engine FORD CAPRI 1974 Owner's Guide
Page 53 of 205
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52 Chapter 1 Engin e
68 Connecting rods and gudgeon pins -Il~nmination a nd renovation
Refer 10 Sccuo n 18.
69 Cr,lIlkshnft -e~(lrl1in<ltion and renOV;ltion
E~amUle the four 'lIil;" l>e .. "n9 Journals and the s,~ Cfanlq>nls. whIch should illl be smooth Iln(1 IHlJhly polIshed II there arc any dllCP Ulooves. 01 deep scratches ;mo lhe.e ,s a sirn,l,lr <loI0"ola 1,on in the corrc5pon(fulH Iwaring sh(:ils. 1ho crallksh<l h should he reU'Ound. 2 II the JOUr1l<lts <I,e ,n noml conditIOn and 11 IS slIspec!(1d lhnl th e cI,Hlkshnh mily he suH,eocmly worn 10 fL'(IUIiO ,cYllndrng. II IS wa. 1h SCClo.II;t! the advice of ,) "'11111 Ford ,1\jCIlt. 0' cWllkshaf1 regllndlng servIce. 3 If ,he C1ank sh"f( IS '!](IIouml. till) wOlks w,1I ,1lso sUIW1y rhe new hC,lIIl1US wt\lt.;h WIll he rCII"'''!!! 10 Jl\atch Ihe lournal d,nmOlf"S.
" Check the spiuol bu,1"n!) III Ihe .ea. 0 1 the Cfankshall on manual l.ans.mSSlon m()(lels :mllil necess;uy .enew II
70 Mail' and biu·end heafinUs -olwillinmion and H)!1ovation
Ilelo,r to Seo.:lIOIl 20
71 TilninU oellrs -e~i1miniltion find renOVlltio n
Re f
el to Sec t,on 21.
72 Flywhee l/ d riveplale -Okamitliltiotl lind ronovtttion
Inspf:CI lhu ffywhf)l)I 0 ' ([ttvl'pl,,": fOI (!;U";'\lC ilnd 1:I".1I:k Ih;'1 Ihe ""!I H".u docs uol have .IIlY \)Iok"n o. l);Idly wOtn teeth. :1 On ''''''''';11 I'''"''''US~IO'' mnd"b ,I IS pOSSII.Il) 10 'CHew the I"'!l \]C,II .'S Ilesl:<Ihe(] ttl SeCtlim 22. IHlt on olllt()I\IHIIC IlilllSn"SSlon ,,, o(lels It IS nOl tlOss,bl" 10 le",OVf) 110" ""!I 11"01. hom Ihe dllVel)lttlc
73 Valves (",d v"lvo sO,,1S -tJkiu"illHtion lind renovation
[xallutle Ihl} v,tlves 101 IlIls "lid !l,ooves lind the valve SIems to. e~c,'SslV') we,l' III d'~loIIIOII' 2 Ek,""l1ltJ Ihe v,oIVil hf)"d 10' SI!.!"S 01 hu",u,U of the vOllvo seillS lind ch .. !ck Ihe ht 01 Ihl) villves III Iho v,llve UUldes . 10 SCl) II Ihe villve uu,des il,e WO!ll
3 We"" valve U",dcs c;'" be r l),lIned O\It lind vlIlves w'th overs.~e Siems lilted II iI v<llve !lulClt: h<ls h(."Cn ,eamed oUI. Ih(l eOllespon(fing vlllv(l sent must he rdOlCe(1
" Villves illld v~Ivo se .. ts whlc" show JollIe s,on 01 wear. call he lilpped in.
S To 1,1P the valves. In tt s u ction Iype gnmlonu 1001 to Ihe villvc hettd. smeil' a lu tle COil.se c;ubo.unllulll urmdmu pOIste on to I he sealing I~c e 01 Ihe vnlve ond inserllhe valve 11110 the cyJonder he"d. Rub Ihe stern of the v al ve gundlng 1001 hetween the palms 0 1 the hands. so Ihal Ihe valve,s ,otllle(l hHckwards 1I11d lo.wa.ds When II IS lelt lhOlI culling has
ceased. loft Ihe villvc. rotate It th.ough 90·, lowe. 1 and fepCill the u"n(llnu o.:.e.atlon . • e dlslllbulill9 the g"nd,ng pas!O on Ihe seal if necessilry. Conlinue Ihe process unlll a mllll gwy bOlnd IS pfoduced OIloun d the complete pe"phclY of hoth the vlllvc and t he valve seil l G RepoiJl Ihe opcrilllO" US" 'U fine o""d,nU I).Jsle. 10 ohtil'" <I I,ne.
IInlsh. then clean lJoth Ihe valvcs and Ille v alve seals 10 ,emove IIU \llIces 01 u"ndlno pash:! 7 II 'I IS convenl,,1lI 10 liIke Ihe eyhndc. he<ld and the valves 10 a wo.kshojl wllh the necosstt.y cquipment. II is In. h ellef to have illi Ihe va lves <lod Ih,,,, seJts ",f"ced. so IhOlI alilhe villves and sellts OIle lit the co""Ct ''''Ule and h ;lve Ihe COllect w,dlh o f conlllC1.
74 Dccarbonising -go notal
When Ihe cyllnde. heilds (li e removed. eilhe. in Ihe Course ovelhJul Of for inspection 01 bows 0. villve condllion when the e IS in Ihe CM . il IS nO'''1<I1 to remove 1111 CMhon deposits from the I Cfowns and heild
2 Th is is hesl done wilh 0 cup shilped wire hruSh ilnd iln elect." and is laorly slriliuhlforw,!,d when Ihe engine IS d'S<llilnlled an,
p,slOns removed Somel,,"es h.l. d SPOIS 01 ca.bon iI.e nOI , .emoved exc e)) t by iI SCf,'pCI . When cleanln!) Ihe p'Slons wllh a SCI IiIke care nOllO dam.lge Ihe sudace 01 the ,)iSlolI.,n (lilY WlJy . 3 When Ihe en!l",e IS in Ihe car. ceria", prCCau tlons mUSt be t whe", dcca.OOrllSIno the pistons' c.owns in o.del 10 p.evenl dislo, pieces 01 carbon 1.111;110 into Ihe inlerior 0 1 the ellgme which c cause dillllilgC to Cylindcr hores. pis Ion .10d lings 01. 01 allowed the Woller jl.1sSolues. llilrllilOC 10 'he Willer pun.,). Turn the engine so Ihe p'S lOn lleinU Wal ked on IS Mlhe top 01 lIS slIoke and then mas l Ihe a(llttcen l cy'",der bores ilnd ilil sU!roundl",g wttt(" l"cket alii wllh papel and .1!!hes,ve 1ape Press !lwasf) ,nto Ihe gil(l illI .ound pislon 10 keep Cilrbon pa,lIcles alit ,,"d Ih(ln SClilpe 1111 c,lfllon awa hand Do not usc iI power thin and wile hntsh when Ihc enguI(lls II, ettr as II WIt! virlUillly be 1Il1posslhie 10 kcop alf the cal ball dUSI clc, the engine. When compleled. c.1wlully c'ear OUI the OH,,,se moun(I ",II 01 Ihe (liS lon With ,1 mlllc h SlIck or somelhl"U Sllm 'iI • . bringing ciI.bon palhcles wllh It. R c,lellt the p(()r,e~s onlho o the. p,slon C'OIol II IS nOllecormllended Ih.lll1 "'ljJ 01 "uhon IS leit .ound Ihe edge 01 p,slon on I h(l Iheory Ih"t ,I Will ,11(1 all consumplion. ThiS WilS valli
Ihe eiliite. dilys 01 10nU stroke low .eVYlnO en!)lIles tJUllllodern enUil fuels ilnd Itrb"canlS C,1use less cOIIOOn deposils OInyway and any. b ehind lend merely 10 cause h O I .SpO IS.
75 Oil PU"',) -disnwntlino. eknmin"liOil ,,"d reOlssembly
The Oil pump mm"Itt;"S a I)ressure 0 1 ilbout 2 8 kgl/cm' (3 Ihf/in') lInd unless Ihere is ,1 sIo",IIcanl (hop In 001 P'(lSsuro willel ,)loved to he due 10 the Pllln,). rillhn. Ih;", 10 wo", heil'm!)s. 11 IS be .
t o le"ve Ihe 011 pump und'S hilhed. 2 To d'smanlle Ihe pump. fll:.1 ,emove II hOln the en!l'ne ns desc,,1 III SUClion 58 3 Remove Ihe IWO bolts seCulII1!J Ihe en d cover 10 the body 1 'emove the covel ilnd 1he .ehel v;" ve "sscmhly. Ihen Ihe Iwo P"
fOIOI assembly.
" Remove ,he IWO bolts lind ,,,ke Ihe p,ck·up w he lind SCIl' lIssembly oft Ihe pump housin!1 S Wilsh all lhe pilrlS In petlo'. usc iI hlllsh 10 cleol" Ihe Inside 01 1 pump ho usinu ilnd lhe p.cssu,.., .elle' vil've eh'!lnbel. ilnd milke 5' Ihilt ,111 p,tltlClcs 01 dill ilnd mewl n,e ,emoved Allow the pttrlS 10'~ n;IIUf,lllyor blow them d.y G Check Ihe Illslde ollho Puml) houSII'9. Ihe OilIer .;w:e ilnd Ihe 101 101 dilfllilUe and e~cesSIve weill 7 E~ll'''Ule the I111lling su.lace 01 lhe I)Ump cove. 101 we,lr It Ihe CO' IS sco,ed. o rooved. a. shows ilny s'g ns o f wea •. a new covef must I hlled 8 W,lh the ,otor assembly filted in the hOuSing. place a straighl·ed!. over Ihe end 0 1 the housing <lnd measure the .o tor end play. If 111 exceeds 0.1 04 mm (0004 in). Ihe ouler race. Shilfl and ,Olor must t renewed olS an assembly. 9 M eOlsllle the rOlor·IO·houslng clea'ilnce. which should not exce e 0304 mm (0
.012 in) OInd Ihe Inner 10 oute. rOlor gap. which should b 'oss IhOln 0.020 mOl (0008 i n ) II oulside these dimenSions. a ne" pun,,) Should be fitled 10 Check that Ihe leroel vollve and its sea Illig ,Ire Iree of dan'ilge all' thaI the .elief vOl've sp.ing ha s nOt collapsed. 01 is damaged. and 1 new paIlS ,f necessil rv. 11 Reassemble Ihe pump by IUSI lilting the lillie. IJnd outer rOIOr) Ihen lubric.11inU them wllh enUOne OIl. '2 Apply e ngine 011 to Iho rehcl vlllve plunuer <lnd sp""g ilnd Inse l Ihem inlO thei
r hOUSing Relll the Sjll1llU cal) and Ihe pump covel '3 Refit t he cov e. allolchrnenl sc.ews 1111d IlghlenIhelll1 0 the to.qu' wrench sen ing giv<m In ,he Spec,flcalions Altel t1uhtemng the screws
chec k thOlI Ihe 1010r moves freely 14 Refil the PlCk·up lUhe <lnd stralnel as semhly 10 the puntp body usi nU a new gOlskcl OInd then insert and hUhten the IWO IIxHlO screwS
procarmanuals.com
Page 55 of 205
) 54 Chapter 1 Engine
,n the "Oill hand ror;ke. covc. ~nd mlO Ihl) en!IHlC Ih'ouUh .111 .1(1,1pl0' bene,.!!> the (.1,hl"l)ll01 The sys\cm '!nSlI.ct; 11\.11 !lIlhurnl lIilSCS ille .ChunNt to Ihe enU'"e fOI fUllher (:orlllJ\'~I'OIl
78 Engine reassernbly - gcner<l l
Rolli' [0 Se(IIOn 20
79 C,lInsllllll -re';II'I1I)
SI"h, Illc SpM.,<1 "",th li S ChitrllfCI1'" "ml [""I onin Ill" r:;HlI:.hall ;oml ,, the kr,y 2 LlIb",':"I" lh" c"m~h,111 lo",.,als w,lh <:Ill)"") nd ,llld ~I,d" Ihe ' ·.IIlI~hah "' hOln\h" hOIl!. 1.II-IItH C;UI~ 10 ~""P ,1 ~1',IO!lhl. SO ,I', nvt III rl.mlil!1" II", /:.III1,h,,11 I)","'IIO~ 3 rr! th., (.l", ~h"h 11""~1 ,)1",,, wuhou! ;, !1.'~"('1 fIt lI,e two (,(lInl\I:!,,,nk hr',lei rr,!,'"lll'!! serews ;1I,d 11\lhl"" III"",
80 Cranksh .. ft reblti,,!!
~V'lh lilt: "II\IIIH' "p',ul" ,low". I. 'v ";I, h "I II", "1'1"'11"',""'0 h.,I,,",s ''''10 Ih" "1'1""1''''''1: u.",ll .• '~" wI·h. 111,'''''''1 ~,,,,, Ih." Ih" 1<" ""'!II.IIIO 0" II", I""""'!I '~P"'I""IV ""!!,,!!,,,I '" ,II" ':C"":~I"""h"!I ~I{)I '" II,,: 1; • • u'"c;I~" WI'!> Illh., "Id I""""'!I~ .,," I"""!I ",!tW:Il. ItI.lk" .;",1.111,,10:01 e.lch I .. """,!! hill! IS '''Iud • III III.., 1'1.,, ;11 h"ll wh";h,, W.IS ",mo"..,d Fn Iht:: Ih'u~1 w.lsh".s 10 <1;lcl. ~,,11l 01 11", CI:'II • .., I...,a''''!I. Ih" 0''''''''''([ l;lI;"s 01 Ihe wa~I'e.s IJelll!! Oulw;!lds (1"11 1 16) n"I.""II,c II"tI~1 w.l~I""s 11 1)lar.r. w,lh UH}.1SC 2 FII Ihe low ll anO "!1 halv",s 10 the app,op""h: I>";'''''!I ,;nps 1"1 Ihl1 IllIuSI wM,h.."s on ellll(!' S,dCl "r Ihe <""'"11 I>e;"'I1!l ':"1', Wllh Iho 1.," 01 Ihe w" she. Iitied "1i0 Ihe slOI It' IluI be''''''!1 <;;'1' Rel<lll' Ih" rh"'~1 w" she,s '" 1)I"ce ""'Ih !IIIMSo! :I LIII" '<:<111) Ihe c:o.lnk<:<,:.c l,e;IIln!! h.,I""s Will, '"'0''''' ,"I .11,,1 I .• l.o;I"IIV low,,, Ihe ':'''Ill~hilh unlO 111,,111 'I r"k" <:;,d, I>o:.1""!1 e:il!> '" hlln. lulll'G'h, 11<; hl'''''''!1 h;,u W'III ""II""! ",I AI'I,IV ""!I""] ".1 III IhH ('I,,,,ksh.lr, 1001lll,,1 ,,,,eI III 1111' !"'''''''H':''P W,III Ih" ""ow 11('''I1'''!llO"".''d~ IIH' ''''''1 01 II,n ""!lIII" L.e:h I""II"'H ""1' '''''~I I", ,"',1I.·d '"~ IIHi 1l('S""'" 100'" whll.h II W.IS II,IIl1lvod ~ I"'.",, II,,: 1""0 ,,,I."""'!, holts ;",d 1'!IIII"1 Ih,,,,, It) 11"1 10",IIe w",",.h ~('I''''H 11''''''' '" Ih.., SI,..:(' . .r,,:,,'I("'~ r,u" II,,· e:I,llIhh,,11 Ii) "II'",,: Ih.'1 II 11I1"Il!S 1"".jV. III'lorn I'IL"'!! Ihe "oxl hei""'11 1:011'_ II lh,' .:"lI1l~h.,h ,I""" ""I 1<1",10: III:<.:IV. Icn'o",! Ih'l l'l"""'\1 r.iljl Hnll check 11>.lllhll I>";""I!I ~hl!!l~ l1.w<I sc.,h,ld p,npedv ilmllhal IllI! hcall"H cap '5 Ihc CO"'''.I 0110) 10' Ih.'1 l'I/Slllon ij r'l Ihe oall~~h.ll1 ~,·V PI''':e Ihl! o.l,,"~hilll !lCil' 011 Ihe en,l ollh.., , .•• lIIl~II.,h .11101 1)0','111111 II hV 1,·lllpO •• ",ly "iII"!! II", e:'.111bh.o1l p"II"V .11 .. 1 II,,, OI'UIl1,,1 wil~II" •• ",,1 holl T'!I" I,·" Iho ""II. Ih(:" 1l!"'0"(! Ihe 1,,,11. w;o~he. ;11,11 ,-,,,,,ls","1 pulh:V 7 M""slI'" Ihll (l alll~h"'1 "",lIIo;lI ("'~I! Secholl 27) ..... h,ch sho"ld he .-IS Sll(!c,f'ell II "(;Ce~S;"V. hlmll .1 belwecn lior:s" hlll'l.~ bv IlIseltll1!J 11"U51 w.lsh",s of Ihe .11 }I)lOp".IIe 11nck"css
8 1 Pi~tons a"d COl1l1ectin g rods ~ re fitting
RclC' 10 $CCI'O" ;:t!)
82 Oil pump -refillin U
P"lTle
Ihe oilllUlllp L>V 1IIIol1g Ihe IlIlel 1101l wnh Cl1g,"e 0,1 and Ihen flJlat,ng Iho dllvcshilh 10 d,sl"L>ule Ihe 011 wllh," the I'lI"'P hodv 2 Inselllhp. pOll1led end ollhe dliveshMI "'to Ihe PWIlP hodv and III Ihe clop 10 .etain II 3 Place Ih o pUIliP U1 I)051110n . cngnU!! Ihe d""e~h;JII and Iheo inseH Ihe ' .... 0 llitallung IJolls r'\lhlet1ll1.., holts to thC lo.que w'lInch SCII,ng
\I,,,(:n III Ihc SpClcol,c,lIIons < Rell lihu boll SClCU.IIlU Ihe 0,1 pick up luhe 10 IhCl ",nln I)C;UU1U cap ",,(I "U"l"" II 10 Ihe ~j}ec"H,d 10'ljue. F
ig. 1
.16 Cr.1J1 kshilft Ihru st wash ers ~ ;orrowed (Sec 80)
83 T illl i,,!! !I ClH'S illid I rOll 1 pla to rclillill!!
Apply 1""'III'!1 1:1>"'1","11<1 In Ih " (11,1,,1 ""!I" nllh" 1"'''1 "n,loI Ih. <,yin""" hl(1{.k ;"HI l<J Ihp 111.11 I •• co: I,f III" 110111 allilj1I(/I IAilh) ;:t 1'''~llIf1nlllll !1.J~k('1 'lilt! "d"plm pl;Il". ",),;""11\I,,·,,, w"h Iwo holl
'''~"I\'''' flll!!", II!III 3 r,l II", ada •• lm 1,lille f(,,,,IUICelllunl ( F,\! 1 17). IIlS"' lIS IllIC(j b olt· ;""j II!)I>I'''' tI":",, 111,," II,IllIJV(l Ihl) IWO PI(,v'(lu sIV III~I),wd local"'!
1o"lh < no:l,1 the e:"nlsl1.1 lt ge".. Sf> Ih.ll Iho kP.VW.1VS "I I>ulh Ihl} CI.lnkshall ill1Illlol: e:.1t11sh"'1 "H) In lone ;11111 Ih,: ",,,,ks on Ihe tW,lIS .1,Q on 11m Silllll
I",,, II", <.I:'l1ksllo1ft \1";11 hilS IWO "';IIks Oil 'I alII I " " mipOIWnl Ih;n 111"V iIIe l'OSI\loncd as ~hown ,,' f.U I!; [) M""~,,,e Ir." I:lldllo.1l 01 II", <:.1I1l~hall ;,ft,,, '"~"'IIIIII Ihe t:alllsh;oIl "''''''''''!I hull ami lI\1hl"IIIlI\1 , 10 Iho: 111"1'''' wII,I1I:h ~I:H"'!I U,,,e,, III 1111, SI'"",I,,;;llll)lIS 11", cillll:;h:.11 1;"dllu"l e:"" I", ;111",'01"01 lIy f,ItIl'lI .'
Ilelf'·I,".1 1''''lIlh ~I'.".'·I G M""~,,,e'II": 1"".ll.l~h ul II,,, 1:O",,,h.111 !I",,, ill 1"lIl ··'IIl.,lly ~1'.1(:",1 PIII"i'. .",,,,,,,1 "s I""'I"""V lh.~ ~hull"ll", 0 7.2 In 0 32 """ (000910 001:l "I) 7 AIII,IV 1"'''h''!1 (:O"'P(111,,<1 II! Ihe cII(:uII11r:"",ce ollhe 1",uIIU CO"..,, 101111 I.",,~ .IIHI It) l hl) 100111 01 Ille ;"I.'pIO' pl.'le JI,d oil." up Ihe 1I1l11r'>{'
co"el 8 1l,,1'1 Ih" ",,"'kshall j)l11l!:V to pO~'I'IHI Ih.., IIIIIIII!} '.0"'1<. rhcll mSCIl III" 1""'''11 CO"", hOlls alld t'H"I"" Ih..,111 10 Ihll 10'<1"(: .·"~IIe:h Sr:l1Illg
11''' 1)'' UI Ihe SI'I1t:o/'C;l\'OllS
9 Apply ,0"lIuIII C0111llOll11d In 01111 f.,.:c 01 Ihl! e:,.,,,1 ~11i,11 llullllV w;o~I"", pl.lcc Ihls s,de 10w",US 111(; I'tlilev . ItISC.I Ihl! pull,;V SCCUH"!I holl ,,"(1 ilUhlCIl II 10 Ihc SP':Cllll1d tOlqllC
Fi
U.1 .17 Adap te r plato reinlo lcclllcnt (Sec 83)
procarmanuals.com
Page 56 of 205
7
Chapter 1 Engine
Fig . 1.1 8 R ear oil sen I ilnd ildaptcr pliltc (Sec 84)
84 Renr oil se;1i ,,,,(I lIywheel - rc fitti"u
1 I'll the ()n!J"I(~ .r,," ,,(1"1'10' pla1<:1 and s(:clIre ,I wllh 'I S IIv(: holls. 2 Smenr en\J1ne (ld OlltO the CI,mkshah '''". Smear 0,1 on the lip 01 the sea l tlnd pos(( lon tlon ';".11 on th e cran hha ll. 3 Align the seil l c;""er holos wllh Ihose 011 the cylrnd(:, hlock . Insell the loul bolts and 11!lhlCll Ihem 10 the SpeCifIed 10lqUfl 4 F it the flywher.:l . or dllveplalc on au lOlllallC lwnsrnis sion Illodels.
InSerll h e six holl S ;",d u\llole rllhem 10 Ihe 10 lque w rench sell"'U Uiven in lhe Speclllcm'olls
8 5 Sump -rciiuill!)
En~",,, lh;ol Ill" ru,rI "'!) ',u.l,u :e s 01 hoth IllI.! Slimp a"d t h e c(,1nkcilsc ,lie cl ea" ,mol IIi,1I n", '.""I",!) SlIrJ ,u;e 01 the Sli mp IS not d'S lo lte d. 2 Apply IO" ,I,,,!! c"'''pollnd 1 0 the pOUltS wllel(~ Ihe l"llllll) cover ablilS lhu ,;yir r"lr" 1,Io ck .lIId where Ihe rea' 001 $u,,1 carr.(:r "dIOIllS II 3 Pln ce tloo \J,,~k"l '" fJo~.t.on, lIt tlo" SlIm l} ,'Ild IIlS(). 1 lhe r0Io1111il1l)
bolts ImUO I tl!lhl 4 PrO!lres~lvely 1I!llIt,," llw sump holt s 011 opposIte I'ilr ts lIllt,1 all 0 1
t
hem ,H" il l tl", ~ 1"":lllI"d IOlllUU , 5 FII ,1 now w;,~h", 10 Ihe ~Ul1lp II"'UI pili!) , IIlscrl lhe dl,lIll pllll) and
t ,uhlen ,t
8 6 Cylinder h e"ds re;rssernbly
L~y the cylrnd" r h",.\! on .IS s Ide. luhrrcnt e cvcry valve Uu ide with eng;l1(! oil. ,lilt! ,"~,,"t the valves 11110 the \Ju, dc Irom whIch lh ey wele remov(:d 2 To ,WOld d<l(11;U)III\) lhe II p 01 the stern 0,1 sonl , with consequent rncreJsed 0.1 con~UI1'ptIUIl. wrnp <I p.cce 0 1 ndheslvc wpe. or fo il. fOund the \JrOove o f cvery v,llve SWill Sh( le lhe scn ls over t he valve sIems and push th clll over th.: lupS of the vnlve u",des 3 Remove Ihe "dh"~lve wpc. or fOIl. horn Ih e vnlve S1(~I1IS. 4 F,t the valve sp"nl) ovc, the valvc. Wi lh thc close cOllcd end 10wnrtis the Cylrnd er head. lhen fll thc sprin\J relarne r on top 01 lhe
sprlll\). 5 US1ll\J a vnlve ~prul!) compresso r. com press lhe splln\) lus t enou\)h 10 inse,t the IWO Splil COIl,,15 If lhe vnlvc spml(j is compressed 100 filr.
lhero.s dilnlJC' oltl1<.: ~I""IU rcW""C' dillllil\)IIlU tllC villve SHlm 011 sen l
G Ahcr "lsert")!J tit" ~pllt collets. r eleilSo the spllny compressor (111(1
rcmove II 7 C hcc k th"t lh..: ~pl'l cull":IS hilve seilled properly and t<lp the top o f
t he v"lve S1C1lI hUhl1y w llh a plJstrc headed hJmrne, to ensure 1I11S,
Fi g. 1.1 9 Tightening sequenc e for cylinde r head bolts on the 3.0 litre enuine (Sec 8 7)
a Repe"l liln pruccdwn orven III p;ua!Jrnphs 1 to 7 o n the (CmJlnlllU
v,llv"s
87 Cylinder heads - re fitt;nu
11 the tappels w ere rcmoved. luiJricnle lhe lilppets nnd I heu hores wnh enoine orl nnd insor t thOlll wilh lhc;, d Ished cnds uppermost Ensule lha l every tappet ,s rclltlcd Into lhe hore hom whIch II wns
t nkcl1
2 Mak e sure tha t Ihe rna t"'!1 surlaccs o f lhe cylinder block. cyl lndor henrJs ;Uld 1111,,1 Ill,lIlIlold ;lIe de;"l. then plnce new cyhndcr head \Ja~kets ove, the Wildes un thn cylrmh" block. Tho cyirnder head \I,,~k ~IS beilr thO malkln\! TOP f:nON T ilnd nced to h e pOSII,oned
cOII(:ct ly .
3 Low ul Ille cyl ""lcr he,1ds ov"r the" posl tlonrngst u(!s, Although t he cyhlld\~r headS ,"0 Id entlc;,I, they should h,lVe been Illtlrke d when remuved ilnd should be lehllUd III thcrr ()IIUinal positions t1 Inse rt the cyirndcf 11I)"d boilS f"'!I(:r t.!Jh l then tIghten lhelll prUglC SSlv(: ty OIl the olde, shown III r,U I l!J and III llle stnucs",s U iven
m the SpcelirC;lt'OnS
88 Rocker arms and cover
s -refiUing
Ensure Ihm "II Ihe puslllOlls ,lie ,nselwd I!ltO the" p'llpor placos ;II1<J lh at thc" lowcr ends nle on\J"gcd in the ClipS o f the t"ppelS 2 Place the roc ker arms over tho jlllshrods. fIt the fulcrlllll seMS and ;ldllJS 1o r nulS. an d liuhten the ntl)usting nulS !"'ger light 3 Se t No 1 cyllllder at TO C <Jnd reh t the dis tllbu tor (see ChilP1C' 4) 4 I\dlust the vil tve clea ra n ces as descrohed in the foll o w rng Section 5 FIt the roc ke' covers , uSlIl g Ilew \Jilskc IS . ens uring tho t the gilskets arc senlOd e venly n il round l ho cylinder hend. Fit the cover altilchlllont
l
)olt S nntl lighten them t o the spec ,f led torque.
89 Valve clearnnees -checking nnd adjustment
R eier
to SeC!lon 3 5
90 Engine ancillaries -refitting
R eier 10 Sec tIon 46 and ref, t lhe I. ste d componenlS w,th refercnce
to th e Chaptels ind,cilte(f
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Page 57 of 205
56 Chapter 1 Engine
91 Engine -refilting
Rcf'tlIng the engine is a rCllcrsnl alth e removJI procedure given In Section 44. bUI in addrhon note the following 1)O;I1IS:
(,,) Ugh/I)' 9(0"50 Ihe ycar/)QIC ;npu{ Sh,ll{ (m,lI/v.,1 transmission) (b) Check tlMllhe dlileh fc/c,He .7Im is cOIf(!clly loentcd (m,lllu,)1 (fiJn$miSS;OIl) (e) Adiusl (he clutch cClbfll ,15 (/(!sCllbcri ill Clwp/fN 5 (m,mu,,1 flilMmission) (d) BelOfc COfl/weliny the engine /0 {I!(! ,W{omMIC {MOSl/tllSion check 111M /he /O((/lle con vet/or is fully 01l9,19N/ wilh lite /f,lfI smiSSI()II pump by reh'/(!IICa to CIWp/Of 6 (e) Refll' file ,)II/QIII,llie ("'''lllltHiOIl WillI 1141/11 ,15 dcsCfI/)t'd III Ch,lpWI 6 (/) Ad/usllhe lellsioll 01 the IJowor steeling IIlIfIIll MId .11/emMa. !lnvalid/(s) ,15 d(!scfI/)ml in Ch,?pICIS 10 i/lld 2 f(!SpcC/lv(!/y (!I) Fill Ihc cooJillfl sys/cm (el,.l/'/C' 2) ,md /lOW,!' Slcc/IIIY
SVS/l:tII (ella,'/Cf 10), 1111:11 fIIlllle mlylllc Willi od (SeC/lOll ti~) ("ho/Q)
92 E n £line -initial start-u p after major overlwul or re pair
Hel",
10 Sect Ion 38
PART C, FAULT D IAGNOSIS
93 Faull diagnosis -engine
Sympto m
(n!Jlne f.111s to tllm OVCI whim ~t;llt", IS Opc,;) lcd
Enll"n) lUIIIS ill no.",al ~pced. hili dous not 51,IIt
E"u'ne SlOp s ilnd Will not 'estill t
Enll'Ile
.",slucs, O. lUll S unevenly
L~ck of powc. illlt! poo, comp.esslo ll
91 1 T OPPln! 1 lIl) tile ""'II"") wIth od
ReilSOn(S)
DI~ch.1'Hed 01 delec tlv" 1o:,lle.y
Dilly 01 lI)os" lI.11tc.y le.,ds
O"f '!I:llve sl; IIt", soL"",,,, I. ,II SW'II: " Odl'ctlvl' s lillte. "UIIOf
Dilly 0 ' III"ken e"!I"IC "'''1111''11 SIt;IP
1\I1'"111 ':Ol1lpOlu",ts Will (If ,1;""1) DefectIve low te nSIOIi le"d Detective o. InCOllec,ly :,,, 1 ,:"III"C I h,e;oke. (,I "PI.I,,:a"fe)
Oe f"ctlve condense. (If '11'lllIo,;.,"lc) O'st"hulor cal) defec tIve. or celltral h,ush HI (irs l,,"uto ' cap Ilot m,,~, COfltilf.t w'th th e .otor a"n Ifls.ulhc,em petrol "' tilllk V.1pOOf Iud '11 luel hlle (," hut cOl1{lIuolls)
Fuet pump I:uhlfe E~O:Hs51ve c hoke, caus,,,u spillk pluUs 10 hccolllt) wet
IU"I1I(HI 1,,,IUle result Ill!.! 110111 b.cakdown. or prescncc o t w;'1ler \,Inti w(: 1 cOnthllOIlS l:n:k 1.11 tud. at luel IJlock, l!Je
loose 19111tlon Icads F(luIIV s J)n. k 1)Iuli T'(1ckin£l on d,slllbuto. cnjl IIlsuliltion
InCOIICCll11lxtu'e 'Ullilion 100 telilldcd Dilly con[,lCI blcakc. POlll1S (,I ajlplPcablc). or loose connection'
<I'SI""\,IIO'
Faully Of loose condense' ( II ~)JpIPcilblc) Lea kin U ca.hu.eItOJ. o. lII.lll1fold JOlllt
D"lectlve v.,lves Blown cyIP"de . head £lasket
WOlll bo.es OJ dilm ilye<l ,,,slon
Wo.n cylinder bOles Do::tt)cllve v~Tve Stenl seals Le<lks
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Page 58 of 205
,. Chapter 2 Cooling system
Cont ents
AntIfreeze mixture Cool ing system -draining, Cooling system -filhng Coo ling system -flushing " D,ivcbcllS -femoy~1 and refilling Expansion lank -removal and reflllmg F;)n hub be,Hing (3 .0 lit re eng ine) -renewal . Fault diagnosis -cooling system
Sp(lcifiCiltions
System type
Thermostat
Opening lempel<Jhn e 30 hue engirlcs 28 hlle enUrrl es . ___ ..
F ully open lernpcln1 ulc. 30 hlle engines , ... . _._ .. .... 2.8 hlle eng1ll es .. , ..... . _._ .. _
M'ninlllnl IhennO SWI Havel _
Orivebelt tension
O()lleCI,on JlHOwily between pulleys (longeSI run)
Prossure cnp setting
3 0 lure engines -._ .. ,. "._ 2 8 hire engin es _
System capncit y
30 htle eng ines .. , .... 2 8 lille engines
Ioorque Wrench settings "lIe fHlgil)( :s
'" ~JI~;·;~~;~'·." _ ... , .. " , e"noSl~t 110[151119
G 3 5 4 10
" 12 15
Gene',,' description RmhalOr -.ellloy;,I, inspection, clCilning imd refllting RO\ J\inc rn<lmlcnance .
TcrnpC'<l\u,e gauge sender lmil -removal ilnd fe/rHlng .
Thc'1ll0SW I -removal, testing and !(~fl1llllg . Viscous drive fan -removal and refilling. Willer pump -,cmevn l and refilling
1 7 2 13 8 11 9
P,cssu"scd. With beil ·drlven pump ,1"d larl (VISCOUS (hive type on 1.1u:, moduls). IhcrrnoSWI ... nd expansion \,lflk on I"W' Illodels
85 to 9S ·C (185 to 208'F) 79 to 83" C ( 1 74 to lSl'F)
9910 10TC (21010 2Hi"F)
9 T C (207'F) 7.0 nun (028 Ill)
100nll)1 (0.4 in)
091 klll/enl' ( 12 .9 Ibljin') 0 .8510 1.10 klli /elll' (12110 15.6 Ibf!m')
931111e (16.4 pinl) 8.71111e (15 3 p inl)
No.
710 10 710 10 161020
81011 17 10 20 9 to 13 810 11 20 to 25 201025
Ibf ft
5 to ., 5 to ., 12 10 15
6 108 13 to 15
7 10 1 0 6108 151018 1510 18
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Page 59 of 205
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58 Chapter 2 Cooling system
Goneral descriptio n
Tho coo1inU sys tem IS of tile flfCSSll"sc d type consiSling of 11 helt·driven pump. h0l11 mourllc d .ild,ator and thermOSI"! Th e hClt·rhrvcn 1,111 IS of SI;mf!ard type on carly models, bllt of VISCOUS drive IYlle ( l) holO) on lalC I models. the lallci jllCOrPO'ilUllg iI speed 1I0)'I<1110n (I(!vkc, On 3.0 hue cnOllles t he IhcollOSlill IS IOCillcd (I( tho,'! 011 tiel to tl lC tOp hose. but on 2.8 htre engines i, is localcd on the 11110 1 hom 1ho baliom hose . Lmc. models <lIe f'lIed wllh .. n CXPilllSioll !lIlIk Tho s ystem functiolls as follows With the cnuine col(I, the thermos! .. ! is closed and the cool;1I11 is I)Ull1 llCd thfOU!Jh Ihe enU'ne wilIClwlly5 tln(t h(l,ller only When the enuuII) ,cilches a prcdCIClmulcd ICmpc<nIIllC. t he [hCllnos!al oll'ens alld the COolant lImn cllculales down IhrOlluh the r,ld,nlor 10 provide <ldd,IIOlwl r.oolll1\) Where <In C'I)ans,oll tauk IS " ed. th,s cnsurcs th.11 the cooimu system IS always h,n by collectlnu coolant when th(! CII\JIIlC IS hOI olild 1f!l l11lllnu It as Ihe enUlnc cools
Fin. 2 .1 Coolinu systelll (3.0 lilro cngine) (Soc 1 )
Fig. 2 .2 Cooling syslcm (2.8 litre engine) (Soc 1 )
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Page 60 of 205
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'tz
Chapter 2 Cooting system 59
1 I VISCOUS (IPlVC I,m coupling (I,~mpc,alu,e sensitIve 1VIle shown) 2.5 Tuppill\l -lIplhc COlllilll1 h,vel in the c~J)alls,on \;lI\k 27 Checkin U the drive-belt IClls,on (28 hire CIlUulC)
2 Routino Illaintcnanco
Altho ,n1C, ... "ls SPOC""]!! utlhe Rouhnc M .. "UcnanCf! SOChOr! on Ihe 110111 01 the m;uu,a1 c;lrIy oul the lol1oWl!ljl p.occduoes
Check cnoling syslcm lor /c,1k.~ 1 In spe cl Iht! coolin!! sysh),l) hose s 'llcludlll!) the ,adIOiIO' :,"<1 Iwate. hoses for damage. detcriOlllll0n i1nd sccullly If Ihelt) is I'Irly IOulle;1I'01] of swelling 01 p<lflshinu ,en ew the hoses . 2 Chock the ,a<li;uo . fa . dilmaUc ;lUd leaks, ,llld clean ;lny dchlls from Ihe coolmg fillS.
Check coo/tint level 3 Whe r(l Ilrl expanSIon 11lnk 's hlte d (I"te. Illodels) lhc I;oolnnl ICv!:1 can tJC check ed without .enlov,nu the pr<lssu.e C;'f};1S the lank ,s made of t.anslucent f}I"st'c. The t(lnk should he ;1PP'OX"l1;1tdy hllil lull wuh the cool.,,, t lust cove.in\J the pillst'c lev<l l ,"d'CH tO '. W,th i1 h ot CI1U"'c the level 1"',11 he ShUlllly hiuher 4 On ciuhc •• nodfJIs not f'U e(1 w,th 1111 exp lln:;'(l1I wnk the level "'''~t be Checked with the .. muine cold . Unsc.ew Ihe .ad,alO' p.essu.e cap and check Ih,\( the cool,u'l leve l IS hetween 25 0 111111 (1.0 In) ~II(I 35 0 111m (1.'1 In) helow the base of the filler ne ck . 5 Top·up the flurd level USing the COllect sohl\lon of wa!IJ' and ;mtilreele with the enuino cold (photo) 11 the c"Ulne is wal"'. the P'<lss,,"e Cilpmust be remov<ld slowly to illiow Ihe PICSSUfC 10 e sc ape U'llduilily. otherWise the pres su.e d'OI) fllily c~use thc coulllni to hod over cllusi,,!) I)Clsolla l Injury.
Check drivebelt conditioll and tensioll 6 Inspect the complete lenlJth 01 th e tJrovehell(s) for dClello.,llIon which WIIIIlI)f)e,lf ,lS h1lyll1U 0' UlilZinU to the 1)Ulley cUl1t ilC t su.fi\Ccs. 7 Check th(lt the deflec tion 01 the d.ivebclt{s) midway hetween the wate. pump i1nd (litelnntor pulleys is i1pp.ox,,11i1tely 100 111111 (O 4 OIl) under 1ll0de'i1 le thumh p.essule (photo). 8 Whe.e ~Idiustillent is neceSS(I'y. loosen Ihe Ililefllilto. p,vot and adjustment bolts. re l)OSlloon the alternilto. then tighten the b olts. A leve. mill' be used at the pulley end o f the IIlterna tor 10 o b1;lIn Ihe
COf/ec t tension If .equir e d .
9 Run the enuine f o r severlll minutes Ihen rec hec k t he lension.
Renew,1/Jtilreeze 10 O.am i1nd flush Ihe CO(lhng System as descrlhed in Sections 3 and 4 . 11 F,II the coollllg system With Ihe correct solullon of watel and amlf,ccle as desc"hed in SeClions 5 and 6 .
3
Cooling sysl e m -drai"inU
If pOSSIble. ensu,e thilt the engine IS cold belo.t! d.al"i"lJ Ihe cool ant. 10 aVOid the fisk of scalding.
2 Remove Ihe .adlatOf or expanSIon tank IIlIe. cap. If the eflUlnc IS hot. Ih ls must be done vl;lry caul,ously, because a sudden release 0 1
Fig. 2.3 Clltawa y view o f Iho expan sio n tlln k showin g tho plastic lovel indicator -tH rowed (Sec 2)
P'".'·S5U'0 CilIl ,esull II. the cool(lnl !.>oIling i1nd blOWing Oul. On ,1 hot enUlIle. plilce iI cluth ove, the caf} and lurn il ve. y uently. '0 release tim p,ess\lIe slowly. 3 flel110ve the SplilSh shield frOI11 b enomh the ra(II;IIOf. of i1pplrcilble
" Unless !he coolilnt IS beinu discarded and thc ca. 's over (I slilt illJle
d'illl1. ,,'"ce a deiln IWO i1nd a half gallon Conl;1ine. underneath the ,adlaIOl. !) Rel110ve the radlatOl bOllom hose lind allow the coo'al11 10 drili" . 6 If the SyStel1'IS to be completely d,ained. rcmove the cyhnde. block d.;1I1' pluU and draIn oul Iho .emainlng coolant hom tho engine . ThiS d'illf' plug IS locilted all the s,de of the cyl inder block to Ihe rear of the oiliolicr. 7 On 1I10deis wilh all eXJ}ilnSlon tank 'emove the rad.alO' cap as well
4 Cooling systom -ftushing
In IUlIe. !he cooling syStel11 Will lose ils efficiency because o f a bu,ld'lIp 01 .uSI and sedunen t in the radiator. To clean the .adliltol. .emove thc IllIer Cill) i1nd 'he bOllom hose ilnd !lush Ihe radialo" by inse.llng a hose in Iho f,lle. car> neck i1nd funninu Wille. th.ough fOf about tr.m I11mules . 2 If Ihere is a Ilea vy aCCUmuliltlOn 01 sediment. it is betler to .eve.se
flu sh Ihe .adl~tor. by connecting the water supply 10 Ih o boltom of the rilclmof alld allowinu II 10 flow oul of the tOIl. Speclnl hose adapters arc avai lable to enahle thIS to be done w ith the rild.ator In I)OSllion. but It is p,efe.able '0 removc the lad,ato. and tum il upside down.
3 Remove t he thernlos,a, (Section 8) then .eve.se lIush Ihe engine wi,h a W1l1e. hose u n lll clean waler flows from the .ndlat Of bottom h ose connectIon.
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Page 62 of 205
...
Chapter 2 Cooling system 6 1
8 ThermOSI"t -removal. lor-ling and re fitting
3.0 litre /~n{lIllL' 2 $lilCkclI Ihe clop 0 1 the top 110M) to the ril.loiltor and rcmovc the hoso (photo) 3 UndO ;II,.t ,,:move tho "\4> hnltS ;'Ind Sllr"'!J w,lshers sccUlor'!1 Iho thermO$I,'t h',,,SU'!1 to the q·\·",Io·, heil.l. 4 T,1plh" 1"'''~'''!llIe'ltlv ,','h " pl"Sllc·he.ldcd hiln1l11e •. to h rc,lk th.! g,1sk('1 s".11 Ih"I c".eflilly 1,It fh" hOlls.ng 011. Remove the !J"~k.:l '" one p,,; •. ,, ,11"'~~Ihle. ()Ihe'''''~,' ',1 I"pC hOlh loim Inces 1Oc.lc;rn olllh'l fen,nu's "llh" !Fhket 5 M,,,~ II", fl"'"ulls\;)!!n :,I,,",v whu:h W"v rllund ilnd wlllc.h "";ov up II'S IoI",d, ""'0 u~,) it ~c",wd, ",' III ' fi",ove Il lrOIll Ihe IrOUSII1!1
28 h/le 1:111/1111.' 6 51,u:~'·" II", I l'I's s,.'!;"''''\! II", •.• d.,IIO. holtou. hose and Ihrl hf'.llr;r ho~1't 10 II,,· 111"''''01>1,,1 I"'''~'''!I .ulIl careful Iv remove Iho hose" (ph01<1)
7 Undo .",,1 ''''''<lve Ihe III,,·.· h"ll~ a",1 SP"Il!J w.lsh". s Sf,C"""!) til(, Ihe"II<1'I.1 I""""'H 8 T.'I' II,,· II"'''"''~I;'I h"""''''1 w,th ;, soh "ea.l1,d h;lflllll'" !O .,,'slll.k
II ,11U11,II Ih,: ('{lV"1 ;tw.,v ( ,.1"'1"1 R,'tCove, Ihe ',0111 cuver !Jaskct.1 II.S
unclilr11,\!I".t "11"',wls', ~(:'.II"· .t "II Abo If,mlJVI' Ih" sr';11 !) C;"r;lullv ".I~" Ihe 11""",,"1." (1111 CIt ,,~ how;II'!). """I!! c;""I,,1 10 notc ",1",.11 w.IY '(lund 'I ,~I""·,, (phulo)
All cnyin()s 10 Teslthe Ih",moslill 1o. r"''''<: h,llctIO""'!J hv suspr:llcI ",U 1I Oil a string In" saucep.,n 01 cold ".,1,,, tOHcthe. WIth a !h.). momc1Cr ,,,,"I (he ",nIl!' <IIul lIote the tcmp., •.• I,"!; "I whIch Ihe (lrerrnost;l 1}c\)II's 10 open 1 1 COll'll.l'rl Ihe nOted 1O'IIlPl!lil lurCS wilh Ihose 5pcclhc,1IlO"" ;1 the llC\I""''''H 01 th,s Chililter \)Ive" on tli.)
II they dill.,.
!:on~ldp.ralrlv Ihe Ihe ,mOSlil! mUSI 1.>" "~ncw"d 1 2 If the Ihr:.lllos,... t daM not lully OJlr:!! II. IJO.IIIHI Woll er. or doc s not close dowII ,1~ Ihe water cools. Ihen II ."ust he d, scmded illl(1 il new one frur:d Should Ihe thCrmOSWI he ~Iuck opCO when cold Ih,s w"l IISu.,Uy Iw appil,elll "'hen fcmovmu II from the huusing.
13 Reflllll'!jlhr: the'mOStnl 15 the . everSf'l Sf!ll"Cor.", 10 rClllov.ll AlwilVS
(:"SUIC IIr,)1 11l<! milling lilces il.e eleiln am! ""1 II Ihe Ihe. mOstill
hOIlS"'!1 .s h",Uv corroded fll " oew hOIl':"'!1 Alw;lvs 1I<:f, il new 1),lSkel .1,,(1 Sf'l.11 II "llphc;lhle (phow) T'!lh",,, II", !,I"'IUUI! 1 holts 10 II,,~ s t)C{:llreci \1>111'''-' wrr:"ch SCllrr'!! (pholo) Rd,tl zh,., coolln!1 svSlem "s d('!>(rrhecl "' 5"ct,on 5
9 Walnr jll""I) _ romO"'11 ilnd refilli,,\)
Dr;,,,, IIr ,· , OJol",!) SVMIIII1 as rlllsc,,).,. d ", S','-I""I 3
3 0 iiiif.' VI/yllw 2 5t.,d"·,, Ih', II .. "" ,,1110'(\;,10' ,1'O"IItll .!! hOJI\~. Jlush Ihe illle,nal!)r low;lIds II .. , "n'I"'O, hit IhH dllvetH,l1 '''''11 lilt· wah" pump twlley ;md ",move .1 3 S tack"n th" lowe. 'ilc1,;.IO' hose d ,p .1 l ilt: ,nt., 1 cunnechon 10 th., 11I,1lt1) Ca ... lr,tiv eilSf) Ihe ho~c hom Ihe W;.I." pu"'p r:lIlOw 4 SI.Ir.k"lI 11r" hosc clrp ,ltthe rCill 01 thc ,,,'mp ;'1111 cilfel"IIV eil:>c the Iro:.c hl)llI Ih,· 1''''''1) !, 5!:10:I0,,,,, tl", IIHld hObO r.hp SIIII" I"d .11 Ih" Inl' of the pump ""d ':;I"'h,IIV ""~,, Iho h oso I,om (he lOp 01 Ihe I'U'''I' G U,"I., Ilro: 11"",0 !toll~ SOC\Jrln\j Ihe walcI pump to the cvl. ,,!! c ' Dloek NOh) III;" ".".h hoi I IS 1,1(0d w,lh;1 sjl ""!J washe, ,111,1111,,1. ,'s Ihe Dol l 's 1.,1l'ped bv II", Iii" pulley. 11 Will hC necessary tu l"ogresslvelV s lncken till) holts alld pilil Ihe W.ltcr ))ump il",ny "0111 Ihe cvlinder blocl.: The )ocm,on 01 Ihe hailS should be "oled, so Ihm Ihey ilre reflued on Iherr 011\)",,,1 POSlllons. 7 Oncc all ItHee boilS hilve been unscrewed hom Ihe cVlrnde , blod the Wille, P""'P m"y he 'emoved ilnd Ihe 0.1sk(:1 se';'ped off
, '.,
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82 Thermosl"l hOU5111g ilnd lUll hose (3 0 l 'l'c ellUllle)
"'(~ .• ',. . .(. .
" ,t>
~ ~) ;;f;\!?r
~' , ((~.~ ::";--
~ -.;~ . ." ... -'
~
" ' ,1 . -'
iP" ~,,,
, : 1 '
8 9 Rcmov,ng Ihe IhefnlOSI<I( 128 h\lc en\)II,e)
.. ,''''' ' A ~ ~ I.-
~~. "Is.\. ,,-~-,,~ -, .. ~"'1"1 .
~
86 ThelmOS!,;1 hous;"\) w"h b01\o", hose d isconnected ""d he,1(Cr hose connecled (2 8 hl.e enU IIle)
'.
,
., ( c ,
jj, ~
8.13A F,n ing a new Ihe,mOSla l hou5'r1U gasket (2.8 loire en[llllc)
• It .,
"
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P'
''''' "'" ~)?-,
. f . " "I ' , I ' {. I
l~/
), ".
r
. f .,
, 1 ,;~,
88 Rcmovrng the Ihe.moslnt housing \28 litre engine)
~
',' . -. , '" , ' ..
~,t;
'~'" " . ",
""". L '~cl, \ -./ . -~ ,\'( dr-
, ':'''''~' ._,,1 r;;~
:~';-. '$! \§' ! .... .
{'
8 13B TlghlCnrng the thermOS!ill hous,ng L>olts (28 hl.e enu.ne)
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Page 63 of 205
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62 Chapter 2 Cooling system
2.8 litre engine 8 Remove the radrator ,lnd Shroud as descrIbed In SectIon 7. 9 Remove the dlll/cbell (Section 10). 10 Remove the ftm and pulley (Section 11) 11 Remove rhe lhcrmosln (Section 8). 12 D,sconnr:c l the hose 110'11 the therm ostat rca r elbow. 1 J Unhoh the wale, pump from the engme, nOlmg the loem'ol] of
(1
ench IJ0l11'15 they arc of Yil"OUS lengths (phOlos). 14 $OilpC aU the (lasket .
All ellgines 15 Rchumg is 11 reversal 01 removal, bUI elc",'1 the l11m'ng rolCC~ .111< ollw<lys usc 11 new g,15kct (photo) Tighten OII!S {Inti boilS 10 Ih. spccoflcd lo'que . Rcf,1I1hc cooling syStem .. s clcsc"bcd in Section 5
/
Fig. 2.4 Therllloslllt iln d Wil le r pump components on the 3 .0 litH! engine (Sees 8 and 9)
9 1 3A Unbolting the water pump (2.8 li!le eflg inr:) I
Walt"
l)lJtlljJ " I-Iousi"g 2 Bo/( 5 G,lSI<N 3 ',,1IIslc, hose 6 fI'CIIIIOSt,1t
9.138 Waler pump and impeller (2.8 hue engine)
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9 .1 5 Fitt ing the water puml' gaskel (2 8 hire engine)
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Page 64 of 205
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Chapter 2 Cooling system 63
10 Orivcbelts -rcmoval .. nd refitting
Where ilpphcilhle. remove the power slecrinl] pump d rive b elt w Ith refe rence to Ch<lptcl 10. 2 Loosen the ill!CfI1iltor Pivot ami adjustment holts. swivel th e altcrniltor in to the engine, then slip the belt{s) from the pulleys. 3 Loc;rtc the new bcll(S) on the pulleys. then tension with reference to Section 2. 4 Reier to Chilptcr 10 when ,clllt ing the power stcrmlln pump drivellclt .
11 Viscous drive fan -rcmovllt ilnd refitting
Fm hest acce~s to th e fan. 1"~1 ,,:(l10VH th e ""hatol "s dc~c"hcd Ifl
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SectIon 7 2 Remove the drivcbel\{s) (Section 10) 3 Wlwlc the filn hils ,1 centrill bolt unscrew Ihis ilnd wllhdrnw the fan from the extension Shilh. 4 If the Ian IS secured by <l concealed nut. idenlly a 32 mm (11/ 4 m AF) spnnner illodlfied ns shown in Fig. 25 should be used The Ihickness olthe ~pnnner J<lWS illust nOI exceed 5 nllll (0.2 ill). Jnd II is ImporwnllO re<llise Ihnllhe nul hns il [eft -hnnd thread. AlternJllvely.
It is possdlle 10 Ullscrew two 01 the pulley boil S so Ihm il spilnner 01 nor m<ll Ihickness can be used 10 unscrew the nUl 5 W,lh Ihe [<III <lssl'lIIhly ICllloved. unbolt the I<ln Irom Ihe VISCOUS co!lphn\J (ph010).
G II necess<lly lIl1lJOIl Ihe pulley (;lIId eXlCllsion Shillt wherc npplocilhlo) 1,0111 Ihe huh (lnn\Je (phoIO). 7 11u1'l1Ing IS il levers;)1 01 (emov<ll. hUI ti!lhlCn Ihe holls/nul 10 the ~p,)c,lil'd tU'Ciue. nefti the rnchiltor wah relercnc,) to Sec tion 7 and Ihe rillvl'I'CI1(S) Wit Ii Iderencc to Sect ion 10.
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Fig. 2.5 Manifold spanner lor removal of the viscolls drive Inn (Sec 11)
x -2[j 0 "'''' (I 0111) Y -1201ll1ll(05ill)
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11.5 80l1s securing filn 10 viscous cuupling 11.6 Unholting the w<llcr pump pulley (2.8 litre engine)
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