air condition FORD CAPRI 1974 Workshop Manual

i12.
38 Chapter 1 Engine
20.6A Mil,kIl1H S 011 the reverse 01 ,1 hl!1 ClI,t tlP.ilrnlH sh ell (, .... owed) 20.GEl ·S1.1n<!;u(l' 1l1;J.kinns on Ih.} O(,vmsc 0 1 ., m,un bCil,ong sh(:U (ilrfown(/) 20.7A PI,&#39;~liY<lUo u~ed 10 Check the 'un, clemallco 0 1 m.110 nnd blu-end bea"ngs (imowed)
2 BCilrll1!j shells 111 (lootl condItIon h,IVC 1)C"fU'O surfaces wllh il smooth. (lyen m.m s,tvcr /u,ey coloUI .111 ave._ Wam hCillln!IS wIll show piuches 01 il d,t(clcnt colour when the hctlring mottll h<ls worn nWily nnd exp o~&#34;d lho undcilny O''',,[lo cd bC1'lllIlIJS will be PltI..,!! [)r scored II the 1:,;&#34;&#39;~!>hMl IS III good cOII(1I110n ,t IS n1(:.cly " qUC!ol10n of "hlilllllllU ,1"0Ihl;l SCI 01 hC.111"!Js th;;! SiUllfl s,~e. A new Oilllksh;,h WIll I1C,,<I new hc,,,u'(j shot ts ;ls il II},"!!) , of cour~c 3 The (II'UII,al hOle ill the cyhn(ICr hh;x:k l110ly have hoon !o,wndard 0' lhll rllSI !IIild.: ovcrs,~c ;mel in the taller IIlswncc llus WIll he ,mhCillud by Ihe 1>","II1!I c"ps wh,ch wol l he m",ke(1 wnh while piunl I) The oll!)""ll S'l!} 01 Ihe CI<lnkshMt manl hem Illy 10llln,11s Ill<ly hnve
heen stnnd;ud a. 0 .25 nun (0.010 .n) unde,s'le. II the lournnis were underS'le Ofty.nally. Ih.s w.1I he ind.cale d hy a ween str,!)e o n Ihe lus l halance weigh I 5 The o"wnal size 01 the bly-end IOUll1:l1 W<lS elth!} , s[,lnd<l.d or 0 .25 mm (0010 tn) undersile_ 11 undersrze. Ihe corresponding .0Utll<l' web w.1I he 1l\11.k ed With a urecll ~pOI. 6 II Ihe Ue<lrttlIJ shells <I.e 10 be renewed. lilke the old oues alollY to you. sUPI)"e. and Ih;s Will aC I "5 " check th"l you ,IIC ttel1lllU Ihe co.mCI SI/ .e 1I1:,1"11!15. Undel sil.e hen"IlUs n.e 1ll.1.ked as such on Ihe ..... ve.se I<lc(, (1IhOlos)
- , The ,WII II"1I clea.,l"ce 01 [h" hC"""!lS m,ly he ch"cled U~I&#34;!J PI<lsu!J.1!IC lhn 1,I<lSIIC th,cild IS IKlsllloned o n Ihe lou,nal Ihen tim
l ,e;IIII1() ~IH:II "n(l C,IP IISSOllliJtr,d . ,lilt! 1110 l)Oits/nulS 11!Jlllcncd 10 Ihe speerllod 10'(lul1 W hen Ihe C<ll) IS ,cmoved. Ihe Width 01 Ihe Ih,e<ld IS me<lsul(.~1 wllh <I canl !F1Uue whic h Ill(hcates the ftrrmmU cle<lmrr ce (photns).
21 T iroin g gOMs -oxailliniltion .1nd renovat;OH
I,,~t>(:ct Iho !)(:<I' teeth 10' d'llllilge. o r Siuns 01 e~ccsslVC wea, which Will C;JUse nOI SY Ope'<l tlon 2 The IliIckln sll helween Ihe CHIllSh,111 Hem nlltl Ihe ClllllkSh"h geal
muS I nOI exce ed 027 mm (0011 In) .md Ihe bilckl<l sh should be checked al lou, d,lIe,(: n t POilU S a.ound the pellphc,y 01 Ihe yea. (pholO)
22 Flywheel _ examinntion and renovatio n
hl~l)t&#34;;t Ihe lIywheel lor danln!Je and ch"ck Ih(: ling tical 10.
,1nd d.llll,I!IC 2 If th'l .1I1!1 IIC'" IS h,utiy worn Of has IllISSIl1!J It!clh II shaul. ,e!lew,·d Til" old 11111.1 call ho 'emoved Ironl tile lIywhecl by CU1\1 1l0 lc h 1I.·lwc"n two leeth With <I h;lcks<lw <111(1 thell Sl)irmng 1 " 1:01 .. ch,~d 3 Tn III ,I lIeW "nil !Jeill ,eqlllies h!};oIUln Ihe fino 10 2Q4"C {4Q ( ThiS c<ln tH: dOlle hy polish;ng fou, equal spnccd seCI,ons of Ihe · laYing .1 o n <I SUII,lhle heM ,eS'S tm,1 sudace (suc h liS Ille bucks) he,'lIng It evenly wnh n hlow lamp or 10.ch unlolthe polished a,eas <I IIUllt yellow Illll Do not ove,hen, or the hnrd we,lfill\! P,ol)C,lles he lost Till! 'JeM has <I Challlle.cd inne, edge which should go ilg,l Ihe shoulde' when pul on I he lIywheet When hOI ellou!Jh place U<Jilf 111 position qUickly. IIlPPlIlg il hOln e IS ,lecessmy. <lnd let It ' n.1lUr;llIy WIthout Iluench .. l!' III <lny w<ly
23 Oil "ump -distl1;l!llling. cxarninntion nnd reassembly
II 011 [lU'''1> w~,&#34; IS slIspecw(l il is pOSSlhle 1 0 OOIJIIl n 'CpJII Check fVI W("" 11151 li S desc!lbed IlIte! in IhlS Sec llon ilnd II conlun vhlain ,III IIVCI "(lui kil O' il new pump_ The twO f O tors <I.e a m<l1C P<ll< <llld 'Ulf\)" smgle ,eplncenlcllt unl\. Whe.e t he ,Olor ilssembly I
he le·l,s~(1 <llId Ihe OU(O •• otor. pOIOr to dISIT1,111tlrng. mUSI oe m<l,ke(".
Its hont f,IC e ,n o,de, to ensu,e cOllecl .e ilssembly 2 Remove Iho u&#39;I&#34;~e PIP(! and 0,1 slfaUle' If flOI ;:rlre<ldy 'emoved 3 Note the IdaHI·e POSIII OII ollhO 011 pump covel nlld body nlld Ii (111(10.11111 lemove the oolls and spung was he,s {,}hO loj Llfl i1wav COVflr. <1 Cn.efuliy .emove the ,0lOrs hom the housmg 5 USlnll <I cem.c lJunch. lOp ~ holo;n Ihe cellt.e 01 t he p.esslHe" v.llve Sl'airUg plug. (rnilko a note W obtain a new one) _ 6 Screw OIl <I sell-tapping screw and. uSIng iln open-ended spanl wilhd,aw Ihe Scillrng plug.
,
20.7B Cil.d U<luge 10' checking widlh 0 1 PlilstiU3ge 2 1 2 Ch(ock,ny the timing gea, backlash 23.3 Unbolting Ihe 0, 1 pump cove.
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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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Chapter 9 Braking system 147
Br;'lke IlIlInU
Wheel Adjustment
"m
cylinder --·-·_.L
-::&#39;~~:.J/
I
'j
~
l
~
• shoe hold down spring/pin
Br.lke shoe
Fig. 9
.5 Rear brake shoe components on later m odels (Sec 7)
All models 11 Check the wheel cylinder lor leaks and lor Ioee moyemen t of the
piston(s). Apply a hule brake urease to Ihe shoe contac t points on the
backpla te. wheel cylinde r, anchOr and sell-adjusting mechanism. On
early models check th<lt the wheel cylinder is free \0 moye up <lnd down in the backplate <lnd "pply <l hule brake grease to the sliding Surfaces .
12 Fit the new brilke shoes using a reyers .. 1 01 the remoyal procedure,
but check that the self-.. djusting mechanism is set to the minimum
posi tion belore refilling the drum .
13 Finilily apply lhe loo tbrake firmly several times. On later models this will actua1e the self-adjus ting mechanism; however. on e<lrly models, re le<lse the footbr<lko then <lpply the hondbrake seyerill times until the ra tche t is heard to s top turning.
'
Wheel cylinder _ remo yal. oyerhaul and re fitting
Remove lhe rear urake shoes as described in Section 7.
2 Fit a hose clalllp to the fle~ible hose leading to the reaf br .. kes. If a hose ci<lmp is not <lyail<lble, tig hten a piece 01 polythene sheet beneath the Iluid reseryoi r hiler cap to help reduce any lIuid loss. 3 Unscrew the union nut(s) connecting the rigid b rake line(s) to the re<lr 01 the wheel cylinde r.
4 On pre Oecembe r 1974 models remoye the split pin and clevis pin Irom the handb rake leyer <lnd pull 011 the rubber dUSI cover. Pull oul the two U·shaped plates and withdraw the wheel cylinder. NOle that
the spr ing plate is inser ted from the piston end 01 the wheel cylinder.
5 On I.ller models unbolt the wheel cylinde r from the backplate .
6 To dismantle thO wheel cylinder, remoye the clip where fitted then
prise the rubber boo t(s) from the cylinder body.
7 Extr.lct the piston( s) <lnd separa te the rubber boot(s)
8 Remoye the piston return spring .
9 Prise the seal(s) from the piston(s) , 10 Clean all thO compo nents in methylated spirits or clean hydraulic fluid then inspec t them for wea r and damage. Check the cylinder bote and piston{s) 10f scoring and corrosion. and il eviden t renew the
complete w heol cylinder. If the components are in good condition
ob tain a repair kit 01 seals.
i.
i I
II
j
I ;
procarmanuals.com

1 Chapter 9 Braki ng system 1 49
,1 M aste r cylinder -overhaul
With tho m<lster cylinder removed (SeClion 10) clean the exterior sudaces.
Girling type 2 Removo the SCleW$ and withdraw rhe fluid reservoir. twisting i as necesS,,'y from Ihe end seal. 3 Remove the twO seals afler cdraC ling the circlip ovor Ihe cnd seal. <1 Using II hOKagon key. unscrew Ihe relainer and hit oUllhe primary
recuperating valvo. Oepress Ihe primll'y piston during Ihis procedure. 5 Exl.;'!ct Ihe primary and secondary pistons. IOgether wi,h their associated components. noting Ihe order of lemOlln l. H nccessary top Ihe master cylinder on a block of wood or use air pressure from il foot pUIllP through the inlel porlS. G Separate rhe primmy ,10d secondary l)is10 11S irani lha intermediilte
sprinu . Uso tho !inUe.s 10 remove tile Ulilnd seDI from the primil'Y
r""' lon .
The secondil'y piSlon assembly should ho sOfh"ated by lilting the u"mblo leaf ove , Ihe shouldered cnd 01 tho viston . Using the lingo,s.
rr 'wo the se<ll from Ihe second,lfy I).ston . l ,opross Iho sccondilry sprinH. illiowinn Ihe vDlve stern 10 slide throu!Jh the keyholo in tho thimble. thus releasing tho tension on Iho
spnJlg
9 Dotach lhe villve space ,. tilking c<lre of the spring washer which win he lound IOCille(1 under tho villve he<l(!.
Teves (ATE) type 10 Dopress Ihe primary piston, thon oxtrnCtlhe circlip from the mOUlh of th o c ylindo r and also unscrew Ille SlOp screw. 11 Extract the primary piston componen ts noting Ihe order 0 1 removal. followed by Ihe secondary piston componenlS. If necessary top the
master cylinder on a block of wood or use air pressure from a 1001 pump through tho inlet ports. 12 Prise the seals from the pistons, nOling which way round they are lilled. then il necessary remove tho springs and seals. The prima ry
pis ton spring is retained by a screw.
Both types 13 Clean all tho components in melhylated spirits or brake fluid then
inspec t them for wear and damage. Check the cylinder bore and pistons for scorinu and corrosion. and if eviden t renew the complete nI<lster cylinder. If the componen ts are in good condition obtain a
.opair kit of seals. 14 Di p Ihe piston and seills in hydrilulic Iluid then reassemble Ihe m<lster cylinder in revorse order to dismantling. Make sure that Ihe seals a ro assemble d tho COffect way round as previously noted. Note thaI the secondary seals may be idontif ied with a silver band. On Iho Girling Iype make sure Ih<lllhe shim on Iho end valve is fined with liS
convex side against Ihe shoulder nange. Belore refiuing the fluid reservoi r on lhe Girling type ch ock that the recupera ling valve is open wllh Ihe prim<lry piston released, and closed when I he piston is
depressed.
1
2~
3~
13
1
2
3
4 5 6
7 8
R
22
21
Fig. 9
.8 Exploded view 01 the Girlin g master cylinder (Sec 11)
Filler cap 9 Seal 16 Secondary piston
Seal 10 MaSler cylinder body 17 Seal
Seal !Clainer
11 WiJslrer 18 Rell11i1er
Fluid reservoi r 12 Reservoir relaining screw 19 Spring
Seal
1 3 Seal 20 Spring fl/Miner
Relainer
14 Primary piSlon 21 Valve
Primary fCCllpCfaling valve
15 Spring 22 Seal
Circlip
10
!
" 1 ,
1
I
!
!
I ,
J
,[
1
I
I
; .
!I ' i ;.
procarmanuals.com

,
156 Chapter 9 Brakin g syste m
Secondary cc1ble (early models) 5 Loosen 1I1c lock.nut ~nd unscrew the adju stment ferrule from the right-hand rear clevis.
6 Remove the split pin and clevis pin securing the secanda.v caulo \0 the left-hand Icar operating le ve l. 7 htrac the clip, remove the clovis pin. and withdraw the pullcy wheel from the lever on the Ical a~le. 8 Remove Ihe cable from the lever.
Transverse rod (later models) 9 Disconne ct the cable from the righi-hand rear opCfating Icvcr by
removing the split pin and clovis pin. to Uncl.p the cable hom the 'Hlnsvcrse rod . 11 Remove Iho spli, pin and clevis pin securing the fod 10 the Icft·h~nd le;!1 operating lever . 12 Slide the transverse rod Irom the guide on the rOM axle . 13 Check thO {luide bush lor wear and dama ge and renew It il necessary by prising il oul and pressing a new bush irllo POSilioll.
All models 14 Refining is a r e versa' of removal. but lubr icllto the lin kage as )scflhed in Section 2, and atljl' stthe cable as (fescri bed in Section 18.
21 VilCUUrll sorvo unit -dosCrilHion
A vacuum servo unit is linod Into the lir,lk e hydrallirc cil cu il. 111 series with I he 111,1S ler cylinde f. to provide assiswnco to the dllver whlln Ihe brake pedal is depressed . Thi s reduces the eHolI le{luired try the driller to oper,lIe the brakes, under all brak ing condi tions .
This unit operates by vacuum, obtained from Ihe indu ction mnni rold and comprises basicall y iI booster diilphragnl and check lIallle . The servo unit and hydraulic master cylinder are connected
t o gether so that th e serllO unit piston rod acts as the master cylrnder pUShrod. The driller's b rilking ellon is trilnsmitted through allot her PIi ShlOd 10 the serllO unit piston and ils built-in COmrol system . The scrllo unll pislon docs not fit tightly inro the cylinder. but has a strong ,lltl flhril!Jlllto ke el) liS edges in COllst ilnt COntaCI with I he cylinder Willi_
23 rilult diagnosis -hrilking system
~ylllptom
-'ceSSllle ped,,1 u;tllel
nrakcs pull 10 ono Side
Or;tke ludder
E~cessive eHor l to stop car
so ensuring an i1inigh t seal between the two parts, The fo rward
chamber is held undelllaCUUm condi tions cleilted in the inle t manifold of the engine and during periods when the brake pedill is not in use, the controls open a passtlge 10 the rear ch ambe ., so placing it under lIacuum conditions as well. When the b.ake pedal is dep.essed. the lIacuum pass.Jge to the rear chamber is CUI oH and the chamber expos ed to atmospheric pressure. The consequent rush 01 ail pushes
the servo piston lorward in tile lIacuum chamber and operates the main push rod to the m.Jster cylindcl. The controls are designed so that assistance is given under all condllions. When the brakes are 1'101 requ ired, vacuum in the rear chamuer i s .e -es tabl ished when the br.Jke ped.J1 is released . All air Irom the atmosphe.e entering tho rear ch.Jmbe. is passed through II sma ll air trlter. Und er normal opcr.Jting cond itions tho IIflC(IUm serllO unit is lIery relraule and does not require ollerhaul e~cepl at IIcry high mile,1geS. In this case it is far bcner 1 0 o bta in a serllice e~hange uni l. r,1the, than rcp;ti . the o,igi'lo11 unit . Although inlernal components we,e once .Jv'lIlaule 10 ' ovcrhauling purposes this service has no w been
d,scont,nue(t .
22 Vacuulll servo unit _ remOlla l MId re filtillg
I RemOIlO the master cylinder as desc.ihed In Section 10. 2 D,scolllwc l thc vacuum hose from the non·return lIalve on the serllo \lI1it. 3 Work i,,!) insido thc cal. remOlle th e lower l;t cia panel below the stccring column. 4 E~tractlhc clip and l)ul1 outlho clellis pin attaching Ihe push.od to the l ootu .ake ped;t!. 5 Unsc.ew the nuts securing thc mount ing b.ack.et to the bulkhead.
then withdraw thc serllo unit and bracket from the engine COlllp,lJtlnen t, 6 UnSClew th e nuts ar1(1 serlar,lle the braket 110m the SCIIIO uni, . 7 netrning IS;t rell e.sal 0 1 remOllal w ith leference .Jlso 10 Section 1 0 when retrumg Ihe master cylrnder.
Renson(s)
RC.Jr blake self adju sting mechanism faulty All i n hydrilulic system
WOIll or cont,llllina led /rnin{Js Seized Caliper or wheel cy linde r
E~cessille run-out or distortion of discs o. drums
Worn Of cont aminated linings Brake backplate or caliper l oose WOIll suspensio n bailloints
SerllO unit faulty
Worn or conwmin.Jted linings
I
J
procarmanuals.com

)76 Chapter 11 Bodywork and fitting
General description
The body is of all-s teel welded construction with impact ilbsorbing hont Dnd rear sections . Anli-burSllocks nrc lilted 10 the doors, ilnd the
t ailgDte is supponcd by \J<ls- filled d ,lmp crs. All window glass is of toughened safety type. The front seots Me 01 reclining bucket type. whde the '(Jill sealS mJy be of individufli bucket type or bench type. The level of lIim both ;IHellor ,H1(1 exterior vanes accordll1lJ 10 the Pill!lCular model.
2 Routine nwintenancc
AI the in1erVills speCIfIed in the Routine M"IIl\cnilnCe section in the front 0 1 the nl<lnual c,my out the lullowlI1!J procedures.
Check seal bellS 1 ThorouUh1y check nil sent hellS 101 frayu10 . cu\s, <I,unage Or dctCHnrmion and If ncccssnry Ii"new thell) . Check lor sccu"ty
iheck and lubricafe bonnet and door locks 2 011 the bonnet lock ilnd sillety c~tch ilnt! check thilt they oper~lle correctly. 3 011 illl the (Ioor check strilps ilrld lock hilrwls 4 011 the luel 1IIIer CilP hlnw:! ilnd lock
Check underbody protective coatiog 5 W,th the CM supponed on i1xle stilnds. check the cond,tlon 01 the un(lelbody protcctivc coating. i1nd wherc neceSSilry clean <lny dilll1ilged i1rCilS ilnd ~pply il ncw coming. It the car is 51111 wrlhlll the corrosion w~rranty period check the terll1s illld conditions 01 the
w<lrrilnty lirs t.
3
M,,;ntcll<lI1Ce ~ bodywork ilnd underfrilme
The gorH)!<l1 condlt<on 01 iI vehicle' s hodywor k IS the one thin\) that SluruhC<lntiy Mlects ,ts v<lllle Maintenililce is easy but needs to he leu"lilr. Ne!)lcct. p;lItlctllilrly <liter mU10r dama\}e. C,)I lead qUIckly to hllther delCIIor<ltlon and costly !Cpolir hIlls It IS <"'ponant ;rlso to keep watch on those palts 01 the vehlde not lIl)lllcdr;'tllly vl~lblc. lor IIlstance the undersIde. Inside "II the wheel ~II(;h(ls ,l"d th(l lower pillt ')1 th e engine COlllP'IIt"'Cnt. The bnSlc 1l1&#34;inlen~IIl{;c rOutlile lor the hodywork is wilshlllU -')rder"hly WIth <l lot 01 wnlCr. !rom" hose . T1l1s WIll rcmove 1111 the
ose solids which lIl.1y have stllt:k to the vehIcle. It is i",portant 10 Ilush these oU in such a way ilS 10 prevent \}lIt 110m scratching Ih(l Irni sh . T11e wheel arches o1I1(f unded'nrne need w~lshln9 in the s;rrne
Wily to remove any aCCUIllUI,lted mud whIch WIll retillll mOlslu re <llld tend to encournge rust. P&#39;:lIado~ically cnough, the besl timc to clC.1n Ihe urrderl,arne and wheel ilrches is in wet weill her when the mud is Ihoroughly wei and 5011. In very wet weilther the undcrfrarne is usuilily cleaned 01 large ~ccumuliltions Jutorl,"l1cllly amf this is a good lim(l
f or inspection. Periodically, except on vehicles w'lh iI wax· bnsed underbody protec tive cO<lling. it is 11 good ideil to have Ihe whole 01 the underframe 01 the vehicle steam cleaned. engine compartment included. so Ihat a thorouuh Insp(lction C<1l1 be ca"ie(l out to see Wh,lt minor repilirs ,lnd renoviltions are neceSSilry . Steam cleaning is available at many g<1lage5 and is neceSSilry for removal 01 the accumul<ltion 01 oily g,ime which sometimes is allowed 10 become thick In cer t<lin areas . If steJm cleaning f<lcilities are not i1va;!aole. there nre one or two excellent grease solvents aVilililble which can be brUSh <lpptied. The (Iir( can then be simply hosed off. Note thaI these methods should not be uS(ld on vehicles wilh wax·based underbody proteclive coating or the coaling w ill be removed. Such vehicles should he inspected i1nnualiy, preferably just prior \0 winter. wh(ln the underbody should be washed down and any damage to the wax coaling rep aired. Ideally, a completely fresh coat should b(l applied. It would illso be worth conSidering the lise of such wax·hased jotection lor injectio n into door panels, srlls, box sections. etc. as i1n i1dditional saleguard a\Jilinst rust damage where such protection is not provided by Ihe vehicle manufacturer.
After w<lshing paintwork, wipe 011 with <l chillllois lemher to give an unspoiled clear finiS h. A coat of clear protective wa~ polish will gIve added p rotection i1gilins t chemiCill pollutants in Ihe ilir. II the pilintwork sheen hilS dulled or oxidised. use a cleilner/poli5h(lr comhinntion \0 restore the brilliilnce 01 the shine. This lequires il l'llIe eHort . but such dulling is usually caused b(lcause rcgulilr washing has been neglected. C<lIe needs t o be Inken WIth mewl1ic paintwork, as speciill non·"brasive cleilner/polisher is required 10 lIvold dllmaue to the fInish. Alw<lys check thM Ihe door and ventililtor opening drilin holes and pipes <lre completely cle<lr so Ihilt wilter Ciln be drained oul. Bright work should be tre<lted in the Silme wily ilS pllint work W indscreens and windows Ciln be kcpt clear 01 the smeary film whrch oftcn appenrs by the lise 01 iI proprielilry gl1l5S cleaner. Neve, use any lorm of wax or other bOdy or chromium polish on glass.
4 Mnintenllnce -upholstery MId eMpets
Mats and C<lrpets should he h,ushed or VilCULU!! deill1ed rngulJ' Iy to keep them free of gilt. II they <lre badly stilrned remove Ihem hom thc vehicle for scruhbing o r sponging Jntl m<lke ql,ite sur e thr:y art) <f,V before re!rlling. Scms and mtcroOI tlim p,lnels clln he kept clean by wiplll!J WIth <l damp cloth. II they do hecome still ned (which '-:<111 he more <lpp<lrelll 011 IIgll1 coloured upholstery) use <l illlie ilq",d deter\Jent ilnd ,1 soil nllli brush 10 scour lhe \}rime out 01 the ()lalll 01 the rnnlerinl . Do nOI 10r!Jetto keep the he,ldlining clenn in the same w,1y as lhe upholstery. When using liquI{1 cle,1ners mSlde Ihe vehie.l e do not over-wet the surf!lces beinu cle<lned . Exces~lve damp could !Jet inlO the 5e,IIns nnd padded in1erior C.1USil1n sWins. offensive odours or evell rot II the IIlside of the vehicle gets wet accidenl.1lly it is worthwhrle t;lking some I,ouble 10 dry il out properly. par ticularly where cMpet5 i1re involved Do rlo/lc,we oil or clec/,ic helllClS illsiclc Ihc vchicll) lor tllis l!Urposc.
5 Minor body dnnl<lge -repair
rhe phOlo{Jr.1phic SCl/rICIICCS 011 P,IflcS 174 ilfld 175111051'.11" Ihe OIWfil/iofl$ d"lo1Ifcd ill Ih" 101i0willY suh·SCC(IOII$. Note: Fo, mon' (il-1,1iIL'd ili/OlilialiOIl 01/)01/1 I}odywork fCfwir. Ihe U"ylll:s P"hlislllilY Group pu/)/ish II book by Lilli/say POller c!llIed The C,If lJodywork H"II,11f Mill",al flII:~ lIIeorpor"ll!s ;lIlo,,,,,l(ioll on sllcli <Is/wets as rIIsl (rcallllc,rl. Ih1!IJlin!/ <Ifill 9',15S frb'l) ((!p,1irs, ,1S well ,15 rlvlilffs olr 11/011) <1fll/JllioIlS rcpai,s IIIvofvirry weldlllY i",d p,lltel belrlillg.
Repair of minor scratches it) bodywork II the scratch is very superllclill, MId docs not penetrilte 10 the Illelill 01 the hodywork, repnir is very simple. LIghtly rub the area 01 the scratch with a pilintwork renoviltor, or il vcry line CUtlll'\} p<lSle, to relllOVe loose paint frOI11 thc scratch and 10 clear the surrOlllldlll\J hodywork 01 Wil X polish. Rinse the alca woth cleMI wilte,. Apply lOuch·up pnint to Ihe scrntch using iI IrIle p~1I11 brush, continue 10 apply fi ne faye rs of point until the surlilce 01 the pamt ,nthe scril lch is level with the surrounding p<liIllWork. Allow the new p<linl nt le<lst two weeks 10 hMden: then blend it into the surrOUlld in\}
pa il11work by rubbing Ihe sC/Dtch men w ith iI pilintwork renovator or a
very line culling pils te. Finally, opply wax polish. WhNe the scrotch has penctrDt(ld right through to the metill of the bodywork. causing the mowl \0 rust. iI d ifferent repa ir lechnique is
required. Remove any loosc rus t fronl the bottom 01 the scra tch with a penknile. then apply rUSI inhibiting paint 10 prevent the lormation 01 rust in Ihe future. Using n rubber or nylon appliCiltor fill the scratch with bodystopper paste. II requ ired. this paste Ciln be mixed with cellulose thinners to provide a very thin paste which is ideal for filling narrow scratches. Before t he stopper·paSI(l in the scratch hardens. wrilp il piece 01 smooth COllon rJg i1round the lOp 01 J linger. Dip the finger in cellulose thinners and then quickly sweep it i1CIOSS the surlace of the 5topper-pJste in the scratCh: this will ensure tha t the surfilce 01 the stopper,pilste is slightly hollowed. The scratch can now be p<linted over as described eMlier in this Section.
Repair o f dents ill bodywork When deep denting 01 the vehicle's bodywork hilS taken plilce. the
first wsk is to pull the dent out, untrl t he affected bodywork almost
procarmanuals.com

) Chapter 11 Bodywork and fittin g 17 7
~!t~InS its oriOin,11 sh~flC. There is lillie point in trying to restore the original s hllpe complClC ly, as the me1011 on the darnllged arca will have stretched on impact ilnd cannOl be reshaped fully !O its original contou r, II is belter to bring the level of the dellt up to 11 poin t which is aboul ~ in (3 111111) below the level 01 the surrounding bodywork . In cases whe.e the dent is very shallow anywi'lY. i, is nOI worth trying \0 pull 1 ou t 111 all, II the ull{lersidc 01 the dent is accessible. il can be hammercd oul gently from behind, using a malleI with a wooden or plastic head. WhilSt doing Ihis. hold a suitable block of wood l'flllly a{),111151 the outside 01 the panel 10 absorb the impact from the hammer blowS and thuS Il,event 11 Imge area of the bodywo.k hom being 'belled,ouf, Should tho dem be in a section of tho bodywo.k which has iI double skin or SOI1IIl other filclOr mokil1g It inaccesslhle from behind, a
dllferent technique is cillied lor, Drill severill sm;1U holes through the
mewl II1slde the i1reil (Jilrtlcul,ldy in tho deeper section, Then screw long sel1·tap~ing screws into the holes IllSt suffIcien tly for Ihem to gilln iI good purchase In the mewl. Now the Ilen t C"n he 1)lJlled out by pulllllg on the protruding headS of the screws wllh iI pnll of pliers. The no.t stilgo of the rep,lir is the .emOllill of the PilUlt from the 113Ued meil, and hom nn Inch or so of tho SurroundlilU 'SOUfl(r
Jdywork , Tills is accomplished most oilslly by usil1U a wire brush or ab&#39;~sllle pild on " ,)owe< dflll, ~,lthou9h It Clln he done Just i1S e ively hy hnmf usmg shoots 01 1I1)'i151110 P.l,)C •. To COlll,llete the p<epa.al.on 10' f,IIul9, score lhe SUrlilCe 01 tho b;1re melDI wllh a sClewdflvor or the tilnu 01 a I.le, 0' altCf11<1l1voly, dlill s"'<l1I holes in the ilflec ted ,lICi1, ThiS Will p,ovlde a .eillly {lood 'koy' lor th e hiler pnsle . To coml)leltl the rep<lir sec the Secuon on flllinfJ ,lnd re spr"yIl1 9.
Repair of fIIst holes or gashes ill bodYWOlk Romovo i111 point f rom the affected ;lIen i1nd from ifn IIlch or so 01 the surrounding 'sound' bodywork. using ;1Il nll.a$llIe pnd or 11 wire brush on 0 power drill. If these iIIe not i111",lahle a few sheets 01 abrasive pilper will do the job JUSt as offoctivilly Wrth the paint removed you will be able to gauge the sovori ty of the corrosion alld
thorelore decide whether to renew the whole polllel (II this IS possihle) or to .ep[lir the affoctod illoa. New body Po1nols arc not ,1S expensive as mos t flCOple think and it is often (Iuicker and mo.e satislacto • .,. to fit" new t)anelthan to auempt to rellair larue n.e,1S 01 corrosion.
RenlOlifl all f,llln\Js hom the .. lIeeted a.o" cxcoptthose which Will
act ~s ,1 uu,(ie t o the oliUllwl shape 01 the (i,lIlla\je(i bodywork (ell hn,1(1lnll1l) ~h.~lIs etc). ThOll, USlnu tin snIps or ~ h"cks<lw hl<ldtl. remOV"
all 100SI) met,,1 ,,,,d allY other IIwtill b;I(I'Y 1IIIo.:t..,d hy cOffosion H"lIllller tIro cdIJlls 01 lire hole Il\wartfs In Older to CW1Ite a shulrt
d epreSSion fo r Ih c frllcr pas\(!
'll/lle hrush the aHected Me[l to 'CIilOlle tiro powdery rust from the ,ICO 01 the lelllilllllll!l lIlet,,1 P;lInl thc "flected arc" wllh lUst
IIII"I)ltll1l) p""'t. If the hilck 01 the ,usle.1 me,1 's accesSlhle treolt tillS
" delo.o frlhflU cml t<lke p'[lee It w ,1I he neecs s"'y 10 hlock tho holo in
some w".,. . Th,s COil be [lchl(~ved by tho use 0 1 aluminium o. Illastlc
me sh. or altlflll1l1um t",Joe. AlulIll"'um 0' pl;1strc mesh IS Il.oh"bl.,. lile hest m<lw",,'to use lor a
lar\Je holo. Cut a I>.eeo to tho "pprOXlfll"te Srte ;1n(1 sh[lpe 01 the hole to he frlled. then pOSit lOll It in tho 11010 so th;rlltS ed!leS arc below the lovel 01 the sUffoundrng bodywork. It c"n he ret"mcd in position by sevcral blobs of hiler paste [lround Its per'l)lIelY,
Aluminium wpe should be us ed lor slll ;rll 0' vCly narrow holes. Pull a picce oil tho .011 ond tri'" It to tho apIl<OXlillOtO size and shape
r equired, Ihe n pull off the backrng p,1por (If used) and stick th e tape
ove . the hole, rt C[ln be overlapped II tho thickness of one piece is
i nsufficient. Burnish down the 00ges of tho tapO With the handle 01 "
screwdrillC ' or srmllOf, to ensure that the ",po.s securely auached to the
metal undomeath .
Bodywork rCIJ<1irs -filling a"d re-sprayi"g BefOte uSlIlg thiS Seetion, soe the Sections on denl. doep scratc h.
rust holes "nd gash repai.s . M~ny types of hodyfllfer Me ~val&#39;ahlo, but Uonerally spe~k.ng those nrOpnelOry kits which conlain 0 till of f illor paste and a tube of resin h~fdener Me best for this type of rcp,llf A wide, !ieKilJle pl<lstic 0' n.,.lon apl)llc~tor wrll he found Invaluable for irupn.tinu a smoOl h and well cO'''<>ured fUlish 10 thc surface 01 Ih c filler , h up a hulc fille. 011 a cle,,,, piece 01 card or boo.d -measure tho
hardener carefully (follow the m"kCI's instructions on the pack) othe.wrse thO folic. Will !>tt too rill)luly or tOO Slowly . Using the
"pplicator apply the filler paste to Ihe prcpared area: draw the
applicalOr across the surfaco 01 tho IllIer to achieve the correct contour and to lovel the fillef surface. As soon /1S it contour that approxim"tes 10 thO corrOCt one is achielled, SlOp wo.kinU the pas le - il you carryon too long the pasto will becomc sticky and begin to 'pick up' on tho
app lic"tol. Continue to add thin layels of Iiller paste at twenty· minute intervals until the level of the filler is just pfoud of the surrounding bodywork Once the IllIer has hardened, excess can be removed using a met;!1 plane or IiIe. F.om then on. progressively finer grades of abrasive paper should be used. starling with a 40 grade p.oduction paper and l.nishing With 400 o."de wet·and·dry paper . Always wrap the abrasille p"pcr IIrOUlld a flat rubber, cork. or wooden block -otherwise the surfaco 01 the frller Will nOI be completely flat. DUling the smoothing of the fIller SUI face the wel·and·dry paper shoufd be periodically rinsod in walCr. ThiS will ensure thaI alle.y smooth linish is imparted 10 the frller (It th O flllni SHIIJO. At t!\l S st1lge the 'dont ' shoul(! be surrounded by a ring of bme
mowl, whIch in IUfn Should he encirclod !.Iy the finely 'feathered' edge
0 1 th e good paintwork . Rinse tho repair nrea wilh clean water, until all 01 the dust I>roduced by the rubblllu·down operation has gone. Sp."y the whole .ep.1ir a.oa with" light coat of primer -this will show UI> any ,mpcrfOChons in lhe su.face of the fll1e •. Repai. theso Iml)CdectlOIlS with frosh 1,110' paste or bodySlOpper, and onco mOte
smoOth the sUfl<lce WIth "b.asille I>aper, If bodystopper is used, it c"n he mixed wllh cellulose thinnors to lorm a really thi n p.1Ste which is Idt(lllo, "'''ng smilll holes. Repeat this spray and repair procedure until you a.o satIs fied th"tthe sudaco of the filler, and the fe<lt hered edge of
thl'.! pnintwork nrc perfect. Ctean thO rep"ir ;lfea with clean water and .1l1ow to d.y fully, The .ep,," arc" is now ready for 1",,,1 sprilying. Paint spraying muSI
he call1od out in a w".m, dry, wind loss and dus t free atmosphero. This condition can be created mtllicially II you have access to a large indoor working "reil. but rl you nre lorced to work in the open. you Will have to pick your day lIe.y ca.efully . II you a.e working indoors. dousin\J the
floor in the work mea with water will holp 10 SOllie the dust which would otherwise be in the iltmosphe.e . If the ,epai. mea is con fined to one bod.,. pilllOl, mask off tho SUffoundlflg panels; lhis Will hell) 10 minllllise tho effocts 01 a slight mis,match in lH,lint colou.s Bodywo.k hUUlUS (eU ch.omo strips. door handles Otc) Will "'SO noed to be
"';1sked ot! Use uenume fII<lsklflg t.1I)1) nnd sOlloral thicknesses of II(JWSI)aper lor the n .. ,sklllg opor<ltlOIlS, Ilelole commenCing 10 sp.ay. aU1t.1lO the nerosol cnn thoroughly.
thon s pray n tes t mea (<In old till. or similar) until tile techniq llO is mastered . COlier the rep,lII me" with n thick coat 01 primer; tho thlcknoss Should be bUilt up usrng sever,,' thin layers 01 pninl ratller th,ln one ttllck one. USUI\J 400 Ura(le wet·ond·dry p,lper. lub down tito surface of the jlflfller until it IS renUy smooth . While dOIng thIS. the work aroa should be thoroughly doused with watel, and the wet·.1nd·dry 1)'11>0' I>enod,cally . insed III w"ter. Allow to dry befo.e sprayinu 011 mOl(l ,laln t
S ilray on t he t op CO"1. "\Jain bUlldmu ull the tluckness by usul9
sOllof1lllhlfl'"ye .s 01 p<111l!. S Ia .t spraying in theCllnlre 01 the .epair mOil and theil, USH\g a clfcular mOllon, work outwards untrlthe whole ropmr
"rea ond al>out 2 inches 01 tho surrounding origmal pallltwork IS COvered Remolle allm"sklng mnteflaf 1010 15 minutes alter spr<lylll\J on tho frnal cont of pamt. Allow the ncw pault at leil5t twO weeks to hnrden. then. uSIng" paintwo.k .enovatOr 0'" very fine culling paSte, blend the edges of Iho
paint Illto the OXlst lng paintwork . Frnally. apply wax polish
Plastic compOllc"ts Wllh the use 01 mo.o and more pl"stic l>ody components by the
vehrcle manufac turers (eg bumpers, spolle.s. and in some cases major
body panels). reCllilcation 01 damago to such items .hilS .t.>e<:0me a
mOller o f eHhor emruSling relhl'r wOtk to a specialist m thiS field, o. renewing complete components Rep"ir by the DIY owner is nOlleillly feaSible owing to Ihe cost of the equipmen t and materials reQui.ed for effecting such repairs. The baSIC technique inllolves making a grOOllo
atong th o hno of the crack in the plastic using a rotary hurr in a pow~r drill. The damnged pal! is then welded hack togeth er by uSing a hot "" gun to heat up nnd luse a pl<lstlC IllIer rod IUtO the g.oove . Any excess
plastiC is then remolled an(lthe Mea .ubbed down to a smooth l in ish. I t IS Ifnpo.t3nt that a IllIer rod 0 1 tho correc t plas tic IS used. as body components can b e made of a lIaliety 01 dlHerenl types (eu
polyca.bonate. ABS, poIYllropylene) .
procarmanuals.com

2"4 Index
",-----------------------------------------------------------------1 -
ligh\s operation check -16 w~she( fluid levels check/lop up - 16, 217, 219
engine
crankcase emission valve renewal -16, 27
fluid leaks check -16 oil i1nd filter change -16, 26 oil filler cap clClIning -16. 26 oil level check/lop up -16 1I;llvo clearances check/adjust -16. 46
exhaust system condition check -16
fuel sySlCm <lir cleaner temperature control check · 16. 67 air filte, element renewal 16, 67. 79 fu el fIller renewnl (fuel injection models) --16, 80 fuel hoses condition check · 67 idhng speed/mixture check/ad)llSl -16, 73, 79 inlet tllllniioid nuts/holts UUll1cn -16, 27, 83 vilcuum hoses check -16 ignition system contact brC<lkcr points renew"j (3.0 hire eng1l1e) -16, 89 dlS1riiJulor Cilp, (olor, HT le<lds [111(1 co,1 c!e ,ln/cileck - 1 G. 88 (hst"hlltor lubrication -1 G dwell angle check/~diIlSt (30 hue elllJ'ne) -16. 89 sp,lrk pillns cle"n/re-UJp Hi, 95 sp~rk phl\)s renew· 1 G, 95 limin\) check -16 . 94 real axle 01 1 level check/top lip 16, 133 s~fely prec,HltiollS -12 sC(vice schedules -13 suspension Jnd steellfl!) power steerlllg drivebel1 cond,tlon/tenslon Check 16, 161 power steering fluid level Jlld hoses check 161 steering components condition check -16. 161 suspension condition check --16.161 transmission ~utom~tic tr~nsmission brake b,l lld ~dJuSlmenl -16. 123 i1(,tOlmllic transmission Ionk,lge luhricmion -16, 123 oil/fluid leve l check/IOI) up -16, 104. 123 lyres IH(!SSUres chcck/~dJllst -16. 158 we<lr/d~m~gc check -16. 171 whllels comlilion I:llCck 171 Manifolds (cnrburettor nlodels) Icnlov,,1 and 'Cf'tl"'!) exhnust 76 inlet 75 'nnifolds (fuel injection models) relllov~1 and rell!1Ul(J
exhaust -85 Inlet 83 M ,lIlua l g e<Hb ox (iescriptlon -104 fault di~gllosis 122 f,ve -speed disenIJil!)emcnt o f 5th \jeM - 121 dlSnl~ntlmg -111 exallHnat ion Jnd renovation -119 "'put shaft dlsmantlln\j ami rNlsscmbly -109, 119 mainshalt (lismalllllllg and le,l ssc"li}ly -115 reassembly -119 four-speed (lismantllng -106 examination lind renovation -109 input shah dismantling and reassembly -109 I~ygcar dosillanlhng ilnd reilssellli)ly -109 reilsscrnhly -110 gcarchilnge lever (lour-speed) modlflcmions -111 ma intenance, routine -104 removal and reflu;ng -104 speclficmions -102 IOrque wrench SCHings -103 Manual g ea rb o x ./Ild lIutol1w tic trMlsmissioll -102 c( scq M aster cylinder (brllking s y stem) ovcrhaul _ 149 ~ernoval and relltlin\) -148 tvr'rror
o
removlll and relltting lldjustllble exter ior -192 interior -192
Oil pump
p
28 Iotre engine dismantling. examination and re~sselllhly -38 ref in in 9 -42 3 0 li tre englllc dismantling. eX~lllinmion ilnd reass embly .-52 [elit\lng -54 removill 50
Pedal ,1cceler,ltOr 75 bra k e · 152 clutch -101 Pisto n an d connec ting rods ref,nin\j -42. 51 Pistons and pisto n rin\js exanllna\lon ,1nd rcoova\lon 36,51 Pi sto ns. connecting rod s il11d bearin\js (3.0 litre cngine) [lmlov,11 51 Propeller shaft 128 d s, .'r/ Prop elle r shaft cenlre bcarln!J r()&#34;l]w~1 12!J
descrip1l011 28 I"ul l (i iaunosis - 131 removat and rel,UlI1U -128 10rque wrench seHlIlgs -128 univers~1 10lllts inspection 130 Pushrods 35< 51
R
Rndi,lto r rel11ov~I, Inspcctoon, cie<ln'll!l ilnd ",fIIlIlIO GO Rildiator grille removal and refll\lng 179 Radio/cassette pl,ryer
<emovill ilnd reflttln\J 226 Radio equipment. mobile Iflterlerence- free IIlst;lllat,on ,-226 Rcar ,1Xle -132 e/ seq Rear axle ,1xle reilr cover rClllov,, 1 and rellttln\J -135 axleshah beoliing rcnewill 135 removal ilnd relilling 134 descllpt,on -132 fauit (/lilgnosis - 141 limited slip (hiferentoill -140 rnainterlilllCe, routine -133 overhllul -136 pinion oil seal renewal -135 removal ilnd refltling - 133 specifoCiltions -132 IOrQue wrench sellings -132 wheel stud fenewal -140 Rear drum brilk e s
rear hilckpl~te removal and rclluin(J -148 shoes renewal - 14 6 wheel cylinder removal, overhilul ~nd ref'lllllg - 14 7
Rear lamp and b ulb removal and refttling - 216 Rear number plilte lamp and bulb removal ilnd relilling -216 R ear su spension description - 158
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