oil change FORD CAPRI 1974 Workshop Manual

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'6 Routine maintenance
)
Every 250 miles (400 lUll) or weekly -whichever comes first
Check the engine 011 level and lOp up " OCCCSSJry (Chapler 1) Check and adlus t lhe IYIC pressures (Chilplcr 10) Clean the windscreen and windows C lean the hcadlamps
Every 6000 miles (10000 km) o r six Illonlhs - whichever comes fir s t
£II[1ille (Clwpter 1) Change engllle 011 and IIher
Cleiln oil flilm c"p Chcck 10 1 ,IllY fluid leaka!)e ,n enUme CO'llp:lnUlCIl1
Cooling syslem (Clwptet 2) Check cool:'lnt level
Fuel syslem (Clmpler 3) Check idh"U mi~lUle (cmiJUiello1 IllUdels onlv) al I"SI se.v,ce ollIe, overhaul C heck idllllg sj)ee d
Ignition sys/Cm (C/I,Wler 4) Clean ,1nd re!)"p Sl)".k plu!)s (.:on!nC ' breilkCl Illudels olllv) Cle an and check d'Shibu\o. C"I). '010'. HT lealls mId co.1 (COllWct
bleaker modcls only) Check elwell angle (cOntact b.e"ke. mo<lel s only) Check i900\OOll hlllillg (COnt:'lC1 break er models only)
Cllltch (e/Mllter 5) Check adjuSlmenl
Bri/king sys/Cm (Ch,1pter 9) Check selva
Che ck hydraulic flu id h,vel
Ch(: ck p"ds :'Illd sho(:s lor wear Check h.ake hllcs and hoses
Suspension .wel stvi'ring (Chi/pICr 10) Check tyres 10' w ear and dam:lge Check steering COmp{lIlCnlS l o r w e:l l "lid d.1nlilue
Bodywork. .111d fittings (Clwptef 11) C lu .. >ek se"t belts fa. we .... damage :lnd secwity
Elvc(ric.11 systcm (Ch,7jJ(ef 12 ) Check Ope.iltoon 01 "Uhts Check wilsher flUId levels Check b.1ltery eleclrolvle lev el
Every 12000 miles (20000 kill) or 12 mOll1hs - whichever comes first
III .1(/(lIlioll 10 Ihe 6000 m/le sciler/Ille
Engine (Ch.1f)ter 1) Check and adlUSI valve clearanc es
r"' .......... ~.~-.... ._ •• -.... __ .... . 3lii1&l •
Cooling system (Chapter 2) Check condition "net tension of 1111011)<1101 dflvehelt
Fllel sys tem (Chapter 3) Tighlcn inlel IIHlnl lold boits/nuts Check vacuum hoses Check e~hiluSI syst em Check ll1r ctonne. temperature cOllllol (,I applicable) Renew fuclllllC ' (fuel injec tion models only)
Ignilion system (Chapler 4) lubricate th e dis'flbulOf (conUlel br eake r models only) Renew the coninCt hu,akcr points (II nppllcJblc) Renew the spMk plugs
Transmission (Chapter 6) Check ool/th"d level Lulmc;ue automatIC 1.,'Insmlss,on IInk:'lue
Rcar axle (C/MplCt 8) Check 011 level
Bli/king system (Chaplet 9) Check v,lcuun' hose
llliJllc:'l1C Ihe handhlake Imk,loe
Suspensioll {//j(J swelill!J (C&#34;.1plt~( 10) Check condItIon and hlllSlon o f POWI.II ~I!&#39;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&#39;~&#39;f/u/e
[nyino (CIWpICf 1) f!ell'!W crankC:l $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
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a
26 Chapter 1 Engine
PART A, 2.8 LITRE ENGINE
General dcscril>liOIl
The 2.8 !lIte cnnlne IS of GC,Il1;l1l V(l Qve.hctld v<llvc type. The (OI,llsh;,l l .s loe;lIed centrally In the tylimler block ;lnd IS (Iliven by hchcill \JC~ars from the 0,'nk5ho1h, The vtllvc$ mil opcrillcd hy !:lppCIS. pusluods ill'\(1 rocker 'UIllS. The cylinder hCilds ate of the cross flow (lcsl\J1l With the mlC1 11\,111,lold IOCiltfld on lOp 01 the cylinder hlock between the twO cyhmle. hCilds .111(1 the exhnust m.1nofolds on the outside of the heads Tho r.omhincil c,ankcaso ;1I1d CylUldc. hlock IS madc 01 ens! "011 AllilChcd 10 Ih .... 1>01l0'11 ollhe clankcl'ISC IS a pressed steel sump whIch ,lets ns a &#34;&#39;~&#34;\lOIl fa. the cnWllc 011 I\hlll1l1l1lll11 ,1110y p'Sl0ns illC conl1CClcd 10 lhe Clanksho1l' hy ~I !.1·C"OII 10lucd s&#39;l~1 COllnCChng lods ,1n(l glld\Joon pillS Two I:Olllp'f'SSIOII 111'\)5 a/HI onc 0.1 (:onllol Illig, ,,11 101:;111,,1 al,ov(! lhe !llulgtJon 1)111. alo Io110d. Till) la'lIed c."nksh"'1 ""'s in lOll' ilia", iJca'lI1gs. and en(lIioal 's (:Olll.ollcll hy II110M w;lshc.s 00 No 3 1I1;lIn bO~&#39;IIl!J. The dllv(! 00'" IOf
the d'SI"hutOf ,m(t 0,1 pump is located in flont 01 the 'Oil! Cilm bC;1rIog lub"cation IS by means of a bi-rotor 011 pump
2 Routine lll;lintelHlnco
I\llho inlo.vals sj)ecilio( in 1110 Routine M~&#34;&#39;lcn,1ncc $CCllon II from 01 Ihe m~nll;ll carry 0111 the 'ollowlng p.ocedu.es.
Change engine oil. renew otl tiller olld clean oil filler c. 1 Apply Ihe hil&#34;clb.~kc Ihon jack III) Ihe lrolll 0 1 Ihe Cill and Sil l on ilKlc Sliln(\s. Alle'nnlively pOSll10n Ihe Cill ovc. ,111 &#34;,~pcCtl(ln I 2 rlace a SUlliluh:1 cont~Ule. beneillh Ihn sum1) Ihen tlns.;."w dHun ph.!) (photos) ~nd (If""' the 001 3 Wh.le the o,l.s cI.,}lninu unserew Ih" 0,11.110. '-:;111,,<190 USII'H a' wl()nch ., Clean Ihe d.;IIn plug and Sltllllllhen ,elll Ihe pili!) and IIUhl"!! 5 CtCill1lhc IllIer COlllil(:1 mea 01 11i(, CXlenSIOII blackc. 6 Sme:1f a fIlm 01 enUlnc 011 011 Ihe now 0111.1Ir,. ",hhe. u,&#39;~k(&#34; I screw lion IImoi " JlISI CO(l\;1CIS the t&#34;n~k&#34;l 1 ,1(:(, (photo) 1'",111
Fig. 1.1 EKptoded v iow of tho 2 .8 titro engine Illain c0I11I)ononl5 (Sec 1 )
I T!,ellliostnl hUl/slII!) 5 U y poss /Just! /l,J/Jyc
"
Cr;III.sllllll gear 13 Od pump dflVOS/l,l/l
2 'h':III.ostn/ 6 Ifl/.:1 " ... ",ilold 10 Flywheel 14 M{J;n b e{Jflng CilP
3 W,J/er PUJllP , C{J/lJS/",/I/llfI/SI/J/OJ//! /I Cr{Jnbh<J/1 splgol bO<Jring 15 Od pl/mp 1/ I mllllg "over 8 COJmsfwl1 gem 12 Od seM
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Chapter 6 Manual gearbox and automatic transmiss ion 111
24 Chec k the plilY between the selector finger and 3.d/top geM selC{;lOr .a,1 (F,O. 6 .1 6) . lh,s d,mens,on shou ld be 0.9 mm (0.035 in). lo m"ke t he chec k. move the selec to. leve. up to the .everse gea. SlOp. Us.ng a lever. push 3.d/top gear selector .all \0 the rear and then
measure th e clea .ance by rnsel1lng leeler gauges betwee n 3rd/top gear selector rild "nd seleClOr finger. If th e cleM,mce 's no t ns specified. it shou ld he conecled by chnnging lhe .everse interlock geM plunger for one whIch will give the ,'PI).opria te clearance. 25 F,t a new gasket 10 the e~lension housing cover. Posilion the
cove •. ,nSOI I the fi~ing bolts nnd lighten Ihem 10 Ihe torque wrench Solt1inlJ g,ven in the Specifications. 26 M,1kc su, e th atthe geMl>o~ dmin plug is I,tted and tigh tened where apphc, 1hlc. then I,ll the uenlbo~ 10 the COffect level with the specl l'ed
,,'
10 Gcnrchnnge lever (4,sjleccl ) - m odificnlions
1 To ,mp,ovelhe \]flnr ch nngc movemcntlJctwecn lh(: Hea.s. , smallm CO".,r levcl Sl)!"'g ,s 1'lIr,<:I. the new 51)/,nU d,amclr'!' bc inU 20 mill (008 aga,nst the orig,n;r l sp.,n!) IIiarllctm 01 2.5 nUll (0 .1 0 inl.
Fig. 6 .15 Cover. d ewnt balls and sprinus (Sec 9)
Fig. 6.1 7 Gearchange lever components (Se c 10)
A Spliny B Rct.1illiny pin C Pf;JSlic C ilP
Dlillcnsion X mUSI be gloater Ilran dimension Y
2 To renew Ihis sp.ing. lir sl remove the gear lever unit from the trnnsmission as given in Section 3. 3 Press or drive out the roll pin and remove the plastic cup (F ig . 6.17 ) ;rnd spring .
4 When reassembhng. check that the pin di('!meter is less thiln the width 01 th e slots (X ,n Fig. 6.17), II necessary grind down the pin and
d e·llUrr the slots by ca.e ful filing . When filled the pin slotS mus t face upwMds. 5 If the gear leve. was loose when in use. an O-ring can be filled in placo o f Ihe retainer sOill as shown in Fig. 6.1 8 .
6 When this flng ,s fmed an(I the gear leve. reIOCalr:!d. screw the retainer cap inlO pos,tlon so th ilt It jus t touches th e O·ring . Mark the relntlve pOSitions of tile cap <lnd selector hou sing. then llghlen the cap " fUll he. 15 mm (06 In).
11 Goarbo~ (5·speod) -disillantling
1 Clean the e~tello. 01 Ihe gearbox w.th paraffin .,nd w.pe d.y. 2 Remove the clutch release beallng and allli lele",ng 10 Chapter 5.
0035;11 10.9 mill}
Fig. 6.16 Plav between selec to r finuer and 3rd/4th geM selector rail (Sec 9)
.. : . :,'. :", .
fLJ
··· ..
A
Fig. 6 .18 Cross· section of gear lever showing 0 ·rin9 (A) location (Sec 10)
i
i
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) Chapter 6 Manual gearbox and automatic transmissio n
121
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1 5. 17 MC~Sll&#34;nu corchp· 10·SPCI1(lOIllClcr drivcgc,l' dImension 1 5 .1 8 Sc lcCl0f Sholl! t1sscmlJ lcct 1521 FIlling selector sh1lft/boss fall pin
15.23 Speedome ter dJlvcgcn, cove.
IOCkmg cOI1l,ol hy Inserl;"y the 1)111 ;lnd 1>lu9 2 1 Ahgn the holes. then (lillie Ihe roll pin il1lo the sc lcCIOf boss ;111\1 SI~ICC1Of s h<lh (photo) 7.2 tnserllhc ~clCClOr lock lll{J pin lind spnng, npl} !Y sonlcr t o the plug ·'uc.1ds. then insert ,111<1 liUhlcn lllc plug uSlIlg ,Ill Allen k ey.
_ 3 Fit Ihc SPCCdOIllCICI dnV(!IJciII to tho r(!J' ex tenS Ion housing. Apply " ionic scali.., 1 10 Ihe cove. Ihe'l pro ss II 111\0 \he housinU (phOI0) . . nornavc the 1 (!U1llOHUl1y flHed bolts 1'001 Ihe mlCfllIcd.nle housing. •.• en scle<:1 4th {Jom. 25 Slick n new \Jaskot 10 the e~tcnSlO&#34; housing with glC,1se. ,md fot the hOusing 10 Ihe inle,mcd'Jle housi"g T .. ke c", e nOI to (I,ml<lge t he 'e'"
all seal. ,1"d m,1ke sUle th<ll Ihe sclecto, shah cenll<thSlng SWinl] loc .. tcs on the pin (photo).
26 Insert the bolt s .:md tighten them to thespcclflod to'Que In d,agon .. 1 sequence. Befo.e Inserting the Ih.ee bolts which go light through tllo
main c .. sing ... pply se<tl<lnt to their threads 27 Selec t levelse \Je .. r <tnd loc .. te the connector on the re .. r o f the
se leclor rod . Support the rod wi th a piece of wood. then drive in the '011 pin_ Selec t neutral. 28 Press the .eil' cover into the extension housing .
29 Check that the 5th gea. interlock slceve is corrcctly .11ognoo. then 'nscrt thc Sth geil' locking pin and spring.
30 Appl y some scalallt to the 5th geilr locking plate. 10Cilte It on thO extensio n housing. an d inselt nnd t igh ten th e bolts to I h e specIfIed torque. 31 Fit the Ueilrbo~ top covcr. together WIth a new gas\(et. and lighten
the boilS to t he sf1eclf.ed tOfQue in diagonal sequence. 32 F u the clulC h relCilSe bearing guide sleeve (oil slot dow nwllfd s). together with a new gilsket. and lighlen th o boi lS to the specillt~d torque in d;ilgon;11 sequence. Where neceSS;1ry apply seal,.nt to the bolt threads_ 33 Fitthe clutch bell housing to the Iron t 0: the gearhox. together woth new gaske t. Apply sealant to the bolt threads. thcn inse n the boilS .~d tigh ten them to Ihe SIXlcllled 10rQue in diagonal sequence. 34 Inscrt and trgh le n the .ev(usinl.l Ioght switch in Ihe ex tensio n housing
1525 Selec tor sh aft spring pin (arrowed)
35 FIt the clutch reLease l"l'lIIng and a.1Il wuh .efercnce 10 Chnl)\ el 5.
16 G e(lr box (5-spee{l) -d isellg i:lgem enl of 5th gear
I I
is possI ble 'or vducles hu,l t bclo.e NovcmiJer 1983 to have i:l p.oblem WIth 5th ne". Illillplllg Ollt of cnuanClllcn t during normal
(hlv lnu
2 ThiS 1I0uhle Cilll he rcc tl',cd hy suhstitutinu nlod,hc<l 5th ge.1'
componen1S t o Inc lude thO hub. o!\Ulk ""gs .. nd sci(.-ctor 'ork.
3 Rem ove Ihe gearbo_ "s de$("bed in SectIon 3. This wrll nCCCSSlla te lemov ing the ge(l' Icvcr "nd lu"C I cove. whIch is held In ,)OSltlo n by TOOK typc sClews . 4 Removo the clutch Hlleilse bearing and tevcl 110m the bclthousing . 5 Unbolt ami lemovc the lOP covel. 6 C"ory out the opel,1t'0"S dcsc llbed in par "graphs 8 10 1" 01 Seclion
" 7 M"r\( Ihe ex.1Ct IIOS""o n of t he speedometcl wormdrive on the milinshil lt (lnd then draw it off using a pulter .
8 Extr"ct the ci. et,p "nd H)move the 5 th sp(lcd sync hro unil/rom Ihe
mJinsh"lt. 9 Dismanlle the synr.hro "nd reasscmble using the new p" rts, When I Itting t he b"ulk lings. m"ko sure that theil bevelle( 1 side is tOwa.ds the
re,,' o f Iho ge",box. 10 Caffy out the ope,,,,,ons desCfibed in jh"lfilgraphs 16 to 22 and 25 1027 in Section 15. 11 Inser t the 5 th ge<lr locking pin and spring to Ihe extension housing_ 12 SmC<lr the 5th gear 'ocking pla te WIth seal"n t and locate It w ith nuts hand tight. I 3 Adjus t the gearchange mechanism by pressing the gear lever lully
1 0 the light whIle "1 tho} neul'il' mode and then tighten the locking plate nutS to ill o 'que 0125 NIIl (l8tbl It). 14 Fit the top cove. olnd gasket and I he clu tc h release components.
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Chapter 8 Rear axle
Contents
Axle rear cover .. lemoval and .etliling Axlosha!! bearing -renewal Adcshah -removal and refltllng . Fnul1 diilgllosis -re3. ,1xle Gcncr<ll description. Limited-slip difterenlial -generill
Speci fic", iOl1s
Gel \cra' Axle dcsI\)n<lIoOIl _ Type
Hallo . uhllei'ml C"llilClly •• I>IIC;1I11 type. O ,lIcnmll.1I sIde 90;u ('"dllo;u 1'''''011 turning torque (~ell&#34;llJ) Crown wheel and pill 1011 backlilsh
Torqu e w re nch settings Bc,uinu (31) \0 axle Cilsing Cover \0 axle caSing CrOWllwheel Axlcshalt bearmg retainer /backplate . Drove pinion nut ....... ....... .. Rear 51),ing U·boh Stabilise. bar clamp boll _. Propeller shnfl 10 lear <Jxlo drive flange
General descrilHion
6 !i ,
11 1 10
The rear axle IS of the hypol(f seml·floallnO tYI)oO and is located hy semi·elliptic ro~d springs, In conjunction with a smhlliser har. The dilJerel11inl is intogral Wllh the axle hOUSing and Ihe rear axlo
InuSt he removed to carry out ilny rePil" S to the dll1erellt,,,, wh,ch milY hecorne necessary . J The drive pinion runs in two lapered roller UeiltlllgS, which are "reloaded by a spacer . Early a.l"s have a ',xed lengltl Slh'lcer and I<lter ones a collal>sible spacer (F'{ls 8.1 and 8 2). Both IYlleS of SI>aCer are InlOrchangeable. but c<lre mUSI be taken to ensure th<ll the appropriate
nle lhO<J of delerm ining drove p'nion bcarrng preload is used
The COrfeCI deplh of me~h 0 1 the p,nion in the crownwheel is
PUlIon 0.1 so,, , renew"l . fie;]! .1x10 ove.h;wl Ilear axle ,emOYil. and refIlling f1ollll!w 1ll00intCIHlIlCC • Wheel siud renewal,"
() (Sahshury)
7 8 3 2 ,
Ilypo,d. sem,·flo,lIU1!), onteorill dolle/ent",', limited-slip dollelenl,')1 on 28 Speciill 300.1
I I loire (1.0 l)il11) SAE 90 015 mill (0006 'n) 2510 2 7 N,,, (I 8 to 2.0 IIlI tt) 010 to 020 ,nm (0004 to 0008 in)
Nm 60 10 68 35 to 45 801087 27 10 31 100tol20 25 to 36 401050 60 to 65
Ibl It 44 to 50
26 1033 501064 20 to 23 74 to 89 18 to 27 301037 44 10 48
obwined by Ihe use of selected shims inserted belween Ihe pin ion and rear t<lpered loller bearing. The crownwheel is boiled 10 Ihe dilferen lial c ase, w hich is mounled on IWO lapered rolle r bearings . These bearings ilre preloaded by selec tive· fil shims, positioned on eilher side 01 the dlfferenti<ll housing The d'fferential <l55embly is 01 Ille two pinion Iype, 28 Special models ;lre filled with IIlimiled'slip d<llerential. Th e adesh<lfls are splmed co ehe dlHeren eial side gears <lnd supponed at ehe oule. ends by b<lll· bea.ings . 011 seals <lre filled .11 each
end 0 1 Ihe axle housing . Ove.hauling ehe lear axle requires a variely of spedallools and it is no! recommended Ihal any allernpl should be made tfJ do Ihis unless these lools ~re <II hand,
d
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Chapter 10 Suspension and steering 171
19 4C Removinu the top steering column Shroud 19 G lunitlon SWitch ,1nd wirlllU (A). also COllll'lII upper mOlUllnl!J holt (0) 19.7 Removing the steering column uppcr mounlul(J holt (arrowed)
'5 Secure Ihe SIt:(;(1I1(1 lock 10 Ihe colulIlIl ,lIal ~heil&#39; the h eads I,om ,he m:w holt~ 11) U~e the stecrin\J lock to locate the shaft in Ihe column. then III Ihe )ct,on mdlGltor OICIlJalinn GUll alld Stecrmn wheel. CtlCC~ that Ihe ruadwheels afC st,lIln the 5trai\jht·ahead P05,110l1. 17 Install the Stce!Ul(J column orommet Oil the lowm en(t. 18 LOCille the column assembly ami sr:c",e It wrth the Iwo mOllrlllng bolts. 19 The ((,milliuler of the rellllUI\J proccrl",e ,~ th" reverSI! of lhe removill procedure,
20 F ront wheel alignment and steering ilngles
Accurate front whcel alignment IS essential lor good stoer"'g and lyre WOiJr. Scion) cons,dering the steering angle. check Ihat Ihe tyres
are correctly inflated. tllnt the front wheel s arc nOI IJlJckled. the hub hea"nns arc not worn o r mcorrectly adjusted und thilt the sleflr"'g IlIlkaUfl is in IJood order. wllhout slackness or we,ll at thu Jo,nls
2 WIH;f; 1 "I'!JIununt co&#34;s&#39;st~ 01 loUl I"ctors, C;"lliJcr_ IS the ""Ule "t wilich the front whet:ls ,lie sci from Ihe
verllcal when v'ewud 100'" the IrOnt 01 the c"r 1'0sIt,ve camber 's Ihe .. mount (111 de\J&#39;ee~) th"t til() whucls ,ue toited outwards at the lOp 100'"
thu vert,c;,1
Castor. ,~tho i&#34;&#39;~Jlu between the SIl,erlIlU ,,~,s OIrld.1 v..,'I,e.11 lone len viewud IrOIll p,lch ~,dfl 01 the C,lI 1&#39;0~;llIve castor 's when the ~tcermu ",x,s 'S ",cloned rUiHw,,,ds ill the top jStcerinu ilxis inclin,,{ion 's lhe illl\Jle. when VIewed frOI11 the .It 01 the Cilr. bel ween the verltcal and "n 1Il'''U>I1.1ry hne drawn betwCl)n the upper ilnd lower suspensIon strut p,vots, Toe-i n IS the ilmoUl,t by wh,ch tlte dl5li"'Ce helween the frOrlt
IIlsuJu ed\Je~ 01 the rOildwhecls ('He,lsu1ed m huh heiuht) ,s less thiln lhe d'sWrlCI) &#34;,e<l~ured between the rca' Ins,de edges 3 The imUleS of c"mber. c,l~tor "nd slCe''''g ax,s ilIe SCI ,n produCI'On ~n(1 nre not <ldluswble. 4 Front wheel aliurUlll)n t (loe·"I) checks ilIe best camed out wl\h nlodern set!lIlg equ'pment. but il fC,lsonahly acc1llate alte rnative is hy nle<lns of the following procedure.
5 PI"ce the Cilr on level ground WIth the wheels 111 the sualghl·uheild pos' lion,
6
Oht"in or m"ke <I loe·in unuge Onu IHay eas,ly he Ilwde from it lenyth of rod or t ubinU. cr<lnked to clear the SUIl'P or bcllhousing and h~vmy il setscrew "nd locknut ill one end 7 W'lh the gnuUe. measure the d,stilnce IJetween the two IIlner wheel IIrns M hub helUln ill the Iron I of the wheel. 8 flowte the roadwheellhrough 180' (hillf il tU1[1). hy pushinU or pvlllllg the CM and then me,lsure Ihe d'Stilnce ilgaon at hvb height bel ween lite inner whee! (In,s <It the reil! of the roadwheel. Th,s meaSurernem should eIther he t he Silme as the one Just lilken. or greilter hy no! Ino,e lhan 7 mrn (028 in) 9 Where the 1O~·1II IS founoJ to be ,,,correcl. sla~ken the 10cknuiS 0[1 each tr,lck rod. also t he I lex ,ble bellows clops and rOWle each tr~ck rod . XII equal ilrnourl unlll the correcl toe·,n ,s oIJW'''ed . T,ghten Ihe .k rod ~nd 10cknulS. whole the !JilIIJo,nts ille held III the centre of lhe" ilrCS of trilvel II'S "npcrilllve lh~11he len\Jlhs of 1he trilck ,ods are ~IWi&#39;yS equal 01herw,se thu wheel ilngles on turns WIll he ,ncorrect. If
ne:w components have heen I'lted. set the ro"dwheels ,n the stral\jht·ilheil(f p05otrOn and also cent",lrse the steering wheel. AdJ"st the len\Jths of the track rods hy lllll1ing tltem so th,,! the track rod end IJ,litJoinl studs w,11 drop eils,ly onlO the eyes of the steer inu ilrlllS Measllfe the dislilllces between the centres of the hilllfOllllS illld the grooves on Ihe inner ends of the track rods and ildjust. ,r neceSSilry. so Ihiltthey me equ,ll Thl~ is all lII,t,,,1 sellinlJ only and prec,se ildillstmellt mu~t he carried oul as descrrhed earheL
21 Wheels and lyres -uonNal care and milintenl1nce
Wheels ilild tyre~ shOuld give no reill problems in usc provided thm ,1 close eye IS kept on Ihe", with re\janlto excessive weilr or dilmilge To llns end. the following pOllltS should he noted Ensure thm lyre pressures ",e checked re\Jularly ami ma,ntallled correctly. Checklllg should be c,Hried out woth the tyres cold alld nOI IIlHlledialely alter the vehicle hilS heen "I usc. II the pressures are checked w'th the tyres hOI. iln ap(l,Hently hi\jh readmlJ w,1l be ohw'lled OWlnH to heilt expJnsron. Under n<) Cllcumst<l"ces should ,III ,!lWlllpt he lIlildu to reduce the p,essu,es to Ihc quoted cold r eildlllU ,II thl~ "Ist,once. or effect've undcrinlliltlon w,1I result Undc""f)"I'o" wrll Ciluse ov(;rheiltu\lj 01 the tyre OWin\1 to excn ss,ve fluXlIlU 01 the casin\l. and Ihe Ire,ld w,1I not S,I correctly on lhr! road surfilce ThIS wrll cause it cOllsequent loss 01 adhcs,on alld excess,ve weilr. IlOtto '\lention the danncr of sudden tyre fadwe due to hea t bluld U), Overonfiil t,on w,11 Ciluse rap,rt Wear of the cell Ire part of Ihe lyre tread coupled w,th reduced ndhesloll. hiusher ride. and lhe dan\je, of shock dilmilge occw"ng in the lyre Cilsin\l Heg"liloIy check the tyres lor dilrno1\je 111 the form of cuts or !>"Iucs.
eSpecii\lIy 111 the s,dewalls Remove any na,ls or stones ell\bedded 111 the tread hefore they penetr"te lhe tyre 10 cnuse dcfliltlon If remov,,1 {)i <I nad docs reveill thai t he tyre hilS been punctured. relIt the "JlI so thill ,ts point 01 penelrat,on is Illilrkcd Then inHlled'illely change the wheel and have the tyre repimed by il tyre deiller, Do no/ drive on il tyre in such il cond,"on In lIlilny cilses a punClUre C~ll he sunply repa"ed by tile use of ilil IIlner tube 01 t he correct size ilnd type. If In any doubl ilS to the poss,ble conS<lquences of ilily dlll11ilge found. conSult your locill lyre defiler lor adv,ce Periodically rcmove Ihe wheels and clean any dirt or mud from the 'Ilside ilnd outs,de SUrlilCeS. Ex~mine the wheel rims for signs o f (listing. CorrOSion or other dilmilue. Light alloy wheels "rc eusily
dilll1i1ged by ·kerbing· wh,lst par king. and simililrly stee l wheels may hecome denIed or buckled, Renewnl of the wheel rs very ohenthe only course of rellled'ill ilct,on poss,ble, The balance 01 each wheel Jnd tyre ilssembly should be mainta,ned to ilvoid excess,ve weilr, not only 10 the tyres but illso to the s teering and suspension components. Wheel imbillilnce 's normilily S'\ln, f,ed by v,i)rilllOn through the veillcle·s bodyshell. illthouUh III many c~ses it IS piullcularly nOliceahle Ihrouoh the steenng whuel. Conversely. it ~hould bc noted thilt weilr o r dilnlaUc 111 suspellS IOll or steer ing components may '.:ause e~ceSSlve tyre wear. Out·of·round or out-of· t!Ue lyres, damaged wheels and wheel !leafing weilf/ nlilladJustntent also lilll into th<s Cille\Jo ry Billancing w ill not usually cure v,bration caused by such wear
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procarmanuals.com

)96 Chapter 11 Bodywork an d fittings
of the housing, then remOlle the heal exchanger from the 1ramc and lake ott the fOilm pilcking. 4 To remove the distributor flap from the housing. remove the clip and withdraw the conlrollcvcr sideways. 5 Remove the rcgul<110r flap from the lower section of the housing, Bend bJck the 2 claillping straps sulticicnlly \0 enable the conlrollCIICI 10 be withdrawn (liter i, hilS been turned tow;1rds the side, then remove the regulating flilp. 6 Remove the retaining straps for the blower mOlor cap. by pressing outwards from the inside uSing 11 screwdriver. 7 Deweh the mOlOr from the upper sectioll. Disconnect the motor leads, remove til(! <1 rewining clumps and remove the motor and filiI inw,uds. a When reassembling. positIon thc blower mOlOr so that the clectric<ll connections face IOwards the c<lble fastening iI! the upper section Secllw the n10tOl nnd connect the lea(ls. then 111 the mOlor cap. 9 POSItion thc legul<ltlng tI<lP in the lower section nrul inse, the conl!ollcver by tll,nlllg it IrOlllthc side as necessary and SWIllU It roulld 11110 tilc stral)S . Close the straps usinu pliers . 10 POSItion the dIstribu tor tlap in the lower section and IIlsell the
control lever from the si(lc.
11
11 The remainder 01 the reassembl y procedure is the reverse 01 the
r emova l procedure.
45 Heate r nssenlbly (Smiths standard and heavy duty) -dismantl ing and reassem bly
Standard he,1ler I Remove clips A and B (Fig. 11.32) ilnd remove lhe heater housing
sidc cover complete with flaps (15 screws) .
Heavy duty healer 2 Remove clip A (FIg . 11.32) olnd remove thc hcater housing SIde cover complete WIth flaps (15 screws)
All he,lIers 3 Remove thc heat e~chnnger nnd 10,1111 sen I. <1 Prise off the c"clip nnd remove the Ian I.om the blower motor shall. 5 Detach the blowe r motor from the support (3 nuts and holts). 6 Reassemhly is the reverse of the dismantl ing procedure.
Fig .
11.30 Stilndllrd Smiths h eater (Sec 4 5 )
1 M%r assembly
2 COVt·( and black!:t assembly 3 Control valve operatillg le vel
4 Righr·hand housing cover 5 Dis/ributor flap 6 Fan
7 Control v<llve 8 Housing 9 Demis/e r hose connection
10 Heal eXChanger seal 11 Plenum cflambe! cover
-------------------------------~ 灲潣慲浡湵慬献捯m

2"4 Index
",-----------------------------------------------------------------1 -
ligh\s operation check -16 w~she( fluid levels check/lop up - 16, 217, 219
engine
crankcase emission valve renewal -16, 27
fluid leaks check -16 oil i1nd filter change -16, 26 oil filler cap clClIning -16. 26 oil level check/lop up -16 1I;llvo clearances check/adjust -16. 46
exhaust system condition check -16
fuel sySlCm <lir cleaner temperature control check · 16. 67 air filte, element renewal 16, 67. 79 fu el fIller renewnl (fuel injection models) --16, 80 fuel hoses condition check · 67 idhng speed/mixture check/ad)llSl -16, 73, 79 inlet tllllniioid nuts/holts UUll1cn -16, 27, 83 vilcuum hoses check -16 ignition system contact brC<lkcr points renew"j (3.0 hire eng1l1e) -16, 89 dlS1riiJulor Cilp, (olor, HT le<lds [111(1 co,1 c!e ,ln/cileck - 1 G. 88 (hst"hlltor lubrication -1 G dwell angle check/~diIlSt (30 hue elllJ'ne) -16. 89 sp,lrk pillns cle"n/re-UJp Hi, 95 sp~rk phl\)s renew· 1 G, 95 limin\) check -16 . 94 real axle 01 1 level check/top lip 16, 133 s~fely prec,HltiollS -12 sC(vice schedules -13 suspension Jnd steellfl!) power steerlllg drivebel1 cond,tlon/tenslon Check 16, 161 power steering fluid level Jlld hoses check 161 steering components condition check -16. 161 suspension condition check --16.161 transmission ~utom~tic tr~nsmission brake b,l lld ~dJuSlmenl -16. 123 i1(,tOlmllic transmission Ionk,lge luhricmion -16, 123 oil/fluid leve l check/IOI) up -16, 104. 123 lyres IH(!SSUres chcck/~dJllst -16. 158 we<lr/d~m~gc check -16. 171 whllels comlilion I:llCck 171 Manifolds (cnrburettor nlodels) Icnlov,,1 and 'Cf'tl"'!) exhnust 76 inlet 75 'nnifolds (fuel injection models) relllov~1 and rell!1Ul(J
exhaust -85 Inlet 83 M ,lIlua l g e<Hb ox (iescriptlon -104 fault di~gllosis 122 f,ve -speed disenIJil!)emcnt o f 5th \jeM - 121 dlSnl~ntlmg -111 exallHnat ion Jnd renovation -119 "'put shaft dlsmantlln\j ami rNlsscmbly -109, 119 mainshalt (lismalllllllg and le,l ssc"li}ly -115 reassembly -119 four-speed (lismantllng -106 examination lind renovation -109 input shah dismantling and reassembly -109 I~ygcar dosillanlhng ilnd reilssellli)ly -109 reilsscrnhly -110 gcarchilnge lever (lour-speed) modlflcmions -111 ma intenance, routine -104 removal and reflu;ng -104 speclficmions -102 IOrque wrench SCHings -103 Manual g ea rb o x ./Ild lIutol1w tic trMlsmissioll -102 c( scq M aster cylinder (brllking s y stem) ovcrhaul _ 149 ~ernoval and relltlin\) -148 tvr'rror
o
removlll and relltting lldjustllble exter ior -192 interior -192
Oil pump
p
28 Iotre engine dismantling. examination and re~sselllhly -38 ref in in 9 -42 3 0 li tre englllc dismantling. eX~lllinmion ilnd reass embly .-52 [elit\lng -54 removill 50
Pedal ,1cceler,ltOr 75 bra k e · 152 clutch -101 Pisto n an d connec ting rods ref,nin\j -42. 51 Pistons and pisto n rin\js exanllna\lon ,1nd rcoova\lon 36,51 Pi sto ns. connecting rod s il11d bearin\js (3.0 litre cngine) [lmlov,11 51 Propeller shaft 128 d s, .'r/ Prop elle r shaft cenlre bcarln!J r()&#34;l]w~1 12!J
descrip1l011 28 I"ul l (i iaunosis - 131 removat and rel,UlI1U -128 10rque wrench seHlIlgs -128 univers~1 10lllts inspection 130 Pushrods 35< 51
R
Rndi,lto r rel11ov~I, Inspcctoon, cie<ln'll!l ilnd ",fIIlIlIO GO Rildiator grille removal and refll\lng 179 Radio/cassette pl,ryer
<emovill ilnd reflttln\J 226 Radio equipment. mobile Iflterlerence- free IIlst;lllat,on ,-226 Rcar ,1Xle -132 e/ seq Rear axle ,1xle reilr cover rClllov,, 1 and rellttln\J -135 axleshah beoliing rcnewill 135 removal ilnd relilling 134 descllpt,on -132 fauit (/lilgnosis - 141 limited slip (hiferentoill -140 rnainterlilllCe, routine -133 overhllul -136 pinion oil seal renewal -135 removal ilnd refltling - 133 specifoCiltions -132 IOrQue wrench sellings -132 wheel stud fenewal -140 Rear drum brilk e s
rear hilckpl~te removal and rclluin(J -148 shoes renewal - 14 6 wheel cylinder removal, overhilul ~nd ref'lllllg - 14 7
Rear lamp and b ulb removal and refttling - 216 Rear number plilte lamp and bulb removal ilnd relilling -216 R ear su spension description - 158
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