horn FORD CAPRI 1974 Workshop Manual

7
Chapter 1 Engine
Fig . 1.1 8 R ear oil sen I ilnd ildaptcr pliltc (Sec 84)
84 Renr oil se;1i ,,,,(I lIywheel - rc fitti"u
1 I'll the ()n!J&#34;I(~ .r,," ,,(1"1'10' pla1<:1 and s(:clIre ,I wllh 'I S IIv(: holls. 2 Smenr en\J1ne (ld OlltO the CI,mkshah '''". Smear 0,1 on the lip 01 the sea l tlnd pos(( lon tlon ';".11 on th e cran hha ll. 3 Align the seil l c;""er holos wllh Ihose 011 the cylrnd(:, hlock . Insell the loul bolts and 11!lhlCll Ihem 10 the SpeCifIed 10lqUfl 4 F it the flywher.:l . or dllveplalc on au lOlllallC lwnsrnis sion Illodels.
InSerll h e six holl S ;",d u\llole rllhem 10 Ihe 10 lque w rench sell"'U Uiven in lhe Speclllcm'olls
8 5 Sump -rciiuill!)
En~&#34;,,, lh;ol Ill" ru,rI "'!) ',u.l,u :e s 01 hoth IllI.! Slimp a"d t h e c(,1nkcilsc ,lie cl ea" ,mol IIi,1I n", '.""I",!) SlIrJ ,u;e 01 the Sli mp IS not d'S lo lte d. 2 Apply IO" ,I,,,!! c"'''pollnd 1 0 the pOUltS wllel(~ Ihe l"llllll) cover ablilS lhu ,;yir r"lr" 1,Io ck .lIId where Ihe rea' 001 $u,,1 carr.(:r "dIOIllS II 3 Pln ce tloo \J,,~k&#34;l '" fJo~.t.on, lIt tlo" SlIm l} ,'Ild IIlS(). 1 lhe r0Io1111il1l)
bolts ImUO I tl!lhl 4 PrO!lres~lvely 1I!llIt,," llw sump holt s 011 opposIte I'ilr ts lIllt,1 all 0 1
t
hem ,H" il l tl", ~ 1&#34;&#34;:lllI&#34;d IOlllUU , 5 FII ,1 now w;,~h&#34;, 10 Ihe ~Ul1lp II"'UI pili!) , IIlscrl lhe dl,lIll pllll) and
t ,uhlen ,t
8 6 Cylinder h e"ds re;rssernbly
L~y the cylrnd" r h",.\! on .IS s Ide. luhrrcnt e cvcry valve Uu ide with eng;l1(! oil. ,lilt! ,&#34;~,,&#34;t the valves 11110 the \Ju, dc Irom whIch lh ey wele remov(:d 2 To ,WOld d<l(11;U)III\) lhe II p 01 the stern 0,1 sonl , with consequent rncreJsed 0.1 con~UI1&#39;ptIUIl. wrnp <I p.cce 0 1 ndheslvc wpe. or fo il. fOund the \JrOove o f cvery v,llve SWill Sh( le lhe scn ls over t he valve sIems and push th clll over th.: lupS of the vnlve u",des 3 Remove Ihe &#34;dh&#34;~lve wpc. or fOIl. horn Ih e vnlve S1(~I1IS. 4 F,t the valve sp"nl) ovc, the valvc. Wi lh thc close cOllcd end 10wnrtis the Cylrnd er head. lhen fll thc sprin\J relarne r on top 01 lhe
sprlll\). 5 US1ll\J a vnlve ~prul!) compresso r. com press lhe splln\) lus t enou\)h 10 inse,t the IWO Splil COIl,,15 If lhe vnlvc spml(j is compressed 100 filr.
lhero.s dilnlJC' oltl1<.: ~I&#34;&#34;IU rcW""C' dillllil\)IIlU tllC villve SHlm 011 sen l
G Ahcr "lsert")!J tit" ~pllt collets. r eleilSo the spllny compressor (111(1
rcmove II 7 C hcc k th"t lh..: ~pl&#39;l cull":IS hilve seilled properly and t<lp the top o f
t he v"lve S1C1lI hUhl1y w llh a plJstrc headed hJmrne, to ensure 1I11S,
Fi g. 1.1 9 Tightening sequenc e for cylinde r head bolts on the 3.0 litre enuine (Sec 8 7)
a Repe"l liln pruccdwn orven III p;ua!Jrnphs 1 to 7 o n the (CmJlnlllU
v,llv"s
87 Cylinder heads - re fitt;nu
11 the tappels w ere rcmoved. luiJricnle lhe lilppets nnd I heu hores wnh enoine orl nnd insor t thOlll wilh lhc;, d Ished cnds uppermost Ensule lha l every tappet ,s rclltlcd Into lhe hore hom whIch II wns
t nkcl1
2 Mak e sure tha t Ihe rna t"'!1 surlaccs o f lhe cylinder block. cyl lndor henrJs ;Uld 1111,,1 Ill,lIlIlold ;lIe de;"l. then plnce new cyhndcr head \Ja~kets ove, the Wildes un thn cylrmh" block. Tho cyirnder head \I,,~k ~IS beilr thO malkln\! TOP f:nON T ilnd nced to h e pOSII,oned
cOII(:ct ly .
3 Low ul Ille cyl ""lcr he,1ds ov"r the" posl tlonrngst u(!s, Although t he cyhlld\~r headS ,"0 Id entlc;,I, they should h,lVe been Illtlrke d when remuved ilnd should be lehllUd III thcrr ()IIUinal positions t1 Inse rt the cyirndcf 11I)"d boilS f"'!I(:r t.!Jh l then tIghten lhelll prUglC SSlv(: ty OIl the olde, shown III r,U I l!J and III llle stnucs",s U iven
m the SpcelirC;lt'OnS
88 Rocker arms and cover
s -refiUing
Ensure Ihm "II Ihe puslllOlls ,lie ,nselwd I!ltO the" p'llpor placos ;II1<J lh at thc" lowcr ends nle on\J"gcd in the ClipS o f the t"ppelS 2 Place the roc ker arms over tho jlllshrods. fIt the fulcrlllll seMS and ;ldllJS 1o r nulS. an d liuhten the ntl)usting nulS !"'ger light 3 Se t No 1 cyllllder at TO C <Jnd reh t the dis tllbu tor (see ChilP1C' 4) 4 I\dlust the vil tve clea ra n ces as descrohed in the foll o w rng Section 5 FIt the roc ke' covers , uSlIl g Ilew \Jilskc IS . ens uring tho t the gilskets arc senlOd e venly n il round l ho cylinder hend. Fit the cover altilchlllont
l
)olt S nntl lighten them t o the spec ,f led torque.
89 Valve clearnnees -checking nnd adjustment
R eier
to SeC!lon 3 5
90 Engine ancillaries -refitting
R eier 10 Sec tIon 46 and ref, t lhe I. ste d componenlS w,th refercnce
to th e Chaptels ind,cilte(f
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Clwpter 3 Fuel <lnd exhaust systems 69
The fully ~u!OnHIIIC choke system IS lor.olle(l 011 lh&#39;~ "oill-hami side 01 t he Cn'UUlCltor hody <ll1d CO'llp"ses " h,·mct<lllic SPllllH nud ,1 linkilge 10 lWO offset choke pl<lleS moullted all <1 COllllllon ~pondlc T he choke housillglS hC<llCd by cngul(~ toOlilll1
a Carburcltor -rClllovill <lnd refitting
1 Disco nnect the Iwltery . 2 nc",ovc Iho) "" cle<lncr ilsscrnlJly ,15 delol ,'ed on s, ~ct&#39;un 3 3 Milke ~ur e thnl the coohn\) SySt"l1l IS not UI1<1I)' p""SSUlc). hI' IcmOVII)U the I,ld,a,or ';lP ,llid ,,;[,tl UIU 11 Wi lli the ,,;.ha,or c"I' 111 POSit io n. diSCOllncr. 1 the two hos(:s 1'0111 .he .1'''''l1101IU; dl&#34;~&#34; ,1Ild secure them with Ihe ll open ends upWdrds 1 hIS will cn~ur&#34; nnly.l 1""11' smilll qualll!!y of coolant will h e IOS1 <1 O'SCOllllcct Ihe IIHottie hnk
5 Disconnect the fu,,1 f"ed ilnd ,(:t",,, plp"S I,o'n til" C ... I"'H-tt,,, If •• cl, ,,,pf,, IIYI' " hose dan,p IS l&#39;ltr~d, CUI II,e ,: 1""'1' II> ""n,w" ,t .",,1 "·'''·W II wLlh <I sc.ew Iype hose clamp. 6 D ,scollilect Ih e VilClIlIll' P'P" horn 1100 c."tJU":IiU' It) th" rt&#39;~I&#34;Io(rI&#39;&#34; 7 Reillove Ih e foUl nuts and d~I.1Lh the c."la""liu, .,~~&#34;n&#39;IJly .",,1 gasket hOI1l Ihc ,Ilt.,ke ",."ulold Not,· 1 1m P()~II&#34;&#39;rI "I Ih" d ,·fI"I,I'" pl,l\c 8 fld,1l<nU IS Ihe leve,se 0 1 Ihe rerl10val p,oL"duw. but I,,~t &#39;&#39;&#39;&#39;~L&#39;&#39;&#39;&#39; that the loint laces n rc de,l n ,1nd lrrl<i,11ll"W1d U~l)&#34; ''':W \I.1~k<;1, li\lhten the securrnu nub 10 \he to'que w ":rll .h ~l&#34;It&#34;&#39;!1 !l'Vl'll nl II",
SpeC ifiCatiOnS and wlrt ,III the 1r0$CS Top u p til" ",,,,I"'!I ~y~!t:m II necessa.y. Adjust the ,die ,;p,;Old ;0111 IIlIxtuw a,; d"·,,.,,lred II, 5",.1 ,,, " 12 .
Fig. 3,5 U·circlip 011 the choke operatil\g link (Sec: 9)
A /I
Fi9 3_7 Upper body components (Sec 9)
Flo,lI telaininy pm Ftll.'t c o NlJcdto V;I/V(!
POWCI v.1lvc
9 Weber Cilrhurettor -dismilntlinu [lnd reas~ernhly
Note: On 1977 mod(!/s onw,lf(II /lIP. cmlll/id/ot 11,15 ,1 '/Jy PilIS' tdle IIdIItS/IIIY SP~&#39;W willch IS sc,l/r:iI //I l!lodl/cllOn wl/h <1 willie (}f ljlCY 1,/,'sIIC (:,11' UlI(ler /10 CItC(ff!!s/a/lces should {/II.~ SCI('"W h e /,)t!J/JlNl'd wi/h (Fly 322) 1 R(!II1Ov(! the C.1,h"n;llor I! O"l th e ':Ol!)""' . ,1~ dr;w,lp.oI ,n Section 8. an d cl(!,lIl th.) f:ilrl""etlor extC"Of w'lh 1'.,['01 or a walt' soluhle t"OI",,:l;\,y 1'/,,;)11(:1 J. C;, rdully I"'S" 0,,1 Ihe U'CIIClrp w,th a hC,(lWII"v" •• lIul ,h~COIUlo:cl til" '.ilok" pl"w oj)l:(allnulrnk :I 1\""10\"" tire ~I X ·,,:,,'ws ;'"It ,i,-(;" .h II" , GIl1"""llor "Ill"" body. ·1 Uns';",w llr,) h&#39;n~s nul locnl"d:ot th" ((",I ,nwk,) .'nd d el.1cll Ihe flU'l
Iolt"1 (; T"II Ollt tlo" lIo;i! ,,,t.1"lII'!J pm. ;,nd dd.1{,1r II,,) 110;11 ,Hl d needh~
v:otv" I, R"",,,v,, tlon th,c" ~c,,:ws and d"t.u:1r tlw po","", valvc d';lpl"a!)1ll .&#39;~h,,&#34;&#39;tJly 7 U"hl:",W thn ncedle ~&#34;Iv&#34; ho,,~,nu 8 U"suo:w the It)( and Io:t pt"\Js I. o r" til" c."jJ\""l1m Imdy. not"l\) th .. , p&#34;~.&#39;I&#39;o&#34;s III wh",h 11,,;y ;0,(, f'lll:d ~) I~l&#34;ll()v&#34; (h" two cn ,"b,on luhes ;011'" ,,,'IIOVIII\) the two lll,lIn "" l"II rt<.:t,on t,;ts 10 1l<:!lIUVC lorn sr.'l:ws. t;JkC nil II", ,1co:"I,;r.lto , j)"Il'P co"", ,,,,d ,,,,,,,-.vOl ttl<, d',Ij,lua!l1l> ;Hld 5P(in'l SUlul,,<iy on ""toll'a(ic lri&#34;ISIl&#34;s~&#39;u n
"11,,1<;1, ','rI"'v\! tile &#39;11&#39;tl·~tall d,.lt>lua~I&#39;&#34; 1 1 CIo';j1l .,ll ttlC compontnt s ;oml Ih,,' (.:n,;w" Ihat the lets ,\10 ,u",I".t,,,. :t"III,y I,tow",!) t IHOI,!)11 Ilw'I' I J. Ca,ciully ';C,(,W ", Ih e moxtu,e sc.ews Ul\lI( (,aeh 01 Ih cm con1.1cts
Fi\j. 3.6 Removing the upper h ody -nrrowed (Sec 9)
A II
Fig. 3,8 Jet locatiolls (Sec 9)
Mwn ICIS C Idlc ICIS Air COtt~&#39;CIIOIl ;"IS
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72 Chapter 3 Fuel and exhaust systems
3 Unsc.cw the cenlle bolt and .emovc the cove •. T o p<event 105501 coolilnt 1i.5t .emove ilnd .ufol the p.essurc cnp to . eleilsc any prcssure but do thIs only w,th the engll1e cold. 01 Remove the th.ee sc.ews. dcwch the h(")using ilnd move ,t clcill 01 the cilli)u.ello,. Fo r ilccess to thc lower sc.CW 1 WIll be necess1lry to mnk e up a sUl tilhle cranked sc.ewd.lVer. 5 Oet<ll";h Ihe lI11efllill he<ll shelld.
VtlCllllm pul/-down 6 FII <In el<lSIlC bilnd to Ihe choke plnte leve. illld POSItion 1 so th.11 the choke ptilles ilIe hl)ld closed Open. then .elcase. Ihe \h.oule 10 ensu.e Ihal Ihe choke 1)lilleS close fully_ Unsr..ew the pluU f.om the d,nph'il\jlll unl th en Illilnllilily pIIsh oplm Ihfl d,nplHolum ,'p 10 Its SlOP I. om IIlslde the choke hOUSIng Do nOl push on the I(HI as 11 ,s spflng·londed. but pu~h on the d,.lphln~)l1llllu\J ho(ly. The choko ptille !lllll·down should now llU mO;")$lIIc(1. lISUl!) an lH\lllar~cd !WISt (i. III ~hank " ..,tween Ihe edlJe ollhe cho~e pl"le al\(I the au hOln walt <lnd compa.ed WIth Ihe sl'eclllcd II!fwO Ad)lI~L. ,I l1ecessilI Y. hy SCIOWlrlU the .1dlu stull) SCICW In or oul. lI~III!J a sho,t hl,ldod sc.ewd.,vel Rof'l the end 1)luII "'ld detach Ihe el<l~hC hand on complet.on
Choke phasillg 7 Hold tho Ih'O Hlo 1),1.tly open <In,1 posItIon Ihe last "lin Cilrtl so Ih.1t Ihn last 1(lIe ad)lIstll1H ~C!ew locah)s on lhe &#34;jlIH~f ser.I'OIl 01 Ihe calli Ikh.:ase Ihe ,h,ollle to hold the cam III HilS POSIUOIl. then tlush the choke pl;)ICS clown untIl lhe ~tCp on tht! (::11) lan's ;\!la&#39;n~lthc adJus t Ill!! so"w MO,lSUII) the ChWI;IIICI.: tW!Wel1 lhH "d\!e uf lhe chllk" ,,1;I!e and !hl! au horn wall USUllJ ;") spl".."Clfoeti ~Il.) 11,,11 A't)us\. II llI:c""s;uy. fly
IJ(mdlllU Ihe tau. S Rn"t Ihe intelnal hcal stueld eIlS''''"\1 Ih,lt Ihl! hole ,n the COve'
locmes COrfeclly 01110 Ihe t :le\] C<lSI ,n the hOllsin!! 9 Connectl"e lli.melnl spWln 1 0 lhe chokc levc •. position the ChO~e housing ilnd loosely hI the th.ec Icta,mnu SClCWS 10 R ota\C the housing unt"the malks a.e ahllned then tiuh\l!n Ihe lhree screws_ II Relit Ihe cever. togelher with., "ew Y<ll>kOt. and t'yhten the C"n\'1) bolt. Top up I he coohng s y Slem ,I Ilccess: llY 12 Reconnect!hc h;")lle'y . run thc ell!l'"c :",d Mllu~t Ihe 1,IStldle spccd ;,s d"sCllhed III Ihe 101l0winU Pil';'!I.;lph
Filsl idlv speL'd 1 3 hlc;IlIy" tachomcte. wlIII,c .eq,,"ed !lllmlc. 10 sellhu t,&#39;~1111l1! 'P'" 10 lhe ~peclllncl v.1Iuc . nUll lhc CnnUlc lip to no.,,,al opc.at"I!1 t,:'Upe."lu,e. then ~wO\ch oil ;Jml COllllect Ihn tachomete. (whe.e .wn"a"h,) OpCl1t he Iluollie pal\lally. hnhllhc chokc pl.1\(.)5 lully closed tI'"" 'ele,lse tht.! th,ollie $0 Ih.111he cho~e 1""ch.1111$I11 IS held 'n the fast "II" fK151\10" Relc"$c the cho~1&#34;l pl.ltCS . d" . .:ckllll! lh;lllhcy .cmaln lully olwn (II they ".c not open. Ihe ,lsse rnlJly IS I"ully 01 Ihe cnU"lc ' S 1101 al 01Ie .,11111IJ len'I/C,,'lurc) Wlthoul louchl"H the ;lc c"le."to. ved"I. Sliltl
, ,
~A
Fig. 3.1 9 Choke phasing adjuSlme'lI (Sec 11)
A 0,,/1 8 AUjus/my'"y
Fig. 3 .17 Checking the Vllc .. "m pull·down with l' drill {Scc 111
A t:lils/lc Im",' C V;//:1I11111 (&#39;I&#39;~&#39;f,~lmllull B DIJII
Fig. 3.18 AdjtlslinU the vacullm pull- down (Sec 11)
A 8
Fig. 3 .20 linkage SCI fo r checking fast idle adjustment (Secl1)
procarmanuals.com

74 Chapter 3 Fuel and exhaust systems
, ;
1)'>­
,
Fig. 3 .23 F el '<ll1k coml> onenlS (Sec 13)
A
" C
Se.ll Ruhbcl ill,W/,lIQI S SI!IIIJ..'f lIoil
14 Fuel lank -cronning DrHI rcpl1ir
D SImps E , COllflcetiu"
W,lh IlI1m 11 I~ likely Ihal scd'lllcnl .... .11 COIiC(;1 1f1 the IJOIiUlIl u l the ruel wnk. Con<lcIIsa l'OI\. los-uIIU'U "I !USI ~Hl{1 olhe l lI1'Il,,,' "es. w,lI lISlI;ll1y be found III tllu fuel l~nk ul 111lY eM mUIC Ihan llir"e or lour yeil' s old. 2 Whclllhc wnk is .emoved it should he \lllJOrous ty tlush ()ti Olll wnh p,l'ilfllll I1nd turned topside down 10 tir<llll II r.1Cllllie s n,e ,wil d,lhlc ,11 the I()(:;JI gar ago the lank m;'ly be steam cleaned and the exlCflor fCptllnlCd with" lead bnset! ,J a int 3 Novol weld or br in!J J naked ligh l close 1O;lr1 emply fuel I.1nk until,! hilS been steam clC<lncd out 10/ illicasilwo hours or. washc(t IIIIC'II;'Itly wilh boihng WOler ;lnd delergcnl and ;lllowed 10 SIi",d lor 011 le,1S1 Ihree houl s
15 Fuct lank sender unil _ remov;11 nlld refilliny
Check Ihe h01l1 whL'{)ls Ihen J;lc k ufllhe le;lr of Ihe 17;11 ;'Ind supporl ,1 ilxle sr,llids . 2 SYI/hon Ihe fllel hom Ih e tllcllim k. Wherc ;lpphcilhle d,scol,,'ecl Ihe fuel line hOIll the scnder unll.
" Discormoci Ihe wiring 5 USlllljlWO SC!(lw(i!lvers III Ihe 51015 inlhe sendcr unit ,e lirmlng 1111\1. unsr;'ew Ih o sender (mil loom Ihe tucllilnk Lilt ilW;lY Ihe scaling ling iln d Ihe sender unit. nO llng Ihill Ihe 110.11 must hilng downw;'IrrJs. G Re fill ing is a rever snl of .e moval . bUI clea n lile milling !;lces ;'Inel I II ;'I new sealing ring .
1 6
Fuel lank filler pipe -removal "nel refitting
I Remove the cap horn Ihe hiler pipe. 2 Re movo Ihe .ighl·twnd siele lIim p;'lllei. 3 Peel back Ih e in sul alion clear 0 1 Ih e pipe (:Over fliln cl (Ghia only). 4 Lift outlhe pimel coverinU Ihe spore wheel. 5 Unbolt Ihe IllIer pipe covor panel. 6 Lo osen th e clips and releilse Ihe rubl>C1 oail er from Ih e floor and f,llel pipo (phOIO) 7 Remove Ihe screw al Ihe lO P of Ih e pipo nexl 10 Iho filter cap (photo). 8 Disconnect the hoso and withdra w the I.ller pipe I rom in si de Ih e
car.
o Relill ing
is a rever sal 01 romov;lI,
A
cceleralor cabl o - removal and relining
Removo Ihe
lowe. lac.a panel inSide Ihe ca'.
166 Rull"'" !F"1I1';'I1 "otlom " I I"". la llk flU", l"llll
(
. ,'l
--.
. ~
1(; 7 Fuel lank flUc. Pll~ UppCI 1II0UIIIIII\I SClew (.lIwwL't I)
"
, I;'.' . :~, \;.;
: : i;. "j -' , ,' .... :r: , :&#39;y~ it. ; '., :
Fig. 3.24 Disconnecling Ihe innor cabla from the pedal (Sec17)
Pusll M 11 ,mrl rcfc,uc ill IJ
2 Disconn(:cI Ihe cahle 1<0111 Ihe I)OOal hy unhookoug Ihe clip and rcleasing Ihe ""II:! cal,le 3 Rem oye Ihe IHal:.e servo un:1 a~ dcscfLb c(1 11 Ch;lll lcr 9. Ihen remove the SClew securrn~J Ih(: Oulcr cable to Ihe iJulkhc;'ld
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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
·.i
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procarmanuals.com

94 Chapter 4 Ignition system
i ' .
. --8 2A Removill{J the IllnSlre dust COve, (28 hl'c Cllume)
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, , ,
(\. I ,
" 'v
J 2C W'''I1!j connector i'Uld seCUJlIlg screw (lHOwS)
9 Ignitio n timing -adjustment
Wnh the (.lIs\"OuIO' III!Cd ilS dcscllbed OIl SectIon 6, check Ihilt 1Ill! COHCCt llllllng m;l!ks "'0 ;1119110d. 2 To check the ;1111,,11 (5 t;1I,e) setting, .emovc the (I'51"lIu I0' c;lll [11l\( check IhJllhc rOl0' ;lIm IS PO"1I1119 to the No 1 cylmdc. scgmon!.n the Cill) rndlcmed by the sial on the 11m. 3 On the 3.0 lUre engIne the cont,le l poullS ll\u~1 he ,ust SCI)ilril\U'!J Tho e~ilCt Instant C,1" he checked by connect"'u il 12 vol1 lest lamp between the contilC, brcilke r low tenSIon Iemur),,1 iUl(t O,"lh, W,th the iUnilion Oil, tho d is trlbuto. ShOllld be turn ed nrl\,·clockwisc unlol lho bulb luSlligh(s. " On (he 28 li(re enuule the ("gger arms and stator ;HIllS must bc aligned It not. (um I he (hst"bulOr as necessary . !:i Tighten the (hSI"buto. clamp boll and .ehl the cap 6 Set In thIS way the lUlling WIll be alll)'Olmalely co<rC(:t but a morc ilccurate rne thod IS by using a stroboscopIc tu"ing hghl. 1 HIghlIght the spcclilcd lIming marks on the trrllll1U cover an" cronkshalt pulley WIth wh,le pamt or chalk 8 Connect a timing liijtH to Ihe No 1 spar k pluij le;l d, 9 Disconnect the vacuum mlvance pIpe at tlHl carhure1l0r or au bo~ juel injection) and plug the pipe then .un the engine unt" nOlln,11 ope.ating telllpera tur(!s a.e .eached.
, ..
8 2B UtJlle. vIew 01 the l.imJer Mrn .lrld Call (28 lIt Ie enU"Wj
.1
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.. .."
8 20 Vacuum un.1 sC(:u"ng screw WIth e')Hh lead termmal
10 W,lh Ihe enij1l1e I(lIrng pornt thc \fmlng hgh( at the cr",lksholl1 pulley The wh,le 1),1mte<l mar ks WIll ;lIme", sliltlonary ,111d If thO tlmlno IS COller. 1 (hey WIll be III ahgnment. 11 To adjust the tllnm9. stop (he engine. sla ck en Ihe cl;'lmp bolt iln(1 turn the (I ,st"l)uto. slIghtly_ TIghten the clamp bolt. star t the engrne ;md .Ct;heck the (umng Repeat tillS 11IocedUie unlll Ihe rIlilrks ,)re In
hne
12 To check the mechanrcat adv.1nce. Increase the engIne speed and note whelher the wh,te malk on the pulley moves away Irom the mark on th e pOInter . 11 It docs the mechanical advance is lunctioning 13 W,th the enOlile Idlmu the vnCU\ Jm advance can be checked by suc kIng the oldv~ncu pIpe that W.1S removed from the carburellOI o r air box ThIS should also c.Juse the while rnark on the pulley to move away horn the mar k on the pointer 14 On completIon remove Ihe timlllU hght and rC(:onnec lthe v.1CUUIll pIpe
10 Ignition illlllllifier module (2.8 l i tre enuine) -removal and rClittinu
Thc Iunitlon illl\J}l lflcr module is locmed on Ihe left· hand SIde of the engIne COnlpar tment. tUSI behind Ihe hOnt suspenSIon strut upper mounting.
procarmanuals.com

"00 Chapter 5 Clutch
53 Locmlll\J the (flCllon disc on the
f lywheel 5 .6 Cent,.,l ising the friction disc 5.7 TI\)htIJnlll!) 111" ,: 1,,[, h cover holls
6.4 The plilSllC wlls which .cWin the fclcJSC hcnrinl] in the lever (""owed) G 5 nt:lcas(l levor IOC,11;01) 011 the 1"1101 stud
5 The f&#34;~lI()n rt.!;c must now be Cclltrilloscd SO Ihill when the (IllUme imd !Jci&#34;loo~ .1<0 milled Ihe input shall splmes Will pass 1I110uUll the splines III Ihe )HCIIO!) diSC Id(!,lIly a wlille.s;,' dUh;h (;C!l!r<lIiS IIl\J loul or ;m old !I&#39;~;&#34;I>()&#34; Inpul ~h&#34;fl shuuld be u~cd. hlJt ,rlh.'IIHI(,vcly a woodull 'lIilnd,!:i G,II1 h.., Ill.1<ic to IIIe d,mtJnS lons shown In FlU 53 G InSUlt Ihe ccnlr<ll'SIIl(J 1001 Ih,ulIUh the (fiction diSC <lnd 11110 lhe ·"\jot Ill',"""\! (phOIO). nOlillC tho 1001 or movc II Side tu Side until lhe .etlon d,sc 'S "ccwnlCly centm(l 7 P,oy,ess,vely u\Jhlen two OPPOSl1e cover holts unt,1 the ftict,on F I, fnmly held ") posl1ion. then l'Uhten all the holts proy'esslvely ,d 111 (I,,,yo,,,, 1 sellu,mce (phOIO). 8 flemove Ihe cenH<1r,sin\J 1001. 9 Wipe dowllthe \)e,llilox IIlput shJlt ,md "pply a littic molybdenum Iwscd \Jrease to the sptones an(i spioot b(&#39;~&#34;ng slillacc_ 10 flcf,t the ue.1fbux Wilh ref!!lence to Ch"pwr 6.
6 Clutch release bcnring removal 1Hl(1 rcfitting
Remove thc gcarbox "s dcscflbed in Chaptcr 6. Alternal,vely. illhe cngi ne is to bc removed for repairs. acccss 10 the rclcilse bcminy ,s possible leaving lhe gearbox in position. 2 loosen and back oil the cable adjustmcnl milS. 3 Whcre npplicable. plisc lhe ciulCh cnble fuhhel gaitcr flOm the bell housing nnd unhook thc cahle end lotting from the release fevel. <1 Puilihe release I)ealing hom the \Juide tube. Whcre necessary use a scrcwdrlver to pflse the f)Caring flom the Icvcr and lelease the pfas\lC
tabs (photo).
5 Pull t he rclease IiNCI sldcways to d,sengage it from t he pivot retaining stud (photo). thcn withdraw ,t ovcr thc IJuide tube ,1nd input shah
6 The rele ase beann\) is supplied completc w ith lhe huh (photo). If fC(luired. thc two componenlS can be scparated usinU a VICC and soh metal drill.
)Before relltllng (hc releasc bcariny. apply a lillie molybdcnum "."ase 10 the \llude tubc and contact laces of the release lever 8 flefl!1lng is a ((,versal of remov~l. butllnally chcck the clutch pedal and cable ndlUsllllenl JS descflbed in Seclion 2_
7 Clutch c;lllic -Icnewnl
Apply tlol) Io.",dl!<"k" llien lilCk "I' lilt: j'onl of 11"1 Gil o1l1d suppor( on ax il! ~!and~ 2 PIIS" th" dUlch callie whlJel (jilll'" horn lh" h&#39;·lIhou~u&#39;(j. lousel! the ati,US111l'JllI nul(s). ;IIHI unhook the c;,I,I" ,·nrl IlIllllB hOIll lhe release h,v,,, Pull off the !Jalter (phOlUS) 3 Ikmuv" ti,,) c,lhle frorn lhe hole II) lh., 1,,·lIh&#34;u~&#34;l\J. nUlo)\) lhe posltlun of lhe slccve (phOIO) <1 WOlkln\l illS Ide (hC Cilf. remove the luw,,, I,,,",,, pallel lor <ICCCSS 10 the CIUlCh pedal 5 O'SCOlllH!C ! the cablc from lhe cllllLh !JO'ri.11 t,y puslun\J lhe P'" thf<.)u\Jh the cilhle eye.
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7.2A Prisc all the rubber Ualtef
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procarmanuals.com

·06 Chapter 6 Manual gearbox and automatic transmiss io n
disengilge the gearbox inpu t Shill! hom ,ho clutch p,Iot bearing ,111(1 clu tc h friction disc. I, is imporlanllhal,hc engine and transmi ssion <'lre kept in lino while this is being done. 14 When the gearbox shaft is cleDr of the clutch, remove th e
tran smissio n assembly from bCn(!illh the car.
15 When refiuing, ensure 1il1 the clut ch pilot h earing in the end althe tfilnksha h is ill plilce Jncl is scrviceDble. Tic the clutch lever 10 the clutch housing, 1 0 pr(!venllhe release le.rertrolll slipping out while the ,Wnsmission assembly is being lined. 16 Smear some molybdenum-based grease OntO the end and splines 0' the gearbox input s!mh lind refit the gearbox by reversing the fcmovili p.ocedure. 17 II is impO.IMll when offering up the {jOMOO)(. th,lt il is e~<Iclly in I me with the cranksh~1t. otherwise the ge,l.bo~ inl)ut shah Will not enter
th e clutch ffiction drsc i1nd the Cfankshnft. Ifthe.e.s d.iilcul1y Inlnatinn th e splrnes 01 the gea.box shillt ,1no the frrctio n oisc. select iI \)em to 'CSlrain the movemcnt of the gc,lrbox shillt nnd turn the gearbox
slightly until the splines enter Do not iluempltO lo.ce the tfilllsmisslOn
ontO thO enlJlnO ThiS Illay (i<lmilgc tho spllllcs <Ind nrilke !rtllng
ImpOSSible
'8 Ahe •• el,uinn has been completed. chuck the 011 level Ifl t he .r<lnsmlSSlon and IOI) UI} ns ncce5sary
Gearbox (4 'S II001l) -dismantling
Romoye the lou. bolts hom the 1011 cove. 01 the t.ansm.sslon c~t()&#34;sion housin!J ilnd f.om the lri&#34;&#39;snHs~ir)Ol eo'S<' Ilcmovflthc \:oye. s.
t.1king c<l.e not to lose the th.ee springs untie. tire lran~mlsslun case cove •. 2 Use n In<lgnet to .emove the th.ee selecto. (fc te nt h,ll1s. 3 Remoy o the bolt 110m Ihe selecto. ImUel .111( wllh(l.;rw the 1'''U e.
from th e seloclOl shalt. 4 Remove tho twO bolts from the selectol sh<llt Ileminu sUPlm.t M{ renlOye it .
5 Remove the Ih.ee bolts from the selector hOUSing COVCI. Remove the cove. with the shaft. then ro tate the selec tor sh<lh slrghtly ,lnd withdulw it hom the selectOf hOUSing cove •. 6 Driye out the '011 pin <It the s.de 01 the elflension hOUSing and remoye the .cve.se ge;" .el<ly leve •. 7 Usmg a Ilin punch <lnd <I h,lmm c •. d.ive out the th.ec roll pins from
th c 15t/2nd. 3!d/top and .cve.se oe,1'5 suiliClently to rele<lse the selector lorks . Hcmove 3.d/top \le;" setecto •• ~d f.llcl rp <lnd th en withd!~w tht) selecto. '<llls tow<lrlis the extllllSIOIl hOllsinu . Note the
plullger ill th o 3.d/top selecto. '<1'1. Remoy e Iho th.ee selecto. lorks. J Remoye the plug hom the side 01 the c<lse and usc II m~lgl1et to ~,t&#39;<lct the plunge. beneath it. Gend back Ihe tabs 01 the w<lshers 0' the two boilS on Ihe e~tension housing. Remoye the bllnJO hOlt, 51)11119 <lnd ball <lnd the ,eyerSlng "ghl switch. spring and plunger . II Use two sc.ewd"ve.s and c<llelully ,)uSh th e speedomete. OUI 01 the eKlCns ion housing 12 It there has been no sig n of le<lking from the eKlension hOUSing 011 seal. tako cafe 110t to damage il. II the senl IS delectlye. leve. it out. t nking cllle not to daillilge its se<llil1g. 13 Remoye tho lou. ~ttachment boilS nnd detach the cxtcnsiOIl hous ing hom tho lIansmission casc o 14 Using n long Ihin d.ift. tilp Ollt th e 1~lyshnft from the front to the
rca •. Allow tho laygeal cluste. to drop into the ho ltom 01 the box. out 0 1 mesh wilh tho lIl<1inshalt gea.s. 15 Withd.aw the mainshalt and elflension assembly from the ge<l&#39;bo~ casing, pushing the 3.d/lop syn chroniser hub lorward slighlly to o lllain the necessary clea.ance. A snlall roller beming Should be on Ihe nose olthe m<Jins halt . but il it is nOlthele il will be found in it s lecess in the inl)ut sh<11t and should be .ellloved . 16 Aen love the lou. boilS securing Iho dliye gear hearing retainer to
tho '.ont 01 the gembox and slide the retainel 011 the input shalt. 17 Remov e the circlip hom the outside 0 1 the fronl bearing and tap the outer raco of the bearing to d.ive the inpu t shillt and bea.ing assembly into the gea rbox. then lilt them out olthe box . 18 Remoye Ihe laysha lt geaf cluste •. Ihe two th.ust washe.s and any I"'o se needle 'OIiOfS.
R emoYo the .eyerse idle , shah by sc.ewing a suitable bolt into Ihe end of Iho shah and then leye.ing the Sh;'lit Out uSing Iw o open ·ended spanne.s. Fi\)
.
6.6 Removing the seleclor 10lk rolillins (Sec 4)
A CIfC/'11
Fin. 6 .7 Revorso gear interlock nnd light swil c h (Sec 11)
A Ravelse liyh, switch 8 Swing C Plf/ngcr
o h!/ellocl< ball E Sc,ew IJlug
Rct.1ininy bolt F
5 M<I;nshaft (4·speed) -dismantling and reassembly
Remoye 3rd/top gear s yn chron ise. hub ci.clip Ense the hub amf
thud gear lotwald lly lel/erinu the,n gently wrth a p<lll o f snipe· no sed phe!s. 2 R emo ye the hub. the synchronisel .ing and 3rd gear from the I.ont o f tho mainsha lt. 3 Mount .he plam pal! 01 the mainshah in a soft jawed vice. unlock
th e mainshah nUl and lemoye it 4 R emove the loc kpli/te . speedometer dfivegem. ilS d.ive ball and Ihen level 011 the reaf bea.ing. complcte With bearing IClaine •. Separate the bea.ing and its lelainel. 5 Remove the 011 scoop ring and lils i gear . 6 Removo 1 sl/2nd gear synchronisc. ci.clip and pull 011 the hub with the bi/ulk .ings and second gear. 7 Check thallhere is a mark to align the selec to. sleeve in .elation to the hub. II no malk can be seen. make one with a dab of paint ~nd then dismantle the synch.oniser hubs. 8 8010/0 sta.ting .eassembly. Clean all parts thoroughly 3nd check
their condition. Smear all Pi/ItS wilh tr3nsmission 011 befo.e fitting .
9 Reassemble the synchroniser sleeve and hub so that the nlafks on thorn align . Inse.t the sliding keys and 1IIIhe shdrn\) key sp"ngs so Ihat Ihei. open ends afe stagge.ed re lat ive 10 each other
procarmanuals.com

12. ) Chapter 6 Manual gearbox lind automatic transmission
<II/required. remove the spring clip <lnd d01<leh the selector rod horn the \'ilnsmission selec tor lever. 5 Remove the lou. bolls retaining t he selecto . leve. housing 10 the tran smission tunnel ilnd remove the housing .
6 Remove the l ubbe r 1)lug hom t h e side 01 the sctcctmlcve. housing.
unscrew the nut and prcss the lowe. lever oul of the housing . 7 Unscrew the loc knut on the inhibitor cable alld wit hdraw the pawl. spring ilnd guide bush . a Remove the Allen screw from the T handle ilnd remOve Ill(! hllnd lo. Remove the push button and spring. 9 Using iI pin punch. drive oul the retaining pin ilnd remove thO inhib,jo, mechanism and inhibi tor cab le . 10 Refltling is iI reversa l 01 the above procedure. nOling lhilt lhe
T .handle Allen screw is inserled Irom lhe IrOnt. SO lhilt lhe pus hbtJll0rl rs neareSl the drive r. " Adjust the mechanism liS described In Section 22.
22
Se lector mechanis m -adjustment Fig. 6 .35 Removing the inhibi t o r cable (Se<:: 21)
Almlv the ha ndbtake lhen lack lip the hont 01 the car ;md support on axle stands. A S'NJiyllt IJin 8 Segmen,
~ IT
'--
C Gllide piece
T
JI
Fig. 6.36 Selector mochanism adjustment (Sec 22)
X Locknut y .. 0.' /0 02 mm (0.004 /0 0.008 in)
y
D OpeliJtiflY cable E Rolfer "$SembII'
procarmanuals.com

1 Chapter 8 Rear axle 133
Fig. 8 .1 CrOSS-Sl!ction o f cnrlv rCilr ;1xlo (Sec 1)
A Fixed /ellglh SIJ.1C(!f B Pinion slum
2 Routino mnintcnoncc
C Dd1clCII1.11 S/II"'$
At lhe uHerv"ls specIfIed 111 the HOlltmc M.111l1cn;mc c SCCllon III the 110111 0 1 the mnnu;1I c""y oul the following p,uccdw(!.
Check fcar axle oil level 1 Jilek lIlllhc IvaI of the Cil! ;uHf suPPOtl on axle ~I&#34;nds T o C!lSI'''') li1,'l Ihe Cilr is lellel ;,150 I<lo k III) Ih e IrOnl of th e cm Allefll;. \,vcly . OSI110n Ihe en, ovcr ;m IIlSIJO:ction ,)11 or all .;)mps J. Usmg;J 51111<11110 sqll1lrO key, llrlSe.cw the hiler plu\) I.om Ihe 't·h;md Side 01 tho d'lfcruntinl housmu. USIng a 'mger Or., )llceO 01 bent mowl .otl. check Ihat the OlliS level WIth the b0110111 01 tho f ,lIe . 1)lug hole O f il n>i!xnmun ul 100 mill (0 39 Ill) belo w the holo 4 II necessmy top Ull wllh I he euoree! \)I;lde 01 011 ;IS !Jlvcn '" 'Rceommcmlt'd !"brle,',,'s ImrllhUfls' 00 no! ovcllill thc .em ,nle. o th e.wise thc 011 will ove.he;ll ;111(1 he IO~1 Ihl oUll h Ih e b.e;Ith e. vent 5 Rcht ilnd tiuhten thu hUu. plu\1 Ihen lowe. Ihe eM 1 0 the lJ'ound
3 R e<lr <1)(10 - relllov,,1 ,\Il d refilting
Jack up the le,lI olth e cm ;Jnd sUPPOl1 wllh axl a stan ds 0' hl oc ks
posi tioned lIancnlh the sid(Hllemhe.s . Cho ck thc tronl wheels and rcmove the .ear wheelS . 2 Mark thc p.ol>elle. sh;J1! ilnd .eil' <ule drivc ft3!111cs in .elallon .0 ench olhcr. 3 Unscrew the Iou. fI,lIlge boilS while holding the sh M , wilh a mewl
ha. insc<led through the universal 10Ini. o r by applylllg lhe hJ'ldhrake lower the 'eM 01 th e p.opelle. shafl.
4 D is connect the h,mdlllilkc ti.lIle and. whe.e .1pphC;Jblc. tha
t'ansverse ,od from the .ea. (Ide wl,h refalCnce 10 Chal >!el 9
5 CI<lmp Iha fle~lble hr<lke hosa t o the re<lr a~lc then unsc.ew 'he nuts and disconnec t II /.om the IIgid tJ'ilke pipe all(i ;J~le hrnckel. It a ho se clamp is not av allahle. lig hlen a piece of polythene sheel lIenealh the laSle r cyl inde f till> 10 reduce any fl u id loss and also plug the disco nnecte d hose 6 Jack up the ,ca. ilxle a few Inc heS Ihen unsc.ew and rem ove the sh oc k ab so,be, lowe. moun.,n g lIo115. Prise Ihe shock abso,lIers horn lhe b.ack (lIS on Ih e rca. aKle.
COUAPS'8ll -----i--i!~e&#34;&#39;.!i SPACH'
,
Fig. 6 .2 Cross·sc ction of I"ter rear Ilxle (See 1)
Fig. 6.3 Removing the rear ax le fillo r 1)lug (Sec 2)
Fig. 8.4 Flexible brake hose connection to the .ear axle­arrowed (Sec 3 )
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