ECU FORD CAPRI 1974 Workshop Manual
Page 13 of 205
" .
:ansa
Safety first!
Profession;!1 010101 mechanICS Me , .. ,oned in sare working I)'ocedures. H owever cmhusillshC you Olily be "houl gcuin\j on with lhe job In h'lnd. (10 lake the t ime to cnsule thai yOl" safely IS not pul11t ,isk . A rnomcnt"s lac k of attentIon car, resul t on an i1ccidcn!. as can fnollJJC 10 obSOlvQ COlla;n ClemCIlI,l,y precautIons. There will alwilys be new ways 01 h;IVUlU ac c.ttenls. ;111(1 'he following points (10 not p.eICn d 10 he! n cOlllplchcns,vc liS! Or <111 d,lIlge.s; Ihey ,lI C inlt'!I1dcd rathor to milkc you ilW;UC or the ',sks nnd 10 encourage II sn le ly -conSClOus ilpplOilch ,<> ,,11 wall" yOIl C;l"y OUI all YOUI veluelc.
Esscllli,1/ DOs nnd DON'Ts DON'T .cly on a SU1U1c Jack whtn wOlk'''11 undc'tlCil!h the vchlcle Alwilys usc rch<lulc add,lton,1' m ea ns of SUP11Ott. slu:h ;;IS axle SI;Jnds, securely placed undCl ,1 p.lrl 0 1 Ihe yehi cle Ih"l you k n ow w rll nO I wye W<ly, DON'T DI1Crllp IIO loosen or IrOll1cn IU\Jh'lOr(J"e milS (e ~ wheel hul. nulS) whrlc Ihc IIchr cle .s on D IDd. ,I m .. ly he pullcd 011 DON'T sW'llhe cnUlI1e w,lhoUI I •• ~I asc r"w.n.nu Ihallhc 1I.1'ISllU5S'0" ,s on neulral (or '!'D,k' whe'e DPI)loc,ll,llI) <lrld Ihc p;r,ku'!J h',lkc ;rpphr,d DON 'T Suddenly rerllOIlC the folic. c.'p frorn .1 hOI t:tluhrl\J system COlier il wllh D clOIh <lnd .clcase Ihe p",:,~",f] !1.»dually ',,:.1. or you may
!Jct
scDlde d by CSC"ll'''U cool»111 DON'T allcmpllO d •• 1Ul 0,1 unt,1 you ;IrC SI"C 'I ha s t;uolcd suUrC'crr lly 10 allo,d scalding you. DON'T yrasp any Il"l! 01 Ihc cngll1c , e~h,l\lSI or "'I; ,lyt 'c r:onll'''IC. w.thoul 11151 aSCe!l""II"~ IhD I II IS su fl,c'ently co1J1 10 avoul hUlllln!1 you. DON'T ,lllow brilkc UUld or anllfr eeze 10 conwct vc hlt.le P<lllltwo.k. DON'T syphon 10K'C Ioqu,d s such <IS h, el. hr;lke flui(1 or a"t,hee~e lJy moulh, o r allow Ihem 10 'emall' on your ski n. DON'T inhalc dusl II m.1y he "'IIIIIOUS 10 hCJhh (s.~ A sIJcs lUs bclow). DON'T nllow any s pd t Oil 01 \l'liasc 10 leillaln IJn Ihf]II"OI wilH! ,t up sl/aiyht awDy, bclo.c somcone SIoI'S on .1 DON'T usc 11I·llll",,, s",lnnms 0101 1"" Il)uh wh .. ;h may ~lrp arul ca,,~c I"Ju,y. DON'T HlIellllltlO hit a heavy COIll!lorwnt whlt:h m ay In: J",yoml your ~ap"LrllrlY yet aSSistance DON'T Ilish 10 I,msh D Joh. 01 tiokc unyellloL·d sho.t cu' s DON'T allow ch Ildren 0' alll",~ .ls III 0' ~"rJII"d;", 111I1'1I.",d"d vch,clc DO wCJr eye protecllon whcn usmy powe, 10015 such ;r~ dll". s~l1del, Il1:n<:h w'nde' etc. and wh"n wOl kln\) under Ihe Yel"c lc. DO use a bil",er c.eam on yuu. h al\(ls pliO. to undcrtakrnu duty Johs II will p.otcC t you. sku , from ",IeChon as w,,11 as rnakrnu Ihe dUI cas,c ' to .emoyc afte.wa.ds. h". make sure your hallds <l",,1'1 Ictt sh pper y.
NOIC 110m lon!j"tell11 coni ac t wllh use d ell!l'lle oil r.DIl be or h ealth hala.d. DO keep loose clothlny (culls. hC elc) and lony IIDn w!:11 aliI 0 1 th e way 01 mOllllly l11echamcal pa'is DO .emOllc linus. wnstwmch e tc. helorc WOlk"I!J Oil Ihe veh,cle
espcci<llly the elc cillcal sys!(![) DO ensure thm any hltin~ tackl!! us!:d has a sale wOlklng load ';Itln~ admJualO tor Ihe ,o b DO kee p yoU! wo.k a.ca I'dy rt ,s only 100 eas y 10 fall oye r .. "tlclcs teft tYll1g around. 00 get sOl11eone to c he ck p erro dlcally Ih"t <III IS well. when wOlking illone on the ve hIcle. DO carry out wor k in a I()(Jica l sequence alld check that eve.ythlllg is correc.ly ass ernhled ilnd t'ghlen ed aftcrw.l.ds. DO .emembe. that you. yehlcle's salely <lHects tl1ll1 of yourself Dnd olhers II in douhl on any poinl. uct speci"hst advice IF, il1 s p ile of follow ing 'hese p.ecaullons. yoo a,c unlo.lunOlW cnough to In)ure you.self. sec k medical illlention as soon OIS pOSSible
Asbestos Cc.1;Jin trICI.on. In sutatrn u. scalrny. ;Intl Olher l)roduCls SUCh as b.<lkc hninys. blake bands. clulch tmongs, tmquc conyc.le.S. ~askels, elc -contam asl)C Stos EJllIem e C,lle mllSI be wJ-.en 10 ,l\foid mhll/{llioll QI dll)'rlwlJJ such l)lorltlL"r~' since II IS IUI"~f(/OIlS to Ilehfl/l If on doubl. nssumc thai they (/0 coniJlI1 ashe~los
Fire Rcmembe. al all tunes that pelrol (uasolone) IS hiyhly flaIl1ln:r. N eller smokc. or h.we .1ny kind 01 n"ked tlamo ,1round, wher) wo,! on Ihe vehicle But thc fis k docs nOI end thc.e -a spa.k cauS!:d 10 elccu lca l shOll ·ClrCIIII. by IwO nletD I sUIfaccs contaclinu each oth .... coue lcss IISC of lools. a. eyen by 51,'Ik eleclrrcity bUilt up III you, I·· unde. Cellnll1 condilions, carr Iynite petlol vapour. wh,ch III or t.orrf "
sp<lce IS highly cJlplos,ve Always disconneCt the hallery eD.th l!J,ound) temu,,;" 1>,·1 wOlk"l!J 011 Dfly pall 01 Ihe fuel o. elcc'"cal syst em . .11111 nl:vn, splllrnll Iuol o n 10 a hot engll1e 01 exhaust It 's ICf.om",,,nd,,(i Ih. ll .1 Ille cKtll1{1Ulshor o f a (ype su,I;rlJh: 1o, nll< 1 "leclIICnllues IS k"pt h<lndy ,,1 IllI! !)<I.a(Je n. wOlkplace;o1 <In I,,,
N fN(;' (.y 10 e~lln\Ju.:.h .1 luel or clecl.ic<l1 lue Wllh wal!: .
Fllmes CertJ IIlIUlI1!: S are 11IIlhly 10X 'C arrt! can {IU,ckly cause Ullcnnsc",
IIIlSS ;1IId evcn de,llh ,llIlh;"ed 10 any exlent Pel.ol (!I<lsolonf:) y;'I ' cnmns mlO Ih, s cate~o.y .• 1 S do Ihe vapou.s I, o m Cf],1<1111 SOlv",,,,., '.' a s Ilichiolocthylcne Any dr<lll1l11\J Of pOlHlI11l of suc h yul.llIl" 1\" ~ltould be dOll" III .1 well IIcntilaled ;IteD When IIs'ny clcanliln flUids .lnd solvents. '''<ld lit/! III~.I"" tl' c;"l,dully NOlVIl ' usc ""ncII,lls hOI1' u,un'llkcd COlllallll:lS Ih"y" "'V" ufl po'sonuus V;rI)(lUI S
Nev,,1 'lin lloe "III)ln" uf ~ motor vehicle 111 nn Cllclos(,( 1 ~pace '.1 ns il U.1r,)\Je Exhau st h,m(;s con1<111l Ci'lIUOrl mOlloxlde wh"'h ext.emcly poisonous. , I you Itemf 10 run Ihe engine. always do so I'" o l)en <llf 01 011 ICOlsl h<lve Ihe ,em of (he vehicle outside 'hc w o'kpl., 1/ you <lre lortullale nnough 10 have the usc of OIn inspCCI'OIi
IH.:ver d.ain o r pour pet.ol, nnd neyer .un Ihe engine. wh,le Ihe ve lll IS S1<lndin~ ove. II; (he h,mes, beinU hca yier than ail. w<1I concent/;II ' the 1)01 wi.h I)(lSsl hly lelhal ,esults .
The I1M/ery Never cnllse a spalk, o. Dllow n naked !rUIH. noa. 11m voll" I
h;1\1I:'y II WIn no.",,,lly 1m !JIving 011.1 co.tam al11o"nl of lIyelll'!I'""'<
w h,,; h IS hl\lhly cx, )loSIY c. Alw;.ys dlscon,,!:!;' Ihe hatlc.y e.1.lh (wound) 11:,""11.,1 1,,·1. wo,k,n\) or' Iloe: fuel 01 CI'lctrl~'11 ~ystll"'~ II possl hl() . looson the frller pl"ys or COYer when d,;oQIIl1(1 I
h ntte.y trorn an extern,,1 sou/cc Do n ot chJ'Ue .11 an ()xCCS~'y" .,,1, the Ihllle.y 111,1y hursl Take cal(! when 10PPInU up nnll when cally,nu the h.ltIC'y lh'I.' I:lcctlolvtc. eve n when drlu led . <s Ycry COrrOSIVe ;)n( 1 ~houhl ""I .lllowed 10 conwct Iho Cyes o. ~ .. '" If you eye. need to p'Cj).1H~ eltl<:l.olyle you'Sctl , alwOly S ,1{ld the .. ' slowly 10 Iho) wOlle •. ,lnll neyer the o lher way round Protec • .1(1""
S plilshes hy wea""y ruhbcr uloves Dnd go~gles Whe" JU"'I) stnlt"'u 01 ca r uSlI1g a booster uatw.y. to. negDllv c l'" (wound) vehicles. connecl Ihe )U"'I) leads in t he follow,ng S(){ll"'''' F"st connec t one ,orn ,) lead belween Ihe posllive ( , ) le"',,,,als 01 1 Iwo hallelieS Th,,11 conneC I Ihe Olhc. jump lend lust 10 Ihe neIFII ' ( ) lelmll1 0l 01 Ihe booster hOllery. ilnd then to 0 good eDrth , (groun(l) pOonl on the lIehiclc t o be starled. 1llleas t 18 in ( " 5 erll) f" Ihe hatte.y If I)(lSs.b lc EnSUIe thot h onds and Jomp leads ".e CI C.1, any mOllln!) P<l.IS. <Inc! Ihal (he IwO vehlclcS do not touch . Dl scon". the ICild s 111 lhe .everse order.
MaillS elec tricity When lOSing an elec'ric powcr 1001, in SpeClio n htthl e.c. wh .. wo.ks fro m thc maIns. always ensure Ihm Ihe apphonce is corr(:( ' connected to It s plug nn d th~l. where necessa.y, il is properly eilrlh. (grounded) Do nOI use such Of}pliilnCes in damp condilions ;" agilll1, bewa.e of ereahnu a spa.k or applyillU excessive heal In I'
VIClnlly o f fuel or fuel vnpour
Ignition fiT voltage A seve.e elect"c shock can result from touching certarn parts 01 tl
Iuni lion sySlem. such a s Ihe HT leads, when Ihe eng,n e 's runlli/Hl being cranked. p<I.llcularly If componcniS are dnmp o. the insul<lllOll
d efective . Where an elect.onic 'ynltion syst em .s filled . the HT volt .. , is much hluh(:r and could plove lawl.
"
procarmanuals.com
Page 17 of 205
" ,
'6 Routine maintenance
)
Every 250 miles (400 lUll) or weekly -whichever comes first
Check the engine 011 level and lOp up " OCCCSSJry (Chapler 1) Check and adlus t lhe IYIC pressures (Chilplcr 10) Clean the windscreen and windows C lean the hcadlamps
Every 6000 miles (10000 km) o r six Illonlhs - whichever comes fir s t
£II[1ille (Clwpter 1) Change engllle 011 and IIher
Cleiln oil flilm c"p Chcck 10 1 ,IllY fluid leaka!)e ,n enUme CO'llp:lnUlCIl1
Cooling syslem (Clwptet 2) Check cool:'lnt level
Fuel syslem (Clmpler 3) Check idh"U mi~lUle (cmiJUiello1 IllUdels onlv) al I"SI se.v,ce ollIe, overhaul C heck idllllg sj)ee d
Ignition sys/Cm (C/I,Wler 4) Clean ,1nd re!)"p Sl)".k plu!)s (.:on!nC ' breilkCl Illudels olllv) Cle an and check d'Shibu\o. C"I). '010'. HT lealls mId co.1 (COllWct
bleaker modcls only) Check elwell angle (cOntact b.e"ke. mo<lel s only) Check i900\OOll hlllillg (COnt:'lC1 break er models only)
Cllltch (e/Mllter 5) Check adjuSlmenl
Bri/king sys/Cm (Ch,1pter 9) Check selva
Che ck hydraulic flu id h,vel
Ch(: ck p"ds :'Illd sho(:s lor wear Check h.ake hllcs and hoses
Suspension .wel stvi'ring (Chi/pICr 10) Check tyres 10' w ear and dam:lge Check steering COmp{lIlCnlS l o r w e:l l "lid d.1nlilue
Bodywork. .111d fittings (Clwptef 11) C lu .. >ek se"t belts fa. we .... damage :lnd secwity
Elvc(ric.11 systcm (Ch,7jJ(ef 12 ) Check Ope.iltoon 01 "Uhts Check wilsher flUId levels Check b.1ltery eleclrolvle lev el
Every 12000 miles (20000 kill) or 12 mOll1hs - whichever comes first
III .1(/(lIlioll 10 Ihe 6000 m/le sciler/Ille
Engine (Ch.1f)ter 1) Check and adlUSI valve clearanc es
r"' .......... ~.~-.... ._ •• -.... __ .... . 3lii1&l •
Cooling system (Chapter 2) Check condition "net tension of 1111011)<1101 dflvehelt
Fllel sys tem (Chapter 3) Tighlcn inlel IIHlnl lold boits/nuts Check vacuum hoses Check e~hiluSI syst em Check ll1r ctonne. temperature cOllllol (,I applicable) Renew fuclllllC ' (fuel injec tion models only)
Ignilion system (Chapler 4) lubricate th e dis'flbulOf (conUlel br eake r models only) Renew the coninCt hu,akcr points (II nppllcJblc) Renew the spMk plugs
Transmission (Chapter 6) Check ool/th"d level Lulmc;ue automatIC 1.,'Insmlss,on IInk:'lue
Rcar axle (C/MplCt 8) Check 011 level
Bli/king system (Chaplet 9) Check v,lcuun' hose
llliJllc:'l1C Ihe handhlake Imk,loe
Suspensioll {//j(J swelill!J (C".1plt~( 10) Check condItIon and hlllSlon o f POWI.II ~I!'tllllli dllvthtl1 (II .1l1pllcal,
Check MlspenSlon 101 we;" ;111(1 d;1Il1.1!)e
Bodywork ,1I)d fillings (Clwpler 11) Check opera lion of all locks Check secu.ity 01 dOOf check sl.aps
LlIl)fIcalC locks. door c heck S\','P5 :'Ind fuel fdler cap flap
Check underbody pr olCctive coalm!)
Electrical system (Chapter 12) Check Opcra1l0n of all eleC111!:al IIcm5
Evcry 2<1 000 llIiles (40000 kill) or 2 yc;u s -\Nhichever comes firsl
III ,1(/111/'011 10 the 12000 111"'1 $d'~'f/u/e
[nyino (CIWpICf 1) f!ell'!W crankC:l $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
procarmanuals.com
Page 33 of 205
, ,
)
.'
ClliIpter' Engine
22 Unholt the thcrmOSlilt INlr Woller eillow R()llloVC the ~Jo1~kCl 23 Unboillhe 1II11Ing cover "ml relllove the UaSkCl (photos) 24 Ullscrew Ihe bolt securing the r..~m~h;'lh {le.1. 10 the Cillll$ho1h ;mll pull oHlhl! nCill (photos). 25 Unscrew the fronl ontctnlcrh,lle plil!C {IHllch'llg boilS ':'IIld rel110VI) tllO rn(crnlClhnl C pinto . Remove the \p$kct ,HId ~pnccl (photo~) 26 If the crDr1kshil ft gO;!' nco(ts 10 be removed usc a stand.lld (1UIle. 10 d 'ilW 11 all the CI;mkshilh (phOlO) 27 Unscrew th e camshah thrust pl,lle 50CU''''0 boilS, rcmo"" Ih, ) thrust 1)I.Jle ilnd wi\hdrilw the Cil!l\shatl (ph010S) , 28 Check th,1 tho l)ig-ol1(1 hC.1roll!1 caps Hlld connCCllllU ,ods loll"', ,denl,lic,ltion 11\;1Iks. This IS 10 "n"",,) (h,1I the CUllect CilpS au! [,II,-d (" the COllcc t connecting rods aod nl "',I"""lIlhly 1l1l~ flBed IIl1h"u ~:O"'''.1 cyllndcr hOles NOie thol11 he I)'~IOII'; h,we 1'111 olllOW (0' r\ou;1I1 ma,~"d on Ihe Clown 10 rUdrC,lle Ihe Inrw,r,,1 1",:OIl!1 s ,de (pholOs) 29 flelllove Ihe No 1 cyllnde, I,,!! ,'r,,1 ""IS. Ihen l.1p of! Ih" I,,!! ':Old
cnp I<",.p I"'~ ~h"11 ''''.1fOllgS w'lh Ihe C,1p .1nd COllneCling 'od I, wh,ch lh~,y Me ,eOllIJved . To remove the shell hearings. p,ess "eolllnu on Ihe s,d,) opposilc Ihe g,oovn on hOlh Ihe connCC IUlg ~0(1, Ihe C"I) .• md Ihe h("lllnu w,1I slide 0"1 (photos) 30 W'lhrh.1w Ih" il'~I(ln and co,m(,r:llI1!1 'od "pwards out 0 1 cylind", I,ow hv 1.lpp,ng w'lh lin, h,,,,dl< , 01 " hnmmcr I, 1I,,,le""',1Ih 31 Rtpc:1 II", poo f.·,lwc gIVen ,11 11;'I'''!I',11'105 2!l.1nd 30 10 remove 'C011.1HlH1!1 ,"~IO"~ an, 1 ,:onneclIl1\j fo.b 32 M,,~,) ~II'" Ih,1 II", ,denul'C<liloll O1101r~~ :Iff! vlsrble on 11m no 1""""'0 ':"I'~ ~o lh.l 1 Illcy cnn b e 1(",II"d 111 IlniU o r'Ulllol l pOSl\lon· ,,,as~eH1I,ly 1 he ""1" ."0: Ilumberr.d .llld oll1 ,UIOW IIldIC<lICS Ihc lIon Ill" CI1!I"U, (phoW) Null) lhal as 1.0111 fdMU.~'y 1982 Nos 2 olml 3 f.
."" ",I, "I1I:d wl,h "'11'10 " holls Ulf.'''II(".l\u'!I l' domed head (phot K",'p Ih.· ,.! 101""11,,,,01 ,,,' poslilon.
:13 U"",, Ih" ""a"'"~lllolts ~mllih 011111" Ill.llt' iJ(!.1tltJU f.nps '''I(I
-, "
9 .2 1 Removinu Ihe enu ine oldaplo, pl.rlC 9 23A Unholr Ihe 11111111\1 cover 923B tll1( retllOV(! lhe {JJskel
9 7.IIA Removc l11e secunnu holl 97.110 ,1rHf ~I"I" "II Ihe t:;1I11~h,"1 un,II [) 25A UI1~Clew Ihe Ilults
;Itld .{!tllOVC the UlICltfled'JIC 925C tlml !JiI!.kt:l
,
procarmanuals.com
Page 37 of 205
)
36 Chap te r 1 Engin e
8 Luh"(;;,,,: lh.) VdtVt! ~1t:m w,1h t!"!l'iI" 011 ;mll UIS",. 01 III 111" yak" !)lIId" Sinh: Oil ,'"ew oil ~I:dl 1110) loUin pla~ttc. ~,:"Is !I\) Urlilip. ,,~h"LI,t v .. lvus (photo) !l F" the v,llve ~PUll!1 ,11111 val",", sP""!J 'CI,lUlI" , 10 Usc .1 ~ul1;ol)h.1 valvll ~P''''Ll (:011111,..,,,$0' lU co"'p'"ss th" \I,11.,c sp"nu unlolthc cOIl<:ls C;lI' In, j'ticd It, p05.II0I1 III ,In, ~lnlS "' IIll) y,11110;: stem Release Ihe v:llve 51)/111\1 f.()UlI)I(l'!>sor. 11 A lter filling ,1111he p,uls. 1011' ti m lOP of the v;,lvl] SP""!1~ 1I\llllly wIth 11 plas llc h,'1111l1ur 10 0.;115""'; CO"CC1 sc;n" ,!! ol'he colll:,s
16 Cylinder borl)s -clIn,nina,ioll and rcnov;ltioll
A oww cylllld", " Iwdculy IOII"d I1l1d Ill" wdll, p.II;oll o:llI"""OIl<)ul liS h!'l!lth Ihe a.; """ 0 1 1111: 1",1,11, '",uls ,,, WI',,, lilt) w"lIs III "!Ihl _"'!llcs to 11m \lonl!I""" II'" ,II,.. "' ~"I" Ih,u,,1 litis w",n I"I\.·~ 1,Iacc
PII''':'I'"lIy 0" Ih,<I ~"u'o" 01 III<, c yl""lc' ~W"I'I by Ihu pl~lnll willS ? Il's poss.!)'" to !Iel ;'" ",<1":;'1",,, 01 hUll, W",II hy "'''HIV'''!) th.] cyh"d", h("l(ls Willi the .:t'lI"'e ~I!II '" Ihe ",,, W'lh Ihe p'~\()n ,Iuwn!ll tlon I'llln 10"1 sl~I"S III W'!." <:.111 be ~ee" ;'lId lell 11I~1 hnlow 110.., lap 01 lion bU'1l whe.e Ibe lop I"SIOII "II!) 'eOlcl",$ ,,,"I thu,e w,1I he 01 llot,cc,llJhlhp (otllt:. (h;", IIuIIII.,1 C,"UOII hu,ld up) IIthe,e 's "0 hi) " IS 1,1II1y ,u""oll;ollie 10 uxpectlh,lll,o'u wc;" ,s "ul ~eve,c .1nd .lily I,'ck 01 Cllmp'ps",(", Of ex,,;cs~>vOl OIl . :on:''''''l'l ulIl ,~ 1!t,O 10 wall! 0' brokc n
p'~I(II' IIII\IS '" 1""IOtl~ :1 11>1 'S po""oI)I'1 W 0111"",, ,11""e IlU';oS,,,,,,U ",,, :/O,,,,,lu •. " 'c,IS,"O Ihe I)IlIC II' Ih., tll'''M plalle bt:low Ihe lop ;,nd aU,I'" ill Ihe bon"", 1>1 tho! .:yllllllc' "I Ih.., """'c pl.",.., II 110" ,1,II""" .. ,c '" IIIU.u Ih,'" 0 076 ,"111 (0003 III) II,ell a ",lxJle 'S IlCC',$S;" y S",,,I;,, Iy .. dolle.encc 01 0 076 """ (0003 ,nl o. ",u'e .'c'oss Ihe holO, (I';IIIIel<;' IS as,!!" 01 oVilhly
1;.,II,no 10' ,l,ci.llJlU
i
~~.~-'"'~
4 Any ho.e whIch is siunlllc~nlly scratched or sCOIed Will re botin g. This symptom usuafly indlcalcs thm IhO piSlon o. rill d;,uII;"Oged. Evcn II only one cyhnder is in need o f .cborlnl1 il w,1I ~ necessnry l or nil cylindcrs 1 0 he bo.ed "nd I'lied w il h new 0 p'Slons .. nd rings. You. Fo .d ;"Ouent O f 10cOl' mala. engin, spec,ahst w,1I be ,,1)le 10 .ebo.e ;"Ond Obl;"o"l lhc necessOI'y m,' pistons II Ih e CI;"Onksh~h IS undergoing le!)lin(!ing .. Iso, iI's .. Iden to lei Ihe S"1I10 111m .enovmo OI"d reassemhle Ihc cr:"lnksha' ll1Slons 10 the block. A rOI)utilble I"m no.mOllly U,ves " Uunr .. nl· suCl1 walk In cnses Wflele enl)ines hnve been ,ebo.ed ""e:"llly I. mOl~lmum. cylondc, loners Me OIvOldahle wh,ch mlly be li1l(.·(1 In cases Ihl! s.,,,,c .ehoflnu I).oeesses have 10 be lollowcd an, se.",ces 0 1 a spec, .. h:;1 cnu,nee!U1U ',rlII :"I,C .eq,lIIcd
1 7 Pistons (lnd piston rings -cxaminmio n nnd renoviltio
WOII! p'stons nrul linus Cilil usunlly hI! (to,1\1!losed whe, ~y"'plo',,s 01 "~C"SSlve od cO"Su"'pl,on nn d low COIllI)'''SSIOIl ;,"11 ;"" SO"lCh"U'S. lhouUh nOI OIlwOlys. assocI,ltcd w'lh WOfll cyl ho,cs Comp'ess,on leSl,"5 Ihal "1 ontO Ihe SI),l, k ph'l) hall.:
<lvndahlc OI"d Ihesc c; m ""hc,11e whe.e low pIC~Su!C IS OCCUII"'\I "sunlly accele',lles Ihe mo.e ,I ,s leI! so wh(;n !Im syn'plO'"s occ,,' ao;I.(On can Il0ss,bly sllve the exp <;llsc 01 " '''ho,l'. :1 Anothm sympiom 01 pis ton w,.,,,, IS fl'~lon slnp a ~nockJIIg , hom the crankcase. nOi 10 he confus"d w'Ih h'H'cnd IlC''''''\lI;lI1o
.:;'" he hc,IId cle,loly OIl low cnl)inc speed when Ih".e '5 no lond (, 10' (,xnmpl,,) nnt! '5 much less OIUlhhl" wh()n the "n!line ~ ,,'c.e"$I;s P'SIon weOl' usuOIUy oeCUlS in Ihe ~k"1 Of lower e"d ° l1'slOll OInd IS ",d'ClllCd hy ve",e:"ll ~I,ellk~ III th e WOIil arc" wh, always on Ihe tl""SI S id e II Clln nlso he se!:n whe.e thl} slwl thlC~ IS dlll"ICn l 3 Piston ling ""eM c:"ln l)(l checked by '''SI .emo ving Ihe lIng s
Ihe pis tons <15 descllbed l:lI el In Ih ,s Sect.on. Theil place Ihe rin. the cy luuler hores hOIll Ihe lOll. push,ng Ihem down aboul 4 0 lilli' '") wllh !he head 01 Ihe p'slon (100111 wh,ch the 1111\15 hnve ! ",mo,,!:dl so Ihm Ihey !cSl sqll.l,e 11 Ihe cyhntJe. Tho;n ",easuo, !I"I);lllhe "lids ollhe ""!! w,th II leeler !F.u\lc (photo) 11'1 e~ceed ~p·ec",ed m,lxill1um tlmn Ihe IIIIU needs I!:'WW'" 11 The \l!orwcs '" wln,,;h the "n!lS loc,ne It' !he pl~t<Jn em' IICCO""! ""liHIJ,,,1 '" usc, The cle;"OInce hClw,-,en ling ;Jfld I)lSlOn ,,, !1'OOVl'. "hould nOI c~ceml 0102 111m (0004 In) lor Ihe lOP COII'J"CSS'OIl linus ,1I,d 0 07(j m", (0003 In) lor Ih e lowel 001 co'
"'I!I !J Howevc •. II.S .",e Ihn lll p'Slon IS only wom illlhe linn \lrooves Ihe IIced 10 .enew Ihem fo. Ihls Inul l nlonc IS "OI,dly evcr cncount, Wlle.eve. JJ'Slons me ."newed Ihe we'ghl 01 lhe Iou. PiS:
eOllllcclmU IOd assclllhhes Shouf(1 be kepi wilhill the hilli l VllllaliO a!) (028 Ot) 10 'l.nlnWIII Cl1glfW balancc () To IClllove Ihe p'SlOn IIIl!)S. shde them cOl.eiuUy over IllC lOP 01 pl~lOll. !akin!) ca,e nOi 10 sClillch lhe aluII"'''''Ul nlloy. nevel shde II oU the h()!iom 0 1 Ihe p'ston sk"l. II IS vc'y ensy 10 !)fc,lk the CIISI
I"SIOll fI:'US " Ihey ,,,e 1IIIIIed 011 fou\lhly. so Ihis ope'auoll shoulI dune wUII e~t,c'"e c ;u c. II 's helplul 10 n"lke lise 0 1 old l\lcle. gall 7 L,II one clld 01 tile p'SlOn nn!J 10 he .e'"ovcd OUI o f liS U'OOVI! "'S\.'I I IIIIde. U Ihe cnd 01 Ihe leele . gilugO 8 TlI'" Ihe Icel e. UIlII\le slowly .ound Ihe IIiSIon lind. as ill/l '
173 Check,nt! Ihe 1)'S lon ""g cnu ~l"P wllh a le"le. uallUC
1 7 8A Remov,ng Ihe lOP comp.esSlon ling 17.8B Remov'ng !he second compress,on IIfl!J
procarmanuals.com
Page 40 of 205
Chapter 1 En gine 39
238 Checkirog the rolor lobe cle<lwnce
1 Thoroughly cle"n nil PDflS ,11 petrol or p<l,nlllll nnd w'pe dry US!Il\J a IIon.lluify ,ago The neceSslHy clemill1ces nwy now be checked USUl(J a ,nJChirocd st.aight·edge {il good steel rule} "nd " SCI of leeler g<luges. Tho cII,ic<l1 clearanceS ",e belween Ihe lolles 01 Ihe cen1rc ,01Or Jnt! ~vllvex faceS 01 the oUler '010'; between Ihe lOlor and the pump hody,
and between bOlh rotors olnd Ihe end cover pl"le. 8 The rotor lobe cle<ll"nce rll"y be chccked lISUI\1 feeler \liluncs alld ~hauld be within the lin1lt5 0.05 to 020 mill (0002 10 0.008 on)
(phOIO). 9 The cleal3nce between tile outer r010r ,lnt! pump body should IJC w,thin Ihe limits 0.1510 0,30 mm (O.006 to 0012 'n) (photo). 10 The endltoal clear"nce n1ay be lllC"SlUCd hy plnc,ng n slecl t. !r.l<gh\.edge across the end ar the pump In(1 rneilsu"IlU the g;lp h"tWCCIl the rotors and the straight-edge (phow), The g<lp ill e'ther lutO' ~hould be w,thin the I"nits 0,03 10 0 .10 mnl (0_0012100,004 rn) 11 II the only excessive clearances arc endllo;l1 rt ,s possrhle 10 reduce
II,em by removing t he rotors and l<lpping the [nee ollhe hody on J II;lt b"d ulll,1 Ihe necessnry cleoll"nces <lIC oi)wulnd 11 must be emphJ' t';~"d. however. thatlhe lace 01 tile hody muSl ,nmnUl perlectly 1I<ll "nd "\IJI1 .e to Ihe "xis of the rotor spindle, otherw,se the cleDr<lnceS wdl nOI h,) equ"lllnd Ihe end cove, Will nOI be n press\ue tighl f'IIO Ihe body II ,~"'Orlh t.ylllg. oj ~ourse. II Ihe pump '$ In need of n:newal unywilY hul unless done propedy. ,t r.ould seriously leOPJrdlse the reSI of Ihe ove.h,'ul. Any V<lrlillions III lhe other twO CleJ'illlces should be
overcome wilh ol new unil. 12 W,lh JII P"I!S scrupulously cle<ln. luSI rehl Ihe tChfll vJlve ,lI1d
!.p.ojl!l ilnd IInhlly luhuCJIC w,lh eng;ne VII. 13 Us,ng a SUltilble dl"nu.:ler d"fl. drove in il new se<lhng plug, IIJt s,de (I"lw",ds unl' ;t is flush with the intJke pipe "1<ltUlg LICO . 14 luh"cnle both rolO<S wllh enwne all oln(1 "tlhellllll Ihe hody FIt
Ihn 0,1 pump cover all(1 secure Wllh Ihe holls t l\Jhtcned In iI (('Juon,,1 .1n<l rllOU.css;ve mililner 10 the lorque w rench set\lIlg given'" Ihe
Spr'Crl,c,1t,ons . 15 f'lthe d"veshilft ",to Ihe !Olor dllvesh<lh ;l1l(1 cnsurc Ih<llthe .olO r h"n~ Ileely 16 Frtlhe "lInke p'pe <lnd all st';llller 10 the pump body to\lClhe. wllh ol II"", O.1s~et
24 Lubric"tion system ~ description
The p'essed steel 0,1 sump is allDched to Ihe underside 01 Ihe C'~~kcase and aCls as a reservoir 10' Ihe engine all. The 0,1 pump d,,,ws ~~ 'o01lhe sump via an oil SlrDiner and inlake p,pe. Ihen passes 'I uno , t6 lull. flow olll,tler The 1,lte,ed oil 1I0ws hom the cenlre of Ihe oil ;,~e, elenlenl and passes tluough a shari drilling. on Ihe right.hJnd , ,", to the 0, p,essu re switch and 10 the main gallery (on the e 1· Mld side of II -
F Ie C1ankCllse) th,ough " ttansverse d"llIng. Md °h'''' d"lhngs conneCI Ihe main galie,y to the lou, maUl bellflngs be I C camShaft bea"ngs in their turn are connected 10,,11 Ihe Illain d"~I':ngs The b,g-end bea'lIlgs D,e supplied w,lh 0,ltl1l0\lgh d,ayonJI ) 'nys Iro01 the ne,uest rllilill bearing b'U~\,h~rolhec,ankShaft is ,0 tJtlllg. oil ,$ Ihrown irOllllhe hole in each and e~ bea"ng and ensures splash lul)ric"tlon 01 Ihe gudgeon pins lu b ,I HuSt s,(le 01 the cylmder$. The ttllling \)ears <He also splilSh
~:.;. ' "cilled Ihrough lln 0,1 d"IIon\) . ,J",'
•
2310 Checkillg Ihe endflont
Fig. 1.3 Engine lubricalion system for the 2,8 litre engine (Sec 24)
The c r<lnkshJh third he~.ing lournal interfllillenlly feedS 0", under p ressure, 10 the rocker shafts throuUh ~ drilling in the Cylillder block ~nd cylinder he"d. The oil then passes hack to the engulC sump. v,a
large dllilings in Ihe cylinder block "nd cylinder he"d_
2 5 Cr<lnkcase ventilntion system -description
The closed crilnkc<lSe venlltnt,on sys tem is \Jsed 10 conltol the emiss,on of crankcase vapour. It IS controlled by the ilfllOUf1t 01 ~" drawn in by the engme when ,I is 'unnm;) and the lilrouuhPIJI of Ihe
vent valve_
....
~---------------灲潣慲浡湵慬献捯m
Page 41 of 205
)
40 Chapter 1 En~Jjne
The system IS known .15 the re v SYSlr.m (positive Uilllk colSC ventilatIon) n n d the il(lv~nt.1(JC 0 1 the sy sleln IS 111;;1( should the 'blow h y' exceed the CtlP<lClly oilhc PC V vJlve. excuss fumes ;lIC l'Od llliO the cllninc IhrOU!Jh the ;]11 c tenner
26 £:nuine r C ilssell1bly -generill
To CIlSU", m,1XIIllUIll life wnh I1\IIHlllurl1 (,oublc I,om im ("",hauled cnume, 110[ o"ly Illllst evcry Pill I Ile cOlfcctly ilsscrllllled Inn """yIl 1m\! 11"'S( he spotl{,s~ly clean. <111 0,lw.1yS m ust he c lCJn, Inckmol w,l~h(!IS nn d 5P''''() wa~he,s O,"st o1lw"ys he Iitted wherc n""d.·,1 .u,,1 illl h'mrlnus ,111(1 Oil "" slld,rlO ~"rlilces must be th o rOU!jllly 1"I"Wd l"d (lUIII1\J asscml,ly
2 Be low ols~"lllhly. ,,~new ... ny hol ls. studs '''H I nu ls wlo"", 11""",,b alt.! Ii) ,Illy w;'V ddllh1\J"rj ,II HI wheneve, poss,hlc 1O~" ", , ~P"IIH w ,lslwls Ohl.H n a compktc so:t o( new !)askets ilnd "II n,', p,"IS.", n"r.ess,',y
3 When ",(,it,,,!) p:,ns "n~"'" I h,11 Ihr,y noe ":('I1<,d on Ih, " "!III)', 1 pos,t,ons il"d d"",CI,ons 0,( ~(J"I lops should h e Slllea",rI " II, !I""'~C befo,e (,IIIII\) A Io'l"ul ,FI, k c t "",1I,"lt should h e "sr,d wh,,,,· "'p"ul",d 10 prevCIlI I""k.,!)"
<1 Ap,"1 from yo", no,m.d tools .• 1 supply o f clean "I!I'" .• " ,,,1 C.II' f,II,)( 1 wnll 0.1":,,, "n!)"h) 0,1 ;"1(( a lo,que W "III(;h ;),e ess"'''t .. ''
27 Crallks h ,d l . rc filt;IlU
W'pe th" ""''''IIH ~h,,11 h":"t,,,"~ "I Ilw c,;" ,kcasOJ wnil." 1"."1 "'!I ,"1(1 fll th" m.II" 1"",,'110 UPI"" h.,11 ,h"lIs,,1 posnuJII 2 "11],,,, 111" Ill;" " h",\I"ltl sh,,1 1 ((":,,t,on5 and lot II,,: h:,I( ~h,·II" II' IIw caps (photo) If I hl] old he:"",!!s a,c IWIIl!! ",I,(wd (oll (l1ou!lh II,,~ 'S.I f,dse eculloll'y "1I1"ss Ihey ;"e p r.lCt,r.,lll y new) m"k e "on. -Ih"y ;'''~ fnl!,(( III (10"" ",,!)uI,,1 POSII,O"S
Fi!l. 1.4 ncar milil) he;!,. .,,\) (;'!(1 " .e " (s h ,Hle d) fo r apply ;, sc;.li"!I compound ( $ cc 27)
3 Apply;, 10111" \I"'il~e 10 ",".11 ""It: 01 II", No : """" lJ",I!niU so '"I",n Ih" 11",,' ,1 W,,~ ll"'~ (" ,Illy """Io:I~ ol,ly) ,1 1: ,1 1110: "PI'''' 1o,llv",s o( I III! Ihl"~1 w,,,h,,,~ "110 II", ,, !)lOove s ",.I" "I 110" "';!'" 1 ":;II ,n'l Till, "10,,,, "''',1 (;oce ""Iwa,ds w'th Ih .
1"".01",1 tt' Ih" 00(,,,,,", /r!,,,ly "It,d.'I~, ""Iy) !J I "1",, .• ,10: lilt, u ,,,,kd,;,1 1 111",,, I""""'~I )ouOI,als ,nid thc 1"""""1 ~I',·lb wl!h ''''!IUH! 0, 1 (1IIIt,to) G I'I,u'" Ill<: ,,,,lI 111,"0 h ca""~1 0,1 """I "' pOS'I'O ll 01) Ihe end 0 ':'dl lk,h,,1 1 AIII"""t'vcly fll II l" lu. ., ",,,,,I,,lIy I"wu, tho cr;,,) ksll.,11 "* , tho (;!iHlk<":ilSC 8 I\pply;) lI"n r O;oIIll( ) o( ~e;oluI!J compound 10 Ille n'ilHng fac , th" ,:,;o""O:iI~" .,,,rI IIlI! ,(:", niilni I'CiI""(l <":,IP (p hu to)
27 2 F'IIIIl~I,1 h~'" "'g shell to Ihc I C'" rllJ") h e;)"I1!) Ci'P 27 [) O,I,, )!! No : ''';I ,n he;,,,,,!) UPI","( shell 278 A pplY"'1I sealtn!) compound t o the ,ea, m,I'" I W;),,,I[J rap
D l]
27.11 T '!Jh1l!'''''H (he "''''') heil"n,) Cilp bolt s 2 7 12 Te'"pO'ilrtly sll~k a d hes,ve tilpe on the 'Cil' of Ihe c'ilnkshilit when f'H in u lilt 'Cil' 001 sUill 10 P'01l!(;1 Ihc seal lops
',,::;;Am p.
procarmanuals.com
Page 43 of 205
42 Chapter 1 Engine
28 G TempO'i1'y holl 101 IOC;l1inO the mlc""t:thiUo: plale 29 5 0'1111(1 the )l'~10n linUS 29 7 0,11I1{J the cyllnde. hOlo
";; '. '''' . :~ .,
.. : .
..-2 9 8 US'''H (I plSl0n "l1g compressor when uiSerhn!llhc p,ston "110 the hore 30 2 Chet;kln~1 the Sial) washer I)OS'['OIl on the 0,1 pump d""csh"fl 31.3 O,llhe tlywheel holls bel o re ',",ng
(j 1,1 II", two f.t:"11'~ holts ItI1!jl.:r·"!lhl then 101 ;Hlorlm' two holls t'''''IHH""ly 1o. IIU:"I"'!I purposes T'!Jhtcli the CCIllle sec"""!J hails th.·" It''''"Yll the '"ml""'''Y Io,u "d 1000,umU bulh (photo)
29 P istons Hnd COIH1(!cli"g rods -refitting
WI, ... , ('.101,1" the COIU1I;:(.I,n\l ,ad h"U of tll c !l0U·end bO il'lIlll 1111d rh e IInde,sulu ollh(l ~hcll h .... "l1y ;lnd IIIIhe sh ell hc"rlllU "' pO$IIIOn WIth It S Im :, IIUI!llonuuc OIl!"'!I'!!! with the COH CSpo tUhnU CU[-OU1 ",the lad :1 If II", old hC.l.II'!)S 'lrllnea.ly n.;w nlld nrc hell'U re!ltu:d Ih en ensure Ihey inn ,dlll"d III Ih"" cO"I.'Cr 1000.UioilS on the COUOCI ,ods :1 The 1%lOn5 , c:;()n ll'l",,~ With c:;onm;c:;t"'u ,ods. mo f,tted 10 the" IH,::es from th(l lOP 01 Ih'! block
'1 luc ilte the p'stoll ""u Hap s III th e 101i0w inU rllilnnCI .
TOil 1['0' fr Olll Ollt· sir/e of /l,e Oil conl,o l 'IllY "ehc.1/ t'xf/8mle. y,l!) Cellt", 150 /tom lire O/Jilosi/e SI(/e of fire Oil cOII(101 ""Y l,el,cM cx,r.lnr/<!l ya{J
Bo/lom or! cOll/,,,1 ""9 HeI,cal eXI',lIIdel' 01l 110s,/ e I/IC /II,lfAed {J,S/OII "on / side
ad cOIl/,OI ''''y, III/':"llrHI',J/c lings 25 film (1 0 ill) c.,,1/ sie/e of tllC /Jchcall;xl1amh'l 9,7/'
5 Well lulJllc~le Ihe pl~lon iln d ring s w il h e ngine oil (phOlo).
6 Fit n unlve.salring compressor Imd I>'epalc 10 insell Ihe fllsl p'Slo n IIItO IIw ho,e. Mnke sure 11 is Ihe corrcct piSlon·conneClinu lod ilSse'l.hly 101 Ihill par',culil' boro. Ihillthe c onnecting lad is Iho COII(.'(:I Wily .ound and th3tthe fron t of Ihe piston (mmkcd with an arro w 01 11 notch) ,s 10 Ihe fronl ollhe engine. 7 Lul )l'Ciltc Ihe Cylmd,:r \)o,e (photo) and inserllhe conncCllIlU ro d a"d p, ston nsse ",!;ly ,nlO Ihe cylinder !loro up 10 Ihe botlom of the pislon IIIllJ com plessor 8 Genlly hUI f,,"'ly Illp Ih~ l/ls!On Ihrough Ihe piston "ng compressor nllu "'I u Ihe cyhnd er 1)(.1'''' uSlI'g Iho shah 01 a hammer (phOtO) 9 G".""nu~ly luh",c"I" 11,,, ,,"ank,),,) 10U"",ls with engllle 0,1 JII{ltu.n Ille ClI,nbh;,lt so 11\1,1 III" e'<lnkpin 's If) Ihe mOSI advanlageous
POSIIUHl 10' Ihe CO'"1(JI:I"'(I .ods 10 il(! dr l.w n \)lIto" 10 WOlle !:In,l n rhe cOIl''''CIi''U ,ad heillOflU Cilp ilild hack 01 the 5 1 he<lIlIl\J. ,IIId f'llhe Sh<..'11 henllng III pos'1I 0n ellSI""'U Ihilt lho local '
10llHue ill lh e b<lck olthe hClII"'U cIlU"ges w'lh the locating groove
Ihe cO""OClmg rod Cill) 11 Gcn e.ouSly lulmc,lI e Ihe shell h,)IHIlIU ,lIld oller up lhe conncct' .od bCil''''U cal> 10 Ihe connect,n n rod 12 Ret,n,nu the cU'U1eCtlf'H lod lillIS, 13 Tluhten the nulS w.lh a 10f(lue wrench 10 the sllCc,hed SClling 14 When "II Ihe p'Slons i1nd conneCI",u ,uds h,we b(lcn filled. rO I,' the Cf.1l1ks hillt 10 check Ih"l eve'yl""'u 'S Ilec. :Ind Ihill Ihere are' hiUh SI.>OIS cauSi ng bUl(llIIg
30 Oil pump -re fitting
Ensure the l1lillmg lilces 01 Ihe 0,1 pump ;Jnd Ihe clankcase n cle'lIl . 2 Inse.1 the hexilgo nal 0.1 pum p drivesh"fl wilh Ihe pointed en lowil,ds the <1ist"bulor localion. The SlOP washer (photo) must IJ posil ioned 127.5 mm (5.020 in) foom the lounded end 01 t h driveshilll 3 FII th o od pump 10 tho cfankcose and secure wilh t wO boll "9hle llcd to Ihe spec,f,ed 1 0'(lUe N ote: When a flew or overhaoled 0 pump is bl!illY IiI/cd. II should be /illed wilh enyine Olll1l1d lurned . b hand 101 om: comple/e ,evolution before being fil/ed. I his will po"" /he plm.p
3 1 F lywheel and clutch _ refilling
1 Fir Ihe engino IIdap lol pla le on Ihe twO localing dowels 2 Ensure Ihe milling faces of Ihe lIywhc(;1 and crank shaft arc cleal
,lnd fit t he flywh eel 10 tho Cliln kshnll. aliUn",U Ihe nla,ks made ii' (hsrn;Jnthny. unless n ew l>arlS a.e being lilted
procarmanuals.com
Page 44 of 205
)
Ch<lpter 1 EnUine 43
---3 Fit Ih e si~ flywheel sec"""\1 11()1I~ (n, t"dl <lnd hghtly t'ghten
(phOto ).
4 Chock the secur ing boilS
flywheel 10 "'~1'.111' ,I fro", tll,nlll\J. <1nd tighlen Ihe in il (li<1110I1ill <111(1 plO!i'''~~''VU l11<1ntJer 10 the speclf,ed
IOf~:iil l he clutch (Iosf: ilnd p"'~"'l"" pl.rle iI~s"mbly 10 Ihe flywheel 5 . ,ure Ihe disc ,s I he co"",:1 w.,y lo"nd (see Ch<1plor 5) rTlJk,ng . 6 Secure the pr~ssum pl"h~ "~~I:mhly Wllh the ,ct.1U1Ing boIlS. enl'Jlise Ille clulch dISC "Sill\) .11' old !i,,,"I>OX ,npul slwh 0' sul\ahle ~1Jnd,el Jnd thel1llghten Ih,~ ",I""'II1(II,,,IIS to Ihe sp~clfl()d tOlque III <l
diagonal Jnd pr09,esS1ve m;II'"<.;1
32 TiOling geMS ilild li,nin(1 COVIH refitting
I Check Ih<llthe keyways '" II", "~lId "I 110" f:I;,nkshilfl arl) cicilil ;,,,,1
Ihe keyS ;110 f,ee I,on' hili'" III II,,, I.,y'> ",(" II,,, k<.;yw;IYs 2 If Ihe c'<lnksh<1h Ueill w.". I('II,,,v,,d H"hl 11 I" Illn "';Hlk~h"fl U~II\\I iI w'IJule diJnlete ' lube 10 (I. ,VI: ,I 1"lly I",m<: 1\11,,,nilllve ly t","pola"ly
u~c 1 M pulley Jnd boll to P""'S ,I "" (pll"I"~)
';
. ,
. -\.
...
I't'
3 hI Ih'~ c,"n~h<lh y(~ ... on Ihe <':<lI1>';h,,1( wIth Ihe punch ""Ilk III
,111(I'"nOIlI with the mark on tho cr,ll1bh.1ft HO<l' (phOIO) NolO Ih<lt r! lh'~"J ,110 IWO punch lIl<lrks all Ihe cr,IIl ksha fl Ile.l •. ensure th,rl the COIled lll.llk IS <lh!JIl!:d (F,\!_ 1_5). .! FII Ihec;II"~h<lh 1I'1nr ret<lIll"'H w,,~III" "nd hall T'Hhlen(he Ilot! to Ihe ~1",cr!,e,IIOIque 5 II .wall,,!>I!) use a dl<ll Y<lu\Je 10 ch(,,;k (he C<ln'shaft elldfll)<lt
(pholo) 6 Oel~'lllllln th" pO~lIlon of Ihe OIl sedllll lI,c l"llIlly C()V('I, Ih'-:II d"vc Oll( Ille old su,,1 (ph010S) . 7 0,·.011 1110 100111 i."rIOO of Ihe 1111"",1("Io;no plate ;",.1 the I.ICe of Ille 111""'0 f:OVI". nll,l IOO<l1 Iloth n1<llll1'1 f;":,,s Willi sIJ<rIn>(1 COlllpOIHH I fI f'''~lt''''\'' IIIJW !!'I,.kl,1 all Ihe Illlr:fIl",(ilil(n plall' "lid Irl lire ,,,,,,n(l ('I)V", 10 lire cyirnd,,, hlock Inserl Ihe I,,,II~ f'II\IOI l'Uln D C.,III,,, Ih" ("'''II!) cover ~rolilid II", nuse of IIw (.,.II,k~h.lft USnl\) v"",,'" C,oI'I"'"s .11 I'JII' dl~mCI!lc pO'"I~. 11",,1 fully 1'\lhIo:II 111" hailS
(1'1",1") 10 1 " 1 11,,, f'''111 n,l ~(, .. I tn the 11111111(j .:ov"r .111tl .haw 01 11,10 lh" 1'()~'IIOI\ ,h.I""))II,,,<I '" P'''''()'''I'II 6 US"l\) a sock"t ,,,,d I,oft Iph"t",.,) 1 1 T""l ;o"y p,,,I,,,d,,,O U<1skel f,olll II,,, ~"'llP ",;'(IIl\1 f.":,, (pilato)
~ ..
:U 'lA Loc"lo the cr,lnksh<1fl U", II 01 111" e ,.",hhilh
322B ,. ,HId uSO Ihc pull"y In pruss It on 323 Alryn"".",t d01S 0" lhu III\lII1~) \le<l'S
lh"l
~ .. ,
..,
, ,
., ' ,
32 .61 Checklllg Ihe pOS,I'Oli of Ihu old 0,1 se<ll in tile IlI\lIIly cov",
32.10A Fi11lllg the c,,,nkshJfl fronl 0,1 se<11 using a sockut ~nd 11011
32 6B OflVII1!j 0111 the ""'lIlg COV(:r 0,1 se<11
32. 10B F,tluU posItion o f Ihe e<aoks!rJIt
f ,ol1l orl ~",~I III Ihe 1Ir1I11ly cove,
procarmanuals.com
Page 50 of 205
Chapter 1 Engine 49
----------------~--~----------------= anuill transmiSsIOn models, remove foul clops <lnd remove Ihe 16 On h(11 sing cover . On ilulonHll lC tr"nsmIS~lon models dIsconnect Ch.llCh au lug the 011 cooler hoses. and P It the Irans!1lI$S10n then remove th e l'illlsnllSS lon to-engine 17 Suppa <
bolt~ n automatic 1.,J;lsmission .models. drilm the torque conve!ler ,\Ild 18 Ihe drivep l<lte boilS wllh ,clerence 10 Chnpler 6. UO~~~~ Ihe weight 01 tho engine on thc hoist ilnd then pull tile euuin!} " d \0 separJIC;1 1'0111 the \'<lnSIllISS'OIl. 0 " [lU10111<1(1(; IlilI151"'5' 10' ..... 31 , I
. odelS make s"re Ih,lt the torqlle converter ,em,,!!)s lilly 1f1 1he $lOI1 m transmission . 20 When the engine hilS been SCpM,lICd from 11l(l 11.,11$1111551011, 1,lllh!.! . ,lowly chccklll9 j,equently to see (hMllle CflUllle does not loul " ng,ne . ~nv part of the bo?ywork. 21 W hen the engUle 's cle,lr of the iJody . lower it to the ~lfOun(i. Of
Ir~nsler it to a WOrk lJench
4 $ Engine disill1lotling -generill
Refer \0 Sec t,on 7
46 Engine illlcillilrics -removi\1
..
1,',lh the engine sep,l rated from th" t r;IIl~:nHS~r()" remove Ihe ~.tcrnally mounted componelliS ;l~ lulluw~
C;J//)Ulello, i.lnd fllcl {lump (C"'1!,lt" 3) IlIlel ,wll exhiwsl tII,wi/a/ris (Chaf!/t't 3) Sp,>r/( plugs and drS/fllmlor (Chaplet 4) AllCllwlor (Chaplet /2) F.w ,7I!d policy (CII,71I1C' 2) W.JICf pump ,wd Ihcffllos/.1I (Clmp/t't 2) C, ,1IIkc,lSC vcn/iliilion lubc 011 {,f/CI (Scc/ion 40) Ol/Icvl!! r/rpsllc/o; and {,/lCf C,?!, [II!1int' 1II01tn/ill.ll h,.1r:kvls Ciulell (Ch,7/I/l'l 5) Powl'r S/Cl'l/IIN 1'(11111' (Ch;lll/Vf 10J
<11 Cylind(Jr heads relllowti with engine in car
I
Q,scunnecllhe IJiltlery le,lds ") ~cmove the splilsh slucld. by renuJVIII<j 10\" holts nnd luur chps J II.lee il cOrltilm er 01 10 Irtre (I·' 6 pint) r.ap.lr.lty unde!l1e,Ilh Ihl.! ~"lr.llor. remove the rmll:l\or hallam ho~e and drilill Ihe system Rr:rnove the rad "l\()r lap ilose . !l Rcrl10ve Ihe au Clealler. d'SC(lnner.t lile h,el p'pe fro m the ~MI;;"rllor and Ihe l"e,lIiler hose hom Ihe rocker cover.
, R ernove the servo V,lCUlUl1 hose I<om tile Inlr:1 l11illlllold ~ enlOve Ihe IllIe e bolts and rem!)ve II,e Ihrollie Irnkaqe lI<ilC~l;t .omllic le wo1h Irll kilge '
~ DI~conrlccl Ihe rilll,.llul hose from Ihe ilulomallC choke D,s·
,onneCI the vac\JUnl h"e I<om cariJU!l:1I0r .
• D,sconnect" I I I 10 0 le ea( <orll Ihe lempelnllllc sende< Unit.
co I I~con"ecllhe HT ICilds Irom the spark plugs and IrOlillhe Ign'llon I ,1od remove Jlw L T I I I I .
MId I I If . CiI( 10 lie dlSl1i Julor Reillove aile h Xlng bolt 11 0
' I
a Ihe dlst"I>[1I0r ilSsemlily.
'Sconllect Ihe all II 51 halts' , ' ernillOr Cil) es. ilcken the ailelllntor 1110ul1l11lg un( <emovelh~d b I hi· '" ... live C I. I en remove the fllCrnfilor h XlIlg bolts rernove the ~I' . 12 R " erniltor ')nd liS I,x,ng lIrackel. CIlIOVe Ihe Spa k I cOvers d "p uos. Remove Ihe IIUIS secufII1(.l Ihe rocker 13 R an hll 011 tho covers. emove the I I I . . mlel III f IVC '0 IS sec linn\) the onlet lII,1(l,lold and take 011 lile 14 l an, old complr:te Wllh ca<lIurello, OOson Ihe rock turned a ·d er """ .ldjust"'g nulS ulI\ll Ihe !Ocker arms can be ) hoe Or SI CI(F'(J 1 10) Ihen rCOllOV!.! Ihe pushrods ilild lily them oul Itl PO,ition l~llS I, lill.!1[ finds through a sheel 01 paper 011 which Ihelr III I Ie ("",II,e . I
Pusil rod . C,II1)e "Oled. 11 IS very Imporl<lIlI Ihal the IOtnOVCdS .1<0 r(;f,tted \0 Ihe same villve as Ihat from which they were
"IOC>! "
Fi~,. 1 .10 Turn the rocker (HillS to olle side 10 relllove the pushrods (Sec 47)
15 n,,,,,ove Iwelve lIolts ilnd delilch Ihe exh,lusl I1\,lrlllolds frOI" Ihe cylrrlrtr:f he,lds. 16 Sinckell the cyhmter hend boilS progressively in the revtnSe order to Ih"l shown ill FIll 1.19. IlcrllOVC Ihe bolts nlld hit olt Ihe cylindOf head.
It lile (.Iilsket has stuck and the cylrnder heJd cannot lJe lifted off. wp the cylinder heild wllh n hide·f.1cert. or plnstic·headed hJmmer. 00 nOI try to pri se IlIelil off wllh a screwdrivOf Of rtilillage WIll result.
4 8
Cylinder he,l(ls -rernovfli wilh engine O\lt o f car
Follow Ihe sequence (.I,,·elllll SectIon '17. 51;lItll1g.l1 PillillJl1lph 10. dl$lcoa,d,n!1 leil.!lellCeS to pa'is willch hJve alreildy bcen rcmuved
49 Villve$ _. removal
Rt:rllove the d('POSIlS /'0111 tire corllb\lsl,on chambers ~nd vnlve
h eads by ScrilPIl1!l and W" ~ b'\Ishlll(.l Tilke CJre nOI 10 scratCh the cyllnde, he~d gaskel lilces 2 Lay the CylOl(ier hemt on ,IS sllll) .llld h t the lo,~ed cnd of .1 VJlve spllng compressor ove, the ~plln9 rctiluler ""d ti le head uf the complessor screw in Ihe cenl'e of Ihe v"lve head 3 Compress Ihe sprrng abolll " qUJller 01 an Ulc h 10 Iree Ihl} split colle l hom the top 0 1 the v,llve stelll. If Ihe sPltng ,eliHner "nd collel Slicks. do not screw the co",p,essor down lurlhc< . bec"use IIIIs lII.ly dJr11J\je the valve Slem. bUI lJp the sprong reliluler sha,ply wllh a Ioghl
hammer. 'I When the Iwo halves of Ihe collet h')ve been '(:nloved. onscrew the spllng compressor umrl Ihe spring IS no longe, compressed nnd
remove Ihe compreSSOr . 5 f1Olllove the spltng retnlner. the spflng and the oil seal from Ihe villve Slem. Ihen wrlhdrflw Ihe villve from I he cylinder head. 6 D iscard the valve Slem all senls and plflce Ihe Olher componenls to\jellrCt. identilying them so Ihal they arc refItted III the correC I plnce
III Ihe cylinder head. 7 Remove Ihe sp,11k plugs from Ihe cyhnder hend. II nOI alrendy
removed.
50 Rocker arms -removal
1 Remove the SIIfI nul from Ihe foch" .1'111 Illoullt,n\) stud 2 Lift off the rocker <Hill b')ll seiltin\! and Ihe roc~er Mm and Iny Ihe tl1<ee parIS 10<jethe r II IS ImpOrtilllt Ihat Ihe locke' arm. its hall SCJling and nUl ale refa ted \0 I he snme stud as Ihe one 110m which Ihey were
re moved.
procarmanuals.com
Page 51 of 205
\.
50 C hapter 1 Engine
51 T llp pcts -removat
Remove the 1<lP11C1S I.om their bores with ,1 1ll1lgnct "nd pl,lee them ,, 11 r,lek in sequence. 2 If (lny <lIe (1I111cull10 remove, .ot.:l1C the crnnkShilh. willch wIll Ciluse the cilrllshilll 10 lurn lind move the IilppclS 10 ,elcilse them hom <Iny
!.111m "' thell bores.
5 2 Crnnksh<llt pulley -remov al
Prel/cntlho CJ,lIlkshilf l hom 'Ot:ll111(J. by lillllmUl!J the flywheel,' the (jl1nin.! 'S 0111 01 the C;1I, o' hy 10ckll1\1 Ihe transmIssion ,I the cnOllle IS 51,11 III the Cill . 2 Rclcilsc the p"lIny boll hy l,oUlU 1l '111\1 511.11111C. ;'Ind rapptl1\J the sp,lnnc. ShiH ply, thon remove Iho holl ;1I\d washer 3 Usc il S I).ockcl pllile. 10 (h"w the pulley olllhe Cfilnkshall. Do not ilUOl1lpl 10 lever II oH, bC(:.lIlSl; the engllle [,onl COV(II IS j,aulle ;111(1 Icvcrn'H ilU1l1l1S1 11 Ill;)y (11510'1. or even InC.11; II.
4 Wilhdraw Ih~ Wood'uH key hom the end of th(! CllInk5hah and pl,lC,(! " w'lh Ihe pulley. til(! holl alld its washer 5 The C'.1nk~h;)h p"lIey m;oy he ICliloved wilh Ihe eno,,,e III Ihe C:\I. hilt ,I 'S IIIsl tU!Ccss;o,y 10 ,emove Ihe ',ld'illO' :lI1d thc rh'vehelts
53 Flyw heel -remov[ll
P,even llhe flywhcel hum 101m",!) by FHlHllln\J Ihe lin!) !lcal ;ollain~1 ;In imp.ovised SIOI). 2 On nlodels willi nl;lnu:ol 1I;o"$""S5'01i. Icmove Ihe Clulch plessure 1)1;lle and disc :os described in Ch:op!Cr 5. 3 Rele.lse Ihe s,~ bolts secu.in!1 Ihe flywheel 10 Ihe CllInksh;oll .lnd lefl\OVC I,ve of Ihenl.
4 Whilc supporling Ihe tJywheel III pl;ll':e .• emove Ihc Sixlh hoi' ,'11d Iolt Ihe lIywheel otl c;o,elully. so 111:01 Ihe m;lllllg su.lilccs of flywheel [lild c.;onksh;oit ;o.e 1101 dllm,'ged
5 4 Sump -removal
W"h lhe '''1(1'''') oul fli the e,". CII~"'C Ihal Ihe sump has 1o('CIl d,amvd ;ond then lilln the engll1C ()VCI so tl1011 Ihe sump's U l)I)ClmOSI F" wOOr1CII bloc"s tn Slll)lmrl tim en!l'ne 'n Ih,s POSIIiOIl . 2 Remove 11m h()IIS seCUlln( J the oil Sump 10 Ihe CI.1nkColSe o1nd rClllOVO Ihe SUll1p_ 11 the sump IS stuck 10 the c r;ollkcasc . II should be reh;lIsctl hy 1"'SII1\1 olle SIde wllh 11 sClcw drover. 3 To !Cn,ovtl .Ile sump wllh Ihc CIIU"HJ Hl tloe eM. 11151 IcnlUVC Ihe
d'l)S llck :ond d'SCOIlII(!Ct Ihe hatlery 4 Remove Ihe luur holts ;ond lou. Ch,)S ;ond dCI.leh Ihe OIl splash
shIeld.
5 Pl;oce a Con'"lIlcr 01 at lellst 6lttre (106 JlIllI) cal,,-.elly heneath Ihe SUml). remove Ihe d,ain pl\l(l ;ond d,aln Iha sump. Reflilhe d.am plull and (11)hlen II 10 Ihe 10lqUO wrench seilIng gtven In the SIXlClflC;JIIons G Del:och the engme fubl)CI mounllngs, by lemovlng the" nuts an(1 w:oshe!s. 7 Romove the ciampinI) bolt hom the tal) ;oml bOIlOI11 endS 01 the Steellll!.) intellnediate sh(lil. rush Ihe lap end 0 1 Ihe shlilt upwollds unlll Ihe lowcr ell(1 Clin be dlsenga\led 8 PI<lCo:o jack undOI Ihe lI;ol15mis5ioo nnd use II to HlIse Ihe engine Slr\lhtly.
9 Remolle I he Inur boilS securing Ihe fronl anlj·roll har to the Slde·membei (lnd the l()ul boilS securing each engHle mounling blllckel to .lIe sidenlCmber. 10 Remove the 011 sump Imlts lind I I the sump hns sluck to the crilnkc;ose .• elellse the sump by press ing 'I sideways wilh a screwdriver.
55 FrOllt cover -removlll
If Ihe engHle IS In the CM. II wllllnSI he necessaly 10 dlsc()nneC lthe l!allefY. drll'" 11m coolll1\) sys tem ;ond lel110lle Iho radiillor. 2 loosen the alternalol mounllrlg bOilS. SWlrlg the aitemalor downwilids .0w:Olds the cyltnder block and lemove Ihe drive belt
3 Remove the bolt Irom the cenlro of Ihe cooling Ian .. nd pull (
Ian and clutch assembly. 4 Remove Ihc boil an d wilsher from Ihe centre of the cran pulley .. nd I hen use ., claw puller 10 drilw Ihe I)ulley ofllhe sha nOI anempllO lelle, Ihe pulley ott. t)Ccause Ihis may .esull in dllm. t he Irani covcr.
5 Rcmove the si~ bolts secuung Ihe sump 1 0 Ihe honl cover an, t he cleven bolts securing Ihe I ront cover 10 the Cylllldcl block . G lIlt Ihe cover ott ;ond remove Ihe g;oskel.
5 6 Tillling gears -relllov;ol
1 Remove the honl cover 10 e xpose Ihe IImlnu ueo1/S 2 Removc Ihe bolt and washer sccu"I1IJ Ihe fat!Je gear I,
cn,nsIl1'll t. IhCIi pull.he geill ol! and Icmovc tho Woodllll! key. 3 Dlllw the ileal hOI11 Ihe cr;onk!;h:oh am! remove Ihe Wood'utl
57 Carllshaft -r erllov;ol
The camsh:olt nwy be rCUlovfld wllh the cll!JlIle 1<1 Ihe car •• lollowlng p!Cpol.aloIY wo,k IS co1med out. 2 0,,,,,. Ihe cootong syStelll nnd .emove Ihe .ad,mOl 3 Dlsconneci the ballery. 1 Remove Iho sp.1lk pili!! IC.1ds 1,om Ihe spalk 11lugs. 5 D,s':Ol
eCI the le;ods I,ull' Ihe :l lt'!11\.110r. remove Ihc allelllalo·
l i S (hivebell. G Undo "nd rem ovC tho screws S()CIIIII1U Ihe .0dcl covers and It Ihe rocke. covels and Iheir ilaskcls 7 Sincken lhe nulS secullnu the rocker ~"ns unlollhe locke' arm, he swung aside . 8 Remove the pushrods. idenlllylllg each one as .. IS lemoved. so 1 Ciln be rell1l ed in Ihe same position 9 Remove the cylmde. heads, <IS doscllbed in Sec l,on 47. then Lmagnet 10 tilt out Ihe tappels. PI;oce each t;oPI)Ct WIth Ihe pus which il Oper;oleS, so th<ll Ihey :olso WIll he relliled in t lle;1 0';1 POSlt101l5. 10 Remove the Iiont covel liS descrohed 111 SectIon 55. 11 The cllrllslwh pl:!lc IS secu.ed w,th twO cro5s·hc;od counlel,
screws. These cannOt be removed wI,h an oldm;OlY screwdliver ,lily nllempt 1 0 do so WIll resull OIl Ihe sc,ews bemU d",na\.l<:d. I Impact SCfeW(!IIver is nOI ilva,lnl)lo. the SCIOWS m;o¥ he Icmoved w sui l:oblc key lInd the urace 01 a sockel scI 12 Remove t he c.1m5ho1ll IhllJS I !)lolW 011\(1 the space. hclund II 13 Pull the c;omsh;oll lo.ward to wllhdl,1W 'I. 100f 111\1 Cil!e 10 ~ee" Sh,'lllfl Ime. 50 Ih;ollhe edges ullhe cams do nOl rt,1mnge Ihe cam~ beilllllUs_
58 O il pump -r e m oval
Remove Ihe crill1kc:ose sump as ;olleady dcsc"hed 1 2 Remove Ihe boll aUJchmg the 011 scrcen 10 the Illalll 00111.119 (
/ /
Fig. 1.11 Oil pump o n tho 3.0 f itre efluill(l (Se c 58)
F
procarmanuals.com