check engine FORD CAPRI 1974 Owner's Manual

)
Chapter 3 Fuel and exhaust systems 67
Torque wrenc h setting s Fuel P\JlllP Inlet n'<llllioid Swgc 1 Swgc 2 Swge 3 StJge 11 (<lhe, runninu enome for 15 minutes <II 1000 rpm) Exl1;lllSl n1<ln,lold to downpipe Exil;lusl U·holts ,11\d ci.lmps C~rblllClt(}(
Pari R Fue! iniaclion syslem
G ene ra l SyS1c'" Iype Idl e sp ce d CO "o,![ ull" Fu el p"mp rfelov(!ry (nHrHrl1lJlll)
SyS1cn, P&#34;)~&#34;&#39;&#39;&#39;U Fvcll,mk Co1P,lC '(y
Torque wrenc h settings Fue l ,11,>1,,1.,,101
W",m "p &#34;&#39;~11I1;,1O&#39; 51<1,1 V,llvt: A\J~&#39;h;&#34;y i'" duvlC(! Air eh.""I>", Bal1)o I>ull~ Fuel d'SI"hu\or W",nl up '«!lul,l1or (MIO) W,llln·up rC(jul<lIOr (MS) 1I11C(:1I01) pipes Fuel pllfnp. fi lter <lnd ncculllul<llor
PART A: CARBURETTOR SYSTEM
Gener,,1 description
TI", 1",,1 sy'>I<'1ll <;onSIS1$ of " reM moulI1ed fuel wl1k. il {hilpluo1\Jn1 type 1",,1 1l"'''P d"v(JIl I,om the C,lIllSh<lh !lnd " (lu,11 vellll'" lio .. ""h''''!II\! <::111,,""110< There Jle two SepJ IJle eKI"luSl <1sselllhllC s.
eJr.h COII~&#39;Stll&#39;!I 01 ,I hont pIpe nnd leson<lto r. mtell"ed'ille pIpe <1nd Slknl"ul. '" HI J 1<111 pIpe <llld Sllcncer The <lir CICJllCf 011 Iiller models II1C<J'I101;lleS , te"'pcr<ltlllC control II,'I).
S omn models !"ay he hlled wIth a p,llted vacuum switch (PVS) to p'eVUl1t fI"1 SpulS aud nllsl"'"0 OCCll""'\) when the enllllle is cold "lid flll"""'1 WIth hJlI or pMllJI choke. When the enuine IS cold (below 71 C I i GO F» the I'VS IS closcd. In tillS cond,I'Oll. c;lIhurenor v,lClIllln IS ,'Pl'hed directly to Ihe d,st"lnilor V'J the Ilon·return v;)lvc. whIch &#34;lIow~ (he va ClJllI1I Jdv,lIlee to IJc milll1lolll1e( 1 lIntier <1cccieIJt.on.
prc .. en ('''Uliat spots or mlsf""'\J .... ·ho)lI the eng"'e h<1s re<1ched liS norm;ll ope,mll1\J lemperJtllle Ihe PV S I, open In tillS condltloll lhe C<1rbUle1l0' '5 connected 10 Ihe
d ,s t"hu!Or v.a lhe PVS.
2 Rouline lll<linlen <1nce
AI the IIlIclv<lls spec II led 111 the RoutlllC Malfllelwnce seClion Ullhe "0111 of lhe IllJllll<l1 CJrfY out the followmg procedures.
Check and adjust the idling speed find mixture 1 Refel to Sect.on 12.
Check condilion of fuel hoses 2 E>.n''''lle illl Ihc fuef hoses on the eng ine compartment and on the fu!:1 ""'k. for SIgns 01 leilkJge or eletellowt,on. 3 Che ck the secullty 01 <lll fuel hoses Tighten the IIllet mnno 'lold
holtS 4 Rel"r to Sect,on 19 Jnel t.ghlcn tile IIllet I11J",101d bolts III the
)
s!:q uence (jlvcn
Renew the ilir filler element 5 D'$ coruWct lhe hauery. G Remove lhe twO nuts secullng the air cleaner lid nnd remov e tile
N rn 16 to 20
4 to 8 8!O 15
'8 to 2 2
1 8 to 2 2 20 to 27 38 to 45 20 to 2 4
Ibl It 12 to 15
3 to 6 6 to 11 13 to 16
13 to 16 15w20 28 to 33 15 to 18
1305<:h K ·JetfOnic COlltonnous inlCCllon !JOO .1. 25 rpm 1 25 I 0.2 930 a cc cvcry 30 scconds 5 f)5 I 0.25 kUI/crn' (789 I 36 11l1/on') 580 hlrc ( 12.7U<lI)
Nm Ih l It 32 to 38 24 10 28 7 to 10 5 to 7
7 to 10 5w7 7 to 10 5 10 7 7w!l 5 10 7
18 to 20 13 10 15 11 to 15 810 11 5 to 8 4 \0 6
5 10 8 4 to 6 181020 13 t o 15
hd . 0" I;>ter models the ltd rnily be secuted with sprong IJSleners. 7 LIlt Out the paper clement <llld d,scmd it.
8 Cillelllily clc<lll the inside of lhe Dif cleJner body. !;"IlS''''Il\J thilt no dllt IS illiowed 1 0 drop into the cmhurCl1or. !J I'll <l IICW element "nd tclot the <l" clc<lner lid 10 Recor"lect the IJ,1twry
Check air cleaner IClllpcril{(lrc control (whcrc (i{{cd) 11 By looking through thc main ,101 cle,llle' spout. nOle the pos'tlon 01 lhe 1I"1l v<llve. Wilh lhe engIne stmionJIY Ille lI"p should he lully closed 12 SlJr t Ihe engine <lnd check the oper,ll,on of the lI"p vJlve W.lh the engine Idling the IfilP should open Jnd s tily open 10 ,1110w hot all "liO lhe <1" cleilllCr. Note: II is essen/l,ll/liall/llS lesl is C,lIllC(/ OUI wilililic ClIljlllC cold. If the 11"11 !CIIlJ"lS closcd whell the ell!l",e '5 st,IIIC(lthell 1herc IS <l fmill 'n eilher Ihe dl<lpilfilllill unH Of he~t S(oll50r "nd thcy should he tcsted JS follows. 13 Check the vilClium supply p 'pe for leilks Jnd renew It II suspec l
F ig . 3 .1
Air tamper<l ture controlle d nir cleaner (Sec 2 )
A 8 C
VaC(I(lm mUlor FIlip valve I-IC<1I sensor
o 1-101 all in",ke E Culd illl U!wh,
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) Chapter 3 Fuel and exhaust systems
FiU _ 3.13 Components to he checked (Sec 9)
A
8
C/u':(:A fur wP.olf alJd (/illlli'f/I.l Clwck '(If .~/I&#34;lIitJfJ
C CI)(xk for hd,ill{J {) Check (Of spfrlling
10 Weller cnrhurettor ""tom,lIie choke - rcmov,]L overhaul
and refitlinu
1 DlsconlH!~1 Ihe i)illicry nC\j<ll lvc IC.ld. 2 RClllOVC lhe <I" ,Icaller ns dcsc"hcd in Section 3
3 UnscI!;w the contlC hoi! ""d remove the cover. 1 Remove the three SCfClWS. dewell the housing <lnd unhook the bi·mctallic spring
5 Detach Ihe interna l hCill shield . 6 Remove the smgle U· clip and disconnect the choke plote OpCfilting link, 7 Remove the three screws, disconnect the choke link ,It lhe opefiHing lever nnd dctilCh the chokl:! assembly . 8 Remove the three screws <lnd dC1<lch the v"cuum d,aphr<lgm assemhly. 9 Oisn1nlltle the !Clllnin,nU p"rts of the choke n1cch"n lsm. 1 0 Cle,ln ,III the components. II1spect them lor we"r [111(1 damaUe MId wipe them (hy with" IInt ·flee cloth. Do not use [lny lui>ric"nts dlllinU
le"sselllhly. 11 Ik"ssemhle the choke meCh'1I11SI11. 12 Relit ll1e v"CUUIll til"phl1'lI)lIl alld hOUSII1,). enslllinu th"t lhe (hilphl,l()fIl IS lIolt before lile housing IS fllted. 13 Ensure thm the O-IIllg is correctly locmed in the choke housinU then reCOllnect the lower choke I",k Position the assembly and secure il WIth the thr ee sClews . ensure thnt the upper choke link loc"tes
cOlrectly tluouUh the c"rlJlJretlOf body 111 RecOllllec t the upper choke Imk to the choke Sp"l(tie. 15 Check the V"CUUIll pull· down <lnd choke phasing. [IS deSCribed in
Sect ion 11 1 G RelIt Ihe mlern,,1 heat shield enSlllinu that the hole in the cover loculCs correctly onto the peg C[lst III the housing. 17 Conllect the bi·mewl Sp"llg to the choke lever. position the housing and loosely lit lhe Ihree relnining screws. 18 ROlnte the houstng untIl Ihe marks ,lre "Iigned. then light en Ihe three screws. 19 Refll lhe cover logether WIth [l new g<lSkCI and lighlen Ihe centre bolt. Top up the coohng sySleml1 neceSSJry. 20 Reconnect the batlery. run the engine and adjust the 1"51 idle speed. "s descflhed in Section 11. 21 RefIt the ,111 cleaner.
11 Weber carbur e l tor automnt ic choke -adjustment
Note: lile pfOccc/<IIe is dcscribed for a C,,,bUfel/or wllieh is fl/ler! ill Ihe C,lr. bul wllh llic cxccptiun of fast idfc specll alljUSlmcnl. alf tiisks «In bc c,1rried oul 011 Oil! bcnch if fcquitcd where Ihc cafbuff!/lOf has
bccn rcmoved 1 D 'scOllncct Ihe bn(lcty canh lead . 2 Rcmove the illf cleaner. ilS deSCribed in Seclion 3.
.l.I. .... , •• ,. ••. • .. .• . ,,~ ......... , •• , •• .;..,.: .•• ' •.•••• 1 . ;."
.,.', .,1,,/. 1,,' .. 1 . .. . , 1.,.: .. 1,.1.1,.1 .•. : ...
J
Fig. 3.1 4 F loat level adjustment t<lg -<lrrowed (Sec 9)
Fit!. 3.15 Automatic choke housing re taining screws­ilrrowed (Sec 10)
.------
./ /' (
Fig.
/
3 .16 Automatic c hoke h ousing alignment (Sec 10)
A Rich c B Normal scl/lllg
marks
71
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Chapter 3 Fuel and exhaust systems 75
;\1.325 Prisillll oul tho re l<lin in\] clip (A) when removing IIIH acceluralOr callie (n) (Sec 1 7 )
~ fl""",V<: Ilw au eli!.",u. ;IS d .. ,~r.&#34;&#39;J(:d III Sf·etlan 3 5 1',,11 011 tlo" ~I&#34;&#34;VH ,,,HI d,s<:OlUI'!Cl 111" I&#34;&#34;~II<: sock", 110m 110"
cOlll,,,1 IIIIK"!I" G I'll'." Ih" ",,,,,,1 '''','UHrI!l <:lIp hom the IlIi,,;k"l 7 U~&#34;&#39;!I a ~,:&#34;,wd&#34;v&#34;r. d"I"CSS tile pl<l~1U: \.,1)$ "" II", '"\'"''''' wild" tw""I",!) 11,,~ 1(JI,,,,,cr. (1)I,n pull hall' the 1ll0lultorl!J 1".ICk!:! If Ihl~ pIOY"S (I,H":\lI, milk" 01 """ovatlOol \0 the d&#34;&#34;f!&#34;s,O&#34;~ !),v,m on FIll 326. ,unl p,ess Ihls ooW lh' lalls to IclcJse them 8 RChHinU ,$ <1 revers.11 01 lemovi'll, 1m! ad,,,st 01 as fullows. f&#39;lac&#39;~ i' wCI(Jh 011 the <lecelcf,lIO' pcci"l 10 hold 1 '" HS fu lly depressed POSIt 1011. On <llJlOll"nle lIilllsmisslOIl models chevk Ih,11 Ihe downslull c;lble IS nOI pn:oven llll\j 1,,11 mnvement. Bild oil Ihe ,1(il'lslnH)nl ~Ieeve ami "dlust It so Ih,'1 the t lHollle plates ;lIC IU~I fully Up';I1. n",,,,,VI! Ih" welOh! illl<l check Ihe opel at lOll of Ihe ''';<:el",,,tOl 1',,<1;,1
111 Accelerato r Sl,,'fl and ped,, ' -rc "'ov;,1 ;,nd relilti"u
'o le: If /I" ., IU:(/"I ",!ly ,.~ to &#34;(~ /f.'/!/oVI:1I /("1,:, (0 1""""1';'1"" 12 [)I~.,:,,,,,,,&#39;cl (h" 1",lle,y lea(ls ? r",," liNd" t lw C,II lemove Ihe 1;)(;';1 It""", 1';,,,,,1 II I, '''WII\l:d hy ,,<&#39;I(:W~ (IlHO) OIII""e S{;WWS (LHD) "IIIII!I Ihe ''',II "dUI! ami C;1Il tJ" IUH:lopp"d l,ulll lhe hont l~d\)c 3 n"lllove th" ,u;cole'''lot cilhlc hom Ihe p"dal sha h olS ((e~&#34;&#34;h&#34;d III
Secll"" 113
RI-IO variilnls 4 DI~(u&#34;ncct Ihe IHake ope',IiIl1\J IOd ill Ihe b'ake ped;rl. thcn 'enluve tio" I"aslcr cylinder ,lilt! sc,vo lllHI nell" to Ch,lpl!!' 9 101 lUll lol'l
'nl')lll1alI1111
5 WO,kllll) I I"OIl\)h (he ,e,l' bulkhead III the C "IJ"'C vo"'p,"t""!1I1. pull Ollt lire sh;rft "nd S"CUI1I1() chp () Rotate Ihe I1\)ht·h,,,,d Shil l I IIIO'"ltlll\) bush Ih,ou\)h 45' ,n e'lhe' d1lCC1l011 ;)nd pull II Out 7 DetaCh Ihe <lcceil:!"lto, sh<Jft ilsseml,ly
LHD vmi,!IIls 8 Loosen Ill" clamp illHI dewch Ihe sh;rlt exlClls,on ,oct. 9 C;uefully rlllve Out the ,,\)Ilt·hand 1110unlll\\) bush 'ewln, n\) clop 110111 Ihe sh;)h, thcn slide Out Ihe sh;)h ulll,1 ,t louches the hCitlC! IJOx 10 Detach thc "U1l1 h,H\d mount'n\) bush I,om thc ped;)1 1J0~ by 'Olilllll\) tlHolIUh 4 5' 11 ellhe, ducctlon, (hen pulhng It oul The ilccelera!{), slHlit [l5seml;l), Cilll 'lOW be removed
AI/models 11 Oetach II", 'em;lIl\ll\Y bush ;rm] clIp hOIll lire shalt. ) To re11l0V" the pedill, pl1se the f!;ln\Je ilway Irom the SPIYO( on lire snail. lhell ,emove the p"dal and sp"ng 13 WI,en ,eflll"'!! tire pedal. locilte the sp''''U on Ihe SPIUOI shall, lilr,, clop th" 11""\)"$ 01110 Ihe SP'\JOIS ilnt! check lhilt Ihe pcd;)1 I"vots
cO"lIetl),
Fig. 3.26 Accele ra to r cable rc moval 1001 (Sec 1 7 )
A _ 250",,,,(10,,,)
() ~ Cell(fe IlUlidl /11 /J!Uv;d" ',1,SL'd -'''ullld ... ,
14 ncllll"'() the pud.ll shilft ,s Ihe ,eve,su 01 Ihc lelllov,,1 IHocerhllC, lolinwlllU whIch It w ,lI he 'H!CUssa,y to ;ullllS I It,,) cailic. "5 d"scllt)IJ d 11 Si,(.t'OIl 16 OIL Rill) v;",allts. dlcck lh;ot the I)(:d;oll"'$ 6 tn 14 ",m (02" 1{) 0 55 'Il) I,ft 110'" the nflu posit 'on If IIo,,"ss.u y ild)"st Ih!! pedal
Iofl up ~!Op !O ach'"ve I h,s
19 1"lc t Ill[l"il o ld -rClllov;l1 ilnd rcfitting
1 DIsconnect (he biltlc,y ne(),1Ilve IUild. 2 D'illli Ihe coolm\) syslem (Chapter 2). ,emovc Ihe d'StllIJU1{)I (Chapl", 4), and remove the C.llilll'et!O' (SectIon 8) ] DI~<:OIlI,,:ct til!! rl!m,IIIiUlI) hoses ;rlld Willi'\) <1 UllSV,P.W the 'nlet m;r,ulold holl~ p'ouress,vd), III II", &#34;,v,,&#39;~r: oldl)I 10 that lflvell II, 1"1) 327 5 LIft 11'1) II,let Ill;H"lold frum tlH! o:yhlHit;, hr:;lds ;",(1 II''''<JV'' II", cornlJlIlcd \Iilskct li To 'errl lhe Il\lell1"""lold, I&#34;~I t:I(~all Ih" 1I1;1I11'!1 I,u,;,'s 7 Appl y seil lll'!1 co"'po,,,,d whe ,,, Ihe lowe, I:O''''"'S 01 IIw cyllllde' IH',lIb IIII-,ul Ihe ,;yhnd<], 1>10(:k 8 LUCil(e il lIew \)Jsk\lI Oil lh" Il(lild~ ;",(( block :J Fll the Ullet '11;UlIlo ld then II'S"II II,e holts olml i<\)ir(ell them 11Iou,ess lvcly ,n Ihe scqllencu shown In F,U 327 alld ,n lire sw\)es
\)IVCll '" the Spec,fr~.lt&#39;ons 10 The '''lllillll'''\) proced",e IS" 'eve,s,,1 01 ,elHoval rlefrlllhc cool",'J s)'stem WIth Icfe'cnce 10 CI"lpte, 2
Fig. 3.27 Inlet III,mifold bolt tightening sequcnce fo r 3.0 litre engines (Sec 19)
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)
Chapte r 3 Fu el an d exhau st systems 79
Ii
0) G
\E )
' .. ~ ee)
Fig. 3.33 Fuel injuctiOIl system circuit di<lUrnrn (Sec 22)
1 /J,1I1C 1V C W"lflll (If! luyu/',lor plMC
2 Sialicr I/Iolor /) Axll/,-"y ,1i, device G Theo1lO/lmc switch
3 fgnitioll switch E FIII;I/Iump H St,lfl valve
A M,lin con(Iol r(;/,)y F S<!fCly swllcil on senso! J Impulse module
8 Power supply rcl.1Y
Tho safety switch is provided to cut olf illl power !O the fuel injection sySl(!m if the air sensor plJIC (mixt\HC COlllrol assemhly) IS il the rest position even if the ignition switch IS all. The s[lfcly switch would ell! off the power to the fuel pump for oillllpic ,I il fllOJllmu W<lS darnol\jC(t 111 ,111 t1cciden t or hurst through deHH,or,11'QIl lhc ~wltch is located close to the mixlluc cont,ol lin'!. On f,lIer models th\! Sille ty switch h<ls been repl<Jccd by <I S<llcly control module. ThiS Illodule supplies power 10 Ihe luel pump prOVided Ill.ll It IS "xe,vlIl\j pulses Irom Ihe 'V'1I1Ion co,I, Ihese pulses helnl) evidellce thm the env,ne is 1I'''ning. When the engine stops lor wh<ltever reason. the salely control ule cuts 011 power to the fuel pump.
23 Aoutino maintenance
AI the IntelV<lls specihed ill the Routine Milmtenill1ce 5 eC1l0n ,n the Ironi 01 the m<lnual cmry oul the lollowing procelillle$.
Check (Jnd adiusl idfing spoed 1 COllnecl11 11Ichomeler to Iho engine then rlJll the enVine to 110rmal Oper<llll1g lemperilture. 2 Incre<Jse the engine speed to 3000 rpm lor 30 seconds then allow
., '
,. ,
< &#39;(:,,~ , • . . ;::~t,·· . , ,
.' ) . ;~ ~~;:;: ~iJ&#34; .. ,
n fr.X l
the engllle 10 'die.
3 Check Ihill I he idle speed is lIS given in the Specificmions ilnd il nccnssary "dlust the idle speed screw 10cllted heneillh Ihe Ihrottle housinv {photo).
Check conditiorl o f fuel hoses " Reier to SeClion 2.
Tighte/l the inlel manifold boilS and /luis 5 Refur 10 Section 29 and lighten the inlel rll<lnlfold bolts illld nuts in tile sequence viven.
Reflew Ihe fuel filter 6 Refel to Sec tion 25.
Renew the air filter element 7 Disconnect the h<J\leIY. 8 Release the spring clips on the air cle"ner {phow) 9 Lill Ihe <lir cle"ncr cover. logether W ith the fuol distributor
assembly, ,1rld hit out the air filler element {photo). 10 Cle<lnthe inside o f the ai, cleilner body and covel 11 F,t il new clement then refitlhe cover. 12 Reconnect the bllllery,
23.3 Idle speed ildjustrnellt sc rew (arrowed) 238 Releasing the .. II cleane l spring Clip 23.9 Removing t he air filter element
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I',
I t, ' .
;
!
" , ' .• I
! 1 I'
: 1'1 1 . ,
I
I '
I
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,
~ Chilpter 3 Fuel and exhaust systems
~5 4513 ,111<1 "'f hose s 2550A D",conneclinu the maUl "" supply t.unkul!! 1.011 the 1111~hue cont.ol 111111 25501l mid th'OI1I C houslIlU
"",'
25 53A UnsCII)w the holts. 255311 ,,,"U)IIC the ~&#39;&#34; chal11bcr ~5 53C ;11111 'cmoY(: the Haskct
,
25 5 4A UlIsc'ew the 11101l1lt;IIU bolts. 2554 U ,lIld remove the UIIL'CtOrs 2556 The "'Jecto, Q·rinU seal (a"owed)
56 Rcl,llll.g IS 11 reve rsal 01 rcmoval. hut mtlke SUiO Iha l til.., "l)OC Iors .IIC clea n and III new O'lIng seals (pholo). Also rencw the;IU chamber gtlskel.
26 I( H o mixture -adjustment
Noto: 11!e miJllllfe s"/liIl9 is preset during (!for/actiOIl of II", eM ,'nd shOll1ll 1101 &#34;ofllwll~ require "djIISlment. If I!~&#39;W r:QfIIl&#39;O&#34;Cllf.~ l)f 'he sys({)m ""VI! bccn flllCd. IlOwever. tile mix/IIII! (;,1/1 be mi,l/steil as lollows "Silly /II) cxlwlls/ y,l$ <lIw/yscr ,lIJd I,le/Wlllelcr Ad",.IIIIWII/ is 1101 possllJ/c wi/lioll/ "'1 c}(h,1I/s/ gas {J1J,1/ys<'r RUII the enuine unlll il is ill Iho nOllnal Op"';fllng ItImpcr.l111'1I Connect an (&#39;~haUSI gas analyser and a tachollle!C' (.f not l'III,d as
Slandard equlplllcnt) III iI(;COnlDncc with tIn: nH!llul;I(;WH"'s 111-SIIUCllons
3 Incroase the enyulC speed 10 3000 'pm and hold it the,e 10' 30 seconds to Sl<lblh se thc c~hausl U,1ses and then allow the engine to return 10 Idl'flU. <1 Check the readHlIJS Oil Ihe test 1I1st.uments with those speci fied. If ;ulJustment is ,equuoo '''5t turn the 1(lIc speed screw to give the COffec t
Idle speed .
5 Break oft the lalllpl:q)lOol cap 110111 the mj~ture conlrol screw on lap 01 Ihe fuel uistllbulOi. 6 S tabilise the cxhausl Ua ses as dcscllhc·d ,n paragraph 3. 7 In sert 11 3 r1\I AUcn key onto Ihe heau 01 the mixture SCfew and tum the SCfew urlld the COlfeCI CO re<ldlllU IS oblailwd (phoIO). R eadjust thc Idle sI)('cd SCfew 8 II th(' ml~lurc adJuslmcnl cannot be Imalrscd wilhm 30 seconds from th(' moment 01 slahllrS Iny the exhaust uases. repeat the oper1!l.ons dcsclIlJ~d '" pa.lIU'3ph :I 1",;Iwe COnllnUlllU 1100 ad)U SlI1l0n l jlrocedv.e
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Q
Chapte r 4 Ignition system
®
0 -
-@ @
Fig. 4 .1 Diagwll1 of the hre(lkerlcs5 ignition syslem on the 2 .a litre engine (Sec 1 )
A higgcf ",,(I stiltor ,1(111$ 8 Am/Jlt/icf modufe C Iylll/ion SWJ/i:lr o BMI£'fY E 'm:lmJIIl"/l:f F COIl G D is/nUll/a , c.-,/! H Ho/or .11111 J 5p,1fK, IJ/ug K 'fi''l)CI co,1
Gcneral de:;criptio n
To ;l(; h.cvc OP\I"'U'" pCl lo.mancc hom an CIl(lUlC ;\Old In mCCI ~1&#34;&#34;\JCUt e.h,1u~t C""5s"m r .. '<tu"cments. 1 rS css"m.althat the I"el/a" rtllxh"C 101 thc ,;on,hUS\IOli .; h;,,,,I,, ). I~ 1\J,ule'll ill ".:II :ttV the "\Jhl I,,'U, wlill'YC to enlJ"lc ~pCe&#39;l ;.nd 10ild The 1\l'lIt,on svsto'" .,.ovilies the
- '),uk nece ss1Hv to start thc: Illlxlu<c I>1I1I""!1 ;md the In~t;&#34;l\ ill wh'ch ,union occurs IS Y;lrI"d auwnJ.1tlC;lllv as ""\line Opet(lt'U g cOl1llot'I)I1 $ d';1r1ge The ''In,tlon systc)t1I COIIS '5 15 01 a PWll;IIV (low tc n slon) CUClnt ill"t J ondarv (1I1g11 tens,on) Cirelnl. Wlwl I he '\lnI\IOIl IS SWltchlid on. CUlrellt IS fe d 10 Ihe coil p r;111;uv wirl(hllUS nnd i1 IIHl\l11Ctic f,p.ld IS cst~lbhshC(1 At Ihe r equired 1)0"11 o r 101l1\10n. the pri"':Irv CItCl/lt IS Ifl tcrruptClluV the conlnct hfenker POUlIS OllCflmg (3 .0 hire e"gI01(I) or the \l'g\le. tJrfllpasslt'g the s tator ;11111 (2 8lrt,e enUn .e) The milunCIiC
f 'eld collilpscs :Ind il 5tlCOndntV hi~h YOIIIl~~ In 'nduced i n the se~ond,1rv win(lin\!s. This HT volt:lUc IS te d via th e d'SH ,IJUtor rOIOI :Iun
1 0 the lelevllllt spnrk plu~. Alter dcllvenng the spar k the pmnnrv cirC Uli
I S re-energised lind the cvcle .s rep-Cillcd. The igni tion t iminu '5 Controlled centro lugllllV JnO UV II vacuum IHl II t o compensme lor englflC speed ,1no 10lld On Ihe 3.0 litre enginc the i~l1;lion s y Stelll II1corporales a b,1ita $1
resistor wire which effcctively UOOSIS th e HT volw~e durlllg SHul,ng.
2 Routine m aintenance
At Ihe in tervals speCIfied in tl w Rouline Ma;ntenance section in the fran I of the nl;Jnua l cJrrV out the foll owmg proc edures .
Clean and adjust Ihe spark plugs. or renew Ihem 1 Refer to Sec tion 11.
Clean ofld chec k fhe distribulor cop. rolor. NT leads illlr/
t. Re lease the twO chI'S securmg Ihe (h Slllbu101 cap 10 Ihe d'5111l1utor uodV and I, ft away t he ca l) . ereJn Ihl;l C:lP inside and oul wilh a dtv
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Fig. 4 .2 (J"II(ls t resistor wire locilted on tho left·h'Hld side of the ongino compartment -urrowed (Sec 1)
clO lh . Closely inspec t the ",side of thc cap and the si. segments. It there are any siUns of Cr<1Ckulg 01 ,f the segmentS are bumcd o. scorl;ld e~cessivelv the Cal) will h ave to be renewed.
3 Also Check Ihe cenlrc segment (3.0 htr a en\]ine) or carbon brush (2.8 IIlre engine) f or wailr. 4 Remove the rOIOI arm i1nd check 1110 ' cra ck ing and burning of the melal scgmem (pholo). On the 2.8 h ire en gin e check tM Sp<ing· tensioned cngine spee d limiter incorp-ori1led in the lOlor illlll for tr ee movement (phoIO) . On trw 3.0 litte cngme c h ec k Ihat the HT conductor spting on the rotor arm has sulficienllension to contactlhe centle segment in Ihe C(lp.
S W'th Ihe . o to r aIR. removed. lub.icate the felt pad in the Centr e of the distfluutor sh ah wilh twO drops o f enyine oil. 6 Rel;lthe rOtor arm and dt$Uluutor cap (photo).
d
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) Chapter 4 Ignition system 89
2,4A ncmovllI\J the ' 010' rum (28 hire enuino) 2413 The engine speed tllnnel 011 tho ,oto. :lIm (2_8 litre ename) 26 Secul;nn lhe dl surUlllor cap wilh Ihe sp.;ng clops (2.8 "lie engme) A Swing C fail/lillY COIlf.lCt n MQving CQII/act
27 ChcckUl!J Ihe HT tcad le.min;!ls on the (hSlllhutOf 1:.111 2 .8 11I"iliol1 COlt and WlIlIl!! 4 .2 Remov,ng I he COlllaCI h.eilke. low lenS 'OIl le,lds
7 W"H) o;iean the HT Itlad,; llm! check Ihc'" 10' (;onll'[IOI1 Pull the 1(';'Ids homlh!) dl~l&#34;h&#34;10f Cilll one;H <IlOilO ;)IId 'Hake SUIC th"III O wmcr IlilS 10llnd 115 w.1y 11110 the so~k CI tI.!II'Hrl"ls . Clo1l1l <lny I:I>IIOSiOIl "W,IY . Ien .eln the IC!1ds (I)hoto). 8 Glc,," Ihu '!jll'l,on cOIl lowe. ;md check the HT le,,(1 ;IS p.eYiously . ,scJllled (photo)
Check .1nd Mljus( (h£! cont<1c t brc<1ker dwell "flyle (3.0 fi/re
engillt!) !l Ruler to S<lClion 3
Check arid adjllst Ihe ignilion timing 10 Rcler to SectIon 9 .
Reflew /lit.' conl,1CI breaker points 11 Reier to Secuon 4 .
3 CO I1\aet ureaker points (3.0 litr e er>gine) -adjustment
1 Remove thO dis touutor cap and ro tor afln (Sect ion 2) 2 Gentlv I)rrse Ihe contact ureaker points open and e~an\ine the conditIon of Iherr faces. II they are .ough. pined o. dlfty II WIll ue IlCCeSSi\'y 101 new paIn IS to be fined. 3 If Ihe pOInts ale sallSfaclory. Or have been ,enewed. measu.e the gap Uel ..... een the points with feele . gauges. by turning Ihe Clankshaft unlll I',e heel 01 Ihe ureake. arm is on a high poinl of Ihe C<lI11 . Consult the Specd,cnl;ons al Ihe uon;nning 01 th is Chapter 101 ttm correc t sOll;ng
I If Ihe gal) IS IIlcorrCCl, slacken Ihe contact plale SOCuflllg screw(s). , le n "lserl a soewd"ve. ;nlO the sial p.ovided al Ihe edge of Ihe COntaCI ptalH and move the plate unlli lhe gap is corrcc\.
5 Tlghlen Ihe sClew(s) and .echeck Ih e gap.
6 Rein the .010. ;"1IU1 ensurIng th,lt II IS cOflectly located In the sial at
I he lOp 01 the carn Relltlho d'SI"lJuIO' CilP and .elain III IIOS;llon wnh Ihe Iwo clIps . 7 On 1110de.n el1gll'os a mo.e ,1CCu'ale mel hod 01 seHIIlg Ihe I>o;nts Hal) .s by means o f a dwell me lel . NOI only docs 111110 l11elhod give a
IHL'Cisc 1)0 .. 115 gap I)UIII also evens oul ally v,llta llons 111 Un,) cnused by wear "' I he dlst"'lUtor sh ah 01 uushes 0' dlHCf()nce s HI any 01 the heIgh ts 01 Ihe Cil'" peilks 8 The dwell allU1c IS Ihe numt)C. 01 deglee s th, ounh winch Ihe
dIstributor cam lUI liS dUring the IlCrlod betweell Ihe ",S\ilIlIS 01 closu<e and oJlcnmu of Ihe conI act b.e,lker ponlls It Cilll only be r.hech~d wllh
a dwell mele' connecled III aCcor d,lnce wllh lh. } maker's II'Slfl.r.;I'OIlS 9 II Iho angle IS nOI as gIven 111 the Spe<:.hcatl ons. ildluS t the po",ts u~p If the dwell annie's 100 ,,,'ge ,ncrease Ihc IJO'''15 9,111. II th e dwell [lI1gle ;s too small . 'educe Ihe points Uap
4 Conlilct hre[l ke r points (J.O litre engine) -removal and refitting
Remove the d'SlflbutOi C"P and 'OlOr arm (Secl;on 2) . 2 Slacken th e self·tappiu\J sc.ew which secllres the condense. illld low lension lead s 10 the conl,lel ureake. ilssembly ilnd slide oul lhe fo.ked cable telfllll,al;OnS (phOIO). 3 Undo and .emovc Ihe Iwo screws whIch secu.e the contact b.eake' uase pll'Ie 10 thO d'SlflbulOr ilfld hit off the cUlltact b.eaker assembly
(phOIO) .
4 Befo.e IClilling the conlact b.eake. assemhly. smear Iho dlstrluu to . cam wllh a trace 01 g.ease 5 FIt I he conlaC I 1)I(,ake' and its cl,Jlnping sr.;.ew~. but do nOI fully I;ghten the sc.ews \lnlll Iho contilC I b.eake. !I,111 h;IS u een adlusled as descflbed In Sec tion 3
6 R ell l th e rotor "fin and d.stflhuw. cal ). &#34;&#34;&#39;1I&#34;&#39;~1 tI,e IWO clops 10 secure lhe cap.
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procarmanuals.com

90 ) Chapter 4 Ignition sys tem
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<1 3 Contact hlcnkc. mOUIlJrrlO ~CH)WS (,lrrowcd) 63 Dlsconncclinu the V<lClJlHll .1dvllllcC p'pe G.4 OlsconneClill\) Ihe eallh lend
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65 Pull tile wires 10 rhSCOlll1CCl the mull"I)I.,\) COlll1eClor 6.6 flOIO. arm al;\jncd with the slOI on t he d,strlhutor hrnly rim (allowed) 6 .7 C'ilnkshall polley nOlch and Imling covel gr,1(lahOn (28 hIre cn!l'ne)
5 Condenser (3.0 l itrf~ rnllJillo) -testing. removal (lnd rcf ittinu
The PU'I'OSI) 01 tilt) ccmd"",.er (sorllclull(!S know .15 .1 capacItor) IS ensure lh.1I wli,m II", ',()IIi."; ( I!UJakcr POUllS open thew IS no ~po1&#39;~&#34;&#34;1 a~Hl&#34;S ilWlll whIch would C,llIlie ,ap,d weill 011hcu r .. ees ilnd
'!I'Il' ",slue 2 The CUIHIUIlSt" .s hUed !II I>luallel wnh the conlJCI h,e;)kc. points. II '1 becomes r""lly, ,1 w,lI C;II,,'" 'IJ'''IIOI' fa,lure ,15 the conlilCl hreaker 1'011115 1'0',11 he pH)VI!fIl,:ti hom cOllcclly 1Il1elfurlcmu che low ccnsion qrCIIIL 3 II Ihe en!)'lIe becomes very dlHlcul1 co SWrl 01 begins to I11ISS afrer
severill null'S of I lInl1l11\l . and che I)lcilker poinls show signs 01 e l\ceSSlve blllllllll/. Chen chI) condlu o n of Ihe condenser muSI be suspecI One f".ther !C:.t can II" milde hy sepa,ahl1U che points by hilnd wilh the ,umtlon 5WIICtl(:(1 on IItl"5 IS ilCCOoul),,"Il1led by a mighl trash. II IS ,ndu;:allve Ih .... 1 the comlcuscr has I0111cd <I Wiltrout special teSI C<IUlI)lIlc"t the only safe Wily to dl .... Unose condenser 1I0ulJle.s 10 • ..,pll .C" .... suspect 111111 wuh a new one .... nd noCe II Ihe,e is ,my II"p,ovem..,,\I 5 To remove the conden:.cr from Ihe dlSlllbulor take off the (1ISllll)ulo, Cl(1) 1IIld 1010r ;um 6 Slilcken Ihe sel f 'larmll1!) S(:ICw holding Ille condense, IC,ld and low !ension ICild 10 Ihe COIIWo.llul!l,kel I)OU1IS. Shde oullhe forked lerminal on Ihe en(1 of Ihe COf1(lense . lel1d Undo and remove the condense, .el11l1linU screw ;md remove II,e condenser f.om Ihe breaker plille. 7 To rehtlhe condense" s1Illply ,everse the orde, of removaL
6 D istributor (illi en\)ines) -rcmoval and relittin\)
1 k ,1pphcablo II.HlH>VU the 1111 ele,me" ilS descllbed in Chapler 3
2 Remove Ihl! dl ~l&#34;bulo&#39; C;Ij> only (SeClion 2) 3 D,sconlle\:t Ill.., V<oCU\1I1I .. lIvi'lllce pipe (pholO).
4 Whelu l1ppllcnblu dl:;col1l1ecl Ihe eilrlll 1t.!.1(1 hOIll Ihe lerl11ll1nl 011 the d1SI"h11101 budy (pholo) 5 D'scol1l1eCllh(l (h$lrrlJulO, lllulll·plul) COUllcctO'. To dlsconneCllhe plu!!. the w .. ('s IllUSI ho hold and pulled, nOI Ihe plu\) Ilself (pholo). G 'Turn Ihe un\)ine unlrllhe rotor n.m IS poinlrno 10 Ihe No 1 cyhnder SCIJlllun l In the d'SI"hUlor cap. On lalCr models Ihls IS 111so IndiCilied by [I slol on Ihe (I,sl"I)(O(o' hody rml (phOIO) 1 Check also Ihilllho nOlc h m Ihe Cr;lI1kshah polley is III hoe wllh Ihe com,c( '''[llk on Ihe tilllin\) cover (photo) On (llu 30 ht.e eng me Ihe Illinks arc III 2" Inte.v.l ls. hUI on Ihe 28 Ilire enU"le Ihey are on 3' tIllelVals Sec Ihe Speclhcallons fo. the correCI SClllng. Milrk Ihe IIOS'llon of Ihe d'SI"uutor body .n ,el[llion 10 Ihe cyhnder head 8 Bemove Ihe Single holl ill Ihe baso of Ihe d'StrIUUIOI ilnd slowly hI! out Ihe d'SlllhulOf wlthoul IUlilillg its body As lhe dislllbulO' ,s removo.'{llhe skew geM will turn the rOIO, arm clockWIse. Ml1,k Ihe new IlOSlllon of Ihe rOlO' aim on the , .. n Illhe.e IS nOI illreildy a mink Ihe.e (pholos) 9 To reilithe dlstlluutor ensu,e thaI the liming milrks ilre Slill ahgned ilS deta,led rrllJarag'ilph 7 of Ihls Sec lion. Hold the diSlrib Ulor ove' the cylrndc. hel1d so Ihal the hody 10 Ihe cyllnde. head milrks are in alrgnmenl 10 POSlllon the 'Olor arm towiI,ds Ihe mluk on Ihe d,S trrbulol body ilnd slide Ihe assembly inlO l)Osition on tha engine As Ihe geJrs mesh. the ro lor WllllUtI1 ilnd align wllh No 1 segmenl in Iha dlSlrrbulor cap.
1 1 Relit the securing bolt 10 the bnse of Iha dlSlrrbulor bUI do nOt fully Ilghlen ;IllhlS Slage. 12 Check 11I11t on Ihe 3.0 hlr a engme the dlstrlbulo, VJcuum unil is lilcing fo,wilrds. parilliellO the centrO line of Ihe el1\)ine. or on Ihe 2.8 lil,e engine Ihe VilCUIIIll unil is lacing in Ihe duection shown in F ig. 4 .4 . 13 Reconnect Ihe IllUlli·plu\) conneClor. The manlJf~Clurers recom· mend Illill Ihe Illulli·plu!) is 'illed wilh il lilhium hased grease. 14 fleconneCllllu earlh lead (it applicable) and t he vJCUUm advance pipe. 15 Reier 10 Section 9 and se l Ihe 'gnition IlmlllO. 16 Refll Ihe all cleane. (if applicable).
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Monsurin g plug gnp . gaugo ;;:;;;-;;;"",,',,"," ignition sysICm spccilicalions) should have a sliUht 'drag' when slid between the olocuuch~s. Adjust {[liP if necessary
N orm al. r, dcpo~il~.liUlolly coaled corc nose. increasing by around 0.00 1 in (0.025 mm) pc, 1000 miles (1600 km). Plugs ideally suited to en\j ine. "nd engine in good
condition
Oil fouting. Wet. oily dr~pOl;its. cal,se eventually misfirc. Fllult : wmn bores/ilision 'ingSOf valve guidcs: sometimes OCC"'!! (temj.lO'Hrilyl d .. ring lunning-in
poriOd. Plug~ C()I1 IJ() H! u~ecl "ftc. thorouUh cleaning
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in Electrode demoge. ;;;;,:;;;;;;;:;;;~;~;&#39;;::;;i ;;,,, ",,;; h;,
bumed, glazed appearance. Fa ult: pre')gnohon Check: as 101 'Overheating' bllt may be more sovero. Discard plugs ar1d rornedy fault belorc piston or v31vc d~&#34;,age occurs
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.. ", . ~,&#39;&#39;&#39;&#39;:c.&#34; ~~:~~~~~~::i, Adjusting plug gap. Tlu, plug gap is, 03rth electrode inwards, or oulwards, as I correct clearance is uillaim!d. NOlO II,,! use 01 tho COlfcct tool
spark ami I I' Chock: cMhulOllor , • sellings, 1I0al level ,lIld iot siles; c hoke (lJlOla lion .mel cltlanli n()ss 01 ai, fillel. Plugs can bo rc­usod <Ifter cle<lning
:"1 Overhoating EI()cuud'ls h,lVO \Jlilwd ~ppcaf3nce, CO'O noso vely while lew dello~iIS. f;I!I't Ilh,O uvelheatinu. Chec k: plug
vlJlue, iunitiun limill H. I"clu t;lillle I1Itillu (tOO lowl <Ind luel
mixture lWQ w('ak). DisC<lrd ,,(\I!lS and cure la ult immedi~toly
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i Split cor o noso (mny npllollI i 8 crBck). Damage is
sel f.evide nt, bUI cruc ks will only showalter cloaning. Faul t: pre­ignition 01 wrOIl!) !)ap settin!) technique. Check : ignition liming,
cooling SYStCIl1. 1",,1 O C t;"" .. r alin!) (too low) and fuel mixlure lton woak) . Discilld "Iu!)s. ",Clllv laul t immediately
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Chapte r 4 Ig nitio n sys te m
6,SA Unsc rew the clamp bolt, 680 ... and remove the (tistJlbu to. 68C Rotor nnn alignmen t ;]lter re movnl Irorn engine
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F ig . 4.3 IU "i\iol1 timinu ma,ks o n the 3,0 lit.e e:1Uine (Sec 6)
Allow ;//(lic<1leS din'cliu" 0' !(JIM;oll
7 Distributor (3.0 litre engine) -overhaul
W,th the diMJlhuto. removed from the entl,ne. 'emove the rotor arm and the cont.1CI breaker assembly . 2 Prose Ihe small Clfclll} I'om the v"cuum u,,,t p,vo l IXJSt. 3 flemove th e two sc,ews wh,ch sucure the hfllaker pl,lI!! to Ihe d,slJlbu tor body and hit the ,}I'rte orl.
" Slacken Ihe self'lappmg SCfew which SC<:UlCS the condense, and low tenSion leads 10 Ihe contact l .. eaker a ssembly and shde OUI Ihe lo.ked ca ble terminations, 5 Undo imd remove Ihe condenser rCI.1,nlfl!.l screw and remove the condense •. 6 Remove the c" chp. lIiJt washer and wavy wash er from the pivot post. Se parat e the two plates by h,ingmu the holding down se,ew Ihrough Ihe keyhole sial in Ihe lowe. 1)late , Ta ke care not 10 lose the e.Jrt h spring on the prvo t flOst. 7 Remove the two se,ews seeu"n\) Ihe vilCuum un,t to the d IS t"lHIIO' hotly .Jntl remove the vacuum uni t. S To d,snl.JllIle Ihe vacuum unll, remove the plug I.om the end 01 the
unit (md withdraw the spring. vacuum stOp and shims 9 Oelo,e disll1<1ntling th e centJllugal .Jtlvance mech.Jnism. note thM th e tw O spri ngs arc d.lle.ent and ma,k them so th.Jtlh ey .Jre ref'tled in th ei r OJlgHlall}lilces . Remove the sp. ings. pJlse all the circ lil)S securong the cenlJlluga i weights. nl.J.k the weight s 10 'dent'fy their o"ginal positions and then remove them ,
1 0 M3<k which 0 1 th e end slo ts on th e n'cchan,c.J1 .Jdvanctl pl;]le
lages w llh the s tol) m Ihl! ;]C hOn I)I"le II II" s IS not dono. II rs ~ s, llle to h.Jve th e ,oto, ,'Jln 180' from 'I S COf/,-ct pOSition. 11 Remove the lelt pad 1 10m t h e centre 01 the C.JIll. e~pand the circhp
x - ------:::-.
z
y -
Fig . 4.4 Distrihutor lilting position on the 2.8litrc e ngine (Sec 6)
XX Re.1r "U;,.' of ellgmc yy V,1CI/(JIII flllil Mas Z = 0 '10 11/'
A Triggcr (lffll U Slillor l!fII!
whICh'S Ihen exposed Ilntl ,emove ,I L,lt all Ihe Ci"n and 1l(IV3ncc plJle ;Issemul y,
12 Do nOI .cmove t he d,stJluutor Sl)indle unless II 's necess.l'y to "1 a new ge.n. 0' S I)iJldle To remove Ihe uear . usc <1 IlUnch Ilnt! hJmmer t o dJlve outlhc lock P'" and Ihon pull tl)() !.Ic", frO'11 Ihe sprndle T"ke cn,e
1 0 rOIil'" ilny slums, 0' wllshe,s wh,ch fll.Jy be In led . W,t h the ueJ' lell'Ov\:(\. the sl)lIldle .Jsscmbly can be withd,awn hom the d ,s'Jlhu tor 13 Belore reassembhng. ca,elully clc.J1l the body 01 th e d,s lnbulOr and "II a s CO'llpo llent p"'ts. II th e sp,n(!ie has been .emoved. lulmenlC II w'lh e'lu",e oil h efor e ,ellssemhly. 14 Reassenlbly.s <1 SUa'ghtIOrw<1Jd ,eve'SilI 01 d,sman tling bUI t he,e Inc several pointS which shoold be noted.
15 Lut)JJc;]te th e ce Jltlil ugnl weights and otho. p3rtS ol the cenlrifugal
advnnce mechanism. the diSlrrbutor shah a nd Ihe pa'l 01 the spindle wh,eh c.l"'es Ihe cam assembly. using engine all. Do not orl excess,vely. 16 " Ih e dr'veshnlt hilS heen .emoved. firSt re fi t th e thru st wash ers below tho action plnte. bolore "'se,ting the S h .l h into thc disl. ih llto,
hody . FII the w3vy washer .Jnd IhrUSI washcr to the lowe! end 01 the shah and then relilthe ge.Jr. secuJlnU it with a new spring p in. II a now gear. or a ne w u"ves hnfL h,15 been fllt ed . a n\lW hole should be d"lIed .1t 90' 1 0 Ihe e~is&#39;U1g hole 17 Alte • .Jssemhhng the centJll ug.J 1 weIgh ts .Jnd sprrngs. check that Ihl!Y movo hccly. w,thout I)inding, 18 8clOle assemblmg Ihe breaker pla tcs . make sure thill the three nylon bearing slUds a.e located "1 tht) h oles ,n the uPllC' uearinU plale and Ih3tthe e.Jrth,ng sprrng ,s foiled to the p,vOt post 19 On complet'on of assemlJly. adlust the conlnCl b'eake , gilp to the spc cified selling
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