oil FORD CAPRI 1974 Repair Manual

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Chapter 3 Fuel and exhaust systems 75
;\1.325 Prisillll oul tho re l<lin in\] clip (A) when removing IIIH acceluralOr callie (n) (Sec 1 7 )
~ fl""",V<: Ilw au eli!.",u. ;IS d .. ,~r.&#34;&#39;J(:d III Sf·etlan 3 5 1',,11 011 tlo" ~I&#34;&#34;VH ,,,HI d,s<:OlUI'!Cl 111" I&#34;&#34;~II<: sock", 110m 110"
cOlll,,,1 IIIIK"!I" G I'll'." Ih" ",,,,,,1 '''','UHrI!l <:lIp hom the IlIi,,;k"l 7 U~&#34;&#39;!I a ~,:&#34;,wd&#34;v&#34;r. d"I"CSS tile pl<l~1U: \.,1)$ "" II", '"\'"''''' wild" tw""I",!) 11,,~ 1(JI,,,,,cr. (1)I,n pull hall' the 1ll0lultorl!J 1".ICk!:! If Ihl~ pIOY"S (I,H":\lI, milk" 01 """ovatlOol \0 the d&#34;&#34;f!&#34;s,O&#34;~ !),v,m on FIll 326. ,unl p,ess Ihls ooW lh' lalls to IclcJse them 8 RChHinU ,$ <1 revers.11 01 lemovi'll, 1m! ad,,,st 01 as fullows. f&#39;lac&#39;~ i' wCI(Jh 011 the <lecelcf,lIO' pcci"l 10 hold 1 '" HS fu lly depressed POSIt 1011. On <llJlOll"nle lIilllsmisslOIl models chevk Ih,11 Ihe downslull c;lble IS nOI pn:oven llll\j 1,,11 mnvement. Bild oil Ihe ,1(il'lslnH)nl ~Ieeve ami "dlust It so Ih,'1 the t lHollle plates ;lIC IU~I fully Up';I1. n",,,,,VI! Ih" welOh! illl<l check Ihe opel at lOll of Ihe ''';<:el",,,tOl 1',,<1;,1
111 Accelerato r Sl,,'fl and ped,, ' -rc "'ov;,1 ;,nd relilti"u
'o le: If /I" ., IU:(/"I ",!ly ,.~ to &#34;(~ /f.'/!/oVI:1I /("1,:, (0 1""""1';'1"" 12 [)I~.,:,,,,,,,&#39;cl (h" 1",lle,y lea(ls ? r",," liNd" t lw C,II lemove Ihe 1;)(;';1 It""", 1';,,,,,1 II I, '''WII\l:d hy ,,<&#39;I(:W~ (IlHO) OIII""e S{;WWS (LHD) "IIIII!I Ihe ''',II "dUI! ami C;1Il tJ" IUH:lopp"d l,ulll lhe hont l~d\)c 3 n"lllove th" ,u;cole'''lot cilhlc hom Ihe p"dal sha h olS ((e~&#34;&#34;h&#34;d III
Secll"" 113
RI-IO variilnls 4 DI~(u&#34;ncct Ihe IHake ope',IiIl1\J IOd ill Ihe b'ake ped;rl. thcn 'enluve tio" I"aslcr cylinder ,lilt! sc,vo lllHI nell" to Ch,lpl!!' 9 101 lUll lol'l
'nl')lll1alI1111
5 WO,kllll) I I"OIl\)h (he ,e,l' bulkhead III the C "IJ"'C vo"'p,"t""!1I1. pull Ollt lire sh;rft "nd S"CUI1I1() chp () Rotate Ihe I1\)ht·h,,,,d Shil l I IIIO'"ltlll\) bush Ih,ou\)h 45' ,n e'lhe' d1lCC1l011 ;)nd pull II Out 7 DetaCh Ihe <lcceil:!"lto, sh<Jft ilsseml,ly
LHD vmi,!IIls 8 Loosen Ill" clamp illHI dewch Ihe sh;rlt exlClls,on ,oct. 9 C;uefully rlllve Out the ,,\)Ilt·hand 1110unlll\\) bush 'ewln, n\) clop 110111 Ihe sh;)h, thcn slide Out Ihe sh;)h ulll,1 ,t louches the hCitlC! IJOx 10 Detach thc "U1l1 h,H\d mount'n\) bush I,om thc ped;)1 1J0~ by 'Olilllll\) tlHolIUh 4 5' 11 ellhe, ducctlon, (hen pulhng It oul The ilccelera!{), slHlit [l5seml;l), Cilll 'lOW be removed
AI/models 11 Oetach II", 'em;lIl\ll\Y bush ;rm] clIp hOIll lire shalt. ) To re11l0V" the pedill, pl1se the f!;ln\Je ilway Irom the SPIYO( on lire snail. lhell ,emove the p"dal and sp"ng 13 WI,en ,eflll"'!! tire pedal. locilte the sp''''U on Ihe SPIUOI shall, lilr,, clop th" 11""\)"$ 01110 Ihe SP'\JOIS ilnt! check lhilt Ihe pcd;)1 I"vots
cO"lIetl),
Fig. 3.26 Accele ra to r cable rc moval 1001 (Sec 1 7 )
A _ 250",,,,(10,,,)
() ~ Cell(fe IlUlidl /11 /J!Uv;d" ',1,SL'd -'''ullld ... ,
14 ncllll"'() the pud.ll shilft ,s Ihe ,eve,su 01 Ihc lelllov,,1 IHocerhllC, lolinwlllU whIch It w ,lI he 'H!CUssa,y to ;ullllS I It,,) cailic. "5 d"scllt)IJ d 11 Si,(.t'OIl 16 OIL Rill) v;",allts. dlcck lh;ot the I)(:d;oll"'$ 6 tn 14 ",m (02" 1{) 0 55 'Il) I,ft 110'" the nflu posit 'on If IIo,,"ss.u y ild)"st Ih!! pedal
Iofl up ~!Op !O ach'"ve I h,s
19 1"lc t Ill[l"il o ld -rClllov;l1 ilnd rcfitting
1 DIsconnect (he biltlc,y ne(),1Ilve IUild. 2 D'illli Ihe coolm\) syslem (Chapter 2). ,emovc Ihe d'StllIJU1{)I (Chapl", 4), and remove the C.llilll'et!O' (SectIon 8) ] DI~<:OIlI,,:ct til!! rl!m,IIIiUlI) hoses ;rlld Willi'\) <1 UllSV,P.W the 'nlet m;r,ulold holl~ p'ouress,vd), III II", &#34;,v,,&#39;~r: oldl)I 10 that lflvell II, 1"1) 327 5 LIft 11'1) II,let Ill;H"lold frum tlH! o:yhlHit;, hr:;lds ;",(1 II''''<JV'' II", cornlJlIlcd \Iilskct li To 'errl lhe Il\lell1"""lold, I&#34;~I t:I(~all Ih" 1I1;1I11'!1 I,u,;,'s 7 Appl y seil lll'!1 co"'po,,,,d whe ,,, Ihe lowe, I:O''''"'S 01 IIw cyllllde' IH',lIb IIII-,ul Ihe ,;yhnd<], 1>10(:k 8 LUCil(e il lIew \)Jsk\lI Oil lh" Il(lild~ ;",(( block :J Fll the Ullet '11;UlIlo ld then II'S"II II,e holts olml i<\)ir(ell them 11Iou,ess lvcly ,n Ihe scqllencu shown In F,U 327 alld ,n lire sw\)es
\)IVCll '" the Spec,fr~.lt&#39;ons 10 The '''lllillll'''\) proced",e IS" 'eve,s,,1 01 ,elHoval rlefrlllhc cool",'J s)'stem WIth Icfe'cnce 10 CI"lpte, 2
Fig. 3.27 Inlet III,mifold bolt tightening sequcnce fo r 3.0 litre engines (Sec 19)
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Chapter 3 Fuel and exhaust systems 77
Fig. 3.29 CUlling the reM o f tho exhaust system to facilitate its removal (Sec 21 )
6 Usu a hadsa w 10 CII I II"Ul'!lh Ihe .e:!. Cxh:!ust p'pe ilhoul 240 mm (94 .n) ItOm Iho! ''';]' ollho I.onl tI:S(HlilIO' (r.O 329) 7 Removtlihe IHII sl:(:IIIIIl!llhe I.:a. sllrm cm hlolt:kel clamp. SWU1!llhc hl"ck,,1 ell,;" ot 1111, sol"nc", :tni! ,,",I ,lcll lit" ",n, e xhausl ~(,CII&#34;n. 8 Ot.lt.1Ch ,1", 11"'110VI) Iho I"a. IIIOUnlll'!IIIIIIlw. :tnd IIIa(.k,,1 clallip 9 Rell1uve Iho hont P'P" LJ r:lallip and dill I oH 1111) Iron I pipe . D"t;tcll Ihe f(:sonn lo' 1I100mlll'!! h.ack", and Ih" wll plpt: 111111. If filled 10 Slilll 1e!11!1Il!j hy SCllhlll\j il nlo"k 115 I'"'' (1 8 III) 1,0m Ih', CIII ends ollhe ,csonnto. 10 Silence. pipe I I POSition Ihc .csonnlOl and ltont II'IX! ilSS(lmhly. loosely SUCIIIC ,110 the hr,'CkC I and man,Iold connCCIoOIi 12 Slide a se.vice sleeve (FlU. 3.30) 01110 Ihe .eson ;IIOf I"I)C. pos,"on,nu lI S end In Ime with Ihe s O lhed ma.k m,llle p.eviously. 13 F'llhe Silence. l)lpe mlO Ihe sleeve up 10 lI S sCli hed ma.k and .ehl Ihe .e:!. StiOIlCt" c l."up ItJo~ly Wilcil hlhll!llhe clamp. ensutc Ihm liS
;IIlUlet! end .s IIpp • .:tlnn~1 111 1\l1!II'lhe I!xhatls l syst"m sn Ih;11 .. I tin 1IOilit IS 'I Ile;u,,' Ih;)l 1 25 "'''' (1 III) 10 "lty i:Oll'pOllelll. o. 1',111 01 Ihe t,,,dywn,k TI!lilteli th\)
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FiU . 3.30 F itting the service sleeve to Ihe eKhausl system -arrowod (Sec 21)
II1n n llol(1 conn(:(:tlon and Ihen screw on Ihe nUlS of Ihe .esonnIO' clnlllflllll111 13 mm (0. 5 m) of Ih.end Pfotrudes Ih,ough Ihe nulS. 15 1'0SIlion Ihe IWO U·dmllps on Iho service steeve and li!Jhlen the n\llS 10 thu IO'IIIHl w.ench sc1ttng Uiven in lite SPCClhC,ltions 1 G [1"" 1 lit,) 1;111 pIpe 111m of "pP'OP".1W thon reconnect Ihe b.ll\e'y. M:ttllhe OllOine and chock 10' 10,lk 5 17 Low,,, the c," 10 Ihe Wound.
PART B, FUEL INJECTION SYSTEM
22 Goneril! description
The 111,,1 "'1"Cllon sySlem fitted 10 Ihe 2 .8 hIre engIne IS o f the COllltlllHlIlS '''IL'Cllon Iype ;tnd sttppltes " p.ecisely conuolled (IUnllllly (II ;I\()lII,":d hll:1 10 "nch c ylt1lde. undo. fill Ollo.nttng condItions.
A U C
Fllel plllllJl FII~·1.1C&#39;·&#39;&#39;&#39;&#39;IUI •• tul '''mUIr) IWlls",!}
Fi g.
D f F
3.31 Locations o f the fuel illjection system compo non IS
Fuel "'WI G rhemlolime switch
(Sec 22)
K
L Relays ilnd line (lise Im,lu'se module OrstllbulQr/mixture cO/wol "",I W,l. m·up leguliltol H Allxrfi,lfV illf device J Stilll valve
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78 Chapter 3 FlIer and exhaust systems
TIlls system, when comp1lrcd with conventlon,lI c.Jrhwctlo, ~rrilngemen1s. <lchicves <l mOIO IlccUl.1te control 01 lho <Jil/fuel mi~l\l,e resul ting in ro(tuccd omission levels and improved prcrforrllilnco . The 'llllln coml>oncms of tho fuel inrcclton system lall into three
tI'(lllPS
A FI/ef Milk Fuef Plllllf! F/lel .?CCIIIIW/<1IOI Fuel filler F/lel ,IISltihular ,w(/ millime con/rol l11ralllc MIlllll/ce/Of "',1/1'115 AI( ch.ll11/"1(
B W<lIIII 'IIIJ wyu/,1/()r AIIII,{Wty .1;r (/I:VJc.' Simla! ",MH' 7 hCIIII<J/mifi SWitch
C Wilil/[I Hd,.ys SMt'ly SWitch
The fuel pump IS 0 1 eh,CIIICtllly operated. ,aile. cell Iyp" A .",SS (IIC rchd ..,:,1..,0 'S mco,p[)I;oh~(1 III the pwnp 10 preY",l! f:XCOSSlvn
p"'SSUIC la"ld III) '" tho event of ,1 ,,)Sl"Ctlon III th e pipelollf!s The fuel ,I(:c\llllula lor ha~ 'wo lunf.luItlS. (t) In 4'ill1I,)(:I1 llll! IIIII,,;,'U)!l 0 1 lhe luclllow. HHlu.:.iI ,ml hy Ihe I)\I"'P ;IIIf' (II) 10 11I;""t,"" Iud I&#34;&#39;&#34;&#39;~&#39;&#39;&#39;&#39;&#39; ,,1";1 .h" .:o,!.m" h;os Iom,n sw"dn,,' "If TillS p.r.v"rlls .• v; 'po", IIH:1o; .lo.:vel"I'III!1 w,th t:'Hlf.O:'I""nt 100' ~t,&#39;<tIllU plohl"",s The f'lcl filter '1I1:"'I'OO;lleS two l"ll,e. 1,111" "Imlllllits to ""SU'" th,lt lhe '",,1 1!!,uoOh,,,!) 11,,: 11O)I:ctrrJl) syst,,111 comp"""lIIs IS "UUII'I"I"ly flce hom tlo.l The fue l distribulor/mi.l!ture control Msemb ly . The Iud dlsl"bulor C0I111ols Ihe '11I,lntl 'y of fuel bein!1 dehveled 10 tho CII!)Hle.
OIlS""l1g .h'lI each cylrndo. fCCOlves Ihe same ;lII1OtUlI. TIlt! mlxhlW COIII.ol aSSemhly ,ncorpo'illes ,III IIi, senso. pl, 1le ;m d cOlllml plllll(le •.
6
9
The iI" sen~or 1)1"le is locilled in 'he main nIl Stlealll be.ween the iI'r clr:wller ,1nd the Ih'Ol\Io bullerfly. Du'ing idling. the ~irflow hits Ihe sensor plate which in tu.n '<lises a contrOl pluiloer which nHows fuol.o How P.1St tho plunger and oul of Ihe injeclor v.llves. lnC/ease s in enornn speed cause inC/eased air flow which ,aises the conlfol plulIge, "nd so admits mo.e fuel. Tho throttlo valvo assembly ;s moun led in .he rIl<lUI all ;nlilke hetween tlte mixture contrOl ,1ssembly arid Ihe ai. challiber. The Ihrollie villvo plate is cOlltlOlied hy a cilble connected to Ihe ilccelerntor podOll The injector valves a.e located in the Inle! 1I1o111110ld "nd OlIO dt.!sl{jllod '0 01)0011 ill a fuel pressuro of 3.3 kof/cm' (46. 9 Ibf!III'). T he air Chiltllber is mounted on thO top of 'he ell!Jlno iln.t fUllctlons ,1S an a"xlhillY inlet nWllifold dllcctill!J arr horn the sensor ,,'011(1 '0 e,1ch indIvidual cylinder. The wilrlll'up rogula tor IS 10f.il1Cd 011 Ihe I,ont of the CnU,"e ;01,,1 '"f.orpur"tcs il hi·met,.1 st.ip. VilCUUlIl di"llh.,IUI11 and cOl11lol Villv!! Th" funcI,oll 01 the ronulato. 'S to enri ch tho lucl/a" n".IUlf) Ih",no lire W,II'" III) Ptillod ;md iI'SO:ll lull thmttlo Of1"Clallon . Tho auxiliary iii, dovice IS locaterl nil tlln Iron! f.If." "I Ih" "" dlilnll ..... r. II ,:ons,sts of a Ilrvoted plil'o. h, ·metal Slrrll ,),1(1 h,,;,ter 1:011 Til" PU'P IIS" 01 IIIIs tlcvlce IS to supply an PI&#39;crcOl~&#34;d vnhlllw III 1""1/",, 11"'1",(1 dl"Pl1!J cold idling r~llltcr 51111i1011 to Ihe 101,,1 1111" sy~h,m Orr 1:,)lIIIII"IIOII;,yoIJIS Ti,e fuel sta.1 valvo is locillud 011 the l]Iall l;,1f dl,II""!!' iI"" ", all ,,1o.."(:tllc.llIl' tlt)C,,,tcd 1111')(;10' , lIS PIII I)()SO IS 10 SIJI.ly fudrrllO ti ll! ,111 r .... '. ;'1 ,;,,111 ~&#39;~rrt&#34;&#39;!J ThiS Iud tomcs II"m 'ho fuel ,r. :.t"IUIIO' ,lilt' IS oIlo"'If,·d III II", ,III Ch;II))I,,,. wllh an frOIlI Ih..., auxllo;II Y ,1" d...,V,4·" Tho TI", .. I110Iil}10 switch IS sl:'(lwod Into Ihe (:lltl "U) mll.1CCI't lu lit!! wa'lIIup 11'\)111,110' Th(l SWItch ,IICOIPO(.1I1.'S" COIII;tCI ~Ill. &#34;&#34;lIIcl~1 ~I&#34;p .",,1 IWO h(:iltcd elmn(:ms The switch comrors thc sta.1 v,llve by hl'llIlIllI the PCIIO<i 01 fuel in)CCllO'1 frOIll Iho valve anti ill$o pr(:vellllllU ti,e valve frOIll IIllcc"ng any luel ilt all when sta,',ng a hOI cngule. Electrical re'ays and luses. These a.e loc,, 'cd undc. the faci" p;IIIIJI Oil tlte ri!)ht·hilnd sj(lo on Ihe intc.io. 01 Ihe C'If. Tho .()I,1yS cnlllp.bo Ihe 111;1111 contrOl foray and [hn powef SIJpply '01,1y.
Fig. 3.32 Fue' injOCliOrl system flow diagralll (Soc 22)
1 Flle/lall/(
"
Mu;/ulc CUIIIIOI ,mif 6 IIIIOlfic pla/c assembly 10 S/;II/ villve 2 Fuel PIIII/I' 5., Fucl (Iistllbutor 7 Inicc/or valvc /I 'hell1JOlimc sw,lch 3 Fuel i'CC/IIIIUI"tul 50 Alf SCIISOI 8 WiJllII·Up regula/or 4 Fuel '"10:1
"'
Plcssule regtllillQI 9 AU~IIt&#34;aIY air device
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Chapte r 3 Fu el an d exhau st systems 79
Ii
0) G
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Fig. 3.33 Fuel injuctiOIl system circuit di<lUrnrn (Sec 22)
1 /J,1I1C 1V C W"lflll (If! luyu/',lor plMC
2 Sialicr I/Iolor /) Axll/,-"y ,1i, device G Theo1lO/lmc switch
3 fgnitioll switch E FIII;I/Iump H St,lfl valve
A M,lin con(Iol r(;/,)y F S<!fCly swllcil on senso! J Impulse module
8 Power supply rcl.1Y
Tho safety switch is provided to cut olf illl power !O the fuel injection sySl(!m if the air sensor plJIC (mixt\HC COlllrol assemhly) IS il the rest position even if the ignition switch IS all. The s[lfcly switch would ell! off the power to the fuel pump for oillllpic ,I il fllOJllmu W<lS darnol\jC(t 111 ,111 t1cciden t or hurst through deHH,or,11'QIl lhc ~wltch is located close to the mixlluc cont,ol lin'!. On f,lIer models th\! Sille ty switch h<ls been repl<Jccd by <I S<llcly control module. ThiS Illodule supplies power 10 Ihe luel pump prOVided Ill.ll It IS "xe,vlIl\j pulses Irom Ihe 'V'1I1Ion co,I, Ihese pulses helnl) evidellce thm the env,ne is 1I'''ning. When the engine stops lor wh<ltever reason. the salely control ule cuts 011 power to the fuel pump.
23 Aoutino maintenance
AI the IntelV<lls specihed ill the Routine Milmtenill1ce 5 eC1l0n ,n the Ironi 01 the m<lnual cmry oul the lollowing procelillle$.
Check (Jnd adiusl idfing spoed 1 COllnecl11 11Ichomeler to Iho engine then rlJll the enVine to 110rmal Oper<llll1g lemperilture. 2 Incre<Jse the engine speed to 3000 rpm lor 30 seconds then allow
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< &#39;(:,,~ , • . . ;::~t,·· . , ,
.' ) . ;~ ~~;:;: ~iJ&#34; .. ,
n fr.X l
the engllle 10 'die.
3 Check Ihill I he idle speed is lIS given in the Specificmions ilnd il nccnssary "dlust the idle speed screw 10cllted heneillh Ihe Ihrottle housinv {photo).
Check conditiorl o f fuel hoses " Reier to SeClion 2.
Tighte/l the inlel manifold boilS and /luis 5 Refur 10 Section 29 and lighten the inlel rll<lnlfold bolts illld nuts in tile sequence viven.
Reflew Ihe fuel filter 6 Refel to Sec tion 25.
Renew the air filter element 7 Disconnect the h<J\leIY. 8 Release the spring clips on the air cle"ner {phow) 9 Lill Ihe <lir cle"ncr cover. logether W ith the fuol distributor
assembly, ,1rld hit out the air filler element {photo). 10 Cle<lnthe inside o f the ai, cleilner body and covel 11 F,t il new clement then refitlhe cover. 12 Reconnect the bllllery,
23.3 Idle speed ildjustrnellt sc rew (arrowed) 238 Releasing the .. II cleane l spring Clip 23.9 Removing t he air filter element
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80 Chapter 3 ~lIel and exhaust systems
24 Ai r cloanor -removal and re filling
1 Remove Iho elomerll as dllsc"hed III Sect,on 23. 2 Work,nn under Iht! left ·hand honl wheel arch. unboll the illr clenne, hOdy f,om Ih e s,de of the engmo compnl1lllen\. 3 Rohuil1g IS n rove rsal 01 tho lomova l I)rocodule wl lh relelence 10 $(1(;11011 23,
25 Main system compono n ts -rellloval "l1d rofitling
Fllel p /llllP 1 Thn hll)1 pump IS loc.lwd "' " lI,hlw.. 1ll011111111U .lUflchod 10 Ihe "!Ihl h"n{1 51th! 01 lhe 11I/,llal1k (phnIO) ') D,sC:OllllCCI Ihe h<lllulY 3 Rol'-',1S0 Ihe IHeSSUle OIl tim SyS hllll I,y lelllpOI<I"ly looSl'!I1I1'l1 Ihl)
le"l1 line IIIlIon on Ih e lu«1 dlSlllhul<ll C,11l:h Ih o sm<lll <lmOunt 01 luel wh" .. h CUllies oul 111 <I p":c:e III dOlh 4 Wllh Ihe ,eil l of thl! c:a, flve. <In IIlspeCt'OIl pit or sUllahlv rfllscd.
cl;lIllp l hl) 111(:1 IIIIUI hose IIC1W,,':1I1he ludl;lllk ,1ml th « 11111111) uSlnH ,1 h",ke hose cl,IOUjl or sHlIII;" If Ih oro ,s only ve.v hnle 11101111 I ho 1IInk. illl 11"lIl<1llvO 10 cl,1mplI'!l1hc ho~() IS 10 dram Ihe Innk onCIl Ihe mlOI hose 10; ,h~c:ol1nCClu&#34; !". OIs.:nrUlI){:I IIlI! Iud ",Ie! ,llId uIIII" 1 IIIIJoI:S I.nUl Iho pump G Cn,"'ully ut",llily Ihf! dm:I"c:al C:(&#34;UH~C1l00S 10 IllI! pump nil"
&#39;&#39;&#39;~t:un&#39;&#39;&#39;~.1 11",," 7 I ,.,,.,~&#39;&#39;&#39;&#39; the 1I!l11l hoilid Illd 1'lIlk SUPI)(Jl IIII(f Sl'ilP Illell unh(lll ll,,~ lul,I)". mOlllllll'H ami 111,,1 JlUlll!' 8 !'IISf) the pllmll "("n the "'OIull"'!! !) Ilcfllllll!j 's il IUliers,, 1 01 ,emOVi.1
FiU. 3 .34 R Oilr viow o f
A Ink'1 pi,ll}
fuel,HIIl'I) (Soc 25)
8 Fucl'WIII/'
..
) 2~ 1 Fllel pump showing Wlflflg ond oul'el pipe
~ .. . . ~ ~ ... ,
2510 Fuel accumulatO'
Fuel accumulator 10 The fuel accumulatO I is bolted to the Ical 11001 above Iho lear "Klc (phOIO). 11 Disconnect the bflltCly . 12 Releaso the preSSIJle in the system as descllbed in PfllfltJlilph 3, 13 I'lilCO the leal of th e car ovel ,1n inspection pit o. lilise il on ' ilmps O. fldo·stands. 1 4 D,sconnectlhe fucl pipes I,om the lu el accumul,110r and catch Ihe s<llflll qUflllt'ly of fuel which Will bo released. 15 Remove the Iwo Illollnling SCfOWS and remove Iho acculllulf1lOr. 16 RefollinlJ i~ a ,eve,s,11 of ,emoval. hut lemovo tho floor panel hom Ins,de Ihe lum,ji'ige COIl1I )il'lnlenl and relit Ihe p,oteclive Cflp5 over lhe SC(()W Ihronds .
Fuel filler 17 The luel 1IIICr 's locmed 011 th e wheel olfch in Ihe lelt hand side of Ihe .mU"'o COIllI)"' ln,elll (1IhOto).
Fi U. 3.35 ConeCI 10Ciliion o f fuel filler oullel pipe (Sec 25)
A B Fuel "'ICf Ou/lelll'lle c Engine comporlmenl side p,wel
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Chapter 3 Fuel and exhilust sys tems 81
1 8 Disco"nect the hllllmy 1 9 Relc,,~e tl", .. ,e5~II.e In t he system "s described in palaglaph 3 22 P lace some cluth hcnc,llh the luel flhel then disconnect the mlet ilnd outlet ", lions 2 1 Rcmollc tht) mOIlI1lIlI11 sc.cws ,1od withl1,,,w Lhe fuel f,ltc ,. Remove
the bl:lclwt II 'ltICIlS$:I'y 22 RchulI1U IS a .ellcls:l1 01 ,emoval. but m"ke sure tha t the 1,ltel is
pQs. t.onnd thll I:Olfe ct W,ly 10un(l. "n(1 Locate tile OUIICI plj&#39;JC:I~ snown
io FiH. 33!)
Fucl tlisfllbu{(}r 23 The f""t d&#39;~L&#34;I&#34;&#39;lor .~ IOr.i'to(1 on top 0 1 the "" flltl'!'. 24 DISCOnl"" .t thu !o:m",y 25 n,;L&#34;&#34;~,,, thO! L&#39;&#39;&#39;&#39;&#39;,~II&#39;&#39;~ III (hI'! system:ls d"sl:"lmd in piull u,a"h :I"" t compL"L"ly 11,111"11" tho I,,,, d 111111 ",Hon 26 DI~r.&#34;&#39;UII&#34;. t tl,,, """,11'1'1111 f,,(:II'"C$ 1,<)ul til(! llis t,d,utOI 27 UIIS&#39;~&#34;:W ,I", nll"l1 """m'"'n sc",ws alld hit Ihe IIISIIIIJlIIOI away 28 RHhll""1 ".,' &#34;,v&#39;:I~,,1 "I rr""OvilIIJlJ IIISC a IIIiW coppe, w&#34;~.h,,, r:ach ~,de of Iht: '1',"'1" IIIIIW&#39;~ ",,(I dO not OVf!rI'UII1I:rllhe llIliol Imils 9 Hall" Ih" :.y·.1t:1I1 I""",u'li t: heckr.d by yo"r dllatCr: 30 I\dl&#34;~t th" "II" &#34;I~:I&#34;t :II\l IIIHXIIlIfl as ,leScII",,1I III SectIons 73 ,IIld 26.
W"",,·/I/I/I.'ylll;/fOf 31 The w."'" "I' "'!I"I"tl1l 's loc ;llt,d on till! hunt of the ""!I"'" ""xtlO t he c(X,l"'H ~y~t&#34;l11 nuth, t I:lhow 32 D,sco",,, • .: ! tl", lhlllCI" 33 Flcleasc Ihe prcssllfc In the sySlcm as desc"hed in parag'''I)h 3 34 Discount: GI Ihc lIacuum hose ilud wi"uy plllg (photo) 35 D'SCOI1"I:CI the fuel hiles (l)holO) 36 Unsc,ew the Iwo sockcl·he;lded uolts ;lnll wllhd';lw thll 'C!jUI;ltol . 37 Ref,(lln\1 IS ,1 ,cve.sa' o t ,emOIl"' . hut lise a new copp .. " wa~hcr eilch Si(lc 01 tim h,ll1l0 \llllons (phOIO) 00 nOl ove,l>ghtcil lh" I"'''on cenlre hol ts
Fuel S f"ff v:llvc 38 T hc luel stMI 1I:llve is located on thc ligl1l ·hand s,de of the lIir ch"mhel. 39 DIsconnect the bmlory . 40 Disconnect the elcctlic p lug and fuel supply pipc from th e lIalve (pholo) 41 Unscrew tho twO socke t·headed mount,ng bolts uSlllg an Allen
key .
42 Ref,,,,,,!) IS .1 'ellcrS:l1 of ,ernOllal. but u~e II ncw moullting flange !lasket Use" new copper w"shel all each SIde of the """10 union lind do nOI ovnlllllhien the Centrc holt.
A!lxih~1I&#34;Y "i,. r/(!vicc 1\3 Thc i",x,h.n y "" rlcvice is 10C"II,1I On the IIU"t hal1d flOllI of thu lIir cha",!,,", 1\4 O lsc0I1"", .1 Ihe hallerI'. 1\5 D.scr"'''.,ct tl,(, eleCt,ic p l11\1 ;,ml IWO illf hoses IrOI11 the ""vice (phoIOS) 116 Unsc",w tl", two 'UO"nIl119 holts .11,,1 hit tl"l ;rss",,,t,ly i!Wlly. 1 7 Fl"f,It'''H .s ;1 HIIIC,s,,1 of 'elllolllli
Foel injocrurs 48 D, sclI"""'.t Ihe h;lll",y. 1\9 O, sr.<J""r:CI Ih.) :u:cclcrlltor cahlc and il.ad."t r,olll I"e th,onle "ssemhl y 50 D'SC OIII",, :t Ih" m;" " lIir SUI)ply l,ullk",!! 10o", ,he "uxtll,e cont,ol u"It ;1I1I111r",1I1" "ouSlnH (,lhotos). 5 1 DI~,:ulll&#34;&#34;: t .II\.! IIlect,ic ,llll!ls from thc walm'''I) r~I,,&#39;atOl. the th.)ltIl{Jtu"" sWllch. thl") lI\lxllia,y air device amI the fuel St.1,t vDlve . 52 D,sc",,,,,,,:t the: hlel SIlIIP'''' ,)ipc hom the St.1,t v;lllle Dlso the V"CII\lm II'II\.! hom tho W;lrm up 1O{jIJlmol . 53 Unl)()lt tht: a" chmllbCf (ei9ht bolts) and move il c lcar of the in le. ",al1i 'ol(l. To completcly ,emOlle il, disconnect the rClllaining hoses. Belllove 'he UaSkC ! (,) h o to). 511 UnSCICw Ihc ",oun,ing boilS <lnd pull Ihe i"leclO's loom Ihe mlet Illal1itold 1,)"1)101 55 Usm!) IWI) ~p&#34;nrIC&#39;S. loosen t"e UIII!)" n"IS .,,1(1 d.s,:onncct Ihe miCCIO'S fr<llll tht: fuel IIIles .
25.3 4 D,sconncct'no Ihe wII'no plug . 25.35 ... "nd fuel hncs from the W""'H'P !egulato! 25.37 Re new tho copper wilshcrs each side 01 the banjo union
25 .4 0 A DisconnectIng Iho tuel slart valve
wiring plug
, "-
2 5 .4 06 ... and fuel supply pipe
•
25.4 5A Au xilia,y air dcvice w ifin g plug.
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,
~ Chilpter 3 Fuel and exhaust systems
~5 4513 ,111<1 "'f hose s 2550A D",conneclinu the maUl "" supply t.unkul!! 1.011 the 1111~hue cont.ol 111111 25501l mid th'OI1I C houslIlU
"",'
25 53A UnsCII)w the holts. 255311 ,,,"U)IIC the ~&#39;&#34; chal11bcr ~5 53C ;11111 'cmoY(: the Haskct
,
25 5 4A UlIsc'ew the 11101l1lt;IIU bolts. 2554 U ,lIld remove the UIIL'CtOrs 2556 The "'Jecto, Q·rinU seal (a"owed)
56 Rcl,llll.g IS 11 reve rsal 01 rcmoval. hut mtlke SUiO Iha l til.., "l)OC Iors .IIC clea n and III new O'lIng seals (pholo). Also rencw the;IU chamber gtlskel.
26 I( H o mixture -adjustment
Noto: 11!e miJllllfe s"/liIl9 is preset during (!for/actiOIl of II", eM ,'nd shOll1ll 1101 &#34;ofllwll~ require "djIISlment. If I!~&#39;W r:QfIIl&#39;O&#34;Cllf.~ l)f 'he sys({)m ""VI! bccn flllCd. IlOwever. tile mix/IIII! (;,1/1 be mi,l/steil as lollows "Silly /II) cxlwlls/ y,l$ <lIw/yscr ,lIJd I,le/Wlllelcr Ad",.IIIIWII/ is 1101 possllJ/c wi/lioll/ "'1 c}(h,1I/s/ gas {J1J,1/ys<'r RUII the enuine unlll il is ill Iho nOllnal Op"';fllng ItImpcr.l111'1I Connect an (&#39;~haUSI gas analyser and a tachollle!C' (.f not l'III,d as
Slandard equlplllcnt) III iI(;COnlDncc with tIn: nH!llul;I(;WH"'s 111-SIIUCllons
3 Incroase the enyulC speed 10 3000 'pm and hold it the,e 10' 30 seconds to Sl<lblh se thc c~hausl U,1ses and then allow the engine to return 10 Idl'flU. <1 Check the readHlIJS Oil Ihe test 1I1st.uments with those speci fied. If ;ulJustment is ,equuoo '''5t turn the 1(lIc speed screw to give the COffec t
Idle speed .
5 Break oft the lalllpl:q)lOol cap 110111 the mj~ture conlrol screw on lap 01 Ihe fuel uistllbulOi. 6 S tabilise the cxhausl Ua ses as dcscllhc·d ,n paragraph 3. 7 In sert 11 3 r1\I AUcn key onto Ihe heau 01 the mixture SCfew and tum the SCfew urlld the COlfeCI CO re<ldlllU IS oblailwd (phoIO). R eadjust thc Idle sI)('cd SCfew 8 II th(' ml~lurc adJuslmcnl cannot be Imalrscd wilhm 30 seconds from th(' moment 01 slahllrS Iny the exhaust uases. repeat the oper1!l.ons dcsclIlJ~d '" pa.lIU'3ph :I 1",;Iwe COnllnUlllU 1100 ad)U SlI1l0n l jlrocedv.e
-
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·s
Chapter 3 Fuel and exhaust sys tems 83
1.6 7 I\dJ&#34;~IIII!J II", n&#34;~h&#34;&#34; ~ t:&#34;&#39;w
27 F"HII;Hlk. $1)I"ll)r ,Uli( and Idll)r pipr. -Ufm() r(ll
The 1(,11101.',.1 ,11111 "dlu",U pH.II.",hJlf:S ;1Ii! SII"II,II III Ihose !I'V"'I III
Sec lions 13 10 16 Ilow'IV<:f. Ih., ~.:&#34;,h:r "nlt.s 1 ... :;.1.,,1 o n ti,e letl h"tHl side 01 lhe "ml tank (phOIO) "lid Ihl) luel I'UIIII' 'S ~l&#39;C&#34;&#34; .. d 10 lh(: righl·h"ml $ 1110 .
28 ACGelerilto r c;thlO -removl.1 "nu relitling
27.1 F tHlll(1l1k ~&#39;!tldef "nil
29 Inlel manifold -rcmoval and re li inU
Ilclm In S')(:tlon 19. bUI Irl sJ(w d 01 ,.,((\01.'11'(1 thc cilllnllc1l0f,
" ,movc Ihe "'I"I:IOIS (Inti iii. chilmhef as dc-sc"hed in SeC t.on 25. N Ole th,,1 the.c IS one nul ill eilch end of Ihe m(ln,Iol(l. ;md 111m the bOltS (lIe of d,ife.enl Icn(jlhs (phow). 2 Also unbolt Ihe oUlle t elbOW and will/n·U)) .e(jul"lo, 1ll0unlin(j hlilckct hOIll I he "onl of the inlet nI(lIl ,lold (phOl0S). 3 Follow the I'ghtening seQuence uiven III Fig. 3.36 w hich d,lIels IrOIll the 3 ,0 hIr e engine (photo)
28.1/ llel110vlll\l the sleeve hom Ihe end 0 1 the (lCceh:r.lI0r c"hle 28,1 B Plisinn O\'! til " 11,1,,11\I0 chp 2a.le Removmg tile ilccclcrmOI cntJle 110111 Ihe IT,oull ting bracko l
---,
I
~ =-~==) ,
~. ,
,
'1,'
29 1 A Un~(.:r1:w the Inh,t m,llulol( l ho lls
J
29 10 (emove tilt) IW!IS
r " ' , , &#39;~;
29, I C ... 1If1(11,/t off the ma(\, Iold
I
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~9.1D Tn~ Inrel m<lnirold (loskm
"
-'. I.: .,
I
:
29 2A Unscre w Ihe holts ...
) "Ig 3.361n101 m<lnifold nul ilnd bolt lightening sequence for 2 .8 lilre enginos (Sec 29)
- z-.~,.......------...-.
,
29 1 E Se,~hn!J !;oIllJ)ound locJlIon 1l"IOIc fo1lU1!J the O,ls~&#34;t
,
292B . ;md rClilOve the outlet elbow alld WllPlll·Up rcuu l,1\or mOunt",\) Ilr;1Gk..,t
293 TlulllcnUl!) tho IIIle l mnn "old IHIIS nnd botls
,
d
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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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