open bonnet FORD CAPRI 1974 Workshop Manual
Page 49 of 205
:as::.w.'q
48 Chapter 1 Engine
110 Routine '!lain!cnanc!!
At the 1I11Clv"ts specifIed III Ihl! ROutlll!! M"inlcni'lnce sectIon in thO !rom althe mil"l).11 cnlfy out the followmg procedures.
ClwlIgc ollgiflO oil. reflew oi/Ii/fer t/lld clean oil filler cap 1 Rdo, 10 S()C\'OIl 2
Check illld <1r/jllsl vMvc c/c,7f<1nccs 2 Rcfe. 10 Scellon 89
TigMt'lI mll;( IlliIlldold hollS 3 RP.1110VU Ihe ;", Llr:"llcr ;unl lI!Jh1cn the Inlet rlIi'1ll,fotd holts 10 Ill" spccll",d ,ollluO wIlh .oleumc!! to Chapter 3. On comple\lon re lu the au deane.
R(JIII.'w Ihe cmllkc'ISf! l.'mission v,Jlve " Ad", In SIl<:\lUIl 7
41 Major operations \lOssi!>lo with (lilgine in car
T 10" lollow,n!) ""'1111 Ot",,;otlOIlS Illay he r.'If.icd Ollt wlthou, ""''''VIII!lllw';!)!luH!
(.,) /r,·", .. vmy .1",1 "'/'/flll!! III!! ,:ylmd ... , "1.'01(1", (II) {,"'IIIIJVIlIf/ tllld "d'I/IIIO (/1<: /ltmll!l 1I,·.ItS (i:) 11,:IIIIIVIII.'I.IIItI,dll/III!/ /IIt] I!II{/IIIL' 11II1I/11!""I1/III!I~ (II) III'II"'~IIIY .",,1 "-'''/lilly/he Im!lIll~'I!It];,,""" ",;" "'111"'/"'.'1 (,') /{"/IIIIVHI!I .mlf ,,-,"II"'II,IIt] (;;/II'S/l."1
42 M" jot Ollcra lio ns requiring engine removnl
The followll1~lll1alm ope"II'OIiS may be c,lIIlI~d OUI allC! ,cmoval of Ih" !!II!I"W
(01' /r,''''''''''''! ,mlf ,,:III/my llit] fly"'/md (b) 1,'I;"""'III!I ;lIId 1I:"lIiII!! lIlt] II.'''' "';1111 '''.·;IIIIIY vII sl~.ll (,;) f,',:/lWVIII!1 11",1 ,,:hl/myllll" ,:,.mAr:;,.w stlll'p· (,I) 11,·wIIV"'!1 .md It"/tflmyl/t,) 1.-"/II,,.t:I"'!1 tOri 1t~·;"'''!1 (,.) /1,.",,,,.,,,.'1 .md II-,!t/lmylll,) ,,,sl,"'.~ .1111/ ,;ullltL'd"'!1 IUds II) ".,.""",,,,.'1 .lIId tdll/myll"-' "II /lllillfl (.'/) f'"'·"'''V''''f ,11101 td'IIIII,,'''t] (I.mAsh .. ", ;/lul",;,,,, ht];mllYS fli) J,',·IIU1V'It!l .1111111.'1t1/1II!I fl,t, C,lll/.f/"dl 1141.<111."5
A lth""!lh 'I'~ 1)(,·.~d,le 10 1(~II1()~clhe SUI"P W'lh lhc C"gllHlII' the ca'. I! IS 1(":o""",·,,~I,,d thai 101 ,Illy ope"u,olls wh'ch .elt""e Ihe .emov,d 01 IIH: ~""'P. ~,,<:h ;,~ the ,eOllov,ll nf Ihe CI,'nksh;lfl alllll"o c!l(II)c<I''''Us.
tl,,: ""!)"'" ,~ '''''''IV'·!!
43 Mctho(ls of engine removal
The ""!I""~ 'n"V he hfWd oul e'the. 0'1 us own u. III u."t wuh Ihe I""'~""!>~'{)" On I1lo.I\lIS l'I1t.'<I w'th ,1UlOm"toc 1'''"S''Hss.on 1 . s ",co"""""d,;d Ih;,1 Illc ellUlile he hfled out on 'IS OW". unless <I ~III'~IiIl'tJ;" <':I;'''£, or o~ .... ,hll"d hO'SI 's <lvn,lnhle, hecolu~e 01 the wc'ght f, ,<:IO' II Ih" ''''u'"e ;lIu t 1"I"S""S5'O" <I.e .emoYcil as a uIHllhey have W hI! hf!Loti o.n at " Yery Ml'Cp il"UIC. so mako sure Ihill the.e ,s stllI,cuml hrl"'~1 "'-"0111 nvndalJlc.
44 Engi"e -rcmoval
Open imd p.O)) up Ihe bonnet lhen covel Ihe w'ngs w'lh CIOlhs. o~ <:n.(l11O.1,d. 10 Il,olecl Ihcm hom scr<ltches (luling Ihe subsC(IIHlrH O)le(,ll'O"S '1 Millk til" outline of Ihe hOllllel 1""IlCS and 1hen w,th the help 01 an "ss,stim l. ""nove tl'l! 1o". lK.ln'll! se'l:Ws . ,t;l lIilse the bonnet stily and e.udtlllv hl l tl'l: lmnnet cre", 3 [)'~CO""l:<:t Ih(: l'il1I .... 'y lends. tIllT10ve Ihe hnlln'y clilmp bOlt <lnd hfl
II", IJ.,U",v oul <1 fle,l/oyu lhv ,II' cle<ln(!/.
5 flc"'ovu 111,· ~pl.'~h ~h,(;ld hy "''''<1VU'H II", hlllt~ ,1,,<1 cI'p~ 6 PI,lce ... ~:Il"I.I·nf" of 10 lot", 11"16 JI"'I) r:,'I),II·, tv ,,,,,Iu.,,, !,
'iI(I'<lIO'. ""novc Ih/"! ""h:OIO' hun",,, h"", .1,,,1 ,h"", th" r.Il"I.l,, · 7 RcmfJv,~ Ih,' "1'1)1" hll~" I,n'" Ih" ",";,1", I''''''P n'·'I1"~" Ih, 110m Ihl) all d,,1I,·I.I,,, pa" .. 1 ""d I""" lh" ,;"""t,,, ~h"",,1 ;'"d ,.
Ihem
8 flc"'"~,, Ih., I",,, hllll~ ...... · '"II'!I th", """.11',, til Ih" '''UII Ila" hfl Ihc "1(10,,10, ""t
\) D,sc""''',,:1 Ih,· ',,11 w",.·, hm,,, 1"111' Ih" w"tt·, 1"""11 ;",.t a"I, cho~e
10 fle"",,,,, tht! -l.lI"·' ""'10' h,·;11 ~h,,'ld .11,,1 II"·,, ,I,,, '''''''·'·1 tho I,om Ih" ,,11"""'\0 " t'·IIIt"·'."'"'' '.""d,·, 111"1. "1"'''"11 1./,,1 ;111,* mOIO'
II R"IIl'l"" Ih,· ...... " huh ... "''' ~""'!I th.· 11""nl,· h"k"!IU I,
aSS(lmhly to Ih" .1\1<'1 ",.",,1,,101 .lIlfl "·"If"·,, It Ipl'Il.IIt 1 2 fl'''''<l~'' Ih,· '" .. I .. Il'· ... ""101 II,,· 10,,·1 1''''''1' (plo(II"). Ihe,
vnCll"Ill hn,." I",,,, Ih,· ,"1,·1 " .. ",,1,,101 .",,1,1,,· "oJ )."· ... ~II"· I",,, fll. conn,-ct", .11111 , .. I.· ... t I""" tl,,· .,,1 IW""";'" '" .... ,,,,, 13 R""",,,,, tl", •...• , 1",l b ""·"""'!I Ih" '.1.",,·, "",r,,, .""t ",,,,(,,. 14 flell1""" Ih,· I.\() """ 10, 01 ..... ·"'''''·''1 II,., ,,,hi,,·, """I.'I"'~ III, en(Jllh1 """,,'I"'!I' 15 RII"'(J~" tt,,· I.'." ~"'I~ f""" '·.11 h ,·~h.""t n.",,),· ,11,,1 ,II".,,,,,,, e~h,'"~1 il'l"'S ),'"'' III" ,·~I,.".,t ",.""f',lel
114 12 Fuel j)1""p ". d 1,,0;1 I,"t;
I;" ,
1:-,
!
~ ,
procarmanuals.com
Page 174 of 205
Chapter 11 Bodywork and fittings
Contents
i'ldIUS\<lblc CXtCliOI mi"Ol fIJ",ov;l1 ,,,,d rcl'UII'1J 37 Bonnet 101l1OIIal, rclltlon!.! ,Hal ildJUSllllcru 26 BOlmCl Julcilse c<lblc lOI1>Oy,ll and luhlllnq 25 ~ 'PCIS ,,:~mO\l.11 <llld ,d'UUl(i' 8 ,['c consolc rCIllQVill <llld ,e('lIU1(J 32 DC""~lcr nOll.lcs rCIllQY;l1 ilOld re/lullI\) 46 o -,cmOllill ilnd rcl,tlu'(J 20 Door lock ilsscmbly .. rCIllO\l[l1 <lnu refll!lllIJ 16 000' privnlc lock·· Icmo",,1 "nd 'chUm\) 2 1 000' 'ilules -uolcill\J ,lIld recl,/,eiltion 7 00o, remOle control h,H\(II() .. rCI110vili ,lilt! rchllmU . 12 Door Irim pallol -rcmoval <lnt! .chltin\) 13 DOor w indow 1r<11ll0 -.emovnl and ,cl'UIIl\) _ 18 Door window glilSS -rcmovi\1 [lmi rcflU lllU 17 hlcnOf door handle -fcrnov;)1 I'Ind 'Clltlln\J 15 Face level venls -rClllov<J1 <llld !Clotting 47 Fac'a p<Jncl -removal ,md .el,wng ..... 31 Fuel Iiller flap ~ rNlloval and ref, tting ... " 30 Gener", description .. ... ...... " .. _. _ .. _._ ......... _ 1 H~ater "ssembl y _ rcrnov,,1 ilnd refittin<J .................. ........ _ 43 Heater asscmbly (Bchr) ~ disrnallliing ilnd Hlilssembly _ 44 Heatcr assembly (Smiths stnndnrd mlll heavy dUly) .. dismiH1lling
and reassembly.... .... ........ ..... ..... 45 HCillcr controls ~ ildluSlmenl . 40
Specifications
Torque w rench settings Se.llbel ls :
) pillar .\ lIoor .............. ............. .......... _ ._ ..... .. . Openlnu rcar qUilrter glass tougle 10 C pIllar.
Heal"r cOlllrols removill im(1 rchUrn!! lIemcr Willer villve (heilvy dull' he;II'~r) rcrnoval and rel,ttrng I"tc"or m ,,,or -remov,,1 and refrtllng . LOild spnce I"", pifflel -refl1ov~1 and refillmu M,l,nten;mcc bodywork ,1nd underfr;lflle M;r,nICnnnce • upholstery imd C;Hpets Millo r body dilm<lue -repil ir Minor body dnm<l(Je -repair. Openi"U reM qUiII ler gl'15S nssenlbly -re",ovnl ,lI1d refitting Rild,nlor g"lIe -removal and refl\1ln9 ReM qll<lrter trim Iwnel .• removal <lnd relitting _ Rout,ne m,lrntenance Seal bellS -gener;rl
SeillS -remov,,1 ilnd refilling Sunroof -rcmoval an(1 ref ininu. Sunroof bracket an(1 dnve ilssernbly _. removal and refitting SUrlrool PJnel -<ldfU51fnenlS
T;rilgJte -removal "nd refilting Tailgnte p"vale lock -removal "nd refillinu Tailgate striker plate -removal "nd refilling Tailgate window glass -removnl and relittin(1 Window frame moulding "nd door weatherstrips -rcmov,,1 refitting Wrndscreen -removal ilnd rellllltlg
NIH
2010 30 35 10 42 4.5
Ib l It
15 to 22 26 1 0 31 33
41
" 38
" 3 4 G 5 23 ,
22 2 3G 39
" 35
33
27 28
" 11
"nd 19 10
----------------------------
.. !i
procarmanuals.com
Page 177 of 205
)76 Chapter 11 Bodywork and fitting
General description
The body is of all-s teel welded construction with impact ilbsorbing hont Dnd rear sections . Anli-burSllocks nrc lilted 10 the doors, ilnd the
t ailgDte is supponcd by \J<ls- filled d ,lmp crs. All window glass is of toughened safety type. The front seots Me 01 reclining bucket type. whde the '(Jill sealS mJy be of individufli bucket type or bench type. The level of lIim both ;IHellor ,H1(1 exterior vanes accordll1lJ 10 the Pill!lCular model.
2 Routine nwintenancc
AI the in1erVills speCIfIed in the Routine M"IIl\cnilnCe section in the front 0 1 the nl<lnual c,my out the lullowlI1!J procedures.
Check seal bellS 1 ThorouUh1y check nil sent hellS 101 frayu10 . cu\s, <I,unage Or dctCHnrmion and If ncccssnry Ii"new thell) . Check lor sccu"ty
iheck and lubricafe bonnet and door locks 2 011 the bonnet lock ilnd sillety c~tch ilnt! check thilt they oper~lle correctly. 3 011 illl the (Ioor check strilps ilrld lock hilrwls 4 011 the luel 1IIIer CilP hlnw:! ilnd lock
Check underbody protective coatiog 5 W,th the CM supponed on i1xle stilnds. check the cond,tlon 01 the un(lelbody protcctivc coating. i1nd wherc neceSSilry clean <lny dilll1ilged i1rCilS ilnd ~pply il ncw coming. It the car is 51111 wrlhlll the corrosion w~rranty period check the terll1s illld conditions 01 the
w<lrrilnty lirs t.
3
M,,;ntcll<lI1Ce ~ bodywork ilnd underfrilme
The gorH)!<l1 condlt<on 01 iI vehicle' s hodywor k IS the one thin\) that SluruhC<lntiy Mlects ,ts v<lllle Maintenililce is easy but needs to he leu"lilr. Ne!)lcct. p;lItlctllilrly <liter mU10r dama\}e. C,)I lead qUIckly to hllther delCIIor<ltlon and costly !Cpolir hIlls It IS <"'ponant ;rlso to keep watch on those palts 01 the vehlde not lIl)lllcdr;'tllly vl~lblc. lor IIlstance the undersIde. Inside "II the wheel ~II(;h(ls ,l"d th(l lower pillt ')1 th e engine COlllP'IIt"'Cnt. The bnSlc 1l1"inlen~IIl{;c rOutlile lor the hodywork is wilshlllU -')rder"hly WIth <l lot 01 wnlCr. !rom" hose . T1l1s WIll rcmove 1111 the
ose solids which lIl.1y have stllt:k to the vehIcle. It is i",portant 10 Ilush these oU in such a way ilS 10 prevent \}lIt 110m scratching Ih(l Irni sh . T11e wheel arches o1I1(f unded'nrne need w~lshln9 in the s;rrne
Wily to remove any aCCUIllUI,lted mud whIch WIll retillll mOlslu re <llld tend to encournge rust. P':lIado~ically cnough, the besl timc to clC.1n Ihe urrderl,arne and wheel ilrches is in wet weill her when the mud is Ihoroughly wei and 5011. In very wet weilther the undcrfrarne is usuilily cleaned 01 large ~ccumuliltions Jutorl,"l1cllly amf this is a good lim(l
f or inspection. Periodically, except on vehicles w'lh iI wax· bnsed underbody protec tive cO<lling. it is 11 good ideil to have Ihe whole 01 the underframe 01 the vehicle steam cleaned. engine compartment included. so Ihat a thorouuh Insp(lction C<1l1 be ca"ie(l out to see Wh,lt minor repilirs ,lnd renoviltions are neceSSilry . Steam cleaning is available at many g<1lage5 and is neceSSilry for removal 01 the accumul<ltion 01 oily g,ime which sometimes is allowed 10 become thick In cer t<lin areas . If steJm cleaning f<lcilities are not i1va;!aole. there nre one or two excellent grease solvents aVilililble which can be brUSh <lpptied. The (Iir( can then be simply hosed off. Note thaI these methods should not be uS(ld on vehicles wilh wax·based underbody proteclive coating or the coaling w ill be removed. Such vehicles should he inspected i1nnualiy, preferably just prior \0 winter. wh(ln the underbody should be washed down and any damage to the wax coaling rep aired. Ideally, a completely fresh coat should b(l applied. It would illso be worth conSidering the lise of such wax·hased jotection lor injectio n into door panels, srlls, box sections. etc. as i1n i1dditional saleguard a\Jilinst rust damage where such protection is not provided by Ihe vehicle manufacturer.
After w<lshing paintwork, wipe 011 with <l chillllois lemher to give an unspoiled clear finiS h. A coat of clear protective wa~ polish will gIve added p rotection i1gilins t chemiCill pollutants in Ihe ilir. II the pilintwork sheen hilS dulled or oxidised. use a cleilner/poli5h(lr comhinntion \0 restore the brilliilnce 01 the shine. This lequires il l'llIe eHort . but such dulling is usually caused b(lcause rcgulilr washing has been neglected. C<lIe needs t o be Inken WIth mewl1ic paintwork, as speciill non·"brasive cleilner/polisher is required 10 lIvold dllmaue to the fInish. Alw<lys check thM Ihe door and ventililtor opening drilin holes and pipes <lre completely cle<lr so Ihilt wilter Ciln be drained oul. Bright work should be tre<lted in the Silme wily ilS pllint work W indscreens and windows Ciln be kcpt clear 01 the smeary film whrch oftcn appenrs by the lise 01 iI proprielilry gl1l5S cleaner. Neve, use any lorm of wax or other bOdy or chromium polish on glass.
4 Mnintenllnce -upholstery MId eMpets
Mats and C<lrpets should he h,ushed or VilCULU!! deill1ed rngulJ' Iy to keep them free of gilt. II they <lre badly stilrned remove Ihem hom thc vehicle for scruhbing o r sponging Jntl m<lke ql,ite sur e thr:y art) <f,V before re!rlling. Scms and mtcroOI tlim p,lnels clln he kept clean by wiplll!J WIth <l damp cloth. II they do hecome still ned (which '-:<111 he more <lpp<lrelll 011 IIgll1 coloured upholstery) use <l illlie ilq",d deter\Jent ilnd ,1 soil nllli brush 10 scour lhe \}rime out 01 the ()lalll 01 the rnnlerinl . Do nOI 10r!Jetto keep the he,ldlining clenn in the same w,1y as lhe upholstery. When using liquI{1 cle,1ners mSlde Ihe vehie.l e do not over-wet the surf!lces beinu cle<lned . Exces~lve damp could !Jet inlO the 5e,IIns nnd padded in1erior C.1USil1n sWins. offensive odours or evell rot II the IIlside of the vehicle gets wet accidenl.1lly it is worthwhrle t;lking some I,ouble 10 dry il out properly. par ticularly where cMpet5 i1re involved Do rlo/lc,we oil or clec/,ic helllClS illsiclc Ihc vchicll) lor tllis l!Urposc.
5 Minor body dnnl<lge -repair
rhe phOlo{Jr.1phic SCl/rICIICCS 011 P,IflcS 174 ilfld 175111051'.11" Ihe OIWfil/iofl$ d"lo1Ifcd ill Ih" 101i0willY suh·SCC(IOII$. Note: Fo, mon' (il-1,1iIL'd ili/OlilialiOIl 01/)01/1 I}odywork fCfwir. Ihe U"ylll:s P"hlislllilY Group pu/)/ish II book by Lilli/say POller c!llIed The C,If lJodywork H"II,11f Mill",al flII:~ lIIeorpor"ll!s ;lIlo,,,,,l(ioll on sllcli <Is/wets as rIIsl (rcallllc,rl. Ih1!IJlin!/ <Ifill 9',15S frb'l) ((!p,1irs, ,1S well ,15 rlvlilffs olr 11/011) <1fll/JllioIlS rcpai,s IIIvofvirry weldlllY i",d p,lltel belrlillg.
Repair of minor scratches it) bodywork II the scratch is very superllclill, MId docs not penetrilte 10 the Illelill 01 the hodywork, repnir is very simple. LIghtly rub the area 01 the scratch with a pilintwork renoviltor, or il vcry line CUtlll'\} p<lSle, to relllOVe loose paint frOI11 thc scratch and 10 clear the surrOlllldlll\J hodywork 01 Wil X polish. Rinse the alca woth cleMI wilte,. Apply lOuch·up pnint to Ihe scrntch using iI IrIle p~1I11 brush, continue 10 apply fi ne faye rs of point until the surlilce 01 the pamt ,nthe scril lch is level with the surrounding p<liIllWork. Allow the new p<linl nt le<lst two weeks 10 hMden: then blend it into the surrOUlld in\}
pa il11work by rubbing Ihe sC/Dtch men w ith iI pilintwork renovator or a
very line culling pils te. Finally, opply wax polish. WhNe the scrotch has penctrDt(ld right through to the metill of the bodywork. causing the mowl \0 rust. iI d ifferent repa ir lechnique is
required. Remove any loosc rus t fronl the bottom 01 the scra tch with a penknile. then apply rUSI inhibiting paint 10 prevent the lormation 01 rust in Ihe future. Using n rubber or nylon appliCiltor fill the scratch with bodystopper paste. II requ ired. this paste Ciln be mixed with cellulose thinners to provide a very thin paste which is ideal for filling narrow scratches. Before t he stopper·paSI(l in the scratch hardens. wrilp il piece 01 smooth COllon rJg i1round the lOp 01 J linger. Dip the finger in cellulose thinners and then quickly sweep it i1CIOSS the surlace of the 5topper-pJste in the scratCh: this will ensure tha t the surfilce 01 the stopper,pilste is slightly hollowed. The scratch can now be p<linted over as described eMlier in this Section.
Repair o f dents ill bodywork When deep denting 01 the vehicle's bodywork hilS taken plilce. the
first wsk is to pull the dent out, untrl t he affected bodywork almost
procarmanuals.com
Page 187 of 205
Chapter 11 Bodywork and fitting
ilpphcolble. remove Ihe lugg,1ge COlllpillllllent book. Cilrefully prise ilwilY the trim pnneL 5 Ref,uing is the reverse of the rernovnl p,ocedure, but on cOll1pl elOoll, tighten Ihe semuelt bolt to the specif ied torque.
23 OPI)rlirlg reM qUMter glass ilssembly -removal and refittin g
flemove Ihe trim covers f,olll Ihe 8 -pilnel and the qUilrlCr willdow ~U"O\rr10 (1,un) Where ilpplicilble first remove Ihe reM seillbelt inerl i.) r",,1 (S"r.lro" 36) 1 R(!lllove Ihe two toUUfe rewinrn\j screws ilnd ,emove Ihe tog\jle (,om Ihe le,lI C'p ,lI;u
:I Hemove Ihe WIIlO OW frillllC wemhe'Slrip then d,ive oul Ihe 1"~t~Jlc-(() cill!:h relollnin" pill ilnd remove Ihe IOggle . <1 flr:fnllll!J IS Ihe reverse of the reillovill plOcedure, but luhricale the II p,t L" IUIl!I'! P'VOIS With il SOilP 50ltl1ion prior 10 hHrIlO Ihe Ulass :r~~""'''ty AdJusl Ihe IO!JOlc. or w Cillhe rS H'l) lIan\je. to ilcl\leve 8 to 10 n (03100 <1 In) !Flp hetween Ihe glass olnd the WeillherSlr,p flan\je.
I 'Uhl"" Ihe to!I!Jh ! screws to th e speclfred lorque.
211 Load spa,-e Irim panel -r e 'noval nnd re fitting
H",,,,,v,, Ih" ,(!ar <iua,ter l"lll panel, as P,(!v,ously de5crr lwd :> f'ulllll<~ S<:;H forwa,d and remnve Ihe wn secul l"O sr.rcws . II may .• I~;o I,,~ necessary 10 (/(!Iach Ihe ba ck 10m p,lrwl (f,ve screws) J Ren'ovo Ihe inleriof hUllt connection a"d Ihe se,lliJilck lock kn ob H"d Ihe" 'emove the panel. <1 fluf'lInlli is the reve rse of the removill procedure, EnSlUe 111,,1 Ihe ~ollnd deildenin\j nwterioll is correctly posilioned and tha i Ihe I,nn panel does nOI foul the sem releilse hinge mectwniSIll_
25 BOil net release c(lble -r e m ova l an d re fitting
I" It", <:v<:nl 01 Ih!) rdcn~e cilhle hreilking. it is posslhle 10 rerilOve Il,,, ,.Hir.llor !II ,lie to Otu""le Ihe lock spring hy hil"d. Grrllc rCrllov,,1 'S oI""tl With II, S,,,:tron 9. hul SUIC(! ii's nOI poss,hle to open Ihe bonnet. II WIlli", 1""11.1 a Iotlle d,lfl(;ull (lilou!lh nOlm,poss,bl(!) 10 WI in ilCCCSS 1011", 111'1>' " "~1aU""\I scrc ws. In """()VI~ II,,! ,,,ICilSC cabl!) II, normal CllcomS I,l n ces . rcn,ov!) Illc ,;,11" "Pl'u, cowl plain :1 I,,,,,, "'s,de IIie ca r. !(!1Il0VC bOlh Ihe cl(!vrs pins and tire sprlllg and ."""cl lire II!h,a se cahle fro", Ihe control le vcr (photo) II Sl;":~,',, 11 1I~ caht(! adJustcr elll"'p and release the cil bl!) /rO'll Ih!) h",k lock ~P""!I !-, n,,,,,,,ve It", c;,IJle "'''I,nn'!) clrps, th(!n plllllh(! cable th'oll!Jh the rI .... 1 1'"",,1 to re"'ove 11. I; n"frltrrl!1 01 Ihe cilhle IS essen li,lll y th(! 'eV(!rse of tir e r(!Ill oval PI(r<:,·rtUI". "dJIJ~t,ng ;1$ "(!cess.l!y. t o rCrilOve any cable slac k. For
•
Fig. 11 .1 4 QUMter windo w fixing screws _ .. rrowed (Sec 23)
lurllH), ,,,fonnatlon ou thiS. [(:1", II) pn,a\jlaph 6 of Ihe follow,,!U Scctron
2 6
Bonn et -removill, refitting and ildjuslnlCnt
Open 11l(! honne t 10 ,ts fulieSI eXlflnl. USrrlU n suiwble nnplemen!.
scrrhn .1 Irne around t he hrn!Jes, Remove Ihe screw seCUflllg Ihe enrlh le.ld where ,1ppircnble (photo).
2
Rcmove Ihe Iwo holts ilnd wnshers secu"no ench SIde of Ihe
bon"el 10 ItS hrnoes (phOIO)_ W'I" ass,swnce, , t C,ln IlOW he lofted off. 3 flefm"'(J IS ,) reve,s.,1 of remov,, 1 jlrocedure Before lullV "ulHenulU Ihe seCllri ll!1 holts, ensule Ih<l the h"'IICS ,"e alrUllfal wilh the scrrlwd III;rrks Tills w,1I C "SlHe CorrC(:1 ahU'''"(!nl, 1 11 ,I IS found Ih;1 lhe honne l requi,es adlus lment. Ihis C;ln be cfl(!c tud rl) III(! vC'IICill plilllC hy sl,lcke'''ng the calch post locknut illld scre wrnU Ihe calch pOSI III Of oul F Ofe-and·nh adjustment Ciln he dfecICd by slac kenrn!) Ihe I"n\je boilS
5 AdJusl"ble hump ,uhbe,s .lIe also provIded ""d these should be pos'troned "s "eceSSilry 10 Slop vlhrailon, b U I JI Ihe Sal1le time muSI allow the bo""el 10 he closed eas,ly 6 Adlustmenl of the bonnel 10ckrnU sprrnU Ciln be Illa(fe hy sinckenlllg Ihe cable CI.11111> o n t he upper crOSSIll('mhcr and shdlnH Ihe outer c<lhle II"olllJh the clop <lS necessa,y When cOfl(!clly positioned. Ille hood lock spfI"ufcnbfe SetTing (hmcnsion should he as shown in F'g 11 15 T ighten Ihe clnll'p screw when the ildlllsl'nenl is
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26, 1 Removing bonnet enrth lead 26.2 Remov ing bonnel hinge boilS
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Page 199 of 205
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Index
A
Accelerator cilble removal ilnd refining -14 shnft ilnd pedal removal and refining -75 Air cleaner removill Jnd ref,nrng cal buren or mod cis -68 fuel injecllon models -80
P rnator .,rushes inspecllon. removal and refilling Bosch -202 Femsa -203 Lucas - 202
dismantling and rcassembly -203
removal and refining -201 Antifreeze mixture -60 Automatic transmission descrip tion -122
B
downshift cable removal. refi11ing and adjustment -121 extension housing oil seal renewal -121 faull diagnosis -127
maintenance. routine -123
removal and refOlting -123
selector mechanism ildjustment - 126 rcmovill. overhaul ilnd refl11lng -125 speclflf:iltions -103 SI.1r1er IIlh'bilm/reVerse lamp switch remov<ll <lnd refIlling - 127 lorque wrench senings -103 'iliary (driving) light ,oIigrllnell t 212
Bilttery clrilrgmg _ 201 description and testing -200 removal and rcfll\lng -201 Big-end bearings -37. 52 Bleeding the hydr<lulic system brakes -152 power steering -168 Bodywork IJnd fittings -173 el seq Bodywork and fittings bonnet -186 bumpers -1 78
centre console -189
demister
noules reOlov<l1 and refi11ing -197
description _ 174
doms-178.180. 18210 185 face level vents removal and refItting -197 facia panel -188 fuel filler flap -188 heater -192 to 194. 196 10<ld space trim panel removal and refitting -186 -'alnlenance
) bodywork and under/rame _ 176 routine _ 116
uphOISlCry
and carpets -176 mirrors
-
192 open rem quarter glass assembly
removal and refitting -186
re~r qllMlcr trim panel removal and refitting -185 repi'lir millor damaue -178 minor damage -176 sent belts -191 seats -192 sunroof-189la 191 lailgate -180. 187. 188 torque wrench scuings -173 windscreen -180 Bodywork repair sequence (colour) -174, 175 Bonnet release c<Jble removal ilncl refitting -186 removill. reflt1ing and adjustment -186 Bml<ing systll'm -14201 seq Braking system deseriPlion -142 lilUl1 di<lgnosis -156 fOOlbrake ped .. 1 removal ')nd rel ining -152 fronl disc brakes -144,145 handtHake -153 \0 155 hydraulic system bleeding -152
p ipes <lnd hoses -151 n1<lintcnance. routine -143 n1<lSler cylinder -148. 149 presslilc uIHe"~llIial switch removal and relitting -150 pressure reducing v~lve rernov~llInd refining -151 rear drum brakes -146 10148 specif'Cil!ions -142 stop IJmp swilCh removal. refi11ing ilnd adjuSlmeJl1 -152 lorque wrench se11ings -142 vacuum servo unil -156 Bulbs. lamp 'Tenewnl -213 to 217 spcclflcntions -199 Bumpers removal and refIlling -178
c
Camshaft (3.0 litre engine) retitting -54 removal -50 Camshaft and camshaf t bearings examination and renovation 2 _8 litre engine -35
3 .0 litre engine -51 Camshah and front intermediate plate (2.8 litre engine) refilling -41 Capacities. general -6 Carburetlor (Weber) aulomat ic choke
adjustment -71 removal. overhaul and retitting -71
dismantling and reassembly -69 general -68 idling adjustment -73
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