 28 I"ul l (i iaunosis - 131 removat and rel,UlI1U -128 10rque wrench seHlIlgs -128 univers~1 10lllts inspection 130 Pushrods 35< 51
R
Rndi,lto r rel11ov~I, Inspcctoon, cie<ln'll!l ilnd ",fIIlIlIO GO Rildiator grille removal and refll\lng 179 Radio/cassette pl,ryer
<emovill ilnd reflttln\J 226 Radio equipment. mobile Iflterlerence- free IIlst;lllat,on ,-226 Rcar ,1Xle -132 e/ seq Rear axle ,1xle reilr cover rClllov,, 1 and rellttln\J -135 axleshah beoliing rcnewill 135 removal ilnd relilling 134 descllpt,on -132 fauit (/lilgnosis - 141 limited slip (hiferentoill -140 rnainterlilllCe, routine -133 overhllul -136 pinion oil seal renewal -135 removal ilnd refltling - 133 specifoCiltions -132 IOrQue wrench sellings -132 wheel stud fenewal -140 Rear drum brilk e s
rear hilckpl~te removal and rclluin(J -148 shoes renewal - 14 6 wheel cylinder removal, overhilul ~nd ref'lllllg - 14 7
Rear lamp and b ulb removal and refttling - 216 Rear number plilte lamp and bulb removal ilnd relilling -216 R ear su spension description - 158
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fault diagnosis -172 leaf spling .emoval. bush renewal and refitting -165 maintllnance. louline -161 shock absorber remoyal and refitting -165 stabiliser bar removal and refitting -165 lorque wrenCh settings -158 R"ays -225 Rep.ir procedures, general - 9
Rocker e rms (3.0 litre engine) examinat ion and renovation -51 removal - 49 Rocker arms and coverl (3.0 litre engine) ref itting -55 Rocker assembly (2.8 litre engine) dismantling. examina tion and reassembly -34 Routine maintenance stt Maintenance. routine
5
Safety precautions - 12 Seat belts -191 Seats .emoval and refining -192 Sidelight bulb renewal -213 Spare parta buying -8
to carry in ca. - 19 Spark p lugs conditions (colour) -91 lemoval. servicing and .elilling -95 Speedometer cable renewal - 226 Stabiliur bar Iront -163 rear -165 Starter moto r
description -207
d ismant ling and reassembly -207
removal and refi tting -207 testing on engine -207 Steering column removal. overhaul and refitt ino -170 desc.iption -158 faull diagnosis -172 f,on t wheel alignmenl ~nd steering angles -171 gear (manual)
ove,haul and adjustment -166 removal and refittin g -166 maintenance. rouline -161 power steering bleeding -168 gear removal and refitting -168
pump femoval and refining - 168
specifications _ 157 torque wlench senings -158 track rod end balljoint renewal-167
whea' removal and refitt ing -168 Sump 2.8 litra engine
refining -44
removal and refining with engine in car -34 3.0 litre engine refitting -55 removal -50 Sunroof bracket and dr ive assembly lemoval and refitting -191 panel adjustments -189 removal and refining _ 190 Suspension lfnd steering _ 15 7 tl seq Suspension see Front suspension Imd Re ar suspension jtches removal and relining
Index
T
central facia - 225
door p illar - 224 handbrake warning light _ 225 hazard warning -223
ignition -224
instr um
ent cluster illum ination _ 224 light and windscreen wiper (Series II) -225 load sp':)ce lamp -225 steerin g column multi-Iunction -224
s top lamp - 152
Tailgate priv ate lock removal and relining -187 .emoval and refilling -187 striker plate removal and relin ing - 188 wnsher
nozzle removal and refitting -217
pump rllmov31 and refitting -217 window glass removal and relitting -180 wiper mOlOr and linkage remoyal and refitting -217 Tappets (3.0 litre engine) remoyal -50 Tappets and push rods el<amination and renovation -35, 51 Temperature gauge sender unit removal and reliHing - 64 Thermostat removal. testing and refitting -61 Timing gears examinat ion and rcnovat ion -38. 52 Timing gears (3.0 litre engine) removal -50 Timing gears and front plate (3.0 litre engine) relining -54 Timing gears and timing cover (2.8 litre engine) refill ing -43 Timing. ignition adjustment -94 Tools gencral -10 to cally in car - 19 Towing -7 Tyres
u
care and maintenance -171 presswes -158 size -15 8
Underframe
maintenance -16. 176 Upholstery maintenance -176
v
Vacuum servo unit (braking system) description -156 lemov~! and refining -156 Valves clearances checking and adjustment -46 . 55 Valves (3.0 titre engine) removat -49 Valves and va lv e seats (3.0 litre engine) examination and renovation -52 Vehicle identification numbers - 8
255
procarmanuals.com