torque FORD CAPRI 1974 Workshop Manual

General repair procedures
Whenever scrvie,,,U. repair or overhaul work ,$ c;nric<i out Oil the eM or its components, ,t IS nl:c",ss;uy In nUsc."o the lollowtll\j procedures (Iud ulslruct'{JIlS. Ttus w,lI assis t III ca"ylll(j out Ihe opcrJlion eff Iciently ,1nd to " p,()lcsslollal slanlia,d of workmimstup
Joinl mating ftlces ,7l1d gaskets Where 1'1 gasket IS lIsed tmlwl:CIl the ",,,,ill\1 [<lees 01 two components, OnSlIr(l Ih;)t It IS renowed un Icassclllhly. Bnd 111 it dry unless O(IHJlwise Slaled III the rcp;Hr plOGcdw() Milke SlUe that the nmling (<lees nrc cle;m [lnd dry with "II II,lees of uld \Ja~;kCl rClllov ct1 When cleaning 11 tOnH j<lCC. use il 1001 which,s not likely to scorc Or dalllil(lC the l<lcu, [l1ll1 reillove <lny 1>I'''s or nIcks wnh an oilstone or hno Ide.
Make SUfi) lh,,[ tnppcd holes nrc ciedncd WIth il pI pc clcilncr, and kcep thcm flcc 01 101l1llng compound If tillS IS helll\) used unless
speCIfIcally Instructed otherWIse Ensure that "II ollfrtes. (:hannels 0 1 pIpes ,lie Clt'ill ilnd blow thlough Ihelll. p,eleriluly llsing compressed ill(
ai/ seal s
Wheneve, nn od sCill is removed flom its wOlkll1\1 10Ciliion, eIther mdlvidu"lly or "s p"rt of iln assemhly, It should be lencwcd The very finc sc"lIng IIp of the sei'll IS e"slly dama\Jcd and WIll not seal If the surface it COI11<1(:15 IS not completely c lean and free frOlll
SCHl\ches, nicks 0' grooves. If the o'iginal scaling surfi'lce of the COlnponern cannOI he restorCd, Ihe component shoul d he renewed, PrOlect lhe lips of the scal from any surlace which mi'lY damage them in the course of fmlng. Usc wpe or a conical sleeve where POSSIble, LUb ricate the senl lips WIth 011 befole fruing and, on dual lipped se"ls, fill the space be twcen the hps With grease. Unless otherwise stated. all seills must be hlled with then sealing hps toward the lubricilrH to he seillcd Use iI\ubuli'l' <111ft 01 block 01 wood 01 the npploprime sIze to II1sta ll
) I he scal ilnd, lithe sCi,1 housing IS ~houldeleu. drive the seill down to the shoulue,. If the scal hOUSIng is unshouldcred, the seal Should be fItted with its lace flush W ith the hou$lIlg top face,
Screw IhrCiU/s and lasleoings Always cnsurc that a blind t"pped hole is completely free from orl. U
reilSe,
wilte, or other flUId hcfore instatllng the hott a' stud. Fililu'e 10 do tillS could C,luse thc housm\) to c"lck due to the hydrilulic <1ction of the bolt or slud ilS It IS sc,ewed '" When tluhtenlllU ,1 cilswllilled nut to ilCCCpt iI spht pin, tIghten the nut to the speCIfIed torque, whele ilpphcilh le, and then lIghten furthe, to the next split pin hole Ncver slilckenlhe nulla "lrgn a spirt pin hole unless ~t<l1ed III the ,epil" plocedure When checkIng or retlghwnlllg il nut or holt 10 ,1 specified 10'Que setUIlg. slilcken the nul o r bolt iJy a qua'ter of a turn. "nd then retighten to the speclflcd setting
Locknuts, /ockt.1bs and wasliers Any fo1SlC(1Ong which wdl rotate agaillst a cO!llponen! or hO\ lsing in the course of lI\)hlemng shmrld illways hilve a wilsher between it ilnd the relevil"t component 0' hOllSlllg Sprm<J or spirt w.1she,s should illwilyS be rencwcd when they ilre uscd to lock a c'"trcnl con'ponem such n5.1 blg·end beillmg letalll"'g nut 0' bolt. Locktilbs which il'e fohied over to re t;1in a nut or bolt should illwilyS b e renewed. Self -lockIng nU1S c<ln be reused in non-crit'cal il reJS, p roviding reSlstJ l1Ce Ciln be felt when t he lockmg portion passes ove, the bolt or stud th,eild. Spht pillS must always be ,eplaced with new ones 01 the correct size lor the hole.
Special tools Some repal( procedures III this manuill enWil the lise of special 100ls such ilS il p,ess, two or t hree-legged pulle,s, spring compressors etc Wherever pOSSIble, suitJble ,eildrly ilvailable altcrnatlves 10 the manul(lctu,ers special tools a,e descrrbed, and are shown in u sc. III
SOllle Inswnces, where no a lterniltlve IS poss ible. II hilS been necessary 10 resort to the use of a manufilclurer"S tool and thIS has been done for reilsons of safety as well as Ihe eHlcien! completion of the repair
operation. Unless you are highly Skilled ilnd hilve a thorough unde,standlng of the procedure desc(lbed, neve, " tWlllpl to bypass the use of any specl,,1 tool when the procedure descrIbed specllies ils use, Not only IS I here a ve,y great risk of pe,sonal Injury, but expensive dillllage could be causJd 10 Ihe components involved
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I.
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24
Cylinder block Bore d'iJrllCIC ' mm (.n). SI;'1ncli'll(t {j.,1CICS ,
2.3and4 .. OverSIze UI,lcics. A ... Il and C
Crankshaft Endfl0i1 1 mill (OIl) .
Camshaft nUllS! plme Illtcknc~s 111111 (m). Red Blue Endflo;'1 illm (m)
Pisto ns elc.uance III bo.e ""11 (Ill) Rm!J !J&#39;~P mm (m) Top. CClille BUliom
Connecting rods BO!I "lid IHJ.IIUI!IIUn'UHU r, h: ;,. ;uu";C m ... (m)
V<llves SCil l ilnllh.~ Villvc clc'Hance (col{l) mm (tn) Inle! •.. E~haust Valve tmllng IlIlnt ollens Inlel closes [Kh&#34;u~l olle&#34;~ E~hallSl closes TilPt",, 1 :;1(111 ..,le ,u:lIlcfl I1UI1 (,n)
V"lvI! ~1I11&#34;!J (11)1] 1''''WI, "'III (,,,) SlcIII III !lIIId" CI0.);1I"'1I:1) ,,,'" (II') 1,,1,,1
E&#39;h,&#34;&#39;~I
Lubricatio n systmn e"p.1';' ly W,t h t,llc' W,thout hll(:' 0,1 p,eS~I&#34;e (111111111,,,11' 1ll 80 C) 750 'PIII 7000 .pm
Torque w re nch sctlings Malll hea.",u CalIS B'g·cnd ClIPS C .,II.kshalt pulley boll C;.III sh;.lt Oem Call1shilit th'ust vlme Flywhcel
TUlII"\) cove' To hlock To .1(111pt(II I)I;II C 0,1 pump 0,1 pUll',. covel Rocke. ~hall Slimp
Staue 1 SI:lge 2 0" dUlln pllill CyIUI(I,,;, heild bolb SI1I\Jf! 1 S I; 'UI , 2
S Ing.., 3 (;dlCI 10 1020 nUllul(lS WilH)
Chapter 1 Engine
93.0 10 1093020 (3 6618 10 36(22) InCr(!mcnlS of I 0010 (e.ClO04 )
935201093530 (3 .68 19 10 3 (823) I ncrements 01 0010 (0.0004 )
0080100280(000311000110)
3.960 10 3 985 (0 1559 10 0 15(9) 3986 to <1 011 (0 1569 to 0 1579) 002 to 0 10 (00008 (000039)
0028100048 (00011 (000019)
038 10058 (00150 to 0027.8) 038 !O 0 58 (001 50 100 0228) 038 to 1 110 (00150 10 00551 )
0006 10 0 064 (00002 10 0 0025)
46"
035 (0014)
0 40(0016)
24 -oroc 72 ' ABOC
73 ' OBOC
25 ' ATDe
0023 10 a aGO co 0009 10 a 0024 ) 525 (2 06(9)
a
020 I n 0 063 (0 0008 to 0 0025) a 046 to 0 089 (0 0018 to 00035)
1 25 h ilC (7 5 Pilot) 400 litre ("l0 IJIIlI)
1 a kol/cm' ( 14 2 II>IIIIl' , 28 kul/clII' (398 Ihf:,n')
Nfll 90 to 104 29 to 34
4 2 to 50 42 to 50 17 to 21 65 to 7 1
17
t o 2 1
1 3 to 1 7 141017 91013 59 10 67
4 107 7 10 10 2 1 1028
39 to 5 4 54 10 69
Ihf It 6610 77 21 to 25 3 1 1037 31 10 37 13 to 15 48 1 0 52
13 10 1 5 101013 10 to 13 71010 44 1049
3105 5 10 7 15 to 21
29 10 4 0 40 10 5 1 70 to 85 S I;'lle 4 (:,Itt" '",,",nU enumc to , 15 .llIl)Ules ill 1000 fpm)
Ror;kl1' cow:! ...... ..............•..
95 t o 1 15 Bilek 011 1/2 "to 7 IU'I) and .elolQuc one bOlt al a l'I11C 10 Stagc 3 valu<] 310 5
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Chapter 1 Engine
: Part B: 3.0 litre engine
General
)
rr
T ype .. Bore Slroke
Cubic capacoly .... Compression 111100
cylinde r block Bo,e dlnmCler mrn (In): $wndMd urnelcs. A B.CllndD DverSilC {)Inel!} A
Cranksh aft Endllonl mrll (III) ..
Camshaft ThruSI plate tlllckness mm (III) EnclllO;1! 111m (In) .
Piston s Clearances III bore mm (111) nlllg gap mm (tn) Top .. Cenue BOllom ..
Connecting rods Blg·end hea,ony running clearance mm (In)
Valves Seill :myle . V,llve clearance (cold) mm (m) Inlel .. E~h<l&#34;sl V,llve 111111(19. Inlel openS Inlel close~ . hhanS I opens ExhaU~1 closes T.1Ppel s.de clc,u<lllce 111m (111) V,llve $P""l) Iree lellUlh mill <nl) SICI11·IO·\llIldc clCilr,lllCC IIlIn (Ill) Inl el E.h;IUSI
Lubric<Jtioll system C,lp;lCny
W'lh 1,ller W'lhoUI "iter ..... " .. 0, prCSSllle (nllillmum <lI 80 C).
750 'P'" 2000 rpOOl
Torque wrench settings Ma,,.. be",IOO C.IIl S ..... . B'o -end Cill)S .... CrMllsh<lh pull(!y . Cilnlsh,1ft IJ(lil' ... f Ivwheel,'(h Ivej)l" te Fronl Cove, 0,1 I)UI11Il "n·d J)i~&#39;;·.~J;
0,1 pump cove,. . ... , ........ . Sump
Cvlind e, l1e,l(1 boit s .. SI<lge I Slage 2
S iage 3 (nite r 10 10 20 mlnules wart) ;Iau(! ~ .• ,., .. , .•.• ,., ...• ' ., .... , ., ... , .. ,. ,., .. , .. R laue 5 (,!her running englllc fur 15 rlllnu!t:s ,11 1000 ,pm) OCker cover Dd el'JIlI p1uy·· .. . . ..
n",), 0.1 senl cill/ie ,
6·cytonder ohv in 60' V 'o,mallon 9367 rum (3688 in) 72 .42 nun (2851 In) 2993 cc 89· ,
936·17 10 93 658 (3 68o!) 10 3 6873) Illcrements of I 0010 (0 0004) 9 4036 10 !"I4091 (37022 to 3 70" 4)
0080100780(000311000110)
533'\105384 (0210 10 0 212) 0153100254 (0006\10)
0036100051 (000141000020)
0254100508 (0010 100020) 025· 100508 (0010100020) 025·1 10 0 38 1 (0.010 10 0 015)
0006 \0 0.064 (00002 \0 0.0025)
032(0013) 055 (0022)
79 B mc 67 ABDC 70 UaDC 14 ' ATOC 0013 10 0 05 1 (00005 to 0 0020) 47955 (1.8880)
0020100063 (00008 10 0 0025) 0048100050 (00019 10 00020)
500 hue (88 prill) 1 25 hIre (75 pml)
10 kUf!cm' (14 .2Ibl"n') 2 8 kuf/cm' (398 lbl/in')
Nm 68 \0 76
53 \0 59
55
10 62 551061 69 to 76 1510 18 17 10 2 1 8 \0 12 8 1011
10 301050 82 10 92 110\0 1 17 11010117 3105 27 10 34 16 \0 20
Ibf ft 50 10 56
39 10 44 41 1 046 4 1 1045 51 1056 11 \0 13 13 1015 6\09 6\08
7
22 1 0 37 61 10 68
8 1 1086 81 to 86 2 10 4 20 to 25 121015
25
procarmanuals.com

Chapter 1 Engine 45
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33 7 ApplylllU se~lInu COIll I)(IUlld to the unnkshnlt pulley wash"r
34 Cylinder hcads. rocker gCM and inlct manifold - rc lin ill(j
Lubricate the valve tnppets wllh cleiln cnUlIle otl ;md Ulse,1 th,,'" It! th o cylindcr block. Ensurc they ille fm"d in thei . OIlDlIlal tOGillrOIl~ 2 EnSIHe tha t the mnllng lilces of thc cylinder hlock ilnd 1he cyllndel h~,lds a.e clean, 3 Position the new cylrnder hCild \I,1skets over 1he \Julde I>ushe~ on the cylinder block. Chec k thm they ilre correc 11y locilled The n!Jht ilod 1, ,11.hnnd gilskets il,e different TIl(: onskets ilrc rn,lrke d FRO NT TOP (pIl Ol0S)
!
.'
/ . .-,,~ .. ~
Fi(J 1.7 T iuiltening sequence fo r cylinder he<ld holts on the 2.8 litre enuin e (Sec 34)
,1 C,l rel"lly lower thc cylrndc r hcads 01110 Ill" r:ylorulcr hlock ,'r1d ht lir" h"IIIII'!1 d"wn holts willch should hc !rrr,1 io!Jirliy ollr:d 5 T'Hirlt;1l tl,,: holts. ttl th" ~&#34;qllp.llce shown 'Il r-'!l 17, '1l1he St,l!JCS as ~pe<:tlI&#34;d It) Spf:clhcaltOllS (phOl0) G Luilrr""I" tile plIshrods wIth el1Uine OIl and Insp.rl them til the <:yllluh" hlock 7 I'laen Ill<! 011 $pl<lsh shIelds In pOSl\lOI1 on Ihe cylInder hC<l<is <lnd ht the rocker shi,fJ <1ssernblres . GUIde Ihe locker <lrln mijllSllng screws IIlIO the puslrrod sockets (photo) 8 TI\jhU!1l the rocker shilll secllfino bolts prO\J,ess ivcly to the
specrfred torque (photo). 9 RelIt the ,nle l l\\al1llold 01<; descrlbell III Ch,lpte' 3 1 0 Adlll~;1 the valve cien,nnces <15 desclllwd In Sect Ion 35.
~4 3A TIl(: dlfferencc hClween the left nmt ','Ilht head gnskets The ""OW mdlcoltes
. oot 3438 CyJrnder head \1,1Skt:1 pOSrilon
rnarkinos
•
r.
/ 1':' .j I
, I • 1 ... , 345T. h ' , __ ..1 I!., u U lco"I\I 1he cyhnder head bolts 34,7 Guidlfl~J 1he roc ke. ilrm il<l)\l5t1l'g sc rews onto the pushrod5
3 4 8 Tightening the .ock !:! shnit bolts
procarmanuals.com

Chapter 1 Engin e 47
--;; ble chec k ~II littings nnd elcct"cill connections. Ensu,e thnt the 2 .,",or is correctly lilted ilnd Ihil t Ihe IUnil,on tlmmg StJtlC Selllll\) 's distrlU
I CI , t II in doubt Ie el 10 1npler . eorr~~ ~10VO 1110 SPJlk plugs nnd the '- ' conneC lion from Ihe 1\)111110n 3 '1 Turn Ihe engine over on Ihe st~rler motor unlil Ihe 011 pres~!II{! co'· . light is e~til1gu,shed or unlIt 01' pres sure IS .ccorded on IIl{!
warnu"lg . d I This witt ensure Ihill Ihe engme ,s no l Slarve 0 0,1 dU"I1!11he g~~ge,. I,w minules running alte. IflIlJ.1t SI.:lrl·Up. The l uel syslulll W Ill ,,,toea . I· • be p!"iOled dunng IllS ope.atlon.
: SOReconne<:llhe '_ ' conneclion on the 'IIn'tlon co,1 and ,elll th e sp.:llk
lugs and loads .
Stilrl .Ihe ~ngme .. ~ AS soon as Ihe engme Ilfes and .uns. keel) ,t gOll1g ill il lilst \lckov(;.
nl (no las te,) and bring it up 10 nOlll1nl wo.kong ICmpernturc ~ ~s the engine WilflllS up there WIll lie (){I(I smelts nnd SOfll~ "mol Il
hom pariS getting hOI and uUI.l1Ing olf all (leposIl5. The Signs IU luok
10' arc l eilks 01 w<l!er or Ol!. which WIll hll uhvlOus If SllrlOus Che(:k ,d~u he exhauSII)ipe llnd I1lJI111old connections as lhese do nOl ,lIwilY s Iond :he
i•
exact gos liUht position unlil lhe w:1I1l11h ;oml vlh!al'On hiwU ;I(;t,," on Ihem, and il is almos t CllrWU1 th.11 th(ly WIlt ncrHI I'Hhw1l1l1H hllth". Tills should be done. of course. wllh Ihe C"( ,,nc slopped 7 When nOrmal running lefllJ}Coallll e hilS hecn .cnch",<I. &#34;dl,,~t th" l"'OiflC ,die speed as desoil}Cd In Ch.1ptc. 3. 1 S lOP Ihe engine and wnll a lew ""11,,1,,,5 10 sec ,I any I"l",cam or tool')flt os dflJlP lng out when t he ",nuone oS ~tallona.y 9 Alief the enuinc has run 10. 20 ""lltltIlS .(!move lhe en!Jllu: .oc~e, cove's ~nd rocke r shafts .1nd rllCh(,c.k Ihe tluhtncss 01 lhe cylondc . Ioc.111 boilS (photo). Also check the tiuhlness 01 lhll sums) bolts. In hOlh taSCs usc iI torque wrench. 10 Road teSllhe tar 10 chcck Ih.11 thC Im"nU IS correCI ~n<l Ih"t Ih" enOine is giving the necllss~ry Sl1100tllllr.SS <ind power. Do 1101 .ace Ihe
(lnuine -il new bemings and/or pistons "nve hcen lIlted II shollid he
I' !.tilled as a new engine and run IIl.1t.1 .cducc(1 spcud tor Ih~ IUS I 1000 miles (1600 km).
PART B: 3.0 LITRE ENG INE
39 Gener;!1 description
ThC !lcne'il' conl,uu'illion 0 1 the 3 0 hue enuine is sil11l'nr 10 the 2 8
( \:\.~ ,..d r •• -~~ .. ; ~
389 Recloeck,,'u Ihe Iluhlness 0 1 Ihe cyhnder head bolts afte. ,,,,,.loIlU lhe enu")e fOf 20 'I1In ul('"5
hire nllu""1 d(:~c&#34;hed III Sec(,on 1. Thc Slunillcan t dltferences iI.e .1S follows
(i') FI,'I •. yllll(/vr ht',1(/$ ",'III the combustion cl.,1mba,s itl lila I&#34;.~I()IIS (b) Imhvr(/",llly IIIOUlIlCd rOC~t&#39;f ,Jrms illstead of a lockct sitaft (c) W"lvr pump 10C,11cd 011 Ihe ,i!llu of the allgine ((f) DiSlfllmto' ,WI/ orf ,,"1/11' (I,ivell f,om thc front of thc c,lrmllllft (e) ML'ch,mic.1llllcl,Jl/flfP ollcfMed by ,1f1 ccccntric on tllC frolll vllhc c,lmshMt (f) /rr.';" (Ill sC;llloCMCII '" ,1 S':l'olfall: c,ltric, (y) OJ! trltvr IOt';llvl/ on tlw "I}fI1 lef(-h,mrf sidc (If tlw clI{Jlln'
Fig. 1.9 Sectional view o f tho 3.0 litre engine ( Sec 39)
i
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'j
~ .... ------------------------------.. ~; 灲潣慲浡湵慬献捯m

Chapter 1 Engine 49
----------------~--~----------------= anuill transmiSsIOn models, remove foul clops <lnd remove Ihe 16 On h(11 sing cover . On ilulonHll lC tr&#34;nsmIS~lon models dIsconnect Ch.llCh au lug the 011 cooler hoses. and P It the Irans!1lI$S10n then remove th e l'illlsnllSS lon to-engine 17 Suppa <
bolt~ n automatic 1.,J;lsmission .models. drilm the torque conve!ler ,\Ild 18 Ihe drivep l<lte boilS wllh ,clerence 10 Chnpler 6. UO~~~~ Ihe weight 01 tho engine on thc hoist ilnd then pull tile euuin!} " d \0 separJIC;1 1'0111 the \'<lnSIllISS'OIl. 0 " [lU10111<1(1(; IlilI151"'5' 10' ..... 31 , I
. odelS make s"re Ih,lt the torqlle converter ,em,,!!)s lilly 1f1 1he $lOI1 m transmission . 20 When the engine hilS been SCpM,lICd from 11l(l 11.,11$1111551011, 1,lllh!.! . ,lowly chccklll9 j,equently to see (hMllle CflUllle does not loul " ng,ne . ~nv part of the bo?ywork. 21 W hen the engUle 's cle,lr of the iJody . lower it to the ~lfOun(i. Of
Ir~nsler it to a WOrk lJench
4 $ Engine disill1lotling -generill
Refer \0 Sec t,on 7
46 Engine illlcillilrics -removi\1
..
1,',lh the engine sep,l rated from th" t r;IIl~:nHS~r()&#34; remove Ihe ~.tcrnally mounted componelliS ;l~ lulluw~
C;J//)Ulello, i.lnd fllcl {lump (C"'1!,lt" 3) IlIlel ,wll exhiwsl tII,wi/a/ris (Chaf!/t't 3) Sp,>r/( plugs and drS/fllmlor (Chaplet 4) AllCllwlor (Chaplet /2) F.w ,7I!d policy (CII,71I1C' 2) W.JICf pump ,wd Ihcffllos/.1I (Clmp/t't 2) C, ,1IIkc,lSC vcn/iliilion lubc 011 {,f/CI (Scc/ion 40) Ol/Icvl!! r/rpsllc/o; and {,/lCf C,?!, [II!1int' 1II01tn/ill.ll h,.1r:kvls Ciulell (Ch,7/I/l'l 5) Powl'r S/Cl'l/IIN 1'(11111' (Ch;lll/Vf 10J
<11 Cylind(Jr heads relllowti with engine in car
I
Q,scunnecllhe IJiltlery le,lds ") ~cmove the splilsh slucld. by renuJVIII<j 10\" holts nnd luur chps J II.lee il cOrltilm er 01 10 Irtre (I·' 6 pint) r.ap.lr.lty unde!l1e,Ilh Ihl.! ~&#34;lr.llor. remove the rmll:l\or hallam ho~e and drilill Ihe system Rr:rnove the rad "l\()r lap ilose . !l Rcrl10ve Ihe au Clealler. d'SC(lnner.t lile h,el p'pe fro m the ~MI;;&#34;rllor and Ihe l"e,lIiler hose hom Ihe rocker cover.
, R ernove the servo V,lCUlUl1 hose I<om tile Inlr:1 l11illlllold ~ enlOve Ihe IllIe e bolts and rem!)ve II,e Ihrollie Irnkaqe lI<ilC~l;t .omllic le wo1h Irll kilge '
~ DI~conrlccl Ihe rilll,.llul hose from Ihe ilulomallC choke D,s·
,onneCI the vac\JUnl h"e I<om cariJU!l:1I0r .
• D,sconnect" I I I 10 0 le ea( <orll Ihe lempelnllllc sende< Unit.
co I I~con&#34;ecllhe HT ICilds Irom the spark plugs and IrOlillhe Ign'llon I ,1od remove Jlw L T I I I I .
MId I I If . CiI( 10 lie dlSl1i Julor Reillove aile h Xlng bolt 11 0
' I
a Ihe dlst"I>[1I0r ilSsemlily.
'Sconllect Ihe all II 51 halts' , ' ernillOr Cil) es. ilcken the ailelllntor 1110ul1l11lg un( <emovelh~d b I hi· '" ... live C I. I en remove the fllCrnfilor h XlIlg bolts rernove the ~I&#39; . 12 R " erniltor ')nd liS I,x,ng lIrackel. CIlIOVe Ihe Spa k I cOvers d "p uos. Remove Ihe IIUIS secufII1(.l Ihe rocker 13 R an hll 011 tho covers. emove the I I I . . mlel III f IVC '0 IS sec linn\) the onlet lII,1(l,lold and take 011 lile 14 l an, old complr:te Wllh ca<lIurello, OOson Ihe rock turned a ·d er """ .ldjust"'g nulS ulI\ll Ihe !Ocker arms can be ) hoe Or SI CI(F'(J 1 10) Ihen rCOllOV!.! Ihe pushrods ilild lily them oul Itl PO,ition l~llS I, lill.!1[ finds through a sheel 01 paper 011 which Ihelr III I Ie ("",II,e . I
Pusil rod . C,II1)e "Oled. 11 IS very Imporl<lIlI Ihal the IOtnOVCdS .1<0 r(;f,tted \0 Ihe same villve as Ihat from which they were
"IOC>! "
Fi~,. 1 .10 Turn the rocker (HillS to olle side 10 relllove the pushrods (Sec 47)
15 n,,,,,ove Iwelve lIolts ilnd delilch Ihe exh,lusl I1\,lrlllolds frOI" Ihe cylrrlrtr:f he,lds. 16 Sinckell the cyhmter hend boilS progressively in the revtnSe order to Ih"l shown ill FIll 1.19. IlcrllOVC Ihe bolts nlld hit olt Ihe cylindOf head.
It lile (.Iilsket has stuck and the cylrnder heJd cannot lJe lifted off. wp the cylinder heild wllh n hide·f.1cert. or plnstic·headed hJmmer. 00 nOI try to pri se IlIelil off wllh a screwdrivOf Of rtilillage WIll result.
4 8
Cylinder he,l(ls -rernovfli wilh engine O\lt o f car
Follow Ihe sequence (.I,,·elllll SectIon '17. 51;lItll1g.l1 PillillJl1lph 10. dl$lcoa,d,n!1 leil.!lellCeS to pa'is willch hJve alreildy bcen rcmuved
49 Villve$ _. removal
Rt:rllove the d('POSIlS /'0111 tire corllb\lsl,on chambers ~nd vnlve
h eads by ScrilPIl1!l and W&#34; ~ b'\Ishlll(.l Tilke CJre nOI 10 scratCh the cyllnde, he~d gaskel lilces 2 Lay the CylOl(ier hemt on ,IS sllll) .llld h t the lo,~ed cnd of .1 VJlve spllng compressor ove, the ~plln9 rctiluler ""d ti le head uf the complessor screw in Ihe cenl'e of Ihe v"lve head 3 Compress Ihe sprrng abolll " qUJller 01 an Ulc h 10 Iree Ihl} split colle l hom the top 0 1 the v,llve stelll. If Ihe sPltng ,eliHner "nd collel Slicks. do not screw the co",p,essor down lurlhc< . bec"use IIIIs lII.ly dJr11J\je the valve Slem. bUI lJp the sprong reliluler sha,ply wllh a Ioghl
hammer. 'I When the Iwo halves of Ihe collet h')ve been '(:nloved. onscrew the spllng compressor umrl Ihe spring IS no longe, compressed nnd
remove Ihe compreSSOr . 5 f1Olllove the spltng retnlner. the spflng and the oil seal from Ihe villve Slem. Ihen wrlhdrflw Ihe villve from I he cylinder head. 6 D iscard the valve Slem all senls and plflce Ihe Olher componenls to\jellrCt. identilying them so Ihal they arc refItted III the correC I plnce
III Ihe cylinder head. 7 Remove Ihe sp,11k plugs from Ihe cyhnder hend. II nOI alrendy
removed.
50 Rocker arms -removal
1 Remove the SIIfI nul from Ihe foch" .1'111 Illoullt,n\) stud 2 Lift off the rocker <Hill b')ll seiltin\! and Ihe roc~er Mm and Iny Ihe tl1<ee parIS 10<jethe r II IS ImpOrtilllt Ihat Ihe locke' arm. its hall SCJling and nUl ale refa ted \0 I he snme stud as Ihe one 110m which Ihey were
re moved.
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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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)
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&#34;)~&#34;&#39;&#39;&#39;U Fvcll,mk Co1P,lC '(y
Torque wrenc h settings Fue l ,11,>1,,1.,,101
W",m "p &#34;&#39;~11I1;,1O&#39; 51<1,1 V,llvt: A\J~&#39;h;&#34;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~&#39;Stll&#39;!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 &#34;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
)
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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Chapter 4 Ignition system
Contents
"'ondcnsc! (30 Iotre cnUIIlC) teslI llU . removal and rc h1!ln g .... 5 '"tact b.ellkc . POIllIS (3 .0 litre CIlUIIlC) ,lI 11us1mC lll 3 ConlilC ! brCi.ke< POintS (30 lIue cnumc) -Hlllloval fllIIl rclr ninH . " f&#34; &#39;~lnb\llo, (1111 CIl\ Ji llCS) lema",,1 .lIlt! .cll1l1n\) (j nhlllOr (28 lilre Cilomo) -overhalll.. 8 D,stributor (30 h\le cnuinc) overhaul . 7 Faull diagnos is -iUm\loll system. 12
S rICcificin ion s
System ty pe
3.0 lit.e engine 2.8 litre engine
Convent ional ignition
Distributor
ROIDlion Condense, cnp<lcity Cont<lC' blenker U<lP Dwell .1llule . HT lend res.s t""ce .. FIIIIlU orde.
Iqnition timing
c 1 !H6 model yC<l' 1976 model ye.1. onw<l.ds
Jil
I',im<lry ,eSI~\<lnce Second<l.y &#39;C~lst<lIlCe
Spark plugs
Type Elect. ode U<l$> .
8reaker/ess igllilion
Distributor
Rotation .. HT lead rCSlstn llCe .
Firing order
Ignition timing
Coil
Primary rcs,sWnce
Secondary resis lan ce ............... .
Spark plugs
Type Electrode {jap .
,1/ systems
Torque w rench settings SpD,k p lugs (3.0 litl(l CIl!JUlC) SPD,k plug s (2 8 hl,e engine)
Geller,11 dCSCfll>, ioll 19r1lllon tnnphlicr Inodule (2 8 hire engine) -. emov,l l and 'Ch1tmO ... ......... .............. . IUrlltlon timinlJ -ndJuslmcnl . flOulUl!) Ill;untenancc . Spark plugs -rem Oval, servicing an d .cl'!lu \g ,
ConvcmiOllill. with cantilCl tu cilke. Br eake rlcss. clCCltOnic
Clockwbe 0 2110025 mid
0 .61 mm (002510) 36" t o <10 · 30000 ohm mOlX"U,uU 1 <1 2 5 3 6
10"' B1 DC 11\· BTDC
0!l5 10 1.60 ohm 50001 0 !l300 o h m
M ot
o,,,,,lt AGR 22 o. Ch;lIllp lon RN 9Y C 060 IlHIl (0024 in)
Cl ockw,se 30000 ohm Il1<lXII11l"11 1- 4 2 5-3 6
12 *
BTOC
0 .
75100.85 o hm 5000 to 6000 ohm
Moto"ra" Super AGR O .GO mill (0024 in)
N rn 30 to GO 25 to 38
22C 0' ChJlllplon RN 7YC
Ibl It 22 to 30 1 8 to 28
10
9
2 11
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,6 Chapter 4 Ignition system
9 The spark plug gaf} is 01 conside rable impor1~e. as. if it is too lilrge or too small. the size of the spark ilnd its efficiency will be seriously impilired. The spilrk plug should be set to the ligure given in thl} Specifications ill the beginning of this Chapter; IOTa sel it, measure the gilp with a/cere, gauge. and then bend open. or close. the outer plug electrode untillhe correct gap is achieved. The centre electrode should never be benl as this may crack the insulation ilnd cause plug fAilure if nothing worse. 11 Relit the plugs, and re/ilthe leads from the distr ibu tor in the correct I"ing order. which is given in the Specifications. Screw the plugs in by hilnd initiilily then tighten them to the specified torque using the plug spilnnel.
12 Fault diagnosis -ignition system
By lar (he nlo1jori (y 01 brCJkdown and running troubles ilre caused by InUits In the igrlOlron system er(her in (he low (enSlon or high tens ion circuns There <ire two mnin symptoms Indlca(lI1g Igni(ion IJults. flthel (he "ngine WIll not Start or lire. or the engine is dIffIcult to SWr( and misfiles If it is a regulnr misflte the fault IS almost sure to he in the Icondary or hIgh tenSion cirCUlI. !f the misfir'"g is intermittenL the "HI lt ~oliid be ;n either the high ur low tension circuits. If (he car stops suddenly. or WIll not stilr( ilt ,111, I( is likely thm the lault is in the low ten sion cncwt. loss of power ,1nd overheating, tlpar t from f,lUlly c,lrl>LJratlon or fuel Injec tion Setlln(Js, ilre normally tllle to faults in the d,strrllulOr Or 10 Incorrect I(Jrlltion tlllllrl!J .
Engine fails 10 staft 1 If the engine falls to StM( and t he cal was IIJnning norll1t1l1y when.t wns IJst used, first check ther e is fuel in the petrol wnk. If (he engille tums ovel normally on (he starter 1I10tor and the bilHery is evidently well chmged. then the lault mny be in either the high or low tension circuits. Firs( check Ihe HT circuit. Note: If lire hal/cry is known 10 hI! {(Illy ch,}lged, Ihe ignilion liglll cOllies on, ,1I)d Ihe s/arler 1II010r {,lils /() tum IIIe ongine check the tightness o f the le'lds on the biltlely terillinilis ,1I)d <1Iso (lte seCUIIHWSS oflhe e,l,th leold (0 irs cOllllec/ion 10 tire body It is qui(e common for tlie le,1(ls /0 Ii,}ve wOlked loose. l.'vc'1I If Ihey look ,1n(/ lecl seclI,e. /I one 01 the boll/my ((:{minM {Josts [11.'1.1' vC'IV liot wi".." (Iyiny (0 wOlk Ihe s/mler 1II0tOl (his is ;/ sUie IIId'C,7/IUI/ 0/ ;/ I;wlty COllllel;('On 1(1 1h.11Ie"lIillal. 2 One of tile commonest rOilsons lor bad stmtln!J IS wet or d;UllP sp,uk plug lead~ and dlstribu(or. Hemove (he distllblltor cap. H "JOdenSil(Ion is v iSIble IIlte!llillly dry the CJp With il rag and also wIpe ;lCf the leads nelu the cap_ 3 If (he enUiue sull fmls 1 0 St.l.t. check that cunent IS reachlllg (he JUS, by dlscounectln!1 ench plug le,l<1 in turn ilt the sp1Hk plllU end, .. ,ld holdlllg Ihe end olthe callie about 5 mm (0.2 Ill) aWilY from the cylillder block. Spin the enu'ne all the sta rter motor. 1 Spa,klllg between the end of the cable ilnd Ihe block should he fa"ly strong With J strong leuulm blue spark_ (Hold (he lead WI(h wbber to ilvold elec(IIc shocks) If Clluelll is reilching (he plugs. then rel110Ve them and clean and reg,lp them. Tho engine should now SWrt 5 If there is no spilrk ilt the plug leilds. wke of! the HT lead from the cenlre of the d'sltibutor C<lP and hold i( (0 the block i1S belore. Spin the engine on Ihe SWrter once more . A Inpid succession of blue sparks hetween the end of the loau and the block ind'cate thilt (he coil is In order and that the distributor cap.s cracked, the rOlOr mm faulty, 01 the carbon brush in the tOp 01 the distributor Ctlp or rotor Mm spr ing is nOt making good contact Poss,bly, (he POintS me in had condition (mechanical contaCI hrOilker) . Renew them ns doscribed in Ih is ChnJ)ter, Sec tion 4_
6 If Ihere me no spmks Irom the end of the lend 110m the coil check the connections atlhe coil end of the lead. If il is in order 5(31 1 checking (he low tension circuit. 7 Use iI 12V voltmeler or a 12V bulb ilnd two leng(hs of w ire. On conventional distributors switch on the ignilion i1nd ensure tha t the points arc open. On breakerless dlstlibulOlS ensure thilt Ihe segments on the rOlor are nOt adJilcenl to (he triggel coil. Make a tes t between the low tension wire to the COil ( + ) terminal nnd eilrth. A leading of 7 (0 8 'lollS should be obtained. N o reJding indiCiites a break in the supply from the ignition swilCh or il f,1UIl in the ballast resiswnce wire. A correct rending indicn(es a faulty cojl or condensel, or n blok en lend between the coil ilnd the distrIbutor. On breokedess ignition systems the (rigger coil and ilmplificr module are suspect . H~ve (hem checked by a Ford dealer. . 8 Take the condenser wire off the points assembly Jnd with the points open test between the moving point ilnd eMth. If there is now a leildrng then the tault is in (he condenser. Fit a new one as dcsclibed in this Chapter, Section 5 9 W,th no reilding from the moving point to eilrth, wke ,1 reildrng between eil/th ,1nd the ell or negiltive ( - ) teminal ot (he COIl. A rendm(J here shows a broken wire which will need to be renewed hetween (he COil ilnd dis(rihutor. No retlding confirms thil1the coil hilS failed ilnd must be renewed, afler which the eno"te wdl run once more Rcmtmher (0 rel,t tho condenser wire 10 the pomt$ ilssemhly.
Engine misfires 10 If the enOlnr. mlsfues re!Julariy. run It ilt a f~st irllrng speed. Pull off eilch 01 the plu(! C,lpS III hUll nnd hsten t o (he note 01 the engrne. Hold the phl(J cnp In il dry cloth or with a rubber g love <IS addition,of protection au"inst il shock frOll1 the HT supply_ 11 No d,ifercnce in eng me running will he noticed when the leild 110m the defective plug is removed. Removing th e lead from one at the good cylinders will accentuilte (h e misfire. 12 Remove the plugleild from the end o f the defective plug ilnd hold il tlbmlt 5 i'lli'll (0.2 in) nwny from the hlock_ SWrt (he enoine. If the sPJ'king is fairly strong and regul"r the I""'t must lie in the spnrk plug 13 Tho plu~J mily be loose, the Insulation mav be crtlcked. or the points may have burnt away g,ving 100 wide tI unp lor the spark to juml). Worse stoll, one of the points may hnve broken off. 11 II there IS no spilrk ilt the end of the plu\J lend, or ,f It is weak ilnd IIlIermiHent, check the Ignition leild from (he distrdwtor to the plug. If the IIlsulJtlon IS cracke( 1 or pCIIshed, renew the lead_ Check the COrlilections Jt the distllbutor CilP_ 15 If (here is s(111 no spark, eX,lmllle the dlstlil)utor CilP cillefully fa, (r"dIllU. ThiS Cilll be recoor1,sed by a very thm black line running between two or more electrodes. 01 between "n elec lrode and some
other Pollt of the dlstllhu(or. These lilles J,e p,lths which now conduct electllcit y Jcross the CJp lhus lewng it run to e,,'th. Tile only answer IS a new distllbutor CilP_ 16 APilit frorn the Ignition tll1l1ng being Incorrect. other Ciluses of rlllsl,,,ng hilve already been denl( w l(h under Ihe section dealrng with the f,lriUre of Ihe enuine to star I. To reCi!p - these 0110 Ih,lt:
(,J) The cOllm.lV be {,lufly giving ,111 iniNmil/elll mislile (b) Thele limy he ,1 (/iJmiJged wile or loose cOrlflee/ioll in till! low (eflsion circuil (c) The condensel /II,lY I;e shOll circuiling (i{ filled) (d) There nwy be a meehanic,lllolUI! IiI Ihe dis/flbll/or (bfOken dliving spindle or eOlllac/bleaker spring. if filled)
17 If the ignition (iming is too far reto1lded, it should be noted thallhe engine will tend to overheat. and there will he a quite no(iceable drop in powel. If the engine is overheating and Ihe power is down, and Ihe ,oni(ion tim in!) is correct. then Ihe carburenor or fuel injection should be checked, i1S ,I is likely that this is where the Iilult lies.
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