check oil FORD CAPRI 1974 Owner's Manual
Page 53 of 205
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52 Chapter 1 Engin e
68 Connecting rods and gudgeon pins -Il~nmination a nd renovation
Refer 10 Sccuo n 18.
69 Cr,lIlkshnft -e~(lrl1in<ltion and renOV;ltion
E~amUle the four 'lIil;" l>e .. "n9 Journals and the s,~ Cfanlq>nls. whIch should illl be smooth Iln(1 IHlJhly polIshed II there arc any dllCP Ulooves. 01 deep scratches ;mo lhe.e ,s a sirn,l,lr <loI0"ola 1,on in the corrc5pon(fulH Iwaring sh(:ils. 1ho crallksh<l h should he reU'Ound. 2 II the JOUr1l<lts <I,e ,n noml conditIOn and 11 IS slIspec!(1d lhnl th e cI,Hlkshnh mily he suH,eocmly worn 10 fL'(IUIiO ,cYllndrng. II IS wa. 1h SCClo.II;t! the advice of ,) "'11111 Ford ,1\jCIlt. 0' cWllkshaf1 regllndlng servIce. 3 If ,he C1ank sh"f( IS '!](IIouml. till) wOlks w,1I ,1lso sUIW1y rhe new hC,lIIl1US wt\lt.;h WIll he rCII"'''!!! 10 Jl\atch Ihe lournal d,nmOlf"S.
" Check the spiuol bu,1"n!) III Ihe .ea. 0 1 the Cfankshall on manual l.ans.mSSlon m()(lels :mllil necess;uy .enew II
70 Mail' and biu·end heafinUs -olwillinmion and H)!1ovation
Ilelo,r to Seo.:lIOIl 20
71 TilninU oellrs -e~i1miniltion find renOVlltio n
Re f
el to Sec t,on 21.
72 Flywhee l/ d riveplale -Okamitliltiotl lind ronovtttion
Inspf:CI lhu ffywhf)l)I 0 ' ([ttvl'pl,,": fOI (!;U";'\lC ilnd 1:I".1I:k Ih;'1 Ihe ""!I H".u docs uol have .IIlY \)Iok"n o. l);Idly wOtn teeth. :1 On ''''''''';11 I'''"''''US~IO'' mnd"b ,I IS pOSSII.Il) 10 'CHew the I"'!l \]C,II .'S Ilesl:<Ihe(] ttl SeCtlim 22. IHlt on olllt()I\IHIIC IlilllSn"SSlon ,,, o(lels It IS nOl tlOss,bl" 10 le",OVf) 110" ""!I 11"01. hom Ihe dllVel)lttlc
73 Valves (",d v"lvo sO,,1S -tJkiu"illHtion lind renovation
[xallutle Ihl} v,tlves 101 IlIls "lid !l,ooves lind the valve SIems to. e~c,'SslV') we,l' III d'~loIIIOII' 2 Ek,""l1ltJ Ihe v,oIVil hf)"d 10' SI!.!"S 01 hu",u,U of the vOllvo seillS lind ch .. !ck Ihe ht 01 Ihl) villves III Iho v,llve UUldes . 10 SCl) II Ihe villve uu,des il,e WO!ll
3 We"" valve U",dcs c;'" be r l),lIned O\It lind vlIlves w'th overs.~e Siems lilted II iI v<llve !lulClt: h<ls h(."Cn ,eamed oUI. Ih(l eOllespon(fing vlllv(l sent must he rdOlCe(1
" Villves illld v~Ivo se .. ts whlc" show JollIe s,on 01 wear. call he lilpped in.
S To 1,1P the valves. In tt s u ction Iype gnmlonu 1001 to Ihe villvc hettd. smeil' a lu tle COil.se c;ubo.unllulll urmdmu pOIste on to I he sealing I~c e 01 Ihe vnlve ond inserllhe valve 11110 the cyJonder he"d. Rub Ihe stern of the v al ve gundlng 1001 hetween the palms 0 1 the hands. so Ihal Ihe valve,s ,otllle(l hHckwards 1I11d lo.wa.ds When II IS lelt lhOlI culling has
ceased. loft Ihe villvc. rotate It th.ough 90·, lowe. 1 and fepCill the u"n(llnu o.:.e.atlon . • e dlslllbulill9 the g"nd,ng pas!O on Ihe seal if necessilry. Conlinue Ihe process unlll a mllll gwy bOlnd IS pfoduced OIloun d the complete pe"phclY of hoth the vlllvc and t he valve seil l G RepoiJl Ihe opcrilllO" US" 'U fine o""d,nU I).Jsle. 10 ohtil'" <I I,ne.
IInlsh. then clean lJoth Ihe valvcs and Ille v alve seals 10 ,emove IIU \llIces 01 u"ndlno pash:! 7 II 'I IS convenl,,1lI 10 liIke Ihe eyhndc. he<ld and the valves 10 a wo.kshojl wllh the necosstt.y cquipment. II is In. h ellef to have illi Ihe va lves <lod Ih,,,, seJts ",f"ced. so IhOlI alilhe villves and sellts OIle lit the co""Ct ''''Ule and h ;lve Ihe COllect w,dlh o f conlllC1.
74 Dccarbonising -go notal
When Ihe cyllnde. heilds (li e removed. eilhe. in Ihe Course ovelhJul Of for inspection 01 bows 0. villve condllion when the e IS in Ihe CM . il IS nO'''1<I1 to remove 1111 CMhon deposits from the I Cfowns and heild
2 Th is is hesl done wilh 0 cup shilped wire hruSh ilnd iln elect." and is laorly slriliuhlforw,!,d when Ihe engine IS d'S<llilnlled an,
p,slOns removed Somel,,"es h.l. d SPOIS 01 ca.bon iI.e nOI , .emoved exc e)) t by iI SCf,'pCI . When cleanln!) Ihe p'Slons wllh a SCI IiIke care nOllO dam.lge Ihe sudace 01 the ,)iSlolI.,n (lilY WlJy . 3 When Ihe en!l",e IS in Ihe car. ceria", prCCau tlons mUSt be t whe", dcca.OOrllSIno the pistons' c.owns in o.del 10 p.evenl dislo, pieces 01 carbon 1.111;110 into Ihe inlerior 0 1 the ellgme which c cause dillllilgC to Cylindcr hores. pis Ion .10d lings 01. 01 allowed the Woller jl.1sSolues. llilrllilOC 10 'he Willer pun.,). Turn the engine so Ihe p'S lOn lleinU Wal ked on IS Mlhe top 01 lIS slIoke and then mas l Ihe a(llttcen l cy'",der bores ilnd ilil sU!roundl",g wttt(" l"cket alii wllh papel and .1!!hes,ve 1ape Press !lwasf) ,nto Ihe gil(l illI .ound pislon 10 keep Cilrbon pa,lIcles alit ,,"d Ih(ln SClilpe 1111 c,lfllon awa hand Do not usc iI power thin and wile hntsh when Ihc enguI(lls II, ettr as II WIt! virlUillly be 1Il1posslhie 10 kcop alf the cal ball dUSI clc, the engine. When compleled. c.1wlully c'ear OUI the OH,,,se moun(I ",II 01 Ihe (liS lon With ,1 mlllc h SlIck or somelhl"U Sllm 'iI • . bringing ciI.bon palhcles wllh It. R c,lellt the p(()r,e~s onlho o the. p,slon C'OIol II IS nOllecormllended Ih.lll1 "'ljJ 01 "uhon IS leit .ound Ihe edge 01 p,slon on I h(l Iheory Ih"t ,I Will ,11(1 all consumplion. ThiS WilS valli
Ihe eiliite. dilys 01 10nU stroke low .eVYlnO en!)lIles tJUllllodern enUil fuels ilnd Itrb"canlS C,1use less cOIIOOn deposils OInyway and any. b ehind lend merely 10 cause h O I .SpO IS.
75 Oil PU"',) -disnwntlino. eknmin"liOil ,,"d reOlssembly
The Oil pump mm"Itt;"S a I)ressure 0 1 ilbout 2 8 kgl/cm' (3 Ihf/in') lInd unless Ihere is ,1 sIo",IIcanl (hop In 001 P'(lSsuro willel ,)loved to he due 10 the Pllln,). rillhn. Ih;", 10 wo", heil'm!)s. 11 IS be .
t o le"ve Ihe 011 pump und'S hilhed. 2 To d'smanlle Ihe pump. fll:.1 ,emove II hOln the en!l'ne ns desc,,1 III SUClion 58 3 Remove Ihe IWO bolts seCulII1!J Ihe en d cover 10 the body 1 'emove the covel ilnd 1he .ehel v;" ve "sscmhly. Ihen Ihe Iwo P"
fOIOI assembly.
" Remove ,he IWO bolts lind ,,,ke Ihe p,ck·up w he lind SCIl' lIssembly oft Ihe pump housin!1 S Wilsh all lhe pilrlS In petlo'. usc iI hlllsh 10 cleol" Ihe Inside 01 1 pump ho usinu ilnd lhe p.cssu,.., .elle' vil've eh'!lnbel. ilnd milke 5' Ihilt ,111 p,tltlClcs 01 dill ilnd mewl n,e ,emoved Allow the pttrlS 10'~ n;IIUf,lllyor blow them d.y G Check Ihe Illslde ollho Puml) houSII'9. Ihe OilIer .;w:e ilnd Ihe 101 101 dilfllilUe and e~cesSIve weill 7 E~ll'''Ule the I111lling su.lace 01 lhe I)Ump cove. 101 we,lr It Ihe CO' IS sco,ed. o rooved. a. shows ilny s'g ns o f wea •. a new covef must I hlled 8 W,lh the ,otor assembly filted in the hOuSing. place a straighl·ed!. over Ihe end 0 1 the housing <lnd measure the .o tor end play. If 111 exceeds 0.1 04 mm (0004 in). Ihe ouler race. Shilfl and ,Olor must t renewed olS an assembly. 9 M eOlsllle the rOlor·IO·houslng clea'ilnce. which should not exce e 0304 mm (0
.012 in) OInd Ihe Inner 10 oute. rOlor gap. which should b 'oss IhOln 0.020 mOl (0008 i n ) II oulside these dimenSions. a ne" pun,,) Should be fitled 10 Check that Ihe leroel vollve and its sea Illig ,Ire Iree of dan'ilge all' thaI the .elief vOl've sp.ing ha s nOt collapsed. 01 is damaged. and 1 new paIlS ,f necessil rv. 11 Reassemble Ihe pump by IUSI lilting the lillie. IJnd outer rOIOr) Ihen lubric.11inU them wllh enUOne OIl. '2 Apply e ngine 011 to Iho rehcl vlllve plunuer <lnd sp""g ilnd Inse l Ihem inlO thei
r hOUSing Relll the Sjll1llU cal) and Ihe pump covel '3 Refit t he cov e. allolchrnenl sc.ews 1111d IlghlenIhelll1 0 the to.qu' wrench sen ing giv<m In ,he Spec,flcalions Altel t1uhtemng the screws
chec k thOlI Ihe 1010r moves freely 14 Refil the PlCk·up lUhe <lnd stralnel as semhly 10 the puntp body usi nU a new gOlskcl OInd then insert and hUhten the IWO IIxHlO screwS
procarmanuals.com
Page 55 of 205
) 54 Chapter 1 Engine
,n the "Oill hand ror;ke. covc. ~nd mlO Ihl) en!IHlC Ih'ouUh .111 .1(1,1pl0' bene,.!!> the (.1,hl"l)ll01 The sys\cm '!nSlI.ct; 11\.11 !lIlhurnl lIilSCS ille .ChunNt to Ihe enU'"e fOI fUllher (:orlllJ\'~I'OIl
78 Engine reassernbly - gcner<l l
Rolli' [0 Se(IIOn 20
79 C,lInsllllll -re';II'I1I)
SI"h, Illc SpM.,<1 "",th li S ChitrllfCI1'" "ml [""I onin Ill" r:;HlI:.hall ;oml ,, the kr,y 2 LlIb",':"I" lh" c"m~h,111 lo",.,als w,lh <:Ill)"") nd ,llld ~I,d" Ihe ' ·.IIlI~hah "' hOln\h" hOIl!. 1.II-IItH C;UI~ 10 ~""P ,1 ~1',IO!lhl. SO ,I', nvt III rl.mlil!1" II", /:.III1,h,,11 I)","'IIO~ 3 rr! th., (.l", ~h"h 11""~1 ,)1",,, wuhou! ;, !1.'~"('1 fIt lI,e two (,(lInl\I:!,,,nk hr',lei rr,!,'"lll'!! serews ;1I,d 11\lhl"" III"",
80 Cranksh .. ft reblti,,!!
~V'lh lilt: "II\IIIH' "p',ul" ,low". I. 'v ";I, h "I II", "1'1"'11"',""'0 h.,I,,",s ''''10 Ih" "1'1""1''''''1: u.",ll .• '~" wI·h. 111,'''''''1 ~,,,,, Ih." Ih" 1<" ""'!II.IIIO 0" II", I""""'!I '~P"'I""IV ""!!,,!!,,,I '" ,II" ':C"":~I"""h"!I ~I{)I '" II,,: 1; • • u'"c;I~" WI'!> Illh., "Id I""""'!I~ .,," I"""!I ",!tW:Il. ItI.lk" .;",1.111,,10:01 e.lch I .. """,!! hill! IS '''Iud • III III.., 1'1.,, ;11 h"ll wh";h,, W.IS ",mo"..,d Fn Iht:: Ih'u~1 w.lsh".s 10 <1;lcl. ~,,11l 01 11", CI:'II • .., I...,a''''!I. Ih" 0''''''''''([ l;lI;"s 01 Ihe wa~I'e.s IJelll!! Oulw;!lds (1"11 1 16) n"I.""II,c II"tI~1 w.l~I""s 11 1)lar.r. w,lh UH}.1SC 2 FII Ihe low ll anO "!1 halv",s 10 the app,op""h: I>";'''''!I ,;nps 1"1 Ihl1 IllIuSI wM,h.."s on ellll(!' S,dCl "r Ihe <""'"11 I>e;"'I1!l ':"1', Wllh Iho 1.," 01 Ihe w" she. Iitied "1i0 Ihe slOI It' IluI be''''''!1 <;;'1' Rel<lll' Ih" rh"'~1 w" she,s '" 1)I"ce ""'Ih !IIIMSo! :I LIII" '<:<111) Ihe c:o.lnk<:<,:.c l,e;IIln!! h.,I""s Will, '"'0''''' ,"I .11,,1 I .• l.o;I"IIV low,,, Ihe ':'''Ill~hilh unlO 111,,111 'I r"k" <:;,d, I>o:.1""!1 e:il!> '" hlln. lulll'G'h, 11<; hl'''''''!1 h;,u W'III ""II""! ",I AI'I,IV ""!I""] ".1 III IhH ('I,,,,ksh.lr, 1001lll,,1 ,,,,eI III 1111' !"'''''''H':''P W,III Ih" ""ow 11('''I1'''!llO"".''d~ IIH' ''''''1 01 II,n ""!lIII" L.e:h I""II"'H ""1' '''''~I I", ,"',1I.·d '"~ IIHi 1l('S""'" 100'" whll.h II W.IS II,IIl1lvod ~ I"'.",, II,,: 1""0 ,,,I."""'!, holts ;",d 1'!IIII"1 Ih,,,,, It) 11"1 10",IIe w",",.h ~('I''''H 11''''''' '" Ih.., SI,..:(' . .r,,:,,'I("'~ r,u" II,,· e:I,llIhh,,11 Ii) "II'",,: Ih.'1 II 11I1"Il!S 1"".jV. III'lorn I'IL"'!! Ihe "oxl hei""'11 1:011'_ II lh,' .:"lI1l~h.,h ,I""" ""I 1<1",10: III:<.:IV. Icn'o",! Ih'l l'l"""'\1 r.iljl Hnll check 11>.lllhll I>";""I!I ~hl!!l~ l1.w<I sc.,h,ld p,npedv ilmllhal IllI! hcall"H cap '5 Ihc CO"'''.I 0110) 10' Ih.'1 l'I/Slllon ij r'l Ihe oall~~h.ll1 ~,·V PI''':e Ihl! o.l,,"~hilll !lCil' 011 Ihe en,l ollh.., , .•• lIIl~II.,h .11101 1)0','111111 II hV 1,·lllpO •• ",ly "iII"!! II", e:'.111bh.o1l p"II"V .11 .. 1 II,,, OI'UIl1,,1 wil~II" •• ",,1 holl T'!I" I,·" Iho ""II. Ih(:" 1l!"'0"(! Ihe 1,,,11. w;o~he. ;11,11 ,-,,,,,ls","1 pulh:V 7 M""slI'" Ihll (l alll~h"'1 "",lIIo;lI ("'~I! Secholl 27) ..... h,ch sho"ld he .-IS Sll(!c,f'ell II "(;Ce~S;"V. hlmll .1 belwecn lior:s" hlll'l.~ bv IlIseltll1!J 11"U51 w.lsh",s of Ihe .11 }I)lOp".IIe 11nck"css
8 1 Pi~tons a"d COl1l1ectin g rods ~ re fitting
RclC' 10 $CCI'O" ;:t!)
82 Oil pump -refillin U
P"lTle
Ihe oilllUlllp L>V 1IIIol1g Ihe IlIlel 1101l wnh Cl1g,"e 0,1 and Ihen flJlat,ng Iho dllvcshilh 10 d,sl"L>ule Ihe 011 wllh," the I'lI"'P hodv 2 Inselllhp. pOll1led end ollhe dliveshMI "'to Ihe PWIlP hodv and III Ihe clop 10 .etain II 3 Place Ih o pUIliP U1 I)051110n . cngnU!! Ihe d""e~h;JII and Iheo inseH Ihe ' .... 0 llitallung IJolls r'\lhlet1ll1.., holts to thC lo.que w'lInch SCII,ng
\I,,,(:n III Ihc SpClcol,c,lIIons < Rell lihu boll SClCU.IIlU Ihe 0,1 pick up luhe 10 IhCl ",nln I)C;UU1U cap ",,(I "U"l"" II 10 Ihe ~j}ec"H,d 10'ljue. F
ig. 1
.16 Cr.1J1 kshilft Ihru st wash ers ~ ;orrowed (Sec 80)
83 T illl i,,!! !I ClH'S illid I rOll 1 pla to rclillill!!
Apply 1""'III'!1 1:1>"'1","11<1 In Ih " (11,1,,1 ""!I" nllh" 1"'''1 "n,loI Ih. <,yin""" hl(1{.k ;"HI l<J Ihp 111.11 I •• co: I,f III" 110111 allilj1I(/I IAilh) ;:t 1'''~llIf1nlllll !1.J~k('1 'lilt! "d"plm pl;Il". ",),;""11\I,,·,,, w"h Iwo holl
'''~"I\'''' flll!!", II!III 3 r,l II", ada •• lm 1,lille f(,,,,IUICelllunl ( F,\! 1 17). IIlS"' lIS IllIC(j b olt· ;""j II!)I>I'''' tI":",, 111,," II,IllIJV(l Ihl) IWO PI(,v'(lu sIV III~I),wd local"'!
1o"lh < no:l,1 the e:"nlsl1.1 lt ge".. Sf> Ih.ll Iho kP.VW.1VS "I I>ulh Ihl} CI.lnkshall ill1Illlol: e:.1t11sh"'1 "H) In lone ;11111 Ih,: ",,,,ks on Ihe tW,lIS .1,Q on 11m Silllll
I",,, II", <.I:'l1ksllo1ft \1";11 hilS IWO "';IIks Oil 'I alII I " " mipOIWnl Ih;n 111"V iIIe l'OSI\loncd as ~hown ,,' f.U I!; [) M""~,,,e Ir." I:lldllo.1l 01 II", <:.1I1l~hall ;,ft,,, '"~"'IIIIII Ihe t:alllsh;oIl "''''''''''!I hull ami lI\1hl"IIIlI\1 , 10 Iho: 111"1'''' wII,I1I:h ~I:H"'!I U,,,e,, III 1111, SI'"",I,,;;llll)lIS 11", cillll:;h:.11 1;"dllu"l e:"" I", ;111",'01"01 lIy f,ItIl'lI .'
Ilelf'·I,".1 1''''lIlh ~I'.".'·I G M""~,,,e'II": 1"".ll.l~h ul II,,, 1:O",,,h.111 !I",,, ill 1"lIl ··'IIl.,lly ~1'.1(:",1 PIII"i'. .",,,,,,,1 "s I""'I"""V lh.~ ~hull"ll", 0 7.2 In 0 32 """ (000910 001:l "I) 7 AIII,IV 1"'''h''!1 (:O"'P(111,,<1 II! Ihe cII(:uII11r:"",ce ollhe 1",uIIU CO"..,, 101111 I.",,~ .IIHI It) l hl) 100111 01 Ille ;"I.'pIO' pl.'le JI,d oil." up Ihe 1I1l11r'>{'
co"el 8 1l,,1'1 Ih" ",,"'kshall j)l11l!:V to pO~'I'IHI Ih.., IIIIIIII!} '.0"'1<. rhcll mSCIl III" 1""'''11 CO"", hOlls alld t'H"I"" Ih..,111 10 Ihll 10'<1"(: .·"~IIe:h Sr:l1Illg
11''' 1)'' UI Ihe SI'I1t:o/'C;l\'OllS
9 Apply ,0"lIuIII C0111llOll11d In 01111 f.,.:c 01 Ihl! e:,.,,,1 ~11i,11 llullllV w;o~I"", pl.lcc Ihls s,de 10w",US 111(; I'tlilev . ItISC.I Ihl! pull,;V SCCUH"!I holl ,,"(1 ilUhlCIl II 10 Ihc SP':Cllll1d tOlqllC
Fi
U.1 .17 Adap te r plato reinlo lcclllcnt (Sec 83)
procarmanuals.com
Page 56 of 205
7
Chapter 1 Engine
Fig . 1.1 8 R ear oil sen I ilnd ildaptcr pliltc (Sec 84)
84 Renr oil se;1i ,,,,(I lIywheel - rc fitti"u
1 I'll the ()n!J"I(~ .r,," ,,(1"1'10' pla1<:1 and s(:clIre ,I wllh 'I S IIv(: holls. 2 Smenr en\J1ne (ld OlltO the CI,mkshah '''". Smear 0,1 on the lip 01 the sea l tlnd pos(( lon tlon ';".11 on th e cran hha ll. 3 Align the seil l c;""er holos wllh Ihose 011 the cylrnd(:, hlock . Insell the loul bolts and 11!lhlCll Ihem 10 the SpeCifIed 10lqUfl 4 F it the flywher.:l . or dllveplalc on au lOlllallC lwnsrnis sion Illodels.
InSerll h e six holl S ;",d u\llole rllhem 10 Ihe 10 lque w rench sell"'U Uiven in lhe Speclllcm'olls
8 5 Sump -rciiuill!)
En~",,, lh;ol Ill" ru,rI "'!) ',u.l,u :e s 01 hoth IllI.! Slimp a"d t h e c(,1nkcilsc ,lie cl ea" ,mol IIi,1I n", '.""I",!) SlIrJ ,u;e 01 the Sli mp IS not d'S lo lte d. 2 Apply IO" ,I,,,!! c"'''pollnd 1 0 the pOUltS wllel(~ Ihe l"llllll) cover ablilS lhu ,;yir r"lr" 1,Io ck .lIId where Ihe rea' 001 $u,,1 carr.(:r "dIOIllS II 3 Pln ce tloo \J,,~k"l '" fJo~.t.on, lIt tlo" SlIm l} ,'Ild IIlS(). 1 lhe r0Io1111il1l)
bolts ImUO I tl!lhl 4 PrO!lres~lvely 1I!llIt,," llw sump holt s 011 opposIte I'ilr ts lIllt,1 all 0 1
t
hem ,H" il l tl", ~ 1"":lllI"d IOlllUU , 5 FII ,1 now w;,~h", 10 Ihe ~Ul1lp II"'UI pili!) , IIlscrl lhe dl,lIll pllll) and
t ,uhlen ,t
8 6 Cylinder h e"ds re;rssernbly
L~y the cylrnd" r h",.\! on .IS s Ide. luhrrcnt e cvcry valve Uu ide with eng;l1(! oil. ,lilt! ,"~,,"t the valves 11110 the \Ju, dc Irom whIch lh ey wele remov(:d 2 To ,WOld d<l(11;U)III\) lhe II p 01 the stern 0,1 sonl , with consequent rncreJsed 0.1 con~UI1'ptIUIl. wrnp <I p.cce 0 1 ndheslvc wpe. or fo il. fOund the \JrOove o f cvery v,llve SWill Sh( le lhe scn ls over t he valve sIems and push th clll over th.: lupS of the vnlve u",des 3 Remove Ihe "dh"~lve wpc. or fOIl. horn Ih e vnlve S1(~I1IS. 4 F,t the valve sp"nl) ovc, the valvc. Wi lh thc close cOllcd end 10wnrtis the Cylrnd er head. lhen fll thc sprin\J relarne r on top 01 lhe
sprlll\). 5 US1ll\J a vnlve ~prul!) compresso r. com press lhe splln\) lus t enou\)h 10 inse,t the IWO Splil COIl,,15 If lhe vnlvc spml(j is compressed 100 filr.
lhero.s dilnlJC' oltl1<.: ~I""IU rcW""C' dillllil\)IIlU tllC villve SHlm 011 sen l
G Ahcr "lsert")!J tit" ~pllt collets. r eleilSo the spllny compressor (111(1
rcmove II 7 C hcc k th"t lh..: ~pl'l cull":IS hilve seilled properly and t<lp the top o f
t he v"lve S1C1lI hUhl1y w llh a plJstrc headed hJmrne, to ensure 1I11S,
Fi g. 1.1 9 Tightening sequenc e for cylinde r head bolts on the 3.0 litre enuine (Sec 8 7)
a Repe"l liln pruccdwn orven III p;ua!Jrnphs 1 to 7 o n the (CmJlnlllU
v,llv"s
87 Cylinder heads - re fitt;nu
11 the tappels w ere rcmoved. luiJricnle lhe lilppets nnd I heu hores wnh enoine orl nnd insor t thOlll wilh lhc;, d Ished cnds uppermost Ensule lha l every tappet ,s rclltlcd Into lhe hore hom whIch II wns
t nkcl1
2 Mak e sure tha t Ihe rna t"'!1 surlaccs o f lhe cylinder block. cyl lndor henrJs ;Uld 1111,,1 Ill,lIlIlold ;lIe de;"l. then plnce new cyhndcr head \Ja~kets ove, the Wildes un thn cylrmh" block. Tho cyirnder head \I,,~k ~IS beilr thO malkln\! TOP f:nON T ilnd nced to h e pOSII,oned
cOII(:ct ly .
3 Low ul Ille cyl ""lcr he,1ds ov"r the" posl tlonrngst u(!s, Although t he cyhlld\~r headS ,"0 Id entlc;,I, they should h,lVe been Illtlrke d when remuved ilnd should be lehllUd III thcrr ()IIUinal positions t1 Inse rt the cyirndcf 11I)"d boilS f"'!I(:r t.!Jh l then tIghten lhelll prUglC SSlv(: ty OIl the olde, shown III r,U I l!J and III llle stnucs",s U iven
m the SpcelirC;lt'OnS
88 Rocker arms and cover
s -refiUing
Ensure Ihm "II Ihe puslllOlls ,lie ,nselwd I!ltO the" p'llpor placos ;II1<J lh at thc" lowcr ends nle on\J"gcd in the ClipS o f the t"ppelS 2 Place the roc ker arms over tho jlllshrods. fIt the fulcrlllll seMS and ;ldllJS 1o r nulS. an d liuhten the ntl)usting nulS !"'ger light 3 Se t No 1 cyllllder at TO C <Jnd reh t the dis tllbu tor (see ChilP1C' 4) 4 I\dlust the vil tve clea ra n ces as descrohed in the foll o w rng Section 5 FIt the roc ke' covers , uSlIl g Ilew \Jilskc IS . ens uring tho t the gilskets arc senlOd e venly n il round l ho cylinder hend. Fit the cover altilchlllont
l
)olt S nntl lighten them t o the spec ,f led torque.
89 Valve clearnnees -checking nnd adjustment
R eier
to SeC!lon 3 5
90 Engine ancillaries -refitting
R eier 10 Sec tIon 46 and ref, t lhe I. ste d componenlS w,th refercnce
to th e Chaptels ind,cilte(f
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Page 57 of 205
56 Chapter 1 Engine
91 Engine -refilting
Rcf'tlIng the engine is a rCllcrsnl alth e removJI procedure given In Section 44. bUI in addrhon note the following 1)O;I1IS:
(,,) Ugh/I)' 9(0"50 Ihe ycar/)QIC ;npu{ Sh,ll{ (m,lI/v.,1 transmission) (b) Check tlMllhe dlileh fc/c,He .7Im is cOIf(!clly loentcd (m,lllu,)1 (fiJn$miSS;OIl) (e) Adiusl (he clutch cClbfll ,15 (/(!sCllbcri ill Clwp/fN 5 (m,mu,,1 flilMmission) (d) BelOfc COfl/weliny the engine /0 {I!(! ,W{omMIC {MOSl/tllSion check 111M /he /O((/lle con vet/or is fully 01l9,19N/ wilh lite /f,lfI smiSSI()II pump by reh'/(!IICa to CIWp/Of 6 (e) Refll' file ,)II/QIII,llie ("'''lllltHiOIl WillI 1141/11 ,15 dcsCfI/)t'd III Ch,lpWI 6 (/) Ad/usllhe lellsioll 01 the IJowor steeling IIlIfIIll MId .11/emMa. !lnvalid/(s) ,15 d(!scfI/)ml in Ch,?pICIS 10 i/lld 2 f(!SpcC/lv(!/y (!I) Fill Ihc cooJillfl sys/cm (el,.l/'/C' 2) ,md /lOW,!' Slcc/IIIY
SVS/l:tII (ella,'/Cf 10), 1111:11 fIIlllle mlylllc Willi od (SeC/lOll ti~) ("ho/Q)
92 E n £line -initial start-u p after major overlwul or re pair
Hel",
10 Sect Ion 38
PART C, FAULT D IAGNOSIS
93 Faull diagnosis -engine
Sympto m
(n!Jlne f.111s to tllm OVCI whim ~t;llt", IS Opc,;) lcd
Enll"n) lUIIIS ill no.",al ~pced. hili dous not 51,IIt
E"u'ne SlOp s ilnd Will not 'estill t
Enll'Ile
.",slucs, O. lUll S unevenly
L~ck of powc. illlt! poo, comp.esslo ll
91 1 T OPPln! 1 lIl) tile ""'II"") wIth od
ReilSOn(S)
DI~ch.1'Hed 01 delec tlv" 1o:,lle.y
Dilly 01 lI)os" lI.11tc.y le.,ds
O"f '!I:llve sl; IIt", soL"",,,, I. ,II SW'II: " Odl'ctlvl' s lillte. "UIIOf
Dilly 0 ' III"ken e"!I"IC "'''1111''11 SIt;IP
1\I1'"111 ':Ol1lpOlu",ts Will (If ,1;""1) DefectIve low te nSIOIi le"d Detective o. InCOllec,ly :,,, 1 ,:"III"C I h,e;oke. (,I "PI.I,,:a"fe)
Oe f"ctlve condense. (If '11'lllIo,;.,"lc) O'st"hulor cal) defec tIve. or celltral h,ush HI (irs l,,"uto ' cap Ilot m,,~, COfltilf.t w'th th e .otor a"n Ifls.ulhc,em petrol "' tilllk V.1pOOf Iud '11 luel hlle (," hut cOl1{lIuolls)
Fuet pump I:uhlfe E~O:Hs51ve c hoke, caus,,,u spillk pluUs 10 hccolllt) wet
IU"I1I(HI 1,,,IUle result Ill!.! 110111 b.cakdown. or prescncc o t w;'1ler \,Inti w(: 1 cOnthllOIlS l:n:k 1.11 tud. at luel IJlock, l!Je
loose 19111tlon Icads F(luIIV s J)n. k 1)Iuli T'(1ckin£l on d,slllbuto. cnjl IIlsuliltion
InCOIICCll11lxtu'e 'Ullilion 100 telilldcd Dilly con[,lCI blcakc. POlll1S (,I ajlplPcablc). or loose connection'
<I'SI""\,IIO'
Faully Of loose condense' ( II ~)JpIPcilblc) Lea kin U ca.hu.eItOJ. o. lII.lll1fold JOlllt
D"lectlve v.,lves Blown cyIP"de . head £lasket
WOlll bo.es OJ dilm ilye<l ,,,slon
Wo.n cylinder bOles Do::tt)cllve v~Tve Stenl seals Le<lks
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Page 60 of 205
)
'tz
Chapter 2 Cooting system 59
1 I VISCOUS (IPlVC I,m coupling (I,~mpc,alu,e sensitIve 1VIle shown) 2.5 Tuppill\l -lIplhc COlllilll1 h,vel in the c~J)alls,on \;lI\k 27 Checkin U the drive-belt IClls,on (28 hire CIlUulC)
2 Routino Illaintcnanco
Altho ,n1C, ... "ls SPOC""]!! utlhe Rouhnc M .. "UcnanCf! SOChOr! on Ihe 110111 01 the m;uu,a1 c;lrIy oul the lol1oWl!ljl p.occduoes
Check cnoling syslcm lor /c,1k.~ 1 In spe cl Iht! coolin!! sysh),l) hose s 'llcludlll!) the ,adIOiIO' :,"<1 Iwate. hoses for damage. detcriOlllll0n i1nd sccullly If Ihelt) is I'Irly IOulle;1I'01] of swelling 01 p<lflshinu ,en ew the hoses . 2 Chock the ,a<li;uo . fa . dilmaUc ;lUd leaks, ,llld clean ;lny dchlls from Ihe coolmg fillS.
Check coo/tint level 3 Whe r(l Ilrl expanSIon 11lnk 's hlte d (I"te. Illodels) lhc I;oolnnl ICv!:1 can tJC check ed without .enlov,nu the pr<lssu.e C;'f};1S the lank ,s made of t.anslucent f}I"st'c. The t(lnk should he ;1PP'OX"l1;1tdy hllil lull wuh the cool.,,, t lust cove.in\J the pillst'c lev<l l ,"d'CH tO '. W,th i1 h ot CI1U"'c the level 1"',11 he ShUlllly hiuher 4 On ciuhc •• nodfJIs not f'U e(1 w,th 1111 exp lln:;'(l1I wnk the level "'''~t be Checked with the .. muine cold . Unsc.ew Ihe .ad,alO' p.essu.e cap and check Ih,\( the cool,u'l leve l IS hetween 25 0 111111 (1.0 In) ~II(I 35 0 111m (1.'1 In) helow the base of the filler ne ck . 5 Top·up the flurd level USing the COllect sohl\lon of wa!IJ' and ;mtilreele with the enuino cold (photo) 11 the c"Ulne is wal"'. the P'<lss,,"e Cilpmust be remov<ld slowly to illiow Ihe PICSSUfC 10 e sc ape U'llduilily. otherWise the pres su.e d'OI) fllily c~use thc coulllni to hod over cllusi,,!) I)Clsolla l Injury.
Check drivebelt conditioll and tensioll 6 Inspect the complete lenlJth 01 th e tJrovehell(s) for dClello.,llIon which WIIIIlI)f)e,lf ,lS h1lyll1U 0' UlilZinU to the 1)Ulley cUl1t ilC t su.fi\Ccs. 7 Check th(lt the deflec tion 01 the d.ivebclt{s) midway hetween the wate. pump i1nd (litelnntor pulleys is i1pp.ox,,11i1tely 100 111111 (O 4 OIl) under 1ll0de'i1 le thumh p.essule (photo). 8 Whe.e ~Idiustillent is neceSS(I'y. loosen Ihe Ililefllilto. p,vot and adjustment bolts. re l)OSlloon the alternilto. then tighten the b olts. A leve. mill' be used at the pulley end o f the IIlterna tor 10 o b1;lIn Ihe
COf/ec t tension If .equir e d .
9 Run the enuine f o r severlll minutes Ihen rec hec k t he lension.
Renew,1/Jtilreeze 10 O.am i1nd flush Ihe CO(lhng System as descrlhed in Sections 3 and 4 . 11 F,II the coollllg system With Ihe correct solullon of watel and amlf,ccle as desc"hed in SeClions 5 and 6 .
3
Cooling sysl e m -drai"inU
If pOSSIble. ensu,e thilt the engine IS cold belo.t! d.al"i"lJ Ihe cool ant. 10 aVOid the fisk of scalding.
2 Remove Ihe .adlatOf or expanSIon tank IIlIe. cap. If the eflUlnc IS hot. Ih ls must be done vl;lry caul,ously, because a sudden release 0 1
Fig. 2.3 Clltawa y view o f Iho expan sio n tlln k showin g tho plastic lovel indicator -tH rowed (Sec 2)
P'".'·S5U'0 CilIl ,esull II. the cool(lnl !.>oIling i1nd blOWing Oul. On ,1 hot enUlIle. plilce iI cluth ove, the caf} and lurn il ve. y uently. '0 release tim p,ess\lIe slowly. 3 flel110ve the SplilSh shield frOI11 b enomh the ra(II;IIOf. of i1pplrcilble
" Unless !he coolilnt IS beinu discarded and thc ca. 's over (I slilt illJle
d'illl1. ,,'"ce a deiln IWO i1nd a half gallon Conl;1ine. underneath the ,adlaIOl. !) Rel110ve the radlatOl bOllom hose lind allow the coo'al11 10 drili" . 6 If the SyStel1'IS to be completely d,ained. rcmove the cyhnde. block d.;1I1' pluU and draIn oul Iho .emainlng coolant hom tho engine . ThiS d'illf' plug IS locilted all the s,de of the cyl inder block to Ihe rear of the oiliolicr. 7 On 1I10deis wilh all eXJ}ilnSlon tank 'emove the rad.alO' cap as well
4 Cooling systom -ftushing
In IUlIe. !he cooling syStel11 Will lose ils efficiency because o f a bu,ld'lIp 01 .uSI and sedunen t in the radiator. To clean the .adliltol. .emove thc IllIer Cill) i1nd 'he bOllom hose ilnd !lush Ihe radialo" by inse.llng a hose in Iho f,lle. car> neck i1nd funninu Wille. th.ough fOf about tr.m I11mules . 2 If Ihere is a Ilea vy aCCUmuliltlOn 01 sediment. it is betler to .eve.se
flu sh Ihe .adl~tor. by connecting the water supply 10 Ih o boltom of the rilclmof alld allowinu II 10 flow oul of the tOIl. Speclnl hose adapters arc avai lable to enahle thIS to be done w ith the rild.ator In I)OSllion. but It is p,efe.able '0 removc the lad,ato. and tum il upside down.
3 Remove t he thernlos,a, (Section 8) then .eve.se lIush Ihe engine wi,h a W1l1e. hose u n lll clean waler flows from the .ndlat Of bottom h ose connectIon.
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Page 71 of 205
70 Chapter 3 Fucl and exhaust systems
liS seatmu Note ,1nd reco.d the number of lurns, so th,11 the screws can be relltted 10 their orjuin~' settings . Unscrew cilch screw fully and remove it and its SPfing . 13 Che<:k the lIoat <lsscmhly for signs of dnmage nnd ensure thil! the Ii0iliS do not lenk LC;JkinU HOolts can be (leleCled by submerging the UO.l1 III ., pMl of Wilier When heating the wllle •. IC.1ks will be indlc"ted hy lwbhlcs rising 110m t he flOil1. Inspect tho power villvc. pump {l!ilph'ilUm .-md IJilskcts 10' splits . Check lhal the III.oule plJtcs and 1111~lure SCfCw needles (lIO no! worn, 0' ulImagcd, Fit new pllriS where IlCCesSilry 14 Star , ,e(l~scrl1blv by .eh1hnu the pariS ollhe ilceele'alor pump In the orde. shown III Fig 3 12. Also relit thO ;Jnl;'51"n dr,lph,aom as scmhly_ 15 FIt thO two nllXHU(l screws nml spunns, slJltln~1 onch screw 10 11~ O!luul.11 pOSIlUlil nnd relll thO leiS . let plu!IS, emulsion lubes nnd ni,
COlleCtIOn Icts Hi Rein tho power valve dlo'Jlhr"gm nssembly ~s follows. Loosely fIt Ihe Ihree rtrnplungm ret"iIlIIlO screws. comp.ess the return spfln!! ensu"o!) tl>;)t the dl"phr"W11IS 001 IwislP.d Or dlSlorted Ihenl;\Jhlen Ihe scrells ,'mf Ide,lse Ihe SP'1I1!). Check lor correcl IUllc lloomo !ly push Ing Ihe rtl,ll )hr"IJlll down nnd ,hen blockllig the:m hleed holll w,lh ;J f,nue, I1cfcnse the d'ilphr;JUI11 whde 51111 keeplll!J the ,lIf holo blocked [I the fhilPlu"~Jm sl,'ys down. II hns Willed j)rope.ly to Its housing 17 RefIt the Ileedle v"lve hOIJSIII\j, ncedle v;Jlve nnd 110,11 nssemhlv 10
Fig. 3 .9 Emulsion t u bes (V) (Sec 9)
Fig, 3.11 Removin!J tho IIlIli'Slilll dillphragm cover (Soc 9)
Refum sWing 8 Cover
the upper body. 18 Adjuslthe flo." level settings, fi,slly w;l h the upper body verlical .md I he needle villve s hut off lithe meilsurerneot is outsIde Ihe IInlllS given in the SpecifiC<ltlons, hend the IiIg unlll the sett lllfJ IS corlect ;"ul lechC(; k. 19 Check Ihe flOillllilvel by mO<1suung from the body f,lce when tllfl upper body is horizonwl. lithe meilsu,emenl is oulslde Ihe 11111115 g'V(:11 in Ihe Specl ficilhons, I>cnd Ihe Ing umll Ihe SCltll1g IS correct ,,,ul recheck. Far bOlll 11m flam leve l ild!lIstmCIllS Ihl! lIJlflCf body g,~~k'" muSI be remove<1 . 20 Refit Ihe fuel inwke "Iwr ilnd loc.11if1{1 11111. 21 Posilion Ihe Uilsket (lnd relIt the c(llbu.ellor UP1Xi' hody M,lke SUII' Ihill the choke link loc;(1\es through Ihe upper hody correClly 22 Recorlllecl the choke link Mid secure II wllh IIIIl U·clrp 23 AdjuSI Ihe Ih,o\lle 1)1(lleS lor synch,onrlilIIOIi. Wme! h"ck Ihl! .. II" screw unlll II,s r.le,1r ot Ihe IhrOllle mcr.hmliSI11 ilnd Ih{:n 101)5'''' Ill" synchronililllOn "dlust,nu sc.ew. Hold Ihe "ulo·chole pl"tes '" ,m open POSItIon, flIck Ihe Ihrollle ilnd ,,1I0w hOlh pl,1les to r.1o~e IIIlIy T"p bOlh pliltes 10 flnSilre Ih.11 Ihey h,we clnsml r.nl1lph~I{:ly ;111(1 liI(:" ll!Jhlcn the synchrorll~il1l0n sc.ew. To chHck. j)a,lmfly open IhH Ih,nllll! uSll1g the 1(110 sr.rew, SO Ih~1 IllIlre IS n clealanCe! of 0 5111111 (002 HI) betweeo olle of the Ih.011le j)l alL's (lnd li S holC ChHck Iha l the mh,·, plnle hns Ihe s~l11e open;lI\j
Fig. 3.10 Relllovingllie IIccelcrillor pump cover -(lrrowcd (Sec 9)
..
Fig. 3.12 Accelerator pump components (Sec 9)
A B Covcr Diapl/mom c RC/(lfll swing
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Page 72 of 205
) 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"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
procarmanuals.com
Page 73 of 205
72 Chapter 3 Fuel and exhaust systems
3 Unsc.cw the cenlle bolt and .emovc the cove •. T o p<event 105501 coolilnt 1i.5t .emove ilnd .ufol the p.essurc cnp to . eleilsc any prcssure but do thIs only w,th the engll1e cold. 01 Remove the th.ee sc.ews. dcwch the h(")using ilnd move ,t clcill 01 the cilli)u.ello,. Fo r ilccess to thc lower sc.CW 1 WIll be necess1lry to mnk e up a sUl tilhle cranked sc.ewd.lVer. 5 Oet<ll";h Ihe lI11efllill he<ll shelld.
VtlCllllm pul/-down 6 FII <In el<lSIlC bilnd to Ihe choke plnte leve. illld POSItion 1 so th.11 the choke ptilles ilIe hl)ld closed Open. then .elcase. Ihe \h.oule 10 ensu.e Ihal Ihe choke 1)lilleS close fully_ Unsr..ew the pluU f.om the d,nph'il\jlll unl th en Illilnllilily pIIsh oplm Ihfl d,nplHolum ,'p 10 Its SlOP I. om IIlslde the choke hOUSIng Do nOl push on the I(HI as 11 ,s spflng·londed. but pu~h on the d,.lphln~)l1llllu\J ho(ly. The choko ptille !lllll·down should now llU mO;")$lIIc(1. lISUl!) an lH\lllar~cd !WISt (i. III ~hank " ..,tween Ihe edlJe ollhe cho~e pl"le al\(I the au hOln walt <lnd compa.ed WIth Ihe sl'eclllcd II!fwO Ad)lI~L. ,I l1ecessilI Y. hy SCIOWlrlU the .1dlu stull) SCICW In or oul. lI~III!J a sho,t hl,ldod sc.ewd.,vel Rof'l the end 1)luII "'ld detach Ihe el<l~hC hand on complet.on
Choke phasillg 7 Hold tho Ih'O Hlo 1),1.tly open <In,1 posItIon Ihe last "lin Cilrtl so Ih.1t Ihn last 1(lIe ad)lIstll1H ~C!ew locah)s on lhe "jlIH~f ser.I'OIl 01 Ihe calli Ikh.:ase Ihe ,h,ollle to hold the cam III HilS POSIUOIl. then tlush the choke pl;)ICS clown untIl lhe ~tCp on tht! (::11) lan's ;\!la'n~lthc adJus t Ill!! so"w MO,lSUII) the ChWI;IIICI.: tW!Wel1 lhH "d\!e uf lhe chllk" ,,1;I!e and !hl! au horn wall USUllJ ;") spl".."Clfoeti ~Il.) 11,,11 A't)us\. II llI:c""s;uy. fly
IJ(mdlllU Ihe tau. S Rn"t Ihe intelnal hcal stueld eIlS''''"\1 Ih,lt Ihl! hole ,n the COve'
locmes COrfeclly 01110 Ihe t :le\] C<lSI ,n the hOllsin!! 9 Connectl"e lli.melnl spWln 1 0 lhe chokc levc •. position the ChO~e housing ilnd loosely hI the th.ec Icta,mnu SClCWS 10 R ota\C the housing unt"the malks a.e ahllned then tiuh\l!n Ihe lhree screws_ II Relit Ihe cever. togelher with., "ew Y<ll>kOt. and t'yhten the C"n\'1) bolt. Top up I he coohng s y Slem ,I Ilccess: llY 12 Reconnect!hc h;")lle'y . run thc ell!l'"c :",d Mllu~t Ihe 1,IStldle spccd ;,s d"sCllhed III Ihe 101l0winU Pil';'!I.;lph
Filsl idlv speL'd 1 3 hlc;IlIy" tachomcte. wlIII,c .eq,,"ed !lllmlc. 10 sellhu t,'~1111l1! 'P'" 10 lhe ~peclllncl v.1Iuc . nUll lhc CnnUlc lip to no.,,,al opc.at"I!1 t,:'Upe."lu,e. then ~wO\ch oil ;Jml COllllect Ihn tachomete. (whe.e .wn"a"h,) OpCl1t he Iluollie pal\lally. hnhllhc chokc pl.1\(.)5 lully closed tI'"" 'ele,lse tht.! th,ollie $0 Ih.111he cho~e 1""ch.1111$I11 IS held 'n the fast "II" fK151\10" Relc"$c the cho~1"l pl.ltCS . d" . .:ckllll! lh;lllhcy .cmaln lully olwn (II they ".c not open. Ihe ,lsse rnlJly IS I"ully 01 Ihe cnU"lc ' S 1101 al 01Ie .,11111IJ len'I/C,,'lurc) Wlthoul louchl"H the ;lc c"le."to. ved"I. Sliltl
, ,
~A
Fig. 3.1 9 Choke phasing adjuSlme'lI (Sec 11)
A 0,,/1 8 AUjus/my'"y
Fig. 3 .17 Checking the Vllc .. "m pull·down with l' drill {Scc 111
A t:lils/lc Im",' C V;//:1I11111 ('I'~'f,~lmllull B DIJII
Fig. 3.18 AdjtlslinU the vacullm pull- down (Sec 11)
A 8
Fig. 3 .20 linkage SCI fo r checking fast idle adjustment (Secl1)
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Page 75 of 205
74 Chapter 3 Fuel and exhaust systems
, ;
1)'>
,
Fig. 3 .23 F el '<ll1k coml> onenlS (Sec 13)
A
" C
Se.ll Ruhbcl ill,W/,lIQI S SI!IIIJ..'f lIoil
14 Fuel lank -cronning DrHI rcpl1ir
D SImps E , COllflcetiu"
W,lh IlI1m 11 I~ likely Ihal scd'lllcnl .... .11 COIiC(;1 1f1 the IJOIiUlIl u l the ruel wnk. Con<lcIIsa l'OI\. los-uIIU'U "I !USI ~Hl{1 olhe l lI1'Il,,,' "es. w,lI lISlI;ll1y be found III tllu fuel l~nk ul 111lY eM mUIC Ihan llir"e or lour yeil' s old. 2 Whclllhc wnk is .emoved it should he \lllJOrous ty tlush ()ti Olll wnh p,l'ilfllll I1nd turned topside down 10 tir<llll II r.1Cllllie s n,e ,wil d,lhlc ,11 the I()(:;JI gar ago the lank m;'ly be steam cleaned and the exlCflor fCptllnlCd with" lead bnset! ,J a int 3 Novol weld or br in!J J naked ligh l close 1O;lr1 emply fuel I.1nk until,! hilS been steam clC<lncd out 10/ illicasilwo hours or. washc(t IIIIC'II;'Itly wilh boihng WOler ;lnd delergcnl and ;lllowed 10 SIi",d lor 011 le,1S1 Ihree houl s
15 Fuct lank sender unil _ remov;11 nlld refilliny
Check Ihe h01l1 whL'{)ls Ihen J;lc k ufllhe le;lr of Ihe 17;11 ;'Ind supporl ,1 ilxle sr,llids . 2 SYI/hon Ihe fllel hom Ih e tllcllim k. Wherc ;lpphcilhle d,scol,,'ecl Ihe fuel line hOIll the scnder unll.
" Discormoci Ihe wiring 5 USlllljlWO SC!(lw(i!lvers III Ihe 51015 inlhe sendcr unit ,e lirmlng 1111\1. unsr;'ew Ih o sender (mil loom Ihe tucllilnk Lilt ilW;lY Ihe scaling ling iln d Ihe sender unit. nO llng Ihill Ihe 110.11 must hilng downw;'IrrJs. G Re fill ing is a rever snl of .e moval . bUI clea n lile milling !;lces ;'Inel I II ;'I new sealing ring .
1 6
Fuel lank filler pipe -removal "nel refitting
I Remove the cap horn Ihe hiler pipe. 2 Re movo Ihe .ighl·twnd siele lIim p;'lllei. 3 Peel back Ih e in sul alion clear 0 1 Ih e pipe (:Over fliln cl (Ghia only). 4 Lift outlhe pimel coverinU Ihe spore wheel. 5 Unbolt Ihe IllIer pipe covor panel. 6 Lo osen th e clips and releilse Ihe rubl>C1 oail er from Ih e floor and f,llel pipo (phOIO) 7 Remove Ihe screw al Ihe lO P of Ih e pipo nexl 10 Iho filter cap (photo). 8 Disconnect the hoso and withdra w the I.ller pipe I rom in si de Ih e
car.
o Relill ing
is a rever sal 01 romov;lI,
A
cceleralor cabl o - removal and relining
Removo Ihe
lowe. lac.a panel inSide Ihe ca'.
166 Rull"'" !F"1I1';'I1 "otlom " I I"". la llk flU", l"llll
(
. ,'l
--.
. ~
1(; 7 Fuel lank flUc. Pll~ UppCI 1II0UIIIIII\I SClew (.lIwwL't I)
"
, I;'.' . :~, \;.;
: : i;. "j -' , ,' .... :r: , :'y~ it. ; '., :
Fig. 3.24 Disconnecling Ihe innor cabla from the pedal (Sec17)
Pusll M 11 ,mrl rcfc,uc ill IJ
2 Disconn(:cI Ihe cahle 1<0111 Ihe I)OOal hy unhookoug Ihe clip and rcleasing Ihe ""II:! cal,le 3 Rem oye Ihe IHal:.e servo un:1 a~ dcscfLb c(1 11 Ch;lll lcr 9. Ihen remove the SClew securrn~J Ih(: Oulcr cable to Ihe iJulkhc;'ld
-
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Page 76 of 205
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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."'J(:d III Sf·etlan 3 5 1',,11 011 tlo" ~I""VH ,,,HI d,s<:OlUI'!Cl 111" I""~II<: sock", 110m 110"
cOlll,,,1 IIIIK"!I" G I'll'." Ih" ",,,,,,1 '''','UHrI!l <:lIp hom the IlIi,,;k"l 7 U~"'!I a ~,:",wd"v"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""f!"s,O"~ !),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'lac'~ 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 "(~ /f.'/!/oVI:1I /("1,:, (0 1""""1';'1"" 12 [)I~.,:,,,,,,,'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 ,,<'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~""h"d III
Secll"" 113
RI-IO variilnls 4 DI~(u"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", ",v,,'~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"~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'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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