check oil FORD CAPRI 1974 Workshop Manual
Page 10 of 205
General repair procedures
Whenever scrvie,,,U. repair or overhaul work ,$ c;nric<i out Oil the eM or its components, ,t IS nl:c",ss;uy In nUsc."o the lollowtll\j procedures (Iud ulslruct'{JIlS. Ttus w,lI assis t III ca"ylll(j out Ihe opcrJlion eff Iciently ,1nd to " p,()lcsslollal slanlia,d of workmimstup
Joinl mating ftlces ,7l1d gaskets Where 1'1 gasket IS lIsed tmlwl:CIl the ",,,,ill\1 [<lees 01 two components, OnSlIr(l Ih;)t It IS renowed un Icassclllhly. Bnd 111 it dry unless O(IHJlwise Slaled III the rcp;Hr plOGcdw() Milke SlUe that the nmling (<lees nrc cle;m [lnd dry with "II II,lees of uld \Ja~;kCl rClllov ct1 When cleaning 11 tOnH j<lCC. use il 1001 which,s not likely to scorc Or dalllil(lC the l<lcu, [l1ll1 reillove <lny 1>I'''s or nIcks wnh an oilstone or hno Ide.
Make SUfi) lh,,[ tnppcd holes nrc ciedncd WIth il pI pc clcilncr, and kcep thcm flcc 01 101l1llng compound If tillS IS helll\) used unless
speCIfIcally Instructed otherWIse Ensure that "II ollfrtes. (:hannels 0 1 pIpes ,lie Clt'ill ilnd blow thlough Ihelll. p,eleriluly llsing compressed ill(
ai/ seal s
Wheneve, nn od sCill is removed flom its wOlkll1\1 10Ciliion, eIther mdlvidu"lly or "s p"rt of iln assemhly, It should be lencwcd The very finc sc"lIng IIp of the sei'll IS e"slly dama\Jcd and WIll not seal If the surface it COI11<1(:15 IS not completely c lean and free frOlll
SCHl\ches, nicks 0' grooves. If the o'iginal scaling surfi'lce of the COlnponern cannOI he restorCd, Ihe component shoul d he renewed, PrOlect lhe lips of the scal from any surlace which mi'lY damage them in the course of fmlng. Usc wpe or a conical sleeve where POSSIble, LUb ricate the senl lips WIth 011 befole fruing and, on dual lipped se"ls, fill the space be twcen the hps With grease. Unless otherwise stated. all seills must be hlled with then sealing hps toward the lubricilrH to he seillcd Use iI\ubuli'l' <111ft 01 block 01 wood 01 the npploprime sIze to II1sta ll
) I he scal ilnd, lithe sCi,1 housing IS ~houldeleu. drive the seill down to the shoulue,. If the scal hOUSIng is unshouldcred, the seal Should be fItted with its lace flush W ith the hou$lIlg top face,
Screw IhrCiU/s and lasleoings Always cnsurc that a blind t"pped hole is completely free from orl. U
reilSe,
wilte, or other flUId hcfore instatllng the hott a' stud. Fililu'e 10 do tillS could C,luse thc housm\) to c"lck due to the hydrilulic <1ction of the bolt or slud ilS It IS sc,ewed '" When tluhtenlllU ,1 cilswllilled nut to ilCCCpt iI spht pin, tIghten the nut to the speCIfIed torque, whele ilpphcilh le, and then lIghten furthe, to the next split pin hole Ncver slilckenlhe nulla "lrgn a spirt pin hole unless ~t<l1ed III the ,epil" plocedure When checkIng or retlghwnlllg il nut or holt 10 ,1 specified 10'Que setUIlg. slilcken the nul o r bolt iJy a qua'ter of a turn. "nd then retighten to the speclflcd setting
Locknuts, /ockt.1bs and wasliers Any fo1SlC(1Ong which wdl rotate agaillst a cO!llponen! or hO\ lsing in the course of lI\)hlemng shmrld illways hilve a wilsher between it ilnd the relevil"t component 0' hOllSlllg Sprm<J or spirt w.1she,s should illwilyS be rencwcd when they ilre uscd to lock a c'"trcnl con'ponem such n5.1 blg·end beillmg letalll"'g nut 0' bolt. Locktilbs which il'e fohied over to re t;1in a nut or bolt should illwilyS b e renewed. Self -lockIng nU1S c<ln be reused in non-crit'cal il reJS, p roviding reSlstJ l1Ce Ciln be felt when t he lockmg portion passes ove, the bolt or stud th,eild. Spht pillS must always be ,eplaced with new ones 01 the correct size lor the hole.
Special tools Some repal( procedures III this manuill enWil the lise of special 100ls such ilS il p,ess, two or t hree-legged pulle,s, spring compressors etc Wherever pOSSIble, suitJble ,eildrly ilvailable altcrnatlves 10 the manul(lctu,ers special tools a,e descrrbed, and are shown in u sc. III
SOllle Inswnces, where no a lterniltlve IS poss ible. II hilS been necessary 10 resort to the use of a manufilclurer"S tool and thIS has been done for reilsons of safety as well as Ihe eHlcien! completion of the repair
operation. Unless you are highly Skilled ilnd hilve a thorough unde,standlng of the procedure desc(lbed, neve, " tWlllpl to bypass the use of any specl,,1 tool when the procedure descrIbed specllies ils use, Not only IS I here a ve,y great risk of pe,sonal Injury, but expensive dillllage could be causJd 10 Ihe components involved
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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
)
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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7
F a ult diagnosis
II)/lodue/ioll The vt!HCI.., ownor who cicIlI s Ills Or he, OWII 'l1;'IIll!:Il;lIl1.;U iu:,;()!(Io IiH 10 Ih o reCOln r11Clldc d schedules should 110 1 h(lv,} to u~e Ilus ~C(,;tIOIl o f Ihe nl<lllual vc.y ohen. Modelll (.:OI"pone'\! ,,,II ... h,hly is su(';h th ... !. wOYlded \h050 'iems sullleCI 10 we.l. o. dth,IIO,,1110(l ,lte nlS IK!C1ClI or IP.ncwt-d "1lhe sl>CClf'ed ullervals, sudden 1",luIO IS CO"'IIo1I"llvl:ly .;lIC F;'lullS do nOI lISU<ll1y Just h:lPI)C1l as il ,(!'Suit 01 sudden f,Hlure, hUI (h~\clop over 11 period 01 lUlle. M;'Jor mC'ch;uIICal l(HlufCS ,1 P;lIl,c\lI;" "H,) usually preccdcd by chnro1Chmsl'c symptoms OVC< hundredS or (:""" rhOllSilnds of mIles . Those compOl1en lS willch do oCC;15;011"lIy 1,,,1 ""lhoul wn!l1l11g ille ortcll smnll ilnd OJas1iy c,l,,,,,d III 1111) vehIcle W,th ,lilY ",,,It IlIldulU, Ihe I,,~t ~tep IS In ("X:I(le whclI) In heWII """-SII!I"III.ms Sometimes IIIIS IS Uilllll)"S, bill Oil 0111", OCC,'~IfIllS "
I,ul " dell"l:lIl1e wOlk w,1I he 1I~'Cess;lIy The OWIlt]! wllo III"kes h,,11 ,I 110/,,11 h,lpll",,,,,1 ildlustmellts 0' ICplaC'IIl'Cllt s II"IV he ~"cce:.sl\ll III
1:"'"';1,1 I""it (or tiS svmplO"'~), hUI he w,1I toe II0lle t ill) W'~H'" 11111 1.11,11 l eC"'I. ,111<1 he m,ly well 1I,llIe ~penlnlOle 1'llIe lind ",olley Ihnll WIIS """"~~;"Y A COdlll ilild IO!JIenl "PIHO,l<.;h w,1I be lound 10 Ix: """e ~,'I'~I;I(.tUlv '" Ihe 10llU lun Alw;IYs I.I~" IIIto ;Iceollllt ,IIIV W,,,""I\l :"!l"S h. ,'IIII<III""lIlIes Ih"l "','y h'l\Ie heen notIced "' Ihe !)CIIOt! I",~'"d"'\l 111\1 ' ,'ult powe. loss, III;Jh o. low U'"UU() fl:adll1Us , 1I11\1slI,,1 no,~()s 01 1>11''''15, etc and .cIII(:u,he. thill I,ul\l.e 01 cO"'p0l1clll5 s\lc h ,,~ t\l~'" (J, ~p,"k pluus IlI<JV ollly he ('Jollllels 10 sOllie u"dcdy,,,\! 1111111 II", 1',lIle~ wh,ch lollow h(:le 111C ,ntendcd to hclp III Cil~es of f.ld\l le I" ~I,"I ,It to,e.lhlowII on Ihe 10,1(1 n","e IS ;11~0 ,I F,1U!! O';'O"OS'S S"I hll".11 Ih.: I.!nll 01 CilCh Ch.'ptcr ..... h,ch :.lIould he cOllsolh:!1 " thc 11"·t"",,,,,,.,. 'II ...... I.;s I)IOVe u"""ulul VVh,ll1.!ve. Ihe I;lult, ce'I;I'" Imslc 1"""·'1,1,··, "1'I,Iy The~ alC i1S tallows
VellfV Ihe Iilult. Tills IS sII"ply " III,'IICI of hCIIIU SUIC 111,11 you '''''N ".1',11 Ih(l sYlIIl'lOll1s ,lie belolc ~I,IIIIII!I WOII.; T lus IS p;ullcul,IIly ""1"'-"1,1111,1 YOU ille IIIIICSItU"IIIIU i11,1IJ1t 10' SOlllconc else who IIIilV 1101 ha,,, ct(:~c"1r(:d 'I lIe.y acclllately
0011', Ollerlook Ih e obviolls. Fo, e~a",ple, II Ihe IIchlcl!! W01I'1 ~I,'" '~Ih.,,," p(:llol lf'lhe IiInk1 (Ooo't l;1kc anyone t:lsc's word all Ihl$
1).111 'Cul,,, POIII!. ~IId don'l t"l~tlhc luel UilUUC cllhcll) If i1n clCClIlcal 1",,11 I~ ,,,cr,c,lIed. look 10' loose a. bro~ell WIICS belo.e dIUU"'\! OUI the Ic~t !/t;ill
C
U'e tI,e (liscase. n o t th e sym ptom. SuhStltUllng a flilt b.1ltCry ""til il 1"lIy ch;IIW,d olle Will \jt:t you 011 Ihe kUII shouldc., hUI II the \ul(!~dy,,,\) C,IIISC 'S flOt i1Hendel l to. the flew hall", y WIll fJo Ihe SdillC
W"Y S'''"I;nly. Ch,lIlUor,U OII.loulcd spll, k "lu\JS 101 ,] new's\lt W Ill \JCI YOu "'O'·,n!) "11"orl. hUI 'CIIIIIIIII,c' Ihill the .eIlSUIi 10' Ihe lou I",\) (II II ..... ,1~I1 I ~''''!''Y .111 ",colleCI U.;I<lC 01 "luU) WIll hilllC 10 be eSlilt)t.shed ,'nd CO"I.!"I(;cl
.
OO'."t t" k l) iH, ythinu fo r g rante d . l'a,"cul<J<iv. dorfl IOtgct Ih"l il lit.:"" COIIIPOlien t may IIs(:11 Ill! del..,c\lIIC (espec,ally II It'S t)(lcn
'illll,"U II,ulullllthn hool 10' Illolllhs). "n(1 do,"1 1');I~e compon.'nIS out 01 il 1,1\111 diilUnOSIS ~l:ql""'CC JuSI 1>e(;;I"$C Ih ey ",,1 IIew 0' ,,)cen lly IIll",d WII"" you tio IIIInily d'iI!./nosc a (f,IIIcult lillllt, vou'li ('JrOhllbly .""I,se Illill "lillie cIII(lel1(;c wilS IhelC IrO"'lhc stalt
Elcc(ricall,1!1lls EI.:.'Ctrlc,,1 lilults 1':,1" bc mo,e I)uullnu Ih'lII SI.aIUhlfo,wa,d "'CCIl,11I1CIII lalhucs. hut Ihcy MC 110 less susceptible 10 10Utc;ll "n"IVS'S
II lh!1 haslc pllnclplcs 01 OpClil llon ille 1I1I(lelslOod. Vchlcle clecillcill WII"'!) C~ISIS til c~lIcll1c1y "nl'I\IOIl."lIle condi!t Olls hent, IIlb.atlOIl IIlId chcllllcill ill1l1ck :1ml Ihc 1"51 Ih,,,ys 10 lo,,~ 1o. ,lie 100'>1) 01 ,;OllOIiCI I connecliolls 011,,1 b.oken o. Ch.llc(1 w"es, CS!lCc.I"lIy whcre Ih.) WIll'S I';)SS th'Ollllll holcs "' Ihe bodywork 0' ,lit) suhJ ... :I In IIIII'ilIl011 All '''I.!wl·l,o,hed V .:IHcles III CUllcnt prOdur-IIOn h;lIIc one pole 01 Ihe lI,ule'y 'Cil rl hutl'. Ie connecled 10 Ihu vchlclu hodvwOI~, ilml III
lIe"dy ,111 I"orle'" vehlclcs II IS the neUIlI,v!) ( ) 1e""",,11 Thl) va"OU5
"tU(:lu(:;,1 (:o"'tlOIIenIS mOIO'S, bulh hOI(lll'S elc . ;I.e "Iso cOI"'('''I:I",(1 to e.II III. ellhe. by lIIe,lllS 01 a leild or \1"~'Cllv by tlM}If fIlounllnuS
E I('Ctu(: (:Ullmll flows Ih'ough Ihe CO'I'I)Ol1elll and Ihell hack 10 Ihe b"lIe.y 11':1 Ihc hodywolk " Ihe cO"'I'Ol1ell l mOU1I11I1\) IS l(lOse o. <:olludccl, 0' II il lI'lOci pnth bilC k 10 Ihe IWl1clv IS 1I0t av",!"I)lc. ll1e
CHCIIII WIll be IIICOlllplcl!l "IId m"lhln~l.on WIll le$ul l The e"\)IIIe "lid '0' \)c;IIIKJ O ;lIe "Iso eillthed bv lIIeOlllS 01 flc~,hlc lIIel,,1 ~I,,1I1S to lhe hody Or slll)h,lm(!, II Ihese Sll,lPS .11e !{'osc a. ""5SI11\1, SI;lIlcr mOlo'. !lcllewlOr alld 19",I.on "ouble IlIlly rcsull Assulluny Ihe cil.th .Chlln 10 bc sat,s!xto,y, eleclllCOlllaults WIll he duc ()lIhcr to componellt 11111l1uI1(:I,on 0' to delccls III Ihe CUIIClll ~lIl)l1lv Ind,vldu,ll componentS ,,'C de"lt ""lIh If' Ch;op te. 12 . II supply ""nes "'0 IlIokcn 0' clilcked IIl lerll;lllv IhlS resulls '" iln open,cllcu,!. IIlId Iho eaSleS I w"y 10 check for 11115 IS 10 bypass the SuSpCCI wife lelllPo.allly wllh a Icnuth 01 wi,c hi!lImU (I c rocod,le clil) Or su,wble connCC lor m eilch cnd Altemmillely, 11 12V test lillIlP ColO be used 10
vCltly the p.esence 01 supply lIoltage 011 VilltOUS pomlS along the WIIC
lind Ihe IJle<Jk can be thus Isol<Jted.
II ;I 1J",e po, lion 0 1 11 hlle WlfC touc hes Ihc bodywolk 01 otl1Cr e;ulhed IIICtal pall. Ih(l cl(:Cloc'tv wIn lale Ihe 10W·fCSlsrance p"th thus fO"II(.-cl bOlck 10 Ihe blllle.y Ilus.s kno",n as il ShOrl ·cifcuil. Hopefully a ShOIl'Clfcull Wilt blow 11 luse, bUI olhClwlse I( may causc bUIO.ng 01 Ihe IIlsulatoon (am! pOSSIbly IU'lhef shall cIrcuits) Of ellen a flfc ThIS IS why 11 .s lIlildlllsable 10 hVPilSS pcrsls telltlv blowtn9 luses wllh silver 10110. wife
Spmcs [II/(I tool kif MoSI IIdllclcs Me supplIed only " 'Ih sutl,clelll 10015 10' whtel chanUII'll, Ihe M,lUl/t:lII111CC iJml millO' "'pi)i, 1001 kll dCWd cd In To()ls a",/ W()'/o:"'Y I<lClhllt'S , WIth the add'I'on o f 11 hamme., IS t>.obah!v s .. U'CICIll 10' those .e,)3"S Ih at mOSl n,o!OuSIS would conSldcr atlt~m('JlInu al the ,oildslde In add ,t,on a lew Il\)ms whIch C(ln bc I't\(:cr
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a
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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Page 22 of 205
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T
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 $"(fIl,'IIl'V Will el/~(tll.! IIt. ·It rlOI/""{J IS 10I901l<:fI 1 Removc the bOlll1c t "s descllb"d '" Ch,lpw, 11 2 Disconnect thl! llilth)IY ncg;rtlvl.' le.,,1 ,IIHI Ih e ealth l.ill,IL' frun , lh,)
,. '~ , I\; , .,
28 E[lO"lc 011 levI;[ d'pstlck ma,kll1gs 2 13 Removing the Cfankc<1se cnHSSIOIl v<1lve
62 Ea'th cable Oil the alte'''''lOl adl"slIllt:l1t u,,,ckel (<H,owl.!d)
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Page 33 of 205
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ClliIpter' Engine
22 Unholt the thcrmOSlilt INlr Woller eillow R()llloVC the ~Jo1~kCl 23 Unboillhe 1II11Ing cover "ml relllove the UaSkCl (photos) 24 Ullscrew Ihe bolt securing the r..~m~h;'lh {le.1. 10 the Cillll$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
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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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Page 36 of 205
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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
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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 .
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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 ... ,,,
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15 2E RlInlov,nU nil 'nlel valve 15 2F Inltl valve (top) and cxhnust v<1lvU {bot 10m) COlllpo"ents
.. ----------------------------~, 灲潣慲浡湵慬献捯m
Page 37 of 205
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36 Chap te r 1 Engin e
8 Luh"(;;,,,: lh.) VdtVt! ~1t:m w,1h t!"!l'iI" 011 ;mll UIS",. 01 III 111" yak" !)lIId" Sinh: Oil ,'"ew oil ~I:dl 1110) loUin pla~ttc. ~,:"Is !I\) Urlilip. ,,~h"LI,t v .. lvus (photo) !l F" the v,llve ~PUll!1 ,11111 val",", sP""!J 'CI,lUlI" , 10 Usc .1 ~ul1;ol)h.1 valvll ~P''''Ll (:011111,..,,,$0' lU co"'p'"ss th" \I,11.,c sp"nu unlolthc cOIl<:ls C;lI' In, j'ticd It, p05.II0I1 III ,In, ~lnlS "' IIll) y,11110;: stem Release Ihe v:llve 51)/111\1 f.()UlI)I(l'!>sor. 11 A lter filling ,1111he p,uls. 1011' ti m lOP of the v;,lvl] SP""!1~ 1I\llllly wIth 11 plas llc h,'1111l1ur 10 0.;115""'; CO"CC1 sc;n" ,!! ol'he colll:,s
16 Cylinder borl)s -clIn,nina,ioll and rcnov;ltioll
A oww cylllld", " Iwdculy IOII"d I1l1d Ill" wdll, p.II;oll o:llI"""OIl<)ul liS h!'l!lth Ihe a.; """ 0 1 1111: 1",1,11, '",uls ,,, WI',,, lilt) w"lIs III "!Ihl _"'!llcs to 11m \lonl!I""" II'" ,II,.. "' ~"I" Ih,u,,1 litis w",n I"I\.·~ 1,Iacc
PII''':'I'"lIy 0" Ih,<I ~"u'o" 01 III<, c yl""lc' ~W"I'I by Ihu pl~lnll willS ? Il's poss.!)'" to !Iel ;'" ",<1":;'1",,, 01 hUll, W",II hy "'''HIV'''!) th.] cyh"d", h("l(ls Willi the .:t'lI"'e ~I!II '" Ihe ",,, W'lh Ihe p'~\()n ,Iuwn!ll tlon I'llln 10"1 sl~I"S III W'!." <:.111 be ~ee" ;'lId lell 11I~1 hnlow 110.., lap 01 lion bU'1l whe.e Ibe lop I"SIOII "II!) 'eOlcl",$ ,,,"I thu,e w,1I he 01 llot,cc,llJhlhp (otllt:. (h;", IIuIIII.,1 C,"UOII hu,ld up) IIthe,e 's "0 hi) " IS 1,1II1y ,u""oll;ollie 10 uxpectlh,lll,o'u wc;" ,s "ul ~eve,c .1nd .lily I,'ck 01 Cllmp'ps",(", Of ex,,;cs~>vOl OIl . :on:''''''l'l ulIl ,~ 1!t,O 10 wall! 0' brokc n
p'~I(II' IIII\IS '" 1""IOtl~ :1 11>1 'S po""oI)I'1 W 0111"",, ,11""e IlU';oS,,,,,,U ",,, :/O,,,,,lu •. " 'c,IS,"O Ihe I)IlIC II' Ih., tll'''M plalle bt:low Ihe lop ;,nd aU,I'" ill Ihe bon"", 1>1 tho! .:yllllllc' "I Ih.., """'c pl.",.., II 110" ,1,II""" .. ,c '" IIIU.u Ih,'" 0 076 ,"111 (0003 III) II,ell a ",lxJle 'S IlCC',$S;" y S",,,I;,, Iy .. dolle.encc 01 0 076 """ (0003 ,nl o. ",u'e .'c'oss Ihe holO, (I';IIIIel<;' IS as,!!" 01 oVilhly
1;.,II,no 10' ,l,ci.llJlU
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4 Any ho.e whIch is siunlllc~nlly scratched or sCOIed Will re botin g. This symptom usuafly indlcalcs thm IhO piSlon o. rill d;,uII;"Oged. Evcn II only one cyhnder is in need o f .cborlnl1 il w,1I ~ necessnry l or nil cylindcrs 1 0 he bo.ed "nd I'lied w il h new 0 p'Slons .. nd rings. You. Fo .d ;"Ouent O f 10cOl' mala. engin, spec,ahst w,1I be ,,1)le 10 .ebo.e ;"Ond Obl;"o"l lhc necessOI'y m,' pistons II Ih e CI;"Onksh~h IS undergoing le!)lin(!ing .. Iso, iI's .. Iden to lei Ihe S"1I10 111m .enovmo OI"d reassemhle Ihc cr:"lnksha' ll1Slons 10 the block. A rOI)utilble I"m no.mOllly U,ves " Uunr .. nl· suCl1 walk In cnses Wflele enl)ines hnve been ,ebo.ed ""e:"llly I. mOl~lmum. cylondc, loners Me OIvOldahle wh,ch mlly be li1l(.·(1 In cases Ihl! s.,,,,c .ehoflnu I).oeesses have 10 be lollowcd an, se.",ces 0 1 a spec, .. h:;1 cnu,nee!U1U ',rlII :"I,C .eq,lIIcd
1 7 Pistons (lnd piston rings -cxaminmio n nnd renoviltio
WOII! p'stons nrul linus Cilil usunlly hI! (to,1\1!losed whe, ~y"'plo',,s 01 "~C"SSlve od cO"Su"'pl,on nn d low COIllI)'''SSIOIl ;,"11 ;"" SO"lCh"U'S. lhouUh nOI OIlwOlys. assocI,ltcd w'lh WOfll cyl ho,cs Comp'ess,on leSl,"5 Ihal "1 ontO Ihe SI),l, k ph'l) hall.:
<lvndahlc OI"d Ihesc c; m ""hc,11e whe.e low pIC~Su!C IS OCCUII"'\I "sunlly accele',lles Ihe mo.e ,I ,s leI! so wh(;n !Im syn'plO'"s occ,,' ao;I.(On can Il0ss,bly sllve the exp <;llsc 01 " '''ho,l'. :1 Anothm sympiom 01 pis ton w,.,,,, IS fl'~lon slnp a ~nockJIIg , hom the crankcase. nOi 10 he confus"d w'Ih h'H'cnd IlC''''''\lI;lI1o
.:;'" he hc,IId cle,loly OIl low cnl)inc speed when Ih".e '5 no lond (, 10' (,xnmpl,,) nnt! '5 much less OIUlhhl" wh()n the "n!line ~ ,,'c.e"$I;s P'SIon weOl' usuOIUy oeCUlS in Ihe ~k"1 Of lower e"d ° l1'slOll OInd IS ",d'ClllCd hy ve",e:"ll ~I,ellk~ III th e WOIil arc" wh, always on Ihe tl""SI S id e II Clln nlso he se!:n whe.e thl} slwl thlC~ IS dlll"ICn l 3 Piston ling ""eM c:"ln l)(l checked by '''SI .emo ving Ihe lIng s
Ihe pis tons <15 descllbed l:lI el In Ih ,s Sect.on. Theil place Ihe rin. the cy luuler hores hOIll Ihe lOll. push,ng Ihem down aboul 4 0 lilli' '") wllh !he head 01 Ihe p'slon (100111 wh,ch the 1111\15 hnve ! ",mo,,!:dl so Ihm Ihey !cSl sqll.l,e 11 Ihe cyhntJe. Tho;n ",easuo, !I"I);lllhe "lids ollhe ""!! w,th II leeler !F.u\lc (photo) 11'1 e~ceed ~p·ec",ed m,lxill1um tlmn Ihe IIIIU needs I!:'WW'" 11 The \l!orwcs '" wln,,;h the "n!lS loc,ne It' !he pl~t<Jn em' IICCO""! ""liHIJ,,,1 '" usc, The cle;"OInce hClw,-,en ling ;Jfld I)lSlOn ,,, !1'OOVl'. "hould nOI c~ceml 0102 111m (0004 In) lor Ihe lOP COII'J"CSS'OIl linus ,1I,d 0 07(j m", (0003 In) lor Ih e lowel 001 co'
"'I!I !J Howevc •. II.S .",e Ihn lll p'Slon IS only wom illlhe linn \lrooves Ihe IIced 10 .enew Ihem fo. Ihls Inul l nlonc IS "OI,dly evcr cncount, Wlle.eve. JJ'Slons me ."newed Ihe we'ghl 01 lhe Iou. PiS:
eOllllcclmU IOd assclllhhes Shouf(1 be kepi wilhill the hilli l VllllaliO a!) (028 Ot) 10 'l.nlnWIII Cl1glfW balancc () To IClllove Ihe p'SlOn IIIl!)S. shde them cOl.eiuUy over IllC lOP 01 pl~lOll. !akin!) ca,e nOi 10 sClillch lhe aluII"'''''Ul nlloy. nevel shde II oU the h()!iom 0 1 Ihe p'ston sk"l. II IS vc'y ensy 10 !)fc,lk the CIISI
I"SIOll fI:'US " Ihey ,,,e 1IIIIIed 011 fou\lhly. so Ihis ope'auoll shoulI dune wUII e~t,c'"e c ;u c. II 's helplul 10 n"lke lise 0 1 old l\lcle. gall 7 L,II one clld 01 tile p'SlOn nn!J 10 he .e'"ovcd OUI o f liS U'OOVI! "'S\.'I I IIIIde. U Ihe cnd 01 Ihe leele . gilugO 8 TlI'" Ihe Icel e. UIlII\le slowly .ound Ihe IIiSIon lind. as ill/l '
173 Check,nt! Ihe 1)'S lon ""g cnu ~l"P wllh a le"le. uallUC
1 7 8A Remov,ng Ihe lOP comp.esSlon ling 17.8B Remov'ng !he second compress,on IIfl!J
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