cooling FORD CAPRI 1974 Workshop Manual
Page 17 of 205
" ,
'6 Routine maintenance
)
Every 250 miles (400 lUll) or weekly -whichever comes first
Check the engine 011 level and lOp up " OCCCSSJry (Chapler 1) Check and adlus t lhe IYIC pressures (Chilplcr 10) Clean the windscreen and windows C lean the hcadlamps
Every 6000 miles (10000 km) o r six Illonlhs - whichever comes fir s t
£II[1ille (Clwpter 1) Change engllle 011 and IIher
Cleiln oil flilm c"p Chcck 10 1 ,IllY fluid leaka!)e ,n enUme CO'llp:lnUlCIl1
Cooling syslem (Clwptet 2) Check cool:'lnt level
Fuel syslem (Clmpler 3) Check idh"U mi~lUle (cmiJUiello1 IllUdels onlv) al I"SI se.v,ce ollIe, overhaul C heck idllllg sj)ee d
Ignition sys/Cm (C/I,Wler 4) Clean ,1nd re!)"p Sl)".k plu!)s (.:on!nC ' breilkCl Illudels olllv) Cle an and check d'Shibu\o. C"I). '010'. HT lealls mId co.1 (COllWct
bleaker modcls only) Check elwell angle (cOntact b.e"ke. mo<lel s only) Check i900\OOll hlllillg (COnt:'lC1 break er models only)
Cllltch (e/Mllter 5) Check adjuSlmenl
Bri/king sys/Cm (Ch,1pter 9) Check selva
Che ck hydraulic flu id h,vel
Ch(: ck p"ds :'Illd sho(:s lor wear Check h.ake hllcs and hoses
Suspension .wel stvi'ring (Chi/pICr 10) Check tyres 10' w ear and dam:lge Check steering COmp{lIlCnlS l o r w e:l l "lid d.1nlilue
Bodywork. .111d fittings (Clwptef 11) C lu .. >ek se"t belts fa. we .... damage :lnd secwity
Elvc(ric.11 systcm (Ch,7jJ(ef 12 ) Check Ope.iltoon 01 "Uhts Check wilsher flUId levels Check b.1ltery eleclrolvle lev el
Every 12000 miles (20000 kill) or 12 mOll1hs - whichever comes first
III .1(/(lIlioll 10 Ihe 6000 m/le sciler/Ille
Engine (Ch.1f)ter 1) Check and adlUSI valve clearanc es
r"' .......... ~.~-.... ._ •• -.... __ .... . 3lii1&l •
Cooling system (Chapter 2) Check condition "net tension of 1111011)<1101 dflvehelt
Fllel sys tem (Chapter 3) Tighlcn inlel IIHlnl lold boits/nuts Check vacuum hoses Check e~hiluSI syst em Check ll1r ctonne. temperature cOllllol (,I applicable) Renew fuclllllC ' (fuel injec tion models only)
Ignilion system (Chapler 4) lubricate th e dis'flbulOf (conUlel br eake r models only) Renew the coninCt hu,akcr points (II nppllcJblc) Renew the spMk plugs
Transmission (Chapter 6) Check ool/th"d level Lulmc;ue automatIC 1.,'Insmlss,on IInk:'lue
Rcar axle (C/MplCt 8) Check 011 level
Bli/king system (Chaplet 9) Check v,lcuun' hose
llliJllc:'l1C Ihe handhlake Imk,loe
Suspensioll {//j(J swelill!J (C".1plt~( 10) Check condItIon and hlllSlon o f POWI.II ~I!'tllllli dllvthtl1 (II .1l1pllcal,
Check MlspenSlon 101 we;" ;111(1 d;1Il1.1!)e
Bodywork ,1I)d fillings (Clwpler 11) Check opera lion of all locks Check secu.ity 01 dOOf check sl.aps
LlIl)fIcalC locks. door c heck S\','P5 :'Ind fuel fdler cap flap
Check underbody pr olCctive coalm!)
Electrical system (Chapter 12) Check Opcra1l0n of all eleC111!:al IIcm5
Evcry 2<1 000 llIiles (40000 kill) or 2 yc;u s -\Nhichever comes firsl
III ,1(/111/'011 10 the 12000 111"'1 $d'~'f/u/e
[nyino (CIWpICf 1) f!ell'!W crankC:l $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
procarmanuals.com
Page 51 of 205
\.
50 C hapter 1 Engine
51 T llp pcts -removat
Remove the 1<lP11C1S I.om their bores with ,1 1ll1lgnct "nd pl,lee them ,, 11 r,lek in sequence. 2 If (lny <lIe (1I111cull10 remove, .ot.:l1C the crnnkShilh. willch wIll Ciluse the cilrllshilll 10 lurn lind move the IilppclS 10 ,elcilse them hom <Iny
!.111m "' thell bores.
5 2 Crnnksh<llt pulley -remov al
Prel/cntlho CJ,lIlkshilf l hom 'Ot:ll111(J. by lillllmUl!J the flywheel,' the (jl1nin.! 'S 0111 01 the C;1I, o' hy 10ckll1\1 Ihe transmIssion ,I the cnOllle IS 51,11 III the Cill . 2 Rclcilsc the p"lIny boll hy l,oUlU 1l '111\1 511.11111C. ;'Ind rapptl1\J the sp,lnnc. ShiH ply, thon remove Iho holl ;1I\d washer 3 Usc il S I).ockcl pllile. 10 (h"w the pulley olllhe Cfilnkshall. Do not ilUOl1lpl 10 lever II oH, bC(:.lIlSl; the engllle [,onl COV(II IS j,aulle ;111(1 Icvcrn'H ilU1l1l1S1 11 Ill;)y (11510'1. or even InC.11; II.
4 Wilhdraw Ih~ Wood'uH key hom the end of th(! CllInk5hah and pl,lC,(! " w'lh Ihe pulley. til(! holl alld its washer 5 The C'.1nk~h;)h p"lIey m;oy he ICliloved wilh Ihe eno,,,e III Ihe C:\I. hilt ,I 'S IIIsl tU!Ccss;o,y 10 ,emove Ihe ',ld'illO' :lI1d thc rh'vehelts
53 Flyw heel -remov[ll
P,even llhe flywhcel hum 101m",!) by FHlHllln\J Ihe lin!) !lcal ;ollain~1 ;In imp.ovised SIOI). 2 On nlodels willi nl;lnu:ol 1I;o"$""S5'01i. Icmove Ihe Clulch plessure 1)1;lle and disc :os described in Ch:op!Cr 5. 3 Rele.lse Ihe s,~ bolts secu.in!1 Ihe flywheel 10 Ihe CllInksh;oll .lnd lefl\OVC I,ve of Ihenl.
4 Whilc supporling Ihe tJywheel III pl;ll':e .• emove Ihc Sixlh hoi' ,'11d Iolt Ihe lIywheel otl c;o,elully. so 111:01 Ihe m;lllllg su.lilccs of flywheel [lild c.;onksh;oit ;o.e 1101 dllm,'ged
5 4 Sump -removal
W"h lhe '''1(1'''') oul fli the e,". CII~"'C Ihal Ihe sump has 1o('CIl d,amvd ;ond then lilln the engll1C ()VCI so tl1011 Ihe sump's U l)I)ClmOSI F" wOOr1CII bloc"s tn Slll)lmrl tim en!l'ne 'n Ih,s POSIIiOIl . 2 Remove 11m h()IIS seCUlln( J the oil Sump 10 Ihe CI.1nkColSe o1nd rClllOVO Ihe SUll1p_ 11 the sump IS stuck 10 the c r;ollkcasc . II should be reh;lIsctl hy 1"'SII1\1 olle SIde wllh 11 sClcw drover. 3 To !Cn,ovtl .Ile sump wllh Ihc CIIU"HJ Hl tloe eM. 11151 IcnlUVC Ihe
d'l)S llck :ond d'SCOIlII(!Ct Ihe hatlery 4 Remove Ihe luur holts ;ond lou. Ch,)S ;ond dCI.leh Ihe OIl splash
shIeld.
5 Pl;oce a Con'"lIlcr 01 at lellst 6lttre (106 JlIllI) cal,,-.elly heneath Ihe SUml). remove Ihe d,ain pl\l(l ;ond d,aln Iha sump. Reflilhe d.am plull and (11)hlen II 10 Ihe 10lqUO wrench seilIng gtven In the SIXlClflC;JIIons G Del:och the engme fubl)CI mounllngs, by lemovlng the" nuts an(1 w:oshe!s. 7 Romove the ciampinI) bolt hom the tal) ;oml bOIlOI11 endS 01 the Steellll!.) intellnediate sh(lil. rush Ihe lap end 0 1 Ihe shlilt upwollds unlll Ihe lowcr ell(1 Clin be dlsenga\led 8 PI<lCo:o jack undOI Ihe lI;ol15mis5ioo nnd use II to HlIse Ihe engine Slr\lhtly.
9 Remolle I he Inur boilS securing Ihe fronl anlj·roll har to the Slde·membei (lnd the l()ul boilS securing each engHle mounling blllckel to .lIe sidenlCmber. 10 Remove the 011 sump Imlts lind I I the sump hns sluck to the crilnkc;ose .• elellse the sump by press ing 'I sideways wilh a screwdriver.
55 FrOllt cover -removlll
If Ihe engHle IS In the CM. II wllllnSI he necessaly 10 dlsc()nneC lthe l!allefY. drll'" 11m coolll1\) sys tem ;ond lel110lle Iho radiillor. 2 loosen the alternalol mounllrlg bOilS. SWlrlg the aitemalor downwilids .0w:Olds the cyltnder block and lemove Ihe drive belt
3 Remove the bolt Irom the cenlro of Ihe cooling Ian .. nd pull (
Ian and clutch assembly. 4 Remove Ihc boil an d wilsher from Ihe centre of the cran pulley .. nd I hen use ., claw puller 10 drilw Ihe I)ulley ofllhe sha nOI anempllO lelle, Ihe pulley ott. t)Ccause Ihis may .esull in dllm. t he Irani covcr.
5 Rcmove the si~ bolts secuung Ihe sump 1 0 Ihe honl cover an, t he cleven bolts securing Ihe I ront cover 10 the Cylllldcl block . G lIlt Ihe cover ott ;ond remove Ihe g;oskel.
5 6 Tillling gears -relllov;ol
1 Remove the honl cover 10 e xpose Ihe IImlnu ueo1/S 2 Removc Ihe bolt and washer sccu"I1IJ Ihe fat!Je gear I,
cn,nsIl1'll t. IhCIi pull.he geill ol! and Icmovc tho Woodllll! key. 3 Dlllw the ileal hOI11 Ihe cr;onk!;h:oh am! remove Ihe Wood'utl
57 Carllshaft -r erllov;ol
The camsh:olt nwy be rCUlovfld wllh the cll!JlIle 1<1 Ihe car •• lollowlng p!Cpol.aloIY wo,k IS co1med out. 2 0,,,,,. Ihe cootong syStelll nnd .emove Ihe .ad,mOl 3 Dlsconneci the ballery. 1 Remove Iho sp.1lk pili!! IC.1ds 1,om Ihe spalk 11lugs. 5 D,s':Ol
eCI the le;ods I,ull' Ihe :l lt'!11\.110r. remove Ihc allelllalo·
l i S (hivebell. G Undo "nd rem ovC tho screws S()CIIIII1U Ihe .0dcl covers and It Ihe rocke. covels and Iheir ilaskcls 7 Sincken lhe nulS secullnu the rocker ~"ns unlollhe locke' arm, he swung aside . 8 Remove the pushrods. idenlllylllg each one as .. IS lemoved. so 1 Ciln be rell1l ed in Ihe same position 9 Remove the cylmde. heads, <IS doscllbed in Sec l,on 47. then Lmagnet 10 tilt out Ihe tappels. PI;oce each t;oPI)Ct WIth Ihe pus which il Oper;oleS, so th<ll Ihey :olso WIll he relliled in t lle;1 0';1 POSlt101l5. 10 Remove the Iiont covel liS descrohed 111 SectIon 55. 11 The cllrllslwh pl:!lc IS secu.ed w,th twO cro5s·hc;od counlel,
screws. These cannOt be removed wI,h an oldm;OlY screwdliver ,lily nllempt 1 0 do so WIll resull OIl Ihe sc,ews bemU d",na\.l<:d. I Impact SCfeW(!IIver is nOI ilva,lnl)lo. the SCIOWS m;o¥ he Icmoved w sui l:oblc key lInd the urace 01 a sockel scI 12 Remove t he c.1m5ho1ll IhllJS I !)lolW 011\(1 the space. hclund II 13 Pull the c;omsh;oll lo.ward to wllhdl,1W 'I. 100f 111\1 Cil!e 10 ~ee" Sh,'lllfl Ime. 50 Ih;ollhe edges ullhe cams do nOl rt,1mnge Ihe cam~ beilllllUs_
58 O il pump -r e m oval
Remove Ihe crill1kc:ose sump as ;olleady dcsc"hed 1 2 Remove Ihe boll aUJchmg the 011 scrcen 10 the Illalll 00111.119 (
/ /
Fig. 1.11 Oil pump o n tho 3.0 f itre efluill(l (Se c 58)
F
procarmanuals.com
Page 58 of 205
,. Chapter 2 Cooling system
Cont ents
AntIfreeze mixture Cool ing system -draining, Cooling system -filhng Coo ling system -flushing " D,ivcbcllS -femoy~1 and refilling Expansion lank -removal and reflllmg F;)n hub be,Hing (3 .0 lit re eng ine) -renewal . Fault diagnosis -cooling system
Sp(lcifiCiltions
System type
Thermostat
Opening lempel<Jhn e 30 hue engirlcs 28 hlle enUrrl es . ___ ..
F ully open lernpcln1 ulc. 30 hlle engines , ... . _._ .. .... 2.8 hlle eng1ll es .. , ..... . _._ .. _
M'ninlllnl IhennO SWI Havel _
Orivebelt tension
O()lleCI,on JlHOwily between pulleys (longeSI run)
Prossure cnp setting
3 0 lure engines -._ .. ,. "._ 2 8 hire engin es _
System capncit y
30 htle eng ines .. , .... 2 8 lille engines
Ioorque Wrench settings "lIe fHlgil)( :s
'" ~JI~;·;~~;~'·." _ ... , .. " , e"noSl~t 110[151119
G 3 5 4 10
" 12 15
Gene',,' description RmhalOr -.ellloy;,I, inspection, clCilning imd refllting RO\ J\inc rn<lmlcnance .
TcrnpC'<l\u,e gauge sender lmil -removal ilnd fe/rHlng .
Thc'1ll0SW I -removal, testing and !(~fl1llllg . Viscous drive fan -removal and refilling. Willer pump -,cmevn l and refilling
1 7 2 13 8 11 9
P,cssu"scd. With beil ·drlven pump ,1"d larl (VISCOUS (hive type on 1.1u:, moduls). IhcrrnoSWI ... nd expansion \,lflk on I"W' Illodels
85 to 9S ·C (185 to 208'F) 79 to 83" C ( 1 74 to lSl'F)
9910 10TC (21010 2Hi"F)
9 T C (207'F) 7.0 nun (028 Ill)
100nll)1 (0.4 in)
091 klll/enl' ( 12 .9 Ibljin') 0 .8510 1.10 klli /elll' (12110 15.6 Ibf!m')
931111e (16.4 pinl) 8.71111e (15 3 p inl)
No.
710 10 710 10 161020
81011 17 10 20 9 to 13 810 11 20 to 25 201025
Ibf ft
5 to ., 5 to ., 12 10 15
6 108 13 to 15
7 10 1 0 6108 151018 1510 18
procarmanuals.com
Page 59 of 205
,
I ;
I
i
, . I
)
58 Chapter 2 Cooling system
Goneral descriptio n
Tho coo1inU sys tem IS of tile flfCSSll"sc d type consiSling of 11 helt·driven pump. h0l11 mourllc d .ild,ator and thermOSI"! Th e hClt·rhrvcn 1,111 IS of SI;mf!ard type on carly models, bllt of VISCOUS drive IYlle ( l) holO) on lalC I models. the lallci jllCOrPO'ilUllg iI speed 1I0)'I<1110n (I(!vkc, On 3.0 hue cnOllles t he IhcollOSlill IS IOCillcd (I( tho,'! 011 tiel to tl lC tOp hose. but on 2.8 htre engines i, is localcd on the 11110 1 hom 1ho baliom hose . Lmc. models <lIe f'lIed wllh .. n CXPilllSioll !lIlIk Tho s ystem functiolls as follows With the cnuine col(I, the thermos! .. ! is closed and the cool;1I11 is I)Ull1 llCd thfOU!Jh Ihe enU'ne wilIClwlly5 tln(t h(l,ller only When the enuuII) ,cilches a prcdCIClmulcd ICmpc<nIIllC. t he [hCllnos!al oll'ens alld the COolant lImn cllculales down IhrOlluh the r,ld,nlor 10 provide <ldd,IIOlwl r.oolll1\) Where <In C'I)ans,oll tauk IS " ed. th,s cnsurcs th.11 the cooimu system IS always h,n by collectlnu coolant when th(! CII\JIIlC IS hOI olild 1f!l l11lllnu It as Ihe enUlnc cools
Fin. 2 .1 Coolinu systelll (3.0 lilro cngine) (Soc 1 )
Fig. 2 .2 Cooling syslcm (2.8 litre engine) (Soc 1 )
procarmanuals.com
Page 60 of 205
)
'tz
Chapter 2 Cooting system 59
1 I VISCOUS (IPlVC I,m coupling (I,~mpc,alu,e sensitIve 1VIle shown) 2.5 Tuppill\l -lIplhc COlllilll1 h,vel in the c~J)alls,on \;lI\k 27 Checkin U the drive-belt IClls,on (28 hire CIlUulC)
2 Routino Illaintcnanco
Altho ,n1C, ... "ls SPOC""]!! utlhe Rouhnc M .. "UcnanCf! SOChOr! on Ihe 110111 01 the m;uu,a1 c;lrIy oul the lol1oWl!ljl p.occduoes
Check cnoling syslcm lor /c,1k.~ 1 In spe cl Iht! coolin!! sysh),l) hose s 'llcludlll!) the ,adIOiIO' :,"<1 Iwate. hoses for damage. detcriOlllll0n i1nd sccullly If Ihelt) is I'Irly IOulle;1I'01] of swelling 01 p<lflshinu ,en ew the hoses . 2 Chock the ,a<li;uo . fa . dilmaUc ;lUd leaks, ,llld clean ;lny dchlls from Ihe coolmg fillS.
Check coo/tint level 3 Whe r(l Ilrl expanSIon 11lnk 's hlte d (I"te. Illodels) lhc I;oolnnl ICv!:1 can tJC check ed without .enlov,nu the pr<lssu.e C;'f};1S the lank ,s made of t.anslucent f}I"st'c. The t(lnk should he ;1PP'OX"l1;1tdy hllil lull wuh the cool.,,, t lust cove.in\J the pillst'c lev<l l ,"d'CH tO '. W,th i1 h ot CI1U"'c the level 1"',11 he ShUlllly hiuher 4 On ciuhc •• nodfJIs not f'U e(1 w,th 1111 exp lln:;'(l1I wnk the level "'''~t be Checked with the .. muine cold . Unsc.ew Ihe .ad,alO' p.essu.e cap and check Ih,\( the cool,u'l leve l IS hetween 25 0 111111 (1.0 In) ~II(I 35 0 111m (1.'1 In) helow the base of the filler ne ck . 5 Top·up the flurd level USing the COllect sohl\lon of wa!IJ' and ;mtilreele with the enuino cold (photo) 11 the c"Ulne is wal"'. the P'<lss,,"e Cilpmust be remov<ld slowly to illiow Ihe PICSSUfC 10 e sc ape U'llduilily. otherWise the pres su.e d'OI) fllily c~use thc coulllni to hod over cllusi,,!) I)Clsolla l Injury.
Check drivebelt conditioll and tensioll 6 Inspect the complete lenlJth 01 th e tJrovehell(s) for dClello.,llIon which WIIIIlI)f)e,lf ,lS h1lyll1U 0' UlilZinU to the 1)Ulley cUl1t ilC t su.fi\Ccs. 7 Check th(lt the deflec tion 01 the d.ivebclt{s) midway hetween the wate. pump i1nd (litelnntor pulleys is i1pp.ox,,11i1tely 100 111111 (O 4 OIl) under 1ll0de'i1 le thumh p.essule (photo). 8 Whe.e ~Idiustillent is neceSS(I'y. loosen Ihe Ililefllilto. p,vot and adjustment bolts. re l)OSlloon the alternilto. then tighten the b olts. A leve. mill' be used at the pulley end o f the IIlterna tor 10 o b1;lIn Ihe
COf/ec t tension If .equir e d .
9 Run the enuine f o r severlll minutes Ihen rec hec k t he lension.
Renew,1/Jtilreeze 10 O.am i1nd flush Ihe CO(lhng System as descrlhed in Sections 3 and 4 . 11 F,II the coollllg system With Ihe correct solullon of watel and amlf,ccle as desc"hed in SeClions 5 and 6 .
3
Cooling sysl e m -drai"inU
If pOSSIble. ensu,e thilt the engine IS cold belo.t! d.al"i"lJ Ihe cool ant. 10 aVOid the fisk of scalding.
2 Remove Ihe .adlatOf or expanSIon tank IIlIe. cap. If the eflUlnc IS hot. Ih ls must be done vl;lry caul,ously, because a sudden release 0 1
Fig. 2.3 Clltawa y view o f Iho expan sio n tlln k showin g tho plastic lovel indicator -tH rowed (Sec 2)
P'".'·S5U'0 CilIl ,esull II. the cool(lnl !.>oIling i1nd blOWing Oul. On ,1 hot enUlIle. plilce iI cluth ove, the caf} and lurn il ve. y uently. '0 release tim p,ess\lIe slowly. 3 flel110ve the SplilSh shield frOI11 b enomh the ra(II;IIOf. of i1pplrcilble
" Unless !he coolilnt IS beinu discarded and thc ca. 's over (I slilt illJle
d'illl1. ,,'"ce a deiln IWO i1nd a half gallon Conl;1ine. underneath the ,adlaIOl. !) Rel110ve the radlatOl bOllom hose lind allow the coo'al11 10 drili" . 6 If the SyStel1'IS to be completely d,ained. rcmove the cyhnde. block d.;1I1' pluU and draIn oul Iho .emainlng coolant hom tho engine . ThiS d'illf' plug IS locilted all the s,de of the cyl inder block to Ihe rear of the oiliolicr. 7 On 1I10deis wilh all eXJ}ilnSlon tank 'emove the rad.alO' cap as well
4 Cooling systom -ftushing
In IUlIe. !he cooling syStel11 Will lose ils efficiency because o f a bu,ld'lIp 01 .uSI and sedunen t in the radiator. To clean the .adliltol. .emove thc IllIer Cill) i1nd 'he bOllom hose ilnd !lush Ihe radialo" by inse.llng a hose in Iho f,lle. car> neck i1nd funninu Wille. th.ough fOf about tr.m I11mules . 2 If Ihere is a Ilea vy aCCUmuliltlOn 01 sediment. it is betler to .eve.se
flu sh Ihe .adl~tor. by connecting the water supply 10 Ih o boltom of the rilclmof alld allowinu II 10 flow oul of the tOIl. Speclnl hose adapters arc avai lable to enahle thIS to be done w ith the rild.ator In I)OSllion. but It is p,efe.able '0 removc the lad,ato. and tum il upside down.
3 Remove t he thernlos,a, (Section 8) then .eve.se lIush Ihe engine wi,h a W1l1e. hose u n lll clean waler flows from the .ndlat Of bottom h ose connectIon.
procarmanuals.com
Page 61 of 205
'.to.
60 C hapter 2 Cooling system
5 Cooling system -fillinu
Ensure 111m the cylinder hlot.k d',1111 pi,,!! IS SCfCWCU "' rumly wl(1 th .. , tlilihe coolll'U system h(')s'~s .1!tl1n POSl t'''1l and secured wIth hose clops. 2 USH1g ~ 1111~IUIC of 45% nnt,hN!IC ilnd b!/)(, wmer. 1,1) the coolll\lI system slowly. 10 nHnlnlise the fisk of "U locks Ellsure IIKIt the hC;'lC' control IS Wined \0 the 'Hor pOSItIon oll"l'W'~: ,10 IIU lock m.ly 101m Ifl the hemer 3 On fl,lIly models w i thou I 01" C'P"II~OOIi t .. llk. hll the liuhnlU ' 10 llHi
hlvel U'llcn III S!:f.rran 2 then ",ht 1110 Itll,·, ,:,,1' Where nil e~Jlan~lIl1l !OInk .s f,[h:d, t.:olllplclCly 1I1I11u; ,;)Ih;no • .11101 ,.,tn the CilP then h.llll,11 the cxp;ms",11 lank and "JI, the hlle . ,'" " (pholO) Notll 1h.11 thl) pressure (:0111 wIlh the Iln"lol" :,..;,1 "'"~, .• tW;II'S be 1111ed 10 Ihe CXI),1IlS,OIl I.,,,k
I) 01 so"'" "1\\I'''es i'" ,II, 1,1",,01 ~"".'" ", .. y I,,, I'"eti Ifl Ih" IW',h:l hose. Loo~"11 Ihe ~,c:rcw boA"", 1,11""111", ' V·.Io'IIl .",d ,cl'\lII",,, ,I wil,'u hubhle I"·,, W,,,",, 110ws 5 nUll Ih.~ ""\I,n<: al,1 I.'~I "tI,· ~'I"',~IIt~ ·~',.· •. ,I "''''ul,,!> Ih,," "lInw ,I 1U tool iHUII,,1' up til') co(,I.", ' I.·v'" '~!lh ,.'t.''''"r.,; 10 SHCl"," 7.
6 A,IIi1f{W/fl milliu re
Ap,lIl I",,,, II,,, p'''I,,''I',,'' .,,, .. ,,,,.1 1""''''''1 .. ",,(I,t'OIlS ",.1,,0:11 II", usc 0 1 ilnld"·,,,.· I',nvules. II, 11'." I, """",,10 .• 1 I" "IUlI""SI) ':''''CI~IO'' "I Ihe ,:oolu'!1 sy:. I",,, 7. Thc (:ou1l1111 ~y:.lcm I:' ""lIdlly 1I1I.~1 wllh .1 sulu'u", "I II!>'". al1lll,cc~c ;lI,d II.s 'CCOIIIll""lIl"d Ih,'1 II,,, l":u.",,t"He ,s 111,11"1.1"",,1
3 Willi 1011\1·111" tvpes olall1,I,,,cl." ""~"""'" '''''''w lhe Cl)o l:")1 "ve,y IWO VCiI'S. W,III ot hel lypCS. d'iI'lI ",,,I ",10" 110" syslcm cv,,'y Iwelv" "lO'lIhs Wh'f.hcver Ivpe.s used, 'I I11\l~1 b" "'llll' ethylclle Ulyr.oll",s" II The lollow".!) l,1ble !)IVe s;o !J'IId., 10 l""I.":I'uu ;l!)aiIl SI l<u,1 l1"t .1 nUlllt"c of I",;s Ihal1 30% cUl1r.f:ultal,()" wdl"ol !I've P'Oll .. 'Cllr)l] "~;IIn~! CO"OSIO!)
~
-..-.. -::-' , .
I '
If
~
Amount 0 1 ilnlilr(l(lzo 45% 40~ 30')(, 25'\', 20'¥, 15'~,
P ro tection to .J2C( 26"F) 25 C ( I3'F) 16 C ( . 3'F) IJC(·!fF) .'JC(·IG'F) IC(tI.'JF)
7 iladialOr rCllloval. inspection, dcaninu and relittinu
1 O,arn Ih" ,:oolll1U S ySICIII as ~h,s ... 'h,·d ,,' S",:I'OI1 3
2 flclllo\" II", :."t;I s h shlcld (,11,"" .. 1) ;011". 'I:III()VIllII.IS fOIH .. "II-. .11" 10", cft l" 3 0" ;,,,I,,!],.II,,, 1,,1nSIllISs,o n 111011,,1-.. 1'1.":,, ., I'.IV 1><·".·,,11, Ill" " . , "ole' """"",. w'l,e till! un ions de.lll ;111,1 '''}!!,' Ih,,,', Oil'! ~ Iv I'''''' II" j"IH! "",h "",I II", '."010:;' 1""0IlS. I .. 1""v""1 110" h,,~ "111,,,,1 .f O'Sf:"""'· •. 1 110.,1<)1' hosf: ,m'I .... I""" "1'1'1" .,1>1" Ih" "~I""'"'''' 1 .,,,1 h"",) I""" II .. , •• ,,10"1110 :, WI",,,, .1",,1,,:.,1>1,]. 'CIllOV!! tl". "',",w~. -."'."''''!! 110" I.", ,tl"",,1 " "w .ati""", IIo"n p"~'I,on Ihc ~h,,,,,,, '''"., II", t.III 1,1."1",, 1,,1"'1"1 l.l Fo< 1:."'" "f ",movnl ;0150 ,,''''''Vo: IIII' troll! •• ,,10,"0' • "' .... 1 .. I"" "''''')\I'''!! th" ·"."'W~ (,)hOlo). I fl"ltmv,· II", I",,, holls. SP"Il!! .• ",1 11 .• 1 w"·.h,,, .. wll".h ,-,. , "". 11 •• , ... It.,101 I" Ih" 1",," ,W(\cllIl1d Iofllll" ,.UIo.IW' Oll( .;,,,,,r,,Uv. ,."." ""t t. '1.1I11"~I" Ih.· ,."1,. ,1,,, "'.IIr,x (phUlo,,) H W'lio II,,· ,."10.,1,,, ,,"I ollhe c.". II,VI:"." tl"'.10 ,I 10 ,,,"'0",, IIII' ·.I",!." .""1 •. 1"",, til" "~I"'"'' ",,,h,1 lei 01 • . ,,,,,,,",,-~,,d .111. '" Will(:,. 10 """"" ,"'v 11", IH """".1" II Ih" 'ild':l!OI ""IUI",~ '''p.II!, ,I ,~ h..,u,', h) 1.1 .11, ..... :h,"'!!'1 ,."1,.*,,. 0 ' havc Ihc 'cp.", do"" hy.1 tiOlIr"to, ~1 ... ~:,.,Ir:.' !) II yuu .u,' "",,:w"'\] iln cady ':0<1'.'101 ;,"d YOll "!l"nd 10 t,t ., I.,:, " ~1"11 lOp 1.11I~ typ". yuu Will nccd Iu fn 111, HXI'.lI1S'OIl contill"'" COil",,, yOll' FCltd oI"ill", lor Ihe COUCCI IYPII all" h""'!1 dt,liliis should Ih,~ .,. 1he C,1~;C. :,~ :0 ~1"":t:'1 se.v,ce kll w,lI il1:.0 .,,' "~IIII!CfI 10 Refllllll!1 , .. iI t(Jv(:,s(ll 0 1 ,cl11oval .• ,,,' t,lIlh" c:l)ohliH SY~I,,'" w .l h ''''e,enl:e 1 0 S,,,;I'OIl 5 On .1ul0"'''I''; ":"'l.'"'~~l(m 1110d"ls IIII' "I' Ih ,· 1';II1"IIHSS'IJII lI",d w,th .et(l.ence lu CIo""I'" G
S 3 F,IhnU Ihe 'ad,;OIO' WIlh coul:",! 75 Fan s h.oud '(:Ii"""}!) sc.ew (.mowed) 7.6 RernovulU Ihe 1<0111 .adlato r cowl
"
"""
, "
7 7A Upper .mlrillOI 'n1JUIlI"'U IJ()II 7 7B Lowe •• ad'nlo, 1ll0un1111U boll ("!lowed) 7.7C ReIllOVII1\J Ihe rJ(MIO'
procarmanuals.com
Page 62 of 205
...
Chapter 2 Cooling system 6 1
8 ThermOSI"t -removal. lor-ling and re fitting
3.0 litre /~n{lIllL' 2 $lilCkclI Ihe clop 0 1 the top 110M) to the ril.loiltor and rcmovc the hoso (photo) 3 UndO ;II,.t ,,:move tho "\4> hnltS ;'Ind Sllr"'!J w,lshers sccUlor'!1 Iho thermO$I,'t h',,,SU'!1 to the q·\·",Io·, heil.l. 4 T,1plh" 1"'''~'''!llIe'ltlv ,','h " pl"Sllc·he.ldcd hiln1l11e •. to h rc,lk th.! g,1sk('1 s".11 Ih"I c".eflilly 1,It fh" hOlls.ng 011. Remove the !J"~k.:l '" one p,,; •. ,, ,11"'~~Ihle. ()Ihe'''''~,' ',1 I"pC hOlh loim Inces 1Oc.lc;rn olllh'l fen,nu's "llh" !Fhket 5 M,,,~ II", fl"'"ulls\;)!!n :,I,,",v whu:h W"v rllund ilnd wlllc.h "";ov up II'S IoI",d, ""'0 u~,) it ~c",wd, ",' III ' fi",ove Il lrOIll Ihe IrOUSII1!1
28 h/le 1:111/1111.' 6 51,u:~'·" II", I l'I's s,.'!;"''''\! II", •.• d.,IIO. holtou. hose and Ihrl hf'.llr;r ho~1't 10 II,,· 111"''''01>1,,1 I"'''~'''!I .ulIl careful Iv remove Iho hose" (ph01<1)
7 Undo .",,1 ''''''<lve Ihe III,,·.· h"ll~ a",1 SP"Il!J w.lsh". s Sf,C"""!) til(, Ihe"II<1'I.1 I""""'H 8 T.'I' II,,· II"'''"''~I;'I h"""''''1 w,th ;, soh "ea.l1,d h;lflllll'" !O .,,'slll.k
II ,11U11,II Ih,: ('{lV"1 ;tw.,v ( ,.1"'1"1 R,'tCove, Ihe ',0111 cuver !Jaskct.1 II.S
unclilr11,\!I".t "11"',wls', ~(:'.II"· .t "II Abo If,mlJVI' Ih" sr';11 !) C;"r;lullv ".I~" Ihe 11""",,"1." (1111 CIt ,,~ how;II'!). """I!! c;""I,,1 10 notc ",1",.11 w.IY '(lund 'I ,~I""·,, (phulo)
All cnyin()s 10 Teslthe Ih",moslill 1o. r"''''<: h,llctIO""'!J hv suspr:llcI ",U 1I Oil a string In" saucep.,n 01 cold ".,1,,, tOHcthe. WIth a !h.). momc1Cr ,,,,"I (he ",nIl!' <IIul lIote the tcmp., •.• I,"!; "I whIch Ihe (lrerrnost;l 1}c\)II's 10 open 1 1 COll'll.l'rl Ihe nOted 1O'IIlPl!lil lurCS wilh Ihose 5pcclhc,1IlO"" ;1 the llC\I""''''H 01 th,s Chililter \)Ive" on tli.)
II they dill.,.
!:on~ldp.ralrlv Ihe Ihe ,mOSlil! mUSI 1.>" "~ncw"d 1 2 If the Ihr:.lllos,... t daM not lully OJlr:!! II. IJO.IIIHI Woll er. or doc s not close dowII ,1~ Ihe water cools. Ihen II ."ust he d, scmded illl(1 il new one frur:d Should Ihe thCrmOSWI he ~Iuck opCO when cold Ih,s w"l IISu.,Uy Iw appil,elll "'hen fcmovmu II from the huusing.
13 Reflllll'!jlhr: the'mOStnl 15 the . everSf'l Sf!ll"Cor.", 10 rClllov.ll AlwilVS
(:"SUIC IIr,)1 11l<! milling lilces il.e eleiln am! ""1 II Ihe Ihe. mOstill
hOIlS"'!1 .s h",Uv corroded fll " oew hOIl':"'!1 Alw;lvs 1I<:f, il new 1),lSkel .1,,(1 Sf'l.11 II "llphc;lhle (phow) T'!lh",,, II", !,I"'IUUI! 1 holts 10 II,,~ s t)C{:llreci \1>111'''-' wrr:"ch SCllrr'!! (pholo) Rd,tl zh,., coolln!1 svSlem "s d('!>(rrhecl "' 5"ct,on 5
9 Walnr jll""I) _ romO"'11 ilnd refilli,,\)
Dr;,,,, IIr ,· , OJol",!) SVMIIII1 as rlllsc,,).,. d ", S','-I""I 3
3 0 iiiif.' VI/yllw 2 5t.,d"·,, Ih', II .. "" ,,1110'(\;,10' ,1'O"IItll .!! hOJI\~. Jlush Ihe illle,nal!)r low;lIds II .. , "n'I"'O, hit IhH dllvetH,l1 '''''11 lilt· wah" pump twlley ;md ",move .1 3 S tack"n th" lowe. 'ilc1,;.IO' hose d ,p .1 l ilt: ,nt., 1 cunnechon 10 th., 11I,1lt1) Ca ... lr,tiv eilSf) Ihe ho~c hom Ihe W;.I." pu"'p r:lIlOw 4 SI.Ir.k"lI 11r" hosc clrp ,ltthe rCill 01 thc ,,,'mp ;'1111 cilfel"IIV eil:>c the Iro:.c hl)llI Ih,· 1''''''1) !, 5!:10:I0,,,,, tl", IIHld hObO r.hp SIIII" I"d .11 Ih" Inl' of the pump ""d ':;I"'h,IIV ""~,, Iho h oso I,om (he lOp 01 Ihe I'U'''I' G U,"I., Ilro: 11"",0 !toll~ SOC\Jrln\j Ihe walcI pump to the cvl. ,,!! c ' Dloek NOh) III;" ".".h hoi I IS 1,1(0d w,lh;1 sjl ""!J washe, ,111,1111,,1. ,'s Ihe Dol l 's 1.,1l'ped bv II", Iii" pulley. 11 Will hC necessary tu l"ogresslvelV s lncken till) holts alld pilil Ihe W.ltcr ))ump il",ny "0111 Ihe cvlinder blocl.: The )ocm,on 01 Ihe hailS should be "oled, so Ihm Ihey ilre reflued on Iherr 011\)",,,1 POSlllons. 7 Oncc all ItHee boilS hilve been unscrewed hom Ihe cVlrnde , blod the Wille, P""'P m"y he 'emoved ilnd Ihe 0.1sk(:1 se';'ped off
, '.,
" ,
'. (lJ
../ .
82 Thermosl"l hOU5111g ilnd lUll hose (3 0 l 'l'c ellUllle)
"'(~ .• ',. . .(. .
" ,t>
~ ~) ;;f;\!?r
~' , ((~.~ ::";--
~ -.;~ . ." ... -'
~
" ' ,1 . -'
iP" ~,,,
, : 1 '
8 9 Rcmov,ng Ihe IhefnlOSI<I( 128 h\lc en\)II,e)
.. ,''''' ' A ~ ~ I.-
~~. "Is.\. ,,-~-,,~ -, .. ~"'1"1 .
~
86 ThelmOS!,;1 hous;"\) w"h b01\o", hose d isconnected ""d he,1(Cr hose connecled (2 8 hl.e enU IIle)
'.
,
., ( c ,
jj, ~
8.13A F,n ing a new Ihe,mOSla l hou5'r1U gasket (2.8 loire en[llllc)
• It .,
"
_ /.i
P'
''''' "'" ~)?-,
. f . " "I ' , I ' {. I
l~/
), ".
r
. f .,
, 1 ,;~,
88 Rcmovrng the Ihe.moslnt housing \28 litre engine)
~
',' . -. , '" , ' ..
~,t;
'~'" " . ",
""". L '~cl, \ -./ . -~ ,\'( dr-
, ':'''''~' ._,,1 r;;~
:~';-. '$! \§' ! .... .
{'
8 13B TlghlCnrng the thermOS!ill hous,ng L>olts (28 hl.e enu.ne)
procarmanuals.com
Page 63 of 205
)
62 Chapter 2 Cooling system
2.8 litre engine 8 Remove the radrator ,lnd Shroud as descrIbed In SectIon 7. 9 Remove the dlll/cbell (Section 10). 10 Remove the ftm and pulley (Section 11) 11 Remove rhe lhcrmosln (Section 8). 12 D,sconnr:c l the hose 110'11 the therm ostat rca r elbow. 1 J Unhoh the wale, pump from the engme, nOlmg the loem'ol] of
(1
ench IJ0l11'15 they arc of Yil"OUS lengths (phOlos). 14 $OilpC aU the (lasket .
All ellgines 15 Rchumg is 11 reversal 01 removal, bUI elc",'1 the l11m'ng rolCC~ .111< ollw<lys usc 11 new g,15kct (photo) Tighten OII!S {Inti boilS 10 Ih. spccoflcd lo'que . Rcf,1I1hc cooling syStem .. s clcsc"bcd in Section 5
/
Fig. 2.4 Therllloslllt iln d Wil le r pump components on the 3 .0 litH! engine (Sees 8 and 9)
9 1 3A Unbolting the water pump (2.8 li!le eflg inr:) I
Walt"
l)lJtlljJ " I-Iousi"g 2 Bo/( 5 G,lSI<N 3 ',,1IIslc, hose 6 fI'CIIIIOSt,1t
9.138 Waler pump and impeller (2.8 hue engine)
C ' I . .. ;:
9 .1 5 Fitt ing the water puml' gaskel (2 8 hire engine)
procarmanuals.com
Page 64 of 205
)
)
b
Chapter 2 Cooling system 63
10 Orivcbelts -rcmoval .. nd refitting
Where ilpphcilhle. remove the power slecrinl] pump d rive b elt w Ith refe rence to Ch<lptcl 10. 2 Loosen the ill!CfI1iltor Pivot ami adjustment holts. swivel th e altcrniltor in to the engine, then slip the belt{s) from the pulleys. 3 Loc;rtc the new bcll(S) on the pulleys. then tension with reference to Section 2. 4 Reier to Chilptcr 10 when ,clllt ing the power stcrmlln pump drivellclt .
11 Viscous drive fan -rcmovllt ilnd refitting
Fm hest acce~s to th e fan. 1"~1 ,,:(l10VH th e ""hatol "s dc~c"hcd Ifl
y
SectIon 7 2 Remove the drivcbel\{s) (Section 10) 3 Wlwlc the filn hils ,1 centrill bolt unscrew Ihis ilnd wllhdrnw the fan from the extension Shilh. 4 If the Ian IS secured by <l concealed nut. idenlly a 32 mm (11/ 4 m AF) spnnner illodlfied ns shown in Fig. 25 should be used The Ihickness olthe ~pnnner J<lWS illust nOI exceed 5 nllll (0.2 ill). Jnd II is ImporwnllO re<llise Ihnllhe nul hns il [eft -hnnd thread. AlternJllvely.
It is possdlle 10 Ullscrew two 01 the pulley boil S so Ihm il spilnner 01 nor m<ll Ihickness can be used 10 unscrew the nUl 5 W,lh Ihe [<III <lssl'lIIhly ICllloved. unbolt the I<ln Irom Ihe VISCOUS co!lphn\J (ph010).
G II necess<lly lIl1lJOIl Ihe pulley (;lIId eXlCllsion Shillt wherc npplocilhlo) 1,0111 Ihe huh (lnn\Je (phoIO). 7 11u1'l1Ing IS il levers;)1 01 (emov<ll. hUI ti!lhlCn Ihe holls/nul 10 the ~p,)c,lil'd tU'Ciue. nefti the rnchiltor wah relercnc,) to Sec tion 7 and Ihe rillvl'I'CI1(S) Wit Ii Iderencc to Sect ion 10.
t _
~~-~~,==========~)
I( t-ix~
(0
Fig. 2.5 Manifold spanner lor removal of the viscolls drive Inn (Sec 11)
x -2[j 0 "'''' (I 0111) Y -1201ll1ll(05ill)
e
11.5 80l1s securing filn 10 viscous cuupling 11.6 Unholting the w<llcr pump pulley (2.8 litre engine)
procarmanuals.com
Page 66 of 205
15 Fau lt ui(l9"0SiS ~ cooling system
Sympt o m
Overhe<llinl J
En\lIlHl !!ms too cool
loss of COOI,llll
...
Chapter 2 Cooling systern
Reason{s)
Insuff ic ienl coolant Drivehel t slrppinu R;JdralQr core btockcI .1. or H"lIe rpSI"tled Air lock in cool lnll SySWIl1 W mer hose Coll.1psed, or linked, ''''red",\) flow TherllloSI<lt defecl've l!lnll,ol) IUlHI1H m(;orrer .t V'scous fnll "'op,~r,'llvri In~o"ect. or defe(;tlve pr essu re c"p
T hernlostat dtlf.!ct,ve , (), 110 Ih,:flnosut W,ol1n Ihe"Il<l~t';l f"ted
Dcfe~llve p,ess",e cap l,:akln\l hos,!s leak 111 ,ad,mOl. 01 hen"" tOI() TherrllOsl,lt or 111111111 11~I~l~1 In,l k Blown cylinder h'~ild O.l~l." Crn ck(!(1 cy"nd~( bfock, 0, h(:"d
65
procarmanuals.com