wiring FORD CAPRI 1974 Workshop Manual

64 Chapter 2 Cooting system
FiO_ 2.6 Rernovino tho viscous drivn '"n (Sec'1)
A 8 ,,,,,',1/1..·(/ ""f' lock/WI (LH /lorr.;,,') c Mudd"," SIIIIJ!III.'/
1 2 F"n hub bC1lr illg (3.0 litre engine) _ renew .. ,t
Remove
th e drivel>el t (Section 10) then unholt th e 1,111 and pulley. Where il v,scous drive 1,111 ,s j,ued. reler t o Sect ion 1 1. but where ,1 st .. m d;ud Ian is I.Uo<l note the loca t,o n 01 the sp acer s 2 Remove the engme front Cover (sec Gh,lplCr 1 ). 3 flclllove thtl cllel'l> wh,ch 'C1.lIllS Ihe hea,ing in Ihe housing. then I>&#39;e~s Ihe lJ(:arrng . expansion pili\) ,lnt! hub oul 01 the hom cover >1 Press Ih e sh"lt o"t 01 Ih e huh 5 Prcss a nnw sh alt ;1Il(i IlCil""!) as."emh ly 01110 the hOIl5'I1U. so Ih;,t thc CUCIo,) ~I&#39;OOVCS me "' ;,hUrr",err l .. ,n il leI'l Irw c,,,.:IoI) G Pre% on lho h"" 11111,1 ,ts hont lace IS 8581"'" (338 ,n) f,olll Ihl1 tc,l' f;lce 01 Ihc fro nt cover .
7 F,t;r new a~lr.&#39;I1S&#39;OIl "Iug 10 Ih e 5h<lll horc III th e rc .. " !<lce of the 11C<I<I01!J housing 8 fleftl t h e Ironl covet. p"Uey ;md I<ln 9 nellt Ih e drrvcbe h w'th 'ela,ence to Sect,on 10.

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13 3 Disconncchng the wiring hom the l(,rllp .. ",lh "C " .. "tic sellt!.:: . WI't
13 TClllporll\"ro !.F'lIgo sonder ullit -rCr1lov(l1 (lnd refilting
Th ... ICIU IIC'J\U'C UauUc scndc. UII '\'S IOCillcd all the ou\le elbow ,II the f,ont 01 t he cnglllC. 2 H(llc r 10 S "C 110n 3 .. nd d';lllllhc coolm9 system s"H 'Clcrllly 10 bWl!! I he level hclow the auilel elbow 3 Disconnect the w irmS) from the unit (photo) <I Unscrew the scndC' UIlII hOI11 the elbow 5 Retilling.s a r e liC'S," of .cmov .. I, but 101' UI) the s yslcm WItt, rcle.e ncc 10 Sec tion 5
14 EHpimsion liHlk·· .ernOllill .. nd Icfiu ing
Rohlf \0 Sec tIon 3 "nd d'i"" the coolm!1 system suH,c'Cll1ly 10 hun\] the IOllel billow lhu ""honor la p hose. 2 Unscrew the cross ·hcnd rI10urliing screws ,lfl(t 1I1I the lank from t ht: lIIi1cket (photo).
3 D,sconeet the hoses .. m d remove the e~p;ms&#39;on wnk (photos) 4 RellwnU IS iI reyer s,,' 01 re moy"l. but rel,n th e coohng system as oescr ibeu 'n Section 5
142 Removing th e e~pansion ta nk mounting soews 14.3A Disconnecting the side hose ... 14.36 ... and bottom suppl y hose flom lhe
c~pansion t"nk
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74 Chapter 3 Fuel and exhaust systems
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Fig. 3 .23 F el '<ll1k coml> onenlS (Sec 13)
A
" C
Se.ll Ruhbcl ill,W/,lIQI S SI!IIIJ..'f lIoil
14 Fuel lank -cronning DrHI rcpl1ir
D SImps E , COllflcetiu"
W,lh IlI1m 11 I~ likely Ihal scd'lllcnl .... .11 COIiC(;1 1f1 the IJOIiUlIl u l the ruel wnk. Con<lcIIsa l'OI\. los-uIIU'U "I !USI ~Hl{1 olhe l lI1'Il,,,' "es. w,lI lISlI;ll1y be found III tllu fuel l~nk ul 111lY eM mUIC Ihan llir"e or lour yeil' s old. 2 Whclllhc wnk is .emoved it should he \lllJOrous ty tlush ()ti Olll wnh p,l'ilfllll I1nd turned topside down 10 tir<llll II r.1Cllllie s n,e ,wil d,lhlc ,11 the I()(:;JI gar ago the lank m;'ly be steam cleaned and the exlCflor fCptllnlCd with" lead bnset! ,J a int 3 Novol weld or br in!J J naked ligh l close 1O;lr1 emply fuel I.1nk until,! hilS been steam clC<lncd out 10/ illicasilwo hours or. washc(t IIIIC'II;'Itly wilh boihng WOler ;lnd delergcnl and ;lllowed 10 SIi",d lor 011 le,1S1 Ihree houl s
15 Fuct lank sender unil _ remov;11 nlld refilliny
Check Ihe h01l1 whL'{)ls Ihen J;lc k ufllhe le;lr of Ihe 17;11 ;'Ind supporl ,1 ilxle sr,llids . 2 SYI/hon Ihe fllel hom Ih e tllcllim k. Wherc ;lpphcilhle d,scol,,'ecl Ihe fuel line hOIll the scnder unll.
" Discormoci Ihe wiring 5 USlllljlWO SC!(lw(i!lvers III Ihe 51015 inlhe sendcr unit ,e lirmlng 1111\1. unsr;'ew Ih o sender (mil loom Ihe tucllilnk Lilt ilW;lY Ihe scaling ling iln d Ihe sender unit. nO llng Ihill Ihe 110.11 must hilng downw;'IrrJs. G Re fill ing is a rever snl of .e moval . bUI clea n lile milling !;lces ;'Inel I II ;'I new sealing ring .
1 6
Fuel lank filler pipe -removal "nel refitting
I Remove the cap horn Ihe hiler pipe. 2 Re movo Ihe .ighl·twnd siele lIim p;'lllei. 3 Peel back Ih e in sul alion clear 0 1 Ih e pipe (:Over fliln cl (Ghia only). 4 Lift outlhe pimel coverinU Ihe spore wheel. 5 Unbolt Ihe IllIer pipe covor panel. 6 Lo osen th e clips and releilse Ihe rubl>C1 oail er from Ih e floor and f,llel pipo (phOIO) 7 Remove Ihe screw al Ihe lO P of Ih e pipo nexl 10 Iho filter cap (photo). 8 Disconnect the hoso and withdra w the I.ller pipe I rom in si de Ih e
car.
o Relill ing
is a rever sal 01 romov;lI,
A
cceleralor cabl o - removal and relining
Removo Ihe
lowe. lac.a panel inSide Ihe ca'.
166 Rull"'" !F"1I1';'I1 "otlom " I I"". la llk flU", l"llll
(
. ,'l
--.
. ~
1(; 7 Fuel lank flUc. Pll~ UppCI 1II0UIIIIII\I SClew (.lIwwL't I)
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, I;'.' . :~, \;.;
: : i;. "j -' , ,' .... :r: , :&#39;y~ it. ; '., :
Fig. 3.24 Disconnecling Ihe innor cabla from the pedal (Sec17)
Pusll M 11 ,mrl rcfc,uc ill IJ
2 Disconn(:cI Ihe cahle 1<0111 Ihe I)OOal hy unhookoug Ihe clip and rcleasing Ihe ""II:! cal,le 3 Rem oye Ihe IHal:.e servo un:1 a~ dcscfLb c(1 11 Ch;lll lcr 9. Ihen remove the SClew securrn~J Ih(: Oulcr cable to Ihe iJulkhc;'ld
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Chapter 3 Fuel and exhilust sys tems 81
1 8 Disco"nect the hllllmy 1 9 Relc,,~e tl", .. ,e5~II.e In t he system "s described in palaglaph 3 22 P lace some cluth hcnc,llh the luel flhel then disconnect the mlet ilnd outlet ", lions 2 1 Rcmollc tht) mOIlI1lIlI11 sc.cws ,1od withl1,,,w Lhe fuel f,ltc ,. Remove
the bl:lclwt II 'ltICIlS$:I'y 22 RchulI1U IS a .ellcls:l1 01 ,emoval. but m"ke sure tha t the 1,ltel is
pQs. t.onnd thll I:Olfe ct W,ly 10un(l. "n(1 Locate tile OUIICI plj&#39;JC:I~ snown
io FiH. 33!)
Fucl tlisfllbu{(}r 23 The f""t d&#39;~L&#34;I&#34;&#39;lor .~ IOr.i'to(1 on top 0 1 the "" flltl'!'. 24 DISCOnl"" .t thu !o:m",y 25 n,;L&#34;&#34;~,,, thO! L&#39;&#39;&#39;&#39;&#39;,~II&#39;&#39;~ III (hI'! system:ls d"sl:"lmd in piull u,a"h :I"" t compL"L"ly 11,111"11" tho I,,,, d 111111 ",Hon 26 DI~r.&#34;&#39;UII&#34;. t tl,,, """,11'1'1111 f,,(:II'"C$ 1,<)ul til(! llis t,d,utOI 27 UIIS&#39;~&#34;:W ,I", nll"l1 """m'"'n sc",ws alld hit Ihe IIISIIIIJlIIOI away 28 RHhll""1 ".,' &#34;,v&#39;:I~,,1 "I rr""OvilIIJlJ IIISC a IIIiW coppe, w&#34;~.h,,, r:ach ~,de of Iht: '1',"'1" IIIIIW&#39;~ ",,(I dO not OVf!rI'UII1I:rllhe llIliol Imils 9 Hall" Ih" :.y·.1t:1I1 I""",u'li t: heckr.d by yo"r dllatCr: 30 I\dl&#34;~t th" "II" &#34;I~:I&#34;t :II\l IIIHXIIlIfl as ,leScII",,1I III SectIons 73 ,IIld 26.
W"",,·/I/I/I.'ylll;/fOf 31 The w."'" "I' "'!I"I"tl1l 's loc ;llt,d on till! hunt of the ""!I"'" ""xtlO t he c(X,l"'H ~y~t&#34;l11 nuth, t I:lhow 32 D,sco",,, • .: ! tl", lhlllCI" 33 Flcleasc Ihe prcssllfc In the sySlcm as desc"hed in parag'''I)h 3 34 Discount: GI Ihc lIacuum hose ilud wi"uy plllg (photo) 35 D'SCOI1"I:CI the fuel hiles (l)holO) 36 Unsc,ew the Iwo sockcl·he;lded uolts ;lnll wllhd';lw thll 'C!jUI;ltol . 37 Ref,(lln\1 IS ,1 ,cve.sa' o t ,emOIl"' . hut lise a new copp .. " wa~hcr eilch Si(lc 01 tim h,ll1l0 \llllons (phOIO) 00 nOl ove,l>ghtcil lh" I"'''on cenlre hol ts
Fuel S f"ff v:llvc 38 T hc luel stMI 1I:llve is located on thc ligl1l ·hand s,de of the lIir ch"mhel. 39 DIsconnect the bmlory . 40 Disconnect the elcctlic p lug and fuel supply pipc from th e lIalve (pholo) 41 Unscrew tho twO socke t·headed mount,ng bolts uSlllg an Allen
key .
42 Ref,,,,,,!) IS .1 'ellcrS:l1 of ,ernOllal. but u~e II ncw moullting flange !lasket Use" new copper w"shel all each SIde of the """10 union lind do nOI ovnlllllhien the Centrc holt.
A!lxih~1I&#34;Y "i,. r/(!vicc 1\3 Thc i",x,h.n y "" rlcvice is 10C"II,1I On the IIU"t hal1d flOllI of thu lIir cha",!,,", 1\4 O lsc0I1"", .1 Ihe hallerI'. 1\5 D.scr"'''.,ct tl,(, eleCt,ic p l11\1 ;,ml IWO illf hoses IrOI11 the ""vice (phoIOS) 116 Unsc",w tl", two 'UO"nIl119 holts .11,,1 hit tl"l ;rss",,,t,ly i!Wlly. 1 7 Fl"f,It'''H .s ;1 HIIIC,s,,1 of 'elllolllli
Foel injocrurs 48 D, sclI"""'.t Ihe h;lll",y. 1\9 O, sr.<J""r:CI Ih.) :u:cclcrlltor cahlc and il.ad."t r,olll I"e th,onle "ssemhl y 50 D'SC OIII",, :t Ih" m;" " lIir SUI)ply l,ullk",!! 10o", ,he "uxtll,e cont,ol u"It ;1I1I111r",1I1" "ouSlnH (,lhotos). 5 1 DI~,:ulll&#34;&#34;: t .II\.! IIlect,ic ,llll!ls from thc walm'''I) r~I,,&#39;atOl. the th.)ltIl{Jtu"" sWllch. thl") lI\lxllia,y air device amI the fuel St.1,t vDlve . 52 D,sc",,,,,,,:t the: hlel SIlIIP'''' ,)ipc hom the St.1,t v;lllle Dlso the V"CII\lm II'II\.! hom tho W;lrm up 1O{jIJlmol . 53 Unl)()lt tht: a" chmllbCf (ei9ht bolts) and move il c lcar of the in le. ",al1i 'ol(l. To completcly ,emOlle il, disconnect the rClllaining hoses. Belllove 'he UaSkC ! (,) h o to). 511 UnSCICw Ihc ",oun,ing boilS <lnd pull Ihe i"leclO's loom Ihe mlet Illal1itold 1,)"1)101 55 Usm!) IWI) ~p&#34;nrIC&#39;S. loosen t"e UIII!)" n"IS .,,1(1 d.s,:onncct Ihe miCCIO'S fr<llll tht: fuel IIIles .
25.3 4 D,sconncct'no Ihe wII'no plug . 25.35 ... "nd fuel hncs from the W""'H'P !egulato! 25.37 Re new tho copper wilshcrs each side 01 the banjo union
25 .4 0 A DisconnectIng Iho tuel slart valve
wiring plug
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2 5 .4 06 ... and fuel supply pipe
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25.4 5A Au xilia,y air dcvice w ifin g plug.
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)8 Chapter 9 Braking system
8
Fig. 9 .6 Rear wheel cylinder component s on "",I y models (Sec 8)
I Cft,} 2 Rubber hoot 3 Pis/oil
5 Relmll SfJflflY 6 Blcell screw 9 Scff ",',uSilll!! wtdll.:/ 10 At/jlls/my boof
4 Seal I Retaming JlI,~tcs II Ullfufb,;,Ac oj/cUlling level 8 Wheel cyhirdcr body
11 Dip the piSlOn(s) and plSlOn SC<lr(s) in hydrauhc flUId then reassemble the wheel cylinder In rcversc orde . to d,srnanthn\J. Not(! Iha the seal lip must lace into the cyhnder
12 Rein the wheel cyhnder using il f(lversal of Ihe fcmOy.1. procedure. Note lhal on (l,lIly models t he sel l.,ldrusI1I19 .atchet is handed -RH thread on the RH side. and Lit thread on thc LH SIde. 13 On cOlllpletion bleed the hydraulic syslCHll ;'IS described in Section 15.
9 ROilr backl}lato -rClllovn! (IIHI mfittillg
Remove th ... wheel cylllllier ~s <Iescllhed in Section 8. 2 Remove the ~KleslHlit (h~lfsll.1II). wllh reh,rel1ce 10 Ch,lpler 8. Ihen pll the h.1ckpl,11C.
Thoroughly cle,ln the b~ckpl.1te ~nd Jxll) casing Ihen relit the h .. 1ckplJte with reference to ChJpter 8 Jnd Section 8 01 this CIl.1pler.
Fig. 9.7 Re .. r whoel cylinder components on lilter models (Sec 8)
1 Rubber boots 2 Se'lls 3 PiS/OilS 4 Re/vm spring
5 Wheel cylinder body 6 Bleed screw 7 OVSI cover
1 0 MJsle r cylinder -rcmov;11 Jnd refitting
P lace a ~wllcIH&#39;hJe COI11~lIler benem h Ihe mJ$le f cylinde r 10 cmch ,1ny spIlled Ihud ... Mil also place ~on,e cloth on Ihe surrounding hodywork ;lml componems 2 Disco"nect Ihe wirinlJ lrom the low tluid winni,,!) sw,tch on the ,evelvoir 1,lh.1I r:ap (photo).
3 UIlSI:f(lW lill) reservoir 1011111 cap and dr"w out the flui(1 using J syphon or sucl'o" l(,be <1 Unsocw ("u un'on Illl(S IOnd rlist:onncct Ihe b,ake lines. 5 Unscrew lOud r emove (ill) nlolUwng nulS and washers Jnd lilt the mnster cyl",du' hom Ihe Siuds Oil Ih e servo lmll. G Empty llin tlu,d 11010 llie con l,urlcr Jnd remove the master cylinder
from Ihe enU",e comp(lrtmeni. Io1k,ng cllre nOI 10 spill Iluid on the bodywolk. 7 HeliuinU 's II ,eve'slIl of removJI. but on completion bleed the hydraulic syslem IIS (Iescribed In Section 15.
10.2 Disconne cting the low lIuid warning switch wiring
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,
.00 Chapter 9 Braking system
PR IMARY CUP
SeCONDARY J CUP _ RETA INER SCREW
INTERMEDIATE RING
SECONDAR Y CUP)
STOP WASHEP. WASHE R
PRIMARY ~ (''''')
CUP PISTON ~lJ ~
SPRIN\G SEAT T 1 WAStE:~L~\C Q I~
PRl~lARY CUP ./
SPRING OISC I -1 '" &#34;&#39;~&#39;f&#34; SPRING i SEAT L ,:-\,/(.&#39;.~·, J ' '
RETAINER • \ . '0 I)J-'0'.'.)'. ',:.,' "'f
I -, " ,O"'j')'" I' . I r -h" .
l J i\\"\" ,jl;
~G«1N w: 1 vl";';':' ~ .. '
" r • • {l"t:';" ,: .• ,-; \{. . ' SNAP . \J, ~;&#39;. PISTON RING
--
1\-\1 ijM:\'.' ,J , ~1.1&#34;9 _ ·S TOP SCREW .....
--
SEAL ','
-'---
WASHEA
---, ,

/ /
SECONDARY CUP
Fig. 9 .9 EKplodcd view of tho Teves (ATE) master cylinder (Sec 11)
, •..•.• -." . I',
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I
'-- ----
---"Ii
-,
I
~J
- . ' , ..... (
F ig 9.10 The Tavos (ATE) maste r cylinder pisto ns as sembled ready fo r reliUing (Sec 11)
12 Pressure di Herent;al switch -desctilHion. removal and refitting
E,lrly mOdels were filled with a pre ssure diHerent ial switch to illurnin~to ~ wolfning l igh t on the in stru men t pilnel in the event 01 a drop in preSsure in eithe/the Iron t 0/ rear hydraul ic circui ts . The switch ir- "'rporates 1I piSton which is kept 'in b alanco' if the pres sures in tho I. and roar ci,cui ts are equal. Howeve/, rl there is a pressure drop in
one circuit. t he pisto n is displaced and the switc h con tacts close .
2 The switc h is loca ted on tha lowe, left .hand side of the eng ine comp,Htrnent and a lthough it was once possible \0 obtain new in ternal
seals these are no longer available. Th e switch may be renewed alone (without Iho hyd,au lic body) by disconnecting the wiring and unsc rewing it .
3 To rernovo the hydraulic body. first tigh t
en a piece 01 polythene shoetinu bene ath th e brako Iluid reservoir fillor cap 10 reduce th a loss 01 fluid .
4 D isconnec t the swit ch wiring.
5 Unscrew the fi
ve union nuts thon disconnec t and plug the pipes.
6 UnSCfew the mouming bolt and romove the unit.
7 Relillin g is a reversa l of removal. but on comple tion bleed the hydraulic system as described in Section 15 .
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Clwptcr 11 Bodywork and fitting 179
AI
I
FiO 11.3 F 'Olll humpe r mnlOOlIill!) (S,!,; H)
1 /"'"., '''''"II/III!} /",11./.."/
830" 1.,10" 1I1I&#34;ld~ Ill" 1"""1"" C(I""" ""'.11111' ~&#39;&#34;·W~ ... " 1,".11,,01 IJencalli pl.I'I,,: C:;IP~
g.2A RClllOVII1\j Ihe uppcr
8 i1ef'III1lU IS the ,eve,se of ,he lemov~1 p.oce<iuI<:! blll do nCoI flilly
tigillell the nulS unlil the 11IIIlIpCI 'S conectly ~lllll)cd
Bumper (rim strips 9 The bUlnpei tllm stilPS c~&#34; b" lemoved. iIlHI'l:pl,lCCIIH:OOI$lollcd. hy P '0 lh(:rll,n ~nd oul of Ihe 'l:I;"",nu U'OOVC S Till: )oh IS 1ll,,,Jc a 1o111e ea~&#39;<J: ,f a so,~p and W,Hei soiOIlO" '5 apploc:d to til" T ~h .. p"d r(:1<III'"'I )
grOov e
(2.. (6"") --
Fi! 1 11.' Roar hUIl'pcr ",Olu,lin(l (Sec 5)
87 Ikal I"JIl'p'" "'1.11"""1 nlJt~ (dllllw"d)
.. "
... &#39;~{&#34;&#39;;~~...,:r--~&#39;~~
. . _",1'--
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9 .2B ... and IOWN I,,(I,atOl (lrdlc mOIlIlI"'U ~crcws
9 Radialor grille -removal Dnd refitting
1 Discoilneci th e bmtery eDllh lead Open the 1)01'"'"

•
2 Remove the moun''''1J screws and W,"SI""5 ,,,,d loll "w,IY the 911l1e (photo). On early mod(:ls II IS necessary lO (1'$[01"",<: 1 th" ,nd,cator wiring belore the 11"l le con be rc:move d hilly 3 Reiollin(l IS a revels,11 of removn l.
'I
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")256
W
Water pump reliuinu -44. 61 removal -61 Weights. vehicle - 6 Wheels care Jod rll<lillteMnCe .. 171 nuts/bolts torque wrench selling -158 stud renew,,1 (rear) _ 140 Windscreen removnl nod ,ehtling -180
)
Index
W indscree n washe r nozzle removal and refitting -219 pump removal and refitting -219 Windsc ree n wipers arms and blades removal and relitting -220 fault tracing -219 motor and lin kage removal and refi1ting -218 mOlor dismantling and roassembly -219 switch (Series II) -225 Wiring diagrams -235 to 249 Working facilit ies -11
."
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