FORD CAPRI 1974 Owner's Manual

Page 21 of 205

a
20 Fault diagnosis
Carrying a lew spares eM) :\l1VO you a lono walk!
WHhou t 100 ,ulIeh trouhle in the event o f il hrC<lkdown should he c,llllod EXI}(lflcncc ;md aV.1II.lbl!! sp.1c e w,lI mOdIfy the list helow, lout Ihe lollowOI1U noay ~;lIIC havul!/ 10 Cilll on IHO/(!$Slonal ,1SS'S '<lIlCC
S ,Im/( I"uys. dm/JI .1IIri ,:ollt'c/ly Y;'I/ II"(/ III h:;J(/ .~/I{I&#34;III!lI:,lIJ {II"Y .:1H>II1I" to 11).11:/0 /I" .. fllllY '(ltllu.'.\'{ fit"" lin-,/lsllI/w'IIt
DrHII/mim [(JIm, (:lIlIdulI.~VI IIlId C&#34;&#34;Ii&#34;:II&#34;&#39;HI~&#39;.&#34; I'omls (;'s ;,/I/lII(.','I/)/e
IJllv/.'lmll(s) ,.'/I11:II/VJlCY IYl't' m"y suffu;t, SlIill!! {(I,ft'S S •. '/ of //111//:'/1,,1 "ylll bill/,S 1/1/ 0/ ",dlll/Ol 5<:;,11:, ,mil IlOst: '>,md.1UI! t&#34;~II;III.1&#39;1 /),111(1I1!IC Roll OlllllilJIMlt/y IIIl'l' Lf>llylll of sulillflll WIIC Lc"yllt of ci.:cIIlC,llllt·.
rUiC" Of mSIICC/IQIII;III'11 (eilllliot/blt' ;,S II.'S( I;IIIJIJ) OMlt'IY 111111/1 Il'mls Tow" Q/IC Iym(/Oll WJiClllloo/lllY ,ow/osol Llfll! 01 c"Yllle Oil SeMcI I eMI olltyr/wlIll(: /f",d Emeif/CoCY WII/({SCIt'ell W(JIm ({live cl'II$ Tube 01 Idlel IJ,1S((;
II Sllilro IU(l 1 IS Cil",c< I .• 1 Ciln dcs'Ollod for th(l pu'pose should hc uscd 10 m&#34;l&#34;,l(~e rrsks of le<Jkngc Hnd colhsion damage. A IIISI a,d kil and il Wil,n,ng 1I1,1I1gI0. wh"sl not ill wesenl compulsory In Ihc UK, (Ir C
ohvlOusl y senSible ilems !O carry u addl1ion 10 Ihe nbove When 10urll1g nll,oad 11 mny ue advisnu le 10 carr y nddlllonnl spares
WhiCh, evon 'f you cnnnOi III thcm yowscll, could snve hav'"(J 10 Willi wh,le p<lrlS MC OUlillned The IlCms below lIIi'y be worih cOlls,derr"y
Chi/eli {JII( I (/U Ol/it' eab /es Cy/md/H " ",7/ IIPsll:rn AlfclI/MOt /)lIIsiles Fllel (Jump 111/1.11'1 11:11 Tyte va/vI! cote
One of Ihe 111010llng 0'ganlSilll0ns w<ll he ahle 10 advrse 011 nVil,l"bllrly o f fucl elC III lore'gll coumlles,
Engine w ilt no ! starl
Ellgillc taits 10 ((IIf) W/IL'II slilrlc r ()p vra le d 1' 1;11 h~lll.&#39;ry (.ud,;,,!!,!, u~.., rlmlll'uolds, 01 push Sl.1rt) nnllclY 1(:rnllll.,ls Ions!! 01 cntlod,!d BaltelY ll.1,tll to hody dd"cl'vu Enwnc e(utll S I,,1)) 100Sll 01 broken Sl.1rtel 1II0lO r (or so lulloid) "",,,ng loose or IJroken
l\ulOn1 ;II,e II1!11srllr~s,()&#34; seleClor ,n W'OIlIl pos",on, or Inhd)!' sW/lcli fHur,y '11""'Oll/SI (lr lu, sw,'ch folUllY
M i'ror mech:u"C.11 ,,,,lure (Se'lUre)
Sli&#34;!~1 Or sole"ord 'ntorrloll rilul! (seo Chaplllr 12)
A
simple les t lamp is useful fot checking electrical fault s
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T
Fault diagnosis 21
Starter motor ((/rns cngino slowly Parti ali V disch~rilcd b<ltlcry (rClch"'!le. usc Jump INlds. or push
sian) Ballerv terminals loosc or COli oded Batte.v earlh 10 body delcctrvc Enuine ear th s tr,1p loose Slarle. motor (or solenoid) wiling loose Slaricr mOlr ill1crnlll laull (see Chaple. 12)
Engine ((/"'S normally but 1,1ils ( 0 SIMI Damp or dirlV HT !eads <lnd dlS1"h\l10r CllP (cr<lnk cngine and
check 10 ' sp<l.k) DirlV or inco.rClCtly g;1ppe(1 .1I51"h(lIOf pomls (If nppllc<lblu) No fuel In wnk (chcck 10' dchvclY .11 C;1dJU.etlor) EKceSsive chokc (hOI cn\JlIlc) O. II1su l!,clenl choke (cold CI\\)Il1c) Fouled or incorrCCtly \lapped ~pnlk p1l'\lS ('1I1I10ve. clean .11)(1
regnp) Olher ignilion syslcml",,11 (~ee Chapler II) Olhel luel sySlem 11Ildl (se c Ch"plm J) POOl compression MaJOf mechanic;1 1 l<l,hlle (ell c~lIllsh.11t \I',;1r ICClh sl"ppc<l)
Ellgine lires but will not fUll In su!hcicnl choke (cold flfl!)lIln) Arr le"ks al CilrUurC110. 0' mlill m;1",lolli FuClI sta,vatlon (sec Ch"111C' 3) []"lIast rCSIStor de!ecllvn. or OIlier 'H",II<HI f,lIlll {s.~e CIl;1""" ill
Engine ClltS Ollt ;1nd wilinOI roslinl
fngine culS out suddenly -ignition I,wlt Loose or d'$Conncetcd l T wi.es WCI HT Icads o. d'S I"buiOI C;1P ("lIer tr;1VC'SOll!) w;1'er spl;1sh) Co,1 o . condenser lallulc (cheek 10' SI);lIk) Olhc. ignition laull (see Ch,'plfll 4)
Eflgine mistires belore CUlling oul IlIcll,wlt Fuel I,,"k Cillply Fllel pump dClfecl1vc o. 1,ltcl IIlo .; k(H! (dwck 1m dellvl"V) Fuel tank hllcr vcnl blut;kcd (StII; llon Will II" flV,{Io"'1 Oil lI~h&#34;&#39;~II&#39;H C,11l) C;1llJulCIIor nccdlc v"lvc SIII;klll!J (WIU.'1I1 "ppI1c"hle) C,1lUwellor leiS blocked (ha:l COIII,lIl1ln,Hcll) Othcr lllcl sys!Cm l<lult (sec Ch~,II<!I 3)
DISCHARGED
BATTERY
lSin.MIN
POSITIVE
JUfl11) Slart lead conneClions f o r neg!Hive earth vchicles­connect le;1ds in orde r shown
fllgine euls Ol1t -olhor eimses SCIiOliS ovcrhC~ling Mnior mcch<lnic,,1 !<lilUIC (elJ cmllshMt drive)
Engine ovcrhe<Hs
Igllitioll (llo-clwrgcj wt1fllillg IigM illuminated SI;1ck o. broken d"vchelt felCn$IOIl 0' Icncw (Ch;1ptr,r 21
Ignitioll warning light /lot illuminBted Coollllll loss .Iuc 10 In!emnl 01 CXierr'JI ICJk<lile (sce Ch"PICI 2) TlIClmO~I<ll "clecllve l.ow 011 leve! fj.,lkcs hllldlll'J R;1(1"llor clomJcd cXifllllJlly or IlIICIIl<lIlV EnU"'e W<ltclw~ys cIO!JUC(1 'Un'h{)Il !IInll'!) Incorrcct or <lIIIom"IIC .1<1V;IIICC nl.lllllIlCI,OIIll'!j MIxture 100 we,lk
NOIC: Do 1101 ,11M coM WMCf 10 ,111 oV~-f/&#34;&#39;.I(C(1 ~·lIy&#34;&#39;., Of d,,,",l[Jf1 m,ly I/)SII/I
l.ow cnuinc oil JlfC!ssuro
G,wge reads low or warning lighl Illuminated wilh engillc
rWllling Olllcvcl low or mCOlfeel 0.,,<10 Deit.'Ctivc gllU!jC 01 sendCI 11111 Wife 10 sendCI UIII' C.1I.hC(1 Engonc ove.hC.1l ing O,lllllcr CIO!19c<1 01 byp,1SS v;1lvc delccllvc O,I ,llcssule lehef v'llve dc!ec tlve Oil pick-up strllll,e. ciomled 0,1 pUIllP WOIil or IllOlllllll1\l~ I\,osc Wo,n Ill,l'" 0' h'!J-cn(i hC.1I1I1!)s NOlO: Luw or! 1"t'HlifU III a IImh III&#34;C&#34;f1~&#34; (.'IIYIIIC .J/ 11l;~()VI.&#39;r I.~ 1101 1II.'I:<.'",.","/y,1 (.",lIlSV {o, CIIII{:"/U Suddel! fJf&#39;~SS!lle {U$S ,11 SlIced IS {M "'/!IC SI{Jl!lflca"l (I! ,my cve/l/. .:In',·j. I/le .<I,U/ye or ...... l/lllllyl,yIJ/ S(1/1(h'f /)<.'/VIC cIJfI.h·flllm,y 1/1<.' C/I!l1IJ1!
Crank engine and chock for Sl)ark. Note use of il)sulated tool 10 hold plug load
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En!J"lO noises
Prc-;f/lli/ioll (plirkiny) Of) ,1Cce/efariOI) IncouCCt W .... de o f fucl '!IIII ,rOn IImonU OIlCOOlCCI
DIMlrbulO1 l,lUIiV or worn
Wnrn 0. IllIlI;1(I,u5tod cil,l)urcnor O. Idling setlrllgs EKCCSSIV(l c;uhon htuld_"I) In cnuulo
Wl!i~&#39;llil/!I or wheeLing nuises Lc,,~onu V,1CUUI11 hose
L""kllllJ Ci'lII),I1(:110 1 0. lIl.ulI/old !FI~.kcl IIlnwlIlH IWild U.1S ~Cl
Fault diagnosis
T,1pping or mUlillg InCOlroC I v:1've clcil,.-.nccs WOIll v.llve flO",
Broken ,)ISlon "no (r,cllm!! nOIse)
Knocking or IIWI/Ipiflf/
Unlnlenllon,'IIll(!ch"'"Cill t.:Orl!<lei (on'all hl;ld(l~) WOUl (/"vchch
I'olll) h o.,,' COllltlOnonl 1,1\11, (HCIU·<.1t{Jr, Will'" !>lItH,) ,-I':) WO", !Jlu-end h(l;u"'!IS ('f)!JUlolf Iw,wy klladuHI jH',h.II' un
de.IO;'1(I)
'A'0'11 Ill.1U) be",",!!S (',"nhhll(1 a'lOl ~n()d&#39;&#39;&#39;&#39;!1 I&#39;&#39;&#39;&#39;&#39;&#39;&#39;&#39;&#39;)~ WI'" undcr IOild)
P' Slnn st,lp (mo~t 110!I<:1!;,1>1" when cold)
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Chapter 1 Engine
Contents
Par! A: 2.8 litre engine C;JrllS llaft and CillllShJft be,lrIllgs (;XilOlllllilllon ilnd renovil!"Hl Cnrnslwft and frenl inlCrrned l,1!C pl,ne rcfl1l&#34;l~1 Connecting rods ;lnd gudneon pons c",,,nlO\,lllon "nd
,enovntion
C'nnkcnsc venlll;Jl,on Systelll de~Crlpll(&#34;1 C'<lnkshilh -cxallllllill,on find '<]110V<lIIOn Cr,lnkshall -rellll ing CylInder bores· eXil'1lI1l<l110n and r""ov;,[,on Cyl ,ru ler IWild s dISlllilntiln\). 'enov,II,O(1 <lnd "':<IS5cml,ly C\'l.ndo, hCil(ls. roc~cf (jCi!1 <Iud or,I<;1 manIfold ,ullt!",,)
Englile dlsrnill1tlin9 (IlUmc -ulIlI,,1 SIMI up <lher !HilIO' oV("h,ud or lOP;!"
E"U"'() rehl(ml) [W)lne -rcmova l EnOme nnc,lInries -,ell!I&#34;lU~ E'''9''0 ilnClllarrcs -Wlllov;!1 EnOone componentS -eXi!rlllll.1I'O" lor wear En\)IIlC dtsmant lm9 -goner<ll ("\l,ne rCilsscmbly -(Jeneml Flywheel _ examin<llion Mld rcnO"ill,on 1:lywheel ,1n(l r.lulCh -rclillrr1\)
G"ncr<ll descrlpuon , .. , ....... , .. . l~Il&#34;r.m&#39;oll syswnI -descripllon M.,,,, ,'nd b'(J·end hcarrngs C~.:Irll&#39;n&#34;l,on .:IIHI 'CIl()Vall() '1
M.llo. operat,ons posSlblc WIlh enWIlf! rr1 car
M "IO. operatIons reqrllJlIl(J enOrrr() ,enloval Mr.:lhmb of cnll'nc '(:l11ov;l1 011 IH"'lp rl&#39;~m.lt)ll&#39;&#39;&#39;g. eXil,nrrr"l.oll and &#34;,,,~~c&#34;&#39;lrly all pump 'ufrtlrrlU i'lslo"s and C<Jnn&#39;)~I,ng rods ,ej't!II'1 1 PI~lon~ ,1"d p'\IOn "11115 cx<r""""I.o" ""d 'c"o"al'OIl nOt:~(&#34; ,1~scml)l y d,smanl),nu, c~a&#34;&#34;II,&#39;tl&#34;&#39;l ;rnrl ,e<l\SCIl,!Jly nout'I'c m:' llllvnance Sump "'IlI<.",,,1 alld ICI'1111111 wIth ""H"'() 111 ca, S"",P. W.'h:, pump il'l!! crarrkshalt pulley ,cf,lIll1(J . f&#34;PI&#39;cl~ ,,,,(I push, ods·· exallrrnill<on "nd ,enOVill'OI1 Tlln'l\ll \I<:,IIS C Xilm",,11'On ,111(1 'cno""I'OIl r""",!) \)O".l'S ,,"d III",ng cuver 'ef'll,no V.,I,·" r:I&#34;.II;rnc,,~ ~heck&#34;&#39;I) ,111(1 &#34;ellu~lmcrl1
P;1I1 B . 30 IIlre oily/lie C"",\h,lll ",f,1("UI C;1I&#34;~lrafl ""no·"',1
C.""sl>"fl
and c. ,nrsh;rfl !re,&#39;rr&#39;IO~ 'JX,IIllrrlaHon ,mel 'CIlO""l lun Corr'lectorry ,ods and yud(jeon p illS exa"'"'ill,on <rod ,,,I10v,11'on
Cr, lrr
k
c"se vClrtdm,o;, ~~s·t~nr descJlPtlon ~&#34;lrrhlr.,ft ()x;r'l1Ill,' I'On ,IIHI ,...,novatlon C',1n\;slraft ",I'illlI9
Spcciiic;ltions
P,11/ A · 2 8 li(ro engine
General TI,pc 130<.., St'uk..,
Cul)Ot Cilp<rCrty COIl)I)&#39;u~s,o&#34; ,;rIll)
" 28
'" 25
'" 27
" 15 :j~ ,
38 37 6 :\G 8
" 7 26 22 3> ,
24 20 3 4
;.>3
30 29
" 12 ,
>0 33 >3
" 32 :J5
70 b7 G5
68 77 GO 80
Cliu,~sh<rft "nd Ill,,,n II':""')(IS ,ellroval C",nbhilf1 p"ll<:y ,o.;,lIov,,1 C&#39;&#39;&#39;&#39;lk~hafl ",.11 011 ~nal 'f·rrl0v,iI
Cylonrle, ho'es " '.'"\1("'11011 ,H,d ,cnoval'o" Cylll"I", heads ,,,as~r&#34;&#34;I,ly Cylrnde, h("uh ",f'll""1 CylrlH)." he,ub """"v,,1 wulr "'l!)rr1fl '" ca, Cyl",{i(H he;rds """ovill wllh CUlJrllC o"t 01 car Oec,rrl)on'\II'\J \1"'le",1 E'l<llrlfl "ul,,,1 '.t.lIl·" I' "Ito;, 1""10' (}v(:,h,,,,1 0 ' '"p.'" E&#34;~IIIW ,dill'''\) Enll'llf! ,ernov,,1
EIl;I'"C ilIlCllla"o:s
E'''!JI,t!
,me,I I,IIII:s
[Il!!"'" C"" 'I)O"o.;"ls E"B"'e (1&#39;~Ill&#34;nll,n!J ['"1''''' &#39;,~,&#39;s&#39;,&#39;&#39;&#39;&#39;&#39;I,ly Hywh",,1 ,,,,,,,,val
I(;j,wou
""IIov.1 1
\)0)'\1),,11 \1("",,.11
Flywir""lld"""plale f!X ,I!lUnil l(On allli IflnOVill lo n
Front covc, ,cmov.11 Gcm:ral descI,pt,o" lub'lcat,On syslmll (Icsc"pt,o'l
M,1I1l a"d hllj·C"d h"""nys I!x.lrn,nilt,on ,!I,d &#39;enov~&#39;t,on Ma)o' OJ),,r,rl'OIlS possllJle w'th ""\JIllf! orr C,If MalOr op,,'<rt,ons '''(1'''''''1) ~n\I&#39;IlC rcnroval Melhods of "nOrr1e """ov .. 1 0,1 PUrI\I' (11!.nlanll'I'Ii. (;x.- """,;rI'()11 ,,,'d 'o:rssOllllrly
001 P"'''fl ",hI I"'!! Od pw"p ",,"ov,,1 f&#39;1~((JI&#39;S ,IIul '.(111''''' :111''1 '0(1,; ,,:I, tl,n!!
1 ",1011'; ,11,(1 P&#39;~lOIl ""llS (,x;r"''''''l,on ,,,,,I ,cnoval,on PI~,1Orrs, ct)&#34;rrr.:~trrro ,,,ds .lIl(f hoal lllO,; removal n,),11 0, 1 s('ill ilrld flywlrcr:1 rcl,tlll'(j !'loclq" <rr:rr,; cx;rtrlrrl.,lr<JI ' dllli ICI;oviltlon
Hock", a""s ",,"o"ill nor.k v ' a'IlIS ;rnd C()V,~&#39;S ,e flllll1ll . I~O\lII&#34;V m;r"llell.,nC(!
SU"'P <cfll1,"g S(I"'P &#39;~Illov;rl Tappl,I'; rv,nov;rl
r,1pl)('l __ "ri d plIsI"ods ex.rrnlll.1t'OIl ,rrl(f ,cnovallOll Trn"n(1 Ilc,II'; cx,IIIW,;rl lO'1 ,1(1(! 'ellOV<lt,oll
Trn"n\1 I)C,lr'; "Jmov;,)
T",,,,,O
IIC,&#34;~ ,'(ld frO"l plale rcf<tl,nU
Valve c.1(;'U,rrlCcs cIrCl!k,n\) and ;ru lustmCII I
Valvcs <r:ollluv.11
ValveS arrd valvc SIJ;IIS ex;","nJI,on ,md renOv<rl lon .
Part C: Fault ditlljnosis F;rull (f&#39;<ry&#39;IO~&#39;S <:"\)11")
G ·cylrndc, ollv \II GO V fu,rrrJl,on 9303 mm (3 663 ,n) 6850 mm (2 697 ,n) 2792 cc 92 1
61 52 60 66 86 87
" 48 74 92
" 44 00 46 62 45 78 53 72 55 30 76 70
" ~2 43 7 ~;
82 58 81 67 50 84 63 50 88 40 85 !.>.1 !i l 6,'
" 56 83 59 40 73
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24
Cylinder block Bore d'iJrllCIC ' mm (.n). SI;'1ncli'll(t {j.,1CICS ,
2.3and4 .. OverSIze UI,lcics. A ... Il and C
Crankshaft Endfl0i1 1 mill (OIl) .
Camshaft nUllS! plme Illtcknc~s 111111 (m). Red Blue Endflo;'1 illm (m)
Pisto ns elc.uance III bo.e ""11 (Ill) Rm!J !J&#39;~P mm (m) Top. CClille BUliom
Connecting rods BO!I "lid IHJ.IIUI!IIUn'UHU r, h: ;,. ;uu";C m ... (m)
V<llves SCil l ilnllh.~ Villvc clc'Hance (col{l) mm (tn) Inle! •.. E~haust Valve tmllng IlIlnt ollens Inlel closes [Kh&#34;u~l olle&#34;~ E~hallSl closes TilPt",, 1 :;1(111 ..,le ,u:lIlcfl I1UI1 (,n)
V"lvI! ~1I11&#34;!J (11)1] 1''''WI, "'III (,,,) SlcIII III !lIIId" CI0.);1I"'1I:1) ,,,'" (II') 1,,1,,1
E&#39;h,&#34;&#39;~I
Lubricatio n systmn e"p.1';' ly W,t h t,llc' W,thout hll(:' 0,1 p,eS~I&#34;e (111111111,,,11' 1ll 80 C) 750 'PIII 7000 .pm
Torque w re nch sctlings Malll hea.",u CalIS B'g·cnd ClIPS C .,II.kshalt pulley boll C;.III sh;.lt Oem Call1shilit th'ust vlme Flywhcel
TUlII"\) cove' To hlock To .1(111pt(II I)I;II C 0,1 pump 0,1 pUll',. covel Rocke. ~hall Slimp
Staue 1 SI:lge 2 0" dUlln pllill CyIUI(I,,;, heild bolb SI1I\Jf! 1 S I; 'UI , 2
S Ing.., 3 (;dlCI 10 1020 nUllul(lS WilH)
Chapter 1 Engine
93.0 10 1093020 (3 6618 10 36(22) InCr(!mcnlS of I 0010 (e.ClO04 )
935201093530 (3 .68 19 10 3 (823) I ncrements 01 0010 (0.0004 )
0080100280(000311000110)
3.960 10 3 985 (0 1559 10 0 15(9) 3986 to <1 011 (0 1569 to 0 1579) 002 to 0 10 (00008 (000039)
0028100048 (00011 (000019)
038 10058 (00150 to 0027.8) 038 !O 0 58 (001 50 100 0228) 038 to 1 110 (00150 10 00551 )
0006 10 0 064 (00002 10 0 0025)
46"
035 (0014)
0 40(0016)
24 -oroc 72 ' ABOC
73 ' OBOC
25 ' ATDe
0023 10 a aGO co 0009 10 a 0024 ) 525 (2 06(9)
a
020 I n 0 063 (0 0008 to 0 0025) a 046 to 0 089 (0 0018 to 00035)
1 25 h ilC (7 5 Pilot) 400 litre ("l0 IJIIlI)
1 a kol/cm' ( 14 2 II>IIIIl' , 28 kul/clII' (398 Ihf:,n')
Nfll 90 to 104 29 to 34
4 2 to 50 42 to 50 17 to 21 65 to 7 1
17
t o 2 1
1 3 to 1 7 141017 91013 59 10 67
4 107 7 10 10 2 1 1028
39 to 5 4 54 10 69
Ihf It 6610 77 21 to 25 3 1 1037 31 10 37 13 to 15 48 1 0 52
13 10 1 5 101013 10 to 13 71010 44 1049
3105 5 10 7 15 to 21
29 10 4 0 40 10 5 1 70 to 85 S I;'lle 4 (:,Itt" '",,",nU enumc to , 15 .llIl)Ules ill 1000 fpm)
Ror;kl1' cow:! ...... ..............•..
95 t o 1 15 Bilek 011 1/2 "to 7 IU'I) and .elolQuc one bOlt al a l'I11C 10 Stagc 3 valu<] 310 5
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Chapter 1 Engine
: Part B: 3.0 litre engine
General
)
rr
T ype .. Bore Slroke
Cubic capacoly .... Compression 111100
cylinde r block Bo,e dlnmCler mrn (In): $wndMd urnelcs. A B.CllndD DverSilC {)Inel!} A
Cranksh aft Endllonl mrll (III) ..
Camshaft ThruSI plate tlllckness mm (III) EnclllO;1! 111m (In) .
Piston s Clearances III bore mm (111) nlllg gap mm (tn) Top .. Cenue BOllom ..
Connecting rods Blg·end hea,ony running clearance mm (In)
Valves Seill :myle . V,llve clearance (cold) mm (m) Inlel .. E~h<l&#34;sl V,llve 111111(19. Inlel openS Inlel close~ . hhanS I opens ExhaU~1 closes T.1Ppel s.de clc,u<lllce 111m (111) V,llve $P""l) Iree lellUlh mill <nl) SICI11·IO·\llIldc clCilr,lllCC IIlIn (Ill) Inl el E.h;IUSI
Lubric<Jtioll system C,lp;lCny
W'lh 1,ller W'lhoUI "iter ..... " .. 0, prCSSllle (nllillmum <lI 80 C).
750 'P'" 2000 rpOOl
Torque wrench settings Ma,,.. be",IOO C.IIl S ..... . B'o -end Cill)S .... CrMllsh<lh pull(!y . Cilnlsh,1ft IJ(lil' ... f Ivwheel,'(h Ivej)l" te Fronl Cove, 0,1 I)UI11Il "n·d J)i~&#39;;·.~J;
0,1 pump cove,. . ... , ........ . Sump
Cvlind e, l1e,l(1 boit s .. SI<lge I Slage 2
S iage 3 (nite r 10 10 20 mlnules wart) ;Iau(! ~ .• ,., .. , .•.• ,., ...• ' ., .... , ., ... , .. ,. ,., .. , .. R laue 5 (,!her running englllc fur 15 rlllnu!t:s ,11 1000 ,pm) OCker cover Dd el'JIlI p1uy·· .. . . ..
n",), 0.1 senl cill/ie ,
6·cytonder ohv in 60' V 'o,mallon 9367 rum (3688 in) 72 .42 nun (2851 In) 2993 cc 89· ,
936·17 10 93 658 (3 68o!) 10 3 6873) Illcrements of I 0010 (0 0004) 9 4036 10 !"I4091 (37022 to 3 70" 4)
0080100780(000311000110)
533'\105384 (0210 10 0 212) 0153100254 (0006\10)
0036100051 (000141000020)
0254100508 (0010 100020) 025· 100508 (0010100020) 025·1 10 0 38 1 (0.010 10 0 015)
0006 \0 0.064 (00002 \0 0.0025)
032(0013) 055 (0022)
79 B mc 67 ABDC 70 UaDC 14 ' ATOC 0013 10 0 05 1 (00005 to 0 0020) 47955 (1.8880)
0020100063 (00008 10 0 0025) 0048100050 (00019 10 00020)
500 hue (88 prill) 1 25 hIre (75 pml)
10 kUf!cm' (14 .2Ibl"n') 2 8 kuf/cm' (398 lbl/in')
Nm 68 \0 76
53 \0 59
55
10 62 551061 69 to 76 1510 18 17 10 2 1 8 \0 12 8 1011
10 301050 82 10 92 110\0 1 17 11010117 3105 27 10 34 16 \0 20
Ibf ft 50 10 56
39 10 44 41 1 046 4 1 1045 51 1056 11 \0 13 13 1015 6\09 6\08
7
22 1 0 37 61 10 68
8 1 1086 81 to 86 2 10 4 20 to 25 121015
25
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26 Chapter 1 Engine
PART A, 2.8 LITRE ENGINE
General dcscril>liOIl
The 2.8 !lIte cnnlne IS of GC,Il1;l1l V(l Qve.hctld v<llvc type. The (OI,llsh;,l l .s loe;lIed centrally In the tylimler block ;lnd IS (Iliven by hchcill \JC~ars from the 0,'nk5ho1h, The vtllvc$ mil opcrillcd hy !:lppCIS. pusluods ill'\(1 rocker 'UIllS. The cylinder hCilds ate of the cross flow (lcsl\J1l With the mlC1 11\,111,lold IOCiltfld on lOp 01 the cylinder hlock between the twO cyhmle. hCilds .111(1 the exhnust m.1nofolds on the outside of the heads Tho r.omhincil c,ankcaso ;1I1d CylUldc. hlock IS madc 01 ens! "011 AllilChcd 10 Ih .... 1>01l0'11 ollhe clankcl'ISC IS a pressed steel sump whIch ,lets ns a &#34;&#39;~&#34;\lOIl fa. the cnWllc 011 I\hlll1l1l1lll11 ,1110y p'Sl0ns illC conl1CClcd 10 lhe Clanksho1l' hy ~I !.1·C"OII 10lucd s&#39;l~1 COllnCChng lods ,1n(l glld\Joon pillS Two I:Olllp'f'SSIOII 111'\)5 a/HI onc 0.1 (:onllol Illig, ,,11 101:;111,,1 al,ov(! lhe !llulgtJon 1)111. alo Io110d. Till) la'lIed c."nksh"'1 ""'s in lOll' ilia", iJca'lI1gs. and en(lIioal 's (:Olll.ollcll hy II110M w;lshc.s 00 No 3 1I1;lIn bO~&#39;IIl!J. The dllv(! 00'" IOf
the d'SI"hutOf ,m(t 0,1 pump is located in flont 01 the 'Oil! Cilm bC;1rIog lub"cation IS by means of a bi-rotor 011 pump
2 Routine lll;lintelHlnco
I\llho inlo.vals sj)ecilio( in 1110 Routine M~&#34;&#39;lcn,1ncc $CCllon II from 01 Ihe m~nll;ll carry 0111 the 'ollowlng p.ocedu.es.
Change engine oil. renew otl tiller olld clean oil filler c. 1 Apply Ihe hil&#34;clb.~kc Ihon jack III) Ihe lrolll 0 1 Ihe Cill and Sil l on ilKlc Sliln(\s. Alle'nnlively pOSll10n Ihe Cill ovc. ,111 &#34;,~pcCtl(ln I 2 rlace a SUlliluh:1 cont~Ule. beneillh Ihn sum1) Ihen tlns.;."w dHun ph.!) (photos) ~nd (If""' the 001 3 Wh.le the o,l.s cI.,}lninu unserew Ih" 0,11.110. '-:;111,,<190 USII'H a' wl()nch ., Clean Ihe d.;IIn plug and Sltllllllhen ,elll Ihe pili!) and IIUhl"!! 5 CtCill1lhc IllIer COlllil(:1 mea 01 11i(, CXlenSIOII blackc. 6 Sme:1f a fIlm 01 enUlnc 011 011 Ihe now 0111.1Ir,. ",hhe. u,&#39;~k(&#34; I screw lion IImoi " JlISI CO(l\;1CIS the t&#34;n~k&#34;l 1 ,1(:(, (photo) 1'",111
Fig. 1.1 EKptoded v iow of tho 2 .8 titro engine Illain c0I11I)ononl5 (Sec 1 )
I T!,ellliostnl hUl/slII!) 5 U y poss /Just! /l,J/Jyc
"
Cr;III.sllllll gear 13 Od pump dflVOS/l,l/l
2 'h':III.ostn/ 6 Ifl/.:1 " ... ",ilold 10 Flywheel 14 M{J;n b e{Jflng CilP
3 W,J/er PUJllP , C{J/lJS/",/I/llfI/SI/J/OJ//! /I Cr{Jnbh<J/1 splgol bO<Jring 15 Od pl/mp 1/ I mllllg "over 8 COJmsfwl1 gem 12 Od seM
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) Chapter 1 Engine 27
oint t ighten II ~ further 3/4 l urn ~ Remove the t,l ler C,ll> all the left· hand side of the engine and I,ll the g ine with th e correct quantity and grade 01 od (photo), ;n RemOve the OIllcllcl dipstIc k and wipe it clenn. th en fe -insert'! and emove it Jg<llll The all level should b e up 10 the Ill,UimlJlll llliHk ;phOIO). but nolC thnt Ihls check is only nCCUJiltc ,/ the C<1I IS on level
grourod. 9 If neCeSSary. lOp up the level nOI1l19 thaI the diSlnncc between the minimum and 1l1.1X"mHll level marks rep rescms ,1pprox imil\cly 1.0 hIre
(1.76 p int). 10 CICJfl the 0,11,1101 CilP then refit il .
Check and adjust valve cle<lmnces
11 Refe r 10 SeClian 35
hgMel) inlet manifold bolts 12 Remove the ,111 chamiler and \'oh\on the Inlet 111.11"lold hnlls ({J the spec ified lOrque WIth Icfcll!IlCe t o Ch~ptl!r 3 On compl"I")1I ,(:111 Ihe
JII chnmbcI
R enew (fie crankcase ellli,~sion valve 13 pulithe v(1lvl.' (1Pl(I'hose 1'0111 tlw leM 0 1 Ihe "ohl·l1(1nll locker caver
(photo). 14 [1.clc;lse tile cl'll ill1<1 ",movc the v(1lve foorn the h ose 15 Fit the new valve.n levr:rse ordel
3 Major operations possible with eng inc in car
Thc fol lowrng ma lo r operat,ons Cilrl he C;1<ned out WIthout removing Ihe CIl\IIIIC from the CM.
(,1) Removal al>d rufilliny ollfl~&#39; cyh,,(h,r heiufs (h) Removal ami rehlllilg 01 rocker shall aml/lllslliods (e) Rcmov,11 ,m(/ ,elilllilg of {'Or!( elwine mOllnlings (rf) R/,fIIov,rI ,11[(/ reliltirry 01 (lie flywlleel (geillbo>< lI:muved) (t') Remov,ll amI rufl/liny olille Slimp 011(1 oil f)(!fIIP (I) Re/IJov,)1 ,11111 rehltiny of Ilw liming yl."ilf$ (y) RCIlIOvo1l ,mil relilliny ollhe biy-crlflln',llinys
,
(It) Rl.'tttOV,ll ollnf ,ellllmg of IIII.' 1".'·(Ofls ilfld cOrlfleelmy rods (,) Rcnewal 01 tI", c ,i/nkslliplt 11(1,,1 Sl'it! rtI IIIIII"y C(lVCI
4 Major operalions requirillg erlgirlo rO!lloval
T he followlllg IHaJOI opernl'OIlS ,,,.IV I", Cill!ICli out ilfl'" 1t'l\1o,",ll of tir e englllC:
(<1) Rcmuvi" iJllr! Id,lllIIY 01 If." ,.,.ttt~Sfti&#34;l .,11(1 II>,1ftl 11,-,tlIIIYS (IJ) !1ellclV,11 ollfw o,wksft,dl II'." .~,.&#34;,
5 Methods of engine removal
Althol!OIr It ,~; flo~~lllle to .. ,1)1,,\·,· tI .. , "WIlli': .:Illd U"iU!'vX <IS ,111 ils~c,)lhly ,t IS 1"':OIlHllellllc1l th,'t th" "II!I"I<, ,S "'1\10v(,1! ,,~ ,I ,;OP<I ',) k Uil il If t))(, ell!)"'!! '·'1111 ~lendlOx ille II·"'"v,.d .,~ ,ill ,hSI:mhly 01 11ilS to I,,) hft,.,d Oll l ;, 1 n '"'''v ~t&#34;l;p o1<l(Jle ;111(1 I", iI&#34;~ .1 &#39;.()n~ ilcl.1hl(, Irlt."\) he'oll! IS rcqu"cd 2 If the wo,k 1>')IIlg \IIldCllilkcn &#39;C&#39;I&#34;&#39;&#39;&#39;&#39;~ Ih ... 1(,IIIl ),,)1 of tl .. , \i,),IIbo~ ,IS well as the (:1l!1" 1" ,t 's l ecomnH:lld,'pJ 11\,11 tip,) O",Hho x 'S ,,,,OlI<.)v()(1 fr&#39;~l (nil"r to Chap('" 0)
o Ellgino rcmovill
II IS t',,-,,.'IIII.-,1 If! h,v" <1 fl<wd "'!I_'1. ,,,,,I lI\1i 'IAf" sl,mds rI "" IIISI)I."(;/io" fill IS 1101 itvad,11!1e lltu $1!i("""':L' 01 OIIL'I,111utJS I'SI,'d m II,,~ Sec/lull'S !lol ",llcal ,H Ilic 1)(I$,liOIl 0111"." fWf~()1I "n(/",I:'''III!J II".' Ivork . 01 lite /001 III IllS Iwnd. Will (/1."lcr/mllt' 10 a ccrlaill CXlt'lII Ilic ut(lv, ill ,vlllcil the IICCCSS,lIV OPI!l,11wIIS illC /let/ortt/cd ObvlolislV /lw '."tI{f1ll1.' C,lllllOI Iw ,ctt/ol'cd 1fI1111 cvcrylf""fJ IS dl~cotllrccl&#34;&#39;/I 11I1tt1 II i,,,d tlw lollow"'fi $"(fIl,'IIl'V Will el/~(tll.! IIt. ·It rlOI/""{J IS 10I901l<:fI 1 Removc the bOlll1c t "s descllb"d '" Ch,lpw, 11 2 Disconnect thl! llilth)IY ncg;rtlvl.' le.,,1 ,IIHI Ih e ealth l.ill,IL' frun , lh,)
,. &#39;~ , I\; , .,
28 E[lO"lc 011 levI;[ d'pstlck ma,kll1gs 2 13 Removing the Cfankc<1se cnHSSIOIl v<1lve
62 Ea'th cable Oil the alte'''''lOl adl"slIllt:l1t u,,,ckel (<H,owl.!d)
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28 Chapter 1 Engine
al1crn;1IOf ,1d,ustmcnl braCket (phot,,)
3 Dr,un the coohnO SY~&#39;cm <'1nd ,emoll" IIw 1,1<1'.1101 ,1S (InSCribed "' ChnplC' 2 <I Remove t he cxp;ms,on !i1nk and h'dd", ,15 dcscullcd III Chnptcr 2 (1Ih010S) 5 D'sconncct the hoses from lilt, i".x.hnrV ,ll! villI/c . 1helnl ost,ll hOllsm\j. nil!! the heater lulles on the hulkhnnd.
6 DisconneCt the h'nkc SCrllO vacuu", h 050 Irom the "" chamber 7 Disconnect t he IIllel duci hom the ""onlc hOusln\) and nH~tUlc control 111111 8 DIsconneCt the IIl.on'e cilhle w.lh ",1.·",,,c(1 to Cha,l le. 3 n Pull the CC&#34;I&#34;~ itT ICil\, lmm the <1",,,1,,",,, C.11> ,l oll PO~I1,on (Oou" s,dn
1 0 D'sc:onnCCl ,hc mirth plUH I.um th., ,1"""'''''01 11 DISCOIllH:CI the W""lO hum th" 1&#34;&#34;&#39;I~&#34;.ll&#34;,e IFllI!)U scnd...,f 111'" (phOlo). lhc.mo!"1111 SWlh:h. Wi"'" "I' &#34;~I&#34;&#39;,&#39;IOf. i!uxlh;uy ;111 ,r.&#39;VIC&#39; ~ ,1nd coli! Sl.1.1 Vil!VO
12 UIIS, ;I"W Ihc '''11 011 ,,"1 and dl~r.&#34;,,,,,&#39;, I Ih" O,! lI,eSs,"!! !F'U!JIJ h"" (phQlo) 13 D,sr.UIII'ccllhe IW"h "d,le hOOIlII,,'II,,· h"lkh(:, 1d (I,hnlo) 1'1 rO~lllon ,I ~\lII;IIII&#34; 1:01\1,,,,,,,, 1'''''''.,11, th" I,owe. ske""!1 '''''''I' Ihen <11~(:ollll&#39;~&#39;:llhe ilu'd ho~es (CII<IIII"1 III) "nd d 'il lll Ihe (1",,1 1'1,1':1' II,,~ htlses 011 0111) ~uln 15 R,:m()v.: Ihe ,111,,,";oIOl;lS d&#34;sn&#39;I~&#39;,I&#34;1 C":h.llllnr I'} 1 G fl,,,,u,v,: Ilw 1",wI'1 ~h&#34;&#39;II&#34;!1 1"""1' ,101\·,·1,,·11 ;'S d"sl:fII'c,1 III eh"llI"1 >0 17 fl,mIDv" Ih" <III dl",,,,I,,·, 11":11 ,"'II",V<: II,,: 1I11",: IIlIS. 1",'VIf'!1 111<:11, l'li,,,, I,,,1I III 11m I"d I,w,s .• 11"'1111 .... "". II,,· I,,,,'" III '''''. ",I.· lid", hi Ct.""I". 3 III, Ih" 1I:1I1l",,,1 1"'".".1",,,
1 8 AIIl'ly Ih" h,~&#34;dlJ,,&#39;ke tlll '"I, ••. k "II Ihe 110111 0 1 the c", alld s"PI' 011 il~lc ~1,II,ds 19 A .m'ovo: Ih" s.,~llcr mow, ;,~ d,.:, ... ,hcd III Ch"",c, 1 '} 20 R","ov" Ih.] clu lC h c"t,le 1"JlI' Ih,~ \I&#34;;&#34;b()~ wllh ,.,1'''I'I'CI; ChnplC' 5 2 1 U .. 0>1 .... w , .. , d ",'novc Ih" 0,1 r,h,·, <;."!II,I!lc ($1:(:11011 21 22 OI~,&#34;(&#34;&#39;&#39;&#39;&#39;&#39;&#39;:1 II", hoses "011 II,,· " .. ,,,,,Ic. 23 U~&#34;I!I .1 '/7 ",," sll;mn,,, "" .... I .. W II,,: ~,occI.11 nul "",:"IIn(1 1 IlxIClls"'" h',II.k',1 II) Ihe 0,1 c(,,,I"1 H","m'c thc h",o,:kcl. 101Io.:!I"" w III<! w&#34;~h,,,&#34; "",1 0 ''''u (phOI'" '}' 1 Un" "·W 110" "uiS I,olll III,· I.'," ""'1''''' 1I""JI' I,IlHS {p""I": 7() l!nl",IIII", ,,,h.1U~1 P'PI!S I""" 11,,·1, ·1( .",01 II!II" C~h.IU&#34; II&#34;.&#34;H!()I, I", Ih"11 III "n" ~It&#39;ll ;'If> UIII,ull th,· !w;&#34;I)O~ !1Il'" 11"" "!I"'" "d,'I,T(JI 1'10110: '}7 Lm'''' 110,· ,;," 10 Ihc WOlIn&#34;~ 78 51'1'1''''1 II." !I,·,uhOx willi" 1",11,,\' I." I 29 All."" " 1.""'1 10 II", "n!I"'" , .. "I i"',1 I &#34;~,, ",. W"''1J'1 I" ''',11101, ';I'!I"'" ".,1 .. ", "." ~&#34;,t.1hlc &#34;I.~ ,. I", "II,,,·, I ,I~: hlll si cll., , ... '" .""UI th" h""1 " I II,,· ,:.h,&#39;&#34;~1 ",.",,1..',,·, :I() T" P"""'" d, .. II.tUC 10 II" , ,~., h,I" .. ,,, "'I' ,"" . ,hI", .""'. "'m" 110<:111 ""I" :,.1,·,,,,,,:,, '0 Ch,'pl'" I
: n li,,~, "'w 110" !JI&#39;,)lhO~ III .. n" ",. I,,,t ...
:17 n." .... · II ... &#34;&#34;~I&#34;&#34;: wh,'" ~I&#34;&#39;: '''I I ... • ""'1"'" """,nl""I', It",,, It :.II)lh·1I I&#34;,,,~, ... 11'1,,,10) Ii "',' I,.. I .. Iplo" III "'''''I.I",,· ly ''''''OVI: I I
"!II'I h,""I""""'I"", W,lh II,,·, '"I''''' &#39;,lI~&#34;&#39;&#34; I,·,,, ','I I,,, I", .. ~, .... . P' ,I I"'W,IId·,! .. ol""'II""! IC ,I 1«,,, . tl,,· '1··,,,1,,,, ,,,,01 (,,,',"1(,,, dll""'''' :C! Wh,'11 110.· , Io,t, 10 IS ,I",,, "I II,.. '1,·.lIIH" "'p,,1 "Io"! 1 loll tho: "'''111
III"" Ih,' ""'1,1", &#34;&#34;&#34;I~~&#39;I&#34;&#39;&#39;&#39;&#39;&#39;I '\',,1,· ."",toll" ,I " .. ~I II", '.""("",,",, , '" "I" "', ''''', i pl" .. o 1
" " ,
" )
....... '.
"
G 4A fl"nlovlI'g Ihe QXP,IIlS IOlt t.1l1k "'O[l"III' U b,.1Ct..CI ujlpc, ""
,1nd lowc. Sr.ICWS 6 11 TCI""c",t".c U'lUge stJOdCf U<II. wlllfl lJ (iII.owetll
6 12 0,1 P&#39;~SS&#39;&#34;C gauge IInc (llo0wcd)
.--~--. ...-,~ .. - -.-... -"',
6.13 Rcmo~&#39;ng Ihc ea,lh Cllb le I.om Ihe bu!khe"d 623 IlcIlIOI"'!)lhc C~I~ns,on b,ac~.et (,'lfowedl trO'1i Ihl' 0<1 COOle,
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Chapter 1 Engine 29
624 Left-hJnd cI1!I'"c i)lO(lI1I"'(ll1l1l 6:12 LIIllll!l Iii\! ''''!)Ull: deal 01 Ihu rnOlllllln!) hr,lCkel~ G 33 L,Illll\) thr, ('''!JI''e hom the engine c()nlp~rtrnr!lll
7 Engine d isl1lil"tling -(Jenerill
\'Vhcn Ihe cn!I"'o I~ lelllovud ['0'" the ':'H. 'I. n"d p;olllc"bdy ,IS aCCCSSOllIJS. are v"llle"IlJle 10 d.lm;I!IC If 1&#34;)~~d)lo, 111(""11 the ('''Hill') Ull il stand. or fnlhng thiS. Illnke sUle II IS SUPI!'.)II,,, I In ~(Ich it "'oll'l",r th.ll rt W ill nOI bc dillllJocd whdsl "ndOll'!I t 'jlhl nub ;rrHI hollS . 2 Cleanliness,s ""pollanl wh..,n d, s"""'II,"!) tl,(~ cn!)&#34;H~ to prcvllnt e xposed PMIS from contnm,nnt ,on B(dore ~1:llt&#39;&#34;0 Ih\! (hSIll;lnt lll'(j operJtions. cle;:!n Ihe oulsldc 01 Ihe ell!J1IlC wllh 1';H"Um. 0' a !.food greilSe solvent II 11 IS vcry diriy. Carry outlll1s clc;lIu"\I ,Iway frolll the area in which Ihe [lismilnliino IS to ta ke place_ 3 If an eng ine S1<lnd is Ilot IIv;"lllalJlu callY OUI Ih e wo,k on ;, hurrch o r wooden pimfolll,_ Avoid work"'U with thc Cfl\)lIlC (illcctly Oil " concrete Iloor. as Wit preSelllS ,1 re,ll ~olllce 01 troulJle <1 As pilrts o1Ie )cn'ovcd. cl~&#39;o1n lh(:11 '" .1 p"I<,II", 11.1111 Never ",,,,,u,se l''''ts woth Inlelll.l1 Ollw.1ys III po1r,lll", lo"t w'pe dowII c",d"lly w,th iI pCllol·damponcd I;&#39;~) Clean OllWilys w,lh w,'" 5 It '5 advlSilhlu to I"we ~;&#34;&#39;Iahh! co&#34;la&#34;u,,~; to hold ~.&#34;&#39;all ItelIIs III lhcII O'OIiPS as tlus woll help wl\(~11 ",assn",hlll'!) Ihu CII!I"'e ;)1,,1 a lso p,ev(:nl posS,I>I" los~
G Always Ohtalll (;oolll'lele s"ts 01 (la~knls wll,,,, Ihu C"!l'"U 'S IoU'"!! (I,sll'''"tled It IS a !Jood poll(:y to always j,t Ilew \l"skeb III v'ew 01 thc rCI"I'vely 5,,,,,11 CO~t IIwolv!!d l\et.1'" the old !F"knts when (lisIllilllllo"!J the en\J"'e With .1 v,ew to \lSII,\! them as .1 patlCln to ,""ke a rCpl,lcemellt !Ja~ket ,t a new olle 'S 1101 "vallable_ 7 \'\,hun pO%Ihle. "d,t "lOiS. holts illld washe,s III Ih e", loc,ltloll5 liS nu s helps to p,otcct the IlIru,ld5 flom d;u""IJe ""d Will ~Iso b e helpful wh~&#34; t.he enO&#39;&#34;~ 1S to"",\! reilsse"'hled. ;os II uSl<llllishes lhell locilt'o( 8 flew", IHlSUrVlco,lble lIems unt,1 the new pails ;HC obl<lllH!d. 50 Ihilt Ihe ,,~w P,III C.ll' 1m chcr-ked ,1\)<IIIISt the old pill I 10 e&#34;~&#34;,e that the r.o&#34;e~, ' tem hilS 1"'011 supplied
8 Engine ilnciffMies -relllovnl
AlthoUIJh the Ilems listed Ill;"ly 1m ,,,moved separ~(o)ly wllh the ''''O",e installed (as tI"scliheci '" III(J ,eh:Volnt Chapters) II IS more ,1pP'Opfiaie 10 lake thclI' oil illter the cnOlllc has hcen removed Irom lhr, f.;11 wh(", e xtensive d iSlllil'l1hllO IS hell'!1 cilifieri 0111. The items .11(1'
Friel init1c/I(Jri svs/I.'II> cOlllponellls (Clmplcr 3) DlS/fibulOf (CII,1/>IN 4) Filn ilnd w.llcr IJUIIIP (Cilill'lL'r 2) Power slccring PUm/' (CII,lp/N 10) IlIkl MI(J cX/)<lUSII!I.lndold.~ (CI!.1f!/er 3) C/uld, (C/,.lplef 5) Sl,m" 1,IIIgs (Cfwplcr 4 )
9 Engine -disIlHlIltli,,\)
1 fh,nH)V( ' tloo Oil lev,,1 (hp~t&#39;ck_ 2 UnSClcw the cellire ~Iecve a",1 "!1II0ve tile 011 coolel ilnd g,lske t (pholo) 3 II lIot done prCV'Oll sly. u nscrew tile ~wnp drollll pili\) ;"Inri drJ11l the oll IIlto a Sllolahle conl,,,"c' <1 Unholt the engine mounlings (photos).
5 Unhol t the power steeling pUIllP Idler pulley illld h rilCkel (photo).
6 D,scollncct thc bYPil5S huse 1 '0111 till) tll"ill\) cover ,eill elbow (photo).
1 Hernovc t he rocker covcr secll""\) boilS "nd hit off the covels (photo). DlscGlllle(;t the b,e.llher hose where ,1pplocJble. 8 Undo the rocket shah seClIring holts and remove the ,ocker s hahs Jild 011 splash stllelds (photos). Notc wh,ch Wily the splas h shIelds "re
920,1 cooler show"'!J centre ~Ieeve 9.4A Left·h~nd Side enUlne 1II0Ullt '"0 948 RI\)hl·hand Side enU11le moul11lng
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