engine FORD CAPRI 1974 Owner's Manual
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Chapter 1 En gine 39
238 Checkirog the rolor lobe cle<lwnce
1 Thoroughly cle"n nil PDflS ,11 petrol or p<l,nlllll nnd w'pe dry US!Il\J a IIon.lluify ,ago The neceSslHy clemill1ces nwy now be checked USUl(J a ,nJChirocd st.aight·edge {il good steel rule} "nd " SCI of leeler g<luges. Tho cII,ic<l1 clearanceS ",e belween Ihe lolles 01 Ihe cen1rc ,01Or Jnt! ~vllvex faceS 01 the oUler '010'; between Ihe lOlor and the pump hody,
and between bOlh rotors olnd Ihe end cover pl"le. 8 The rotor lobe cle<ll"nce rll"y be chccked lISUI\1 feeler \liluncs alld ~hauld be within the lin1lt5 0.05 to 020 mill (0002 10 0.008 on)
(phOIO). 9 The cleal3nce between tile outer r010r ,lnt! pump body should IJC w,thin Ihe limits 0.1510 0,30 mm (O.006 to 0012 'n) (photo). 10 The endltoal clear"nce n1ay be lllC"SlUCd hy plnc,ng n slecl t. !r.l<gh\.edge across the end ar the pump In(1 rneilsu"IlU the g;lp h"tWCCIl the rotors and the straight-edge (phow), The g<lp ill e'ther lutO' ~hould be w,thin the I"nits 0,03 10 0 .10 mnl (0_0012100,004 rn) 11 II the only excessive clearances arc endllo;l1 rt ,s possrhle 10 reduce
II,em by removing t he rotors and l<lpping the [nee ollhe hody on J II;lt b"d ulll,1 Ihe necessnry cleoll"nces <lIC oi)wulnd 11 must be emphJ' t';~"d. however. thatlhe lace 01 tile hody muSl ,nmnUl perlectly 1I<ll "nd "\IJI1 .e to Ihe "xis of the rotor spindle, otherw,se the cleDr<lnceS wdl nOI h,) equ"lllnd Ihe end cove, Will nOI be n press\ue tighl f'IIO Ihe body II ,~"'Orlh t.ylllg. oj ~ourse. II Ihe pump '$ In need of n:newal unywilY hul unless done propedy. ,t r.ould seriously leOPJrdlse the reSI of Ihe ove.h,'ul. Any V<lrlillions III lhe other twO CleJ'illlces should be
overcome wilh ol new unil. 12 W,lh JII P"I!S scrupulously cle<ln. luSI rehl Ihe tChfll vJlve ,lI1d
!.p.ojl!l ilnd IInhlly luhuCJIC w,lh eng;ne VII. 13 Us,ng a SUltilble dl"nu.:ler d"fl. drove in il new se<lhng plug, IIJt s,de (I"lw",ds unl' ;t is flush with the intJke pipe "1<ltUlg LICO . 14 luh"cnle both rolO<S wllh enwne all oln(1 "tlhellllll Ihe hody FIt
Ihn 0,1 pump cover all(1 secure Wllh Ihe holls t l\Jhtcned In iI (('Juon,,1 .1n<l rllOU.css;ve mililner 10 the lorque w rench set\lIlg given'" Ihe
Spr'Crl,c,1t,ons . 15 f'lthe d"veshilft ",to Ihe !Olor dllvesh<lh ;l1l(1 cnsurc Ih<llthe .olO r h"n~ Ileely 16 Frtlhe "lInke p'pe <lnd all st';llller 10 the pump body to\lClhe. wllh ol II"", O.1s~et
24 Lubric"tion system ~ description
The p'essed steel 0,1 sump is allDched to Ihe underside 01 Ihe C'~~kcase and aCls as a reservoir 10' Ihe engine all. The 0,1 pump d,,,ws ~~ 'o01lhe sump via an oil SlrDiner and inlake p,pe. Ihen passes 'I uno , t6 lull. flow olll,tler The 1,lte,ed oil 1I0ws hom the cenlre of Ihe oil ;,~e, elenlenl and passes tluough a shari drilling. on Ihe right.hJnd , ,", to the 0, p,essu re switch and 10 the main gallery (on the e 1· Mld side of II -
F Ie C1ankCllse) th,ough " ttansverse d"llIng. Md °h'''' d"lhngs conneCI Ihe main galie,y to the lou, maUl bellflngs be I C camShaft bea"ngs in their turn are connected 10,,11 Ihe Illain d"~I':ngs The b,g-end bea'lIlgs D,e supplied w,lh 0,ltl1l0\lgh d,ayonJI ) 'nys Iro01 the ne,uest rllilill bearing b'U~\,h~rolhec,ankShaft is ,0 tJtlllg. oil ,$ Ihrown irOllllhe hole in each and e~ bea"ng and ensures splash lul)ric"tlon 01 Ihe gudgeon pins lu b ,I HuSt s,(le 01 the cylmder$. The ttllling \)ears <He also splilSh
~:.;. ' "cilled Ihrough lln 0,1 d"IIon\) . ,J",'
•
2310 Checkillg Ihe endflont
Fig. 1.3 Engine lubricalion system for the 2,8 litre engine (Sec 24)
The c r<lnkshJh third he~.ing lournal interfllillenlly feedS 0", under p ressure, 10 the rocker shafts throuUh ~ drilling in the Cylillder block ~nd cylinder he"d. The oil then passes hack to the engulC sump. v,a
large dllilings in Ihe cylinder block "nd cylinder he"d_
2 5 Cr<lnkcase ventilntion system -description
The closed crilnkc<lSe venlltnt,on sys tem is \Jsed 10 conltol the emiss,on of crankcase vapour. It IS controlled by the ilfllOUf1t 01 ~" drawn in by the engme when ,I is 'unnm;) and the lilrouuhPIJI of Ihe
vent valve_
....
~---------------灲潣慲浡湵慬献捯m
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42 Chapter 1 Engine
28 G TempO'i1'y holl 101 IOC;l1inO the mlc""t:thiUo: plale 29 5 0'1111(1 the )l'~10n linUS 29 7 0,11I1{J the cyllnde. hOlo
";; '. '''' . :~ .,
.. : .
..-2 9 8 US'''H (I plSl0n "l1g compressor when uiSerhn!llhc p,ston "110 the hore 30 2 Chet;kln~1 the Sial) washer I)OS'['OIl on the 0,1 pump d""csh"fl 31.3 O,llhe tlywheel holls bel o re ',",ng
(j 1,1 II", two f.t:"11'~ holts ItI1!jl.:r·"!lhl then 101 ;Hlorlm' two holls t'''''IHH""ly 1o. IIU:"I"'!I purposes T'!Jhtcli the CCIllle sec"""!J hails th.·" It''''"Yll the '"ml""'''Y Io,u "d 1000,umU bulh (photo)
29 P istons Hnd COIH1(!cli"g rods -refitting
WI, ... , ('.101,1" the COIU1I;:(.I,n\l ,ad h"U of tll c !l0U·end bO il'lIlll 1111d rh e IInde,sulu ollh(l ~hcll h .... "l1y ;lnd IIIIhe sh ell hc"rlllU "' pO$IIIOn WIth It S Im :, IIUI!llonuuc OIl!"'!I'!!! with the COH CSpo tUhnU CU[-OU1 ",the lad :1 If II", old hC.l.II'!)S 'lrllnea.ly n.;w nlld nrc hell'U re!ltu:d Ih en ensure Ihey inn ,dlll"d III Ih"" cO"I.'Cr 1000.UioilS on the COUOCI ,ods :1 The 1%lOn5 , c:;()n ll'l",,~ With c:;onm;c:;t"'u ,ods. mo f,tted 10 the" IH,::es from th(l lOP 01 Ih'! block
'1 luc ilte the p'stoll ""u Hap s III th e 101i0w inU rllilnnCI .
TOil 1['0' fr Olll Ollt· sir/e of /l,e Oil conl,o l 'IllY "ehc.1/ t'xf/8mle. y,l!) Cellt", 150 /tom lire O/Jilosi/e SI(/e of fire Oil cOII(101 ""Y l,el,cM cx,r.lnr/<!l ya{J
Bo/lom or! cOll/,,,1 ""9 HeI,cal eXI',lIIdel' 01l 110s,/ e I/IC /II,lfAed {J,S/OII "on / side
ad cOIl/,OI ''''y, III/':"llrHI',J/c lings 25 film (1 0 ill) c.,,1/ sie/e of tllC /Jchcall;xl1amh'l 9,7/'
5 Well lulJllc~le Ihe pl~lon iln d ring s w il h e ngine oil (phOlo).
6 Fit n unlve.salring compressor Imd I>'epalc 10 insell Ihe fllsl p'Slo n IIItO IIw ho,e. Mnke sure 11 is Ihe corrcct piSlon·conneClinu lod ilSse'l.hly 101 Ihill par',culil' boro. Ihillthe c onnecting lad is Iho COII(.'(:I Wily .ound and th3tthe fron t of Ihe piston (mmkcd with an arro w 01 11 notch) ,s 10 Ihe fronl ollhe engine. 7 Lul )l'Ciltc Ihe Cylmd,:r \)o,e (photo) and inserllhe conncCllIlU ro d a"d p, ston nsse ",!;ly ,nlO Ihe cylinder !loro up 10 Ihe botlom of the pislon IIIllJ com plessor 8 Genlly hUI f,,"'ly Illp Ih~ l/ls!On Ihrough Ihe piston "ng compressor nllu "'I u Ihe cyhnd er 1)(.1'''' uSlI'g Iho shah 01 a hammer (phOtO) 9 G".""nu~ly luh",c"I" 11,,, ,,"ank,),,) 10U"",ls with engllle 0,1 JII{ltu.n Ille ClI,nbh;,lt so 11\1,1 III" e'<lnkpin 's If) Ihe mOSI advanlageous
POSIIUHl 10' Ihe CO'"1(JI:I"'(I .ods 10 il(! dr l.w n \)lIto" 10 WOlle !:In,l n rhe cOIl''''CIi''U ,ad heillOflU Cilp ilild hack 01 the 5 1 he<lIlIl\J. ,IIId f'llhe Sh<..'11 henllng III pos'1I 0n ellSI""'U Ihilt lho local '
10llHue ill lh e b<lck olthe hClII"'U cIlU"ges w'lh the locating groove
Ihe cO""OClmg rod Cill) 11 Gcn e.ouSly lulmc,lI e Ihe shell h,)IHIlIU ,lIld oller up lhe conncct' .od bCil''''U cal> 10 Ihe connect,n n rod 12 Ret,n,nu the cU'U1eCtlf'H lod lillIS, 13 Tluhten the nulS w.lh a 10f(lue wrench 10 the sllCc,hed SClling 14 When "II Ihe p'Slons i1nd conneCI",u ,uds h,we b(lcn filled. rO I,' the Cf.1l1ks hillt 10 check Ih"l eve'yl""'u 'S Ilec. :Ind Ihill Ihere are' hiUh SI.>OIS cauSi ng bUl(llIIg
30 Oil pump -re fitting
Ensure the l1lillmg lilces 01 Ihe 0,1 pump ;Jnd Ihe clankcase n cle'lIl . 2 Inse.1 the hexilgo nal 0.1 pum p drivesh"fl wilh Ihe pointed en lowil,ds the <1ist"bulor localion. The SlOP washer (photo) must IJ posil ioned 127.5 mm (5.020 in) foom the lounded end 01 t h driveshilll 3 FII th o od pump 10 tho cfankcose and secure wilh t wO boll "9hle llcd to Ihe spec,f,ed 1 0'(lUe N ote: When a flew or overhaoled 0 pump is bl!illY IiI/cd. II should be /illed wilh enyine Olll1l1d lurned . b hand 101 om: comple/e ,evolution before being fil/ed. I his will po"" /he plm.p
3 1 F lywheel and clutch _ refilling
1 Fir Ihe engino IIdap lol pla le on Ihe twO localing dowels 2 Ensure Ihe milling faces of Ihe lIywhc(;1 and crank shaft arc cleal
,lnd fit t he flywh eel 10 tho Cliln kshnll. aliUn",U Ihe nla,ks made ii' (hsrn;Jnthny. unless n ew l>arlS a.e being lilted
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44 C hapter 1 Engine
32 11 TUUHU"' !J the !la~~(:1 "(11ll Ihe sump m.ll11'Y face
33 SIII11I ), wal n r 11111111' and cr<1l1ksh "ft pullev _ relil1inU
Ch!all the 1II:11111U I;ICcs or rhe C •• ll1kC<1!;!! ;md sump EII SlUC rh.,1 till! UrooveS III the su.ll C;1IIIa.s ;lIe clc;on .
2 fll1hc ,ubl)Cf sc;')ls mille !JfOOVCS of rhe seal ';.lrrle.s . Apply s<:;IIIIl<r cOrllJ>ound hcnC:l1h lila cnd~ 01 the ICar su.,1 (pholos) 3 lOCil!C rhe SId e un~kc's Wllh rhen !;Ihs under Ihe CUI 'ouls III rho rubber s(m ls (photo) 11...,1,1111 lh\: !)"~kl!ls wllh a IUlle scalonU cunlJlO""d If nccnss;u y
" LOI:.llulhn ~1I"'p "" th" !I"~~"I~, "",1-,.""1 S""~ rh,11 Ill" holt h"l!;~ ,"" ~111I ah!Jlllld
~) 1"11 Ill" ~1I"'p s"':"""!1 hullS "".I "lIhl,,,, 11\"", 10 Ih" (;Ollllt:1 r",'1"" " ' IWI) SI'\!I"S .IS ~p",;,I"'d "' Sp"t:,hl.illHms ;11 rhl! I",O''''''''!! of It"" Ch.ll'll"
U 1'111<: .... a n"w \FI.,>klll r)1111HIII111111!1 COV", a n d In th .... Wilt'" p"mp "'1 III .... th",,""o~I,u alit! th'llIlI()~t, lI IlOlI~III!J. lutCI to Chapter 2 Fit Ih'l " "n wahl' ,,'how IU\lII IIH)' Wit II n ne w !J.I~k", ., Coat th .... C ';lIlksll,'lh pulhly wasil .... , wuh ~nahll(J COrllp(Jlllld F it tlU I pulillY. w,.shur illid sUet""'I) holt T,!)lIlun Ille holl to tl)() spn(;tr"'d 10ul"e (phulo)
8 tocate t h e 001 coul .... , Oil til() cylllldu, hl()( :k . IO<J {"II(:r w'lh n 1l"W SI';. I. Ihcll "IS!),' "", ~h'(:VII,lIld " 11'11"",, Wll h thc cuolC! p'pes IIIIUI"d ,IS ~h()W'1 nl F'II 1 G
F'g . 1.5 Correct t im in g geM IllMk alignment where the crllnk shaft ye.., h ;)s two m..,ks (Se c 32)
l
Fig. 1 .6 Oi l cooler fitting angle (Sec 3J)
A RC.lr f.1CC of cylmdCf blOCk
32 2A F'tilllg Ihe rubbef se:!1 to Iho IlIllIng cover 3328 Apply s(:.llul!) compound benenth lhe re.ll rUUb!:1 s!:,,1 333 lOCJIUlg the SIde g;)skct IJbS beneath Ihe seals
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Chapter 1 Engine 45
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)
33 7 ApplylllU se~lInu COIll I)(IUlld to the unnkshnlt pulley wash"r
34 Cylinder hcads. rocker gCM and inlct manifold - rc lin ill(j
Lubricate the valve tnppets wllh cleiln cnUlIle otl ;md Ulse,1 th,,'" It! th o cylindcr block. Ensurc they ille fm"d in thei . OIlDlIlal tOGillrOIl~ 2 EnSIHe tha t the mnllng lilces of thc cylinder hlock ilnd 1he cyllndel h~,lds a.e clean, 3 Position the new cylrnder hCild \I,1skets over 1he \Julde I>ushe~ on the cylinder block. Chec k thm they ilre correc 11y locilled The n!Jht ilod 1, ,11.hnnd gilskets il,e different TIl(: onskets ilrc rn,lrke d FRO NT TOP (pIl Ol0S)
!
.'
/ . .-,,~ .. ~
Fi(J 1.7 T iuiltening sequence fo r cylinder he<ld holts on the 2.8 litre enuin e (Sec 34)
,1 C,l rel"lly lower thc cylrndc r hcads 01110 Ill" r:ylorulcr hlock ,'r1d ht lir" h"IIIII'!1 d"wn holts willch should hc !rrr,1 io!Jirliy ollr:d 5 T'Hirlt;1l tl,,: holts. ttl th" ~"qllp.llce shown 'Il r-'!l 17, '1l1he St,l!JCS as ~pe<:tlI"d It) Spf:clhcaltOllS (phOl0) G Luilrr""I" tile plIshrods wIth el1Uine OIl and Insp.rl them til the <:yllluh" hlock 7 I'laen Ill<! 011 $pl<lsh shIelds In pOSl\lOI1 on Ihe cylInder hC<l<is <lnd ht the rocker shi,fJ <1ssernblres . GUIde Ihe locker <lrln mijllSllng screws IIlIO the puslrrod sockets (photo) 8 TI\jhU!1l the rocker shilll secllfino bolts prO\J,ess ivcly to the
specrfred torque (photo). 9 RelIt the ,nle l l\\al1llold 01<; descrlbell III Ch,lpte' 3 1 0 Adlll~;1 the valve cien,nnces <15 desclllwd In Sect Ion 35.
~4 3A TIl(: dlfferencc hClween the left nmt ','Ilht head gnskets The ""OW mdlcoltes
. oot 3438 CyJrnder head \1,1Skt:1 pOSrilon
rnarkinos
•
r.
/ 1':' .j I
, I • 1 ... , 345T. h ' , __ ..1 I!., u U lco"I\I 1he cyhnder head bolts 34,7 Guidlfl~J 1he roc ke. ilrm il<l)\l5t1l'g sc rews onto the pushrod5
3 4 8 Tightening the .ock !:! shnit bolts
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46 Chapter 1 Engine
35 Vnlvo clearances -checking lind adjustment
Adll'S 1 the inle t Jnd c~h"ust villvc clcnrnnce s when lho engine is cold, he lween 20 <Inc! 40'C (68 i1rl<l104'Fj. Clear,1nces ille impor tant II the CIC;)IilIlCC is 100 !J,eil1 the v,1lycs will 1101 open as fully as they should. They will ;lIsa open 'ille 1111(1 close early. Ihis will alfcel the engine perform,mec. IIlhe ch!"'anccs arc 100 smalilhe valves mlly not close COnl l)lelely which could resull in lack 01 compression and ve,y soon. hurnt out valves .md valve SOillS 2 When tummy the cngmc dUflng valvo clearilllce adrustments ,llways 1l11111ho cnuulC ulthe duoel'0n 01 norlll;")1 10\<lI;on hy means 01 a ~1)illlllCl on the puliey nul 3 Tt"" tht! cnyulC imd <JlIgn the C!llnksh<1ft pulley 111;l,k With tho O'I11",k on the 111111111) cove. 1 If Ihe c.,lnksh.111 pullev IS 10t.1ted Unckwn.ds ,lilt! IO.W,l.ds sl'ghtIV.
th e valves 01 N o 1 or 5 cy lll1(le l Will he seen to be rocking (the two lOCker .1.ms movlI1(J '" oppOS'to tlireCt,ons). If thc vlllvcs 0 1 N o 1 cylinde • .1IC lockll1~J. ,Ol:lhl the CI:lllksllol ft th.ough 360' so thl1l those 011 No 5 cylinde. ,lie ,ock"'!J 5 W hen the vlllves oj No 5 cVhnd':I :lre In thiS position. check the v:llve cle.1 .. lOlces 01 No 1 cyhndc, by IIlseillng a leder gnugc 01 the
S llcclfled thickness hetween Ihe lock e ' ,'1111 :lnri the vnlve stem. ArlluSt the cl("II:lncc. It necess,"Y. hy hlmong the lOCkCf null ndJushn!,l screw 1011111 the speCified cfenlnnce IS obtained (1Ih010) Inle t nnd edlo1u~t v;,lv'~ cle;IIances a.e rh(/.!.ell\. 6 II the engine IS now IOt,~tcrl '/301 II hun the v.1lv .... s 01 N o 3 cvlll"l!":r w,1I he rockul~J ,111<1 the v;olv"s 01 No ,I CVlll,!s,!r r..1I' he checked ,lnd I1dJus t()d .
7 Proceed to ;"Idlust Ihe cf":II:II'CCS .1I:COrdrn\1 1 0 th" '''rnO o!(ler ;"IS lollows. F,U 1 .8 shows the cvlOildel IHHllhe.s "nd valves Irsl .... d OIl tllell eou eer o.rlcr. wo,k",U Ilorn Ihe llOlIt 01 the engone .
Valves rocking No 5 Cldimler No 3 cylm(lcr No 6 cylmticr No 1 cylll/tier Nu 4 CylllltilH Nil 2 cylll/tie,
Villves to ndjust No 1 cyltll(lef (ill. ,'x) No" cyllmler (III. ,'x) No 2 cylm(lcr (ill. ex) No 5 cylilltier (cx. ill) No 3 cylmdcr (ex. IiI) No 6 cylimft'r (ex, ;n)
8 r-11 the rock er COV~!' U,1skcIS ;IIHI rockc. covers (photo). T 'Uh ten the S(!C'''rI1 !) holts to Ihe speCi fied twqllc
~:j?0
ex-0
(;\G-in
~G-E'X
r:\G-in
0G-E'X
ex---{) 8 4 G-in
. n 1
in--v FRONT "'""
of
Engine
Fig. 1.8localio n of inlet <HId exhaust valves (Sec 35)
" .
l
I
36 Engine anciIiMies·· ref itting
Rcle' 10 SCClrOIl 8 "ud rul,t the Irsted COllllJor""'t~ \Vllh rele,erlce to Ihe Chaple,s mtl'C,lh)(!
37 Engino -refitting
Rcf,wn!) the cngrne '$ D reve,sDI 01 the ,emoval procedure given or Section 6 . hili III Ddd,uon note Ihe lol/owing pOin ls
(,l) (b) ,oj (II)
(c)
Llyfuly (frc,lSC fhc yembox illfml shaft Ch~'ck 111,11 /h,· clulch rcle,'se ,11m IS correctly loca/cd AdIIlS/ Ihe CfffU;h C,l"'C as (Iescfibed til Chilpler 5
Ad,US/ Ifle tcnSfo n of Ihe powef sleell;IY pump ilnd ,,1/emilIO ' "nvd1ell(s) ,IS (/eSt'nlwtilll CII,lplefS 10 alld 2 respcc/ively Fill Ille COQIIIUI sySlem (Ch.lp/er 2) "1/(1 powcr stecling SYS/VIII (ell"!!I,.:, 1 0). Illen I,II/lic Cflgine w,III 011 (Scc/ioil 2)
38 Engine -in,t;"l stMt 'lIl) ,,/ter major overhaul or rcpnir
M"ke su,e thai th.:: h:l1tc1y ,$ fuliV cha,u.::O '!IId Ib,"" alliub rrcafl tS coolant and lucl ,lie '''III''''',sl,..,,,
.... ~ __________ .................................. r
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Chapter 1 Engin e 47
--;; ble chec k ~II littings nnd elcct"cill connections. Ensu,e thnt the 2 .,",or is correctly lilted ilnd Ihil t Ihe IUnil,on tlmmg StJtlC Selllll\) 's distrlU
I CI , t II in doubt Ie el 10 1npler . eorr~~ ~10VO 1110 SPJlk plugs nnd the '- ' conneC lion from Ihe 1\)111110n 3 '1 Turn Ihe engine over on Ihe st~rler motor unlil Ihe 011 pres~!II{! co'· . light is e~til1gu,shed or unlIt 01' pres sure IS .ccorded on IIl{!
warnu"lg . d I This witt ensure Ihill Ihe engme ,s no l Slarve 0 0,1 dU"I1!11he g~~ge,. I,w minules running alte. IflIlJ.1t SI.:lrl·Up. The l uel syslulll W Ill ,,,toea . I· • be p!"iOled dunng IllS ope.atlon.
: SOReconne<:llhe '_ ' conneclion on the 'IIn'tlon co,1 and ,elll th e sp.:llk
lugs and loads .
Stilrl .Ihe ~ngme .. ~ AS soon as Ihe engme Ilfes and .uns. keel) ,t gOll1g ill il lilst \lckov(;.
nl (no las te,) and bring it up 10 nOlll1nl wo.kong ICmpernturc ~ ~s the engine WilflllS up there WIll lie (){I(I smelts nnd SOfll~ "mol Il
hom pariS getting hOI and uUI.l1Ing olf all (leposIl5. The Signs IU luok
10' arc l eilks 01 w<l!er or Ol!. which WIll hll uhvlOus If SllrlOus Che(:k ,d~u he exhauSII)ipe llnd I1lJI111old connections as lhese do nOl ,lIwilY s Iond :he
i•
exact gos liUht position unlil lhe w:1I1l11h ;oml vlh!al'On hiwU ;I(;t,," on Ihem, and il is almos t CllrWU1 th.11 th(ly WIlt ncrHI I'Hhw1l1l1H hllth". Tills should be done. of course. wllh Ihe C"( ,,nc slopped 7 When nOrmal running lefllJ}Coallll e hilS hecn .cnch",<I. "dl,,~t th" l"'OiflC ,die speed as desoil}Cd In Ch.1ptc. 3. 1 S lOP Ihe engine and wnll a lew ""11,,1,,,5 10 sec ,I any I"l",cam or tool')flt os dflJlP lng out when t he ",nuone oS ~tallona.y 9 Alief the enuinc has run 10. 20 ""lltltIlS .(!move lhe en!Jllu: .oc~e, cove's ~nd rocke r shafts .1nd rllCh(,c.k Ihe tluhtncss 01 lhe cylondc . Ioc.111 boilS (photo). Also check the tiuhlness 01 lhll sums) bolts. In hOlh taSCs usc iI torque wrench. 10 Road teSllhe tar 10 chcck Ih.11 thC Im"nU IS correCI ~n<l Ih"t Ih" enOine is giving the necllss~ry Sl1100tllllr.SS <ind power. Do 1101 .ace Ihe
(lnuine -il new bemings and/or pistons "nve hcen lIlted II shollid he
I' !.tilled as a new engine and run IIl.1t.1 .cducc(1 spcud tor Ih~ IUS I 1000 miles (1600 km).
PART B: 3.0 LITRE ENG INE
39 Gener;!1 description
ThC !lcne'il' conl,uu'illion 0 1 the 3 0 hue enuine is sil11l'nr 10 the 2 8
( \:\.~ ,..d r •• -~~ .. ; ~
389 Recloeck,,'u Ihe Iluhlness 0 1 Ihe cyhnder head bolts afte. ,,,,,.loIlU lhe enu")e fOf 20 'I1In ul('"5
hire nllu""1 d(:~c"hed III Sec(,on 1. Thc Slunillcan t dltferences iI.e .1S follows
(i') FI,'I •. yllll(/vr ht',1(/$ ",'III the combustion cl.,1mba,s itl lila I".~I()IIS (b) Imhvr(/",llly IIIOUlIlCd rOC~t'f ,Jrms illstead of a lockct sitaft (c) W"lvr pump 10C,11cd 011 Ihe ,i!llu of the allgine ((f) DiSlfllmto' ,WI/ orf ,,"1/11' (I,ivell f,om thc front of thc c,lrmllllft (e) ML'ch,mic.1llllcl,Jl/flfP ollcfMed by ,1f1 ccccntric on tllC frolll vllhc c,lmshMt (f) /rr.';" (Ill sC;llloCMCII '" ,1 S':l'olfall: c,ltric, (y) OJ! trltvr IOt';llvl/ on tlw "I}fI1 lef(-h,mrf sidc (If tlw clI{Jlln'
Fig. 1.9 Sectional view o f tho 3.0 litre engine ( Sec 39)
i
"
'j
~ .... ------------------------------.. ~; 灲潣慲浡湵慬献捯m
Page 49 of 205
:as::.w.'q
48 Chapter 1 Engine
110 Routine '!lain!cnanc!!
At the 1I11Clv"ts specifIed III Ihl! ROutlll!! M"inlcni'lnce sectIon in thO !rom althe mil"l).11 cnlfy out the followmg procedures.
ClwlIgc ollgiflO oil. reflew oi/Ii/fer t/lld clean oil filler cap 1 Rdo, 10 S()C\'OIl 2
Check illld <1r/jllsl vMvc c/c,7f<1nccs 2 Rcfe. 10 Scellon 89
TigMt'lI mll;( IlliIlldold hollS 3 RP.1110VU Ihe ;", Llr:"llcr ;unl lI!Jh1cn the Inlet rlIi'1ll,fotd holts 10 Ill" spccll",d ,ollluO wIlh .oleumc!! to Chapter 3. On comple\lon re lu the au deane.
R(JIII.'w Ihe cmllkc'ISf! l.'mission v,Jlve " Ad", In SIl<:\lUIl 7
41 Major operations \lOssi!>lo with (lilgine in car
T 10" lollow,n!) ""'1111 Ot",,;otlOIlS Illay he r.'If.icd Ollt wlthou, ""''''VIII!lllw';!)!luH!
(.,) /r,·", .. vmy .1",1 "'/'/flll!! III!! ,:ylmd ... , "1.'01(1", (II) {,"'IIIIJVIlIf/ tllld "d'I/IIIO (/1<: /ltmll!l 1I,·.ItS (i:) 11,:IIIIIVIII.'I.IIItI,dll/III!/ /IIt] I!II{/IIIL' 11II1I/11!""I1/III!I~ (II) III'II"'~IIIY .",,1 "-'''/lilly/he Im!lIll~'I!It];,,""" ",;" "'111"'/"'.'1 (,') /{"/IIIIVHI!I .mlf ,,-,"II"'II,IIt] (;;/II'S/l."1
42 M" jot Ollcra lio ns requiring engine removnl
The followll1~lll1alm ope"II'OIiS may be c,lIIlI~d OUI allC! ,cmoval of Ih" !!II!I"W
(01' /r,''''''''''''! ,mlf ,,:III/my llit] fly"'/md (b) 1,'I;"""'III!I ;lIId 1I:"lIiII!! lIlt] II.'''' "';1111 '''.·;IIIIIY vII sl~.ll (,;) f,',:/lWVIII!1 11",1 ,,:hl/myllll" ,:,.mAr:;,.w stlll'p· (,I) 11,·wIIV"'!1 .md It"/tflmyl/t,) 1.-"/II,,.t:I"'!1 tOri 1t~·;"'''!1 (,.) /1,.",,,,.,,,.'1 .md II-,!t/lmylll,) ,,,sl,"'.~ .1111/ ,;ullltL'd"'!1 IUds II) ".,.""",,,,.'1 .lIId tdll/myll"-' "II /lllillfl (.'/) f'"'·"'''V''''f ,11101 td'IIIII,,'''t] (I.mAsh .. ", ;/lul",;,,,, ht];mllYS fli) J,',·IIU1V'It!l .1111111.'1t1/1II!I fl,t, C,lll/.f/"dl 1141.<111."5
A lth""!lh 'I'~ 1)(,·.~d,le 10 1(~II1()~clhe SUI"P W'lh lhc C"gllHlII' the ca'. I! IS 1(":o""",·,,~I,,d thai 101 ,Illy ope"u,olls wh'ch .elt""e Ihe .emov,d 01 IIH: ~""'P. ~,,<:h ;,~ the ,eOllov,ll nf Ihe CI,'nksh;lfl alllll"o c!l(II)c<I''''Us.
tl,,: ""!)"'" ,~ '''''''IV'·!!
43 Mctho(ls of engine removal
The ""!I""~ 'n"V he hfWd oul e'the. 0'1 us own u. III u."t wuh Ihe I""'~""!>~'{)" On I1lo.I\lIS l'I1t.'<I w'th ,1UlOm"toc 1'''"S''Hss.on 1 . s ",co"""""d,;d Ih;,1 Illc ellUlile he hfled out on 'IS OW". unless <I ~III'~IiIl'tJ;" <':I;'''£, or o~ .... ,hll"d hO'SI 's <lvn,lnhle, hecolu~e 01 the wc'ght f, ,<:IO' II Ih" ''''u'"e ;lIu t 1"I"S""S5'O" <I.e .emoYcil as a uIHllhey have W hI! hf!Loti o.n at " Yery Ml'Cp il"UIC. so mako sure Ihill the.e ,s stllI,cuml hrl"'~1 "'-"0111 nvndalJlc.
44 Engi"e -rcmoval
Open imd p.O)) up Ihe bonnet lhen covel Ihe w'ngs w'lh CIOlhs. o~ <:n.(l11O.1,d. 10 Il,olecl Ihcm hom scr<ltches (luling Ihe subsC(IIHlrH O)le(,ll'O"S '1 Millk til" outline of Ihe hOllllel 1""IlCS and 1hen w,th the help 01 an "ss,stim l. ""nove tl'l! 1o". lK.ln'll! se'l:Ws . ,t;l lIilse the bonnet stily and e.udtlllv hl l tl'l: lmnnet cre", 3 [)'~CO""l:<:t Ih(: l'il1I .... 'y lends. tIllT10ve Ihe hnlln'y clilmp bOlt <lnd hfl
II", IJ.,U",v oul <1 fle,l/oyu lhv ,II' cle<ln(!/.
5 flc"'ovu 111,· ~pl.'~h ~h,(;ld hy "''''<1VU'H II", hlllt~ ,1,,<1 cI'p~ 6 PI,lce ... ~:Il"I.I·nf" of 10 lot", 11"16 JI"'I) r:,'I),II·, tv ,,,,,Iu.,,, !,
'iI(I'<lIO'. ""novc Ih/"! ""h:OIO' hun",,, h"", .1,,,1 ,h"", th" r.Il"I.l,, · 7 RcmfJv,~ Ih,' "1'1)1" hll~" I,n'" Ih" ",";,1", I''''''P n'·'I1"~" Ih, 110m Ihl) all d,,1I,·I.I,,, pa" .. 1 ""d I""" lh" ,;"""t,,, ~h"",,1 ;'"d ,.
Ihem
8 flc"'"~,, Ih., I",,, hllll~ ...... · '"II'!I th", """.11',, til Ih" '''UII Ila" hfl Ihc "1(10,,10, ""t
\) D,sc""''',,:1 Ih,· ',,11 w",.·, hm,,, 1"111' Ih" w"tt·, 1"""11 ;",.t a"I, cho~e
10 fle"",,,,, tht! -l.lI"·' ""'10' h,·;11 ~h,,'ld .11,,1 II"·,, ,I,,, '''''''·'·1 tho I,om Ih" ,,11"""'\0 " t'·IIIt"·'."'"'' '.""d,·, 111"1. "1"'''"11 1./,,1 ;111,* mOIO'
II R"IIl'l"" Ih,· ...... " huh ... "''' ~""'!I th.· 11""nl,· h"k"!IU I,
aSS(lmhly to Ih" .1\1<'1 ",.",,1,,101 .lIlfl "·"If"·,, It Ipl'Il.IIt 1 2 fl'''''<l~'' Ih,· '" .. I .. Il'· ... ""101 II,,· 10,,·1 1''''''1' (plo(II"). Ihe,
vnCll"Ill hn,." I",,,, Ih,· ,"1,·1 " .. ",,1,,101 .",,1,1,,· "oJ )."· ... ~II"· I",,, fll. conn,-ct", .11111 , .. I.· ... t I""" tl,,· .,,1 IW""";'" '" .... ,,,,, 13 R""",,,,, tl", •...• , 1",l b ""·"""'!I Ih" '.1.",,·, "",r,,, .""t ",,,,(,,. 14 flell1""" Ih,· I.\() """ 10, 01 ..... ·"'''''·''1 II,., ,,,hi,,·, """I.'I"'~ III, en(Jllh1 """,,'I"'!I' 15 RII"'(J~" tt,,· I.'." ~"'I~ f""" '·.11 h ,·~h.""t n.",,),· ,11,,1 ,II".,,,,,,, e~h,'"~1 il'l"'S ),'"'' III" ,·~I,.".,t ",.""f',lel
114 12 Fuel j)1""p ". d 1,,0;1 I,"t;
I;" ,
1:-,
!
~ ,
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Page 50 of 205
Chapter 1 Engine 49
----------------~--~----------------= anuill transmiSsIOn models, remove foul clops <lnd remove Ihe 16 On h(11 sing cover . On ilulonHll lC tr"nsmIS~lon models dIsconnect Ch.llCh au lug the 011 cooler hoses. and P It the Irans!1lI$S10n then remove th e l'illlsnllSS lon to-engine 17 Suppa <
bolt~ n automatic 1.,J;lsmission .models. drilm the torque conve!ler ,\Ild 18 Ihe drivep l<lte boilS wllh ,clerence 10 Chnpler 6. UO~~~~ Ihe weight 01 tho engine on thc hoist ilnd then pull tile euuin!} " d \0 separJIC;1 1'0111 the \'<lnSIllISS'OIl. 0 " [lU10111<1(1(; IlilI151"'5' 10' ..... 31 , I
. odelS make s"re Ih,lt the torqlle converter ,em,,!!)s lilly 1f1 1he $lOI1 m transmission . 20 When the engine hilS been SCpM,lICd from 11l(l 11.,11$1111551011, 1,lllh!.! . ,lowly chccklll9 j,equently to see (hMllle CflUllle does not loul " ng,ne . ~nv part of the bo?ywork. 21 W hen the engUle 's cle,lr of the iJody . lower it to the ~lfOun(i. Of
Ir~nsler it to a WOrk lJench
4 $ Engine disill1lotling -generill
Refer \0 Sec t,on 7
46 Engine illlcillilrics -removi\1
..
1,',lh the engine sep,l rated from th" t r;IIl~:nHS~r()" remove Ihe ~.tcrnally mounted componelliS ;l~ lulluw~
C;J//)Ulello, i.lnd fllcl {lump (C"'1!,lt" 3) IlIlel ,wll exhiwsl tII,wi/a/ris (Chaf!/t't 3) Sp,>r/( plugs and drS/fllmlor (Chaplet 4) AllCllwlor (Chaplet /2) F.w ,7I!d policy (CII,71I1C' 2) W.JICf pump ,wd Ihcffllos/.1I (Clmp/t't 2) C, ,1IIkc,lSC vcn/iliilion lubc 011 {,f/CI (Scc/ion 40) Ol/Icvl!! r/rpsllc/o; and {,/lCf C,?!, [II!1int' 1II01tn/ill.ll h,.1r:kvls Ciulell (Ch,7/I/l'l 5) Powl'r S/Cl'l/IIN 1'(11111' (Ch;lll/Vf 10J
<11 Cylind(Jr heads relllowti with engine in car
I
Q,scunnecllhe IJiltlery le,lds ") ~cmove the splilsh slucld. by renuJVIII<j 10\" holts nnd luur chps J II.lee il cOrltilm er 01 10 Irtre (I·' 6 pint) r.ap.lr.lty unde!l1e,Ilh Ihl.! ~"lr.llor. remove the rmll:l\or hallam ho~e and drilill Ihe system Rr:rnove the rad "l\()r lap ilose . !l Rcrl10ve Ihe au Clealler. d'SC(lnner.t lile h,el p'pe fro m the ~MI;;"rllor and Ihe l"e,lIiler hose hom Ihe rocker cover.
, R ernove the servo V,lCUlUl1 hose I<om tile Inlr:1 l11illlllold ~ enlOve Ihe IllIe e bolts and rem!)ve II,e Ihrollie Irnkaqe lI<ilC~l;t .omllic le wo1h Irll kilge '
~ DI~conrlccl Ihe rilll,.llul hose from Ihe ilulomallC choke D,s·
,onneCI the vac\JUnl h"e I<om cariJU!l:1I0r .
• D,sconnect" I I I 10 0 le ea( <orll Ihe lempelnllllc sende< Unit.
co I I~con"ecllhe HT ICilds Irom the spark plugs and IrOlillhe Ign'llon I ,1od remove Jlw L T I I I I .
MId I I If . CiI( 10 lie dlSl1i Julor Reillove aile h Xlng bolt 11 0
' I
a Ihe dlst"I>[1I0r ilSsemlily.
'Sconllect Ihe all II 51 halts' , ' ernillOr Cil) es. ilcken the ailelllntor 1110ul1l11lg un( <emovelh~d b I hi· '" ... live C I. I en remove the fllCrnfilor h XlIlg bolts rernove the ~I' . 12 R " erniltor ')nd liS I,x,ng lIrackel. CIlIOVe Ihe Spa k I cOvers d "p uos. Remove Ihe IIUIS secufII1(.l Ihe rocker 13 R an hll 011 tho covers. emove the I I I . . mlel III f IVC '0 IS sec linn\) the onlet lII,1(l,lold and take 011 lile 14 l an, old complr:te Wllh ca<lIurello, OOson Ihe rock turned a ·d er """ .ldjust"'g nulS ulI\ll Ihe !Ocker arms can be ) hoe Or SI CI(F'(J 1 10) Ihen rCOllOV!.! Ihe pushrods ilild lily them oul Itl PO,ition l~llS I, lill.!1[ finds through a sheel 01 paper 011 which Ihelr III I Ie ("",II,e . I
Pusil rod . C,II1)e "Oled. 11 IS very Imporl<lIlI Ihal the IOtnOVCdS .1<0 r(;f,tted \0 Ihe same villve as Ihat from which they were
"IOC>! "
Fi~,. 1 .10 Turn the rocker (HillS to olle side 10 relllove the pushrods (Sec 47)
15 n,,,,,ove Iwelve lIolts ilnd delilch Ihe exh,lusl I1\,lrlllolds frOI" Ihe cylrrlrtr:f he,lds. 16 Sinckell the cyhmter hend boilS progressively in the revtnSe order to Ih"l shown ill FIll 1.19. IlcrllOVC Ihe bolts nlld hit olt Ihe cylindOf head.
It lile (.Iilsket has stuck and the cylrnder heJd cannot lJe lifted off. wp the cylinder heild wllh n hide·f.1cert. or plnstic·headed hJmmer. 00 nOI try to pri se IlIelil off wllh a screwdrivOf Of rtilillage WIll result.
4 8
Cylinder he,l(ls -rernovfli wilh engine O\lt o f car
Follow Ihe sequence (.I,,·elllll SectIon '17. 51;lItll1g.l1 PillillJl1lph 10. dl$lcoa,d,n!1 leil.!lellCeS to pa'is willch hJve alreildy bcen rcmuved
49 Villve$ _. removal
Rt:rllove the d('POSIlS /'0111 tire corllb\lsl,on chambers ~nd vnlve
h eads by ScrilPIl1!l and W" ~ b'\Ishlll(.l Tilke CJre nOI 10 scratCh the cyllnde, he~d gaskel lilces 2 Lay the CylOl(ier hemt on ,IS sllll) .llld h t the lo,~ed cnd of .1 VJlve spllng compressor ove, the ~plln9 rctiluler ""d ti le head uf the complessor screw in Ihe cenl'e of Ihe v"lve head 3 Compress Ihe sprrng abolll " qUJller 01 an Ulc h 10 Iree Ihl} split colle l hom the top 0 1 the v,llve stelll. If Ihe sPltng ,eliHner "nd collel Slicks. do not screw the co",p,essor down lurlhc< . bec"use IIIIs lII.ly dJr11J\je the valve Slem. bUI lJp the sprong reliluler sha,ply wllh a Ioghl
hammer. 'I When the Iwo halves of Ihe collet h')ve been '(:nloved. onscrew the spllng compressor umrl Ihe spring IS no longe, compressed nnd
remove Ihe compreSSOr . 5 f1Olllove the spltng retnlner. the spflng and the oil seal from Ihe villve Slem. Ihen wrlhdrflw Ihe villve from I he cylinder head. 6 D iscard the valve Slem all senls and plflce Ihe Olher componenls to\jellrCt. identilying them so Ihal they arc refItted III the correC I plnce
III Ihe cylinder head. 7 Remove Ihe sp,11k plugs from Ihe cyhnder hend. II nOI alrendy
removed.
50 Rocker arms -removal
1 Remove the SIIfI nul from Ihe foch" .1'111 Illoullt,n\) stud 2 Lift off the rocker <Hill b')ll seiltin\! and Ihe roc~er Mm and Iny Ihe tl1<ee parIS 10<jethe r II IS ImpOrtilllt Ihat Ihe locke' arm. its hall SCJling and nUl ale refa ted \0 I he snme stud as Ihe one 110m which Ihey were
re moved.
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Page 51 of 205
\.
50 C hapter 1 Engine
51 T llp pcts -removat
Remove the 1<lP11C1S I.om their bores with ,1 1ll1lgnct "nd pl,lee them ,, 11 r,lek in sequence. 2 If (lny <lIe (1I111cull10 remove, .ot.:l1C the crnnkShilh. willch wIll Ciluse the cilrllshilll 10 lurn lind move the IilppclS 10 ,elcilse them hom <Iny
!.111m "' thell bores.
5 2 Crnnksh<llt pulley -remov al
Prel/cntlho CJ,lIlkshilf l hom 'Ot:ll111(J. by lillllmUl!J the flywheel,' the (jl1nin.! 'S 0111 01 the C;1I, o' hy 10ckll1\1 Ihe transmIssion ,I the cnOllle IS 51,11 III the Cill . 2 Rclcilsc the p"lIny boll hy l,oUlU 1l '111\1 511.11111C. ;'Ind rapptl1\J the sp,lnnc. ShiH ply, thon remove Iho holl ;1I\d washer 3 Usc il S I).ockcl pllile. 10 (h"w the pulley olllhe Cfilnkshall. Do not ilUOl1lpl 10 lever II oH, bC(:.lIlSl; the engllle [,onl COV(II IS j,aulle ;111(1 Icvcrn'H ilU1l1l1S1 11 Ill;)y (11510'1. or even InC.11; II.
4 Wilhdraw Ih~ Wood'uH key hom the end of th(! CllInk5hah and pl,lC,(! " w'lh Ihe pulley. til(! holl alld its washer 5 The C'.1nk~h;)h p"lIey m;oy he ICliloved wilh Ihe eno,,,e III Ihe C:\I. hilt ,I 'S IIIsl tU!Ccss;o,y 10 ,emove Ihe ',ld'illO' :lI1d thc rh'vehelts
53 Flyw heel -remov[ll
P,even llhe flywhcel hum 101m",!) by FHlHllln\J Ihe lin!) !lcal ;ollain~1 ;In imp.ovised SIOI). 2 On nlodels willi nl;lnu:ol 1I;o"$""S5'01i. Icmove Ihe Clulch plessure 1)1;lle and disc :os described in Ch:op!Cr 5. 3 Rele.lse Ihe s,~ bolts secu.in!1 Ihe flywheel 10 Ihe CllInksh;oll .lnd lefl\OVC I,ve of Ihenl.
4 Whilc supporling Ihe tJywheel III pl;ll':e .• emove Ihc Sixlh hoi' ,'11d Iolt Ihe lIywheel otl c;o,elully. so 111:01 Ihe m;lllllg su.lilccs of flywheel [lild c.;onksh;oit ;o.e 1101 dllm,'ged
5 4 Sump -removal
W"h lhe '''1(1'''') oul fli the e,". CII~"'C Ihal Ihe sump has 1o('CIl d,amvd ;ond then lilln the engll1C ()VCI so tl1011 Ihe sump's U l)I)ClmOSI F" wOOr1CII bloc"s tn Slll)lmrl tim en!l'ne 'n Ih,s POSIIiOIl . 2 Remove 11m h()IIS seCUlln( J the oil Sump 10 Ihe CI.1nkColSe o1nd rClllOVO Ihe SUll1p_ 11 the sump IS stuck 10 the c r;ollkcasc . II should be reh;lIsctl hy 1"'SII1\1 olle SIde wllh 11 sClcw drover. 3 To !Cn,ovtl .Ile sump wllh Ihc CIIU"HJ Hl tloe eM. 11151 IcnlUVC Ihe
d'l)S llck :ond d'SCOIlII(!Ct Ihe hatlery 4 Remove Ihe luur holts ;ond lou. Ch,)S ;ond dCI.leh Ihe OIl splash
shIeld.
5 Pl;oce a Con'"lIlcr 01 at lellst 6lttre (106 JlIllI) cal,,-.elly heneath Ihe SUml). remove Ihe d,ain pl\l(l ;ond d,aln Iha sump. Reflilhe d.am plull and (11)hlen II 10 Ihe 10lqUO wrench seilIng gtven In the SIXlClflC;JIIons G Del:och the engme fubl)CI mounllngs, by lemovlng the" nuts an(1 w:oshe!s. 7 Romove the ciampinI) bolt hom the tal) ;oml bOIlOI11 endS 01 the Steellll!.) intellnediate sh(lil. rush Ihe lap end 0 1 Ihe shlilt upwollds unlll Ihe lowcr ell(1 Clin be dlsenga\led 8 PI<lCo:o jack undOI Ihe lI;ol15mis5ioo nnd use II to HlIse Ihe engine Slr\lhtly.
9 Remolle I he Inur boilS securing Ihe fronl anlj·roll har to the Slde·membei (lnd the l()ul boilS securing each engHle mounling blllckel to .lIe sidenlCmber. 10 Remove the 011 sump Imlts lind I I the sump hns sluck to the crilnkc;ose .• elellse the sump by press ing 'I sideways wilh a screwdriver.
55 FrOllt cover -removlll
If Ihe engHle IS In the CM. II wllllnSI he necessaly 10 dlsc()nneC lthe l!allefY. drll'" 11m coolll1\) sys tem ;ond lel110lle Iho radiillor. 2 loosen the alternalol mounllrlg bOilS. SWlrlg the aitemalor downwilids .0w:Olds the cyltnder block and lemove Ihe drive belt
3 Remove the bolt Irom the cenlro of Ihe cooling Ian .. nd pull (
Ian and clutch assembly. 4 Remove Ihc boil an d wilsher from Ihe centre of the cran pulley .. nd I hen use ., claw puller 10 drilw Ihe I)ulley ofllhe sha nOI anempllO lelle, Ihe pulley ott. t)Ccause Ihis may .esull in dllm. t he Irani covcr.
5 Rcmove the si~ bolts secuung Ihe sump 1 0 Ihe honl cover an, t he cleven bolts securing Ihe I ront cover 10 the Cylllldcl block . G lIlt Ihe cover ott ;ond remove Ihe g;oskel.
5 6 Tillling gears -relllov;ol
1 Remove the honl cover 10 e xpose Ihe IImlnu ueo1/S 2 Removc Ihe bolt and washer sccu"I1IJ Ihe fat!Je gear I,
cn,nsIl1'll t. IhCIi pull.he geill ol! and Icmovc tho Woodllll! key. 3 Dlllw the ileal hOI11 Ihe cr;onk!;h:oh am! remove Ihe Wood'utl
57 Carllshaft -r erllov;ol
The camsh:olt nwy be rCUlovfld wllh the cll!JlIle 1<1 Ihe car •• lollowlng p!Cpol.aloIY wo,k IS co1med out. 2 0,,,,,. Ihe cootong syStelll nnd .emove Ihe .ad,mOl 3 Dlsconneci the ballery. 1 Remove Iho sp.1lk pili!! IC.1ds 1,om Ihe spalk 11lugs. 5 D,s':Ol
eCI the le;ods I,ull' Ihe :l lt'!11\.110r. remove Ihc allelllalo·
l i S (hivebell. G Undo "nd rem ovC tho screws S()CIIIII1U Ihe .0dcl covers and It Ihe rocke. covels and Iheir ilaskcls 7 Sincken lhe nulS secullnu the rocker ~"ns unlollhe locke' arm, he swung aside . 8 Remove the pushrods. idenlllylllg each one as .. IS lemoved. so 1 Ciln be rell1l ed in Ihe same position 9 Remove the cylmde. heads, <IS doscllbed in Sec l,on 47. then Lmagnet 10 tilt out Ihe tappels. PI;oce each t;oPI)Ct WIth Ihe pus which il Oper;oleS, so th<ll Ihey :olso WIll he relliled in t lle;1 0';1 POSlt101l5. 10 Remove the Iiont covel liS descrohed 111 SectIon 55. 11 The cllrllslwh pl:!lc IS secu.ed w,th twO cro5s·hc;od counlel,
screws. These cannOt be removed wI,h an oldm;OlY screwdliver ,lily nllempt 1 0 do so WIll resull OIl Ihe sc,ews bemU d",na\.l<:d. I Impact SCfeW(!IIver is nOI ilva,lnl)lo. the SCIOWS m;o¥ he Icmoved w sui l:oblc key lInd the urace 01 a sockel scI 12 Remove t he c.1m5ho1ll IhllJS I !)lolW 011\(1 the space. hclund II 13 Pull the c;omsh;oll lo.ward to wllhdl,1W 'I. 100f 111\1 Cil!e 10 ~ee" Sh,'lllfl Ime. 50 Ih;ollhe edges ullhe cams do nOl rt,1mnge Ihe cam~ beilllllUs_
58 O il pump -r e m oval
Remove Ihe crill1kc:ose sump as ;olleady dcsc"hed 1 2 Remove Ihe boll aUJchmg the 011 scrcen 10 the Illalll 00111.119 (
/ /
Fig. 1.11 Oil pump o n tho 3.0 f itre efluill(l (Se c 58)
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Page 52 of 205
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-• the twO boilS sccurong Ihe 0,1 pump 10 the crankcase and 3 R emov
',.,' . the pump assembly nnd ,ts (roves la I-wllh
drilw
59 P istons, c o nnecting rods and bCilr ings -removal
1/ lhe crankcase sump and the cylinder hC<I(ls ,Ire ,elll~)Yc~1. the ' . .od connecting rods can be .em ovcd with the engulCl In the P '$tOn5 . The bearing shctls
C,IIl he removed wIthout 'CIllOVlllg the cylInder ca l. tle-ads. 2 B efore removing any COllncCllrIg rod cnp, make sure Ihal the r del number IS mn.kcd all hoth Il<lr\s. II no mark'119 IS \'I5lhle, pul " """9 marks on Ihe )0111 he folc IcmovillU 11m buils. mil'n ' " . 3 Tu rn , he CI(lllkS Il<,h lHl\,llhe connect Ill\) 10! )('11\\1 Icmovcr! IS;Jt itS
lowest position . . ., Remove the COI1l1CCIIl1\1 ,ud nuts ilnd pull (lit the [)(lalln!) Cilp 5 Rotate ,he crnllkshafl \liH,llhe connCCllrl!l rod 1)"'11(1 removed IS 111 it s h ighes t positio n thon u~() Ihe h,lndle of ~ hanHller to plr~h \Il"
~ssemblv Ollt of the top of thu cyhnder . 6 W,thdrllw Ihe assemhly frorn the cyhntler ,lIld ptace Ihe hCillrnO C,IP
~ck on the connecllrt{J 10(1. 1 If Ihe be.:uinos rue l>CrllO ",newetl. lelnove the uld 1)("""'!15 hy ),,1I1n9 Ihem lound unlrl Ihe nOl ch on Ihe !J(,,,,rnO ~h.,tl rs tlrsenH<10cd
f rom Ihe lecess on Ihe l)e,1r1"U Se,llrnn 'lIlll Ihen hft the IJofI<1rrtlH oul If tho beJrin{Js <11e lemovell ,,,,d the S,lnm ones ,l.e 1":111111 nsctl a!F"n. illS viMlthat Ihey ale .elillcd III Ihe s.lmc scahnH a ... Ihe Olle I.om whIch
thf.'Y WC.C lemoveli.
60 Crankshaft reM oil seal - rellloll,,1
To !emove Ihe 011 sei\1 wllh Ihe ell!J",e In Ihe ca,. Iusl remove Ihe U<lJlhox. or aUIOIllJItC IransmlSSlon .. S de1;Jlted In Ch<lpler 6 On r"anual 1f(lf"Isml~Slon madelS. II is Ihen ncceSS<11y 10 lemove Ihe clllll:h uscmllly ilS descrrllcd In Chllpler 5
2 Releilse Ihe SIX holts S"",,"IO Ihe tlywheel lI11d remOlle I,ve 01 Ihem Wh ,l o holding Ihe flywheel. fCmove thc slxlh bolt and hll ,Iway Ihc lIywheel. 3 n emove the lour hOlts SCI;""IIU Ihe Orl se;rl C<rllle, <rnd 11ft ott Ihu COrlle, Jnd sell l assemb ly . 0 D rive Ihe seal OUI of Ille ca,.,c,. t;rk"'~1 I:;IIC 'H)I In danl;l\l' : I he I""" 0 1 Ihe Col" ICf.
Fig.l.1 2 R ernovinu the rear oil se al from Ihe carrier
(Sec 60)
~ Crank sh aft llnd main
henri nUs -re rnov.r1
, Relnovc" 2 n Ie CIIIl"I" 1'011 Ihe car . 'J, 3 n emovc the ClelC h HSSI~olhly 011 Illllllual transm,ss,on madels ·1 ernove lir", , , ,
L'
·
.... yw lI.le ;lIld Ihe leal 01 sual cal"er. "/-·H. $'i;:.
5 1
<I Mnke SUfe Ihm Ihe c.ankcasc Slimp has bcen d,amed. Ihen turn Ihe eno,nc III>Sld e d own. chock It sccu<el y and .elllove the sump. 5 Remove Ihe Cfnnkshalt pulley (m(l the engIne Ioonl cover. 6 Remove Ihe OIII)Ump anll Slr,uner. 7 Check thm "lIlho rna", and connechnll fod t ..... a"n!l calIS hnlle theu Ide.u,ly,no numbers SlampCll on. so Ih,1t Ihey c.ln h'l ret,tled III Ihell O "Oll1al pOSlllons . 8 Remove Ihe Cf;rnksh,,1t gea •. n Renlove Ihe two nuts ~nd Ihe healing Cal) 01 eac h connecllng rod
"' 111111 ,1n(1 Illy I")ul Ihe he.1""\) cnps In ord~r. 10 nemove the IWO boilS Irom eadl ollhe malll b(:;IIIIIIJ c"ps. hit lilt)
CilP S all .111(1 lay 1111:111 out'" order NOlll Ihm Ih" c~nlle 111:1111 hcn"ng f.':IP has Ihrll~1 wa~hcfs M;l,k Ihetr POSIIIOIIS hili",,, <ornOIlIIlO Ihem. 10 ellsure thaI Ihey :IIe 'el'lled exactly as lemOved 11 Can:itrlly hit Iht) f.lill1k sh;111 0111. I:Ikln~1 eMe 10 ~o"p 01 p;II.1I1(;1 w,th til,) e .. ,nke;rsc. so Ih:'1 Ihe \I""st hC,l"lI\l $urlar.es of lilc upper hea""\) h.1II11:5 iI,e onl rI"mn\jcd 12 HelllOVC tllo I,,,,"'II!I ",sr, IS ['0111 the cyirml", I,iol:k. her"U cnlolul \() IlUIl: Ihe POSItIon hOIl1 whu;" "nl:h 01 the 10\11 !>..,<IImos "nd e.l(.1> 01 lire IWO th,us t wi\~hels We'e ""Hovod
62 Ellgiflo Carl\l)Ollelll~ -e~iHllil\1ltiol1 far we"r
nc:lm 10 Soctll)" I 1
63 noct.e r arillS -examination ;ond nmovalion
llll) siuds 011 whIch Ihe locke, arm~ p,vot arc a pless 101 Into the cyhllder he,1I1. ,111(1 II .1 51'<1'0101 cdUO IS Inld aCfOSS all s'x. II cnn be seell whelhtlf ;"'y h,ll1e 1>f:\Jull II) pull oul. II Ihl5 IS Ihu case. Ihe stud w,1I have 10 h e I..,1ll0vt:d. Ihe hole re,lllll!'\! 0111 ,IIId ,Ill overSlie Stud hllll(1 2 Check Ihal Iht.: Itucuds on the sluds a,e!ll Uood conti'IIOI1 anll that ~ \IJ'(juc 01 nllc.1S1 59 N", (<I 0 Ihl It) 'S fcqlJllnd 10 111111 ,,;Jell .1dJllsh lr 1111 orl..,d 1111..,:1\) ... IIlhls IrHUH) IS nOl "chlcved. III ,I r,,;w ':Idluslcr ,In.) ,I
Silil dl:lrCIUIlI. hi a locknul to Ihe mlluslef 3 EX;IIWlln 1hll Illeke. <1111l~ ;IIH) IUit;IUIlI snalS 10' S'~lns 1.11 rrdH'nU. 1.1< I:XCtJSS we,ll 1111 Ih'l Ilc;o,'nu $IIII"I:<.'S II Cllher p.lll shows excessIve W"'II. 1".111 Ihe ,",.k.)! ;",n a"ti ti,e 1\lle'IliH sent '''u~1 IlIl .enowcd If When I;hcr:klll\l lilt"! rI)C~,)lS ;UIIlS. 'C"IOVI) Ih,;", one .11 a l"no \0 ,,"mlll(llo: allY POS).Ihllrly 01 ,urllS ,Iud seals Ilct:lJn l,tlH ullerchan\)cti. or Ilelll(l 1.,!I1Il:d III Ihe W'OIl(j ~IIIrI
GIf Tappets ,HId pushra()s -elWlllin alion ;lIld renoviltian
ncle. 10 Sm;trr)ll I 3
65 CamslHlIt ,\lid ca!l1sh':llt bC(H inos -c~arl\il\"tion and
renovation
UlllhHSI~C camshaft beaflflf)S ;1fC ayml.,tJle. so II IS poss,hlo \0 SOlly,IUIl , I waul c amsh31t by rCtJtlIl(lrnO Ihe 10uII1als. II the call1s . or skew gllar. atll wOln stOllllocallll y. Of arc d':II11.10,,(I. a ncw call1Sh.1h
IllUSt be I'lled and thc tJcallngs should Ihen also be renewed. 2 WOlll or dalllaUed c;m,sha1t bearings can be replaced by ncw ones. hullh,s re'lullt;:s spI)Clal tOOls and should llc om,usted 10 il FOld dC<1lel. 0 ' 10 (1 wa.kshol) wh,ch undertakes carnshafl reclalnl'nu
G G Cylinder horus _ eXHl11irHltio n and re nov(ltion
Reier
til S(:Cllon 1 G
67 P is tons and t)isto n rillUs -ellamilwlioll ,lIld renov(ltion
R e
lcf 10 Sectlo" 11.
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