light FORD CAPRI 1974 Owner's Manual

) Chapter 10 Susp e nsion an d steerin g 167
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F ig. 10. 13 Ellplodcd view o f the IlHII HHl I steering gear (Soc 13)
No 7.7. d"lI) ''''''''':1\:1 )( !) nit" (035 Inch) deep <Ilong the brOJk I •. , I .. :\w",,,u ll1e h()u~II\H lIud 1he loc~nut. <Jpp,ux,mi)lcly OppOSIte the
"1);"""" IOG,t'''!J huit) III Iho h OllsOIl\j 18 FI t IWW wl""""11 pUI S :11.<1 pt!cn ove, the SUlloumhng meW!. 10 1(.:1;"" them 19 Llghtlv IJ'C,lSC the ,nSlde of the bellows. where they "",II corlt,lC the '''lck .o d s II1SI,111 one bellows. cnsunnu that " locales on the "ack rod groove. then 1, a new 1010111''''9 Ch, ) 20 Add Ihe SI)Cclhcd (IU;II' I'ly 01 SI(,e""u gear OIl. ope •• n ing the rack over liS limue 01 Havel '0 ,15SIS ' thO lubliCilnt in "owrng. Do not OVllrl,1l 21 FII the othOI bullows. then CilllY 0111 the lollowing ildluslmenl prOCedulOs Ideally Ih ls Will IC(IUIIO thc use 01 a diill gilllge ilnd mountlOg block. a 5udace tahlc. il torquc yiluge and iI splrned adilplor. It IS lelt Ihat most peo,)le Will bo ahlo 10 SUitably improvise. using Olhcr equipment. hul II IllIs Cilllnot he done and thO equlpmOnt "sled is lIot ilVillla ble. Ihe 101/ s hould be unllu$tcd 10 your locill Ford Dealer .
22 Wllh the ~Ieelmg Ueilr mountud III iI so h·Jawcd yice. remoye the r,:u:k ~I&#39;ppur coy", pl!!Ie. shim p,1ck. {lilskor. mid sprIng . Also "Jmoye the I"n'on bOilflll\J coyer plalC. sh im pac k and gaskot. It i1ny oil is lost dUIIIl!) thc adJustfllenl procedures thO steering gea r must be rl!'
plc&#39;&#39;&#39;~hcd hclore IllIIng to Iho cm.
P,niOIl bec1ring preload 23 PlilCC the shun p,l c k alld covcr pl1lle 011 Ihe bearinU. lighten the 'JOlts. then s lacken Ihcm 50 .hal Ihe covel platc louches the shim The \' pilck Illll~t (;omj}lIs e ill hlil st three sh ims. one 01 which musl bc Q m,n (0 093 In). tlus bern!) ullllledlalely agaIns t the COYcr plate. 24 Measure Ihl! COV'" pl,lle .to·housllIg gilp. and if outside I he ranUe 02810033 fllill (0 all 10 a 013 In) reduce 'he shim pack th ic kness {If
Ihe UilP is '00 li1rud. or Illcrei lse II ("the gap IS 100 slllilll) unlll Ihls gill) IS Ob'ilillcd Remembe r Ihat lhc 2 35 111m (0 093 III) shim Illustrcmillll
Immcdiately "UilIllSt Ihe cover pl;)'e 25 When the COIICCt \1.11) IS ohl!!lIlcd. rernoye Ihc coy!;'. pl"le. IlIs!.111 thc gasket ilild r efit ,ho coyer ,)IJ tc. Am)ly locklllg lIuid 10 Ihe coyer hOi' th.eilds. lit Ihem ;)"d lighlen,o a 10 11 N m (6 \0 albf It).
Rack sl/iJpcr .1djus(mell( 26 HilYlllg set thO pOlllon bearing preloJd. measure 'he heIght 01 the stopper il!J.OYC the IIIillll body 0 1 the rJck. as ,he rilck is moyed Irom lock \0 lock by turnIng 'he pillion NOIe thc height reilding obtained. 27 Pr CPilre ;l shim pack w hiCh. Including the thickness 01 the 'ilck sloppe r beJring {JilslIet. is 0.05 to 0 15 mill (0.002 10 0 .006 in) thicker than ,he dimcnSlo n lIoted In piuagrilph 26. 2a FII Ihe spring. gas ke t. shim pilck and coyel plate to 'h e ra ck housing (gaske l ncareSt housing) Apply locking lIuid 10 the coyer bolt thrcads. III them illld 10rque tigh.e n to 8 10 11 Nm (6 to 8 Ibl h). 29 Measur e thc ,orque rC(tullcd \0 lurn Ihe p inion throughout i,s mnge of I!.lY cl. ThiS should bc 1 t 3 10 2.03 Nm (0.83 to 1.50 Ibl It); if oulside th,s ,ange. Iilul,y componcnts. lack ollubriCilnt etc. should be
suspected.
1 4
Track rocl end balljo int -renew al
Jack up thc loon. Of thO Cil r and SUf)pOrt on Jx le stands Apply the halldbrilke ;)nd re!llove Ihe applopriil'C Iiont roadwhcel. 2 Slacken Ihe baliJo in l locknut 011 the track rod by iI quarter 01 a turn. 3 Extra ct the spl, t p,n Jnd unscrew thc nul securrng the !Jilc k .od ond
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)8 Ch apter 10 Suspensio n and steering
\0 the SI(lcring Mill (photo) 4 USlIlg" 1)[lIi)onH SCpilriltor tool (photo). reh:o,lS(l the ['ilek rod end from the Slc(!rino ""m 5 Unscrew the h,"'IOlilt hom the ['<lek rod, notmg lhc C~ilCt number of turns required 6 SC!( )w the new 1m ill Oint 01110 til(! 'rac k rod the SilnlC number of turns . 7 FIt the (.<le k lod end In the steering [I,m, SCI(!W 011 the nut illld lighten 11 to the specIfied torque AII\)11 the holes nnd IIlscrt il new spht pin
8 T'Uh!C1l th e h<lIl,DUlI locknut whde holdlrlU the unck rod end hOrllon\<1I, {) ReIn the ,oailwhc()1 ilnd lower the C,l' to the wound. 10 Check ,1(1(1 ;ullllsl til" f,ont wheel ""onmen! <1S desCllhcd ,n Section 20
15 Power steering -hlccdinU
The power ~1P.elln\J SysHllll WIll only need blc",rhnfj Ifl the even! of . .., hell1\J Il1tl<)(hu:ed ",to the system. cu whcn: IH llI:S h;IV() IW(}1l dlscoI1l1cc«:d or whel() J Ifl.lk"(Je has occlUfed To hleed the system ···ocp.ed ;'s (1<,~<:&#34;I)Cd III 1(11) followlllU l),l';)\J,,1I)hs
I Open llH~ hO'Hl()1 ,111<1 cl\p.(:k the Il",d h:v el "llhe Il'Sl'IVi'" Top·llp.t llucess;IIY IIS"'!J (Il<) spe.:II,ed lype of 11(11<1 3 11 11."d IS added. allow two "'''HlWS. th"l1 lUll 11m I;I\U"W at apPI{)xIIllntnly 1500 rp'" Slowly \illll lhe st'!""Il(! wheel 1,0m lo,:k to lock. wlllisl r:l\.,,;klllH and WPP"'!I up Ih e Ihlld unlll th" l"v,,1 ",m;II11S
Stf),li1y ;1<\<1 no molC hubhl"s ilPP":U I II tlw I"S,,,V,,II
" elc ;,", and refn Ihe r"servoll cap ami close II,,, 1>0"",,1
16 Power steering gear rellloval and refittinu
The p'ocedure IS Sllml", to thilt descrd)<)d III Sc(:t lon 12 10' th" m,10u,,1 steeling gC,lf NOlO. how"ver. lhm tile 111011111(1)(1 1)I)Its (jo cOllipletely tl1(ouyh lhe front e,ossmflmhe,. "nd the II.),,, nil IS a,e
I()(;ked wllh sphl pillS. Add,llon"lly lhe lIuld IIIH)S rnu~;t Iw lhsc.onnec · l"d. and atln' ,uI,Um!J the system ~hollid he loppud III' ,lnd Illed wllh lui"",,,!:,, 10 $"(;tl{>n 15 (photos)
17 Power steerillU pump remov;ll "lid rcfil1 ill\J
Loo~&#34;n tl", «II.." Iwlley 1",lck,,1 b"lts. ,el..,ase Ih" d"ve!Jclt lellSlon. Ihcn ,emOVe II", dllvelu:lt I,,)m the P"'''I' pulley Oil 3 0 101", IIIO<il:ls , FI(:k up the tro"l 01 tlH~ ~&#39;&#34; ;lnd support on "xlu SI;IIHis. Ihell 'e"'ove tlll~ ""\llnU spl,'sh ~llIeld Belllove lhe tuul pump , 'Ill til() U"U"U, (Ch;,ptc, 3) lIul 1,,;IVIII!1 th" fu el trncs (;oIHu )Cled .
O ,sc<)nll,,(;1 Ihe IIlIal hnes hom the pump ~nd <1,,111 Ihe IIUI(III)to" sultahl" (;Olliall'", The pIIISS(lIe I",e h,15 .1 sell)w"d (1111011. hul the lehlln Ime 1 5 ,1 ,ulJhCl hose connecl'on (pll()I&#34;~) " Ulliloit (111) powe,· steuIIIIU punlp. (o\Jelhu, WIth thn IllOUnllllU
h,;lc.k(,t ~nd st;)y. wlw,e ;1j)1'11 <:;,I)I". ,!Ill! ","'ove f'DIII Ihe CII!) "le (photos). The "",d..,1 C;'rl lh"" 1m (lnl)nlt"d flOm Ihe pUlllp of nccess;"y, 5 RellltlllU IS .1 ,ev,,&#39;~al 01 I..,moval. "ul l&#34;&#39;Il~lon Ihe lhlvehelt ~Ild "Iced Ihe sy~IC&#39;&#34; wllh lek'e'll:tJ to Sec;1I0ns 2 ,!Ild 15
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18 S teerinU wheel removnl nnd rIllittinu
1 Dlsconneci the lodlielY nCU~lIve le,,(1, 2 PIISC Ih" mOllf hUIll Ihe celn,,) o f Ihe stcclln(j whc,,1 (photos)
15.1 A Powef SICCIIIl(j (je,, ' showUlU pinlOrl and lowe, coupl",U ~h,,11 un,vcfsnl lo;nl 161 B Power steering ue", mountUlg bolt (,,"owed) 1 G 1 C "nd nul (""owed)
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Chapter 10 Suspension and steering 171
19 4C Removinu the top steering column Shroud 19 G lunitlon SWitch ,1nd wirlllU (A). also COllll'lII upper mOlUllnl!J holt (0) 19.7 Removing the steering column uppcr mounlul(J holt (arrowed)
'5 Secure Ihe SIt:(;(1I1(1 lock 10 Ihe colulIlIl ,lIal ~heil&#39; the h eads I,om ,he m:w holt~ 11) U~e the stecrin\J lock to locate the shaft in Ihe column. then III Ihe )ct,on mdlGltor OICIlJalinn GUll alld Stecrmn wheel. CtlCC~ that Ihe ruadwheels afC st,lIln the 5trai\jht·ahead P05,110l1. 17 Install the Stce!Ul(J column orommet Oil the lowm en(t. 18 LOCille the column assembly ami sr:c",e It wrth the Iwo mOllrlllng bolts. 19 The ((,milliuler of the rellllUI\J proccrl",e ,~ th" reverSI! of lhe removill procedure,
20 F ront wheel alignment and steering ilngles
Accurate front whcel alignment IS essential lor good stoer"'g and lyre WOiJr. Scion) cons,dering the steering angle. check Ihat Ihe tyres
are correctly inflated. tllnt the front wheel s arc nOI IJlJckled. the hub hea"nns arc not worn o r mcorrectly adjusted und thilt the sleflr"'g IlIlkaUfl is in IJood order. wllhout slackness or we,ll at thu Jo,nls
2 WIH;f; 1 "I'!JIununt co&#34;s&#39;st~ 01 loUl I"ctors, C;"lliJcr_ IS the ""Ule "t wilich the front whet:ls ,lie sci from Ihe
verllcal when v'ewud 100'" the IrOnt 01 the c"r 1'0sIt,ve camber 's Ihe .. mount (111 de\J&#39;ee~) th"t til() whucls ,ue toited outwards at the lOp 100'"
thu vert,c;,1
Castor. ,~tho i&#34;&#39;~Jlu between the SIl,erlIlU ,,~,s OIrld.1 v..,'I,e.11 lone len viewud IrOIll p,lch ~,dfl 01 the C,lI 1&#39;0~;llIve castor 's when the ~tcermu ",x,s 'S ",cloned rUiHw,,,ds ill the top jStcerinu ilxis inclin,,{ion 's lhe illl\Jle. when VIewed frOI11 the .It 01 the Cilr. bel ween the verltcal and "n 1Il'''U>I1.1ry hne drawn betwCl)n the upper ilnd lower suspensIon strut p,vots, Toe-i n IS the ilmoUl,t by wh,ch tlte dl5li"'Ce helween the frOrlt
IIlsuJu ed\Je~ 01 the rOildwhecls ('He,lsu1ed m huh heiuht) ,s less thiln lhe d'sWrlCI) &#34;,e<l~ured between the rca' Ins,de edges 3 The imUleS of c"mber. c,l~tor "nd slCe''''g ax,s ilIe SCI ,n produCI'On ~n(1 nre not <ldluswble. 4 Front wheel aliurUlll)n t (loe·"I) checks ilIe best camed out wl\h nlodern set!lIlg equ'pment. but il fC,lsonahly acc1llate alte rnative is hy nle<lns of the following procedure.
5 PI"ce the Cilr on level ground WIth the wheels 111 the sualghl·uheild pos' lion,
6
Oht"in or m"ke <I loe·in unuge Onu IHay eas,ly he Ilwde from it lenyth of rod or t ubinU. cr<lnked to clear the SUIl'P or bcllhousing and h~vmy il setscrew "nd locknut ill one end 7 W'lh the gnuUe. measure the d,stilnce IJetween the two IIlner wheel IIrns M hub helUln ill the Iron I of the wheel. 8 flowte the roadwheellhrough 180' (hillf il tU1[1). hy pushinU or pvlllllg the CM and then me,lsure Ihe d'Stilnce ilgaon at hvb height bel ween lite inner whee! (In,s <It the reil! of the roadwheel. Th,s meaSurernem should eIther he t he Silme as the one Just lilken. or greilter hy no! Ino,e lhan 7 mrn (028 in) 9 Where the 1O~·1II IS founoJ to be ,,,correcl. sla~ken the 10cknuiS 0[1 each tr,lck rod. also t he I lex ,ble bellows clops and rOWle each tr~ck rod . XII equal ilrnourl unlll the correcl toe·,n ,s oIJW'''ed . T,ghten Ihe .k rod ~nd 10cknulS. whole the !JilIIJo,nts ille held III the centre of lhe" ilrCS of trilvel II'S "npcrilllve lh~11he len\Jlhs of 1he trilck ,ods are ~IWi&#39;yS equal 01herw,se thu wheel ilngles on turns WIll he ,ncorrect. If
ne:w components have heen I'lted. set the ro"dwheels ,n the stral\jht·ilheil(f p05otrOn and also cent",lrse the steering wheel. AdJ"st the len\Jths of the track rods hy lllll1ing tltem so th,,! the track rod end IJ,litJoinl studs w,11 drop eils,ly onlO the eyes of the steer inu ilrlllS Measllfe the dislilllces between the centres of the hilllfOllllS illld the grooves on Ihe inner ends of the track rods and ildjust. ,r neceSSilry. so Ihiltthey me equ,ll Thl~ is all lII,t,,,1 sellinlJ only and prec,se ildillstmellt mu~t he carried oul as descrrhed earheL
21 Wheels and lyres -uonNal care and milintenl1nce
Wheels ilild tyre~ shOuld give no reill problems in usc provided thm ,1 close eye IS kept on Ihe", with re\janlto excessive weilr or dilmilge To llns end. the following pOllltS should he noted Ensure thm lyre pressures ",e checked re\Jularly ami ma,ntallled correctly. Checklllg should be c,Hried out woth the tyres cold alld nOI IIlHlledialely alter the vehicle hilS heen "I usc. II the pressures are checked w'th the tyres hOI. iln ap(l,Hently hi\jh readmlJ w,1l be ohw'lled OWlnH to heilt expJnsron. Under n<) Cllcumst<l"ces should ,III ,!lWlllpt he lIlildu to reduce the p,essu,es to Ihc quoted cold r eildlllU ,II thl~ "Ist,once. or effect've undcrinlliltlon w,1I result Undc""f)"I'o" wrll Ciluse ov(;rheiltu\lj 01 the tyre OWin\1 to excn ss,ve fluXlIlU 01 the casin\l. and Ihe Ire,ld w,1I not S,I correctly on lhr! road surfilce ThIS wrll cause it cOllsequent loss 01 adhcs,on alld excess,ve weilr. IlOtto '\lention the danncr of sudden tyre fadwe due to hea t bluld U), Overonfiil t,on w,11 Ciluse rap,rt Wear of the cell Ire part of Ihe lyre tread coupled w,th reduced ndhesloll. hiusher ride. and lhe dan\je, of shock dilmilge occw"ng in the lyre Cilsin\l Heg"liloIy check the tyres lor dilrno1\je 111 the form of cuts or !>"Iucs.
eSpecii\lIy 111 the s,dewalls Remove any na,ls or stones ell\bedded 111 the tread hefore they penetr"te lhe tyre 10 cnuse dcfliltlon If remov,,1 {)i <I nad docs reveill thai t he tyre hilS been punctured. relIt the "JlI so thill ,ts point 01 penelrat,on is Illilrkcd Then inHlled'illely change the wheel and have the tyre repimed by il tyre deiller, Do no/ drive on il tyre in such il cond,"on In lIlilny cilses a punClUre C~ll he sunply repa"ed by tile use of ilil IIlner tube 01 t he correct size ilnd type. If In any doubl ilS to the poss,ble conS<lquences of ilily dlll11ilge found. conSult your locill lyre defiler lor adv,ce Periodically rcmove Ihe wheels and clean any dirt or mud from the 'Ilside ilnd outs,de SUrlilCeS. Ex~mine the wheel rims for signs o f (listing. CorrOSion or other dilmilue. Light alloy wheels "rc eusily
dilll1i1ged by ·kerbing· wh,lst par king. and simililrly stee l wheels may hecome denIed or buckled, Renewnl of the wheel rs very ohenthe only course of rellled'ill ilct,on poss,ble, The balance 01 each wheel Jnd tyre ilssembly should be mainta,ned to ilvoid excess,ve weilr, not only 10 the tyres but illso to the s teering and suspension components. Wheel imbillilnce 's normilily S'\ln, f,ed by v,i)rilllOn through the veillcle·s bodyshell. illthouUh III many c~ses it IS piullcularly nOliceahle Ihrouoh the steenng whuel. Conversely. it ~hould bc noted thilt weilr o r dilnlaUc 111 suspellS IOll or steer ing components may '.:ause e~ceSSlve tyre wear. Out·of·round or out-of· t!Ue lyres, damaged wheels and wheel !leafing weilf/ nlilladJustntent also lilll into th<s Cille\Jo ry Billancing w ill not usually cure v,bration caused by such wear
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)76 Chapter 11 Bodywork and fitting
General description
The body is of all-s teel welded construction with impact ilbsorbing hont Dnd rear sections . Anli-burSllocks nrc lilted 10 the doors, ilnd the
t ailgDte is supponcd by \J<ls- filled d ,lmp crs. All window glass is of toughened safety type. The front seots Me 01 reclining bucket type. whde the '(Jill sealS mJy be of individufli bucket type or bench type. The level of lIim both ;IHellor ,H1(1 exterior vanes accordll1lJ 10 the Pill!lCular model.
2 Routine nwintenancc
AI the in1erVills speCIfIed in the Routine M"IIl\cnilnCe section in the front 0 1 the nl<lnual c,my out the lullowlI1!J procedures.
Check seal bellS 1 ThorouUh1y check nil sent hellS 101 frayu10 . cu\s, <I,unage Or dctCHnrmion and If ncccssnry Ii"new thell) . Check lor sccu"ty
iheck and lubricafe bonnet and door locks 2 011 the bonnet lock ilnd sillety c~tch ilnt! check thilt they oper~lle correctly. 3 011 illl the (Ioor check strilps ilrld lock hilrwls 4 011 the luel 1IIIer CilP hlnw:! ilnd lock
Check underbody protective coatiog 5 W,th the CM supponed on i1xle stilnds. check the cond,tlon 01 the un(lelbody protcctivc coating. i1nd wherc neceSSilry clean <lny dilll1ilged i1rCilS ilnd ~pply il ncw coming. It the car is 51111 wrlhlll the corrosion w~rranty period check the terll1s illld conditions 01 the
w<lrrilnty lirs t.
3
M,,;ntcll<lI1Ce ~ bodywork ilnd underfrilme
The gorH)!<l1 condlt<on 01 iI vehicle' s hodywor k IS the one thin\) that SluruhC<lntiy Mlects ,ts v<lllle Maintenililce is easy but needs to he leu"lilr. Ne!)lcct. p;lItlctllilrly <liter mU10r dama\}e. C,)I lead qUIckly to hllther delCIIor<ltlon and costly !Cpolir hIlls It IS <"'ponant ;rlso to keep watch on those palts 01 the vehlde not lIl)lllcdr;'tllly vl~lblc. lor IIlstance the undersIde. Inside "II the wheel ~II(;h(ls ,l"d th(l lower pillt ')1 th e engine COlllP'IIt"'Cnt. The bnSlc 1l1&#34;inlen~IIl{;c rOutlile lor the hodywork is wilshlllU -')rder"hly WIth <l lot 01 wnlCr. !rom" hose . T1l1s WIll rcmove 1111 the
ose solids which lIl.1y have stllt:k to the vehIcle. It is i",portant 10 Ilush these oU in such a way ilS 10 prevent \}lIt 110m scratching Ih(l Irni sh . T11e wheel arches o1I1(f unded'nrne need w~lshln9 in the s;rrne
Wily to remove any aCCUIllUI,lted mud whIch WIll retillll mOlslu re <llld tend to encournge rust. P&#39;:lIado~ically cnough, the besl timc to clC.1n Ihe urrderl,arne and wheel ilrches is in wet weill her when the mud is Ihoroughly wei and 5011. In very wet weilther the undcrfrarne is usuilily cleaned 01 large ~ccumuliltions Jutorl,"l1cllly amf this is a good lim(l
f or inspection. Periodically, except on vehicles w'lh iI wax· bnsed underbody protec tive cO<lling. it is 11 good ideil to have Ihe whole 01 the underframe 01 the vehicle steam cleaned. engine compartment included. so Ihat a thorouuh Insp(lction C<1l1 be ca"ie(l out to see Wh,lt minor repilirs ,lnd renoviltions are neceSSilry . Steam cleaning is available at many g<1lage5 and is neceSSilry for removal 01 the accumul<ltion 01 oily g,ime which sometimes is allowed 10 become thick In cer t<lin areas . If steJm cleaning f<lcilities are not i1va;!aole. there nre one or two excellent grease solvents aVilililble which can be brUSh <lpptied. The (Iir( can then be simply hosed off. Note thaI these methods should not be uS(ld on vehicles wilh wax·based underbody proteclive coating or the coaling w ill be removed. Such vehicles should he inspected i1nnualiy, preferably just prior \0 winter. wh(ln the underbody should be washed down and any damage to the wax coaling rep aired. Ideally, a completely fresh coat should b(l applied. It would illso be worth conSidering the lise of such wax·hased jotection lor injectio n into door panels, srlls, box sections. etc. as i1n i1dditional saleguard a\Jilinst rust damage where such protection is not provided by Ihe vehicle manufacturer.
After w<lshing paintwork, wipe 011 with <l chillllois lemher to give an unspoiled clear finiS h. A coat of clear protective wa~ polish will gIve added p rotection i1gilins t chemiCill pollutants in Ihe ilir. II the pilintwork sheen hilS dulled or oxidised. use a cleilner/poli5h(lr comhinntion \0 restore the brilliilnce 01 the shine. This lequires il l'llIe eHort . but such dulling is usually caused b(lcause rcgulilr washing has been neglected. C<lIe needs t o be Inken WIth mewl1ic paintwork, as speciill non·"brasive cleilner/polisher is required 10 lIvold dllmaue to the fInish. Alw<lys check thM Ihe door and ventililtor opening drilin holes and pipes <lre completely cle<lr so Ihilt wilter Ciln be drained oul. Bright work should be tre<lted in the Silme wily ilS pllint work W indscreens and windows Ciln be kcpt clear 01 the smeary film whrch oftcn appenrs by the lise 01 iI proprielilry gl1l5S cleaner. Neve, use any lorm of wax or other bOdy or chromium polish on glass.
4 Mnintenllnce -upholstery MId eMpets
Mats and C<lrpets should he h,ushed or VilCULU!! deill1ed rngulJ' Iy to keep them free of gilt. II they <lre badly stilrned remove Ihem hom thc vehicle for scruhbing o r sponging Jntl m<lke ql,ite sur e thr:y art) <f,V before re!rlling. Scms and mtcroOI tlim p,lnels clln he kept clean by wiplll!J WIth <l damp cloth. II they do hecome still ned (which '-:<111 he more <lpp<lrelll 011 IIgll1 coloured upholstery) use <l illlie ilq",d deter\Jent ilnd ,1 soil nllli brush 10 scour lhe \}rime out 01 the ()lalll 01 the rnnlerinl . Do nOI 10r!Jetto keep the he,ldlining clenn in the same w,1y as lhe upholstery. When using liquI{1 cle,1ners mSlde Ihe vehie.l e do not over-wet the surf!lces beinu cle<lned . Exces~lve damp could !Jet inlO the 5e,IIns nnd padded in1erior C.1USil1n sWins. offensive odours or evell rot II the IIlside of the vehicle gets wet accidenl.1lly it is worthwhrle t;lking some I,ouble 10 dry il out properly. par ticularly where cMpet5 i1re involved Do rlo/lc,we oil or clec/,ic helllClS illsiclc Ihc vchicll) lor tllis l!Urposc.
5 Minor body dnnl<lge -repair
rhe phOlo{Jr.1phic SCl/rICIICCS 011 P,IflcS 174 ilfld 175111051'.11" Ihe OIWfil/iofl$ d"lo1Ifcd ill Ih" 101i0willY suh·SCC(IOII$. Note: Fo, mon' (il-1,1iIL'd ili/OlilialiOIl 01/)01/1 I}odywork fCfwir. Ihe U"ylll:s P"hlislllilY Group pu/)/ish II book by Lilli/say POller c!llIed The C,If lJodywork H"II,11f Mill",al flII:~ lIIeorpor"ll!s ;lIlo,,,,,l(ioll on sllcli <Is/wets as rIIsl (rcallllc,rl. Ih1!IJlin!/ <Ifill 9',15S frb'l) ((!p,1irs, ,1S well ,15 rlvlilffs olr 11/011) <1fll/JllioIlS rcpai,s IIIvofvirry weldlllY i",d p,lltel belrlillg.
Repair of minor scratches it) bodywork II the scratch is very superllclill, MId docs not penetrilte 10 the Illelill 01 the hodywork, repnir is very simple. LIghtly rub the area 01 the scratch with a pilintwork renoviltor, or il vcry line CUtlll'\} p<lSle, to relllOVe loose paint frOI11 thc scratch and 10 clear the surrOlllldlll\J hodywork 01 Wil X polish. Rinse the alca woth cleMI wilte,. Apply lOuch·up pnint to Ihe scrntch using iI IrIle p~1I11 brush, continue 10 apply fi ne faye rs of point until the surlilce 01 the pamt ,nthe scril lch is level with the surrounding p<liIllWork. Allow the new p<linl nt le<lst two weeks 10 hMden: then blend it into the surrOUlld in\}
pa il11work by rubbing Ihe sC/Dtch men w ith iI pilintwork renovator or a
very line culling pils te. Finally, opply wax polish. WhNe the scrotch has penctrDt(ld right through to the metill of the bodywork. causing the mowl \0 rust. iI d ifferent repa ir lechnique is
required. Remove any loosc rus t fronl the bottom 01 the scra tch with a penknile. then apply rUSI inhibiting paint 10 prevent the lormation 01 rust in Ihe future. Using n rubber or nylon appliCiltor fill the scratch with bodystopper paste. II requ ired. this paste Ciln be mixed with cellulose thinners to provide a very thin paste which is ideal for filling narrow scratches. Before t he stopper·paSI(l in the scratch hardens. wrilp il piece 01 smooth COllon rJg i1round the lOp 01 J linger. Dip the finger in cellulose thinners and then quickly sweep it i1CIOSS the surlace of the 5topper-pJste in the scratCh: this will ensure tha t the surfilce 01 the stopper,pilste is slightly hollowed. The scratch can now be p<linted over as described eMlier in this Section.
Repair o f dents ill bodywork When deep denting 01 the vehicle's bodywork hilS taken plilce. the
first wsk is to pull the dent out, untrl t he affected bodywork almost
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) Chapter 11 Bodywork and fittin g 17 7
~!t~InS its oriOin,11 sh~flC. There is lillie point in trying to restore the original s hllpe complClC ly, as the me1011 on the darnllged arca will have stretched on impact ilnd cannOl be reshaped fully !O its original contou r, II is belter to bring the level of the dellt up to 11 poin t which is aboul ~ in (3 111111) below the level 01 the surrounding bodywork . In cases whe.e the dent is very shallow anywi'lY. i, is nOI worth trying \0 pull 1 ou t 111 all, II the ull{lersidc 01 the dent is accessible. il can be hammercd oul gently from behind, using a malleI with a wooden or plastic head. WhilSt doing Ihis. hold a suitable block of wood l'flllly a{),111151 the outside 01 the panel 10 absorb the impact from the hammer blowS and thuS Il,event 11 Imge area of the bodywo.k hom being 'belled,ouf, Should tho dem be in a section of tho bodywo.k which has iI double skin or SOI1IIl other filclOr mokil1g It inaccesslhle from behind, a
dllferent technique is cillied lor, Drill severill sm;1U holes through the
mewl II1slde the i1reil (Jilrtlcul,ldy in tho deeper section, Then screw long sel1·tap~ing screws into the holes IllSt suffIcien tly for Ihem to gilln iI good purchase In the mewl. Now the Ilen t C"n he 1)lJlled out by pulllllg on the protruding headS of the screws wllh iI pnll of pliers. The no.t stilgo of the rep,lir is the .emOllill of the PilUlt from the 113Ued meil, and hom nn Inch or so of tho SurroundlilU 'SOUfl(r
Jdywork , Tills is accomplished most oilslly by usil1U a wire brush or ab&#39;~sllle pild on " ,)owe< dflll, ~,lthou9h It Clln he done Just i1S e ively hy hnmf usmg shoots 01 1I1)'i151110 P.l,)C •. To COlll,llete the p<epa.al.on 10' f,IIul9, score lhe SUrlilCe 01 tho b;1re melDI wllh a sClewdflvor or the tilnu 01 a I.le, 0' altCf11<1l1voly, dlill s"'<l1I holes in the ilflec ted ,lICi1, ThiS Will p,ovlde a .eillly {lood 'koy' lor th e hiler pnsle . To coml)leltl the rep<lir sec the Secuon on flllinfJ ,lnd re spr"yIl1 9.
Repair of fIIst holes or gashes ill bodYWOlk Romovo i111 point f rom the affected ;lIen i1nd from ifn IIlch or so 01 the surrounding 'sound' bodywork. using ;1Il nll.a$llIe pnd or 11 wire brush on 0 power drill. If these iIIe not i111",lahle a few sheets 01 abrasive pilper will do the job JUSt as offoctivilly Wrth the paint removed you will be able to gauge the sovori ty of the corrosion alld
thorelore decide whether to renew the whole polllel (II this IS possihle) or to .ep[lir the affoctod illoa. New body Po1nols arc not ,1S expensive as mos t flCOple think and it is often (Iuicker and mo.e satislacto • .,. to fit" new t)anelthan to auempt to rellair larue n.e,1S 01 corrosion.
RenlOlifl all f,llln\Js hom the .. lIeeted a.o" cxcoptthose which Will
act ~s ,1 uu,(ie t o the oliUllwl shape 01 the (i,lIlla\je(i bodywork (ell hn,1(1lnll1l) ~h.~lIs etc). ThOll, USlnu tin snIps or ~ h"cks<lw hl<ldtl. remOV"
all 100SI) met,,1 ,,,,d allY other IIwtill b;I(I'Y 1IIIo.:t..,d hy cOffosion H"lIllller tIro cdIJlls 01 lire hole Il\wartfs In Older to CW1Ite a shulrt
d epreSSion fo r Ih c frllcr pas\(!
'll/lle hrush the aHected Me[l to 'CIilOlle tiro powdery rust from the ,ICO 01 the lelllilllllll!l lIlet,,1 P;lInl thc "flected arc" wllh lUst
IIII"I)ltll1l) p""'t. If the hilck 01 the ,usle.1 me,1 's accesSlhle treolt tillS
" delo.o frlhflU cml t<lke p'[lee It w ,1I he neecs s"'y 10 hlock tho holo in
some w".,. . Th,s COil be [lchl(~ved by tho use 0 1 aluminium o. Illastlc
me sh. or altlflll1l1um t",Joe. AlulIll"'um 0' pl;1strc mesh IS Il.oh"bl.,. lile hest m<lw",,'to use lor a
lar\Je holo. Cut a I>.eeo to tho "pprOXlfll"te Srte ;1n(1 sh[lpe 01 the hole to he frlled. then pOSit lOll It in tho 11010 so th;rlltS ed!leS arc below the lovel 01 the sUffoundrng bodywork. It c"n he ret"mcd in position by sevcral blobs of hiler paste [lround Its per'l)lIelY,
Aluminium wpe should be us ed lor slll ;rll 0' vCly narrow holes. Pull a picce oil tho .011 ond tri'" It to tho apIl<OXlillOtO size and shape
r equired, Ihe n pull off the backrng p,1por (If used) and stick th e tape
ove . the hole, rt C[ln be overlapped II tho thickness of one piece is
i nsufficient. Burnish down the 00ges of tho tapO With the handle 01 "
screwdrillC ' or srmllOf, to ensure that the ",po.s securely auached to the
metal undomeath .
Bodywork rCIJ<1irs -filling a"d re-sprayi"g BefOte uSlIlg thiS Seetion, soe the Sections on denl. doep scratc h.
rust holes "nd gash repai.s . M~ny types of hodyfllfer Me ~val&#39;ahlo, but Uonerally spe~k.ng those nrOpnelOry kits which conlain 0 till of f illor paste and a tube of resin h~fdener Me best for this type of rcp,llf A wide, !ieKilJle pl<lstic 0' n.,.lon apl)llc~tor wrll he found Invaluable for irupn.tinu a smoOl h and well cO'''<>ured fUlish 10 thc surface 01 Ih c filler , h up a hulc fille. 011 a cle,,,, piece 01 card or boo.d -measure tho
hardener carefully (follow the m"kCI's instructions on the pack) othe.wrse thO folic. Will !>tt too rill)luly or tOO Slowly . Using the
"pplicator apply the filler paste to Ihe prcpared area: draw the
applicalOr across the surfaco 01 tho IllIer to achieve the correct contour and to lovel the fillef surface. As soon /1S it contour that approxim"tes 10 thO corrOCt one is achielled, SlOp wo.kinU the pas le - il you carryon too long the pasto will becomc sticky and begin to 'pick up' on tho
app lic"tol. Continue to add thin layels of Iiller paste at twenty· minute intervals until the level of the filler is just pfoud of the surrounding bodywork Once the IllIer has hardened, excess can be removed using a met;!1 plane or IiIe. F.om then on. progressively finer grades of abrasive paper should be used. starling with a 40 grade p.oduction paper and l.nishing With 400 o."de wet·and·dry paper . Always wrap the abrasille p"pcr IIrOUlld a flat rubber, cork. or wooden block -otherwise the surfaco 01 the frller Will nOI be completely flat. DUling the smoothing of the fIller SUI face the wel·and·dry paper shoufd be periodically rinsod in walCr. ThiS will ensure thaI alle.y smooth linish is imparted 10 the frller (It th O flllni SHIIJO. At t!\l S st1lge the 'dont ' shoul(! be surrounded by a ring of bme
mowl, whIch in IUfn Should he encirclod !.Iy the finely 'feathered' edge
0 1 th e good paintwork . Rinse tho repair nrea wilh clean water, until all 01 the dust I>roduced by the rubblllu·down operation has gone. Sp."y the whole .ep.1ir a.oa with" light coat of primer -this will show UI> any ,mpcrfOChons in lhe su.face of the fll1e •. Repai. theso Iml)CdectlOIlS with frosh 1,110' paste or bodySlOpper, and onco mOte
smoOth the sUfl<lce WIth "b.asille I>aper, If bodystopper is used, it c"n he mixed wllh cellulose thinnors to lorm a really thi n p.1Ste which is Idt(lllo, "'''ng smilll holes. Repeat this spray and repair procedure until you a.o satIs fied th"tthe sudaco of the filler, and the fe<lt hered edge of
thl'.! pnintwork nrc perfect. Ctean thO rep"ir ;lfea with clean water and .1l1ow to d.y fully, The .ep,," arc" is now ready for 1",,,1 sprilying. Paint spraying muSI
he call1od out in a w".m, dry, wind loss and dus t free atmosphero. This condition can be created mtllicially II you have access to a large indoor working "reil. but rl you nre lorced to work in the open. you Will have to pick your day lIe.y ca.efully . II you a.e working indoors. dousin\J the
floor in the work mea with water will holp 10 SOllie the dust which would otherwise be in the iltmosphe.e . If the ,epai. mea is con fined to one bod.,. pilllOl, mask off tho SUffoundlflg panels; lhis Will hell) 10 minllllise tho effocts 01 a slight mis,match in lH,lint colou.s Bodywo.k hUUlUS (eU ch.omo strips. door handles Otc) Will "'SO noed to be
"';1sked ot! Use uenume fII<lsklflg t.1I)1) nnd sOlloral thicknesses of II(JWSI)aper lor the n .. ,sklllg opor<ltlOIlS, Ilelole commenCing 10 sp.ay. aU1t.1lO the nerosol cnn thoroughly.
thon s pray n tes t mea (<In old till. or similar) until tile techniq llO is mastered . COlier the rep,lII me" with n thick coat 01 primer; tho thlcknoss Should be bUilt up usrng sever,,' thin layers 01 pninl ratller th,ln one ttllck one. USUI\J 400 Ura(le wet·ond·dry p,lper. lub down tito surface of the jlflfller until it IS renUy smooth . While dOIng thIS. the work aroa should be thoroughly doused with watel, and the wet·.1nd·dry 1)'11>0' I>enod,cally . insed III w"ter. Allow to dry befo.e sprayinu 011 mOl(l ,laln t
S ilray on t he t op CO"1. "\Jain bUlldmu ull the tluckness by usul9
sOllof1lllhlfl'"ye .s 01 p<111l!. S Ia .t spraying in theCllnlre 01 the .epair mOil and theil, USH\g a clfcular mOllon, work outwards untrlthe whole ropmr
"rea ond al>out 2 inches 01 tho surrounding origmal pallltwork IS COvered Remolle allm"sklng mnteflaf 1010 15 minutes alter spr<lylll\J on tho frnal cont of pamt. Allow the ncw pault at leil5t twO weeks to hnrden. then. uSIng" paintwo.k .enovatOr 0'" very fine culling paSte, blend the edges of Iho
paint Illto the OXlst lng paintwork . Frnally. apply wax polish
Plastic compOllc"ts Wllh the use 01 mo.o and more pl"stic l>ody components by the
vehrcle manufac turers (eg bumpers, spolle.s. and in some cases major
body panels). reCllilcation 01 damago to such items .hilS .t.>e<:0me a
mOller o f eHhor emruSling relhl'r wOtk to a specialist m thiS field, o. renewing complete components Rep"ir by the DIY owner is nOlleillly feaSible owing to Ihe cost of the equipmen t and materials reQui.ed for effecting such repairs. The baSIC technique inllolves making a grOOllo
atong th o hno of the crack in the plastic using a rotary hurr in a pow~r drill. The damnged pal! is then welded hack togeth er by uSing a hot "" gun to heat up nnd luse a pl<lstlC IllIer rod IUtO the g.oove . Any excess
plastiC is then remolled an(lthe Mea .ubbed down to a smooth l in ish. I t IS Ifnpo.t3nt that a IllIer rod 0 1 tho correc t plas tic IS used. as body components can b e made of a lIaliety 01 dlHerenl types (eu
polyca.bonate. ABS, poIYllropylene) .
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) Chapter 11 Bodywork and fitting 189
/~
32 8A I&#39;,,~c 0111 Ihe alp 32 an ali(I ,(,mo .. c the console screw 329 Removing the hnndbrake lever boot find be~el
Fig.n.la C lock ro:.,,"ov<ll tools (Sec 32)
1 () "'I!! (0 If; "') /J IOO",m (()/I() III)
32 Centre cOIl~ole·· fUIllUV,,1 ,,,,d refiUinu
IJasic tYlle '.111 Ihe caqll:l 110m ;!lolllni the r'OIlI of t im t:()Il~()lo, thun push the " .J <llld hel..,1 out of Ihe hUlls&#39;&#39;&#39;~J DlsCO""CCI the dock 1r~<](ls 2 Remove 11", two SCI(lWS il( Ill(.' reiH cnd ,inti two (I101e hom the clock emt. to 1!.,lu<lst: Ihe cOllsol", 3 rlell10vc the \lP;" l<:vcI ~&#34;(lh, or T·h""dln 1 Lilt 0/11110 consul" As dpphcilhlc. !(:r!'UVC the clock 11l0llrlll1l!) pl<lIC screws "ud/or UCilrstuft lever hoot 5 flchtl;nu 15 the reverse of the 'clllov,,1 1110<:odlllO.
Gfli,1 type (also Il((ed fa I(I/ef nVI)-Glli" modrds) 6 Lift the Cil'PCl hom ;"oulld the IrOll1 oj the console 7 F,.brIC<lte twO sm~11 h",cke!s f,om 1 5 ""n (0 06 ,n) sheet sleel (sce Fig . 11.18) ,1I)d ,nsel1 (hese hel"nd (he IJlilck hewl to ,emove the clock Disconnect the w,,,ng. 8 Remove the two console ,etammg 5c,ews. then prIse oul the Cflp in hOIl! 01 the gearshift lever ~n(f rcmove the screws heneilth (photOs). 9 Cilrefully p,,~e the h;Ul(llJrilkc lever hoot ilnd belel ;)ssembly from tlie conSOle ;)nd remove II (photo). 10 Cnwluily PrlSC out the Gellire pflilel cover hom behind lhe gear lever. 11 Lilt up the cenlle il&#34;llfe~1 and remove lhe screw hom the bottom of the comp,lrtmen1 12 Remove the ;)rrn(CSI h"'\Je screws and place the ;)"nrest in the comp;),tment 13 Remove thc lwo screws ,I[ the hont end 01 Ihe iI&#34;,&#34;e~t rUSC out the cap at the r"ar 01 the console and remove th e scre w • Ca(elully lilt Oli! the 'eilr seCllon. I,onl s(:ctlon and console COlllpilftmcnt 16 Remove the he,ll "'5ul"tll1g pad Irom bene,l1h the consola Cornpnrtment ilr..,a
17 As appliCill)le. remove lhe eleeuical connector from Ihe base 01 cilch senlhelt s(;llk and rcmove the stn lk ".lI1g boll th,ouOh the top of thc consolc. Rcmove the stnlk ilssell1hly thrOuoh tlHl II1SIdc console suppo,!. 18 Pull the cMpet awny hom the SIdes of the 5UPPO,1 assen,bly. then detilch the support hy removIng (he eluht S!)CUW1!J screws. 19 Hefil!lnU is bilS'C,1I1y Ihe reV«($e ollhe !«Illoval procedlHe. hUI Illst ensure lh,11 illl Ihe splle nuts ilre corrCClly loenled on Ihe brflCke(s. Tluhten tile sefllhelt SliIlks to the specilied IOlque.
33 Sunroof piln el -ndjustments
Gap adjustment 1 When closed. a Unp of 5 8 10 6.9 mm (0.2310 027 "') should eXI~t hetwecn thc slIn(oof and (h e CM rool. II;) vmyl roof cover IS lilted. Ih,s gap should he reduced by 1 .78 mm (0.07 Ill). If adlllst'!\(Jnl IS requued. pwceed ns detaIled below. 2 With the sunrool hall open. remove (he sunrool heildhlunll hnlne 3 Close the sUllfool. then pull Ihe hei!dhnll1H hOIll (he Ie." and remove ,I. 1 To ndlust the hOnl 01 the sumoo!. loosen the front Uu,de relillnu1U screws. then whIlst p,essu1!J (he Uuitles IIlwilrds. lighten thc screws. 5 To ;)d,ustthe rear. loosen (he twa h.II1!) screws nt eneh Side of the ,1dlustinU hnsc. thcn p,ess (he reilr shdes mw,uds ,1"d t'Uh!Cn . 6 F,t the hCildllmn(J and hemU",,,,U h,,,ne 7 lithe ild)lIsunenl is slill Incorrect. ,emove (he we,l\hel$I"p from Ille rool panel ;)11(1 hend ,IS mountll1g lIange as necessary
.,.,.&#39;~ ..... ,,--...... ;;
• · .. ···"'·' -·0 . .'--
,"·""",-- 'r
FiU 11.19 Sunroof controllllechanism (Secs 33. 34 and 35)
, . , , , ,
I
,j
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Chapter 11 B odywork an d fitting 1 93
)~--------------------------~-- ------------
Fig . 11 .2 6 Heilter control cil blc 1Hljus tm ent
on SlHn (IMd heilter (S ec 40)
A (),.\·/"UlI/Ot flajl COII/ro//aVllr 8 I/Cgll/;I/O( Il.7p con/fo/h'vt'f
"'!ovy dilly IIfHltOf Chl.-r.k thilt Ihe d'Slflhutor 1I"p levc. ,HId WilIC, cont.ollcve. (FlU 11 28) we 011 Ihc cnd ollhl)" Ir,"vel ilnd clamp Ihe oulC, cablcs "I \IllS lIon.
AlllwMCfS 5 On complct ion. reconrWC I Ihe ulove comp;lr llllent liUhtinU leads.
Ihen lelil Ihe Ulove COllll)nltrllell1 nnd reconnet;1 Ihe hnllelY emlh len {1
41 H OMe r controls - removal and refittinu
1 Disconnect Ihe ballery eimh lend. 2 Rcmove Ihe s teer ing column shroud (2 screws D tthe bOliO",. then pull oul .lIlhe lOp). Lo wer thc stee.ing column (lel\Ving Ihe twO bOltS in position) sufficiently to ullow t he inst.umenl cluster I rim to be remOve d. 3 DIsconnect Ihc switch 10MIs ;lnd remove the instruments cluSIO' t"m. COllll)lot e with cowl "im (11 screws). Rcmovc the instrumont clusle r l!clOI (3 scrcws). 4 Pull oil Ihe hOiltor control knobs. II t his IS 1I0t possIble I><cilk thcm wllh ,1 larue pili. 01 pllors then rCl110vcthc conllols (4 scrcws). 00 not d'SCOIlI1CCt the control ci lhles ilt the heiller. 5 l1uI1Iove t he hCilIC' control PiHlCI ( 2 scrcws). ilenlove the b lowcr
sWItch illI(1 light i"'1 leild5 . D,sconncct the cilhles 110111 tho hCiller COl1lrols Rcll1tlllU IS the .evcrse 01 Ihe rcmovi,l p.ocoduro. du"ng whIch It
.. hc neccssmy 10 adjust th e callies. as dl.'SCfllled III the p.evlous ::. .on Also it w,1I be necessary to obtall1 new hCille. control knobs where npphcable.
42 HCHte r
water villve (hellvy duty heater) -IC lll oval an( 1
refittin g
Drilin
the engine coolant ilnd dlsconncct tho lowe. hosc !rom th c ,aulato. (,efe. to Chapter 2. II necessary). 2 Disconnect Ihe th.ee water hoses f,olll tho Wille. valve. 3 Removo the OUWr cilble from the clip on the WilWr v~lve bracket.
Ihen lenlOve the assembly from the bulkhead (2 screws). 4 Twis t the wate r valve. to disconnect the cable IrOI11 the operilt ing
l ever .
S Relilling is Ihe reve'so of the removal p.occdure. during which ~dJustl\lcnt should be m~do. as described in Section 40 fOf the heavy duty healCf On completion. re li t the rudiutor hose and fililhe cooling SYSt(:rll . us described in Chapler 2 .
43 Heater assembly -re mova l and re fillin u
1 DlsconnOCl lhc tJiltH:ry ea.th ICild. 2 -,,,in the COOIIlI1l. rei!;fliny 10 Chllpte. 2. II neCCSSilry. 3 sconnect th e Wiltcr hoscs from the hoale. he;!t e.chanuc. (phOtO). II I><il':ticable. hlow th.ough Ihe heat e.chunger WIth
2111111
- ' = 1 --·-~··&#34;&#34;I c,
'1,:-1
F ig .
11 .27 Heale r COl\trol cilhle ncJju stm ont on heilvy cJllty hl"latot (Sec 40)
A /),., ·{n/w/III If,}!, CQII/lo/ft'vct
Il"'·I·"1>.1 VU[ CO""'OL U·OL(
".."Tt"CO""'OL -NIL\[
Fig. 11.28 Willer varv e o n heavy duty heilter (Sec 40)
43.3 H eiltel water hoses
i , , . ,,
"
procarmanuals.com

)
Index
A
Accelerator cilble removal ilnd refining -14 shnft ilnd pedal removal and refining -75 Air cleaner removill Jnd ref,nrng cal buren or mod cis -68 fuel injecllon models -80
P rnator .,rushes inspecllon. removal and refilling Bosch -202 Femsa -203 Lucas - 202
dismantling and rcassembly -203
removal and refining -201 Antifreeze mixture -60 Automatic transmission descrip tion -122
B
downshift cable removal. refi11ing and adjustment -121 extension housing oil seal renewal -121 faull diagnosis -127
maintenance. routine -123
removal and refOlting -123
selector mechanism ildjustment - 126 rcmovill. overhaul ilnd refl11lng -125 speclflf:iltions -103 SI.1r1er IIlh'bilm/reVerse lamp switch remov<ll <lnd refIlling - 127 lorque wrench senings -103 'iliary (driving) light ,oIigrllnell t 212
Bilttery clrilrgmg _ 201 description and testing -200 removal and rcfll\lng -201 Big-end bearings -37. 52 Bleeding the hydr<lulic system brakes -152 power steering -168 Bodywork IJnd fittings -173 el seq Bodywork and fittings bonnet -186 bumpers -1 78
centre console -189
demister
noules reOlov<l1 and refi11ing -197
description _ 174
doms-178.180. 18210 185 face level vents removal and refItting -197 facia panel -188 fuel filler flap -188 heater -192 to 194. 196 10<ld space trim panel removal and refitting -186 -'alnlenance
) bodywork and under/rame _ 176 routine _ 116
uphOISlCry
and carpets -176 mirrors
-
192 open rem quarter glass assembly
removal and refitting -186
re~r qllMlcr trim panel removal and refitting -185 repi'lir millor damaue -178 minor damage -176 sent belts -191 seats -192 sunroof-189la 191 lailgate -180. 187. 188 torque wrench scuings -173 windscreen -180 Bodywork repair sequence (colour) -174, 175 Bonnet release c<Jble removal ilncl refitting -186 removill. reflt1ing and adjustment -186 Bml<ing systll'm -14201 seq Braking system deseriPlion -142 lilUl1 di<lgnosis -156 fOOlbrake ped .. 1 removal ')nd rel ining -152 fronl disc brakes -144,145 handtHake -153 \0 155 hydraulic system bleeding -152
p ipes <lnd hoses -151 n1<lintcnance. routine -143 n1<lSler cylinder -148. 149 presslilc uIHe&#34;~llIial switch removal and relitting -150 pressure reducing v~lve rernov~llInd refining -151 rear drum brakes -146 10148 specif'Cil!ions -142 stop IJmp swilCh removal. refi11ing ilnd adjuSlmeJl1 -152 lorque wrench se11ings -142 vacuum servo unil -156 Bulbs. lamp 'Tenewnl -213 to 217 spcclflcntions -199 Bumpers removal and refIlling -178
c
Camshaft (3.0 litre engine) retitting -54 removal -50 Camshaft and camshaf t bearings examination and renovation 2 _8 litre engine -35
3 .0 litre engine -51 Camshah and front intermediate plate (2.8 litre engine) refilling -41 Capacities. general -6 Carburetlor (Weber) aulomat ic choke
adjustment -71 removal. overhaul and retitting -71
dismantling and reassembly -69 general -68 idling adjustment -73
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)
rernoy .. ' and refl Uing -69 spcc,'iC<ltions -66 Carpets maimcnancc -1 76 Centre console removal .. nd refluing -189 Choke . au tomatic _ 71 Cigar 'ighter romoval ;lIld . e 'ru in g -225 C lock (console mounted) .emoval ilnd 'clming 223 el,/tef, -97 cl seq Clutch assemhly ",speclion 99 relluing 99 remov;]1 99 calli e renewal 100 dcsc.illllon 97 laul l d'''[jnos.s 10 nMlllIon,wec. foulorU) 98 pcd,,' rCIllOVill ,mel fcllUII1\) 10 1 release bca"ng .emoval ;mll wl,ulIIU 100 Speclflc,uions 9 7 Condenser (3.0 lilre models ) lCSI,nu. 'CIllO"'o1' MId refllli,,!) 90 Connecting rods (3.0 l itre engine) 5 1.52.54 Connectin g rods amI gudgeon pins examina tion ilnd ICnov;'Jlion 37, 52 Connecting rods ;lnd pisto ns refi Hing ~ 42. 54 Contact breaker points (3.0 litre models) i1djuslOlCm -89 remov1)1 nnd refiuing -89 Conversion fac tors -18 Coofing system 57 CI SCII Coo ling systcm nnhl.cew ",ixltlle GO desC.i,l liOn 58
d'ilUlinU 59
(IlIvchells
G3 e~p:mSloll I nnk 6<1 Ian hub l)()nllllH (30 hilI] 1110<1111,;) 64 f~ull (II;)Ul1osl~ 65
flll".U -
60 lIush"'9 59
",nmlen,lncc. roullllC 59
'ild,nlOr
GO speclficn llon5 57 lem,)er;!lurc unuuc Sf:n(Ie. unil -134 IhcrmOSl<11 -61 10Htlle wrench selll ngs 57 VISCOUS drlv\! 11'111 -63 W1)ler IWIllP 61 Crankca se ventiln tion system 2.8 tol'c engine -39 3.0 rillC engine 53 Cranksh1)ft 2.8 li l.e engine examinat ion nnd rcnoviuion -37 refilling -<10
3 .0 til.e cn gine examination lind renOV1'l110n -52 Crankshilft and main bearings (3.0 litr o engino) removal -51 Crankshllft pulley refitting (2.8 hIre engine) -44
removal ( 3 .0 litre engine) -50 Crankshaft r ear oil seal (3.0 litre engine) .efllling - 55 .emova l -51 Cylinder bores ~xaminalion and .enovation -36. 51 Indo r heads 2.8 titre engine dismanll ing .• cnova lion and .eassembl y -35
Index
D
refining - 45
3.0 litre engin e
. eassembly -55 refining -55 .emoval wilh engIne -49
removal wil h engine in car -49
Decarhonising -52 Dimensions. vehicle _ 6 Dim-dip lighting system _ 226 Disc br1lke s scc Front disc brakes Distributor overhaul 2.8 hlle engIne -93 3 a !r1l0 cng,ne -92 rcmoval and r efIlling _ 90 Doors eXle.io. hllndle ,emoval and refilling - 183 lock 1Issernbly removal and .efilling -184 pillar swi lc h -224
priVill e lock ,ernovill and ref'lIing -185 fnllics tracing nnd feCllik al ion -178 remOle conlroi hnndle removal and refilling -180 Hlmoval and rell\1l11g _ 185 Irim j>ilnel removal and ,efi ning _ 182 window Irnm c
moul(II ng nnd door wealhcrSlrips
removal and refining -185 rcmoval and relining -185 wmdow glass removal and retilling - 184 window regulnlor nssembly
r emoval and relilling -183 Drivebelt s .emov,,1 ilnd refil ling -63 Drum brakes sce Renl drum brakes
E
Eloc triclIl.system -198 e/ seq Electrical systcm altell11110, -201 10 203
ilu xiha.y driving "ghl -212 bmlery -200. 201 bulbs -199.21310217 ciga. IighlOf -225
clock -223
d escrip llon -200 dim-dip ligh ling syslem -226 laull diilgnOSIS -19. 233 ""sher unils and rel1lys -225
fuse s -199. 220
headligllls -211 10213 horn -220
inSI.ument clUSler -22 1 inSI.ument vollage .egula lor - 226 Inmp5 -21410217 mninlenance. fOUline w 200 mobite r"dio equIpment - 226
precautions - 200
rildio /casse tte player -226 specif ications - 198
speedomeler cab le -226 Slmte . mOlOr -207 swi tches -223 10 22 5 lailgall) wash er -217 laHgme wipef -217 to.que wrench sell ings -199
w indscree n washer -219 windscreen wiper -21810 220 wi.ing diagrams -235 10 249
25'
Ii
procarmanuals.com

inlet manifold - 83
main system components remova l and refilling -80 m~intenilnce, routine -79
specificiltions -67 to rque wrench settings -67 Fuel pump carburettor system cleaning - 68 re moval and refilling - 68
testing -68
fuel inject ion system removal and refining -80 Fuel system (carbureUor) accelera tor cable -74
accelerator shah and pedal - 75 air cleaner - 68
carburetlor -66, 68 to 73
description -67 e~ haust manifold - 76 lault diagnosis -85 luel pump -68 fu el wnk -73, 74 fu el lan k fille r pipe -74 fuel tank sender unit -74 inle l manifold -75 mainte nance, routine -67 specifiCiltions -66 torque wrench senings - 67 Fue l tank cleaning and repai r -74
filler pipe removal and re fi\ling .-74 remova l and refilling -73
sender uni t removal and ref il\in g -74 Fuel tank sender unit (fuel injection models) -83 Fuses
G
general -220 specifica tio ns - 199
Gearbo~ see Manual gearbO K Gudgeon pins - 37. 52
pdbrake adjus tment -153 cable(s} and rod removal and refilling 155 lever removal and refitting -154
warnin g hght switc h -225 Headlights alignment - 212 assembl y: removal and refilling ~ 211 bulbs renewal-2 13 Heater assembly: diSI11(lntting and reassembly 8ehr - 19 4 Smiths standard and heavy duty -196 assembly: removal and ret.tting -193 contlols
adjustmen t -192 removal and refilling ~ 1 93 water valve (heavy dUly heater)
removal and re fitting - 193 History o f tho nlodal-5 Horn faul t tra cing . remova l and refilling -220 Hubs, front
bearings renewal -162 removal. ret lu in g and bearing adjustment -16 1 Iraulic systam (brakes) bleed ing - 152 pipes and hoses removal and refilling -151
Index
Ignition switch and lock -224 Ignition system -87 el seq Ignition sys tem amplrlier module (2 .8 l i\(e mode ls)
r emova l and refilling - 94
condenser (3. 0 litre models) -90 COntact bre aker points (3.0 litre models) - 89
description -88
dis tributo r -
90. 92. 93 fau lt diagnosis -96
firing order -87 mainteMnce. routine -88
spare plugs - 91. 95 speci fications -87
t im ing -94
torque wrench settings -87 In strument cluster ill umina tion switch -224 removal and refitting _ 221 Instrument voltage regulator removal and refilling -226 Interior lamp and bulb
removal and refilling -217
J
Jacking -7
L
lubricants and fluids recommended - 17 lubrication chart - 17 lubrication system
M
2.8 litre engine -39 3.0 litre engi ne -53
Main and big·eOld bO(lrings e~amination and renovation -37, 52 Main bearings (3.0 litro engine) removal - 51 Maintenanco , routine bodywork and fillings d oor ch ec k straps security check - 16 locks, door chec k Straps. tuellilte r C<lll flap lubricalion -16 locks operat ion chec k - 16 seat belts wear/damage /security check -16 underbody protective coati no chec k -16, 176
upholstery and carpets - 17 6 windsCtee n illld windows cleilning - 16 braking system
h andbrake linkage lubricat ion -16, 144
h ydraulic fluid levul check /lap up - 16 . 143 hydraulic flu id renewal -16. 144
line s and hoses check -16
pads ilnd shoes we." check -16 , 14 3 servo check -16 . 144 vacuum hose check -16 Clutch adjustment chock -16, 98 cooling syslem
coolan l leve l chec k/top up -16, 59 coolant renewal -16, 59 drivebelt condl tion/wnsion check -16, 59 leaks check - 59 electrical system
ballery elec tro lyt e leve l cheek /top up - 16. 200 equ ipmen t opera tio n check -16. 200 headlamps cleaning -16
253
'i
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•
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