check engine FORD CAPRI 1974 Workshop Manual

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Page 13 of 205

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: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.
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'6 Routine maintenance
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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 $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
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20 Fault diagnosis
Carrying a lew spares eM) :\l1VO you a lono walk!
WHhou t 100 ,ulIeh trouhle in the event o f il hrC<lkdown should he c,llllod EXI}(lflcncc ;md aV.1II.lbl!! sp.1c e w,lI mOdIfy the list helow, lout Ihe lollowOI1U noay ~;lIIC havul!/ 10 Cilll on IHO/(!$Slonal ,1SS'S '<lIlCC
S ,Im/( I"uys. dm/JI .1IIri ,:ollt'c/ly Y;'I/ II"(/ III h:;J(/ .~/I{I"III!lI:,lIJ {II"Y .:1H>II1I" to 11).11:/0 /I" .. fllllY '(ltllu.'.\'{ fit"" lin-,/lsllI/w'IIt
DrHII/mim [(JIm, (:lIlIdulI.~VI IIlId C""Ii":II"'HI~'." I'omls (;'s ;,/I/lII(.','I/)/e
IJllv/.'lmll(s) ,.'/I11:II/VJlCY IYl't' m"y suffu;t, SlIill!! {(I,ft'S S •. '/ of //111//:'/1,,1 "ylll bill/,S 1/1/ 0/ ",dlll/Ol 5<:;,11:, ,mil IlOst: '>,md.1UI! t"~II;III.1'1 /),111(1I1!IC Roll OlllllilJIMlt/y IIIl'l' Lf>llylll of sulillflll WIIC Lc"yllt of ci.:cIIlC,llllt·.
rUiC" Of mSIICC/IQIII;III'11 (eilllliot/blt' ;,S II.'S( I;IIIJIJ) OMlt'IY 111111/1 Il'mls Tow" Q/IC Iym(/Oll WJiClllloo/lllY ,ow/osol Llfll! 01 c"Yllle Oil SeMcI I eMI olltyr/wlIll(: /f",d Emeif/CoCY WII/({SCIt'ell W(JIm ({live cl'II$ Tube 01 Idlel IJ,1S((;
II Sllilro IU(l 1 IS Cil",c< I .• 1 Ciln dcs'Ollod for th(l pu'pose should hc uscd 10 m"l",l(~e rrsks of le<Jkngc Hnd colhsion damage. A IIISI a,d kil and il Wil,n,ng 1I1,1I1gI0. wh"sl not ill wesenl compulsory In Ihc UK, (Ir C
ohvlOusl y senSible ilems !O carry u addl1ion 10 Ihe nbove When 10urll1g nll,oad 11 mny ue advisnu le 10 carr y nddlllonnl spares
WhiCh, evon 'f you cnnnOi III thcm yowscll, could snve hav'"(J 10 Willi wh,le p<lrlS MC OUlillned The IlCms below lIIi'y be worih cOlls,derr"y
Chi/eli {JII( I (/U Ol/it' eab /es Cy/md/H " ",7/ IIPsll:rn AlfclI/MOt /)lIIsiles Fllel (Jump 111/1.11'1 11:11 Tyte va/vI! cote
One of Ihe 111010llng 0'ganlSilll0ns w<ll he ahle 10 advrse 011 nVil,l"bllrly o f fucl elC III lore'gll coumlles,
Engine w ilt no ! starl
Ellgillc taits 10 ((IIf) W/IL'II slilrlc r ()p vra le d 1' 1;11 h~lll.'ry (.ud,;,,!!,!, u~.., rlmlll'uolds, 01 push Sl.1rt) nnllclY 1(:rnllll.,ls Ions!! 01 cntlod,!d BaltelY ll.1,tll to hody dd"cl'vu Enwnc e(utll S I,,1)) 100Sll 01 broken Sl.1rtel 1II0lO r (or so lulloid) "",,,ng loose or IJroken
l\ulOn1 ;II,e II1!11srllr~s,()" seleClor ,n W'OIlIl pos",on, or Inhd)!' sW/lcli fHur,y '11""'Oll/SI (lr lu, sw,'ch folUllY
M i'ror mech:u"C.11 ,,,,lure (Se'lUre)
Sli"!~1 Or sole"ord 'ntorrloll rilul! (seo Chaplllr 12)
A
simple les t lamp is useful fot checking electrical fault s
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Fault diagnosis 21
Starter motor ((/rns cngino slowly Parti ali V disch~rilcd b<ltlcry (rClch"'!le. usc Jump INlds. or push
sian) Ballerv terminals loosc or COli oded Batte.v earlh 10 body delcctrvc Enuine ear th s tr,1p loose Slarle. motor (or solenoid) wiling loose Slaricr mOlr ill1crnlll laull (see Chaple. 12)
Engine ((/"'S normally but 1,1ils ( 0 SIMI Damp or dirlV HT !eads <lnd dlS1"h\l10r CllP (cr<lnk cngine and
check 10 ' sp<l.k) DirlV or inco.rClCtly g;1ppe(1 .1I51"h(lIOf pomls (If nppllc<lblu) No fuel In wnk (chcck 10' dchvclY .11 C;1dJU.etlor) EKceSsive chokc (hOI cn\JlIlc) O. II1su l!,clenl choke (cold CI\\)Il1c) Fouled or incorrCCtly \lapped ~pnlk p1l'\lS ('1I1I10ve. clean .11)(1
regnp) Olher ignilion syslcml",,11 (~ee Chapler II) Olhel luel sySlem 11Ildl (se c Ch"plm J) POOl compression MaJOf mechanic;1 1 l<l,hlle (ell c~lIllsh.11t \I',;1r ICClh sl"ppc<l)
Ellgine lires but will not fUll In su!hcicnl choke (cold flfl!)lIln) Arr le"ks al CilrUurC110. 0' mlill m;1",lolli FuClI sta,vatlon (sec Ch"111C' 3) []"lIast rCSIStor de!ecllvn. or OIlier 'H",II<HI f,lIlll {s.~e CIl;1""" ill
Engine ClltS Ollt ;1nd wilinOI roslinl
fngine culS out suddenly -ignition I,wlt Loose or d'$Conncetcd l T wi.es WCI HT Icads o. d'S I"buiOI C;1P ("lIer tr;1VC'SOll!) w;1'er spl;1sh) Co,1 o . condenser lallulc (cheek 10' SI);lIk) Olhc. ignition laull (see Ch,'plfll 4)
Eflgine mistires belore CUlling oul IlIcll,wlt Fuel I,,"k Cillply Fllel pump dClfecl1vc o. 1,ltcl IIlo .; k(H! (dwck 1m dellvl"V) Fuel tank hllcr vcnl blut;kcd (StII; llon Will II" flV,{Io"'1 Oil lI~h"'~II'H C,11l) C;1llJulCIIor nccdlc v"lvc SIII;klll!J (WIU.'1I1 "ppI1c"hle) C,1lUwellor leiS blocked (ha:l COIII,lIl1ln,Hcll) Othcr lllcl sys!Cm l<lult (sec Ch~,II<!I 3)
DISCHARGED
BATTERY
lSin.MIN
POSITIVE
JUfl11) Slart lead conneClions f o r neg!Hive earth vchiclesconnect le;1ds in orde r shown
fllgine euls Ol1t -olhor eimses SCIiOliS ovcrhC~ling Mnior mcch<lnic,,1 !<lilUIC (elJ cmllshMt drive)
Engine ovcrhe<Hs
Igllitioll (llo-clwrgcj wt1fllillg IigM illuminated SI;1ck o. broken d"vchelt felCn$IOIl 0' Icncw (Ch;1ptr,r 21
Ignitioll warning light /lot illuminBted Coollllll loss .Iuc 10 In!emnl 01 CXierr'JI ICJk<lile (sce Ch"PICI 2) TlIClmO~I<ll "clecllve l.ow 011 leve! fj.,lkcs hllldlll'J R;1(1"llor clomJcd cXifllllJlly or IlIICIIl<lIlV EnU"'e W<ltclw~ys cIO!JUC(1 'Un'h{)Il !IInll'!) Incorrcct or <lIIIom"IIC .1<1V;IIICC nl.lllllIlCI,OIIll'!j MIxture 100 we,lk
NOIC: Do 1101 ,11M coM WMCf 10 ,111 oV~-f/"'.I(C(1 ~·lIy"'., Of d,,,",l[Jf1 m,ly I/)SII/I
l.ow cnuinc oil JlfC!ssuro
G,wge reads low or warning lighl Illuminated wilh engillc
rWllling Olllcvcl low or mCOlfeel 0.,,<10 Deit.'Ctivc gllU!jC 01 sendCI 11111 Wife 10 sendCI UIII' C.1I.hC(1 Engonc ove.hC.1l ing O,lllllcr CIO!19c<1 01 byp,1SS v;1lvc delccllvc O,I ,llcssule lehef v'llve dc!ec tlve Oil pick-up strllll,e. ciomled 0,1 pUIllP WOIil or IllOlllllll1\l~ I\,osc Wo,n Ill,l'" 0' h'!J-cn(i hC.1I1I1!)s NOlO: Luw or! 1"t'HlifU III a IImh III"C"f1~" (.'IIYIIIC .J/ 11l;~()VI.'r I.~ 1101 1II.'I:<.'",.","/y,1 (.",lIlSV {o, CIIII{:"/U Suddel! fJf'~SS!lle {U$S ,11 SlIced IS {M "'/!IC SI{Jl!lflca"l (I! ,my cve/l/. .:In',·j. I/le .<I,U/ye or ...... l/lllllyl,yIJ/ S(1/1(h'f /)<.'/VIC cIJfI.h·flllm,y 1/1<.' C/I!l1IJ1!
Crank engine and chock for Sl)ark. Note use of il)sulated tool 10 hold plug load
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) Chapter 1 Engine 27
oint t ighten II ~ further 3/4 l urn ~ Remove the t,l ler C,ll> all the left· hand side of the engine and I,ll the g ine with th e correct quantity and grade 01 od (photo), ;n RemOve the OIllcllcl dipstIc k and wipe it clenn. th en fe -insert'! and emove it Jg<llll The all level should b e up 10 the Ill,UimlJlll llliHk ;phOIO). but nolC thnt Ihls check is only nCCUJiltc ,/ the C<1I IS on level
grourod. 9 If neCeSSary. lOp up the level nOI1l19 thaI the diSlnncc between the minimum and 1l1.1X"mHll level marks rep rescms ,1pprox imil\cly 1.0 hIre
(1.76 p int). 10 CICJfl the 0,11,1101 CilP then refit il .
Check and adjust valve cle<lmnces
11 Refe r 10 SeClian 35
hgMel) inlet manifold bolts 12 Remove the ,111 chamiler and \'oh\on the Inlet 111.11"lold hnlls ({J the spec ified lOrque WIth Icfcll!IlCe t o Ch~ptl!r 3 On compl"I")1I ,(:111 Ihe
JII chnmbcI
R enew (fie crankcase ellli,~sion valve 13 pulithe v(1lvl.' (1Pl(I'hose 1'0111 tlw leM 0 1 Ihe "ohl·l1(1nll locker caver
(photo). 14 [1.clc;lse tile cl'll ill1<1 ",movc the v(1lve foorn the h ose 15 Fit the new valve.n levr:rse ordel
3 Major operations possible with eng inc in car
Thc fol lowrng ma lo r operat,ons Cilrl he C;1<ned out WIthout removing Ihe CIl\IIIIC from the CM.
(,1) Removal al>d rufilliny ollfl~' cyh,,(h,r heiufs (h) Removal ami rehlllilg 01 rocker shall aml/lllslliods (e) Rcmov,11 ,m(/ ,elilllilg of {'Or!( elwine mOllnlings (rf) R/,fIIov,rI ,11[(/ reliltirry 01 (lie flywlleel (geillbo>< lI:muved) (t') Remov,ll amI rufl/liny olille Slimp 011(1 oil f)(!fIIP (I) Re/IJov,)1 ,11111 rehltiny of Ilw liming yl."ilf$ (y) RCIlIOvo1l ,mil relilliny ollhe biy-crlflln',llinys
,
(It) Rl.'tttOV,ll ollnf ,ellllmg of IIII.' 1".'·(Ofls ilfld cOrlfleelmy rods (,) Rcnewal 01 tI", c ,i/nkslliplt 11(1,,1 Sl'it! rtI IIIIII"y C(lVCI
4 Major operalions requirillg erlgirlo rO!lloval
T he followlllg IHaJOI opernl'OIlS ,,,.IV I", Cill!ICli out ilfl'" 1t'l\1o,",ll of tir e englllC:
(<1) Rcmuvi" iJllr! Id,lllIIY 01 If." ,.,.ttt~Sfti"l .,11(1 II>,1ftl 11,-,tlIIIYS (IJ) !1ellclV,11 ollfw o,wksft,dl II'." .~,.",
5 Methods of engine removal
Althol!OIr It ,~; flo~~lllle to .. ,1)1,,\·,· tI .. , "WIlli': .:Illd U"iU!'vX <IS ,111 ils~c,)lhly ,t IS 1"':OIlHllellllc1l th,'t th" "II!I"I<, ,S "'1\10v(,1! ,,~ ,I ,;OP<I ',) k Uil il If t))(, ell!)"'!! '·'1111 ~lendlOx ille II·"'"v,.d .,~ ,ill ,hSI:mhly 01 11ilS to I,,) hft,.,d Oll l ;, 1 n '"'''v ~t"l;p o1<l(Jle ;111(1 I", iI"~ .1 '.()n~ ilcl.1hl(, Irlt."\) he'oll! IS rcqu"cd 2 If the wo,k 1>')IIlg \IIldCllilkcn 'C'I"''''~ Ih ... 1(,IIIl ),,)1 of tl .. , \i,),IIbo~ ,IS well as the (:1l!1" 1" ,t 's l ecomnH:lld,'pJ 11\,11 tip,) O",Hho x 'S ,,,,OlI<.)v()(1 fr'~l (nil"r to Chap('" 0)
o Ellgino rcmovill
II IS t',,-,,.'IIII.-,1 If! h,v" <1 fl<wd "'!I_'1. ,,,,,I lI\1i 'IAf" sl,mds rI "" IIISI)I."(;/io" fill IS 1101 itvad,11!1e lltu $1!i("""':L' 01 OIIL'I,111utJS I'SI,'d m II,,~ Sec/lull'S !lol ",llcal ,H Ilic 1)(I$,liOIl 0111"." fWf~()1I "n(/",I:'''III!J II".' Ivork . 01 lite /001 III IllS Iwnd. Will (/1."lcr/mllt' 10 a ccrlaill CXlt'lII Ilic ut(lv, ill ,vlllcil the IICCCSS,lIV OPI!l,11wIIS illC /let/ortt/cd ObvlolislV /lw '."tI{f1ll1.' C,lllllOI Iw ,ctt/ol'cd 1fI1111 cvcrylf""fJ IS dl~cotllrccl"'/I 11I1tt1 II i,,,d tlw lollow"'fi $"(fIl,'IIl'V Will el/~(tll.! IIt. ·It rlOI/""{J IS 10I901l<:fI 1 Removc the bOlll1c t "s descllb"d '" Ch,lpw, 11 2 Disconnect thl! llilth)IY ncg;rtlvl.' le.,,1 ,IIHI Ih e ealth l.ill,IL' frun , lh,)
,. '~ , I\; , .,
28 E[lO"lc 011 levI;[ d'pstlck ma,kll1gs 2 13 Removing the Cfankc<1se cnHSSIOIl v<1lve
62 Ea'th cable Oil the alte'''''lOl adl"slIllt:l1t u,,,ckel (<H,owl.!d)
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ClliIpter' Engine
22 Unholt the thcrmOSlilt INlr Woller eillow R()llloVC the ~Jo1~kCl 23 Unboillhe 1II11Ing cover "ml relllove the UaSkCl (photos) 24 Ullscrew Ihe bolt securing the r..~m~h;'lh {le.1. 10 the Cillll$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
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Chapter 1 Engine 35
3 Examine the rocker shah ,md ,oc ker il,ms for we~r, II the rod", alill rl tha t conwcts the valve stem IS conSiderably worn. n,new the " ."'"nl I f it is worn shqhlly step-shnped it may be cleaned up wIth rOc e r ". . a fi ne oil stone. . , commencing Jalluary 1984. modolled ,oc ker shah sp"nOs have ~een fi n ed. Where wppet no,se IS evident 011 e~rlier models hl'lw",en e n g ine speeds of 1500 ,111d 2000 'p'll. the later type 01 SP,,,llIS nl.1Y he
I , n ed .
.
5 Od t he parts and reas~r)!llhle them on therr shahs III thO) n"lI,n;.1 or der With both rockel shafts f,tled the 001 holes must face downw.l,ds to th e cylindel heads Th.s po~"tlon IS lIl(hcated by a notch 011 Oil" "nd
lace of th e rocker shaft
13 Tappets and pushrod s - eXill11inalion 1It HI renova tion
I Examine the v<llve 1;11'1"'1'> 101 wr:<lI "nd (lan1.11Ie. r",new II ~I,·,t"'Lt 2 Check the pusluods for ~"I"S 01 hendiPl\l or we"l Co",,<;t '" 'o:11O".\'
JS ncceSSary .
14 Can,shaft ilnd ciln ls h Hft b earings -cxmninatio n "" d
rCll ovntion
II there is excessIve WO),11 III lhe camsh;lft thp.y will h,lVl! t" lJ" lunc wed. As the 1'1lI1'11 ul '''"1'11 Iwarrll\lS w!(lI"es speel,lI [(",I, thl~ ~houtd be left 10 your 10c,, 1 FOI(! dealer. 2 The camshaft n1;IY show SI\II1S of wear Of) tlH! I)(:''''''!I 1""""'1s 00 C;In lobes. The main d(:elsloll to lake IS what de!)",,, "I I'll"," n ec e ssitaleS renewIng the camshaft. which IS e xpensIve S<:'H"'!IOI da",~ge to t he bearIng 10",()"ls cannO I he ren'OVNI hy ''''I,,,,,I'''!I. runew,)1 0 1 the camshnft IS the only so lutioll J The CJm lobes mny show SlUns of ridgIng or piltmg on Ill" I"U" poin ts . II ridging IS sllghl then It may be pOSSIble 10 rel\\OVC It woth "
lonc oil stone or emery clOlh. The cnm lobes. however. ;"" ~urf;It:e hau Jencd nnd once the h<l,d skill 's penetr;lled wem Will he v,,,y '''pld
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15 Cylinde r heads -dismantling . renova tion and rCils sembly
Clenn the d "t nnd oil off the cylinder he<lds. Renlove lhe carbon deposits Irom tlie combusl10n C I\11'11be,s <lnd vnlve heads with il scraper 01 ,olary wire brush.
2 Remove lilt! valves by comp,ess>llg the valve springs WIth a suiwble v"lve spPlng compressor and loft,ng out the col lets, Relense the v<1lve sprin\j compreSSOI nnd remove the v<1lve sp"ng retainer. spril~,) ami valve (photos). M;llk each valve so that Ihey can be fltled u, the S<1me 10CfltIOn 3 WIth th" v,llves removed. clenn out thC Ci1,lJon Ir{)m the POltS l EXnlllUH! the hearts of the valves nn<lthe v"lve SC,lts for pIt lIng and l1urn ll1\1. If thE' p'tton\l on vall'c and sent IS 511\:)111 II CJll be removed by Uflnclong the v"lve~ and sents togelh(" WIth coalse, ana !hen fIne. valve ~1"ndon!1 P"~h~ Ilihe jll!1lnu IS deep l1lo vnlves will h~ve to be leground on" v;,lv" O""dlnUl\1iJchinc Jnd t h(: S(:ilts WIll have to be reCli t WIll' iJ v;Ilve So,It CUlh" rloth these op(:ratlons .lre n loh 10' your 10(";,11 Ford
d ..,;II(:, or nlUll>l fJngmeerini) speCIalist. 5 Check IhE' valves guides lor wear hy "'s(:'II"U the valve on tho (J",de. the valve stem shovkl move eJslly '11 tho gUide withoul SIde
pl<ly R()newa l 01 wOln gui(lcs requires speelnllOols <111(1 should be left
t o yOl H 101:,,1 Fo, d de"ler G When !J"ndlnU sllgh11y pIned vnlvcs ,'11d '· .llve se"ts w ,th ca,ho,uIHI"ll) pas1e pro1:eed as fOllows Apply ,I Illtio coalse I) "ndon>! p;,S1C !O tlo" valve seal <Ind "S"I~1 ,1 SuctIon lype valve fJ"lHlrn\j tool. UIIl1d th" v"lv" ,nto I1S scat w'th n scnll-IOWry 1\10"':~1ll0'11. IIftu'\I the vil lve fro"" Hm o to li"lO. A light sp rmi) under the valvc head WIl l ass,s l '" 11"5 ope,,,tl"" When a dull mati even surface firnsh ,'jlpeJ,s on bOlh the v"lve ,,,,, I the v;llve seat. clean off the con,se paste .lnd repe"t Ihe \1,ond,nU OP,,,;IlOOI' w,th n I, ne grindln(J paste unli! n contInuous rlnn 01 trUIH U 'ey l1I.1tl I"llsh appears on both vnlve nnc! vollve seat C.1refully
clean off ,III lr;lC()S of 9,in donu paste . Blow Ihrough the gas pass<1ges With comp",ssed air 7 Check the valve springs for dn!1ln\le and .1lso check the free len\jth. rcler to the Spceo/ lcntions at the beginnong of this ChJpter, Renew II defeclive .
.. ··'1:
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,r· ' .
t5 2A Comp' ess the SP'Ii") woth II valvlJ
! ' Il "nU comp,esso, . 1
5 .2£1 thu" """ove the collets (n'il\l'lellC 15 2C. followe(1 by the ,elnmer
1520 ... an d valve SP"Il\!
p,ohe show,,)
t;. "" &' '
'('ii" " 18 ... ,,,
'" ' .
. '
15 2E RlInlov,nU nil 'nlel valve 15 2F Inltl valve (top) and cxhnust v<1lvU {bot 10m) COlllpo"ents
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Chapter 1 Engine 37
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17 8e Tho socond compress,on " 11\1 I~ steppr:d
, .,
4
cOI"es out 01 I1S groOvO. ;;Ippll' sligllt IIpw;;Ird P":SSlJIU SO tlt"t rt ,,:~ts on tllo 1,lrI d ,1bove , It C;;In thon be e<1sed off the pr~ton. wo1h the I,·der u~uge stopping II Irom sl lppllll) 11110 ,1n I:mpll' ~llnov" II It I S ;1rI1' Itut thu tOil pislOn ring thilt It being removed (phO(OS) !l The piston rings must always I>e remov"d trom Ihe tOp 01 Ih"
pi~10n. 10 C heck that the piston ring grooves and ollwal's ,lie IholOl1uhly d CJn Jml unblocked. Piston rings IllUSt ,1lways be hilI,!! (Jv,n Ihe he;){1 01 II,e pis ton and neve r from the bOllom II Th e eilSiest method 10 use when linin\) ,inUS 'S 10 WIHP <l leo lo, \1''''Ue rOlmo tho top 0 1 Ihe pistoll al1(1 place tho III1US on one "t <l (lillO,
. ',lrl'llg wnh tho bottom 011 contlol IIIlII. ovor th" lee le' \FI1t\le The 1~'o:Iel (jauUe , complete wilh rlllO. can then he sl1d down thl) piston ov1!r Ih<) Olher p .ston linn groovos tullil the COIlf:Ct (l!Dove IS ,e<lcll<;d The II'~IOI\ rin\) is Ihon slul olf Ihe leele, 11<1"Ue ,1110 the W0I)VO 12 An alte'nolt,ve mel hod IS 10 I.t the rnl\l~ hy hold",!) tll"l1l ~;"(Ihtly opI~n w ith the thumbs nnd both 01 Ihe ",ril:x r,nqels ThiS II 'elhod '"C[uorcs n sle~dl' h,,,,d ,lIld Ilre,l( C<1ro ol~ il is ei'~1' h; Dllell the ""!! to<, much nlld lltcak II
lB C onnecting ro d s and gudgeoll pins - exami,wtioll ;;Inri f"novation
,
Gudgeon p IllS "ro n sllrlnk fil IIitO the cOl1l1eCllliu wds Netllter 01 lh,,~~ would lIo'1l1~1I1' l1eed .enewal lInl,)ss (he p'stons woro 1J~mq ~h.lnucd. III which case the lIew p'S tOIiS wOlild 0111tol1li$1(;,1I1y h~ ~lIpp"ed Wllh IIew $lJ(IUeoll pillS . .2 C OllllcCtlllU lo(ls are nOI subject 10 wear hut 111 extr<:Ille tnCVIlIS1"IICCS such as ellUlIle se.zure Ihey could he dlstoll~d. Such (OO(I"lons Ina I II h 'I' )~ V'SUi' I' ilppiliOlit but whew doubt e XISIS th"y ~ o uld be checked lor o1l1gn1\\onl ,111d II necessa,1' rellewed or W,l'gh(ened TI " . 01 file )",1.lIlg Caps should ~Iso he ex""I1l1ed lot I!uhcauofls (h I tng ?own whiCh may h~ve been <1ltempted in Iho misl<1ken ,deil .11 heanng slackness could be romed1ed III t hiS wal' If Iher e DIe such !I'Ons (hen (he c F d onllect",u tods <1ntl C<1PS should bo rOllewed hy your 0' ')!lent or locill elluinee'lIlg speci<1hst
19 C r<lnk sh aft -eX"mill<ltion {lnd renov"tio n
~c.a ~~~ll1iIlO the malll ho~,illg louillais nne! Cfo1l1kplllS 10' score 1l1.11~S or Oval~ es. Also check thom tor ov,:tltty using <1 micromet"r (pho(o) e,ce~~v~n excess 01 0025 mm (0001 III) should he .c!)<lrded as
2 CO
llt.;rv I e.c , 0 nOrmal praCtiCe. For d stipulate that undet no , umSIJnces sho II I exces s' U ( tie cranksllillt be .e\)tUund; so tI d,III'J\)e o. cr~nks~a~t.weJr <s eVldelit it Will be neceSSJrl' to Oil",Ul J !lew
, . <,

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3 II the old C"ll1bhollt 'i b.."nH rel'lI(:tl. ch"t:k ttl,1I tl'" o,lw~ys ,1I1I cle,lI Th<s Call he done b, pro hlliU w,tll Wile 01 Ilv ulow,n\) thrOll\lh w,th <111 ,111 I, ,,,, '111..,11 111S[·'·. Ille lIoale 0 1 aI' 011 gUll .1110 the leSp,-,\:tlve o,lw,ll's. eaeh IIIIU! 1J1 <llll11U 011 the p"WIOUS lIolp.. <1rl(l ~qll"t od tlllOllUh Ihe ~I",fl II sholl'c ,-"u e'lle th'OIlUh the Iw xt hole Any 011 will' block<1g e n',,~1 <lIN'OUSt. be cie<1ne(1 OUI p"o. 10 rehllIng Ihe
cran kshollt 4 Check the ,PI!JOI be,1''''!J III the reil' 0 1 Ihe crJnkshalt and ,f
necessary .ene w It
(photo ·
20 Main <111(1 hiu' Cl1d bearings -e~<1ll1ilH!tio1\ and renovation
W,lh C<llCllll s.."v'ClIlg ,\lid ,eU\Jlolr 0,1 ,lIltl f, llcr chJnges. bearings Will last lor ~ ve,y 10liU :'UlC, hul th~y C<1n sltll f,1I1 lor unforeseen reaSOliS W ,th blU ·end b~a''''os the 111(1IC<lI<Oll IS ~ ,egullH .ythymic loud knockIng 1'0111 t h e c-ankCilse The irerl'leocl' (lepen(is on en g ine speed <Inti ,5 pJ<tlCllla ,ly nO(Iccal,ll: wl'lIli tile enu,ne IS undc' 10<ld.
TtI 'S sympt orn '5 ,1cc on,p~'II':HI!Jy " 1,,11111 0,1 P'l:SSuro). <1lthough th is IS II0t normolllv not.ce<1lJll: ~nluss all 011 p,,,s su. e U~lI\)e IS hlted. M olin be"r.nu la,luI~ IS usu<1111' "d,e<11l<d bl' sel'OllS v,h"1I10 rl. parl,cul;lrly al h lghe. enU",e .o)vulullon, <1ccolllpa n,ud by a mure SIUn, f'CJrll d.op '0 0,1 p.essu'l< aod a '1lIlll!J 1 ng' 1101~e
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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,'~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~"d lho undcilny O''',,[lo cd bC1'lllIlIJS will be PltI..,!! [)r scored II the 1:,;"'~!>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"!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";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~," 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'I"~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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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

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