sensor FORD CAPRI 1974 Workshop Manual
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Chapter 3 Fuel and exhaust systems 67
Torque wrenc h setting s Fuel P\JlllP Inlet n'<llllioid Swgc 1 Swgc 2 Swge 3 StJge 11 (<lhe, runninu enome for 15 minutes <II 1000 rpm) Exl1;lllSl n1<ln,lold to downpipe Exil;lusl U·holts ,11\d ci.lmps C~rblllClt(}(
Pari R Fue! iniaclion syslem
G ene ra l SyS1c'" Iype Idl e sp ce d CO "o,![ ull" Fu el p"mp rfelov(!ry (nHrHrl1lJlll)
SyS1cn, P")~"'''U Fvcll,mk Co1P,lC '(y
Torque wrenc h settings Fue l ,11,>1,,1.,,101
W",m "p "'~11I1;,1O' 51<1,1 V,llvt: A\J~'h;"y i'" duvlC(! Air eh.""I>", Bal1)o I>ull~ Fuel d'SI"hu\or W",nl up '«!lul,l1or (MIO) W,llln·up rC(jul<lIOr (MS) 1I11C(:1I01) pipes Fuel pllfnp. fi lter <lnd ncculllul<llor
PART A: CARBURETTOR SYSTEM
Gener,,1 description
TI", 1",,1 sy'>I<'1ll <;onSIS1$ of " reM moulI1ed fuel wl1k. il {hilpluo1\Jn1 type 1",,1 1l"'''P d"v(JIl I,om the C,lIllSh<lh !lnd " (lu,11 vellll'" lio .. ""h''''!II\! <::111,,""110< There Jle two SepJ IJle eKI"luSl <1sselllhllC s.
eJr.h COII~'Stll'!I 01 ,I hont pIpe nnd leson<lto r. mtell"ed'ille pIpe <1nd Slknl"ul. '" HI J 1<111 pIpe <llld Sllcncer The <lir CICJllCf 011 Iiller models II1C<J'I101;lleS , te"'pcr<ltlllC control II,'I).
S omn models !"ay he hlled wIth a p,llted vacuum switch (PVS) to p'eVUl1t fI"1 SpulS aud nllsl"'"0 OCCll""'\) when the enllllle is cold "lid flll"""'1 WIth hJlI or pMllJI choke. When the enuine IS cold (below 71 C I i GO F» the I'VS IS closcd. In tillS cond,I'Oll. c;lIhurenor v,lClIllln IS ,'Pl'hed directly to Ihe d,st"lnilor V'J the Ilon·return v;)lvc. whIch "lIow~ (he va ClJllI1I Jdv,lIlee to IJc milll1lolll1e( 1 lIntier <1cccieIJt.on.
prc .. en ('''Uliat spots or mlsf""'\J .... ·ho)lI the eng"'e h<1s re<1ched liS norm;ll ope,mll1\J lemperJtllle Ihe PV S I, open In tillS condltloll lhe C<1rbUle1l0' '5 connected 10 Ihe
d ,s t"hu!Or v.a lhe PVS.
2 Rouline lll<linlen <1nce
AI the IIlIclv<lls spec II led 111 the RoutlllC Malfllelwnce seClion Ullhe "0111 of lhe IllJllll<l1 CJrfY out the followmg procedures.
Check and adjust the idling speed find mixture 1 Refel to Sect.on 12.
Check condilion of fuel hoses 2 E>.n''''lle illl Ihc fuef hoses on the eng ine compartment and on the fu!:1 ""'k. for SIgns 01 leilkJge or eletellowt,on. 3 Che ck the secullty 01 <lll fuel hoses Tighten the IIllet mnno 'lold
holtS 4 Rel"r to Sect,on 19 Jnel t.ghlcn tile IIllet I11J",101d bolts III the
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s!:q uence (jlvcn
Renew the ilir filler element 5 D'$ coruWct lhe hauery. G Remove lhe twO nuts secullng the air cleaner lid nnd remov e tile
N rn 16 to 20
4 to 8 8!O 15
'8 to 2 2
1 8 to 2 2 20 to 27 38 to 45 20 to 2 4
Ibl It 12 to 15
3 to 6 6 to 11 13 to 16
13 to 16 15w20 28 to 33 15 to 18
1305<:h K ·JetfOnic COlltonnous inlCCllon !JOO .1. 25 rpm 1 25 I 0.2 930 a cc cvcry 30 scconds 5 f)5 I 0.25 kUI/crn' (789 I 36 11l1/on') 580 hlrc ( 12.7U<lI)
Nm Ih l It 32 to 38 24 10 28 7 to 10 5 to 7
7 to 10 5w7 7 to 10 5 10 7 7w!l 5 10 7
18 to 20 13 10 15 11 to 15 810 11 5 to 8 4 \0 6
5 10 8 4 to 6 181020 13 t o 15
hd . 0" I;>ter models the ltd rnily be secuted with sprong IJSleners. 7 LIlt Out the paper clement <llld d,scmd it.
8 Cillelllily clc<lll the inside of lhe Dif cleJner body. !;"IlS''''Il\J thilt no dllt IS illiowed 1 0 drop into the cmhurCl1or. !J I'll <l IICW element "nd tclot the <l" clc<lner lid 10 Recor"lect the IJ,1twry
Check air cleaner IClllpcril{(lrc control (whcrc (i{{cd) 11 By looking through thc main ,101 cle,llle' spout. nOle the pos'tlon 01 lhe 1I"1l v<llve. Wilh lhe engIne stmionJIY Ille lI"p should he lully closed 12 SlJr t Ihe engine <lnd check the oper,ll,on of the lI"p vJlve W.lh the engine Idling the IfilP should open Jnd s tily open 10 ,1110w hot all "liO lhe <1" cleilllCr. Note: II is essen/l,ll/liall/llS lesl is C,lIllC(/ OUI wilililic ClIljlllC cold. If the 11"11 !CIIlJ"lS closcd whell the ell!l",e '5 st,IIIC(lthell 1herc IS <l fmill 'n eilher Ihe dl<lpilfilllill unH Of he~t S(oll50r "nd thcy should he tcsted JS follows. 13 Check the vilClium supply p 'pe for leilks Jnd renew It II suspec l
F ig . 3 .1
Air tamper<l ture controlle d nir cleaner (Sec 2 )
A 8 C
VaC(I(lm mUlor FIlip valve I-IC<1I sensor
o 1-101 all in",ke E Culd illl U!wh,
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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"'"'~''''' ,,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,'<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 •.
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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'crcOl~"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 ~'~rrt"'!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. ""lIIcl~1 ~I"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"aIY air device
·.i
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Chapte r 3 Fu el an d exhau st systems 79
Ii
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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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< '(:,,~ , • . . ;::~t,·· . , ,
.' ) . ;~ ~~;:;: ~iJ" .. ,
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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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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