fuel FORD CAPRI 1974 Workshop Manual

[x] Cancel search | Manufacturer: FORD, Model Year: 1974, Model line: CAPRI, Model: FORD CAPRI 1974
Pages: 205, PDF Size: 43.75 MB

Page 7 of 205

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General dimensions, weights and capacities
Dimensio ns (t y pic .. )) Ov"",11 lo'I1(llh Ov,,,,,11 wIdth Ov",;,11 IlI:!!lill Wh""IIJo1S() Tlack F,on1-30 h(I(!. 28 hire. ReiH. 3.0 !olle 2 .8 litre TlJJnOll(J circle (he1wccll ke,l>s) 30 hire 28 litre
Weights (typical ) 30 S Manl!~1 IIo1I1SI11;%IOI1 . Autulll"j,{; llimsmj~s'on 30 Gill;] . Mallual 1,~nsrnISSIOll Automm,e tl""Slllission 2 8 IllJCClio 'l Roof ",d 10<1d
Ca pilcities (typiCill) EIlB"l(), 3 0 htH) . With tiller
Wrthout filter 28 litre : Wrth frller . Without frlter . COOI"l\1 system 3 0 li tre , 2 8 litre
Fuel sys tem . TrJnsrlllssion
M'III(rJI. 4·speed .
5 ·speed .
Automatic (JPprox)
Rear Jxle. Stee ring geM: MJrlU.11 Power·Jssistcd.
GeJr 001 Fluid Sr:p.lrate rese rvoir Imellr,, 1 reservoir
Series II 4340mm (1709 in). 1698 Illll) «(}(;,9 in) 1357 Ilun (53.4 in) 2559 ""11 (100.7 in)
1353 IlUll (53.3 in)
1384 mOl (54 5 in)
100m(32811)
1155 kg (2546 Ib) 11 <15 kU (2524 Ib)
1185kg (2612 11)) 1174 kg (2588 Ih) 1190 kg (2623 Ib) 75 kg (165 Ib) max
5.0 Irtre
(8.8 pint) 4.25 htre (7.5 pin1)
4.25 litre (7.5 pint) 4 .0 l i tre (7.0 pint)
9 .3 htre (16.4 pin1) 8 .7lotre (15.3 pin1) 58 litre (1 2.7 gal)
2 .0 litre (3. 5 pim) 1.9 Iotre (3.3 pim) 7 .5 litre (13 .2 pim) 1.1 litr e (1. 9 pint)
0.15 litle (0.26 pint)
0 .20 litre (0.35 p int)
2.2 litre (3 .87 Plllt) 0 .50 litre (0.88 pin1)
Series III 4439 mm (174.810) 11398 111m (66.9 in) 1323 mm(521 in) 2563 mill (1009 in)
1353 mm (53.5 in) 1400 mm (55.1 in)
1384 mm (54.5 in) 1431 mm (56.3 in)
98 m (32.2 II) 99111 (325 It)
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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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Page 14 of 205

Routine maintenance
Maintenance is essential tOI C"~l"'Il\J sal"I\,. <lnd de~",jt,l" lor \I1 purpoSe o f gening the best inleflll~ of peduPlllilllCr. nnd economy 110m yOlir car . Over the yeilrs the need for pCflodlC lubnc;lIlon o,II,,!!. gle~slOg ;md so on -hilS been drilSl,cnlly I(,duced. Jf not totally ellmmfllcd. This hJS un/ortllll,lIely Illnded to 11);1(1 sonle ()wn~,<; Illilunk \h<1 because no such action IS tCqLllrox l, f.ompol1,:nb I1,\h ,,, n o 1111\0'" e~ist. or wdllast forever. This is J ~;''''OUS (h:hJS IUII If fOllows [ I""do ,t! thm the t,nges t in;I;;;!1 elcmelll 01 1lI;lIntP.l1olll!;fl IS VI$uil l "X;lIllll1dll"ll and a general sense of awmcness Tills Ill;]\, IC;l(llu [UP,l"S Or ",,,,,wals.
Inll shou!!1 1,,:11' 10.'1'0" I !(l,l(bulc hre,lldowlls. Other neglect resul1s In ullrehillllhly, "H:I(~as(;d ,"nnlll!) COSI~, morC) rnpld weM (lnd depreci. (Ilion of Ihe ".,judI'! III !I':II<: ral
The 1"II<)wII'~1 Sr:r",,:,~ schedules ,"lJ ol I rS I of the maintenance req<IIIf"l\,~'llS 0111<1 Ih" 1I1I':lVol ls <ll wlll(.h Ihey should be cDlfied out. Wiler" appl,r."I, I" lil,:s" I"oce([urcs 01", r.ove ,ed In 9,e.Jle, deta,l IhrOll!)hOlll 111I~ 011,11111"1,1(',,, Ihe hCOUIIH"U of .lach C hnplCr or ChapWr ([IV'S'OII
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~--------------------'--~~~~'~ <i.; ...... \~) ---',..." _. ____ m .' &§Sf" ;)
View of engine compartment (2.B Injec tion)
I Br,lke St'fVO uni/ 12 A" mIN duct 21 f/,ld'o,IOI l"lm c:,/, 31 Coohng sys/em pressure 2 Slarl v<lIve I.? /!lflrllOll carl 22 R<!ill,'/01 C,l!) and CXP,lllsion l<lnk 3 Dislribulor cap 14 Powel s/Ccrmg lIu/(/ 23 AII<1II1<!/()1 32 81,lke master cylinder .] Windscrccn WII)Cr <111/1 wservOll 24 /-/e'l(/lig/'1 aCet'H ':IIV('I 33 F'OIlI suspension top 5 Headlamp rc/, lY 15 Warm I'I! ICYIII,1Im 25 BiJlIl :'y ",0(1l1liIl9 6 Windscrccn washcr 16 PVWL'r s/eeli"y Im"'I' 26 rOj! how 34 nr,lke 1I(1ld ICS(Hvo ir rcservoir 17 DI~/I ,/)ulu, f 1111 xl,,, t' Cl!IJlr "I 27 Dllv"'g "!J/II,d:ry.'llI~e ,,111/ 35 n,..,kc IIUld low Icvel 7 Igllilion mllpl,'ic, 1II0du/,: (11111 28 "wlfllollllle Sl1 lid, cll.:cAiny mClllbr,lllC 8 Fuelliller 18 1111 dUollle, body 29 COUldll 1 It'IIIf!"'''II/IU scndt'l 36 V,lC!l1II1! hose 9 Enginc oil !rllvr C,lf! 19 /JOlllle! sl,"ly IIrIIl 37 Fuscbox 10 Tlf(ollle lrousiJl!) 20 PIIWI]{ s/eC11I!9 11IIlIlf) 30 AII.rt,oIlY .-IIt "~'V't'" II A i, chambcr dflvt:/!r.:/(
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-. . . { .' ~I ~ " : . ',\' ,.~ ~ . . -,. ','. ;,:! ---. , ." .. ~
View o f frOll t undo. body (2 _8 injection)
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3 4 ,
Exhilllsl sys/t'''' {,uIII II'Pol Clutch c.,hI,· ,w'/mi!lJt'f g.li/l:( Od /rU,H Cd,llIdy" Brake c.l/,/uN OWkt· fie.d)l" "yllt,IIII,,; hese
6
7 8 9
F,QII! SIl$/lellSIOII {""Ie t 'ollitolmm Tr,lt'1!. (0(/ emf IMII/mlll RulJ/"" IJdfows Pt)Wf!( s/f!f!,lIIg !leal
'0 Fam l SI",,,II.\I." " .l(
" f)1II d}d{.~
" r.", .., Sump "" ,h,,,,, Iduy , ., U!lIIOIII 1m,,...
'" " S(.JI/"', 11/(1/01' lV/,'/w/11
16 SMile, "'''IQI 17 Fuel !ct-" ,1m/te/llm ,)'pes /8 M,1"'1.1I,!",,,v ox 19 Plopell,·, _,,,,,11
20 MUI"'('''', ("IIYllle IC,ll) 21 511<:1:1/"""</'" cdhle
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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 $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
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Fault diagnosis 21
Starter motor ((/rns cngino slowly Parti ali V disch~rilcd b<ltlcry (rClch"'!le. usc Jump INlds. or push
sian) Ballerv terminals loosc or COli oded Batte.v earlh 10 body delcctrvc Enuine ear th s tr,1p loose Slarle. motor (or solenoid) wiling loose Slaricr mOlr ill1crnlll laull (see Chaple. 12)
Engine ((/"'S normally but 1,1ils ( 0 SIMI Damp or dirlV HT !eads <lnd dlS1"h\l10r CllP (cr<lnk cngine and
check 10 ' sp<l.k) DirlV or inco.rClCtly g;1ppe(1 .1I51"h(lIOf pomls (If nppllc<lblu) No fuel In wnk (chcck 10' dchvclY .11 C;1dJU.etlor) EKceSsive chokc (hOI cn\JlIlc) O. II1su l!,clenl choke (cold CI\\)Il1c) Fouled or incorrCCtly \lapped ~pnlk p1l'\lS ('1I1I10ve. clean .11)(1
regnp) Olher ignilion syslcml",,11 (~ee Chapler II) Olhel luel sySlem 11Ildl (se c Ch"plm J) POOl compression MaJOf mechanic;1 1 l<l,hlle (ell c~lIllsh.11t \I',;1r ICClh sl"ppc<l)
Ellgine lires but will not fUll In su!hcicnl choke (cold flfl!)lIln) Arr le"ks al CilrUurC110. 0' mlill m;1",lolli FuClI sta,vatlon (sec Ch"111C' 3) []"lIast rCSIStor de!ecllvn. or OIlier 'H",II<HI f,lIlll {s.~e CIl;1""" ill
Engine ClltS Ollt ;1nd wilinOI roslinl
fngine culS out suddenly -ignition I,wlt Loose or d'$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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48 Chapter 1 Engine
110 Routine '!lain!cnanc!!
At the 1I11Clv"ts specifIed III Ihl! ROutlll!! M"inlcni'lnce sectIon in thO !rom althe mil"l).11 cnlfy out the followmg procedures.
ClwlIgc ollgiflO oil. reflew oi/Ii/fer t/lld clean oil filler cap 1 Rdo, 10 S()C\'OIl 2
Check illld <1r/jllsl vMvc c/c,7f<1nccs 2 Rcfe. 10 Scellon 89
TigMt'lI mll;( IlliIlldold hollS 3 RP.1110VU Ihe ;", Llr:"llcr ;unl lI!Jh1cn the Inlet rlIi'1ll,fotd holts 10 Ill" spccll",d ,ollluO wIlh .oleumc!! to Chapter 3. On comple\lon re lu the au deane.
R(JIII.'w Ihe cmllkc'ISf! l.'mission v,Jlve " Ad", In SIl<:\lUIl 7
41 Major operations \lOssi!>lo with (lilgine in car
T 10" lollow,n!) ""'1111 Ot",,;otlOIlS Illay he r.'If.icd Ollt wlthou, ""''''VIII!lllw';!)!luH!
(.,) /r,·", .. vmy .1",1 "'/'/flll!! III!! ,:ylmd ... , "1.'01(1", (II) {,"'IIIIJVIlIf/ tllld "d'I/IIIO (/1<: /ltmll!l 1I,·.ItS (i:) 11,:IIIIIVIII.'I.IIItI,dll/III!/ /IIt] I!II{/IIIL' 11II1I/11!""I1/III!I~ (II) III'II"'~IIIY .",,1 "-'''/lilly/he Im!lIll~'I!It];,,""" ",;" "'111"'/"'.'1 (,') /{"/IIIIVHI!I .mlf ,,-,"II"'II,IIt] (;;/II'S/l."1
42 M" jot Ollcra lio ns requiring engine removnl
The followll1~lll1alm ope"II'OIiS may be c,lIIlI~d OUI allC! ,cmoval of Ih" !!II!I"W
(01' /r,''''''''''''! ,mlf ,,:III/my llit] fly"'/md (b) 1,'I;"""'III!I ;lIId 1I:"lIiII!! lIlt] II.'''' "';1111 '''.·;IIIIIY vII sl~.ll (,;) f,',:/lWVIII!1 11",1 ,,:hl/myllll" ,:,.mAr:;,.w stlll'p· (,I) 11,·wIIV"'!1 .md It"/tflmyl/t,) 1.-"/II,,.t:I"'!1 tOri 1t~·;"'''!1 (,.) /1,.",,,,.,,,.'1 .md II-,!t/lmylll,) ,,,sl,"'.~ .1111/ ,;ullltL'd"'!1 IUds II) ".,.""",,,,.'1 .lIId tdll/myll"-' "II /lllillfl (.'/) f'"'·"'''V''''f ,11101 td'IIIII,,'''t] (I.mAsh .. ", ;/lul",;,,,, ht];mllYS fli) J,',·IIU1V'It!l .1111111.'1t1/1II!I fl,t, C,lll/.f/"dl 1141.<111."5
A lth""!lh 'I'~ 1)(,·.~d,le 10 1(~II1()~clhe SUI"P W'lh lhc C"gllHlII' the ca'. I! IS 1(":o""",·,,~I,,d thai 101 ,Illy ope"u,olls wh'ch .elt""e Ihe .emov,d 01 IIH: ~""'P. ~,,<:h ;,~ the ,eOllov,ll nf Ihe CI,'nksh;lfl alllll"o c!l(II)c<I''''Us.
tl,,: ""!)"'" ,~ '''''''IV'·!!
43 Mctho(ls of engine removal
The ""!I""~ 'n"V he hfWd oul e'the. 0'1 us own u. III u."t wuh Ihe I""'~""!>~'{)" On I1lo.I\lIS l'I1t.'<I w'th ,1UlOm"toc 1'''"S''Hss.on 1 . s ",co"""""d,;d Ih;,1 Illc ellUlile he hfled out on 'IS OW". unless <I ~III'~IiIl'tJ;" <':I;'''£, or o~ .... ,hll"d hO'SI 's <lvn,lnhle, hecolu~e 01 the wc'ght f, ,<:IO' II Ih" ''''u'"e ;lIu t 1"I"S""S5'O" <I.e .emoYcil as a uIHllhey have W hI! hf!Loti o.n at " Yery Ml'Cp il"UIC. so mako sure Ihill the.e ,s stllI,cuml hrl"'~1 "'-"0111 nvndalJlc.
44 Engi"e -rcmoval
Open imd p.O)) up Ihe bonnet lhen covel Ihe w'ngs w'lh CIOlhs. o~ <:n.(l11O.1,d. 10 Il,olecl Ihcm hom scr<ltches (luling Ihe subsC(IIHlrH O)le(,ll'O"S '1 Millk til" outline of Ihe hOllllel 1""IlCS and 1hen w,th the help 01 an "ss,stim l. ""nove tl'l! 1o". lK.ln'll! se'l:Ws . ,t;l lIilse the bonnet stily and e.udtlllv hl l tl'l: lmnnet cre", 3 [)'~CO""l:<:t Ih(: l'il1I .... 'y lends. tIllT10ve Ihe hnlln'y clilmp bOlt <lnd hfl
II", IJ.,U",v oul <1 fle,l/oyu lhv ,II' cle<ln(!/.
5 flc"'ovu 111,· ~pl.'~h ~h,(;ld hy "''''<1VU'H II", hlllt~ ,1,,<1 cI'p~ 6 PI,lce ... ~:Il"I.I·nf" of 10 lot", 11"16 JI"'I) r:,'I),II·, tv ,,,,,Iu.,,, !,
'iI(I'<lIO'. ""novc Ih/"! ""h:OIO' hun",,, h"", .1,,,1 ,h"", th" r.Il"I.l,, · 7 RcmfJv,~ Ih,' "1'1)1" hll~" I,n'" Ih" ",";,1", I''''''P n'·'I1"~" Ih, 110m Ihl) all d,,1I,·I.I,,, pa" .. 1 ""d I""" lh" ,;"""t,,, ~h"",,1 ;'"d ,.
Ihem
8 flc"'"~,, Ih., I",,, hllll~ ...... · '"II'!I th", """.11',, til Ih" '''UII Ila" hfl Ihc "1(10,,10, ""t
\) D,sc""''',,:1 Ih,· ',,11 w",.·, hm,,, 1"111' Ih" w"tt·, 1"""11 ;",.t a"I, cho~e
10 fle"",,,,, tht! -l.lI"·' ""'10' h,·;11 ~h,,'ld .11,,1 II"·,, ,I,,, '''''''·'·1 tho I,om Ih" ,,11"""'\0 " t'·IIIt"·'."'"'' '.""d,·, 111"1. "1"'''"11 1./,,1 ;111,* mOIO'
II R"IIl'l"" Ih,· ...... " huh ... "''' ~""'!I th.· 11""nl,· h"k"!IU I,
aSS(lmhly to Ih" .1\1<'1 ",.",,1,,101 .lIlfl "·"If"·,, It Ipl'Il.IIt 1 2 fl'''''<l~'' Ih,· '" .. I .. Il'· ... ""101 II,,· 10,,·1 1''''''1' (plo(II"). Ihe,
vnCll"Ill hn,." I",,,, Ih,· ,"1,·1 " .. ",,1,,101 .",,1,1,,· "oJ )."· ... ~II"· I",,, fll. conn,-ct", .11111 , .. I.· ... t I""" tl,,· .,,1 IW""";'" '" .... ,,,,, 13 R""",,,,, tl", •...• , 1",l b ""·"""'!I Ih" '.1.",,·, "",r,,, .""t ",,,,(,,. 14 flell1""" Ih,· I.\() """ 10, 01 ..... ·"'''''·''1 II,., ,,,hi,,·, """I.'I"'~ III, en(Jllh1 """,,'I"'!I' 15 RII"'(J~" tt,,· I.'." ~"'I~ f""" '·.11 h ,·~h.""t n.",,),· ,11,,1 ,II".,,,,,,, e~h,'"~1 il'l"'S ),'"'' III" ,·~I,.".,t ",.""f',lel
114 12 Fuel j)1""p ". d 1,,0;1 I,"t;
I;" ,
1:-,
!
~ ,
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52 Chapter 1 Engin e
68 Connecting rods and gudgeon pins -Il~nmination a nd renovation
Refer 10 Sccuo n 18.
69 Cr,lIlkshnft -e~(lrl1in<ltion and renOV;ltion
E~amUle the four 'lIil;" l>e .. "n9 Journals and the s,~ Cfanlq>nls. whIch should illl be smooth Iln(1 IHlJhly polIshed II there arc any dllCP Ulooves. 01 deep scratches ;mo lhe.e ,s a sirn,l,lr <loI0"ola 1,on in the corrc5pon(fulH Iwaring sh(:ils. 1ho crallksh<l h should he reU'Ound. 2 II the JOUr1l<lts <I,e ,n noml conditIOn and 11 IS slIspec!(1d lhnl th e cI,Hlkshnh mily he suH,eocmly worn 10 fL'(IUIiO ,cYllndrng. II IS wa. 1h SCClo.II;t! the advice of ,) "'11111 Ford ,1\jCIlt. 0' cWllkshaf1 regllndlng servIce. 3 If ,he C1ank sh"f( IS '!](IIouml. till) wOlks w,1I ,1lso sUIW1y rhe new hC,lIIl1US wt\lt.;h WIll he rCII"'''!!! 10 Jl\atch Ihe lournal d,nmOlf"S.
" Check the spiuol bu,1"n!) III Ihe .ea. 0 1 the Cfankshall on manual l.ans.mSSlon m()(lels :mllil necess;uy .enew II
70 Mail' and biu·end heafinUs -olwillinmion and H)!1ovation
Ilelo,r to Seo.:lIOIl 20
71 TilninU oellrs -e~i1miniltion find renOVlltio n
Re f
el to Sec t,on 21.
72 Flywhee l/ d riveplale -Okamitliltiotl lind ronovtttion
Inspf:CI lhu ffywhf)l)I 0 ' ([ttvl'pl,,": fOI (!;U";'\lC ilnd 1:I".1I:k Ih;'1 Ihe ""!I H".u docs uol have .IIlY \)Iok"n o. l);Idly wOtn teeth. :1 On ''''''''';11 I'''"''''US~IO'' mnd"b ,I IS pOSSII.Il) 10 'CHew the I"'!l \]C,II .'S Ilesl:<Ihe(] ttl SeCtlim 22. IHlt on olllt()I\IHIIC IlilllSn"SSlon ,,, o(lels It IS nOl tlOss,bl" 10 le",OVf) 110" ""!I 11"01. hom Ihe dllVel)lttlc
73 Valves (",d v"lvo sO,,1S -tJkiu"illHtion lind renovation
[xallutle Ihl} v,tlves 101 IlIls "lid !l,ooves lind the valve SIems to. e~c,'SslV') we,l' III d'~loIIIOII' 2 Ek,""l1ltJ Ihe v,oIVil hf)"d 10' SI!.!"S 01 hu",u,U of the vOllvo seillS lind ch .. !ck Ihe ht 01 Ihl) villves III Iho v,llve UUldes . 10 SCl) II Ihe villve uu,des il,e WO!ll
3 We"" valve U",dcs c;'" be r l),lIned O\It lind vlIlves w'th overs.~e Siems lilted II iI v<llve !lulClt: h<ls h(."Cn ,eamed oUI. Ih(l eOllespon(fing vlllv(l sent must he rdOlCe(1
" Villves illld v~Ivo se .. ts whlc" show JollIe s,on 01 wear. call he lilpped in.
S To 1,1P the valves. In tt s u ction Iype gnmlonu 1001 to Ihe villvc hettd. smeil' a lu tle COil.se c;ubo.unllulll urmdmu pOIste on to I he sealing I~c e 01 Ihe vnlve ond inserllhe valve 11110 the cyJonder he"d. Rub Ihe stern of the v al ve gundlng 1001 hetween the palms 0 1 the hands. so Ihal Ihe valve,s ,otllle(l hHckwards 1I11d lo.wa.ds When II IS lelt lhOlI culling has
ceased. loft Ihe villvc. rotate It th.ough 90·, lowe. 1 and fepCill the u"n(llnu o.:.e.atlon . • e dlslllbulill9 the g"nd,ng pas!O on Ihe seal if necessilry. Conlinue Ihe process unlll a mllll gwy bOlnd IS pfoduced OIloun d the complete pe"phclY of hoth the vlllvc and t he valve seil l G RepoiJl Ihe opcrilllO" US" 'U fine o""d,nU I).Jsle. 10 ohtil'" <I I,ne.
IInlsh. then clean lJoth Ihe valvcs and Ille v alve seals 10 ,emove IIU \llIces 01 u"ndlno pash:! 7 II 'I IS convenl,,1lI 10 liIke Ihe eyhndc. he<ld and the valves 10 a wo.kshojl wllh the necosstt.y cquipment. II is In. h ellef to have illi Ihe va lves <lod Ih,,,, seJts ",f"ced. so IhOlI alilhe villves and sellts OIle lit the co""Ct ''''Ule and h ;lve Ihe COllect w,dlh o f conlllC1.
74 Dccarbonising -go notal
When Ihe cyllnde. heilds (li e removed. eilhe. in Ihe Course ovelhJul Of for inspection 01 bows 0. villve condllion when the e IS in Ihe CM . il IS nO'''1<I1 to remove 1111 CMhon deposits from the I Cfowns and heild
2 Th is is hesl done wilh 0 cup shilped wire hruSh ilnd iln elect." and is laorly slriliuhlforw,!,d when Ihe engine IS d'S<llilnlled an,
p,slOns removed Somel,,"es h.l. d SPOIS 01 ca.bon iI.e nOI , .emoved exc e)) t by iI SCf,'pCI . When cleanln!) Ihe p'Slons wllh a SCI IiIke care nOllO dam.lge Ihe sudace 01 the ,)iSlolI.,n (lilY WlJy . 3 When Ihe en!l",e IS in Ihe car. ceria", prCCau tlons mUSt be t whe", dcca.OOrllSIno the pistons' c.owns in o.del 10 p.evenl dislo, pieces 01 carbon 1.111;110 into Ihe inlerior 0 1 the ellgme which c cause dillllilgC to Cylindcr hores. pis Ion .10d lings 01. 01 allowed the Woller jl.1sSolues. llilrllilOC 10 'he Willer pun.,). Turn the engine so Ihe p'S lOn lleinU Wal ked on IS Mlhe top 01 lIS slIoke and then mas l Ihe a(llttcen l cy'",der bores ilnd ilil sU!roundl",g wttt(" l"cket alii wllh papel and .1!!hes,ve 1ape Press !lwasf) ,nto Ihe gil(l illI .ound pislon 10 keep Cilrbon pa,lIcles alit ,,"d Ih(ln SClilpe 1111 c,lfllon awa hand Do not usc iI power thin and wile hntsh when Ihc enguI(lls II, ettr as II WIt! virlUillly be 1Il1posslhie 10 kcop alf the cal ball dUSI clc, the engine. When compleled. c.1wlully c'ear OUI the OH,,,se moun(I ",II 01 Ihe (liS lon With ,1 mlllc h SlIck or somelhl"U Sllm 'iI • . bringing ciI.bon palhcles wllh It. R c,lellt the p(()r,e~s onlho o the. p,slon C'OIol II IS nOllecormllended Ih.lll1 "'ljJ 01 "uhon IS leit .ound Ihe edge 01 p,slon on I h(l Iheory Ih"t ,I Will ,11(1 all consumplion. ThiS WilS valli
Ihe eiliite. dilys 01 10nU stroke low .eVYlnO en!)lIles tJUllllodern enUil fuels ilnd Itrb"canlS C,1use less cOIIOOn deposils OInyway and any. b ehind lend merely 10 cause h O I .SpO IS.
75 Oil PU"',) -disnwntlino. eknmin"liOil ,,"d reOlssembly
The Oil pump mm"Itt;"S a I)ressure 0 1 ilbout 2 8 kgl/cm' (3 Ihf/in') lInd unless Ihere is ,1 sIo",IIcanl (hop In 001 P'(lSsuro willel ,)loved to he due 10 the Pllln,). rillhn. Ih;", 10 wo", heil'm!)s. 11 IS be .
t o le"ve Ihe 011 pump und'S hilhed. 2 To d'smanlle Ihe pump. fll:.1 ,emove II hOln the en!l'ne ns desc,,1 III SUClion 58 3 Remove Ihe IWO bolts seCulII1!J Ihe en d cover 10 the body 1 'emove the covel ilnd 1he .ehel v;" ve "sscmhly. Ihen Ihe Iwo P"
fOIOI assembly.
" Remove ,he IWO bolts lind ,,,ke Ihe p,ck·up w he lind SCIl' lIssembly oft Ihe pump housin!1 S Wilsh all lhe pilrlS In petlo'. usc iI hlllsh 10 cleol" Ihe Inside 01 1 pump ho usinu ilnd lhe p.cssu,.., .elle' vil've eh'!lnbel. ilnd milke 5' Ihilt ,111 p,tltlClcs 01 dill ilnd mewl n,e ,emoved Allow the pttrlS 10'~ n;IIUf,lllyor blow them d.y G Check Ihe Illslde ollho Puml) houSII'9. Ihe OilIer .;w:e ilnd Ihe 101 101 dilfllilUe and e~cesSIve weill 7 E~ll'''Ule the I111lling su.lace 01 lhe I)Ump cove. 101 we,lr It Ihe CO' IS sco,ed. o rooved. a. shows ilny s'g ns o f wea •. a new covef must I hlled 8 W,lh the ,otor assembly filted in the hOuSing. place a straighl·ed!. over Ihe end 0 1 the housing <lnd measure the .o tor end play. If 111 exceeds 0.1 04 mm (0004 in). Ihe ouler race. Shilfl and ,Olor must t renewed olS an assembly. 9 M eOlsllle the rOlor·IO·houslng clea'ilnce. which should not exce e 0304 mm (0
.012 in) OInd Ihe Inner 10 oute. rOlor gap. which should b 'oss IhOln 0.020 mOl (0008 i n ) II oulside these dimenSions. a ne" pun,,) Should be fitled 10 Check that Ihe leroel vollve and its sea Illig ,Ire Iree of dan'ilge all' thaI the .elief vOl've sp.ing ha s nOt collapsed. 01 is damaged. and 1 new paIlS ,f necessil rv. 11 Reassemble Ihe pump by IUSI lilting the lillie. IJnd outer rOIOr) Ihen lubric.11inU them wllh enUOne OIl. '2 Apply e ngine 011 to Iho rehcl vlllve plunuer <lnd sp""g ilnd Inse l Ihem inlO thei
r hOUSing Relll the Sjll1llU cal) and Ihe pump covel '3 Refit t he cov e. allolchrnenl sc.ews 1111d IlghlenIhelll1 0 the to.qu' wrench sen ing giv<m In ,he Spec,flcalions Altel t1uhtemng the screws
chec k thOlI Ihe 1010r moves freely 14 Refil the PlCk·up lUhe <lnd stralnel as semhly 10 the puntp body usi nU a new gOlskcl OInd then insert and hUhten the IWO IIxHlO screwS
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,
i
I II
Chapter 3 Fuel and exhaust systems
Contents
Pari A: C,UbufCIIQr system AccchmllOf cable -removal .1n( rerilling , ........... , ...... . Accclm<J1or shMt ,lOr! pedal -remo"nl (Inc! refIlling All clOllnor lemov;!! and .cf,nono C;).1)tIICItOI ocncrnl C,HIJUICIlOI -<elOovlll "nd ,cfiulIlg E~haust mnn,fold •• ernOIl,,1 ilnd 'ChUII1{J Exh,luSt svstem -removill ,1n(l .elnl ing Fuel 1)\1"'1) cicarllllg Fuel PUrlll) .cmoya! ;mll .ellll1119 Fuel pump I(lS[mg .,_ Fuel lank · cleaning and lel)'111 Fuel t,lllk . wllIav"r ;1I1d Ifllnton!! FlIt:r lank follcr pipe [Cnlollo" ;111(1 H;liuinU Fuel lank sender unO! -/Cllloval and IcllU1no . GcnCr,lr dese/jpllon Inlct manifold -lemollill and refrlllng ..... Routine fllilinlcnancc . Webe. cJrburctlor -dism,lnllmu ,111d reassemblv ,_ Weber C<uhurcttor -idling adjUSlmcnt .
SI}ecifications
PMf A: Cilfborettor system
Gctwrctl System 'Y lloC
Fuel pump delivery l)reSS\lrc .
Fuc l I,ln k c,lpnc,'Y .
Cilrhurcttor lytle Tluol1le baf!el dranwtcr
Vcnlull d"ll'ICICI
Mainjct: 1 !I71\/1975 1976 onwards Idlong speed: 1971\/1975 1976 .............. .. 1977onwilfd5 FilSI idle speed: 1976 1974/1975 ilnd HI77 onwilr(ls
Floal leveL: 6111SS lIoal
PlaStic float
Floill Iravel ...
CO %
111 idle: 197<1/1975 1976 1977 oowards ......... ........ , .................... . Maximum choke vacuum p ull down. 1974/1975 .......... ....... .. 1976 1977 onwards ............... . Choke phasing: 1974/1975 1976 .......... .. 1977 onwards,
17 18 3 7 8 20 21 5 6 4 14 13
16
15
1 19 ,
9 12
Weber calburellor <Illlornal,C choke ,1d juSln'enl Weber carburetlol "",lam""c choke " ,mov,ll . ovclhaul ,1nd letitling
P.1rt 8: Fuel injection system Accelerator cahle -removal and wfl1l1n!J ' Au cleaner -Icmoval ilnd lellll,O!! E~h.1USI maOifold Icmov,ll and whllm!j
Exh,luSt system .. lemoval ,1nd rnf,ttin!1 Fuel l:lnk. sCIld el utUt and follel l"floC !!fmc.,,1 Gene.;,1 descflpt,on
Irlle nuxture • ,1d/l' Slmenl ..
Inle t man,fold .• emoval and 'ef,nn,!]
Ma,n systcm compo nents .emoval and rd,ll'n!) nouline m.1jnlcn,lnce .
P.1r( C: F.1l1ff di,1gnosis Fintlt d,n!]l1osis .. fuel syslem (cadJll,ello,) Faull d'agnosis -fuel system (fuel injeCI,on) ,
11
"
:12 33
Dual vcnlu.i downcfoa"llhl carh,",cl1or. m~IHI"'Ci,lIv Or.cHnlcd (hap'" .agm luel pump. tempcrilh rrc cOllI/oiled air clenne, on sallHl "'0111:15 02510 0.35 kgl/cm' (3.7 1 0 50 1I,l/ln') 580 Il1re (I2 7 1)011)
Weber (Iunl venturi wilh autorn;rt,c choke 3801111 27 nun
1450101 or 1<12 mill 142 mm
800 J. 25 rpm 825 1. 25 'pm 850 l 25 rpm
noo ,., 100 rpm 2000 ± 100 rpm
40.0 mm (1.575 in)
3 4 .3 mm (1.350 in) 12.5 1. 0 .49 mOl (0.492 L 0 .02 in)
2.8:l. 0 .2 1.75 10
5 .0 1 0 .25 nun (0.197 7.0 J . 0 .25 mm (0.276 5.5 :t 0 .25 mill (0.217
2.3 ± 0.25 mm (0091
, 0,01 , 001 , 0.01
± 0 .01
3 .0 :t. 0 .25 nun (0 118 ± 0.01 2 .8 :l: O .25mm{0.110 J. 0 .01
in)
in)
,n)
in)
in)
III)
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Page 68 of 205

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Chapter 3 Fuel and exhaust systems 67
Torque wrenc h setting s Fuel P\JlllP Inlet n'<llllioid Swgc 1 Swgc 2 Swge 3 StJge 11 (<lhe, runninu enome for 15 minutes <II 1000 rpm) Exl1;lllSl n1<ln,lold to downpipe Exil;lusl U·holts ,11\d ci.lmps C~rblllClt(}(
Pari R Fue! iniaclion syslem
G ene ra l SyS1c'" Iype Idl e sp ce d CO "o,![ ull" Fu el p"mp rfelov(!ry (nHrHrl1lJlll)
SyS1cn, P")~"'''U Fvcll,mk Co1P,lC '(y
Torque wrenc h settings Fue l ,11,>1,,1.,,101
W",m "p "'~11I1;,1O' 51<1,1 V,llvt: A\J~'h;"y i'" duvlC(! Air eh.""I>", Bal1)o I>ull~ Fuel d'SI"hu\or W",nl up '«!lul,l1or (MIO) W,llln·up rC(jul<lIOr (MS) 1I11C(:1I01) pipes Fuel pllfnp. fi lter <lnd ncculllul<llor
PART A: CARBURETTOR SYSTEM
Gener,,1 description
TI", 1",,1 sy'>I<'1ll <;onSIS1$ of " reM moulI1ed fuel wl1k. il {hilpluo1\Jn1 type 1",,1 1l"'''P d"v(JIl I,om the C,lIllSh<lh !lnd " (lu,11 vellll'" lio .. ""h''''!II\! <::111,,""110< There Jle two SepJ IJle eKI"luSl <1sselllhllC s.
eJr.h COII~'Stll'!I 01 ,I hont pIpe nnd leson<lto r. mtell"ed'ille pIpe <1nd Slknl"ul. '" HI J 1<111 pIpe <llld Sllcncer The <lir CICJllCf 011 Iiller models II1C<J'I101;lleS , te"'pcr<ltlllC control II,'I).
S omn models !"ay he hlled wIth a p,llted vacuum switch (PVS) to p'eVUl1t fI"1 SpulS aud nllsl"'"0 OCCll""'\) when the enllllle is cold "lid flll"""'1 WIth hJlI or pMllJI choke. When the enuine IS cold (below 71 C I i GO F» the I'VS IS closcd. In tillS cond,I'Oll. c;lIhurenor v,lClIllln IS ,'Pl'hed directly to Ihe d,st"lnilor V'J the Ilon·return v;)lvc. whIch "lIow~ (he va ClJllI1I Jdv,lIlee to IJc milll1lolll1e( 1 lIntier <1cccieIJt.on.
prc .. en ('''Uliat spots or mlsf""'\J .... ·ho)lI the eng"'e h<1s re<1ched liS norm;ll ope,mll1\J lemperJtllle Ihe PV S I, open In tillS condltloll lhe C<1rbUle1l0' '5 connected 10 Ihe
d ,s t"hu!Or v.a lhe PVS.
2 Rouline lll<linlen <1nce
AI the IIlIclv<lls spec II led 111 the RoutlllC Malfllelwnce seClion Ullhe "0111 of lhe IllJllll<l1 CJrfY out the followmg procedures.
Check and adjust the idling speed find mixture 1 Refel to Sect.on 12.
Check condilion of fuel hoses 2 E>.n''''lle illl Ihc fuef hoses on the eng ine compartment and on the fu!:1 ""'k. for SIgns 01 leilkJge or eletellowt,on. 3 Che ck the secullty 01 <lll fuel hoses Tighten the IIllet mnno 'lold
holtS 4 Rel"r to Sect,on 19 Jnel t.ghlcn tile IIllet I11J",101d bolts III the
)
s!:q uence (jlvcn
Renew the ilir filler element 5 D'$ coruWct lhe hauery. G Remove lhe twO nuts secullng the air cleaner lid nnd remov e tile
N rn 16 to 20
4 to 8 8!O 15
'8 to 2 2
1 8 to 2 2 20 to 27 38 to 45 20 to 2 4
Ibl It 12 to 15
3 to 6 6 to 11 13 to 16
13 to 16 15w20 28 to 33 15 to 18
1305<:h K ·JetfOnic COlltonnous inlCCllon !JOO .1. 25 rpm 1 25 I 0.2 930 a cc cvcry 30 scconds 5 f)5 I 0.25 kUI/crn' (789 I 36 11l1/on') 580 hlrc ( 12.7U<lI)
Nm Ih l It 32 to 38 24 10 28 7 to 10 5 to 7
7 to 10 5w7 7 to 10 5 10 7 7w!l 5 10 7
18 to 20 13 10 15 11 to 15 810 11 5 to 8 4 \0 6
5 10 8 4 to 6 181020 13 t o 15
hd . 0" I;>ter models the ltd rnily be secuted with sprong IJSleners. 7 LIlt Out the paper clement <llld d,scmd it.
8 Cillelllily clc<lll the inside of lhe Dif cleJner body. !;"IlS''''Il\J thilt no dllt IS illiowed 1 0 drop into the cmhurCl1or. !J I'll <l IICW element "nd tclot the <l" clc<lner lid 10 Recor"lect the IJ,1twry
Check air cleaner IClllpcril{(lrc control (whcrc (i{{cd) 11 By looking through thc main ,101 cle,llle' spout. nOle the pos'tlon 01 lhe 1I"1l v<llve. Wilh lhe engIne stmionJIY Ille lI"p should he lully closed 12 SlJr t Ihe engine <lnd check the oper,ll,on of the lI"p vJlve W.lh the engine Idling the IfilP should open Jnd s tily open 10 ,1110w hot all "liO lhe <1" cleilllCr. Note: II is essen/l,ll/liall/llS lesl is C,lIllC(/ OUI wilililic ClIljlllC cold. If the 11"11 !CIIlJ"lS closcd whell the ell!l",e '5 st,IIIC(lthell 1herc IS <l fmill 'n eilher Ihe dl<lpilfilllill unH Of he~t S(oll50r "nd thcy should he tcsted JS follows. 13 Check the vilClium supply p 'pe for leilks Jnd renew It II suspec l
F ig . 3 .1
Air tamper<l ture controlle d nir cleaner (Sec 2 )
A 8 C
VaC(I(lm mUlor FIlip valve I-IC<1I sensor
o 1-101 all in",ke E Culd illl U!wh,
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