brake light FORD CAPRI 1974 Workshop Manual

1
134 Chapte r 8 Rea r axl e
FiO. 8.5 Discorlllccti!l9 the rcar sI"biliser Iwr (Sec 3)
7 U~&#34;&#39;!I u"ps (FlU 8 5) I)UU rile s1.1h,l,s(lI b.ll 10 lilt:! lCol. while unstocwIIlIJ the mOlllllnlU I)oIIS from the Ie;)' ;l~II!. flcl110vc the C!JIllI'S 8 W,lh the rC:II Ildc sUlt,lbly SUIlI>o.ICd. lIIlSCICW rhe nulS hom the hallom 01 the U-bolts i1rld reOlOlle rhe lowel S I)llrlU p l;lrcs .. ",t! 1115 .. 1<11015. 9 Wllh rhe help of an asslSlilnt. hft the rem a~lc over the &#34;~<lr ~p&#39;!I1\1s iUld withdraw i t from undcr the CilL 10 To refit the ICtllr axle, lirst cher.k Ihal the upper insul<l ,ors ;lnd 1",lCkclS a.e correctly located on the springs. 11 Wllh rhe help of an assistant hft the rear ;'!Kli! into 1)05'1'011 on the W:1r 5Il flrl!JS. 17. COIIIWC l rhe IUOI)clle. shall 10 Ihe dflllc flanUc with rile IlfClllous ly 111;1,1 " "'o1rks :11111110<1. ,1nd loosely fll the four bOl ts. tOljclhe. W Ith new hl':kw;,s he.s
13 I O.:.lt!"! the ul~&#34;&#39;&#39;&#39;&#39;o.s 1m!! lowe. SP""1J pl~ws all the sp rin!jS thclI "1 Ihn 1)·llo\1s. W!IClhc. wilh Il/!W sld/.locklll\) lIutS T'!Jhlf:l1 thc IHII S l"o!Jlnsslvuly 10 Ihe spo{;lf ,/!(IIOIQUC. III 1')<;,lIe Ihc CI;1I1IP~ 011 liIe Slilhd,scr bilr "'0\I1111\1 tubhers tlrCII pull 1 hili IlltO poslllon WIllI thl) grips <l1l(1 fIt the mountlllll bolts. TIUhtell .Il hl>l1~ 10 the S IICclllI .. '(l toIlIUI) . • ,. j<lck up the reM a~l{l ,1S neceSSilry and push the shock <lhso<be .s
, Ihe" I/.ac ket s. In se'l Ihe nloum"lU bolts and tlghlel1 the nUI S. H i Ilelll Ihe lIexll/le b.,lko hose and lIuhten the nuts. 17 Rel1lovc the hoso cl,lrn p or polythene sh eet then blcL,{/ Ihe hr<lke s n~ d(!sCllhed ill Ch<lpWr 9
t 8 nelll t he h<llldhr<lke c,1blc and. where <lpphcllhle. the tr~&#34;sverse lad II) thfl ICi"lI n K le WIth referen ce to Chapter 9 . 19 T,ohtell Ihe dllve ""nne·to·propeller shall holls to lhe speCIfI ed to.que. 20 R el'l the .ear wheels "nd lowe. the car to the ground. 21 Check Ihe .en. aKle 0,1 level <lnt! top up II 'Hlcessi"lIy .
1 AxleshMt -removal ilnd refilting
Chock Ihe front wheels then jack up the re,lr of the c~r ilnd support with onle stilnds. Remove the .ear wheel 2 Ilelea se the hilndb.nke and .emove Ihe brake drum.
3 USIng a socket through the special holes in the drive lI.::tnge. unsc'ew the bollS secu.ing the b.::tckp late and bearing ,el.::tinor to tho a~le cilSln g (pholo). 11 Withdraw tho a~leshnft. together with the bearing. " it is tight due 10 tho oulor Ir<lc k seizing in the casing tcmporarily refil Iho wheel .::tnll Iwll on the wheel. If Ihis is unsuccessfu l. use n slide hammer allached
1 0 the dtive lIange. or ,1Iternil1ively sc rew two long baits th.ough Ihe jng al diametlicaUy opposite pOInts (FIg. 8 .7) and lighten them I,·...r<jressiv ely un!11 the be.::tring is freo . 5 To .e"l the a~leshafl. IU$I w ipe clean Ihe bcallng .(!(:ess in the casing and al>ply a liule Illhium based glease both 1 0 the casing and bear ing outer !rack . F
ig. 8
.6 RelHoving t h o Mdeshalt .e l'l ining hoits (Soc 4)
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Fig 8 .7 U sing long bolls to ""ithdra"" tho a~leshaft (Sec 4)
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procarmanuals.com

) Chapter 9 Braking syste m 143
2
Fig. 9.1 DU<lI linc hydn.ulic brnke circuit (Sec 1)
1 2 Fron! br,)k(1 disc ,1nil c<1IijJ~&#39;f M,lS/IH cylinder and I/uid resefvoir 3 V,KIIUIn sClva unit 5 ReM drum brake 4 Prcss1ltc (h!fetcH/i.)1 wi/filing swi/cl!
2 ROlltine maintenance
Al III<, u,h!lvals speClficed in the Routine M<JinlellilllCC sectIo n in the frOllt of tlw 11,;)1111<11 Colny oul the lollowlIl(J procedures
Check hrilke fluid Ivvel 1 CI",<;k 110.11 Ilw hrake thud )"vcl in the reselvoir is .1, or nc." lhe 1Il,,~i&#34;&#39;lI&#39;&#34; ',,,10k The ,c~;cr\loi( is localed on the master cylinder on the nghl-hillld sule 01 the IJulkhead III the cl1uine cOIllpnnlllCII!. SliUht Va-"I,ulls of I"vel Will occur ilccordlfl!) to the wear ollhe II/<l ke linings. If lI,v(!1 (hops wW ;1,ds the ""Ilimlllll mn,k the cornplclC hydraulic system should he Chec ked lor le<lks,
2 ·'h tim cm rnlsed. c,lIe1l1lly inspect illl the hydraulic pipes. hoses ;lnt. .. ,lions lor chJlmg. c'ilcks. Illilks ilnd corrosion.
2.4 ;-.-
uejJ.es~ the rubue' membrJne to check the fluid low level
Warning IrUht
3 To top up the fluid unscrew the fill er cap whrle holding the c,lhle connector sWtionar y. and add brake lIuid ns necessJr y. R efit the cnp on completion. 4 When checking the brnk e fluid level it is n good practice to also check the low level wnrning light With the hnndbwke rele<lslId and the iunition switched on. depress the rubber membr<lrlC on the rIl511'VOII hi ler C<ljJ (phOto) If the wilrning light filils to came on check the bulb ill1d <lssocimed circuit.
Check disc p<1d and rear bwke shoe linings 5 Jnck up the Iront nnd rem of the Cilr nnd support all il xle stands,
Re leuse the hilndb'<lke. 6 Although i t is pOSSible to check the Iront disc pari 1illillUS with <l mirror and torch. it is recommended thnt the front wheels <lre Illst
,emoved. 7 Mensufe the thickness 0 1 lining on e<lch disc p<ld <lIlt! If ,lilY IS less thnn 3 .0 mm (0,1 18 in) renew the complete set of front [Jose pnds 8 II the ren, b'nke h<lckplntes incorporn\(! inspection hOles. remove the rubher plugs nnd check thnt the thickness of the hmn\js IS not less
thnn 1 .5 mm (0.059 in)
Fig. 9.2 Handbr a ke lin k ag e lubrication points (arro\Ncd) on early models (Sec 2)
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procarmanuals.com

) Chapter 9 Braking system 145
/ll.Iid reservoir tille , cap \0 help roduce any fluid loss. 4 Where a rigi d brake line is connec ted \0 the calipe r, comple tely unscrOw the union nUl . Where Iho flex ible hose is connected directly \0 Ihe caliper. loosen only .he union (lnd unscrew Ihc caliper f.om Ihe
hose later. S Prise back the laus on the locking plale and unscrew Ihe mouming boilS (photo). The cJliper may now be wit hdrawn ove r th o disc and where neCessary unscrew ed from Ihc flex ible hose, 6 Refilling is a revCfsal of fernOv;!I, but lit a new locking plate and
l ighten the mouming bol ts \0 the specified torque. Bend the Inbs \0 Io<:k I he boils. On comple tion bleed the hydwulic system wit h
reference \ 0 Sec tion 15.
5 Front brake caliper -ovorlulU l
1 With the c~liper removed . cle~n away all external dlr1. 2 Where applicable, prise out the dust cover cirClips <Jou wleilse the
dust covers from the external ~onular groove. : lIr"ct the pistons: keeping them idenhlied side lor s.de. If nt .... "ss"ry. use low [lir P"CSSlU(! frOill a foot pump to lorc e the pistons
IrOIl' lho bores. 4 nove tho dust covers Irom the pistons or bores as apphc<Jblo. 5 Prise tho pisto n seillinU rings from tho hores tnkino Cilre not to scratch the bore suri<Jce. 6 It is impOrliln1 liw i tho twO h<Jlves olthe caliper are not separated under any circumstanr:es . If hydr.1ulic lIuid lenks ,l,e evident from tho join!. the ca liper must be ronewed complete. Thoroughly wash all p.1,t5 in methylated spi ri ts. or c lean hydraulic lIuid. DUling reassemhly. new rubbe .. seals must be lilted. These should bo weiliubricilted. wrth clean
hydrau lic Uuid . Inspect the piSlons and bores for signs 01 weilr . score markS. or damage and il evident. new par ts should be obtained !Cady for lilting. or a new ca lipe r obtained. 7 R eassem ble tho components using a reversal of th n disnwn tling procedure. but before inserting the pis tons dip them in clen n hydrnulic fluid to assist entry through the seals. On comple tion press the pistons fully into the bores.
45 Front brake caliper mounting bolts (arrowed)
6 Front brake discs -in spection. re rnovnl and refitting
Apply the hilndlxake then jn ck up the hom of the car and support on :1xle st:1flds. Remove the Iront roadwheels . 2 Rotate the disc by hand and examine il lor deep scoring, grooving or cf1lcks. light scoring is normal, but if excessive the disc must be
renewed.
3 SCrJpe <Jway any loose rus t fro m the oute r edge of the disc, lhen mensu.e the disc thickrless using a micrometer or cnlipe rs. If less lhan the minimum specified thiCkness rhe disc mUSI be renewed.
RUEO '.(RlW
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1-""£0""""" ~Plf&#39;l ~-____ ttIP
BI&#34;&#39;~( &#34;.&#34;,~&#34;&#34; PI~I()&#39;
4IOUf llltlGOOLI tCCKltlG PLATE
R( 1 Altl{R RltlG
BRAKE (VLIHOER PISTO'l
(l001
Fig. 9.3 EKp loded view of the front brake calipe( on fater models (Sec 5)
RING
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) Chapter 11 Bodywork and fitting 189
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32 8A I&#39;,,~c 0111 Ihe alp 32 an ali(I ,(,mo .. c the console screw 329 Removing the hnndbrake lever boot find be~el
Fig.n.la C lock ro:.,,"ov<ll tools (Sec 32)
1 () "'I!! (0 If; "') /J IOO",m (()/I() III)
32 Centre cOIl~ole·· fUIllUV,,1 ,,,,d refiUinu
IJasic tYlle '.111 Ihe caqll:l 110m ;!lolllni the r'OIlI of t im t:()Il~()lo, thun push the " .J <llld hel..,1 out of Ihe hUlls&#39;&#39;&#39;~J DlsCO""CCI the dock 1r~<](ls 2 Remove 11", two SCI(lWS il( Ill(.' reiH cnd ,inti two (I101e hom the clock emt. to 1!.,lu<lst: Ihe cOllsol", 3 rlell10vc the \lP;" l<:vcI ~&#34;(lh, or T·h""dln 1 Lilt 0/11110 consul" As dpphcilhlc. !(:r!'UVC the clock 11l0llrlll1l!) pl<lIC screws "ud/or UCilrstuft lever hoot 5 flchtl;nu 15 the reverse of the 'clllov,,1 1110<:odlllO.
Gfli,1 type (also Il((ed fa I(I/ef nVI)-Glli" modrds) 6 Lift the Cil'PCl hom ;"oulld the IrOll1 oj the console 7 F,.brIC<lte twO sm~11 h",cke!s f,om 1 5 ""n (0 06 ,n) sheet sleel (sce Fig . 11.18) ,1I)d ,nsel1 (hese hel"nd (he IJlilck hewl to ,emove the clock Disconnect the w,,,ng. 8 Remove the two console ,etammg 5c,ews. then prIse oul the Cflp in hOIl! 01 the gearshift lever ~n(f rcmove the screws heneilth (photOs). 9 Cilrefully p,,~e the h;Ul(llJrilkc lever hoot ilnd belel ;)ssembly from tlie conSOle ;)nd remove II (photo). 10 Cnwluily PrlSC out the Gellire pflilel cover hom behind lhe gear lever. 11 Lilt up the cenlle il&#34;llfe~1 and remove lhe screw hom the bottom of the comp,lrtmen1 12 Remove the ;)rrn(CSI h"'\Je screws and place the ;)"nrest in the comp;),tment 13 Remove thc lwo screws ,I[ the hont end 01 Ihe iI&#34;,&#34;e~t rUSC out the cap at the r"ar 01 the console and remove th e scre w • Ca(elully lilt Oli! the 'eilr seCllon. I,onl s(:ctlon and console COlllpilftmcnt 16 Remove the he,ll "'5ul"tll1g pad Irom bene,l1h the consola Cornpnrtment ilr..,a
17 As appliCill)le. remove lhe eleeuical connector from Ihe base 01 cilch senlhelt s(;llk and rcmove the stn lk ".lI1g boll th,ouOh the top of thc consolc. Rcmove the stnlk ilssell1hly thrOuoh tlHl II1SIdc console suppo,!. 18 Pull the cMpet awny hom the SIdes of the 5UPPO,1 assen,bly. then detilch the support hy removIng (he eluht S!)CUW1!J screws. 19 Hefil!lnU is bilS'C,1I1y Ihe reV«($e ollhe !«Illoval procedlHe. hUI Illst ensure lh,11 illl Ihe splle nuts ilre corrCClly loenled on Ihe brflCke(s. Tluhten tile sefllhelt SliIlks to the specilied IOlque.
33 Sunroof piln el -ndjustments
Gap adjustment 1 When closed. a Unp of 5 8 10 6.9 mm (0.2310 027 "') should eXI~t hetwecn thc slIn(oof and (h e CM rool. II;) vmyl roof cover IS lilted. Ih,s gap should he reduced by 1 .78 mm (0.07 Ill). If adlllst'!\(Jnl IS requued. pwceed ns detaIled below. 2 With the sunrool hall open. remove (he sunrool heildhlunll hnlne 3 Close the sUllfool. then pull Ihe hei!dhnll1H hOIll (he Ie." and remove ,I. 1 To ndlust the hOnl 01 the sumoo!. loosen the front Uu,de relillnu1U screws. then whIlst p,essu1!J (he Uuitles IIlwilrds. lighten thc screws. 5 To ;)d,ustthe rear. loosen (he twa h.II1!) screws nt eneh Side of the ,1dlustinU hnsc. thcn p,ess (he reilr shdes mw,uds ,1"d t'Uh!Cn . 6 F,t the hCildllmn(J and hemU",,,,U h,,,ne 7 lithe ild)lIsunenl is slill Incorrect. ,emove (he we,l\hel$I"p from Ille rool panel ;)11(1 hend ,IS mountll1g lIange as necessary
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FiU 11.19 Sunroof controllllechanism (Secs 33. 34 and 35)
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)
Index
A
Accelerator cilble removal ilnd refining -14 shnft ilnd pedal removal and refining -75 Air cleaner removill Jnd ref,nrng cal buren or mod cis -68 fuel injecllon models -80
P rnator .,rushes inspecllon. removal and refilling Bosch -202 Femsa -203 Lucas - 202
dismantling and rcassembly -203
removal and refining -201 Antifreeze mixture -60 Automatic transmission descrip tion -122
B
downshift cable removal. refi11ing and adjustment -121 extension housing oil seal renewal -121 faull diagnosis -127
maintenance. routine -123
removal and refOlting -123
selector mechanism ildjustment - 126 rcmovill. overhaul ilnd refl11lng -125 speclflf:iltions -103 SI.1r1er IIlh'bilm/reVerse lamp switch remov<ll <lnd refIlling - 127 lorque wrench senings -103 'iliary (driving) light ,oIigrllnell t 212
Bilttery clrilrgmg _ 201 description and testing -200 removal and rcfll\lng -201 Big-end bearings -37. 52 Bleeding the hydr<lulic system brakes -152 power steering -168 Bodywork IJnd fittings -173 el seq Bodywork and fittings bonnet -186 bumpers -1 78
centre console -189
demister
noules reOlov<l1 and refi11ing -197
description _ 174
doms-178.180. 18210 185 face level vents removal and refItting -197 facia panel -188 fuel filler flap -188 heater -192 to 194. 196 10<ld space trim panel removal and refitting -186 -'alnlenance
) bodywork and under/rame _ 176 routine _ 116
uphOISlCry
and carpets -176 mirrors
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192 open rem quarter glass assembly
removal and refitting -186
re~r qllMlcr trim panel removal and refitting -185 repi'lir millor damaue -178 minor damage -176 sent belts -191 seats -192 sunroof-189la 191 lailgate -180. 187. 188 torque wrench scuings -173 windscreen -180 Bodywork repair sequence (colour) -174, 175 Bonnet release c<Jble removal ilncl refitting -186 removill. reflt1ing and adjustment -186 Bml<ing systll'm -14201 seq Braking system deseriPlion -142 lilUl1 di<lgnosis -156 fOOlbrake ped .. 1 removal ')nd rel ining -152 fronl disc brakes -144,145 handtHake -153 \0 155 hydraulic system bleeding -152
p ipes <lnd hoses -151 n1<lintcnance. routine -143 n1<lSler cylinder -148. 149 presslilc uIHe&#34;~llIial switch removal and relitting -150 pressure reducing v~lve rernov~llInd refining -151 rear drum brakes -146 10148 specif'Cil!ions -142 stop IJmp swilCh removal. refi11ing ilnd adjuSlmeJl1 -152 lorque wrench se11ings -142 vacuum servo unil -156 Bulbs. lamp 'Tenewnl -213 to 217 spcclflcntions -199 Bumpers removal and refIlling -178
c
Camshaft (3.0 litre engine) retitting -54 removal -50 Camshaft and camshaf t bearings examination and renovation 2 _8 litre engine -35
3 .0 litre engine -51 Camshah and front intermediate plate (2.8 litre engine) refilling -41 Capacities. general -6 Carburetlor (Weber) aulomat ic choke
adjustment -71 removal. overhaul and retitting -71
dismantling and reassembly -69 general -68 idling adjustment -73
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rernoy .. ' and refl Uing -69 spcc,'iC<ltions -66 Carpets maimcnancc -1 76 Centre console removal .. nd refluing -189 Choke . au tomatic _ 71 Cigar 'ighter romoval ;lIld . e 'ru in g -225 C lock (console mounted) .emoval ilnd 'clming 223 el,/tef, -97 cl seq Clutch assemhly ",speclion 99 relluing 99 remov;]1 99 calli e renewal 100 dcsc.illllon 97 laul l d'''[jnos.s 10 nMlllIon,wec. foulorU) 98 pcd,,' rCIllOVill ,mel fcllUII1\) 10 1 release bca"ng .emoval ;mll wl,ulIIU 100 Speclflc,uions 9 7 Condenser (3.0 lilre models ) lCSI,nu. 'CIllO"'o1' MId refllli,,!) 90 Connecting rods (3.0 l itre engine) 5 1.52.54 Connectin g rods amI gudgeon pins examina tion ilnd ICnov;'Jlion 37, 52 Connecting rods ;lnd pisto ns refi Hing ~ 42. 54 Contact breaker points (3.0 litre models) i1djuslOlCm -89 remov1)1 nnd refiuing -89 Conversion fac tors -18 Coofing system 57 CI SCII Coo ling systcm nnhl.cew ",ixltlle GO desC.i,l liOn 58
d'ilUlinU 59
(IlIvchells
G3 e~p:mSloll I nnk 6<1 Ian hub l)()nllllH (30 hilI] 1110<1111,;) 64 f~ull (II;)Ul1osl~ 65
flll".U -
60 lIush"'9 59
",nmlen,lncc. roullllC 59
'ild,nlOr
GO speclficn llon5 57 lem,)er;!lurc unuuc Sf:n(Ie. unil -134 IhcrmOSl<11 -61 10Htlle wrench selll ngs 57 VISCOUS drlv\! 11'111 -63 W1)ler IWIllP 61 Crankca se ventiln tion system 2.8 tol'c engine -39 3.0 rillC engine 53 Cranksh1)ft 2.8 li l.e engine examinat ion nnd rcnoviuion -37 refilling -<10
3 .0 til.e cn gine examination lind renOV1'l110n -52 Crankshilft and main bearings (3.0 litr o engino) removal -51 Crankshllft pulley refitting (2.8 hIre engine) -44
removal ( 3 .0 litre engine) -50 Crankshaft r ear oil seal (3.0 litre engine) .efllling - 55 .emova l -51 Cylinder bores ~xaminalion and .enovation -36. 51 Indo r heads 2.8 titre engine dismanll ing .• cnova lion and .eassembl y -35
Index
D
refining - 45
3.0 litre engin e
. eassembly -55 refining -55 .emoval wilh engIne -49
removal wil h engine in car -49
Decarhonising -52 Dimensions. vehicle _ 6 Dim-dip lighting system _ 226 Disc br1lke s scc Front disc brakes Distributor overhaul 2.8 hlle engIne -93 3 a !r1l0 cng,ne -92 rcmoval and r efIlling _ 90 Doors eXle.io. hllndle ,emoval and refilling - 183 lock 1Issernbly removal and .efilling -184 pillar swi lc h -224
priVill e lock ,ernovill and ref'lIing -185 fnllics tracing nnd feCllik al ion -178 remOle conlroi hnndle removal and refilling -180 Hlmoval and rell\1l11g _ 185 Irim j>ilnel removal and ,efi ning _ 182 window Irnm c
moul(II ng nnd door wealhcrSlrips
removal and refining -185 rcmoval and relining -185 wmdow glass removal and retilling - 184 window regulnlor nssembly
r emoval and relilling -183 Drivebelt s .emov,,1 ilnd refil ling -63 Drum brakes sce Renl drum brakes
E
Eloc triclIl.system -198 e/ seq Electrical systcm altell11110, -201 10 203
ilu xiha.y driving "ghl -212 bmlery -200. 201 bulbs -199.21310217 ciga. IighlOf -225
clock -223
d escrip llon -200 dim-dip ligh ling syslem -226 laull diilgnOSIS -19. 233 ""sher unils and rel1lys -225
fuse s -199. 220
headligllls -211 10213 horn -220
inSI.ument clUSler -22 1 inSI.ument vollage .egula lor - 226 Inmp5 -21410217 mninlenance. fOUline w 200 mobite r"dio equIpment - 226
precautions - 200
rildio /casse tte player -226 specif ications - 198
speedomeler cab le -226 Slmte . mOlOr -207 swi tches -223 10 22 5 lailgall) wash er -217 laHgme wipef -217 to.que wrench sell ings -199
w indscree n washer -219 windscreen wiper -21810 220 wi.ing diagrams -235 10 249
25'
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inlet manifold - 83
main system components remova l and refilling -80 m~intenilnce, routine -79
specificiltions -67 to rque wrench settings -67 Fuel pump carburettor system cleaning - 68 re moval and refilling - 68
testing -68
fuel inject ion system removal and refining -80 Fuel system (carbureUor) accelera tor cable -74
accelerator shah and pedal - 75 air cleaner - 68
carburetlor -66, 68 to 73
description -67 e~ haust manifold - 76 lault diagnosis -85 luel pump -68 fu el wnk -73, 74 fu el lan k fille r pipe -74 fuel tank sender unit -74 inle l manifold -75 mainte nance, routine -67 specifiCiltions -66 torque wrench senings - 67 Fue l tank cleaning and repai r -74
filler pipe removal and re fi\ling .-74 remova l and refilling -73
sender uni t removal and ref il\in g -74 Fuel tank sender unit (fuel injection models) -83 Fuses
G
general -220 specifica tio ns - 199
Gearbo~ see Manual gearbO K Gudgeon pins - 37. 52
pdbrake adjus tment -153 cable(s} and rod removal and refilling 155 lever removal and refitting -154
warnin g hght switc h -225 Headlights alignment - 212 assembl y: removal and refilling ~ 211 bulbs renewal-2 13 Heater assembly: diSI11(lntting and reassembly 8ehr - 19 4 Smiths standard and heavy duty -196 assembly: removal and ret.tting -193 contlols
adjustmen t -192 removal and refilling ~ 1 93 water valve (heavy dUly heater)
removal and re fitting - 193 History o f tho nlodal-5 Horn faul t tra cing . remova l and refilling -220 Hubs, front
bearings renewal -162 removal. ret lu in g and bearing adjustment -16 1 Iraulic systam (brakes) bleed ing - 152 pipes and hoses removal and refilling -151
Index
Ignition switch and lock -224 Ignition system -87 el seq Ignition sys tem amplrlier module (2 .8 l i\(e mode ls)
r emova l and refilling - 94
condenser (3. 0 litre models) -90 COntact bre aker points (3.0 litre models) - 89
description -88
dis tributo r -
90. 92. 93 fau lt diagnosis -96
firing order -87 mainteMnce. routine -88
spare plugs - 91. 95 speci fications -87
t im ing -94
torque wrench settings -87 In strument cluster ill umina tion switch -224 removal and refitting _ 221 Instrument voltage regulator removal and refilling -226 Interior lamp and bulb
removal and refilling -217
J
Jacking -7
L
lubricants and fluids recommended - 17 lubrication chart - 17 lubrication system
M
2.8 litre engine -39 3.0 litre engi ne -53
Main and big·eOld bO(lrings e~amination and renovation -37, 52 Main bearings (3.0 litro engine) removal - 51 Maintenanco , routine bodywork and fillings d oor ch ec k straps security check - 16 locks, door chec k Straps. tuellilte r C<lll flap lubricalion -16 locks operat ion chec k - 16 seat belts wear/damage /security check -16 underbody protective coati no chec k -16, 176
upholstery and carpets - 17 6 windsCtee n illld windows cleilning - 16 braking system
h andbrake linkage lubricat ion -16, 144
h ydraulic fluid levul check /lap up - 16 . 143 hydraulic flu id renewal -16. 144
line s and hoses check -16
pads ilnd shoes we." check -16 , 14 3 servo check -16 . 144 vacuum hose check -16 Clutch adjustment chock -16, 98 cooling syslem
coolan l leve l chec k/top up -16, 59 coolant renewal -16, 59 drivebelt condl tion/wnsion check -16, 59 leaks check - 59 electrical system
ballery elec tro lyt e leve l cheek /top up - 16. 200 equ ipmen t opera tio n check -16. 200 headlamps cleaning -16
253
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procarmanuals.com

fault diagnosis -172 leaf spling .emoval. bush renewal and refitting -165 maintllnance. louline -161 shock absorber remoyal and refitting -165 stabiliser bar removal and refitting -165 lorque wrenCh settings -158 R"ays -225 Rep.ir procedures, general - 9
Rocker e rms (3.0 litre engine) examinat ion and renovation -51 removal - 49 Rocker arms and coverl (3.0 litre engine) ref itting -55 Rocker assembly (2.8 litre engine) dismantling. examina tion and reassembly -34 Routine maintenance stt Maintenance. routine
5
Safety precautions - 12 Seat belts -191 Seats .emoval and refining -192 Sidelight bulb renewal -213 Spare parta buying -8
to carry in ca. - 19 Spark p lugs conditions (colour) -91 lemoval. servicing and .elilling -95 Speedometer cable renewal - 226 Stabiliur bar Iront -163 rear -165 Starter moto r
description -207
d ismant ling and reassembly -207
removal and refi tting -207 testing on engine -207 Steering column removal. overhaul and refitt ino -170 desc.iption -158 faull diagnosis -172 f,on t wheel alignmenl ~nd steering angles -171 gear (manual)
ove,haul and adjustment -166 removal and refittin g -166 maintenance. rouline -161 power steering bleeding -168 gear removal and refitting -168
pump femoval and refining - 168
specifications _ 157 torque wlench senings -158 track rod end balljoint renewal-167
whea' removal and refitt ing -168 Sump 2.8 litra engine
refining -44
removal and refining with engine in car -34 3.0 litre engine refitting -55 removal -50 Sunroof bracket and dr ive assembly lemoval and refitting -191 panel adjustments -189 removal and refining _ 190 Suspension lfnd steering _ 15 7 tl seq Suspension see Front suspension Imd Re ar suspension jtches removal and relining
Index
T
central facia - 225
door p illar - 224 handbrake warning light _ 225 hazard warning -223
ignition -224
instr um
ent cluster illum ination _ 224 light and windscreen wiper (Series II) -225 load sp':)ce lamp -225 steerin g column multi-Iunction -224
s top lamp - 152
Tailgate priv ate lock removal and relining -187 .emoval and refilling -187 striker plate removal and relin ing - 188 wnsher
nozzle removal and refitting -217
pump rllmov31 and refitting -217 window glass removal and relitting -180 wiper mOlOr and linkage remoyal and refitting -217 Tappets (3.0 litre engine) remoyal -50 Tappets and push rods el<amination and renovation -35, 51 Temperature gauge sender unit removal and reliHing - 64 Thermostat removal. testing and refitting -61 Timing gears examinat ion and rcnovat ion -38. 52 Timing gears (3.0 litre engine) removal -50 Timing gears and front plate (3.0 litre engine) relining -54 Timing gears and timing cover (2.8 litre engine) refill ing -43 Timing. ignition adjustment -94 Tools gencral -10 to cally in car - 19 Towing -7 Tyres
u
care and maintenance -171 presswes -158 size -15 8
Underframe
maintenance -16. 176 Upholstery maintenance -176
v
Vacuum servo unit (braking system) description -156 lemov~! and refining -156 Valves clearances checking and adjustment -46 . 55 Valves (3.0 titre engine) removat -49 Valves and va lv e seats (3.0 litre engine) examination and renovation -52 Vehicle identification numbers - 8
255
procarmanuals.com