fuel pump FORD CAPRI 1974 Workshop Manual

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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'$Conncetcd l T wi.es WCI HT Icads o. d'S I"buiOI C;1P ("lIer tr;1VC'SOll!) w;1'er spl;1sh) Co,1 o . condenser lallulc (cheek 10' SI);lIk) Olhc. ignition laull (see Ch,'plfll 4)
Eflgine mistires belore CUlling oul IlIcll,wlt Fuel I,,"k Cillply Fllel pump dClfecl1vc o. 1,ltcl IIlo .; k(H! (dwck 1m dellvl"V) Fuel tank hllcr vcnl blut;kcd (StII; llon Will II" flV,{Io"'1 Oil lI~h&#34;&#39;~II&#39;H C,11l) C;1llJulCIIor nccdlc v"lvc SIII;klll!J (WIU.'1I1 "ppI1c"hle) C,1lUwellor leiS blocked (ha:l COIII,lIl1ln,Hcll) Othcr lllcl sys!Cm l<lult (sec Ch~,II<!I 3)
DISCHARGED
BATTERY
lSin.MIN
POSITIVE
JUfl11) Slart lead conneClions f o r neg!Hive earth vchicles­connect le;1ds in orde r shown
fllgine euls Ol1t -olhor eimses SCIiOliS ovcrhC~ling Mnior mcch<lnic,,1 !<lilUIC (elJ cmllshMt drive)
Engine ovcrhe<Hs
Igllitioll (llo-clwrgcj wt1fllillg IigM illuminated SI;1ck o. broken d"vchelt felCn$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/&#34;&#39;.I(C(1 ~·lIy&#34;&#39;., 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&#34;C&#34;f1~&#34; (.'IIYIIIC .J/ 11l;~()VI.&#39;r I.~ 1101 1II.'I:<.'",.","/y,1 (.",lIlSV {o, CIIII{:"/U Suddel! fJf&#39;~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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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&#39;&#39;&#39;&#34;&#39;&#39;&#39;&#39;US~IO&#39;&#39; 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,&#39;SslV&#39;) we,l' III d&#39;~loIIIOII&#39; 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&#39;~ 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&#39;&#39;&#39;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 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
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:12 33
Dual vcnlu.i downcfoa"llhl carh,",cl1or. m~IHI&#34;&#39;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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68 Chapter 3 Fuel and ClChau st systems
14 Dlsco""C(:t lhl) V;1CllUlll ~lIprly IUPC (10111 th,: h<:.11 ~Cllsor Oh~r.rv&#39;J Ihe O,) CI; ,hOil Olillc U;1,) villvi) whll!) ,'Ilhe s,.,mc hn~c ;)PpIY"l!1 SUCtIo n 10 Illu cnd 01 lhc ~&#34;ppIV plpn It Ihe 11;111 v,llve &#39;C~1&#34;&#39;S closed then CI!lu:r tlw (i .dplu;)!l11l or 1110 flap V&#34;IV~l IS 1 ,I\Jlly If thl) I lilP now opf;n~. Ihe f;lUII 1":$ III Ih,~ hea l ~(:n ~o(
3 Air clear -rCllloval nml le fittinu
1 Q,seol1ll(;f:l lhe 1I,,1h !IY 2 Remove tli' l two n&#34;l~ '<:t:lII,n!l 111".111 (,"'.III,,, lid "nt! ",m""" II,,, hd. til ... " I,ll" OUI 11", "" 1.1,',,,,.., 0;1,,11\,,111 3 Kuuc.k '>.ILk lh" I"", Iud. l"hs _mel 'CIIlU"" Ihe toUl Ilul:> so'' tuH1!! lh,);oll ch',IIlt" if) !he r.;Hhu"·lw, lu><ly ·1 l.,lr Ihe ,III dol,"'''' hody "It lh" ";II/'Ull111<)1 ,lull &#39;h~UJlIll,,<:l Ih" hOI :\11 'ulm Who·,,, "1'1'1..:,,1)1., ,,1',0 ''''',lIIm,,'' ,h" V;'U;UII'" luv.,., !"i RI,hu"I!I'S lh,· ":"""'S" 0 1 ",nuw .• 1 II"" "'!W 10d'I .• t. .. oJ Ih" "'''1''1011 &#34;Il,·~ ,,,., s&#34;~p&#34;&#34;1 ""d 101., ,"·w P"I"" 0;1,,",, ·,,1 &#34;&#34;I,&#39;~s Ill" &#34;)&#34;~Im!) .. &#34;,,&#39;~ "".y,.I",1I1
4 Funl III "lIP Inst "'\1
H Ih.·", .11" .. II ""Y'"'''' 1&#34;,,1..~ " 1",·I"",,,,,,y •. h d).. .. I 1111"1 I""" P &#34;I~&#34;,&#39;I&#34;&#39;&#34; ':,111 I" , ",.,11" I,V ot"".""" .. ,.I&#34;I~1 110" ",,11"1 1"11" "I II ... It ... 1 1"""1' .,,'U I '.(""","'I",!) II", 11111"1' OI,lh' l I,y., I''''!III, (,I 1"1,,, I"" ~II.,~&#34; I." :' Cr.,,,1.. 111" ""!I"'" .",,' /,h~&#34;,\&#34;&#34; ..... 1"·. 1"" _, "'''''1 .. 1 p,'III,1 '''''''', .... I",,,, .h" '''''''I' .",,1"1 .,11111" I''''''''y .. , .. ... ,,,' :1 To c.h""k 111.11 II,,! I''''''P ,<; w.II"" 'h ~p&#34;&#34;oI&#34; .'IIUIl. ,,,,,,,,,,, ,1 .' p.e&#34;~&#34;,,, !la,,!!,! 1 0 th,! IU""p outkl D'M·,"''' ... '. t III" II r ","", hom 11", co,l. c,;ulk th" ""!)"l{, ;11111 UhM"V" wh",h'" Ih" 1>\1,1,,1 1''''';''''111 " ." SllCCd'e d
5 Fucl purlll) dc,,,,illg
D"I,'I:II (h .) 1",,11111'" 10",,, II,,· 1"""1> ,,,I ... lui", 2 Umlo ,IIlIt """("'" lh,' ( •. ".", &#39;~&#34; ...... _ .. "t 0 ""'1 .""t t.!1 "tt lh,· .... ~III&#34;.· .. 1 "''1'. 1,lk' '''Ht ,.",,1 :l 1 t&#34;&#34;oU~II,ly (.1""" 11", ·,,-ltll"':I'1 "tl'. 1,110;' ,11,,1 III''''t''''\) ,.1,.11,,1,,·, U~&#34;&#39;H a 1);ou'tl>l,,·,11 ,tlHI ( .11"", 1";h"II() '",n<) "" "ny ",·,111"(:1'1 ,I In ,,,,,,,,,,,,,,101,- " tt", "'''''','! ""qll"IlI;" !to ,h"m.IIIIIII'H Dn " .. 1 UVI""!tl'I"" II,,, '.""1", '.,.,.,,\' .• ,; '( (",,1<1 (h~t&#39;&#39;&#39;1 tlon ~.,(t llw,&#34;1 ("'t>
6 Fuel P""'tl ,emovnl ,md .uliuiny
L()U~&#34;II II", h""l! ,.ht ... Io<)l1l Ille IWO C(Jlln," (1011:; ')" It\!! P""' P ;,,,,1 &#39;&#39;&#39;&#39;&#34;0~C Ihl! ho~&#34; If "'''"1)<,<1 IVp" d, .. ~ ,,,e I'lh .. '<:I cu, Ih,-m Iol'(' .",d H'lti.,e.C lh"m w'lh ).C'l'W lH'" • . ht> .. 2 Undo ,lnd "'!II(We (h" [<\0 nul~ ""d ~fI&#34;&#39;l!1 wn&#34;h,,,~ senor'''!! II", jllllnp to (li e 1"11"'\1 rI"'" H!ull'(11Ih' I,uml' nil nCIll()'" II", !I&#34;~~~I 3 n(:l.tinlH lhe 1""111' 'S the &#39;(:YI:&#39;~ 0' '(:11101';11 . hUl de,H' lhe ,,,.,,\11\1 ',lC",S ,lIld 1'1 " r"' ..... &#39;I,l~kc(
7 C;orbllrnU or · gCnc'ill
'Th" c,,,hu .. ,uu< IS nllh" \Vclx.r ci .. ,,1 "CIll,,1I (lownd';1uuhl lVI)C Willi ;111 .1II1UI\1;.U<: (&#39;ho~ (~ 10 (:nsur" C;1Sy S.,\lIII1\1 100'" cold The m,un ;Ultl
IItim U sy~&#34;,,,,s ;IIe dup&#34;t;~ I1 ... '(I. p;,ch b.1 .. cl h<1Y1I\9 S('j).lf<11e SVS1(:II1S supplied Irom 11 (;0"'111011 110<11 ch,lI1'u." A S'"(JtC ,'lcd':f<110' pump 01 Ih~ dJi)ph"lYIll lVt)C supphes hOlh b;lr!<lIS Th", UI<1111 hody 01 111(: C il,j)l)((:I101 tllCO'l)/)I.11CS (t" , ItO"1 cll;""I", •.
Ih'Oltl(l hnrrch, trl.1m YenlU" ,1nd ;lceel,,"IiO' pump ""dy ThC,e ;lJe two tl"01l1" ~p&#39;nt!l,,~ ...... hoch ;"tI IIIU!rconnc cled I)y U<l;u tlu"drnnlS 10 Op",;,I" 'hc Ih,oUI" 1)1,l[t :S s&#34;null.1!&#34;:.ou~ly E,lCh h<1nlo: at cyhndc,s ,s led l,ul[1 <1 ~~pm,ltc IllIoule h~ucllh!OuUh ducls C<lSI III til.; ,,,I~1 1[1 .. ",,101<1 Ineo'l)(lrate(1 ," lhe 110<11 eto."nhC' eo"cr '5 lhe tuel teed onl<l. CO""l'Chon and Ihe 1 ..... "1 ... " "ll.,k(:s to , the lWO h<1"tlls F'!I
.
3 2 O,; ,ur;om 0 1 nir tcmpcr;ohorc contro llC d ilir clcnn.] r (Suc 2) V.I<: IIII11! /",.1,·
f)""d".IfltJJ lllUl f),.II""_"''''
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1 1"1:'1' V;,&#39;~!! I/ul ;'" /I"IV
FiU . 3.3 Air c lcm'er (A) (Sec 3)
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Fig_ 3.4 Fuel pump filter rcmo",,1 (Scc 5)
8 c Pump body
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70 Chapter 3 Fucl and exhaust systems
liS seatmu Note ,1nd reco.d the number of lurns, so th,11 the screws can be relltted 10 their orjuin~&#39; settings . Unscrew cilch screw fully and remove it and its SPfing . 13 Che<:k the lIoat <lsscmhly for signs of dnmage nnd ensure thil! the Ii0iliS do not lenk LC;JkinU HOolts can be (leleCled by submerging the UO.l1 III ., pMl of Wilier When heating the wllle •. IC.1ks will be indlc"ted hy lwbhlcs rising 110m t he flOil1. Inspect tho power villvc. pump {l!ilph'ilUm .-md IJilskcts 10' splits . Check lhal the III.oule plJtcs and 1111~lure SCfCw needles (lIO no! worn, 0' ulImagcd, Fit new pllriS where IlCCesSilry 14 Star , ,e(l~scrl1blv by .eh1hnu the pariS ollhe ilceele'alor pump In the orde. shown III Fig 3 12. Also relit thO ;Jnl;'51"n dr,lph,aom as scmhly_ 15 FIt thO two nllXHU(l screws nml spunns, slJltln~1 onch screw 10 11~ O!luul.11 pOSIlUlil nnd relll thO leiS . let plu!IS, emulsion lubes nnd ni,
COlleCtIOn Icts Hi Rein tho power valve dlo'Jlhr"gm nssembly ~s follows. Loosely fIt Ihe Ihree rtrnplungm ret"iIlIIlO screws. comp.ess the return spfln!! ensu"o!) tl>;)t the dl"phr"W11IS 001 IwislP.d Or dlSlorted Ihenl;\Jhlen Ihe scrells ,'mf Ide,lse Ihe SP'1I1!). Check lor correcl IUllc lloomo !ly push Ing Ihe rtl,ll )hr"IJlll down nnd ,hen blockllig the:m hleed holll w,lh ;J f,nue, I1cfcnse the d'ilphr;JUI11 whde 51111 keeplll!J the ,lIf holo blocked [I the fhilPlu&#34;~Jm sl,'ys down. II hns Willed j)rope.ly to Its housing 17 RefIt the Ileedle v"lve hOIJSIII\j, ncedle v;Jlve nnd 110,11 nssemhlv 10
Fig. 3 .9 Emulsion t u bes (V) (Sec 9)
Fig, 3.11 Removin!J tho IIlIli'Slilll dillphragm cover (Soc 9)
Refum sWing 8 Cover
the upper body. 18 Adjuslthe flo." level settings, fi,slly w;l h the upper body verlical .md I he needle villve s hut off lithe meilsurerneot is outsIde Ihe IInlllS given in the SpecifiC<ltlons, hend the IiIg unlll the sett lllfJ IS corlect ;"ul lechC(; k. 19 Check Ihe flOillllilvel by mO<1suung from the body f,lce when tllfl upper body is horizonwl. lithe meilsu,emenl is oulslde Ihe 11111115 g'V(:11 in Ihe Specl ficilhons, I>cnd Ihe Ing umll Ihe SCltll1g IS correct ,,,ul recheck. Far bOlll 11m flam leve l ild!lIstmCIllS Ihl! lIJlflCf body g,~~k&#39;&#34; muSI be remove<1 . 20 Refit Ihe fuel inwke "Iwr ilnd loc.11if1{1 11111. 21 Posilion Ihe Uilsket (lnd relIt the c(llbu.ellor UP1Xi' hody M,lke SUII' Ihill the choke link loc;(1\es through Ihe upper hody correClly 22 Recorlllecl the choke link Mid secure II wllh IIIIl U·clrp 23 AdjuSI Ihe Ih,o\lle 1)1(lleS lor synch,onrlilIIOIi. Wme! h"ck Ihl! .. II" screw unlll II,s r.le,1r ot Ihe IhrOllle mcr.hmliSI11 ilnd Ih{:n 101)5'''' Ill" synchronililllOn "dlust,nu sc.ew. Hold Ihe "ulo·chole pl"tes '" ,m open POSItIon, flIck Ihe Ihrollle ilnd ,,1I0w hOlh pl,1les to r.1o~e IIIlIy T"p bOlh pliltes 10 flnSilre Ih.11 Ihey h,we clnsml r.nl1lph~I{:ly ;111(1 liI(:" ll!Jhlcn the synchrorll~il1l0n sc.ew. To chHck. j)a,lmfly open IhH Ih,nllll! uSll1g the 1(110 sr.rew, SO Ih~1 IllIlre IS n clealanCe! of 0 5111111 (002 HI) betweeo olle of the Ih.011le j)l alL's (lnd li S holC ChHck Iha l the mh,·, plnle hns Ihe s~l11e open;lI\j
Fig. 3.10 Relllovingllie IIccelcrillor pump cover -(lrrowcd (Sec 9)
..
Fig. 3.12 Accelerator pump components (Sec 9)
A B Covcr Diapl/mom c RC/(lfll swing
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78 Chapter 3 FlIer and exhaust systems
TIlls system, when comp1lrcd with conventlon,lI c.Jrhwctlo, ~rrilngemen1s. <lchicves <l mOIO IlccUl.1te control 01 lho <Jil/fuel mi~l\l,e resul ting in ro(tuccd omission levels and improved prcrforrllilnco . The 'llllln coml>oncms of tho fuel inrcclton system lall into three
tI'(lllPS
A FI/ef Milk Fuef Plllllf! F/lel .?CCIIIIW/<1IOI Fuel filler F/lel ,IISltihular ,w(/ millime con/rol l11ralllc MIlllll/ce/Of "',1/1'115 AI( ch.ll11/"1(
B W<lIIII 'IIIJ wyu/,1/()r AIIII,{Wty .1;r (/I:VJc.' Simla! ",MH' 7 hCIIII<J/mifi SWitch
C Wilil/[I Hd,.ys SMt'ly SWitch
The fuel pump IS 0 1 eh,CIIICtllly operated. ,aile. cell Iyp" A .",SS (IIC rchd ..,:,1..,0 'S mco,p[)I;oh~(1 III the pwnp 10 preY",l! f:XCOSSlvn
p"'SSUIC la"ld III) '" tho event of ,1 ,,)Sl"Ctlon III th e pipelollf!s The fuel ,I(:c\llllula lor ha~ 'wo lunf.luItlS. (t) In 4'ill1I,)(:I1 llll! IIIII,,;,'U)!l 0 1 lhe luclllow. HHlu.:.iI ,ml hy Ihe I)\I"'P ;IIIf' (II) 10 11I;""t,"" Iud I&#34;&#39;&#34;&#39;~&#39;&#39;&#39;&#39;&#39; ,,1";1 .h" .:o,!.m" h;os Iom,n sw"dn,,' "If TillS p.r.v"rlls .• v; 'po", IIH:1o; .lo.:vel"I'III!1 w,th t:'Hlf.O:'I""nt 100' ~t,&#39;<tIllU plohl"",s The f'lcl filter '1I1:"'I'OO;lleS two l"ll,e. 1,111" "Imlllllits to ""SU'" th,lt lhe '",,1 1!!,uoOh,,,!) 11,,: 11O)I:ctrrJl) syst,,111 comp"""lIIs IS "UUII'I"I"ly flce hom tlo.l The fue l distribulor/mi.l!ture control Msemb ly . The Iud dlsl"bulor C0I111ols Ihe '11I,lntl 'y of fuel bein!1 dehveled 10 tho CII!)Hle.
OIlS""l1g .h'lI each cylrndo. fCCOlves Ihe same ;lII1OtUlI. TIlt! mlxhlW COIII.ol aSSemhly ,ncorpo'illes ,III IIi, senso. pl, 1le ;m d cOlllml plllll(le •.
6
9
The iI" sen~or 1)1"le is locilled in 'he main nIl Stlealll be.ween the iI'r clr:wller ,1nd the Ih'Ol\Io bullerfly. Du'ing idling. the ~irflow hits Ihe sensor plate which in tu.n '<lises a contrOl pluiloer which nHows fuol.o How P.1St tho plunger and oul of Ihe injeclor v.llves. lnC/ease s in enornn speed cause inC/eased air flow which ,aises the conlfol plulIge, "nd so admits mo.e fuel. Tho throttlo valvo assembly ;s moun led in .he rIl<lUI all ;nlilke hetween tlte mixture contrOl ,1ssembly arid Ihe ai. challiber. The Ihrollie villvo plate is cOlltlOlied hy a cilble connected to Ihe ilccelerntor podOll The injector valves a.e located in the Inle! 1I1o111110ld "nd OlIO dt.!sl{jllod '0 01)0011 ill a fuel pressuro of 3.3 kof/cm' (46. 9 Ibf!III'). T he air Chiltllber is mounted on thO top of 'he ell!Jlno iln.t fUllctlons ,1S an a"xlhillY inlet nWllifold dllcctill!J arr horn the sensor ,,'011(1 '0 e,1ch indIvidual cylinder. The wilrlll'up rogula tor IS 10f.il1Cd 011 Ihe I,ont of the CnU,"e ;01,,1 '"f.orpur"tcs il hi·met,.1 st.ip. VilCUUlIl di"llh.,IUI11 and cOl11lol Villv!! Th" funcI,oll 01 the ronulato. 'S to enri ch tho lucl/a" n".IUlf) Ih",no lire W,II'" III) Ptillod ;md iI'SO:ll lull thmttlo Of1"Clallon . Tho auxiliary iii, dovice IS locaterl nil tlln Iron! f.If." "I Ih" "" dlilnll ..... r. II ,:ons,sts of a Ilrvoted plil'o. h, ·metal Slrrll ,),1(1 h,,;,ter 1:011 Til" PU'P IIS" 01 IIIIs tlcvlce IS to supply an PI&#39;crcOl~&#34;d vnhlllw III 1""1/",, 11"'1",(1 dl"Pl1!J cold idling r~llltcr 51111i1011 to Ihe 101,,1 1111" sy~h,m Orr 1:,)lIIIII"IIOII;,yoIJIS Ti,e fuel sta.1 valvo is locillud 011 the l]Iall l;,1f dl,II""!!' iI"" ", all ,,1o.."(:tllc.llIl' tlt)C,,,tcd 1111')(;10' , lIS PIII I)()SO IS 10 SIJI.ly fudrrllO ti ll! ,111 r .... '. ;'1 ,;,,111 ~&#39;~rrt&#34;&#39;!J ThiS Iud tomcs II"m 'ho fuel ,r. :.t"IUIIO' ,lilt' IS oIlo"'If,·d III II", ,III Ch;II))I,,,. wllh an frOIlI Ih..., auxllo;II Y ,1" d...,V,4·" Tho TI", .. I110Iil}10 switch IS sl:'(lwod Into Ihe (:lltl "U) mll.1CCI't lu lit!! wa'lIIup 11'\)111,110' Th(l SWItch ,IICOIPO(.1I1.'S" COIII;tCI ~Ill. &#34;&#34;lIIcl~1 ~I&#34;p .",,1 IWO h(:iltcd elmn(:ms The switch comrors thc sta.1 v,llve by hl'llIlIllI the PCIIO<i 01 fuel in)CCllO'1 frOIll Iho valve anti ill$o pr(:vellllllU ti,e valve frOIll IIllcc"ng any luel ilt all when sta,',ng a hOI cngule. Electrical re'ays and luses. These a.e loc,, 'cd undc. the faci" p;IIIIJI Oil tlte ri!)ht·hilnd sj(lo on Ihe intc.io. 01 Ihe C'If. Tho .()I,1yS cnlllp.bo Ihe 111;1111 contrOl foray and [hn powef SIJpply '01,1y.
Fig. 3.32 Fue' injOCliOrl system flow diagralll (Soc 22)
1 Flle/lall/(
"
Mu;/ulc CUIIIIOI ,mif 6 IIIIOlfic pla/c assembly 10 S/;II/ villve 2 Fuel PIIII/I' 5., Fucl (Iistllbutor 7 Inicc/or valvc /I 'hell1JOlimc sw,lch 3 Fuel i'CC/IIIIUI"tul 50 Alf SCIISOI 8 WiJllII·Up regula/or 4 Fuel '"10:1
"'
Plcssule regtllillQI 9 AU~IIt&#34;aIY air device
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Chapte r 3 Fu el an d exhau st systems 79
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Fig. 3.33 Fuel injuctiOIl system circuit di<lUrnrn (Sec 22)
1 /J,1I1C 1V C W"lflll (If! luyu/',lor plMC
2 Sialicr I/Iolor /) Axll/,-"y ,1i, device G Theo1lO/lmc switch
3 fgnitioll switch E FIII;I/Iump H St,lfl valve
A M,lin con(Iol r(;/,)y F S<!fCly swllcil on senso! J Impulse module
8 Power supply rcl.1Y
Tho safety switch is provided to cut olf illl power !O the fuel injection sySl(!m if the air sensor plJIC (mixt\HC COlllrol assemhly) IS il the rest position even if the ignition switch IS all. The s[lfcly switch would ell! off the power to the fuel pump for oillllpic ,I il fllOJllmu W<lS darnol\jC(t 111 ,111 t1cciden t or hurst through deHH,or,11'QIl lhc ~wltch is located close to the mixlluc cont,ol lin'!. On f,lIer models th\! Sille ty switch h<ls been repl<Jccd by <I S<llcly control module. ThiS Illodule supplies power 10 Ihe luel pump prOVided Ill.ll It IS "xe,vlIl\j pulses Irom Ihe 'V'1I1Ion co,I, Ihese pulses helnl) evidellce thm the env,ne is 1I'''ning. When the engine stops lor wh<ltever reason. the salely control ule cuts 011 power to the fuel pump.
23 Aoutino maintenance
AI the IntelV<lls specihed ill the Routine Milmtenill1ce 5 eC1l0n ,n the Ironi 01 the m<lnual cmry oul the lollowing procelillle$.
Check (Jnd adiusl idfing spoed 1 COllnecl11 11Ichomeler to Iho engine then rlJll the enVine to 110rmal Oper<llll1g lemperilture. 2 Incre<Jse the engine speed to 3000 rpm lor 30 seconds then allow
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n fr.X l
the engllle 10 'die.
3 Check Ihill I he idle speed is lIS given in the Specificmions ilnd il nccnssary "dlust the idle speed screw 10cllted heneillh Ihe Ihrottle housinv {photo).
Check conditiorl o f fuel hoses " Reier to SeClion 2.
Tighte/l the inlel manifold boilS and /luis 5 Refur 10 Section 29 and lighten the inlel rll<lnlfold bolts illld nuts in tile sequence viven.
Reflew Ihe fuel filter 6 Refel to Sec tion 25.
Renew the air filter element 7 Disconnect the h<J\leIY. 8 Release the spring clips on the air cle"ner {phow) 9 Lill Ihe <lir cle"ncr cover. logether W ith the fuol distributor
assembly, ,1rld hit out the air filler element {photo). 10 Cle<lnthe inside o f the ai, cleilner body and covel 11 F,t il new clement then refitlhe cover. 12 Reconnect the bllllery,
23.3 Idle speed ildjustrnellt sc rew (arrowed) 238 Releasing the .. II cleane l spring Clip 23.9 Removing t he air filter element
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80 Chapter 3 ~lIel and exhaust systems
24 Ai r cloanor -removal and re filling
1 Remove Iho elomerll as dllsc"hed III Sect,on 23. 2 Work,nn under Iht! left ·hand honl wheel arch. unboll the illr clenne, hOdy f,om Ih e s,de of the engmo compnl1lllen\. 3 Rohuil1g IS n rove rsal 01 tho lomova l I)rocodule wl lh relelence 10 $(1(;11011 23,
25 Main system compono n ts -rellloval "l1d rofitling
Fllel p /llllP 1 Thn hll)1 pump IS loc.lwd "' " lI,hlw.. 1ll011111111U .lUflchod 10 Ihe "!Ihl h"n{1 51th! 01 lhe 11I/,llal1k (phnIO) ') D,sC:OllllCCI Ihe h<lllulY 3 Rol'-',1S0 Ihe IHeSSUle OIl tim SyS hllll I,y lelllpOI<I"ly looSl'!I1I1'l1 Ihl)
le"l1 line IIIlIon on Ih e lu«1 dlSlllhul<ll C,11l:h Ih o sm<lll <lmOunt 01 luel wh" .. h CUllies oul 111 <I p":c:e III dOlh 4 Wllh Ihe ,eil l of thl! c:a, flve. <In IIlspeCt'OIl pit or sUllahlv rfllscd.
cl;lIllp l hl) 111(:1 IIIIUI hose IIC1W,,':1I1he ludl;lllk ,1ml th « 11111111) uSlnH ,1 h",ke hose cl,IOUjl or sHlIII;" If Ih oro ,s only ve.v hnle 11101111 I ho 1IInk. illl 11"lIl<1llvO 10 cl,1mplI'!l1hc ho~() IS 10 dram Ihe Innk onCIl Ihe mlOI hose 10; ,h~c:ol1nCClu&#34; !". OIs.:nrUlI){:I IIlI! Iud ",Ie! ,llId uIIII" 1 IIIIJoI:S I.nUl Iho pump G Cn,"'ully ut",llily Ihf! dm:I"c:al C:(&#34;UH~C1l00S 10 IllI! pump nil"
&#39;&#39;&#39;~t:un&#39;&#39;&#39;~.1 11",," 7 I ,.,,.,~&#39;&#39;&#39;&#39; the 1I!l11l hoilid Illd 1'lIlk SUPI)(Jl IIII(f Sl'ilP Illell unh(lll ll,,~ lul,I)". mOlllllll'H ami 111,,1 JlUlll!' 8 !'IISf) the pllmll "("n the "'OIull"'!! !) Ilcfllllll!j 's il IUliers,, 1 01 ,emOVi.1
FiU. 3 .34 R Oilr viow o f
A Ink'1 pi,ll}
fuel,HIIl'I) (Soc 25)
8 Fucl'WIII/'
..
) 2~ 1 Fllel pump showing Wlflflg ond oul'el pipe
~ .. . . ~ ~ ... ,
2510 Fuel accumulatO'
Fuel accumulator 10 The fuel accumulatO I is bolted to the Ical 11001 above Iho lear "Klc (phOIO). 11 Disconnect the bflltCly . 12 Releaso the preSSIJle in the system as descllbed in PfllfltJlilph 3, 13 I'lilCO the leal of th e car ovel ,1n inspection pit o. lilise il on ' ilmps O. fldo·stands. 1 4 D,sconnectlhe fucl pipes I,om the lu el accumul,110r and catch Ihe s<llflll qUflllt'ly of fuel which Will bo released. 15 Remove the Iwo Illollnling SCfOWS and remove Iho acculllulf1lOr. 16 RefollinlJ i~ a ,eve,s,11 of ,emoval. hut lemovo tho floor panel hom Ins,de Ihe lum,ji'ige COIl1I )il'lnlenl and relit Ihe p,oteclive Cflp5 over lhe SC(()W Ihronds .
Fuel filler 17 The luel 1IIICr 's locmed 011 th e wheel olfch in Ihe lelt hand side of Ihe .mU"'o COIllI)"' ln,elll (1IhOto).
Fi U. 3.35 ConeCI 10Ciliion o f fuel filler oullel pipe (Sec 25)
A B Fuel "'ICf Ou/lelll'lle c Engine comporlmenl side p,wel
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Chapter 3 Fuel and exhaust systems
30 E~haust manifold -rOllloval nnd r e fitting
Rcle . \0 Section 20. but not that 1,11C' models do nOI have n downpipo scaling ring (photos)
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31 E~haust system -removal and ro fitting
Reier to Section 21 (pholO).
85
3" ,A TI!Jhlenrrl!J Iho O~hilUSI mnnilold nuts 30.1 BRight hnnd e~hnust rn.1nilold ·to­downpipc connection 30.1 C Dl sconnec tirrg the lell hnnd e~hnusl downp;,Je hom Ihe manIfOld
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31.1A hhnust system ,ubbe. mountIng (;,,,owed) 31.1 B Irnermed'ilttl oxhilu st system-to-honl pIpe clamp
RT C , FAULT D IAGNOSIS
32 Fault diagnosis -fuel sys tem (CMuurottor)
Symptom
Fuel COlls!ll11ption e~cesslve
Insu llicienl fuel detrvery or weak mi~lure
33 Fault diagnosis -fuel system (fuol injection)
Symptom
~ngine will no t starl (cold 0' hot)
Reason(s)
Ai . 1,ltel clement choked Fuel lenk flom cmbulellor. fuel pump Of luellrlles Gene.ally waUl ca,bu,ettor Needle vnlve StickIng open Incorrec t idling speed <lnd/or mIxture
Clogged fuel Irne
o. hiler
F <ll.lty fuel pump le<lking inlet nI<lnrlold g<lsket We<lk mixture selting
R
llason(s)
Ai. !tow sensa. plale incorroctly sel FauilY fu el pump Fuel lank omply
'J
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Symptom
Engine will nOt Slnr1 (HOT)
Engine will not stal! (COLO )
Engine mIsfires on rond
Unsatisfacto,y ,oad p edomlilnce
Rough Idling (ilIWilYS)
Rough rdllng (during warm -up)
Excessive fuel consumptIon
nglne fUns on
I
C hapte r 3 Fuel and exha ust systems
Reason(s)
AuxiT inry air device not clOSing
Auxilimy ai, dev ice nOl opening SImI villve filulty Thermotime switch nOt closing
L oose fuel pump elec trical connections
System fuel presswe incoflec!
M,xture adjustment incorrect
AUKlhilr y ili, deVIce nOt OllC,ahng cOflec tly
Mixture M1ts utment incolleci leak in system fuel lines
Airtlow sensor plate or cont/otplunger not moving "eely Injector villves leakinU or then OJ)Cnlng pressure too low
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