lock FORD CAPRI 1974 User Guide
Page 37 of 205
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36 Chap te r 1 Engin e
8 Luh"(;;,,,: lh.) VdtVt! ~1t:m w,1h t!"!l'iI" 011 ;mll UIS",. 01 III 111" yak" !)lIId" Sinh: Oil ,'"ew oil ~I:dl 1110) loUin pla~ttc. ~,:"Is !I\) Urlilip. ,,~h"LI,t v .. lvus (photo) !l F" the v,llve ~PUll!1 ,11111 val",", sP""!J 'CI,lUlI" , 10 Usc .1 ~ul1;ol)h.1 valvll ~P''''Ll (:011111,..,,,$0' lU co"'p'"ss th" \I,11.,c sp"nu unlolthc cOIl<:ls C;lI' In, j'ticd It, p05.II0I1 III ,In, ~lnlS "' IIll) y,11110;: stem Release Ihe v:llve 51)/111\1 f.()UlI)I(l'!>sor. 11 A lter filling ,1111he p,uls. 1011' ti m lOP of the v;,lvl] SP""!1~ 1I\llllly wIth 11 plas llc h,'1111l1ur 10 0.;115""'; CO"CC1 sc;n" ,!! ol'he colll:,s
16 Cylinder borl)s -clIn,nina,ioll and rcnov;ltioll
A oww cylllld", " Iwdculy IOII"d I1l1d Ill" wdll, p.II;oll o:llI"""OIl<)ul liS h!'l!lth Ihe a.; """ 0 1 1111: 1",1,11, '",uls ,,, WI',,, lilt) w"lIs III "!Ihl _"'!llcs to 11m \lonl!I""" II'" ,II,.. "' ~"I" Ih,u,,1 litis w",n I"I\.·~ 1,Iacc
PII''':'I'"lIy 0" Ih,<I ~"u'o" 01 III<, c yl""lc' ~W"I'I by Ihu pl~lnll willS ? Il's poss.!)'" to !Iel ;'" ",<1":;'1",,, 01 hUll, W",II hy "'''HIV'''!) th.] cyh"d", h("l(ls Willi the .:t'lI"'e ~I!II '" Ihe ",,, W'lh Ihe p'~\()n ,Iuwn!ll tlon I'llln 10"1 sl~I"S III W'!." <:.111 be ~ee" ;'lId lell 11I~1 hnlow 110.., lap 01 lion bU'1l whe.e Ibe lop I"SIOII "II!) 'eOlcl",$ ,,,"I thu,e w,1I he 01 llot,cc,llJhlhp (otllt:. (h;", IIuIIII.,1 C,"UOII hu,ld up) IIthe,e 's "0 hi) " IS 1,1II1y ,u""oll;ollie 10 uxpectlh,lll,o'u wc;" ,s "ul ~eve,c .1nd .lily I,'ck 01 Cllmp'ps",(", Of ex,,;cs~>vOl OIl . :on:''''''l'l ulIl ,~ 1!t,O 10 wall! 0' brokc n
p'~I(II' IIII\IS '" 1""IOtl~ :1 11>1 'S po""oI)I'1 W 0111"",, ,11""e IlU';oS,,,,,,U ",,, :/O,,,,,lu •. " 'c,IS,"O Ihe I)IlIC II' Ih., tll'''M plalle bt:low Ihe lop ;,nd aU,I'" ill Ihe bon"", 1>1 tho! .:yllllllc' "I Ih.., """'c pl.",.., II 110" ,1,II""" .. ,c '" IIIU.u Ih,'" 0 076 ,"111 (0003 III) II,ell a ",lxJle 'S IlCC',$S;" y S",,,I;,, Iy .. dolle.encc 01 0 076 """ (0003 ,nl o. ",u'e .'c'oss Ihe holO, (I';IIIIel<;' IS as,!!" 01 oVilhly
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4 Any ho.e whIch is siunlllc~nlly scratched or sCOIed Will re botin g. This symptom usuafly indlcalcs thm IhO piSlon o. rill d;,uII;"Oged. Evcn II only one cyhnder is in need o f .cborlnl1 il w,1I ~ necessnry l or nil cylindcrs 1 0 he bo.ed "nd I'lied w il h new 0 p'Slons .. nd rings. You. Fo .d ;"Ouent O f 10cOl' mala. engin, spec,ahst w,1I be ,,1)le 10 .ebo.e ;"Ond Obl;"o"l lhc necessOI'y m,' pistons II Ih e CI;"Onksh~h IS undergoing le!)lin(!ing .. Iso, iI's .. Iden to lei Ihe S"1I10 111m .enovmo OI"d reassemhle Ihc cr:"lnksha' ll1Slons 10 the block. A rOI)utilble I"m no.mOllly U,ves " Uunr .. nl· suCl1 walk In cnses Wflele enl)ines hnve been ,ebo.ed ""e:"llly I. mOl~lmum. cylondc, loners Me OIvOldahle wh,ch mlly be li1l(.·(1 In cases Ihl! s.,,,,c .ehoflnu I).oeesses have 10 be lollowcd an, se.",ces 0 1 a spec, .. h:;1 cnu,nee!U1U ',rlII :"I,C .eq,lIIcd
1 7 Pistons (lnd piston rings -cxaminmio n nnd renoviltio
WOII! p'stons nrul linus Cilil usunlly hI! (to,1\1!losed whe, ~y"'plo',,s 01 "~C"SSlve od cO"Su"'pl,on nn d low COIllI)'''SSIOIl ;,"11 ;"" SO"lCh"U'S. lhouUh nOI OIlwOlys. assocI,ltcd w'lh WOfll cyl ho,cs Comp'ess,on leSl,"5 Ihal "1 ontO Ihe SI),l, k ph'l) hall.:
<lvndahlc OI"d Ihesc c; m ""hc,11e whe.e low pIC~Su!C IS OCCUII"'\I "sunlly accele',lles Ihe mo.e ,I ,s leI! so wh(;n !Im syn'plO'"s occ,,' ao;I.(On can Il0ss,bly sllve the exp <;llsc 01 " '''ho,l'. :1 Anothm sympiom 01 pis ton w,.,,,, IS fl'~lon slnp a ~nockJIIg , hom the crankcase. nOi 10 he confus"d w'Ih h'H'cnd IlC''''''\lI;lI1o
.:;'" he hc,IId cle,loly OIl low cnl)inc speed when Ih".e '5 no lond (, 10' (,xnmpl,,) nnt! '5 much less OIUlhhl" wh()n the "n!line ~ ,,'c.e"$I;s P'SIon weOl' usuOIUy oeCUlS in Ihe ~k"1 Of lower e"d ° l1'slOll OInd IS ",d'ClllCd hy ve",e:"ll ~I,ellk~ III th e WOIil arc" wh, always on Ihe tl""SI S id e II Clln nlso he se!:n whe.e thl} slwl thlC~ IS dlll"ICn l 3 Piston ling ""eM c:"ln l)(l checked by '''SI .emo ving Ihe lIng s
Ihe pis tons <15 descllbed l:lI el In Ih ,s Sect.on. Theil place Ihe rin. the cy luuler hores hOIll Ihe lOll. push,ng Ihem down aboul 4 0 lilli' '") wllh !he head 01 Ihe p'slon (100111 wh,ch the 1111\15 hnve ! ",mo,,!:dl so Ihm Ihey !cSl sqll.l,e 11 Ihe cyhntJe. Tho;n ",easuo, !I"I);lllhe "lids ollhe ""!! w,th II leeler !F.u\lc (photo) 11'1 e~ceed ~p·ec",ed m,lxill1um tlmn Ihe IIIIU needs I!:'WW'" 11 The \l!orwcs '" wln,,;h the "n!lS loc,ne It' !he pl~t<Jn em' IICCO""! ""liHIJ,,,1 '" usc, The cle;"OInce hClw,-,en ling ;Jfld I)lSlOn ,,, !1'OOVl'. "hould nOI c~ceml 0102 111m (0004 In) lor Ihe lOP COII'J"CSS'OIl linus ,1I,d 0 07(j m", (0003 In) lor Ih e lowel 001 co'
"'I!I !J Howevc •. II.S .",e Ihn lll p'Slon IS only wom illlhe linn \lrooves Ihe IIced 10 .enew Ihem fo. Ihls Inul l nlonc IS "OI,dly evcr cncount, Wlle.eve. JJ'Slons me ."newed Ihe we'ghl 01 lhe Iou. PiS:
eOllllcclmU IOd assclllhhes Shouf(1 be kepi wilhill the hilli l VllllaliO a!) (028 Ot) 10 'l.nlnWIII Cl1glfW balancc () To IClllove Ihe p'SlOn IIIl!)S. shde them cOl.eiuUy over IllC lOP 01 pl~lOll. !akin!) ca,e nOi 10 sClillch lhe aluII"'''''Ul nlloy. nevel shde II oU the h()!iom 0 1 Ihe p'ston sk"l. II IS vc'y ensy 10 !)fc,lk the CIISI
I"SIOll fI:'US " Ihey ,,,e 1IIIIIed 011 fou\lhly. so Ihis ope'auoll shoulI dune wUII e~t,c'"e c ;u c. II 's helplul 10 n"lke lise 0 1 old l\lcle. gall 7 L,II one clld 01 tile p'SlOn nn!J 10 he .e'"ovcd OUI o f liS U'OOVI! "'S\.'I I IIIIde. U Ihe cnd 01 Ihe leele . gilugO 8 TlI'" Ihe Icel e. UIlII\le slowly .ound Ihe IIiSIon lind. as ill/l '
173 Check,nt! Ihe 1)'S lon ""g cnu ~l"P wllh a le"le. uallUC
1 7 8A Remov,ng Ihe lOP comp.esSlon ling 17.8B Remov'ng !he second compress,on IIfl!J
procarmanuals.com
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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
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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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",'
•
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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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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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 45 of 205
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44 C hapter 1 Engine
32 11 TUUHU"' !J the !la~~(:1 "(11ll Ihe sump m.ll11'Y face
33 SIII11I ), wal n r 11111111' and cr<1l1ksh "ft pullev _ relil1inU
Ch!all the 1II:11111U I;ICcs or rhe C •• ll1kC<1!;!! ;md sump EII SlUC rh.,1 till! UrooveS III the su.ll C;1IIIa.s ;lIe clc;on .
2 fll1hc ,ubl)Cf sc;')ls mille !JfOOVCS of rhe seal ';.lrrle.s . Apply s<:;IIIIl<r cOrllJ>ound hcnC:l1h lila cnd~ 01 the ICar su.,1 (pholos) 3 lOCil!C rhe SId e un~kc's Wllh rhen !;Ihs under Ihe CUI 'ouls III rho rubber s(m ls (photo) 11...,1,1111 lh\: !)"~kl!ls wllh a IUlle scalonU cunlJlO""d If nccnss;u y
" LOI:.llulhn ~1I"'p "" th" !I"~~"I~, "",1-,.""1 S""~ rh,11 Ill" holt h"l!;~ ,"" ~111I ah!Jlllld
~) 1"11 Ill" ~1I"'p s"':"""!1 hullS "".I "lIhl,,,, 11\"", 10 Ih" (;Ollllt:1 r",'1"" " ' IWI) SI'\!I"S .IS ~p",;,I"'d "' Sp"t:,hl.illHms ;11 rhl! I",O''''''''!! of It"" Ch.ll'll"
U 1'111<: .... a n"w \FI.,>klll r)1111HIII111111!1 COV", a n d In th .... Wilt'" p"mp "'1 III .... th",,""o~I,u alit! th'llIlI()~t, lI IlOlI~III!J. lutCI to Chapter 2 Fit Ih'l " "n wahl' ,,'how IU\lII IIH)' Wit II n ne w !J.I~k", ., Coat th .... C ';lIlksll,'lh pulhly wasil .... , wuh ~nahll(J COrllp(Jlllld F it tlU I pulillY. w,.shur illid sUet""'I) holt T,!)lIlun Ille holl to tl)() spn(;tr"'d 10ul"e (phulo)
8 tocate t h e 001 coul .... , Oil til() cylllldu, hl()( :k . IO<J {"II(:r w'lh n 1l"W SI';. I. Ihcll "IS!),' "", ~h'(:VII,lIld " 11'11"",, Wll h thc cuolC! p'pes IIIIUI"d ,IS ~h()W'1 nl F'II 1 G
F'g . 1.5 Correct t im in g geM IllMk alignment where the crllnk shaft ye.., h ;)s two m..,ks (Se c 32)
l
Fig. 1 .6 Oi l cooler fitting angle (Sec 3J)
A RC.lr f.1CC of cylmdCf blOCk
32 2A F'tilllg Ihe rubbef se:!1 to Iho IlIllIng cover 3328 Apply s(:.llul!) compound benenth lhe re.ll rUUb!:1 s!:,,1 333 lOCJIUlg the SIde g;)skct IJbS beneath Ihe seals
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Chapter 1 Engine 45
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33 7 ApplylllU se~lInu COIll I)(IUlld to the unnkshnlt pulley wash"r
34 Cylinder hcads. rocker gCM and inlct manifold - rc lin ill(j
Lubricate the valve tnppets wllh cleiln cnUlIle otl ;md Ulse,1 th,,'" It! th o cylindcr block. Ensurc they ille fm"d in thei . OIlDlIlal tOGillrOIl~ 2 EnSIHe tha t the mnllng lilces of thc cylinder hlock ilnd 1he cyllndel h~,lds a.e clean, 3 Position the new cylrnder hCild \I,1skets over 1he \Julde I>ushe~ on the cylinder block. Chec k thm they ilre correc 11y locilled The n!Jht ilod 1, ,11.hnnd gilskets il,e different TIl(: onskets ilrc rn,lrke d FRO NT TOP (pIl Ol0S)
!
.'
/ . .-,,~ .. ~
Fi(J 1.7 T iuiltening sequence fo r cylinder he<ld holts on the 2.8 litre enuin e (Sec 34)
,1 C,l rel"lly lower thc cylrndc r hcads 01110 Ill" r:ylorulcr hlock ,'r1d ht lir" h"IIIII'!1 d"wn holts willch should hc !rrr,1 io!Jirliy ollr:d 5 T'Hirlt;1l tl,,: holts. ttl th" ~"qllp.llce shown 'Il r-'!l 17, '1l1he St,l!JCS as ~pe<:tlI"d It) Spf:clhcaltOllS (phOl0) G Luilrr""I" tile plIshrods wIth el1Uine OIl and Insp.rl them til the <:yllluh" hlock 7 I'laen Ill<! 011 $pl<lsh shIelds In pOSl\lOI1 on Ihe cylInder hC<l<is <lnd ht the rocker shi,fJ <1ssernblres . GUIde Ihe locker <lrln mijllSllng screws IIlIO the puslrrod sockets (photo) 8 TI\jhU!1l the rocker shilll secllfino bolts prO\J,ess ivcly to the
specrfred torque (photo). 9 RelIt the ,nle l l\\al1llold 01<; descrlbell III Ch,lpte' 3 1 0 Adlll~;1 the valve cien,nnces <15 desclllwd In Sect Ion 35.
~4 3A TIl(: dlfferencc hClween the left nmt ','Ilht head gnskets The ""OW mdlcoltes
. oot 3438 CyJrnder head \1,1Skt:1 pOSrilon
rnarkinos
•
r.
/ 1':' .j I
, I • 1 ... , 345T. h ' , __ ..1 I!., u U lco"I\I 1he cyhnder head bolts 34,7 Guidlfl~J 1he roc ke. ilrm il<l)\l5t1l'g sc rews onto the pushrod5
3 4 8 Tightening the .ock !:! shnit bolts
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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 50 of 205
Chapter 1 Engine 49
----------------~--~----------------= anuill transmiSsIOn models, remove foul clops <lnd remove Ihe 16 On h(11 sing cover . On ilulonHll lC tr"nsmIS~lon models dIsconnect Ch.llCh au lug the 011 cooler hoses. and P It the Irans!1lI$S10n then remove th e l'illlsnllSS lon to-engine 17 Suppa <
bolt~ n automatic 1.,J;lsmission .models. drilm the torque conve!ler ,\Ild 18 Ihe drivep l<lte boilS wllh ,clerence 10 Chnpler 6. UO~~~~ Ihe weight 01 tho engine on thc hoist ilnd then pull tile euuin!} " d \0 separJIC;1 1'0111 the \'<lnSIllISS'OIl. 0 " [lU10111<1(1(; IlilI151"'5' 10' ..... 31 , I
. odelS make s"re Ih,lt the torqlle converter ,em,,!!)s lilly 1f1 1he $lOI1 m transmission . 20 When the engine hilS been SCpM,lICd from 11l(l 11.,11$1111551011, 1,lllh!.! . ,lowly chccklll9 j,equently to see (hMllle CflUllle does not loul " ng,ne . ~nv part of the bo?ywork. 21 W hen the engUle 's cle,lr of the iJody . lower it to the ~lfOun(i. Of
Ir~nsler it to a WOrk lJench
4 $ Engine disill1lotling -generill
Refer \0 Sec t,on 7
46 Engine illlcillilrics -removi\1
..
1,',lh the engine sep,l rated from th" t r;IIl~:nHS~r()" remove Ihe ~.tcrnally mounted componelliS ;l~ lulluw~
C;J//)Ulello, i.lnd fllcl {lump (C"'1!,lt" 3) IlIlel ,wll exhiwsl tII,wi/a/ris (Chaf!/t't 3) Sp,>r/( plugs and drS/fllmlor (Chaplet 4) AllCllwlor (Chaplet /2) F.w ,7I!d policy (CII,71I1C' 2) W.JICf pump ,wd Ihcffllos/.1I (Clmp/t't 2) C, ,1IIkc,lSC vcn/iliilion lubc 011 {,f/CI (Scc/ion 40) Ol/Icvl!! r/rpsllc/o; and {,/lCf C,?!, [II!1int' 1II01tn/ill.ll h,.1r:kvls Ciulell (Ch,7/I/l'l 5) Powl'r S/Cl'l/IIN 1'(11111' (Ch;lll/Vf 10J
<11 Cylind(Jr heads relllowti with engine in car
I
Q,scunnecllhe IJiltlery le,lds ") ~cmove the splilsh slucld. by renuJVIII<j 10\" holts nnd luur chps J II.lee il cOrltilm er 01 10 Irtre (I·' 6 pint) r.ap.lr.lty unde!l1e,Ilh Ihl.! ~"lr.llor. remove the rmll:l\or hallam ho~e and drilill Ihe system Rr:rnove the rad "l\()r lap ilose . !l Rcrl10ve Ihe au Clealler. d'SC(lnner.t lile h,el p'pe fro m the ~MI;;"rllor and Ihe l"e,lIiler hose hom Ihe rocker cover.
, R ernove the servo V,lCUlUl1 hose I<om tile Inlr:1 l11illlllold ~ enlOve Ihe IllIe e bolts and rem!)ve II,e Ihrollie Irnkaqe lI<ilC~l;t .omllic le wo1h Irll kilge '
~ DI~conrlccl Ihe rilll,.llul hose from Ihe ilulomallC choke D,s·
,onneCI the vac\JUnl h"e I<om cariJU!l:1I0r .
• D,sconnect" I I I 10 0 le ea( <orll Ihe lempelnllllc sende< Unit.
co I I~con"ecllhe HT ICilds Irom the spark plugs and IrOlillhe Ign'llon I ,1od remove Jlw L T I I I I .
MId I I If . CiI( 10 lie dlSl1i Julor Reillove aile h Xlng bolt 11 0
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a Ihe dlst"I>[1I0r ilSsemlily.
'Sconllect Ihe all II 51 halts' , ' ernillOr Cil) es. ilcken the ailelllntor 1110ul1l11lg un( <emovelh~d b I hi· '" ... live C I. I en remove the fllCrnfilor h XlIlg bolts rernove the ~I' . 12 R " erniltor ')nd liS I,x,ng lIrackel. CIlIOVe Ihe Spa k I cOvers d "p uos. Remove Ihe IIUIS secufII1(.l Ihe rocker 13 R an hll 011 tho covers. emove the I I I . . mlel III f IVC '0 IS sec linn\) the onlet lII,1(l,lold and take 011 lile 14 l an, old complr:te Wllh ca<lIurello, OOson Ihe rock turned a ·d er """ .ldjust"'g nulS ulI\ll Ihe !Ocker arms can be ) hoe Or SI CI(F'(J 1 10) Ihen rCOllOV!.! Ihe pushrods ilild lily them oul Itl PO,ition l~llS I, lill.!1[ finds through a sheel 01 paper 011 which Ihelr III I Ie ("",II,e . I
Pusil rod . C,II1)e "Oled. 11 IS very Imporl<lIlI Ihal the IOtnOVCdS .1<0 r(;f,tted \0 Ihe same villve as Ihat from which they were
"IOC>! "
Fi~,. 1 .10 Turn the rocker (HillS to olle side 10 relllove the pushrods (Sec 47)
15 n,,,,,ove Iwelve lIolts ilnd delilch Ihe exh,lusl I1\,lrlllolds frOI" Ihe cylrrlrtr:f he,lds. 16 Sinckell the cyhmter hend boilS progressively in the revtnSe order to Ih"l shown ill FIll 1.19. IlcrllOVC Ihe bolts nlld hit olt Ihe cylindOf head.
It lile (.Iilsket has stuck and the cylrnder heJd cannot lJe lifted off. wp the cylinder heild wllh n hide·f.1cert. or plnstic·headed hJmmer. 00 nOI try to pri se IlIelil off wllh a screwdrivOf Of rtilillage WIll result.
4 8
Cylinder he,l(ls -rernovfli wilh engine O\lt o f car
Follow Ihe sequence (.I,,·elllll SectIon '17. 51;lItll1g.l1 PillillJl1lph 10. dl$lcoa,d,n!1 leil.!lellCeS to pa'is willch hJve alreildy bcen rcmuved
49 Villve$ _. removal
Rt:rllove the d('POSIlS /'0111 tire corllb\lsl,on chambers ~nd vnlve
h eads by ScrilPIl1!l and W" ~ b'\Ishlll(.l Tilke CJre nOI 10 scratCh the cyllnde, he~d gaskel lilces 2 Lay the CylOl(ier hemt on ,IS sllll) .llld h t the lo,~ed cnd of .1 VJlve spllng compressor ove, the ~plln9 rctiluler ""d ti le head uf the complessor screw in Ihe cenl'e of Ihe v"lve head 3 Compress Ihe sprrng abolll " qUJller 01 an Ulc h 10 Iree Ihl} split colle l hom the top 0 1 the v,llve stelll. If Ihe sPltng ,eliHner "nd collel Slicks. do not screw the co",p,essor down lurlhc< . bec"use IIIIs lII.ly dJr11J\je the valve Slem. bUI lJp the sprong reliluler sha,ply wllh a Ioghl
hammer. 'I When the Iwo halves of Ihe collet h')ve been '(:nloved. onscrew the spllng compressor umrl Ihe spring IS no longe, compressed nnd
remove Ihe compreSSOr . 5 f1Olllove the spltng retnlner. the spflng and the oil seal from Ihe villve Slem. Ihen wrlhdrflw Ihe villve from I he cylinder head. 6 D iscard the valve Slem all senls and plflce Ihe Olher componenls to\jellrCt. identilying them so Ihal they arc refItted III the correC I plnce
III Ihe cylinder head. 7 Remove Ihe sp,11k plugs from Ihe cyhnder hend. II nOI alrendy
removed.
50 Rocker arms -removal
1 Remove the SIIfI nul from Ihe foch" .1'111 Illoullt,n\) stud 2 Lift off the rocker <Hill b')ll seiltin\! and Ihe roc~er Mm and Iny Ihe tl1<ee parIS 10<jethe r II IS ImpOrtilllt Ihat Ihe locke' arm. its hall SCJling and nUl ale refa ted \0 I he snme stud as Ihe one 110m which Ihey were
re moved.
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