engine FORD CAPRI 1974 Repair Manual

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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Chapter 4 Ignition system
Contents
"'ondcnsc! (30 Iotre cnUIIlC) teslI llU . removal and rc h1!ln g .... 5 '"tact b.ellkc . POIllIS (3 .0 litre CIlUIIlC) ,lI 11us1mC lll 3 ConlilC ! brCi.ke< POintS (30 lIue cnumc) -Hlllloval fllIIl rclr ninH . " f&#34; &#39;~lnb\llo, (1111 CIl\ Ji llCS) lema",,1 .lIlt! .cll1l1n\) (j nhlllOr (28 lilre Cilomo) -overhalll.. 8 D,stributor (30 h\le cnuinc) overhaul . 7 Faull diagnos is -iUm\loll system. 12
S rICcificin ion s
System ty pe
3.0 lit.e engine 2.8 litre engine
Convent ional ignition
Distributor
ROIDlion Condense, cnp<lcity Cont<lC' blenker U<lP Dwell .1llule . HT lend res.s t""ce .. FIIIIlU orde.
Iqnition timing
c 1 !H6 model yC<l' 1976 model ye.1. onw<l.ds
Jil
I',im<lry ,eSI~\<lnce Second<l.y &#39;C~lst<lIlCe
Spark plugs
Type Elect. ode U<l$> .
8reaker/ess igllilion
Distributor
Rotation .. HT lead rCSlstn llCe .
Firing order
Ignition timing
Coil
Primary rcs,sWnce
Secondary resis lan ce ............... .
Spark plugs
Type Electrode {jap .
,1/ systems
Torque w rench settings SpD,k p lugs (3.0 litl(l CIl!JUlC) SPD,k plug s (2 8 hl,e engine)
Geller,11 dCSCfll>, ioll 19r1lllon tnnphlicr Inodule (2 8 hire engine) -. emov,l l and 'Ch1tmO ... ......... .............. . IUrlltlon timinlJ -ndJuslmcnl . flOulUl!) Ill;untenancc . Spark plugs -rem Oval, servicing an d .cl'!lu \g ,
ConvcmiOllill. with cantilCl tu cilke. Br eake rlcss. clCCltOnic
Clockwbe 0 2110025 mid
0 .61 mm (002510) 36" t o <10 · 30000 ohm mOlX"U,uU 1 <1 2 5 3 6
10"' B1 DC 11\· BTDC
0!l5 10 1.60 ohm 50001 0 !l300 o h m
M ot
o,,,,,lt AGR 22 o. Ch;lIllp lon RN 9Y C 060 IlHIl (0024 in)
Cl ockw,se 30000 ohm Il1<lXII11l"11 1- 4 2 5-3 6
12 *
BTOC
0 .
75100.85 o hm 5000 to 6000 ohm
Moto"ra" Super AGR O .GO mill (0024 in)
N rn 30 to GO 25 to 38
22C 0' ChJlllplon RN 7YC
Ibl It 22 to 30 1 8 to 28
10
9
2 11
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Q
Chapte r 4 Ignition system
®
0 -
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Fig. 4 .1 Diagwll1 of the hre(lkerlcs5 ignition syslem on the 2 .a litre engine (Sec 1 )
A higgcf ",,(I stiltor ,1(111$ 8 Am/Jlt/icf modufe C Iylll/ion SWJ/i:lr o BMI£'fY E 'm:lmJIIl"/l:f F COIl G D is/nUll/a , c.-,/! H Ho/or .11111 J 5p,1fK, IJ/ug K 'fi''l)CI co,1
Gcneral de:;criptio n
To ;l(; h.cvc OP\I"'U'" pCl lo.mancc hom an CIl(lUlC ;\Old In mCCI ~1&#34;&#34;\JCUt e.h,1u~t C""5s"m r .. '<tu"cments. 1 rS css"m.althat the I"el/a" rtllxh"C 101 thc ,;on,hUS\IOli .; h;,,,,I,, ). I~ 1\J,ule'll ill ".:II :ttV the "\Jhl I,,'U, wlill'YC to enlJ"lc ~pCe&#39;l ;.nd 10ild The 1\l'lIt,on svsto'" .,.ovilies the
- '),uk nece ss1Hv to start thc: Illlxlu<c I>1I1I""!1 ;md the In~t;&#34;l\ ill wh'ch ,union occurs IS Y;lrI"d auwnJ.1tlC;lllv as ""\line Opet(lt'U g cOl1llot'I)I1 $ d';1r1ge The ''In,tlon systc)t1I COIIS '5 15 01 a PWll;IIV (low tc n slon) CUClnt ill"t J ondarv (1I1g11 tens,on) Cirelnl. Wlwl I he '\lnI\IOIl IS SWltchlid on. CUlrellt IS fe d 10 Ihe coil p r;111;uv wirl(hllUS nnd i1 IIHl\l11Ctic f,p.ld IS cst~lbhshC(1 At Ihe r equired 1)0"11 o r 101l1\10n. the pri"':Irv CItCl/lt IS Ifl tcrruptClluV the conlnct hfenker POUlIS OllCflmg (3 .0 hire e"gI01(I) or the \l'g\le. tJrfllpasslt'g the s tator ;11111 (2 8lrt,e enUn .e) The milunCIiC
f 'eld collilpscs :Ind il 5tlCOndntV hi~h YOIIIl~~ In 'nduced i n the se~ond,1rv win(lin\!s. This HT volt:lUc IS te d via th e d'SH ,IJUtor rOIOI :Iun
1 0 the lelevllllt spnrk plu~. Alter dcllvenng the spar k the pmnnrv cirC Uli
I S re-energised lind the cvcle .s rep-Cillcd. The igni tion t iminu '5 Controlled centro lugllllV JnO UV II vacuum IHl II t o compensme lor englflC speed ,1no 10lld On Ihe 3.0 litre enginc the i~l1;lion s y Stelll II1corporales a b,1ita $1
resistor wire which effcctively UOOSIS th e HT volw~e durlllg SHul,ng.
2 Routine m aintenance
At Ihe in tervals speCIfied in tl w Rouline Ma;ntenance section in the fran I of the nl;Jnua l cJrrV out the foll owmg proc edures .
Clean and adjust Ihe spark plugs. or renew Ihem 1 Refer to Sec tion 11.
Clean ofld chec k fhe distribulor cop. rolor. NT leads illlr/
t. Re lease the twO chI'S securmg Ihe (h Slllbu101 cap 10 Ihe d'5111l1utor uodV and I, ft away t he ca l) . ereJn Ihl;l C:lP inside and oul wilh a dtv
---we F
Fig. 4 .2 (J"II(ls t resistor wire locilted on tho left·h'Hld side of the ongino compartment -urrowed (Sec 1)
clO lh . Closely inspec t the ",side of thc cap and the si. segments. It there are any siUns of Cr<1Ckulg 01 ,f the segmentS are bumcd o. scorl;ld e~cessivelv the Cal) will h ave to be renewed.
3 Also Check Ihe cenlrc segment (3.0 htr a en\]ine) or carbon brush (2.8 IIlre engine) f or wailr. 4 Remove the rOIOI arm i1nd check 1110 ' cra ck ing and burning of the melal scgmem (pholo). On the 2.8 h ire en gin e check tM Sp<ing· tensioned cngine spee d limiter incorp-ori1led in the lOlor illlll for tr ee movement (phoIO) . On trw 3.0 litte cngme c h ec k Ihat the HT conductor spting on the rotor arm has sulficienllension to contactlhe centle segment in Ihe C(lp.
S W'th Ihe . o to r aIR. removed. lub.icate the felt pad in the Centr e of the distfluutor sh ah wilh twO drops o f enyine oil. 6 Rel;lthe rOtor arm and dt$Uluutor cap (photo).
d
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) Chapter 4 Ignition system 89
2,4A ncmovllI\J the ' 010' rum (28 hire enuino) 2413 The engine speed tllnnel 011 tho ,oto. :lIm (2_8 litre ename) 26 Secul;nn lhe dl surUlllor cap wilh Ihe sp.;ng clops (2.8 "lie engme) A Swing C fail/lillY COIlf.lCt n MQving CQII/act
27 ChcckUl!J Ihe HT tcad le.min;!ls on the (hSlllhutOf 1:.111 2 .8 11I"iliol1 COlt and WlIlIl!! 4 .2 Remov,ng I he COlllaCI h.eilke. low lenS 'OIl le,lds
7 W"H) o;iean the HT Itlad,; llm! check Ihc'" 10' (;onll'[IOI1 Pull the 1(';'Ids homlh!) dl~l&#34;h&#34;10f Cilll one;H <IlOilO ;)IId 'Hake SUIC th"III O wmcr IlilS 10llnd 115 w.1y 11110 the so~k CI tI.!II'Hrl"ls . Clo1l1l <lny I:I>IIOSiOIl "W,IY . Ien .eln the IC!1ds (I)hoto). 8 Glc,," Ihu '!jll'l,on cOIl lowe. ;md check the HT le,,(1 ;IS p.eYiously . ,scJllled (photo)
Check .1nd Mljus( (h£! cont<1c t brc<1ker dwell "flyle (3.0 fi/re
engillt!) !l Ruler to S<lClion 3
Check arid adjllst Ihe ignilion timing 10 Rcler to SectIon 9 .
Reflew /lit.' conl,1CI breaker points 11 Reier to Secuon 4 .
3 CO I1\aet ureaker points (3.0 litr e er>gine) -adjustment
1 Remove thO dis touutor cap and ro tor afln (Sect ion 2) 2 Gentlv I)rrse Ihe contact ureaker points open and e~an\ine the conditIon of Iherr faces. II they are .ough. pined o. dlfty II WIll ue IlCCeSSi\'y 101 new paIn IS to be fined. 3 If Ihe pOInts ale sallSfaclory. Or have been ,enewed. measu.e the gap Uel ..... een the points with feele . gauges. by turning Ihe Clankshaft unlll I',e heel 01 Ihe ureake. arm is on a high poinl of Ihe C<lI11 . Consult the Specd,cnl;ons al Ihe uon;nning 01 th is Chapter 101 ttm correc t sOll;ng
I If Ihe gal) IS IIlcorrCCl, slacken Ihe contact plale SOCuflllg screw(s). , le n "lserl a soewd"ve. ;nlO the sial p.ovided al Ihe edge of Ihe COntaCI ptalH and move the plate unlli lhe gap is corrcc\.
5 Tlghlen Ihe sClew(s) and .echeck Ih e gap.
6 Rein the .010. ;"1IU1 ensurIng th,lt II IS cOflectly located In the sial at
I he lOp 01 the carn Relltlho d'SI"lJuIO' CilP and .elain III IIOS;llon wnh Ihe Iwo clIps . 7 On 1110de.n el1gll'os a mo.e ,1CCu'ale mel hod 01 seHIIlg Ihe I>o;nts Hal) .s by means o f a dwell me lel . NOI only docs 111110 l11elhod give a
IHL'Cisc 1)0 .. 115 gap I)UIII also evens oul ally v,llta llons 111 Un,) cnused by wear "' I he dlst"'lUtor sh ah 01 uushes 0' dlHCf()nce s HI any 01 the heIgh ts 01 Ihe Cil'" peilks 8 The dwell allU1c IS Ihe numt)C. 01 deglee s th, ounh winch Ihe
dIstributor cam lUI liS dUring the IlCrlod betweell Ihe ",S\ilIlIS 01 closu<e and oJlcnmu of Ihe conI act b.e,lker ponlls It Cilll only be r.hech~d wllh
a dwell mele' connecled III aCcor d,lnce wllh lh. } maker's II'Slfl.r.;I'OIlS 9 II Iho angle IS nOI as gIven 111 the Spe<:.hcatl ons. ildluS t the po",ts u~p If the dwell annie's 100 ,,,'ge ,ncrease Ihc IJO'''15 9,111. II th e dwell [lI1gle ;s too small . 'educe Ihe points Uap
4 Conlilct hre[l ke r points (J.O litre engine) -removal and refitting
Remove the d'SlflbutOi C"P and 'OlOr arm (Secl;on 2) . 2 Slacken th e self·tappiu\J sc.ew which secllres the condense. illld low lension lead s 10 the conl,lel ureake. ilssembly ilnd slide oul lhe fo.ked cable telfllll,al;OnS (phOIO). 3 Undo and .emovc Ihe Iwo screws whIch secu.e the contact b.eake' uase pll'Ie 10 thO d'SlflbulOr ilfld hit off the cUlltact b.eaker assembly
(phOIO) .
4 Befo.e IClilling the conlact b.eake. assemhly. smear Iho dlstrluu to . cam wllh a trace 01 g.ease 5 FIt I he conlaC I 1)I(,ake' and its cl,Jlnping sr.;.ew~. but do nOI fully I;ghten the sc.ews \lnlll Iho contilC I b.eake. !I,111 h;IS u een adlusled as descflbed In Sec tion 3
6 R ell l th e rotor "fin and d.stflhuw. cal ). &#34;&#34;&#39;1I&#34;&#39;~1 tI,e IWO clops 10 secure lhe cap.
"
, ,
: I
procarmanuals.com

90 ) Chapter 4 Ignition sys tem
' .
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<1 3 Contact hlcnkc. mOUIlJrrlO ~CH)WS (,lrrowcd) 63 Dlsconncclinu the V<lClJlHll .1dvllllcC p'pe G.4 OlsconneClill\) Ihe eallh lend
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I
I
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,
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65 Pull tile wires 10 rhSCOlll1CCl the mull"I)I.,\) COlll1eClor 6.6 flOIO. arm al;\jncd with the slOI on t he d,strlhutor hrnly rim (allowed) 6 .7 C'ilnkshall polley nOlch and Imling covel gr,1(lahOn (28 hIre cn!l'ne)
5 Condenser (3.0 l itrf~ rnllJillo) -testing. removal (lnd rcf ittinu
The PU'I'OSI) 01 tilt) ccmd"",.er (sorllclull(!S know .15 .1 capacItor) IS ensure lh.1I wli,m II", ',()IIi."; ( I!UJakcr POUllS open thew IS no ~po1&#39;~&#34;&#34;1 a~Hl&#34;S ilWlll whIch would C,llIlie ,ap,d weill 011hcu r .. ees ilnd
'!I'Il' ",slue 2 The CUIHIUIlSt" .s hUed !II I>luallel wnh the conlJCI h,e;)kc. points. II '1 becomes r""lly, ,1 w,lI C;II,,'" 'IJ'''IIOI' fa,lure ,15 the conlilCl hreaker 1'011115 1'0',11 he pH)VI!fIl,:ti hom cOllcclly 1Il1elfurlcmu che low ccnsion qrCIIIL 3 II Ihe en!)'lIe becomes very dlHlcul1 co SWrl 01 begins to I11ISS afrer
severill null'S of I lInl1l11\l . and che I)lcilker poinls show signs 01 e l\ceSSlve blllllllll/. Chen chI) condlu o n of Ihe condenser muSI be suspecI One f".ther !C:.t can II" milde hy sepa,ahl1U che points by hilnd wilh the ,umtlon 5WIICtl(:(1 on IItl"5 IS ilCCOoul),,"Il1led by a mighl trash. II IS ,ndu;:allve Ih .... 1 the comlcuscr has I0111cd <I Wiltrout special teSI C<IUlI)lIlc"t the only safe Wily to dl .... Unose condenser 1I0ulJle.s 10 • ..,pll .C" .... suspect 111111 wuh a new one .... nd noCe II Ihe,e is ,my II"p,ovem..,,\I 5 To remove the conden:.cr from Ihe dlSlllbulor take off the (1ISllll)ulo, Cl(1) 1IIld 1010r ;um 6 Slilcken Ihe sel f 'larmll1!) S(:ICw holding Ille condense, IC,ld and low !ension ICild 10 Ihe COIIWo.llul!l,kel I)OU1IS. Shde oullhe forked lerminal on Ihe en(1 of Ihe COf1(lense . lel1d Undo and remove the condense, .el11l1linU screw ;md remove II,e condenser f.om Ihe breaker plille. 7 To rehtlhe condense" s1Illply ,everse the orde, of removaL
6 D istributor (illi en\)ines) -rcmoval and relittin\)
1 k ,1pphcablo II.HlH>VU the 1111 ele,me" ilS descllbed in Chapler 3
2 Remove Ihl! dl ~l&#34;bulo&#39; C;Ij> only (SeClion 2) 3 D,sconlle\:t Ill.., V<oCU\1I1I .. lIvi'lllce pipe (pholO).
4 Whelu l1ppllcnblu dl:;col1l1ecl Ihe eilrlll 1t.!.1(1 hOIll Ihe lerl11ll1nl 011 the d1SI"h11101 budy (pholo) 5 D'scol1l1eCllh(l (h$lrrlJulO, lllulll·plul) COUllcctO'. To dlsconneCllhe plu!!. the w .. ('s IllUSI ho hold and pulled, nOI Ihe plu\) Ilself (pholo). G 'Turn Ihe un\)ine unlrllhe rotor n.m IS poinlrno 10 Ihe No 1 cyhnder SCIJlllun l In the d'SI"hUlor cap. On lalCr models Ihls IS 111so IndiCilied by [I slol on Ihe (I,sl"I)(O(o' hody rml (phOIO) 1 Check also Ihilllho nOlc h m Ihe Cr;lI1kshah polley is III hoe wllh Ihe com,c( '''[llk on Ihe tilllin\) cover (photo) On (llu 30 ht.e eng me Ihe Illinks arc III 2" Inte.v.l ls. hUI on Ihe 28 Ilire enU"le Ihey are on 3' tIllelVals Sec Ihe Speclhcallons fo. the correCI SClllng. Milrk Ihe IIOS'llon of Ihe d'SI"uutor body .n ,el[llion 10 Ihe cyhnder head 8 Bemove Ihe Single holl ill Ihe baso of Ihe d'StrIUUIOI ilnd slowly hI! out Ihe d'SlllhulOf wlthoul IUlilillg its body As lhe dislllbulO' ,s removo.'{llhe skew geM will turn the rOIO, arm clockWIse. Ml1,k Ihe new IlOSlllon of Ihe rOlO' aim on the , .. n Illhe.e IS nOI illreildy a mink Ihe.e (pholos) 9 To reilithe dlstlluutor ensu,e thaI the liming milrks ilre Slill ahgned ilS deta,led rrllJarag'ilph 7 of Ihls Sec lion. Hold the diSlrib Ulor ove' the cylrndc. hel1d so Ihal the hody 10 Ihe cyllnde. head milrks are in alrgnmenl 10 POSlllon the 'Olor arm towiI,ds Ihe mluk on Ihe d,S trrbulol body ilnd slide Ihe assembly inlO l)Osition on tha engine As Ihe geJrs mesh. the ro lor WllllUtI1 ilnd align wllh No 1 segmenl in Iha dlSlrrbulor cap.
1 1 Relit the securing bolt 10 the bnse of Iha dlSlrrbulor bUI do nOt fully Ilghlen ;IllhlS Slage. 12 Check 11I11t on Ihe 3.0 hlr a engme the dlstrlbulo, VJcuum unil is lilcing fo,wilrds. parilliellO the centrO line of Ihe el1\)ine. or on Ihe 2.8 lil,e engine Ihe VilCUIIIll unil is lacing in Ihe duection shown in F ig. 4 .4 . 13 Reconnect Ihe IllUlli·plu\) conneClor. The manlJf~Clurers recom· mend Illill Ihe Illulli·plu!) is 'illed wilh il lilhium hased grease. 14 fleconneCllllu earlh lead (it applicable) and t he vJCUUm advance pipe. 15 Reier 10 Section 9 and se l Ihe 'gnition IlmlllO. 16 Refll Ihe all cleane. (if applicable).
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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
-," ..
. \\'
in Electrode demoge. ;;;;,:;;;;;;;:;;;~;~;&#39;;::;;i ;;,,, ",,;; h;,
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
.'
.. ", . ~,&#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
, ,.
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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Chapte r 4 Ig nitio n sys te m
6,SA Unsc rew the clamp bolt, 680 ... and remove the (tistJlbu to. 68C Rotor nnn alignmen t ;]lter re movnl Irorn engine
~ I
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F ig . 4.3 IU "i\iol1 timinu ma,ks o n the 3,0 lit.e e:1Uine (Sec 6)
Allow ;//(lic<1leS din'cliu" 0' !(JIM;oll
7 Distributor (3.0 litre engine) -overhaul
W,th the diMJlhuto. removed from the entl,ne. 'emove the rotor arm and the cont.1CI breaker assembly . 2 Prose Ihe small Clfclll} I'om the v"cuum u,,,t p,vo l IXJSt. 3 flemove th e two sc,ews wh,ch sucure the hfllaker pl,lI!! to Ihe d,slJlbu tor body and hit the ,}I'rte orl.
" Slacken Ihe self'lappmg SCfew which SC<:UlCS the condense, and low tenSion leads 10 Ihe contact l .. eaker a ssembly and shde OUI Ihe lo.ked ca ble terminations, 5 Undo imd remove Ihe condenser rCI.1,nlfl!.l screw and remove the condense •. 6 Remove the c" chp. lIiJt washer and wavy wash er from the pivot post. Se parat e the two plates by h,ingmu the holding down se,ew Ihrough Ihe keyhole sial in Ihe lowe. 1)late , Ta ke care not 10 lose the e.Jrt h spring on the prvo t flOst. 7 Remove the two se,ews seeu"n\) Ihe vilCuum un,t to the d IS t"lHIIO' hotly .Jntl remove the vacuum uni t. S To d,snl.JllIle Ihe vacuum unll, remove the plug I.om the end 01 the
unit (md withdraw the spring. vacuum stOp and shims 9 Oelo,e disll1<1ntling th e centJllugal .Jtlvance mech.Jnism. note thM th e tw O spri ngs arc d.lle.ent and ma,k them so th.Jtlh ey .Jre ref'tled in th ei r OJlgHlall}lilces . Remove the sp. ings. pJlse all the circ lil)S securong the cenlJlluga i weights. nl.J.k the weight s 10 'dent'fy their o"ginal positions and then remove them ,
1 0 M3<k which 0 1 th e end slo ts on th e n'cchan,c.J1 .Jdvanctl pl;]le
lages w llh the s tol) m Ihl! ;]C hOn I)I"le II II" s IS not dono. II rs ~ s, llle to h.Jve th e ,oto, ,'Jln 180' from 'I S COf/,-ct pOSition. 11 Remove the lelt pad 1 10m t h e centre 01 the C.JIll. e~pand the circhp
x - ------:::-.
z
y -
Fig . 4.4 Distrihutor lilting position on the 2.8litrc e ngine (Sec 6)
XX Re.1r "U;,.' of ellgmc yy V,1CI/(JIII flllil Mas Z = 0 '10 11/'
A Triggcr (lffll U Slillor l!fII!
whICh'S Ihen exposed Ilntl ,emove ,I L,lt all Ihe Ci"n and 1l(IV3ncc plJle ;Issemul y,
12 Do nOI .cmove t he d,stJluutor Sl)indle unless II 's necess.l'y to "1 a new ge.n. 0' S I)iJldle To remove Ihe uear . usc <1 IlUnch Ilnt! hJmmer t o dJlve outlhc lock P'" and Ihon pull tl)() !.Ic", frO'11 Ihe sprndle T"ke cn,e
1 0 rOIil'" ilny slums, 0' wllshe,s wh,ch fll.Jy be In led . W,t h the ueJ' lell'Ov\:(\. the sl)lIldle .Jsscmbly can be withd,awn hom the d ,s'Jlhu tor 13 Belore reassembhng. ca,elully clc.J1l the body 01 th e d,s lnbulOr and "II a s CO'llpo llent p"'ts. II th e sp,n(!ie has been .emoved. lulmenlC II w'lh e'lu",e oil h efor e ,ellssemhly. 14 Reassenlbly.s <1 SUa'ghtIOrw<1Jd ,eve'SilI 01 d,sman tling bUI t he,e Inc several pointS which shoold be noted.
15 Lut)JJc;]te th e ce Jltlil ugnl weights and otho. p3rtS ol the cenlrifugal
advnnce mechanism. the diSlrrbutor shah a nd Ihe pa'l 01 the spindle wh,eh c.l"'es Ihe cam assembly. using engine all. Do not orl excess,vely. 16 " Ih e dr'veshnlt hilS heen .emoved. firSt re fi t th e thru st wash ers below tho action plnte. bolore "'se,ting the S h .l h into thc disl. ih llto,
hody . FII the w3vy washer .Jnd IhrUSI washcr to the lowe! end 01 the shah and then relilthe ge.Jr. secuJlnU it with a new spring p in. II a now gear. or a ne w u"ves hnfL h,15 been fllt ed . a n\lW hole should be d"lIed .1t 90' 1 0 Ihe e~is&#39;U1g hole 17 Alte • .Jssemhhng the centJll ug.J 1 weIgh ts .Jnd sprrngs. check that Ihl!Y movo hccly. w,thout I)inding, 18 8clOle assemblmg Ihe breaker pla tcs . make sure thill the three nylon bearing slUds a.e located "1 tht) h oles ,n the uPllC' uearinU plale and Ih3tthe e.Jrth,ng sprrng ,s foiled to the p,vOt post 19 On complet'on of assemlJly. adlust the conlnCl b'eake , gilp to the spc cified selling
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Chapter 4 Ignition system 93
8 Distributor (2.8 lilre engine) -overhaul
There arc only two overh"ul jol)s possible. these being the fitling of a t"UUcr carl krtllnd the renewal of the vacuum advance uni\. Excessive
I -
Fig. 4.5 Exploded view 01 the distrihutor fitted to the 2.6 litru cnginc (Scc 6) 13
, DIS/111m/or Cill' 2 HOIQ'lIrm 3 Du,~1 covtJr 4 Rolf I,m , Clrchjls 6 T,iY(Jt'f ,1m! ,lssl.'ml!l y 7 Tii{Jllt'/ coli 8 SWim <lim ,lSsom/)ly
9 Sc/ow
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BaSOI/Mlo
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a·rillg
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" Vacuum ullil
"
Dis/li/)uiQl body
'6 Ch,1 c/.ll11/1
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Clip
weM or dllmage to the distri butor body or drivesh"ft wrll I11C<ln Ihe
r enewal of thO complete distributo •. 2 Refer 10 F'g. 4.5 fo r the order of fomov<ll of tho coml)onents and lightly oil the shalt <lnd vacuum unit MOl during rCilsscrnhly (photos).
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94 Chapter 4 Ignition system
i ' .
. --8 2A Removill{J the IllnSlre dust COve, (28 hl'c Cllume)
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, , ,
(\. I ,
" 'v
J 2C W'''I1!j connector i'Uld seCUJlIlg screw (lHOwS)
9 Ignitio n timing -adjustment
Wnh the (.lIs\"OuIO' III!Cd ilS dcscllbed OIl SectIon 6, check Ihilt 1Ill! COHCCt llllllng m;l!ks "'0 ;1119110d. 2 To check the ;1111,,11 (5 t;1I,e) setting, .emovc the (I'51"lIu I0' c;lll [11l\( check IhJllhc rOl0' ;lIm IS PO"1I1119 to the No 1 cylmdc. scgmon!.n the Cill) rndlcmed by the sial on the 11m. 3 On the 3.0 lUre engIne the cont,le l poullS ll\u~1 he ,ust SCI)ilril\U'!J Tho e~ilCt Instant C,1" he checked by connect"'u il 12 vol1 lest lamp between the contilC, brcilke r low tenSIon Iemur),,1 iUl(t O,"lh, W,th the iUnilion Oil, tho d is trlbuto. ShOllld be turn ed nrl\,·clockwisc unlol lho bulb luSlligh(s. " On (he 28 li(re enuule the ("gger arms and stator ;HIllS must bc aligned It not. (um I he (hst"bulOr as necessary . !:i Tighten the (hSI"buto. clamp boll and .ehl the cap 6 Set In thIS way the lUlling WIll be alll)'Olmalely co<rC(:t but a morc ilccurate rne thod IS by using a stroboscopIc tu"ing hghl. 1 HIghlIght the spcclilcd lIming marks on the trrllll1U cover an" cronkshalt pulley WIth wh,le pamt or chalk 8 Connect a timing liijtH to Ihe No 1 spar k pluij le;l d, 9 Disconnect the vacuum mlvance pIpe at tlHl carhure1l0r or au bo~ juel injection) and plug the pipe then .un the engine unt" nOlln,11 ope.ating telllpera tur(!s a.e .eached.
, ..
8 2B UtJlle. vIew 01 the l.imJer Mrn .lrld Call (28 lIt Ie enU"Wj
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8 20 Vacuum un.1 sC(:u"ng screw WIth e')Hh lead termmal
10 W,lh Ihe enij1l1e I(lIrng pornt thc \fmlng hgh( at the cr",lksholl1 pulley The wh,le 1),1mte<l mar ks WIll ;lIme", sliltlonary ,111d If thO tlmlno IS COller. 1 (hey WIll be III ahgnment. 11 To adjust the tllnm9. stop (he engine. sla ck en Ihe cl;'lmp bolt iln(1 turn the (I ,st"l)uto. slIghtly_ TIghten the clamp bolt. star t the engrne ;md .Ct;heck the (umng Repeat tillS 11IocedUie unlll Ihe rIlilrks ,)re In
hne
12 To check the mechanrcat adv.1nce. Increase the engIne speed and note whelher the wh,te malk on the pulley moves away Irom the mark on th e pOInter . 11 It docs the mechanical advance is lunctioning 13 W,th the enOlile Idlmu the vnCU\ Jm advance can be checked by suc kIng the oldv~ncu pIpe that W.1S removed from the carburellOI o r air box ThIS should also c.Juse the while rnark on the pulley to move away horn the mar k on the pointer 14 On completIon remove Ihe timlllU hght and rC(:onnec lthe v.1CUUIll pIpe
10 Ignition illlllllifier module (2.8 l i tre enuine) -removal and rClittinu
Thc Iunitlon illl\J}l lflcr module is locmed on Ihe left· hand SIde of the engIne COnlpar tment. tUSI behind Ihe hOnt suspenSIon strut upper mounting.
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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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