fuel FORD CAPRI 1974 Owner's Manual

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78 Chapter 3 FlIer and exhaust systems
TIlls system, when comp1lrcd with conventlon,lI c.Jrhwctlo, ~rrilngemen1s. <lchicves <l mOIO IlccUl.1te control 01 lho <Jil/fuel mi~l\l,e resul ting in ro(tuccd omission levels and improved prcrforrllilnco . The 'llllln coml>oncms of tho fuel inrcclton system lall into three
tI'(lllPS
A FI/ef Milk Fuef Plllllf! F/lel .?CCIIIIW/<1IOI Fuel filler F/lel ,IISltihular ,w(/ millime con/rol l11ralllc MIlllll/ce/Of "',1/1'115 AI( ch.ll11/"1(
B W<lIIII 'IIIJ wyu/,1/()r AIIII,{Wty .1;r (/I:VJc.' Simla! ",MH' 7 hCIIII<J/mifi SWitch
C Wilil/[I Hd,.ys SMt'ly SWitch
The fuel pump IS 0 1 eh,CIIICtllly operated. ,aile. cell Iyp" A .",SS (IIC rchd ..,:,1..,0 'S mco,p[)I;oh~(1 III the pwnp 10 preY",l! f:XCOSSlvn
p"'SSUIC la"ld III) '" tho event of ,1 ,,)Sl"Ctlon III th e pipelollf!s The fuel ,I(:c\llllula lor ha~ 'wo lunf.luItlS. (t) In 4'ill1I,)(:I1 llll! IIIII,,;,'U)!l 0 1 lhe luclllow. HHlu.:.iI ,ml hy Ihe I)\I"'P ;IIIf' (II) 10 11I;""t,"" Iud I&#34;&#39;&#34;&#39;~&#39;&#39;&#39;&#39;&#39; ,,1";1 .h" .:o,!.m" h;os Iom,n sw"dn,,' "If TillS p.r.v"rlls .• v; 'po", IIH:1o; .lo.:vel"I'III!1 w,th t:'Hlf.O:'I""nt 100' ~t,&#39;<tIllU plohl"",s The f'lcl filter '1I1:"'I'OO;lleS two l"ll,e. 1,111" "Imlllllits to ""SU'" th,lt lhe '",,1 1!!,uoOh,,,!) 11,,: 11O)I:ctrrJl) syst,,111 comp"""lIIs IS "UUII'I"I"ly flce hom tlo.l The fue l distribulor/mi.l!ture control Msemb ly . The Iud dlsl"bulor C0I111ols Ihe '11I,lntl 'y of fuel bein!1 dehveled 10 tho CII!)Hle.
OIlS""l1g .h'lI each cylrndo. fCCOlves Ihe same ;lII1OtUlI. TIlt! mlxhlW COIII.ol aSSemhly ,ncorpo'illes ,III IIi, senso. pl, 1le ;m d cOlllml plllll(le •.
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The iI" sen~or 1)1"le is locilled in 'he main nIl Stlealll be.ween the iI'r clr:wller ,1nd the Ih'Ol\Io bullerfly. Du'ing idling. the ~irflow hits Ihe sensor plate which in tu.n '<lises a contrOl pluiloer which nHows fuol.o How P.1St tho plunger and oul of Ihe injeclor v.llves. lnC/ease s in enornn speed cause inC/eased air flow which ,aises the conlfol plulIge, "nd so admits mo.e fuel. Tho throttlo valvo assembly ;s moun led in .he rIl<lUI all ;nlilke hetween tlte mixture contrOl ,1ssembly arid Ihe ai. challiber. The Ihrollie villvo plate is cOlltlOlied hy a cilble connected to Ihe ilccelerntor podOll The injector valves a.e located in the Inle! 1I1o111110ld "nd OlIO dt.!sl{jllod '0 01)0011 ill a fuel pressuro of 3.3 kof/cm' (46. 9 Ibf!III'). T he air Chiltllber is mounted on thO top of 'he ell!Jlno iln.t fUllctlons ,1S an a"xlhillY inlet nWllifold dllcctill!J arr horn the sensor ,,'011(1 '0 e,1ch indIvidual cylinder. The wilrlll'up rogula tor IS 10f.il1Cd 011 Ihe I,ont of the CnU,"e ;01,,1 '"f.orpur"tcs il hi·met,.1 st.ip. VilCUUlIl di"llh.,IUI11 and cOl11lol Villv!! Th" funcI,oll 01 the ronulato. 'S to enri ch tho lucl/a" n".IUlf) Ih",no lire W,II'" III) Ptillod ;md iI'SO:ll lull thmttlo Of1"Clallon . Tho auxiliary iii, dovice IS locaterl nil tlln Iron! f.If." "I Ih" "" dlilnll ..... r. II ,:ons,sts of a Ilrvoted plil'o. h, ·metal Slrrll ,),1(1 h,,;,ter 1:011 Til" PU'P IIS" 01 IIIIs tlcvlce IS to supply an PI&#39;crcOl~&#34;d vnhlllw III 1""1/",, 11"'1",(1 dl"Pl1!J cold idling r~llltcr 51111i1011 to Ihe 101,,1 1111" sy~h,m Orr 1:,)lIIIII"IIOII;,yoIJIS Ti,e fuel sta.1 valvo is locillud 011 the l]Iall l;,1f dl,II""!!' iI"" ", all ,,1o.."(:tllc.llIl' tlt)C,,,tcd 1111')(;10' , lIS PIII I)()SO IS 10 SIJI.ly fudrrllO ti ll! ,111 r .... '. ;'1 ,;,,111 ~&#39;~rrt&#34;&#39;!J ThiS Iud tomcs II"m 'ho fuel ,r. :.t"IUIIO' ,lilt' IS oIlo"'If,·d III II", ,III Ch;II))I,,,. wllh an frOIlI Ih..., auxllo;II Y ,1" d...,V,4·" Tho TI", .. I110Iil}10 switch IS sl:'(lwod Into Ihe (:lltl "U) mll.1CCI't lu lit!! wa'lIIup 11'\)111,110' Th(l SWItch ,IICOIPO(.1I1.'S" COIII;tCI ~Ill. &#34;&#34;lIIcl~1 ~I&#34;p .",,1 IWO h(:iltcd elmn(:ms The switch comrors thc sta.1 v,llve by hl'llIlIllI the PCIIO<i 01 fuel in)CCllO'1 frOIll Iho valve anti ill$o pr(:vellllllU ti,e valve frOIll IIllcc"ng any luel ilt all when sta,',ng a hOI cngule. Electrical re'ays and luses. These a.e loc,, 'cd undc. the faci" p;IIIIJI Oil tlte ri!)ht·hilnd sj(lo on Ihe intc.io. 01 Ihe C'If. Tho .()I,1yS cnlllp.bo Ihe 111;1111 contrOl foray and [hn powef SIJpply '01,1y.
Fig. 3.32 Fue' injOCliOrl system flow diagralll (Soc 22)
1 Flle/lall/(
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Mu;/ulc CUIIIIOI ,mif 6 IIIIOlfic pla/c assembly 10 S/;II/ villve 2 Fuel PIIII/I' 5., Fucl (Iistllbutor 7 Inicc/or valvc /I 'hell1JOlimc sw,lch 3 Fuel i'CC/IIIIUI"tul 50 Alf SCIISOI 8 WiJllII·Up regula/or 4 Fuel '"10:1
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Plcssule regtllillQI 9 AU~IIt&#34;aIY air device
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Chapte r 3 Fu el an d exhau st systems 79
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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
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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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80 Chapter 3 ~lIel and exhaust systems
24 Ai r cloanor -removal and re filling
1 Remove Iho elomerll as dllsc"hed III Sect,on 23. 2 Work,nn under Iht! left ·hand honl wheel arch. unboll the illr clenne, hOdy f,om Ih e s,de of the engmo compnl1lllen\. 3 Rohuil1g IS n rove rsal 01 tho lomova l I)rocodule wl lh relelence 10 $(1(;11011 23,
25 Main system compono n ts -rellloval "l1d rofitling
Fllel p /llllP 1 Thn hll)1 pump IS loc.lwd "' " lI,hlw.. 1ll011111111U .lUflchod 10 Ihe "!Ihl h"n{1 51th! 01 lhe 11I/,llal1k (phnIO) ') D,sC:OllllCCI Ihe h<lllulY 3 Rol'-',1S0 Ihe IHeSSUle OIl tim SyS hllll I,y lelllpOI<I"ly looSl'!I1I1'l1 Ihl)
le"l1 line IIIlIon on Ih e lu«1 dlSlllhul<ll C,11l:h Ih o sm<lll <lmOunt 01 luel wh" .. h CUllies oul 111 <I p":c:e III dOlh 4 Wllh Ihe ,eil l of thl! c:a, flve. <In IIlspeCt'OIl pit or sUllahlv rfllscd.
cl;lIllp l hl) 111(:1 IIIIUI hose IIC1W,,':1I1he ludl;lllk ,1ml th « 11111111) uSlnH ,1 h",ke hose cl,IOUjl or sHlIII;" If Ih oro ,s only ve.v hnle 11101111 I ho 1IInk. illl 11"lIl<1llvO 10 cl,1mplI'!l1hc ho~() IS 10 dram Ihe Innk onCIl Ihe mlOI hose 10; ,h~c:ol1nCClu&#34; !". OIs.:nrUlI){:I IIlI! Iud ",Ie! ,llId uIIII" 1 IIIIJoI:S I.nUl Iho pump G Cn,"'ully ut",llily Ihf! dm:I"c:al C:(&#34;UH~C1l00S 10 IllI! pump nil"
&#39;&#39;&#39;~t:un&#39;&#39;&#39;~.1 11",," 7 I ,.,,.,~&#39;&#39;&#39;&#39; the 1I!l11l hoilid Illd 1'lIlk SUPI)(Jl IIII(f Sl'ilP Illell unh(lll ll,,~ lul,I)". mOlllllll'H ami 111,,1 JlUlll!' 8 !'IISf) the pllmll "("n the "'OIull"'!! !) Ilcfllllll!j 's il IUliers,, 1 01 ,emOVi.1
FiU. 3 .34 R Oilr viow o f
A Ink'1 pi,ll}
fuel,HIIl'I) (Soc 25)
8 Fucl'WIII/'
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) 2~ 1 Fllel pump showing Wlflflg ond oul'el pipe
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2510 Fuel accumulatO'
Fuel accumulator 10 The fuel accumulatO I is bolted to the Ical 11001 above Iho lear "Klc (phOIO). 11 Disconnect the bflltCly . 12 Releaso the preSSIJle in the system as descllbed in PfllfltJlilph 3, 13 I'lilCO the leal of th e car ovel ,1n inspection pit o. lilise il on ' ilmps O. fldo·stands. 1 4 D,sconnectlhe fucl pipes I,om the lu el accumul,110r and catch Ihe s<llflll qUflllt'ly of fuel which Will bo released. 15 Remove the Iwo Illollnling SCfOWS and remove Iho acculllulf1lOr. 16 RefollinlJ i~ a ,eve,s,11 of ,emoval. hut lemovo tho floor panel hom Ins,de Ihe lum,ji'ige COIl1I )il'lnlenl and relit Ihe p,oteclive Cflp5 over lhe SC(()W Ihronds .
Fuel filler 17 The luel 1IIICr 's locmed 011 th e wheel olfch in Ihe lelt hand side of Ihe .mU"'o COIllI)"' ln,elll (1IhOto).
Fi U. 3.35 ConeCI 10Ciliion o f fuel filler oullel pipe (Sec 25)
A B Fuel "'ICf Ou/lelll'lle c Engine comporlmenl side p,wel
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Chapter 3 Fuel and exhilust sys tems 81
1 8 Disco"nect the hllllmy 1 9 Relc,,~e tl", .. ,e5~II.e In t he system "s described in palaglaph 3 22 P lace some cluth hcnc,llh the luel flhel then disconnect the mlet ilnd outlet ", lions 2 1 Rcmollc tht) mOIlI1lIlI11 sc.cws ,1od withl1,,,w Lhe fuel f,ltc ,. Remove
the bl:lclwt II 'ltICIlS$:I'y 22 RchulI1U IS a .ellcls:l1 01 ,emoval. but m"ke sure tha t the 1,ltel is
pQs. t.onnd thll I:Olfe ct W,ly 10un(l. "n(1 Locate tile OUIICI plj&#39;JC:I~ snown
io FiH. 33!)
Fucl tlisfllbu{(}r 23 The f""t d&#39;~L&#34;I&#34;&#39;lor .~ IOr.i'to(1 on top 0 1 the "" flltl'!'. 24 DISCOnl"" .t thu !o:m",y 25 n,;L&#34;&#34;~,,, thO! L&#39;&#39;&#39;&#39;&#39;,~II&#39;&#39;~ III (hI'! system:ls d"sl:"lmd in piull u,a"h :I"" t compL"L"ly 11,111"11" tho I,,,, d 111111 ",Hon 26 DI~r.&#34;&#39;UII&#34;. t tl,,, """,11'1'1111 f,,(:II'"C$ 1,<)ul til(! llis t,d,utOI 27 UIIS&#39;~&#34;:W ,I", nll"l1 """m'"'n sc",ws alld hit Ihe IIISIIIIJlIIOI away 28 RHhll""1 ".,' &#34;,v&#39;:I~,,1 "I rr""OvilIIJlJ IIISC a IIIiW coppe, w&#34;~.h,,, r:ach ~,de of Iht: '1',"'1" IIIIIW&#39;~ ",,(I dO not OVf!rI'UII1I:rllhe llIliol Imils 9 Hall" Ih" :.y·.1t:1I1 I""",u'li t: heckr.d by yo"r dllatCr: 30 I\dl&#34;~t th" "II" &#34;I~:I&#34;t :II\l IIIHXIIlIfl as ,leScII",,1I III SectIons 73 ,IIld 26.
W"",,·/I/I/I.'ylll;/fOf 31 The w."'" "I' "'!I"I"tl1l 's loc ;llt,d on till! hunt of the ""!I"'" ""xtlO t he c(X,l"'H ~y~t&#34;l11 nuth, t I:lhow 32 D,sco",,, • .: ! tl", lhlllCI" 33 Flcleasc Ihe prcssllfc In the sySlcm as desc"hed in parag'''I)h 3 34 Discount: GI Ihc lIacuum hose ilud wi"uy plllg (photo) 35 D'SCOI1"I:CI the fuel hiles (l)holO) 36 Unsc,ew the Iwo sockcl·he;lded uolts ;lnll wllhd';lw thll 'C!jUI;ltol . 37 Ref,(lln\1 IS ,1 ,cve.sa' o t ,emOIl"' . hut lise a new copp .. " wa~hcr eilch Si(lc 01 tim h,ll1l0 \llllons (phOIO) 00 nOl ove,l>ghtcil lh" I"'''on cenlre hol ts
Fuel S f"ff v:llvc 38 T hc luel stMI 1I:llve is located on thc ligl1l ·hand s,de of the lIir ch"mhel. 39 DIsconnect the bmlory . 40 Disconnect the elcctlic p lug and fuel supply pipc from th e lIalve (pholo) 41 Unscrew tho twO socke t·headed mount,ng bolts uSlllg an Allen
key .
42 Ref,,,,,,!) IS .1 'ellcrS:l1 of ,ernOllal. but u~e II ncw moullting flange !lasket Use" new copper w"shel all each SIde of the """10 union lind do nOI ovnlllllhien the Centrc holt.
A!lxih~1I&#34;Y "i,. r/(!vicc 1\3 Thc i",x,h.n y "" rlcvice is 10C"II,1I On the IIU"t hal1d flOllI of thu lIir cha",!,,", 1\4 O lsc0I1"", .1 Ihe hallerI'. 1\5 D.scr"'''.,ct tl,(, eleCt,ic p l11\1 ;,ml IWO illf hoses IrOI11 the ""vice (phoIOS) 116 Unsc",w tl", two 'UO"nIl119 holts .11,,1 hit tl"l ;rss",,,t,ly i!Wlly. 1 7 Fl"f,It'''H .s ;1 HIIIC,s,,1 of 'elllolllli
Foel injocrurs 48 D, sclI"""'.t Ihe h;lll",y. 1\9 O, sr.<J""r:CI Ih.) :u:cclcrlltor cahlc and il.ad."t r,olll I"e th,onle "ssemhl y 50 D'SC OIII",, :t Ih" m;" " lIir SUI)ply l,ullk",!! 10o", ,he "uxtll,e cont,ol u"It ;1I1I111r",1I1" "ouSlnH (,lhotos). 5 1 DI~,:ulll&#34;&#34;: t .II\.! IIlect,ic ,llll!ls from thc walm'''I) r~I,,&#39;atOl. the th.)ltIl{Jtu"" sWllch. thl") lI\lxllia,y air device amI the fuel St.1,t vDlve . 52 D,sc",,,,,,,:t the: hlel SIlIIP'''' ,)ipc hom the St.1,t v;lllle Dlso the V"CII\lm II'II\.! hom tho W;lrm up 1O{jIJlmol . 53 Unl)()lt tht: a" chmllbCf (ei9ht bolts) and move il c lcar of the in le. ",al1i 'ol(l. To completcly ,emOlle il, disconnect the rClllaining hoses. Belllove 'he UaSkC ! (,) h o to). 511 UnSCICw Ihc ",oun,ing boilS <lnd pull Ihe i"leclO's loom Ihe mlet Illal1itold 1,)"1)101 55 Usm!) IWI) ~p&#34;nrIC&#39;S. loosen t"e UIII!)" n"IS .,,1(1 d.s,:onncct Ihe miCCIO'S fr<llll tht: fuel IIIles .
25.3 4 D,sconncct'no Ihe wII'no plug . 25.35 ... "nd fuel hncs from the W""'H'P !egulato! 25.37 Re new tho copper wilshcrs each side 01 the banjo union
25 .4 0 A DisconnectIng Iho tuel slart valve
wiring plug
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2 5 .4 06 ... and fuel supply pipe
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25.4 5A Au xilia,y air dcvice w ifin g plug.
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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
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25 53A UnsCII)w the holts. 255311 ,,,"U)IIC the ~&#39;&#34; chal11bcr ~5 53C ;11111 'cmoY(: the Haskct
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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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Chapter 3 Fuel and exhaust sys tems 83
1.6 7 I\dJ&#34;~IIII!J II", n&#34;~h&#34;&#34; ~ t:&#34;&#39;w
27 F"HII;Hlk. $1)I"ll)r ,Uli( and Idll)r pipr. -Ufm() r(ll
The 1(,11101.',.1 ,11111 "dlu",U pH.II.",hJlf:S ;1Ii! SII"II,II III Ihose !I'V"'I III
Sec lions 13 10 16 Ilow'IV<:f. Ih., ~.:&#34;,h:r "nlt.s 1 ... :;.1.,,1 o n ti,e letl h"tHl side 01 lhe "ml tank (phOIO) "lid Ihl) luel I'UIIII' 'S ~l&#39;C&#34;&#34; .. d 10 lh(: righl·h"ml $ 1110 .
28 ACGelerilto r c;thlO -removl.1 "nu relitling
27.1 F tHlll(1l1k ~&#39;!tldef "nil
29 Inlel manifold -rcmoval and re li inU
Ilclm In S')(:tlon 19. bUI Irl sJ(w d 01 ,.,((\01.'11'(1 thc cilllnllc1l0f,
" ,movc Ihe "'I"I:IOIS (Inti iii. chilmhef as dc-sc"hed in SeC t.on 25. N Ole th,,1 the.c IS one nul ill eilch end of Ihe m(ln,Iol(l. ;md 111m the bOltS (lIe of d,ife.enl Icn(jlhs (phow). 2 Also unbolt Ihe oUlle t elbOW and will/n·U)) .e(jul"lo, 1ll0unlin(j hlilckct hOIll I he "onl of the inlet nI(lIl ,lold (phOl0S). 3 Follow the I'ghtening seQuence uiven III Fig. 3.36 w hich d,lIels IrOIll the 3 ,0 hIr e engine (photo)
28.1/ llel110vlll\l the sleeve hom Ihe end 0 1 the (lCceh:r.lI0r c"hle 28,1 B Plisinn O\'! til " 11,1,,11\I0 chp 2a.le Removmg tile ilccclcrmOI cntJle 110111 Ihe IT,oull ting bracko l
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29 1 A Un~(.:r1:w the Inh,t m,llulol( l ho lls
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29 10 (emove tilt) IW!IS
r " ' , , &#39;~;
29, I C ... 1If1(11,/t off the ma(\, Iold
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Chapter 3 Fuel and exhaust systems
30 E~haust manifold -rOllloval nnd r e fitting
Rcle . \0 Section 20. but not that 1,11C' models do nOI have n downpipo scaling ring (photos)
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31 E~haust system -removal and ro fitting
Reier to Section 21 (pholO).
85
3" ,A TI!Jhlenrrl!J Iho O~hilUSI mnnilold nuts 30.1 BRight hnnd e~hnust rn.1nilold ·to­downpipc connection 30.1 C Dl sconnec tirrg the lell hnnd e~hnusl downp;,Je hom Ihe manIfOld
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31.1A hhnust system ,ubbe. mountIng (;,,,owed) 31.1 B Irnermed'ilttl oxhilu st system-to-honl pIpe clamp
RT C , FAULT D IAGNOSIS
32 Fault diagnosis -fuel sys tem (CMuurottor)
Symptom
Fuel COlls!ll11ption e~cesslve
Insu llicienl fuel detrvery or weak mi~lure
33 Fault diagnosis -fuel system (fuol injection)
Symptom
~ngine will no t starl (cold 0' hot)
Reason(s)
Ai . 1,ltel clement choked Fuel lenk flom cmbulellor. fuel pump Of luellrlles Gene.ally waUl ca,bu,ettor Needle vnlve StickIng open Incorrec t idling speed <lnd/or mIxture
Clogged fuel Irne
o. hiler
F <ll.lty fuel pump le<lking inlet nI<lnrlold g<lsket We<lk mixture selting
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llason(s)
Ai. !tow sensa. plale incorroctly sel FauilY fu el pump Fuel lank omply
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Symptom
Engine will nOt Slnr1 (HOT)
Engine will not stal! (COLO )
Engine mIsfires on rond
Unsatisfacto,y ,oad p edomlilnce
Rough Idling (ilIWilYS)
Rough rdllng (during warm -up)
Excessive fuel consumptIon
nglne fUns on
I
C hapte r 3 Fuel and exha ust systems
Reason(s)
AuxiT inry air device not clOSing
Auxilimy ai, dev ice nOl opening SImI villve filulty Thermotime switch nOt closing
L oose fuel pump elec trical connections
System fuel presswe incoflec!
M,xture adjustment incorrect
AUKlhilr y ili, deVIce nOt OllC,ahng cOflec tly
Mixture M1ts utment incolleci leak in system fuel lines
Airtlow sensor plate or cont/otplunger not moving "eely Injector villves leakinU or then OJ)Cnlng pressure too low
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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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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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,6 Chapter 4 Ignition system
9 The spark plug gaf} is 01 conside rable impor1~e. as. if it is too lilrge or too small. the size of the spark ilnd its efficiency will be seriously impilired. The spilrk plug should be set to the ligure given in thl} Specifications ill the beginning of this Chapter; IOTa sel it, measure the gilp with a/cere, gauge. and then bend open. or close. the outer plug electrode untillhe correct gap is achieved. The centre electrode should never be benl as this may crack the insulation ilnd cause plug fAilure if nothing worse. 11 Relit the plugs, and re/ilthe leads from the distr ibu tor in the correct I"ing order. which is given in the Specifications. Screw the plugs in by hilnd initiilily then tighten them to the specified torque using the plug spilnnel.
12 Fault diagnosis -ignition system
By lar (he nlo1jori (y 01 brCJkdown and running troubles ilre caused by InUits In the igrlOlron system er(her in (he low (enSlon or high tens ion circuns There <ire two mnin symptoms Indlca(lI1g Igni(ion IJults. flthel (he "ngine WIll not Start or lire. or the engine is dIffIcult to SWr( and misfiles If it is a regulnr misflte the fault IS almost sure to he in the Icondary or hIgh tenSion cirCUlI. !f the misfir'"g is intermittenL the "HI lt ~oliid be ;n either the high ur low tension circuits. If (he car stops suddenly. or WIll not stilr( ilt ,111, I( is likely thm the lault is in the low ten sion cncwt. loss of power ,1nd overheating, tlpar t from f,lUlly c,lrl>LJratlon or fuel Injec tion Setlln(Js, ilre normally tllle to faults in the d,strrllulOr Or 10 Incorrect I(Jrlltion tlllllrl!J .
Engine fails 10 staft 1 If the engine falls to StM( and t he cal was IIJnning norll1t1l1y when.t wns IJst used, first check ther e is fuel in the petrol wnk. If (he engille tums ovel normally on (he starter 1I10tor and the bilHery is evidently well chmged. then the lault mny be in either the high or low tension circuits. Firs( check Ihe HT circuit. Note: If lire hal/cry is known 10 hI! {(Illy ch,}lged, Ihe ignilion liglll cOllies on, ,1I)d Ihe s/arler 1II010r {,lils /() tum IIIe ongine check the tightness o f the le'lds on the biltlely terillinilis ,1I)d <1Iso (lte seCUIIHWSS oflhe e,l,th leold (0 irs cOllllec/ion 10 tire body It is qui(e common for tlie le,1(ls /0 Ii,}ve wOlked loose. l.'vc'1I If Ihey look ,1n(/ lecl seclI,e. /I one 01 the boll/my ((:{minM {Josts [11.'1.1' vC'IV liot wi".." (Iyiny (0 wOlk Ihe s/mler 1II0tOl (his is ;/ sUie IIId'C,7/IUI/ 0/ ;/ I;wlty COllllel;('On 1(1 1h.11Ie"lIillal. 2 One of tile commonest rOilsons lor bad stmtln!J IS wet or d;UllP sp,uk plug lead~ and dlstribu(or. Hemove (he distllblltor cap. H "JOdenSil(Ion is v iSIble IIlte!llillly dry the CJp With il rag and also wIpe ;lCf the leads nelu the cap_ 3 If (he enUiue sull fmls 1 0 St.l.t. check that cunent IS reachlllg (he JUS, by dlscounectln!1 ench plug le,l<1 in turn ilt the sp1Hk plllU end, .. ,ld holdlllg Ihe end olthe callie about 5 mm (0.2 Ill) aWilY from the cylillder block. Spin the enu'ne all the sta rter motor. 1 Spa,klllg between the end of the cable ilnd Ihe block should he fa"ly strong With J strong leuulm blue spark_ (Hold (he lead WI(h wbber to ilvold elec(IIc shocks) If Clluelll is reilching (he plugs. then rel110Ve them and clean and reg,lp them. Tho engine should now SWrt 5 If there is no spilrk ilt the plug leilds. wke of! the HT lead from the cenlre of the d'sltibutor C<lP and hold i( (0 the block i1S belore. Spin the engine on Ihe SWrter once more . A Inpid succession of blue sparks hetween the end of the loau and the block ind'cate thilt (he coil is In order and that the distributor cap.s cracked, the rOlOr mm faulty, 01 the carbon brush in the tOp 01 the distributor Ctlp or rotor Mm spr ing is nOt making good contact Poss,bly, (he POintS me in had condition (mechanical contaCI hrOilker) . Renew them ns doscribed in Ih is ChnJ)ter, Sec tion 4_
6 If Ihere me no spmks Irom the end of the lend 110m the coil check the connections atlhe coil end of the lead. If il is in order 5(31 1 checking (he low tension circuit. 7 Use iI 12V voltmeler or a 12V bulb ilnd two leng(hs of w ire. On conventional distributors switch on the ignilion i1nd ensure tha t the points arc open. On breakerless dlstlibulOlS ensure thilt Ihe segments on the rOlor are nOt adJilcenl to (he triggel coil. Make a tes t between the low tension wire to the COil ( + ) terminal nnd eilrth. A leading of 7 (0 8 'lollS should be obtained. N o reJding indiCiites a break in the supply from the ignition swilCh or il f,1UIl in the ballast resiswnce wire. A correct rending indicn(es a faulty cojl or condensel, or n blok en lend between the coil ilnd the distrIbutor. On breokedess ignition systems the (rigger coil and ilmplificr module are suspect . H~ve (hem checked by a Ford dealer. . 8 Take the condenser wire off the points assembly Jnd with the points open test between the moving point ilnd eMth. If there is now a leildrng then the tault is in (he condenser. Fit a new one as dcsclibed in this Chapter, Section 5 9 W,th no reilding from the moving point to eilrth, wke ,1 reildrng between eil/th ,1nd the ell or negiltive ( - ) teminal ot (he COIl. A rendm(J here shows a broken wire which will need to be renewed hetween (he COil ilnd dis(rihutor. No retlding confirms thil1the coil hilS failed ilnd must be renewed, afler which the eno"te wdl run once more Rcmtmher (0 rel,t tho condenser wire 10 the pomt$ ilssemhly.
Engine misfires 10 If the enOlnr. mlsfues re!Julariy. run It ilt a f~st irllrng speed. Pull off eilch 01 the plu(! C,lpS III hUll nnd hsten t o (he note 01 the engrne. Hold the phl(J cnp In il dry cloth or with a rubber g love <IS addition,of protection au"inst il shock frOll1 the HT supply_ 11 No d,ifercnce in eng me running will he noticed when the leild 110m the defective plug is removed. Removing th e lead from one at the good cylinders will accentuilte (h e misfire. 12 Remove the plugleild from the end o f the defective plug ilnd hold il tlbmlt 5 i'lli'll (0.2 in) nwny from the hlock_ SWrt (he enoine. If the sPJ'king is fairly strong and regul"r the I""'t must lie in the spnrk plug 13 Tho plu~J mily be loose, the Insulation mav be crtlcked. or the points may have burnt away g,ving 100 wide tI unp lor the spark to juml). Worse stoll, one of the points may hnve broken off. 11 II there IS no spilrk ilt the end of the plu\J lend, or ,f It is weak ilnd IIlIermiHent, check the Ignition leild from (he distrdwtor to the plug. If the IIlsulJtlon IS cracke( 1 or pCIIshed, renew the lead_ Check the COrlilections Jt the distllbutor CilP_ 15 If (here is s(111 no spark, eX,lmllle the dlstlil)utor CilP cillefully fa, (r"dIllU. ThiS Cilll be recoor1,sed by a very thm black line running between two or more electrodes. 01 between "n elec lrode and some
other Pollt of the dlstllhu(or. These lilles J,e p,lths which now conduct electllcit y Jcross the CJp lhus lewng it run to e,,'th. Tile only answer IS a new distllbutor CilP_ 16 APilit frorn the Ignition tll1l1ng being Incorrect. other Ciluses of rlllsl,,,ng hilve already been denl( w l(h under Ihe section dealrng with the f,lriUre of Ihe enuine to star I. To reCi!p - these 0110 Ih,lt:
(,J) The cOllm.lV be {,lufly giving ,111 iniNmil/elll mislile (b) Thele limy he ,1 (/iJmiJged wile or loose cOrlflee/ioll in till! low (eflsion circuil (c) The condensel /II,lY I;e shOll circuiling (i{ filled) (d) There nwy be a meehanic,lllolUI! IiI Ihe dis/flbll/or (bfOken dliving spindle or eOlllac/bleaker spring. if filled)
17 If the ignition (iming is too far reto1lded, it should be noted thallhe engine will tend to overheat. and there will he a quite no(iceable drop in powel. If the engine is overheating and Ihe power is down, and Ihe ,oni(ion tim in!) is correct. then Ihe carburenor or fuel injection should be checked, i1S ,I is likely that this is where the Iilult lies.
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