steering FORD CAPRI 1974 User Guide

,6 Chapter 10 Suspension and steering
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FiU · 10.11 Fl(Wr stniJiliscr b;H flnd piece positioning (Sec 11)
A IJ 2620 I J!J 111111 (/03 101m) 100111111 (0·1 mJ
1"'5 ;",(1 ,0.:1'1 tile t;1\{1 sHoec When l ilted. the wHip'cec should he 1'''~'ll'''H,,1 .15 shown III FlO 1011 DIIIlCIlS'Oll A should he betweell ?!.i 59 nlld 2Gtl 5 ""ll (102 ami 104 JI') :lnd Ih" (h(fmcncc IWlwr!f!1l IllI! two s"I"5 IIll1S! nOI he \l'catc, th.1rl 2 5 nUll (0 1 m)
(l II Ihe IJl,~hcs "' II", (,11(1 11".:';'$ "''1''''<) """,wi,I, II 'llaV I", found "'O'e COI1V"Il<t:IlI 10 ICIIlO"C tin: elld I)leces hom lin: ~1 .. IJllrs"l hal. "l1hough tillS IS nO) eSSen(,nl. Thp. bushns C,l" he p",ssed OLlI liS"'!! <l sU'I;,blc dllft whilst Ihe end piece IS SlJPPOllcd on ,I ~lIIt;)hh, d"IIlH:Wr Ivbe. Filling is s!ln'!Jhtlorw<lrd. the rww hushes helllU p,essed III ul1ul the steel c~se on the Oll1side of the hush is flush WIth the InsIde of tim end piece. Note the position of the semi·cilcliioll lecess III the hus h ilS shown ill Fig. 10.12. 7 Whell refming the swbilisel hill. ,t should he fitted ilt the I loor end l"s1. with the w1)shers and self-locking nuts loosely IIIs1<lllmi 8 The har is then fitted 10 (h e <lXle tlille. lISlng a sUllo1lJle tool to pull It tow;IJds the axle The hrnckets. clamps 1)ml ruhher IlIslitntors should now I,e 1I11.-:d and the hOlts tl(lhtelied to the speCIfied torque. 9 luwI" thl~ v"hiclo to the UlOllnd. then 10,1(1 the veillde so that Ihe
C"'IIJ(.' 01 till: axle tulle ilnd the sprlllO .em eye ,lie Oil the sarll e
h",,/.ul1,11 h.'vel (the wUIOht ",qlllred IS dpp'ox,m<ll!!ly thilt of two adults) The l1uts "nd holts seclIJlliH th,~ Slilb,hser 11.11 10 the lIuor Gill now 1m liUhlc l1ed to the speCIfIed torque
17 Steering ge<l r (malHlal) _ femoval and refitting
Ll..,tore st;IItlnl) set the f,ol,t wheels In the s[ro1lght ·ahead pOSlt rOll
J.!Ck lip the front 0 1 thn C,lr and place s1<Inds unde, the tra ck control 'IIms Lower the CM shl)htly on the Jilek so th,1I Ihe Ililck rods <Ir e III a
IHlill .hOfllonwl posltioll, Apply the han(lhlilke 1111(1 remove the f,ont ro,l(lwheels.
2 Remove tile nul ~lId holt from the elnmp at the front of tile fleXIble COllpll ll(1 on the steerm!j colllllln, Tills cl,IInp hOlds the couplln(J to the pillion splines.
3 Working on the front crossmemlier, knock hilek the lockmg wbs orl the two bolts on each IJck houslllg U ·C lillllp. undo the bolt ~nd remove tbe locking tabs ~nd clamps
4 Remove Ihe split pillS <lnd cnslClialed nuts f,onl the ends of each tlack/od. where they join thn steerlll(J a"IlS Sepmate the Ir~ck rods from Ihe steering mms. using 1) bl1liloint sepJra to r or wedges. and lower Ihe stee.ing ueor (IOWnwillds Ollt of Ihe Cilr. 5 Before lehlting the steer ing gen!. make sure thaI the wheels have rCllll1l1led In the strillght'ilhead posit Ion, Also check the condition of the mounting rubbers lound the housinu and If the y appeM worn. or damilged, rellew them
G Check that the steCflng \jeilr IS also III the sJraiuh t'ilheild POsl\ion.
Th iS cnn be done by ensuflng that the d,swnces hetween Ihp. ends oj bOlh trllek rods 1111(1 the Stec1inu geilr hOllslng on both sides ~re the same .
7 Place the stee"ng Uear in it s 10c<I11on on the crosSlllemher ilnd ill J lll1le tune 1ll<1t!: II p the splmes on the pinion. with t he splines in the cl<lllll) on the steering colulllll Uexible coupimg 8 Relit Ihe two U·cl1)mps. using new lockmg tabs under the bolts.
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Fig. 10,12 COfrect position o f stnhiliser bar ruhher bush {Sec11 )
T'!jht(:n the holts to Ihe speclf,(:{! to"lne, 9 Relit the I.,lck rod ends into the stO)(:IIn!) illluS. refIt (he I:a';[ellolted nllts and II!Jhten them to the slleclfl{)d tOlque Use new spill pillS to '!:t.nn the nuts
10 T'!lhten tho I:I,II"P bolt (HI the steeru'!J COItIllHI lIex'hle couphllU to 1f1n spec&#34;&#34;~d torque. h,)vIlI!) fll~t rnil(\e SlJlOl tholt tlul pin lOll is cOlfecily 10(;"101(1 III t he S"III1CS 1 1 Lower the cm to tho urOllnd. thcn check nrld If neceSSo1ly ildJlIst the front whlwl ;III(J 'Hncnr 015 descrd)ed in Sec lion 20.
13 Stcerinu geM (Illanual) -overhaul <111(1 adjustment
Remove tlllltr ilc k rod nnds (Section 14) then .elllove 1)nd discard the Wile retalnlllg cliPS. remove the hellows and drall1 the I"hricant 2 Mount the stee"ng Ijear in <l soll·j;&#39;wr~d vice and drill olltlho pIllS sec""nU Ihe uack rod housin(Js to IIHI locknuts Celltre'punch the pIns bciore dllll",O thern Use 11 4 111m (0 1 (; lIloh or No, 22) d"lI. but do not d,,11 100 deeply.
3 It IS now Ilecess,l'y to unSClew the housmgs from the IlnilIOUl1s. so IhJt the tr~ck rods. hOIlSUlgS , locknuts. hall se<lts. w"shers Jlld sprinUS
C,IIl he removed. Idenlt y tJIIS rcqUlles the USIJ of spec;al 1001s which should he aVaIlable IrOlll ol Fo.d De;1ler. hu t II implovised grips or wrenches ;lie used. lilke care thnt no p,IIts Me dalllalled (If pa rtS ille darllaUed. "ew Items must be oblall1ed). 4 Remove the rilck slrpper cover pl~le, slliln pnck. (Jasket and shpper. 5 Remove Ihe pUlIon i>enring Ilrelo~d cover pl;1W, slum pack. g<lsket
1)nd lower beilJlnU {; USlIlg a serewdllver. or sinlllill tool, pnse out the pUllon oil seal 7 Clean all d'll <lnd pollnt from the p,nion Shaft. then push tim p'nion out of the housing Withdraw the rilck from the pll1 10 rl end of the sleerlllg ge~r hOUSing 8 T,lke out the p,nton upper beallng ilnd w<lsher, 9 Cleall omJ IIlspect nil the pans for damilge and weJr. Exallline the bush In the end of Ule r;1ck tuhc lurtheSII.om the pinion If worn. it can blJ prnssed out and ~ new hush Iitted. 10 Commence reJssernbly by f ,tting the pinIon UPPIJI be<Jring <lnd waShel II1to the hOllsmg. 11 POSition the r<Jck into the housing <Jnd leave 11 in the centr~1 pOSItIOn,
12 FI t the pinion. ensuJlng thm. after fItting. the lI~t is towa.ds the Jlght·hand side of the vehicle ( " respeCtIve 01 right or le/1·hand drive vehicles). 13 Fit Ihe pinion lower be,lling cover plate. 14 Assemble the rack shppel. SpIIIlg. uasket. shim pack nnd cover plaHl,
15 LubrientIJ the ball Seilts. balls and housings. with the specified gear 011 Screw the locknuts OntO the ends of the steeling (1)ck. 1 G Assemble t he sprlllgs. waShers. bJIl seJts. track rOd ends and housing. Tighten the hOllsmgs. to obwin a rowtionnltorque of 7 N m (5 Ibf It). then lock them w ith the locknuts. Recheck the torque alter tiuhtening the locknut 17 Drill new holes (even If the o ld holes Jre in aliunment). 4 mm {O, 16
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) Chapter 10 Susp e nsion an d steerin g 167
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F ig. 10. 13 Ellplodcd view o f the IlHII HHl I steering gear (Soc 13)
No 7.7. d"lI) ''''''''':1\:1 )( !) nit" (035 Inch) deep <Ilong the brOJk I •. , I .. :\w",,,u ll1e h()u~II\H lIud 1he loc~nut. <Jpp,ux,mi)lcly OppOSIte the
"1);"""" IOG,t'''!J huit) III Iho h OllsOIl\j 18 FI t IWW wl""""11 pUI S :11.<1 pt!cn ove, the SUlloumhng meW!. 10 1(.:1;"" them 19 Llghtlv IJ'C,lSC the ,nSlde of the bellows. where they "",II corlt,lC the '''lck .o d s II1SI,111 one bellows. cnsunnu that " locales on the "ack rod groove. then 1, a new 1010111''''9 Ch, ) 20 Add Ihe SI)Cclhcd (IU;II' I'ly 01 SI(,e""u gear OIl. ope •• n ing the rack over liS limue 01 Havel '0 ,15SIS ' thO lubliCilnt in "owrng. Do not OVllrl,1l 21 FII the othOI bullows. then CilllY 0111 the lollowing ildluslmenl prOCedulOs Ideally Ih ls Will IC(IUIIO thc use 01 a diill gilllge ilnd mountlOg block. a 5udace tahlc. il torquc yiluge and iI splrned adilplor. It IS lelt Ihat most peo,)le Will bo ahlo 10 SUitably improvise. using Olhcr equipment. hul II IllIs Cilllnot he done and thO equlpmOnt "sled is lIot ilVillla ble. Ihe 101/ s hould be unllu$tcd 10 your locill Ford Dealer .
22 Wllh the ~Ieelmg Ueilr mountud III iI so h·Jawcd yice. remoye the r,:u:k ~I&#39;ppur coy", pl!!Ie. shim p,1ck. {lilskor. mid sprIng . Also "Jmoye the I"n'on bOilflll\J coyer plalC. sh im pac k and gaskot. It i1ny oil is lost dUIIIl!) thc adJustfllenl procedures thO steering gea r must be rl!'
plc&#39;&#39;&#39;~hcd hclore IllIIng to Iho cm.
P,niOIl bec1ring preload 23 PlilCC the shun p,l c k alld covcr pl1lle 011 Ihe bearinU. lighten the 'JOlts. then s lacken Ihcm 50 .hal Ihe covel platc louches the shim The \' pilck Illll~t (;omj}lIs e ill hlil st three sh ims. one 01 which musl bc Q m,n (0 093 In). tlus bern!) ullllledlalely agaIns t the COYcr plate. 24 Measure Ihl! COV'" pl,lle .to·housllIg gilp. and if outside I he ranUe 02810033 fllill (0 all 10 a 013 In) reduce 'he shim pack th ic kness {If
Ihe UilP is '00 li1rud. or Illcrei lse II ("the gap IS 100 slllilll) unlll Ihls gill) IS Ob'ilillcd Remembe r Ihat lhc 2 35 111m (0 093 III) shim Illustrcmillll
Immcdiately "UilIllSt Ihe cover pl;)'e 25 When the COIICCt \1.11) IS ohl!!lIlcd. rernoye Ihc coy!;'. pl"le. IlIs!.111 thc gasket ilild r efit ,ho coyer ,)IJ tc. Am)ly locklllg lIuid 10 Ihe coyer hOi' th.eilds. lit Ihem ;)"d lighlen,o a 10 11 N m (6 \0 albf It).
Rack sl/iJpcr .1djus(mell( 26 HilYlllg set thO pOlllon bearing preloJd. measure 'he heIght 01 the stopper il!J.OYC the IIIillll body 0 1 the rJck. as ,he rilck is moyed Irom lock \0 lock by turnIng 'he pillion NOIe thc height reilding obtained. 27 Pr CPilre ;l shim pack w hiCh. Including the thickness 01 the 'ilck sloppe r beJring {JilslIet. is 0.05 to 0 15 mill (0.002 10 0 .006 in) thicker than ,he dimcnSlo n lIoted In piuagrilph 26. 2a FII Ihe spring. gas ke t. shim pilck and coyel plate to 'h e ra ck housing (gaske l ncareSt housing) Apply locking lIuid 10 the coyer bolt thrcads. III them illld 10rque tigh.e n to 8 10 11 Nm (6 to 8 Ibl h). 29 Measur e thc ,orque rC(tullcd \0 lurn Ihe p inion throughout i,s mnge of I!.lY cl. ThiS should bc 1 t 3 10 2.03 Nm (0.83 to 1.50 Ibl It); if oulside th,s ,ange. Iilul,y componcnts. lack ollubriCilnt etc. should be
suspected.
1 4
Track rocl end balljo int -renew al
Jack up thc loon. Of thO Cil r and SUf)pOrt on Jx le stands Apply the halldbrilke ;)nd re!llove Ihe applopriil'C Iiont roadwhcel. 2 Slacken Ihe baliJo in l locknut 011 the track rod by iI quarter 01 a turn. 3 Extra ct the spl, t p,n Jnd unscrew thc nul securrng the !Jilc k .od ond
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)8 Ch apter 10 Suspensio n and steering
\0 the SI(lcring Mill (photo) 4 USlIlg" 1)[lIi)onH SCpilriltor tool (photo). reh:o,lS(l the ['ilek rod end from the Slc(!rino ""m 5 Unscrew the h,"'IOlilt hom the ['<lek rod, notmg lhc C~ilCt number of turns required 6 SC!( )w the new 1m ill Oint 01110 til(! 'rac k rod the SilnlC number of turns . 7 FIt the (.<le k lod end In the steering [I,m, SCI(!W 011 the nut illld lighten 11 to the specIfied torque AII\)11 the holes nnd IIlscrt il new spht pin
8 T'Uh!C1l th e h<lIl,DUlI locknut whde holdlrlU the unck rod end hOrllon\<1I, {) ReIn the ,oailwhc()1 ilnd lower the C,l' to the wound. 10 Check ,1(1(1 ;ullllsl til" f,ont wheel ""onmen! <1S desCllhcd ,n Section 20
15 Power steering -hlccdinU
The power ~1P.elln\J SysHllll WIll only need blc",rhnfj Ifl the even! of . .., hell1\J Il1tl<)(hu:ed ",to the system. cu whcn: IH llI:S h;IV() IW(}1l dlscoI1l1cc«:d or whel() J Ifl.lk"(Je has occlUfed To hleed the system ···ocp.ed ;'s (1<,~<:&#34;I)Cd III 1(11) followlllU l),l';)\J,,1I)hs
I Open llH~ hO'Hl()1 ,111<1 cl\p.(:k the Il",d h:v el "llhe Il'Sl'IVi'" Top·llp.t llucess;IIY IIS"'!J (Il<) spe.:II,ed lype of 11(11<1 3 11 11."d IS added. allow two "'''HlWS. th"l1 lUll 11m I;I\U"W at apPI{)xIIllntnly 1500 rp'" Slowly \illll lhe st'!""Il(! wheel 1,0m lo,:k to lock. wlllisl r:l\.,,;klllH and WPP"'!I up Ih e Ihlld unlll th" l"v,,1 ",m;II11S
Stf),li1y ;1<\<1 no molC hubhl"s ilPP":U I II tlw I"S,,,V,,II
" elc ;,", and refn Ihe r"servoll cap ami close II,,, 1>0"",,1
16 Power steering gear rellloval and refittinu
The p'ocedure IS Sllml", to thilt descrd)<)d III Sc(:t lon 12 10' th" m,10u,,1 steeling gC,lf NOlO. how"ver. lhm tile 111011111(1)(1 1)I)Its (jo cOllipletely tl1(ouyh lhe front e,ossmflmhe,. "nd the II.),,, nil IS a,e
I()(;ked wllh sphl pillS. Add,llon"lly lhe lIuld IIIH)S rnu~;t Iw lhsc.onnec · l"d. and atln' ,uI,Um!J the system ~hollid he loppud III' ,lnd Illed wllh lui"",,,!:,, 10 $"(;tl{>n 15 (photos)
17 Power steerillU pump remov;ll "lid rcfil1 ill\J
Loo~&#34;n tl", «II.." Iwlley 1",lck,,1 b"lts. ,el..,ase Ih" d"ve!Jclt lellSlon. Ihcn ,emOVe II", dllvelu:lt I,,)m the P"'''I' pulley Oil 3 0 101", IIIO<il:ls , FI(:k up the tro"l 01 tlH~ ~&#39;&#34; ;lnd support on "xlu SI;IIHis. Ihell 'e"'ove tlll~ ""\llnU spl,'sh ~llIeld Belllove lhe tuul pump , 'Ill til() U"U"U, (Ch;,ptc, 3) lIul 1,,;IVIII!1 th" fu el trncs (;oIHu )Cled .
O ,sc<)nll,,(;1 Ihe IIlIal hnes hom the pump ~nd <1,,111 Ihe IIUI(III)to" sultahl" (;Olliall'", The pIIISS(lIe I",e h,15 .1 sell)w"d (1111011. hul the lehlln Ime 1 5 ,1 ,ulJhCl hose connecl'on (pll()I&#34;~) " Ulliloit (111) powe,· steuIIIIU punlp. (o\Jelhu, WIth thn IllOUnllllU
h,;lc.k(,t ~nd st;)y. wlw,e ;1j)1'11 <:;,I)I". ,!Ill! ","'ove f'DIII Ihe CII!) "le (photos). The "",d..,1 C;'rl lh"" 1m (lnl)nlt"d flOm Ihe pUlllp of nccess;"y, 5 RellltlllU IS .1 ,ev,,&#39;~al 01 I..,moval. "ul l&#34;&#39;Il~lon Ihe lhlvehelt ~Ild "Iced Ihe sy~IC&#39;&#34; wllh lek'e'll:tJ to Sec;1I0ns 2 ,!Ild 15
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18 S teerinU wheel removnl nnd rIllittinu
1 Dlsconneci the lodlielY nCU~lIve le,,(1, 2 PIISC Ih" mOllf hUIll Ihe celn,,) o f Ihe stcclln(j whc,,1 (photos)
15.1 A Powef SICCIIIl(j (je,, ' showUlU pinlOrl and lowe, coupl",U ~h,,11 un,vcfsnl lo;nl 161 B Power steering ue", mountUlg bolt (,,"owed) 1 G 1 C "nd nul (""owed)
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Chapter 10 Suspension and steering 171
19 4C Removinu the top steering column Shroud 19 G lunitlon SWitch ,1nd wirlllU (A). also COllll'lII upper mOlUllnl!J holt (0) 19.7 Removing the steering column uppcr mounlul(J holt (arrowed)
'5 Secure Ihe SIt:(;(1I1(1 lock 10 Ihe colulIlIl ,lIal ~heil&#39; the h eads I,om ,he m:w holt~ 11) U~e the stecrin\J lock to locate the shaft in Ihe column. then III Ihe )ct,on mdlGltor OICIlJalinn GUll alld Stecrmn wheel. CtlCC~ that Ihe ruadwheels afC st,lIln the 5trai\jht·ahead P05,110l1. 17 Install the Stce!Ul(J column orommet Oil the lowm en(t. 18 LOCille the column assembly ami sr:c",e It wrth the Iwo mOllrlllng bolts. 19 The ((,milliuler of the rellllUI\J proccrl",e ,~ th" reverSI! of lhe removill procedure,
20 F ront wheel alignment and steering ilngles
Accurate front whcel alignment IS essential lor good stoer"'g and lyre WOiJr. Scion) cons,dering the steering angle. check Ihat Ihe tyres
are correctly inflated. tllnt the front wheel s arc nOI IJlJckled. the hub hea"nns arc not worn o r mcorrectly adjusted und thilt the sleflr"'g IlIlkaUfl is in IJood order. wllhout slackness or we,ll at thu Jo,nls
2 WIH;f; 1 "I'!JIununt co&#34;s&#39;st~ 01 loUl I"ctors, C;"lliJcr_ IS the ""Ule "t wilich the front whet:ls ,lie sci from Ihe
verllcal when v'ewud 100'" the IrOnt 01 the c"r 1'0sIt,ve camber 's Ihe .. mount (111 de\J&#39;ee~) th"t til() whucls ,ue toited outwards at the lOp 100'"
thu vert,c;,1
Castor. ,~tho i&#34;&#39;~Jlu between the SIl,erlIlU ,,~,s OIrld.1 v..,'I,e.11 lone len viewud IrOIll p,lch ~,dfl 01 the C,lI 1&#39;0~;llIve castor 's when the ~tcermu ",x,s 'S ",cloned rUiHw,,,ds ill the top jStcerinu ilxis inclin,,{ion 's lhe illl\Jle. when VIewed frOI11 the .It 01 the Cilr. bel ween the verltcal and "n 1Il'''U>I1.1ry hne drawn betwCl)n the upper ilnd lower suspensIon strut p,vots, Toe-i n IS the ilmoUl,t by wh,ch tlte dl5li"'Ce helween the frOrlt
IIlsuJu ed\Je~ 01 the rOildwhecls ('He,lsu1ed m huh heiuht) ,s less thiln lhe d'sWrlCI) &#34;,e<l~ured between the rca' Ins,de edges 3 The imUleS of c"mber. c,l~tor "nd slCe''''g ax,s ilIe SCI ,n produCI'On ~n(1 nre not <ldluswble. 4 Front wheel aliurUlll)n t (loe·"I) checks ilIe best camed out wl\h nlodern set!lIlg equ'pment. but il fC,lsonahly acc1llate alte rnative is hy nle<lns of the following procedure.
5 PI"ce the Cilr on level ground WIth the wheels 111 the sualghl·uheild pos' lion,
6
Oht"in or m"ke <I loe·in unuge Onu IHay eas,ly he Ilwde from it lenyth of rod or t ubinU. cr<lnked to clear the SUIl'P or bcllhousing and h~vmy il setscrew "nd locknut ill one end 7 W'lh the gnuUe. measure the d,stilnce IJetween the two IIlner wheel IIrns M hub helUln ill the Iron I of the wheel. 8 flowte the roadwheellhrough 180' (hillf il tU1[1). hy pushinU or pvlllllg the CM and then me,lsure Ihe d'Stilnce ilgaon at hvb height bel ween lite inner whee! (In,s <It the reil! of the roadwheel. Th,s meaSurernem should eIther he t he Silme as the one Just lilken. or greilter hy no! Ino,e lhan 7 mrn (028 in) 9 Where the 1O~·1II IS founoJ to be ,,,correcl. sla~ken the 10cknuiS 0[1 each tr,lck rod. also t he I lex ,ble bellows clops and rOWle each tr~ck rod . XII equal ilrnourl unlll the correcl toe·,n ,s oIJW'''ed . T,ghten Ihe .k rod ~nd 10cknulS. whole the !JilIIJo,nts ille held III the centre of lhe" ilrCS of trilvel II'S "npcrilllve lh~11he len\Jlhs of 1he trilck ,ods are ~IWi&#39;yS equal 01herw,se thu wheel ilngles on turns WIll he ,ncorrect. If
ne:w components have heen I'lted. set the ro"dwheels ,n the stral\jht·ilheil(f p05otrOn and also cent",lrse the steering wheel. AdJ"st the len\Jths of the track rods hy lllll1ing tltem so th,,! the track rod end IJ,litJoinl studs w,11 drop eils,ly onlO the eyes of the steer inu ilrlllS Measllfe the dislilllces between the centres of the hilllfOllllS illld the grooves on Ihe inner ends of the track rods and ildjust. ,r neceSSilry. so Ihiltthey me equ,ll Thl~ is all lII,t,,,1 sellinlJ only and prec,se ildillstmellt mu~t he carried oul as descrrhed earheL
21 Wheels and lyres -uonNal care and milintenl1nce
Wheels ilild tyre~ shOuld give no reill problems in usc provided thm ,1 close eye IS kept on Ihe", with re\janlto excessive weilr or dilmilge To llns end. the following pOllltS should he noted Ensure thm lyre pressures ",e checked re\Jularly ami ma,ntallled correctly. Checklllg should be c,Hried out woth the tyres cold alld nOI IIlHlledialely alter the vehicle hilS heen "I usc. II the pressures are checked w'th the tyres hOI. iln ap(l,Hently hi\jh readmlJ w,1l be ohw'lled OWlnH to heilt expJnsron. Under n<) Cllcumst<l"ces should ,III ,!lWlllpt he lIlildu to reduce the p,essu,es to Ihc quoted cold r eildlllU ,II thl~ "Ist,once. or effect've undcrinlliltlon w,1I result Undc""f)"I'o" wrll Ciluse ov(;rheiltu\lj 01 the tyre OWin\1 to excn ss,ve fluXlIlU 01 the casin\l. and Ihe Ire,ld w,1I not S,I correctly on lhr! road surfilce ThIS wrll cause it cOllsequent loss 01 adhcs,on alld excess,ve weilr. IlOtto '\lention the danncr of sudden tyre fadwe due to hea t bluld U), Overonfiil t,on w,11 Ciluse rap,rt Wear of the cell Ire part of Ihe lyre tread coupled w,th reduced ndhesloll. hiusher ride. and lhe dan\je, of shock dilmilge occw"ng in the lyre Cilsin\l Heg"liloIy check the tyres lor dilrno1\je 111 the form of cuts or !>"Iucs.
eSpecii\lIy 111 the s,dewalls Remove any na,ls or stones ell\bedded 111 the tread hefore they penetr"te lhe tyre 10 cnuse dcfliltlon If remov,,1 {)i <I nad docs reveill thai t he tyre hilS been punctured. relIt the "JlI so thill ,ts point 01 penelrat,on is Illilrkcd Then inHlled'illely change the wheel and have the tyre repimed by il tyre deiller, Do no/ drive on il tyre in such il cond,"on In lIlilny cilses a punClUre C~ll he sunply repa"ed by tile use of ilil IIlner tube 01 t he correct size ilnd type. If In any doubl ilS to the poss,ble conS<lquences of ilily dlll11ilge found. conSult your locill lyre defiler lor adv,ce Periodically rcmove Ihe wheels and clean any dirt or mud from the 'Ilside ilnd outs,de SUrlilCeS. Ex~mine the wheel rims for signs o f (listing. CorrOSion or other dilmilue. Light alloy wheels "rc eusily
dilll1i1ged by ·kerbing· wh,lst par king. and simililrly stee l wheels may hecome denIed or buckled, Renewnl of the wheel rs very ohenthe only course of rellled'ill ilct,on poss,ble, The balance 01 each wheel Jnd tyre ilssembly should be mainta,ned to ilvoid excess,ve weilr, not only 10 the tyres but illso to the s teering and suspension components. Wheel imbillilnce 's normilily S'\ln, f,ed by v,i)rilllOn through the veillcle·s bodyshell. illthouUh III many c~ses it IS piullcularly nOliceahle Ihrouoh the steenng whuel. Conversely. it ~hould bc noted thilt weilr o r dilnlaUc 111 suspellS IOll or steer ing components may '.:ause e~ceSSlve tyre wear. Out·of·round or out-of· t!Ue lyres, damaged wheels and wheel !leafing weilf/ nlilladJustntent also lilll into th<s Cille\Jo ry Billancing w ill not usually cure v,bration caused by such wear
,.
:.
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Chap te r 1 0 S uspension and steering
Wheel b,ll,lncing may bo carried out wllh the wheel Mher on or off the v eh icle. II b<llanced on the vehicle, ensure thm Ihe wheel-to · hub rclallonshlll is mmked in some way prior to subsequenl wheel renlov<ll so Ihm 11 rllay be re /,u ed in it s origin,,' I>OSItion . Gene,,,1 tyre wear is influenced to" I",oe degree by d.iving s tyle -harsh br;)kmg ilnd "ccelelation or l ast cornering wifl 1111 p .oduce mo,,:~ rapid tyre wear. Interchanging 0/ tyr es may result in mo.e even weill, but this should only be ,nrlied out whele there is no mix 01 tyre types on the vehIcle. However. II is wolth bearin g in mind th"t if this is completely ellecllve. the nelded expense 0/ repl1lcing 11 com pte te set o t lyres simull<lneously is m curled, whICh Illny prove lin,lnCllllly re StllCllve lor many owners. from tyres Il'''y wear unevenly ,lS ,1 . esul t of wheel IlllslltiUfllllent 1"he front wheels should 1Ilw;)ys be correctly "lruned olCcordinO 10 the ~lJllm\JS ~pcclfled hy Ihe vehicle man"l"ctufef.
22 Fault dinynosis -suspension nnd steering
5ylllptOlll
III(; le pulls t o on!! ~Idll
Slecnl1!l ~trll or h eav y
Excessivc pt;Jy in s!Cerinu
W twd wohhtH ,11111 v,h,nIIOI1
Ty,,~ W(~;II 1lI11,VCn
leg,l ! restri ctions "pply \0 the mixing 0 1 tyre types on a vehicle . Bilsic;lfly this means Ihil a vehicle must nOt have Iy,es of dilleling conStruction on the same axle. Althoug h ;1 is nOI recommended t o mIx tyre type s belween Iront <Ixle lind 'ear ax le, the only leg"fly pe rmissible cornbinilllon is Crossply o'ltthe Iront ;lnel rildial "tthe re,1I When mixinU radio'll ply lyres, tOxllle br,lced rad Ials must always go on Ih o front ilxle. WIth ste el brace{! radIals at the rM •. An obvIOus d,sadv"mage of such mixing IS the necesslly 10 carry two sll"re IYII!S to aVOId COntravening the law in the event 01 <I puncture. In \he UK, Ihe Motor VehIcles Con5trUCllOn nnd Usc Regurntlons npply t o Illany a sp ec ts of lyrC f illing nnd u snge. 11 IS sugues ted thnt a copy 01 these regulnt,ons IS o1>I;)'I'Icd from yOll' locn l polrce if in doubt ,1S t o Ihe CUlfCnt lC<Jnr .eQllllClllcnts W Ith rcgard to lYle Condlllon , mnllillum trend del)t h. e tc
Renson(s)
InCOlfect whcel o1lrUlIlllent WC,II In SIISI)()IlS'On 01 SI(""""! I CO""llOnents Ar.r.uic"t .1""'''!lC 1 0 SUSllf,nSlon o r ~I.w&#34; nu compUll"nts IIlr.Olllll:t lyre p.eSSUlt's
Lack 01 SieIJIIIl!J \J<la, lublln;1I11 $elf(,d halllulllI
1"r.O""r:t wheel alrWIUlen t Powc. SIIJIJ'"1U laulty
W orn sleellng Or sus penSIOn 10UliS W en. III couplrnU shllft unlve,sal Joms Worn r,lc k ilnd 1)""On Incorfectly adJuSlcd rack Slrll llC'
RO:Hlwhe els oul 0 1 hnlance flU.ltlwhcels huck led or IhslO,Wd l:iHlhy ur dnmnHed IVII]
Wu,u s tL'f:II"!J Of SUSI&#34;&#34;l~IOn JI1I1lI~ WlJnk Shoc k ;.hso&#39;b&#34;r~
'"collee.1 whee l ;' ''UIIIHlllll We: " III suspenSIon Ot st"""lIg C{)I11POIlCntS Ro,'llwhL'Cls out 0 1 halance WIJ;lk shoc k 'lhso.he'5
I
~. -----------------~
灲潣慲浡湵慬献捯m

)
Index
A
Accelerator cilble removal ilnd refining -14 shnft ilnd pedal removal and refining -75 Air cleaner removill Jnd ref,nrng cal buren or mod cis -68 fuel injecllon models -80
P rnator .,rushes inspecllon. removal and refilling Bosch -202 Femsa -203 Lucas - 202
dismantling and rcassembly -203
removal and refining -201 Antifreeze mixture -60 Automatic transmission descrip tion -122
B
downshift cable removal. refi11ing and adjustment -121 extension housing oil seal renewal -121 faull diagnosis -127
maintenance. routine -123
removal and refOlting -123
selector mechanism ildjustment - 126 rcmovill. overhaul ilnd refl11lng -125 speclflf:iltions -103 SI.1r1er IIlh'bilm/reVerse lamp switch remov<ll <lnd refIlling - 127 lorque wrench senings -103 'iliary (driving) light ,oIigrllnell t 212
Bilttery clrilrgmg _ 201 description and testing -200 removal and rcfll\lng -201 Big-end bearings -37. 52 Bleeding the hydr<lulic system brakes -152 power steering -168 Bodywork IJnd fittings -173 el seq Bodywork and fittings bonnet -186 bumpers -1 78
centre console -189
demister
noules reOlov<l1 and refi11ing -197
description _ 174
doms-178.180. 18210 185 face level vents removal and refItting -197 facia panel -188 fuel filler flap -188 heater -192 to 194. 196 10<ld space trim panel removal and refitting -186 -'alnlenance
) bodywork and under/rame _ 176 routine _ 116
uphOISlCry
and carpets -176 mirrors
-
192 open rem quarter glass assembly
removal and refitting -186
re~r qllMlcr trim panel removal and refitting -185 repi'lir millor damaue -178 minor damage -176 sent belts -191 seats -192 sunroof-189la 191 lailgate -180. 187. 188 torque wrench scuings -173 windscreen -180 Bodywork repair sequence (colour) -174, 175 Bonnet release c<Jble removal ilncl refitting -186 removill. reflt1ing and adjustment -186 Bml<ing systll'm -14201 seq Braking system deseriPlion -142 lilUl1 di<lgnosis -156 fOOlbrake ped .. 1 removal ')nd rel ining -152 fronl disc brakes -144,145 handtHake -153 \0 155 hydraulic system bleeding -152
p ipes <lnd hoses -151 n1<lintcnance. routine -143 n1<lSler cylinder -148. 149 presslilc uIHe&#34;~llIial switch removal and relitting -150 pressure reducing v~lve rernov~llInd refining -151 rear drum brakes -146 10148 specif'Cil!ions -142 stop IJmp swilCh removal. refi11ing ilnd adjuSlmeJl1 -152 lorque wrench se11ings -142 vacuum servo unil -156 Bulbs. lamp 'Tenewnl -213 to 217 spcclflcntions -199 Bumpers removal and refIlling -178
c
Camshaft (3.0 litre engine) retitting -54 removal -50 Camshaft and camshaf t bearings examination and renovation 2 _8 litre engine -35
3 .0 litre engine -51 Camshah and front intermediate plate (2.8 litre engine) refilling -41 Capacities. general -6 Carburetlor (Weber) aulomat ic choke
adjustment -71 removal. overhaul and retitting -71
dismantling and reassembly -69 general -68 idling adjustment -73
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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
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