FORD CAPRI 1974 Workshop Manual
Page 191 of 205
Chapter 11 Bodywork and fitting
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Fig 11.20 Sunroof front g<lP ildjustment (Sec 33)
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Fig. 11 .21 Sunroof reM U<lP ildjustment (Sec 33)
FiU .1'.22 Sunroof heiullt adjustment (Sec 33)
Neighl adjustment 8 lhll lIont edge 01 the SlUllool should he lIu~h with. o r 1 nUn (004 Ill) heluw. the edUe 01 the Cill loul Th" W<lr etlue should be flush wIth. or 1 !nm (004) <lhove. the C<l! !oul II.1djustnwn1IS required. proceed .1S descllhed below.
9 Proceed <lS descflbed rl1 parJg!<lphs 1 to 4 incluSIve. but befole lIgl11erUnlJ the screws. ndlust the sunlool height by t(unmU the ,,<flusHnU screw (FIg 11.22) as necessOiry Tloht!!n Ihe (Julde rot<lllwl\J screws. 10 To adjust the rOM end. loosen the <ldlUSling screws on Ihe link <lssemblies (on the Uillor side of the p.1nel). Adjust the heighl ilrld tiuhten the screws. 11 Check lor le<lks and nOises .• 1dlustinU au,llll. il neceSS<l'y. 12 Fit the he<ldlinlnU <lnd he<l<fhnrng fr<lme.
34 Sunroof -removal ;:H1d refitting
Open the sumool. then m,uk the pOSItion of uoth guide pm assemblies Remove the Uuide pins <lnd gUIdes . 2 Close the sunroof, then IlllSh the button upwa,ds to the Id t
!',",sition.
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llft the hom 01 the sumoo! Olll 01 liS opening. whIlst tu'ning Ihe handle unlil the screws l<ls\(,nlll\J the cable to the base assembly a,e
acceSSIble .
4 Unsc,ew the cable and hit Ollt the complete Slln,oo/. uldudlll\J the b,lse ~ssemhly. 5 Unsclew the hnndle assen1bly. pllil out the handle Jnd escutcheon then ,emove the button conllol RenlQve the cup. G Unsc,ew the gem beming. then remove il. 10geth(1< with lhe plllJon_ 7 Move the cable so th;]t the g,ooved dowel pin ~ppe<lrs in the opcnlllU of the pUl lorl. Pull out the pin and (iisca,d it. The operating c<lhle C<ln now be pulled Olll of the tube assembly_ 8 To ,ef'l the sumool. inst;J1I the ope'nting c~blc into the tube ilssembly. Turn the c~ble m ItS T·lormed end and fil a new grooved dowel pin. Smear n httle \jenernl purpose grease on the cable and whe,e i t Will contact the piniOn. then assemble the pinion and bearing. 9 F It the h<lndle nIp and lit t he button to the lever. 10 FIt the handle an( i escutcheon. then chec k the h~ndle posilion as follows:
(a) Pull t/le bullOtJ clown ,md lum Ihe h.un/le fully clockwise. which sho!llcloow be ,lpptoxim.;(ely 30 degrees ahead of ils original POSilioJ) opposite the cup of the h<lfldfe (Fig_ 11.23) (b) Push the bullOtJ UJI Jlld Iliff! tin: handle fufly aoti-clockwise. whiCh should now be approximately 30 degrees ahead of 1(5 origin.ll IJosi(lon. file handle call b(t reset on the pinioll splill(ts as fU.lCeSsary
11 Insert the Sunroof IntO the opening mId ~tl"ch th(l c<lble 10 the base ilssembly. 12 Carefully move the sumool to the reilr, by lurnrng the handle. then screw on the gUIde pin assembl<es wilh the pin outw,uds. to coincide
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) Chapter 11 Bodywork ar\d fitting 191
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FilJ. 11.23 elweki"\) the sunroof hHndle nlignment (Sec 3 4 )
wllh th" ",.IIk-, " •• "I,~ whO:1l "",,",vt:d NOh! th.,t tile lelt ,lnd "oht·h1lnd gUltit,s .",' ,,,.( "'I,,"cil.LI'!I.,,,I,I,, 13 A,il'''1 II,., ,,",1 , .1<; d"~<-"I""I '" 11", I""V'()US Soctlon
35 Sunloof h',"ckcl M"t d .. ivH n%l)mhly rClllov<Jl,mel
' f ilti"lJ
til" cr .• Ilk to.lt,dh: til" p"I,on dllv" and the hu"",,!) tl,,, ""V''''''') '.1"1'. II"", ""'IIIV" 11't: m irror, f.()"'t,:~v IIUht <lnd ~,,,, v,~,,,~ 3 11,,,,,,,vo: II", w""I~,O:I"""."~ ,1"~f;"I,,,,1 ,,' $,,,;I,on 10. 1 C;""I,oIly ''''''(IV" II", 1"""11,,,",\.1 1,,,,,, "I>ove Ihe ""d,lI" 01 11m win<isc'c'''' 5 Pull 11ll! !I'"ov"d dow,,1 I"" ""I 01 II>" a<:lu;'t'''u cilhJ(, and ,hsGlfd il.
6 Pull bold, Oil Ihe cabl" ~h!lhlly. to (;1",,, 110" d"ve ir~;~,,"'I,ly 01 Ihe cable 7 Reillove Ihe tulle \JlJld'~ S(;"'W ("!)hr·h,u,,l s'de) ,l"d clop (Idr-hand side), ;]Ild remOVO Ihe tull,,~ 8 Ren,ovr~ the screws, 10 rele,lSe the b'ilcket ;]nd dJ1ve ilsse",hly. 9 RehwII!) the ur,1t;kcl il'1(1 drive ,lssembly 's Ihe reV'IIse of the ,emov;,1 p'ocndwe, US"'!! a ""w u,ooved dowel pin. Check 110" h;,ndle
POS'I,oll. ;'S rl,,~cr,lJed ,n I"";'()'ilph 1001 Iho prev,ous Sc,;I,O" and ;]dJu~1 Ih!) "'01. 01 necess,,,y. as de~c"l>ed III Seelion 33.
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FiU 11,24 Tuhe guid e screw ilnd clip a llow"d (S".: 35)
36 S!la t helts -IJener .. 1
All ",,,dels ;H(J hllud with OI1Clt", 1(,(,1 S(!.!I 1,,,11:; In, 110" 1"'''1 """h n",,, ",,;01 ho:llS 01 ,1 s",ul,,. type ,Ire also ilvntl;1I,1,~ 2 I '!I 11 2~ shows Ihe 1I00r -rllo,u'h,(1 hunl S,,"1 1",11 '.I.rl~ Ikn",v.d of II", I>,'~I(: Iype hxu)!1 r~ Sirilitlhlfo,w;"d, IHlIIor GIII,r ;r"d L,("r """Ids II", C""I", console m"SI be parlly removed, ol~ descrrh"d "' S'·,·I,,'" ]2 3 ro ""nove Ihe frOni ~eill belt rn",I,;] re,,1. u~m()ve IhO! "',,, '1","1", III'" POI""', i'S descllbed in SeClion 22. Ihcn relllovc Il>e Ih",!: "ub I,,,,,,
Ihc ,,,,chu, plillC ;rnd lowcr thc nssemtJly Ihrou()h Ihe ;rp"'I\"". whtl~1 feed",!! Ihn hel l Ihrough Ihe sial "' Ihe "ull,r jJ''''ul (ph()I"~l 1 Tu ,emove Ihe ,eilr seill belts remove Ihe cushrun ,,,,,I "",., ",w II",
anchrll holls The "'erlra reels Ciln ue lI"hulted I'om tIH~".II ,.,,10, 1"""'1-. (pholos)
36.3A F,ont S(!ilt belt ilnchor pl;,tc ilnd nuts 36.38 Feedlll\l Ihe honl seill belt IJuouUh
Ihe slOI III Ihl! inner pilllel
36.3C Front seill bell 1llP.,I'il ,eel ;]nrl
;]Ilchor pl,lIe
36.4A Reil! scm belt outer ,lIlehor 36.46 Rear seal belt m,ddle anchor 36.4 C Rear SCJt bell inC'l'a u:(;1
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19 2 Chapter" Bodywork and fitting
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FiU.ll.25 Front sen 1 h e l! ;,IIchorilu e points (Sec 36 )
!; Wlu,,, ",!oWIl!) Ihe se a t hcll~. rn," " ,."'fl thai lin: .l1H:hor pl.,u,s ;H() "n~'t(()lu,d n! Ihe co"eCI an!ll,,~ a"d 1'!lilll,n IllI! h()lt~ 10 11m sp,,(:,I',~d
"'J'lI!
) Adju slilhle exterio r .n ir ror HlInovnl ilnd refittinu
1l,,,,,OV'!
Ih~ doo< 1"1ll panel "~ ,lo:~,-"lJr:d .. , S"C\ ,orl 13 ? Un~c'cw Ihl) mOunllll!) nul,; ... ,of wllhd,aw 110" 'lHllll! f""" IIor: ()ul~"le 01 111() doo,. ill Ihe S,Hll<: I """ I""(!")~I 1Il1' (,,,hies I Io",u,)h liln hole (),holO). 3 fkllltlllg ,s n ,eve'slli 01 ,ellloval
38 Interior m ir ror -remova l ,mel relittinu
P"se Ihe p!nstic cover 110m the nlllio r bilsc (photo)
2 Un!":" .w the C«)~~·heillj scr~wS nnd ,r.move the IlHr fO' and bilse
/,om thp. ,o"f (photo) 3 Rd,tI'fln 'S n ,e"crsal of remo",,1
39 S eilt s - .e lllovill illle! relittin\!
Fronl scals 1 Hef,1 tllp. seat fully In Ihp. len, Ihl'" \ll\sc,ew Ill(! ",ount,n\! hails from the f,ont "I tl", ~fode 'ilil$ (photo) 2 Adlust Ih" seat fully to the fran I. unsc'ew Ihe r~m [nOwllong boits. th~" ,e'nn"" th" SI,,11 frail' the eil' 3 R(,f'II"'~1 os a ,cvllosill of 1I;1110V,oI
Rcnr sl.'als 4 RCIIl"V", lilt) ~';'"ws hom the 10",,, "I th" ~e,ll cosh,on. nnd 1011 the cush,on f",m Ill" cn, (pholo) 5 n"l"a~" 110" s,';l1 from 11m LlPP'" l:oIch«; s). 11«,,, ,,"bolt the hmUes nlHl ",n,,,v., 11<" S""I i>;)cklr:s l
6 n"roIIO!l!! o~ a ",v,~os"l of removal
4 0 Huatflr (;onU'ols <ldju stmen l
D'~{:{"HH:';1 th" iM ll(l'y (l,lOlh I".,d. lhan [Ilnlova Ihe ulova COIll!>;"IO",,,1 by U(\~"'''W''lO 7 ~""'WS ,11 lill) lop <1m! 2 nuts ,1t Iha llot1<J1ll AI·." rI" . .,pnllo:t:t 11le \llnv" (.""' p.((lm()1l 1 IIOhlin\! te<lds 2 M(lv<: III" h""t,) , "untwb 10 <I pOInt? n)(11 (008 Ill) 110m the end pO~'I'o". II",,) ""'H'V') I)Olh OlJtel cal)le clops (sae FI(js_ 11.26. 11.27 nnd 1 1 ;m "S ;!PI1l0pnal())
Slil ndard hei/ler 3 Child thm the (h~lldJ\llor nnll le~J"I;tIO' Jlap favers <I,e ,11 Ihe end 01 Ihelf 1'<lv,,1 ;n,d d;lIop lhe oute, cnl,l"s III Ill,s poslilon
3 ', 2 Adjustahle cxlclio, millOI c;i/)I() cOl1ltol 381 namove the pillstic cover. 382 and lJ"SC'~W the mirro' base
) 39.1 F,ont seat fron t nlounting bolt
39_4 RernovlllU ,ear seat cushion rnoulllIng sClews
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Chapter 11 B odywork an d fitting 1 93
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Fig . 11 .2 6 Heilter control cil blc 1Hljus tm ent
on SlHn (IMd heilter (S ec 40)
A (),.\·/"UlI/Ot flajl COII/ro//aVllr 8 I/Cgll/;I/O( Il.7p con/fo/h'vt'f
"'!ovy dilly IIfHltOf Chl.-r.k thilt Ihe d'Slflhutor 1I"p levc. ,HId WilIC, cont.ollcve. (FlU 11 28) we 011 Ihc cnd ollhl)" Ir,"vel ilnd clamp Ihe oulC, cablcs "I \IllS lIon.
AlllwMCfS 5 On complct ion. reconrWC I Ihe ulove comp;lr llllent liUhtinU leads.
Ihen lelil Ihe Ulove COllll)nltrllell1 nnd reconnet;1 Ihe hnllelY emlh len {1
41 H OMe r controls - removal and refittinu
1 Disconnect Ihe ballery eimh lend. 2 Rcmove Ihe s teer ing column shroud (2 screws D tthe bOliO",. then pull oul .lIlhe lOp). Lo wer thc stee.ing column (lel\Ving Ihe twO bOltS in position) sufficiently to ullow t he inst.umenl cluster I rim to be remOve d. 3 DIsconnect Ihc switch 10MIs ;lnd remove the instruments cluSIO' t"m. COllll)lot e with cowl "im (11 screws). Rcmovc the instrumont clusle r l!clOI (3 scrcws). 4 Pull oil Ihe hOiltor control knobs. II t his IS 1I0t possIble I><cilk thcm wllh ,1 larue pili. 01 pllors then rCl110vcthc conllols (4 scrcws). 00 not d'SCOIlI1CCt the control ci lhles ilt the heiller. 5 l1uI1Iove t he hCilIC' control PiHlCI ( 2 scrcws). ilenlove the b lowcr
sWItch illI(1 light i"'1 leild5 . D,sconncct the cilhles 110111 tho hCiller COl1lrols Rcll1tlllU IS the .evcrse 01 Ihe rcmovi,l p.ocoduro. du"ng whIch It
.. hc neccssmy 10 adjust th e callies. as dl.'SCfllled III the p.evlous ::. .on Also it w,1I be necessary to obtall1 new hCille. control knobs where npphcable.
42 HCHte r
water villve (hellvy duty heater) -IC lll oval an( 1
refittin g
Drilin
the engine coolant ilnd dlsconncct tho lowe. hosc !rom th c ,aulato. (,efe. to Chapter 2. II necessary). 2 Disconnect Ihe th.ee water hoses f,olll tho Wille. valve. 3 Removo the OUWr cilble from the clip on the WilWr v~lve bracket.
Ihen lenlOve the assembly from the bulkhead (2 screws). 4 Twis t the wate r valve. to disconnect the cable IrOI11 the operilt ing
l ever .
S Relilling is Ihe reve'so of the removal p.occdure. during which ~dJustl\lcnt should be m~do. as described in Section 40 fOf the heavy duty healCf On completion. re li t the rudiutor hose and fililhe cooling SYSt(:rll . us described in Chapler 2 .
43 Heater assembly -re mova l and re fillin u
1 DlsconnOCl lhc tJiltH:ry ea.th ICild. 2 -,,,in the COOIIlI1l. rei!;fliny 10 Chllpte. 2. II neCCSSilry. 3 sconnect th e Wiltcr hoscs from the hoale. he;!t e.chanuc. (phOtO). II I><il':ticable. hlow th.ough Ihe heat e.chunger WIth
2111111
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11 .27 Heale r COl\trol cilhle ncJju stm ont on heilvy cJllty hl"latot (Sec 40)
A /),., ·{n/w/III If,}!, CQII/lo/ft'vct
Il"'·I·"1>.1 VU[ CO""'OL U·OL(
".."Tt"CO""'OL -NIL\[
Fig. 11.28 Willer varv e o n heavy duty heilter (Sec 40)
43.3 H eiltel water hoses
i , , . ,,
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~'l4 Chilpter 11 Bodywork and fitting
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complessnd ~" to IcmOVI! ,OIly I.nolar ,,,",,,"1111)11 Alh,,,)attv,,lv pl;)c" clothS JII,l/or I1CW~I)ilP'''S 1)(!I\!;o1th In ,11",,, 1, al'V SI"lld!!" 11 Remov" thc (.over pan,,1. tn!I"lh," wllh II", lw,'t nxch'''''Ie! 10 watel cOI"'~~(:IIOIl \J,;~k...r. f,om th,~ IlLII~I"',1,J (2 ~r:tI~WS) 5 SlackclI till! !1"o1ll~N'" l(l(.k"(li. 111,·" ""''''Vl) Ihl) !)"oI,I,~vf)f The locknut IClIlIlICS a 5p,,(;'al p"!J Sp""""'. ,IV,HI.lhl" hOIll Foul. hllt It IS lIot
d,fficult to 1;)10'11:;\1" ,1 10,, 1 wh'<.-II which wIll do Ih" 1010 6 Rcmove til.., I'n,r,d I';IV (1 ~':II!WS) WI""" til",,, IS a celli'" fOI1S<)t.i. this must hc ICmOVl!ri "Iso (lcfcl to SC,.t'Oll 32 ) 7 Remove Ihe strJ(!IIllli coll,"m sl"olld (2 ~n"ws al tl", hOllUm. th(!n
pull out <H the lOp) Low,", Ih" ~""~""!I coh'''''' (1'~"VI"~llh" two holts in pOSlllon). slIfflCICllllV 10 "lIow tI", "'~I"''''''''I Llllsl,,' till,,, 1l'Il\()v"d S RenlOV<l th"lowl" r"cla p.1II,·1. "'''''1'10'1'' wllh, IIV," 1'.111,,1 R"nHl"" the nsln,;,y ;",,1 O:I!I,H"lt" II!II)I," ,,,,,I ,I,'., '"""'0:1 II" , ,.w'h.I,,·~ II'IIOIO~) 9 RI!IlH"''' tl", !llovo: "'''''p.''t''',,''1 I,V ""," "'W"'!I 1110: ~ ","'w~ oIt Ih" top ,mrl 2 Illns al th" I,olt'"'' AI~o d,'" ,HII)'" 1 II", !11"vII ,.<1'"1',,,111":111 h(JIHlIl!) I"ad~ 1 0 D ,sco'lIH:CI tto,· d"m'~lo:' ,,,,11 1, , ho',,,~. 1<J!l'"lh", w,lir II .. ,,,
CO'lneCI'Olls (1 '01""W ",II.h) 11 D'SI:OII'H,,:t 110" I,ll.'" ""IIt h"~",, h",,, 110" 1"'011," TI"·,,, ,',,:") '''' tI'" 'lilnrt;)ld lHloll<;r .",<1.1 "" II", 1 .. ,,,vV d"IV 1,,·.110" ? Rel\\o"" tlo" IIIw,,, d.l~h 1'.,"0:1 ~"I'I""t ~I"y (1 ~""w) 13 O,s",,,,,,,,,,t II", C,,,,I,,,I (""1,1,,,, (,'"'' 11,,· 1",.,1", .",,1 11", 10",,10"
J.se Rel\\ov,n\! lire il~ht")V
hlowef If!a<l,; 11 Removr: IIHI d"""st',, nOl.lles (Ieff)( to Sect,on 1\6, II necessary). 15 Remo"" the wmdsc'ecn WIPCf 1\\ r h'ilcket 1,0m liS mOUlllrnu 16 Rel110Vl! Ih" 1 he,;!!)1 ~eCWUl!J screws, (photo) Ihen pllilihe hemct 1M enOIl!lir ":;HW,ll1l 101 the wme, COllllectlon p'pc~ 10 CICM the hulkhend TIlt the top of Ihe IrC,lIN IIpwa,d and IOIWilld, ,1n<l w llhdlaW .1 sldewilV~, Ihcn 'e'nove thf! fn.1m !FISkel also. 17 Ref'II"'!) IS the ,e"I~'~u 01 Ihe ,emnvill procedure, dlllln(J wh,ch II w,1I he nIlCIl';~i\'V to ,1dlliSt Ihe h";)I<)! conllols ,1S d(l~cllhed In Sect,on 40. Do not IOlli et 10 I'\lhll)n thl! \lllartl)Vel locknut. On completion, hll Ihe cool"l!1 ~V~I"rlI. as d"~r:,,hed Irl Ch.lpl<~' 2
1111 Heatcr ass(l'lIhlv (Behr) dismantling <Inti rC<lssemhly
Runl""" Ih" d",\I,I",IOI 1I"I'~hol(1 (1 clop) NOI" th,lt Ihe fl.1p ""ll;)UlS II) Ihe 1"""'1 SI,,:tl"') "f the IU)lISI"!! ? R"",ov" tlw ,: I.IInps ~"r.""n!1 Ih,~ IWO h"lv"s 01 the IIm,s,n!j, "srn!) c"ciop pi"",. Iklll"'" 11\" "I'P'" ~"r:I""', ~'Ol"pl"jll w llh tilt, m01o,.from tlw low"" ~""trOI\ 3 Rem,,,,,, tI,!! 1",.11 !!~d'."HJ'" ""tI I",m Ih" I"rn,,, Ihe low!!' SCCllnn
43.16 He,ltcI tnounilng holt (a,rowed)
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195
2
~ --3
4
,
Fig .1129S . tilndard Beh r heater (5 1 ec44)
2 Mowr ,1nd f"n 3 Upper housing 4 Lower housillg Deli/isle, " 5 Helll CXChaosc connection 6 Neil l crl /lye( COVIN plale 7 C ... liJllger 8 Oll/rol {hll' 9 ;,001l011/,1fJ shaN cal CXC hiW 10 Dis/rib I ger sC<ll " . uorll'lp DIS/fibulQr II ap Shilfl
=
J
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)96 Chapter 11 Bodywork an d fittings
of the housing, then remOlle the heal exchanger from the 1ramc and lake ott the fOilm pilcking. 4 To remove the distributor flap from the housing. remove the clip and withdraw the conlrollcvcr sideways. 5 Remove the rcgul<110r flap from the lower section of the housing, Bend bJck the 2 claillping straps sulticicnlly \0 enable the conlrollCIICI 10 be withdrawn (liter i, hilS been turned tow;1rds the side, then remove the regulating flilp. 6 Remove the retaining straps for the blower mOlor cap. by pressing outwards from the inside uSing 11 screwdriver. 7 Deweh the mOlOr from the upper sectioll. Disconnect the motor leads, remove til(! <1 rewining clumps and remove the motor and filiI inw,uds. a When reassembling. positIon thc blower mOlOr so that the clectric<ll connections face IOwards the c<lble fastening iI! the upper section Secllw the n10tOl nnd connect the lea(ls. then 111 the mOlor cap. 9 POSItion thc legul<ltlng tI<lP in the lower section nrul inse, the conl!ollcver by tll,nlllg it IrOlllthc side as necessary and SWIllU It roulld 11110 tilc stral)S . Close the straps usinu pliers . 10 POSItion the dIstribu tor tlap in the lower section and IIlsell the
control lever from the si(lc.
11
11 The remainder 01 the reassembl y procedure is the reverse 01 the
r emova l procedure.
45 Heate r nssenlbly (Smiths standard and heavy duty) -dismantl ing and reassem bly
Standard he,1ler I Remove clips A and B (Fig. 11.32) ilnd remove lhe heater housing
sidc cover complete with flaps (15 screws) .
Heavy duty healer 2 Remove clip A (FIg . 11.32) olnd remove thc hcater housing SIde cover complete WIth flaps (15 screws)
All he,lIers 3 Remove thc heat e~chnnger nnd 10,1111 sen I. <1 Prise off the c"clip nnd remove the Ian I.om the blower motor shall. 5 Detach the blowe r motor from the support (3 nuts and holts). 6 Reassemhly is the reverse of the dismantl ing procedure.
Fig .
11.30 Stilndllrd Smiths h eater (Sec 4 5 )
1 M%r assembly
2 COVt·( and black!:t assembly 3 Control valve operatillg le vel
4 Righr·hand housing cover 5 Dis/ributor flap 6 Fan
7 Control v<llve 8 Housing 9 Demis/e r hose connection
10 Heal eXChanger seal 11 Plenum cflambe! cover
-------------------------------~ 灲潣慲浡湵慬献捯m
Page 198 of 205
7
) Chapte r 11 Bodyw ork an d f ittings 197
Fig. 11 .3 1 H eavy duty Smith s h eate r (Sec 4 5)
1 Housing 6 Plenum chamber covel
2 Hot ai, supply /0 laciil 7 Ois/fibulor flap
connec tion 8 Right·hand hOllsing cover
3 OrlniSlef hos e connectioll 9 Cover ,ltld bfackel assembfy
4 F.ln 10 MOIOI .lSscmlJly
5 HeM exclllmgcr scM
4 6 Dcmister nOlzle s -remova l alld refiuing
r :cngcr's side rtcnlOve thc glove COlllpiUll1lCllt by Ullscrcw"'9 the 7 screws iI the to · 'ld 2 nuts (ll lhe hall()m. Also discoIH'oG I the glovo compJrlrllCIl h\, ,19 Icads. 2 WIthdraw lhe hose frorll\he dCnllSlC . noale (lnd remove the noule (I sClew ). 3 RefItting is Ihe rev erse 01 the .cmovill Il' occ du.e .
Driver'S side 4 Initially proceed a s descullnd in palagr,lphs I , 2 and 3 0 1 SectIo n 41. Additionally remove th O ashu".,. and CIgar Irgluer .
o
Fig. 11.32 He ate r d istributo r flap (A ) and regulator flap (S ) clips (Sec 45)
5 Remove the inSllumen l cluster (4 screws ). disconne<:ling Ihe speedomele . d.ive cable and elect.ical conneClio ns . If lhere is any doubl about Ihe position 01 ~my 01 Ih e ele<:trical connec tions, make a nOle of them fn SI 0' ,111. 6 Withdraw the d ernis te . noale hose i1nd remove the demiste r noule (1 scre w), turning it upward and ou twards so thililhe inlet side 01 Ihe nonle can come ou t first from th e in strument cluste. opening. 7 R efiuing is th e reverse of Ihe removil ' procedure .
47 Fac e level vonts -removal an d re litting
Passengers side 1 Hcmove Ihe gl ove comparlment by unsc!ew 'ng 7 SCfcwS at t he lOp ;Uld 2 !llltS ,11 th e bottom . Also drsconnec t Ihc glove compar tmen l Irghlrng leads. 2 Wrlhclraw I he hose( s) h om th e vent. 3 Remove the vent by unscrewing the 2 flu lS which a rc access ible from the reilr of th e pan el. 4 Rcliu in\j is lhe reverse 0 1 the relllovill procedulC.
Driver's side 5 Inil iall y p'oceed as described rn paragr aphs I, 2 ilnd 3 0 1 Secti on 41. Addrlionally remove Ihe 9 screws at the lO p ollhe rnstrumenl pilnel tllm. 6 W,lh the hose(s) Irom the vent .
7 Remove the ven l by usncrewlIlg the 2 nuts which i1re ,1ccesslble from the reM o f the p.,lnel. 8 Relru.ng is the reverse of the remova l procedure .
••
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1 ' I
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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"~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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Page 200 of 205
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rernoy .. ' and refl Uing -69 spcc,'iC<ltions -66 Carpets maimcnancc -1 76 Centre console removal .. nd refluing -189 Choke . au tomatic _ 71 Cigar 'ighter romoval ;lIld . e 'ru in g -225 C lock (console mounted) .emoval ilnd 'clming 223 el,/tef, -97 cl seq Clutch assemhly ",speclion 99 relluing 99 remov;]1 99 calli e renewal 100 dcsc.illllon 97 laul l d'''[jnos.s 10 nMlllIon,wec. foulorU) 98 pcd,,' rCIllOVill ,mel fcllUII1\) 10 1 release bca"ng .emoval ;mll wl,ulIIU 100 Speclflc,uions 9 7 Condenser (3.0 lilre models ) lCSI,nu. 'CIllO"'o1' MId refllli,,!) 90 Connecting rods (3.0 l itre engine) 5 1.52.54 Connectin g rods amI gudgeon pins examina tion ilnd ICnov;'Jlion 37, 52 Connecting rods ;lnd pisto ns refi Hing ~ 42. 54 Contact breaker points (3.0 litre models) i1djuslOlCm -89 remov1)1 nnd refiuing -89 Conversion fac tors -18 Coofing system 57 CI SCII Coo ling systcm nnhl.cew ",ixltlle GO desC.i,l liOn 58
d'ilUlinU 59
(IlIvchells
G3 e~p:mSloll I nnk 6<1 Ian hub l)()nllllH (30 hilI] 1110<1111,;) 64 f~ull (II;)Ul1osl~ 65
flll".U -
60 lIush"'9 59
",nmlen,lncc. roullllC 59
'ild,nlOr
GO speclficn llon5 57 lem,)er;!lurc unuuc Sf:n(Ie. unil -134 IhcrmOSl<11 -61 10Htlle wrench selll ngs 57 VISCOUS drlv\! 11'111 -63 W1)ler IWIllP 61 Crankca se ventiln tion system 2.8 tol'c engine -39 3.0 rillC engine 53 Cranksh1)ft 2.8 li l.e engine examinat ion nnd rcnoviuion -37 refilling -<10
3 .0 til.e cn gine examination lind renOV1'l110n -52 Crankshilft and main bearings (3.0 litr o engino) removal -51 Crankshllft pulley refitting (2.8 hIre engine) -44
removal ( 3 .0 litre engine) -50 Crankshaft r ear oil seal (3.0 litre engine) .efllling - 55 .emova l -51 Cylinder bores ~xaminalion and .enovation -36. 51 Indo r heads 2.8 titre engine dismanll ing .• cnova lion and .eassembl y -35
Index
D
refining - 45
3.0 litre engin e
. eassembly -55 refining -55 .emoval wilh engIne -49
removal wil h engine in car -49
Decarhonising -52 Dimensions. vehicle _ 6 Dim-dip lighting system _ 226 Disc br1lke s scc Front disc brakes Distributor overhaul 2.8 hlle engIne -93 3 a !r1l0 cng,ne -92 rcmoval and r efIlling _ 90 Doors eXle.io. hllndle ,emoval and refilling - 183 lock 1Issernbly removal and .efilling -184 pillar swi lc h -224
priVill e lock ,ernovill and ref'lIing -185 fnllics tracing nnd feCllik al ion -178 remOle conlroi hnndle removal and refilling -180 Hlmoval and rell\1l11g _ 185 Irim j>ilnel removal and ,efi ning _ 182 window Irnm c
moul(II ng nnd door wealhcrSlrips
removal and refining -185 rcmoval and relining -185 wmdow glass removal and retilling - 184 window regulnlor nssembly
r emoval and relilling -183 Drivebelt s .emov,,1 ilnd refil ling -63 Drum brakes sce Renl drum brakes
E
Eloc triclIl.system -198 e/ seq Electrical systcm altell11110, -201 10 203
ilu xiha.y driving "ghl -212 bmlery -200. 201 bulbs -199.21310217 ciga. IighlOf -225
clock -223
d escrip llon -200 dim-dip ligh ling syslem -226 laull diilgnOSIS -19. 233 ""sher unils and rel1lys -225
fuse s -199. 220
headligllls -211 10213 horn -220
inSI.ument clUSler -22 1 inSI.ument vollage .egula lor - 226 Inmp5 -21410217 mninlenance. fOUline w 200 mobite r"dio equIpment - 226
precautions - 200
rildio /casse tte player -226 specif ications - 198
speedomeler cab le -226 Slmte . mOlOr -207 swi tches -223 10 22 5 lailgall) wash er -217 laHgme wipef -217 to.que wrench sell ings -199
w indscree n washer -219 windscreen wiper -21810 220 wi.ing diagrams -235 10 249
25'
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