oil FORD CAPRI 1974 Workshop Manual

Chap te r 1 0 S uspension and steering
Wheel b,ll,lncing may bo carried out wllh the wheel Mher on or off the v eh icle. II bOSItion . Gene,,,1 tyre wear is influenced to" I",oe degree by d.iving s tyle -harsh br;)kmg ilnd "ccelelation or l ast cornering wifl 1111 p .oduce mo,,:~ rapid tyre wear. Interchanging 0/ tyr es may result in mo.e even weill, but this should only be ,nrlied out whele there is no mix 01 tyre types on the vehIcle. However. II is wolth bearin g in mind th"t if this is completely ellecllve. the nelded expense 0/ repl1lcing 11 com pte te set o t lyres simull 22 Fault dinynosis -suspension nnd steering
5ylllptOlll
III(; le pulls t o on!! ~Idll
Slecnl1!l ~trll or h eav y
Excessivc pt;Jy in s!Cerinu
W twd wohhtH ,11111 v,h,nIIOI1
Ty,,~ W(~;II 1lI11,VCn
leg,l ! restri ctions "pply \0 the mixing 0 1 tyre types on a vehicle . Bilsic;lfly this means Ihil a vehicle must nOt have Iy,es of dilleling conStruction on the same axle. Althoug h ;1 is nOI recommended t o mIx tyre type s belween Iront I;)'I'Icd from yOll' locn l polrce if in doubt ,1S t o Ihe CUlfCnt lC Renson(s)
InCOlfect whcel o1lrUlIlllent WC,II In SIISI)()IlS'On 01 SI(""""! I CO""llOnents Ar.r.uic"t .1""'''!lC 1 0 SUSllf,nSlon o r ~I.w" nu compUll"nts IIlr.Olllll:t lyre p.eSSUlt's
Lack 01 SieIJIIIl!J \J 1"r.O""r:t wheel alrWIUlen t Powc. SIIJIJ'"1U laulty
W orn sleellng Or sus penSIOn 10UliS W en. III couplrnU shllft unlve,sal Joms Worn r,lc k ilnd 1)""On Incorfectly adJuSlcd rack Slrll llC'
RO:Hlwhe els oul 0 1 hnlance flU.ltlwhcels huck led or IhslO,Wd l:iHlhy ur dnmnHed IVII]
Wu,u s tL'f:II"!J Of SUSI""l~IOn JI1I1lI~ WlJnk Shoc k ;.hso'b"r~
'"collee.1 whee l ;' ''UIIIHlllll We: " III suspenSIon Ot st"""lIg C{)I11POIlCntS Ro,'llwhL'Cls out 0 1 halance WIJ;lk shoc k 'lhso.he'5
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灲潣慲浡湵慬献捯m

Chapter 11 Bodywork and fittings
Contents
i'ldIUS\Oy,ll and luhlllnq 25 ~ 'PCIS ,,:~mO\l.11 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 SeillS -remov,,1 ilnd refilling Sunroof -rcmoval an(1 ref ininu. Sunroof bracket an(1 dnve ilssernbly _. removal and refitting SUrlrool PJnel - 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
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2010 30 35 10 42 4.5
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41
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" 3 4 G 5 23 ,
22 2 3G 39
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27 28
" 11
"nd 19 10
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-II he dune with;, S"d",,,, pi .. "., '" i),,;;;,,;;,,~;;,;,; :;I,',"I;,,:n\(~Il. u~;i"U 11/00' I]ssivO!ly Ii,,,,, (I' ad. ~; ,,( W,,1
,Itld dry pal",r. wrapper' around" s AlI"in. "';;II\lI,I,,,'ly of wiltp" ,,,I, ,Iown 11", Iilil'"'' wilh" lin" 11",de W,,1 ,11,,1 dry p,lpl" (1\00 !!'.ulc ,,: 1'",I)"loly h"',1) ""Iii i1 is ,,,,,lly ,"""011, an,1 welllJlctlilcd ;"tu II", ,.,,,,,,,,,,,I"'!II),,i'lIW[) rk . l\I1y tU",,,;I1;"!1 j"'p<:rfuo.;liu"s can now I", 11110·01 I,V c;u"r"lly ill'I,liell kl,i,i,,!! SIDI'per pa~IC
The tOP coat can now be applic(t. When wurk inu 0,, 1 of doors. pi<;k a (hy. Wi"rn and willd·frce day. EnS\JJH sw'oll"di,,'.) ,"CIIS a,e prowclcd from over-sp,ay. Agililt ... II, ... " ij
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nll' whol" ",pili, ,"ea {:,i" now he sp,,,yu(1 0' h,ush-pai"le<1 w ith p,i(""" If sp,ayi,,\!. ens"", "djoinilllJ "(CdS ,lie proICcwd from ov,,' ~p,ay, Not!) 111,,1 "II Whli" Ih,: ~;toppu' hilS hanfuned. '1,1) dnwn Ihe "'Ih,i, ;"ca I",f",,, ;'Pl'lyimJ till' fin,,1 coal of p,imc', [l,,!u'e 'ul,hi,,'J down Ihis I"sl ';0,,1 uf p,im ... ,. "nsu'e Ihe 'cpai, a",,, is blemish I,eu­US') ",0, I) SI"I'pe, il ncccss;uy. To ens",,, II,,,, tI,,, ~",Iace of ,hu IHimu, i:; ,,, Alw, a period of about two weeks, which the paint ,u:uds 10 hi:ullen fully . the surface 01 the repai,ed a,ea cnn he ',;ut' with iI mild CUIlOIlI) compound prior to wa~ polishin'.) When carrying Oul hodywu,k 'epairs. rememl)e, Ihat the qual ity 01 tllu finished joh is proportionJl1O the lime and effult UXIl(,Il(l",1
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procarmanuals.com

)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 2 Routine nwintenancc
AI the in1erVills speCIfIed in the Routine M"IIl\cnilnCe section in the front 0 1 the nl Check seal bellS 1 ThorouUh1y check nil sent hellS 101 frayu10 . cu\s, 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 w 3
M,,;ntcll The gorH)! 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 f or inspection. Periodically, except on vehicles w'lh iI wax· bnsed underbody protec tive cO After w 4 Mnintenllnce -upholstery MId eMpets
Mats and C 5 Minor body dnnl 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 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 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 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
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) Chapter 11 Bodywork and fittin g 17 7
~!t~InS its oriOin,11 sh~flC. There is lillie point in trying to restore the original s hllpe complClC ly, as the me1011 on the darnllged arca will have stretched on impact ilnd cannOl be reshaped fully !O its original contou r, II is belter to bring the level of the dellt up to 11 poin t which is aboul ~ in (3 111111) below the level 01 the surrounding bodywork . In cases whe.e the dent is very shallow anywi'lY. i, is nOI worth trying \0 pull 1 ou t 111 all, II the ull{lersidc 01 the dent is accessible. il can be hammercd oul gently from behind, using a malleI with a wooden or plastic head. WhilSt doing Ihis. hold a suitable block of wood l'flllly a{),111151 the outside 01 the panel 10 absorb the impact from the hammer blowS and thuS Il,event 11 Imge area of the bodywo.k hom being 'belled,ouf, Should tho dem be in a section of tho bodywo.k which has iI double skin or SOI1IIl other filclOr mokil1g It inaccesslhle from behind, a
dllferent technique is cillied lor, Drill severill sm;1U holes through the
mewl II1slde the i1reil (Jilrtlcul,ldy in tho deeper section, Then screw long sel1·tap~ing screws into the holes IllSt suffIcien tly for Ihem to gilln iI good purchase In the mewl. Now the Ilen t C"n he 1)lJlled out by pulllllg on the protruding headS of the screws wllh iI pnll of pliers. The no.t stilgo of the rep,lir is the .emOllill of the PilUlt from the 113Ued meil, and hom nn Inch or so of tho SurroundlilU 'SOUfl(r
Jdywork , Tills is accomplished most oilslly by usil1U a wire brush or ab'~sllle pild on " ,)owe< dflll, ~,lthou9h It Clln he done Just i1S e ively hy hnmf usmg shoots 01 1I1)'i151110 P.l,)C •. To COlll,llete the p Repair of fIIst holes or gashes ill bodYWOlk Romovo i111 point f rom the affected ;lIen i1nd from ifn IIlch or so 01 the surrounding 'sound' bodywork. using ;1Il nll.a$llIe pnd or 11 wire brush on 0 power drill. If these iIIe not i111",lahle a few sheets 01 abrasive pilper will do the job JUSt as offoctivilly Wrth the paint removed you will be able to gauge the sovori ty of the corrosion alld
thorelore decide whether to renew the whole polllel (II this IS possihle) or to .ep[lir the affoctod illoa. New body Po1nols arc not ,1S expensive as mos t flCOple think and it is often (Iuicker and mo.e satislacto • .,. to fit" new t)anelthan to auempt to rellair larue n.e,1S 01 corrosion.
RenlOlifl all f,llln\Js hom the .. lIeeted a.o" cxcoptthose which Will
act ~s ,1 uu,(ie t o the oliUllwl shape 01 the (i,lIlla\je(i bodywork (ell hn,1(1lnll1l) ~h.~lIs etc). ThOll, USlnu tin snIps or ~ h"cks all 100SI) met,,1 ,,,,d allY other IIwtill b;I(I'Y 1IIIo.:t..,d hy cOffosion H"lIllller tIro cdIJlls 01 lire hole Il\wartfs In Older to CW1Ite a shulrt
d epreSSion fo r Ih c frllcr pas\(!
'll/lle hrush the aHected Me[l to 'CIilOlle tiro powdery rust from the ,ICO 01 the lelllilllllll!l lIlet,,1 P;lInl thc "flected arc" wllh lUst
IIII"I)ltll1l) p""'t. If the hilck 01 the ,usle.1 me,1 's accesSlhle treolt tillS
" delo.o frlhflU cml t some w".,. . Th,s COil be [lchl(~ved by tho use 0 1 aluminium o. Illastlc
me sh. or altlflll1l1um t",Joe. AlulIll"'um 0' pl;1strc mesh IS Il.oh"bl.,. lile hest m lar\Je holo. Cut a I>.eeo to tho "pprOXlfll"te Srte ;1n(1 sh[lpe 01 the hole to he frlled. then pOSit lOll It in tho 11010 so th;rlltS ed!leS arc below the lovel 01 the sUffoundrng bodywork. It c"n he ret"mcd in position by sevcral blobs of hiler paste [lround Its per'l)lIelY,
Aluminium wpe should be us ed lor slll ;rll 0' vCly narrow holes. Pull a picce oil tho .011 ond tri'" It to tho apIl r equired, Ihe n pull off the backrng p,1por (If used) and stick th e tape
ove . the hole, rt C[ln be overlapped II tho thickness of one piece is
i nsufficient. Burnish down the 00ges of tho tapO With the handle 01 "
screwdrillC ' or srmllOf, to ensure that the ",po.s securely auached to the
metal undomeath .
Bodywork rCIJ<1irs -filling a"d re-sprayi"g BefOte uSlIlg thiS Seetion, soe the Sections on denl. doep scratc h.
rust holes "nd gash repai.s . M~ny types of hodyfllfer Me ~val'ahlo, but Uonerally spe~k.ng those nrOpnelOry kits which conlain 0 till of f illor paste and a tube of resin h~fdener Me best for this type of rcp,llf A wide, !ieKilJle plured fUlish 10 thc surface 01 Ih c filler , h up a hulc fille. 011 a cle,,,, piece 01 card or boo.d -measure tho
hardener carefully (follow the m"kCI's instructions on the pack) othe.wrse thO folic. Will !>tt too rill)luly or tOO Slowly . Using the
"pplicator apply the filler paste to Ihe prcpared area: draw the
applicalOr across the surfaco 01 tho IllIer to achieve the correct contour and to lovel the fillef surface. As soon /1S it contour that approxim"tes 10 thO corrOCt one is achielled, SlOp wo.kinU the pas le - il you carryon too long the pasto will becomc sticky and begin to 'pick up' on tho
app lic"tol. Continue to add thin layels of Iiller paste at twenty· minute intervals until the level of the filler is just pfoud of the surrounding bodywork Once the IllIer has hardened, excess can be removed using a met;!1 plane or IiIe. F.om then on. progressively finer grades of abrasive paper should be used. starling with a 40 grade p.oduction paper and l.nishing With 400 o."de wet·and·dry paper . Always wrap the abrasille p"pcr IIrOUlld a flat rubber, cork. or wooden block -otherwise the surfaco 01 the frller Will nOI be completely flat. DUling the smoothing of the fIller SUI face the wel·and·dry paper shoufd be periodically rinsod in walCr. ThiS will ensure thaI alle.y smooth linish is imparted 10 the frller (It th O flllni SHIIJO. At t!\l S st1lge the 'dont ' shoul(! be surrounded by a ring of bme
mowl, whIch in IUfn Should he encirclod !.Iy the finely 'feathered' edge
0 1 th e good paintwork . Rinse tho repair nrea wilh clean water, until all 01 the dust I>roduced by the rubblllu·down operation has gone. Sp."y the whole .ep.1ir a.oa with" light coat of primer -this will show UI> any ,mpcrfOChons in lhe su.face of the fll1e •. Repai. theso Iml)CdectlOIlS with frosh 1,110' paste or bodySlOpper, and onco mOte
smoOth the sUflaper, If bodystopper is used, it c"n he mixed wllh cellulose thinnors to lorm a really thi n p.1Ste which is Idt(lllo, "'''ng smilll holes. Repeat this spray and repair procedure until you a.o satIs fied th"tthe sudaco of the filler, and the fe thl'.! pnintwork nrc perfect. Ctean thO rep"ir ;lfea with clean water and .1l1ow to d.y fully, The .ep,," arc" is now ready for 1",,,1 sprilying. Paint spraying muSI
he call1od out in a w".m, dry, wind loss and dus t free atmosphero. This condition can be created mtllicially II you have access to a large indoor working "reil. but rl you nre lorced to work in the open. you Will have to pick your day lIe.y ca.efully . II you a.e working indoors. dousin\J the
floor in the work mea with water will holp 10 SOllie the dust which would otherwise be in the iltmosphe.e . If the ,epai. mea is con fined to one bod.,. pilllOl, mask off tho SUffoundlflg panels; lhis Will hell) 10 minllllise tho effocts 01 a slight mis,match in lH,lint colou.s Bodywo.k hUUlUS (eU ch.omo strips. door handles Otc) Will "'SO noed to be
"';1sked ot! Use uenume fII thon s pray n tes t mea (0' I>enod,cally . insed III w"ter. Allow to dry befo.e sprayinu 011 mOl(l ,laln t
S ilray on t he t op CO"1. "\Jain bUlldmu ull the tluckness by usul9
sOllof1lllhlfl'"ye .s 01 p<111l!. S Ia .t spraying in theCllnlre 01 the .epair mOil and theil, USH\g a clfcular mOllon, work outwards untrlthe whole ropmr
"rea ond al>out 2 inches 01 tho surrounding origmal pallltwork IS COvered Remolle allm"sklng mnteflaf 1010 15 minutes alter spr paint Illto the OXlst lng paintwork . Frnally. apply wax polish
Plastic compOllc"ts Wllh the use 01 mo.o and more pl"stic l>ody components by the
vehrcle manufac turers (eg bumpers, spolle.s. and in some cases major
body panels). reCllilcation 01 damago to such items .hilS .t.>e<:0me a
mOller o f eHhor emruSling relhl'r wOtk to a specialist m thiS field, o. renewing complete components Rep"ir by the DIY owner is nOlleillly feaSible owing to Ihe cost of the equipmen t and materials reQui.ed for effecting such repairs. The baSIC technique inllolves making a grOOllo
atong th o hno of the crack in the plastic using a rotary hurr in a pow~r drill. The damnged pal! is then welded hack togeth er by uSing a hot "" gun to heat up nnd luse a pl plastiC is then remolled an(lthe Mea .ubbed down to a smooth l in ish. I t IS Ifnpo.t3nt that a IllIer rod 0 1 tho correc t plas tic IS used. as body components can b e made of a lIaliety 01 dlHerenl types (eu
polyca.bonate. ABS, poIYllropylene) .
procarmanuals.com

17 8 Chapter 11 B odywork and fitting
If the owner is renewing ~ complete component himself. he will be left with the problem of IlIldmg a sUI1 6
Major u o d y damage - repair
Where serious danHlge has or.cur",d or la,ue aWroperly and. secondly. nneven slresses w,1I be Impos".r nil tli,! S1o:"rmu. (!n\l'n(~ nnrt
Ir 7 Door r The most common C (,1)
Loose door or window winde, ",,,,dft,!; (Ii) Loose 0' lIIiS.lliUned d(Jo, lock c(lillj/olJC!lJl~ (c) Loose or worn relllOle con/iol ""."/."";",i$III
2 It IS quite possrule 10' r,rllies 10 he the ",suit of" [O,,,lrrllirl,Orl 01 111<.1 atrove laullS. so a c;,r(:/ul <.1xanrrrr;riron should he rn",h, 10 ilCIl'UllU1e III<, exact CillrSf:! 3 If cd\Jes A and B (FIIJ . 11 1) should I", p,Hirl l,,) ,md "an he d1ecked by slrrnm\J a torch tlrrou\jh Ihe dOllr \Jap lrom "iJovo 'Irld Irelow the strrker • Cheek the ..
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7 .3 Door striker plate
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(.'----+"<, --'-1 ------<0
00>-----1\.. -~--.
F i!J.1l.1 A lignin!J the s triker 10 lock support plnte (Sec 7)
Edyes A and lJ shoold be 1'.1(.lllel
A
'0- - -- . ,
,'---I.::i.I I ,
--/
F ig 11.2 Lock claw·to·striker cleiHance (Sec 7)
A -70,11111 (028111)
5 Wrlh t he lock in the open positron. check the lock cl milterral on Ihe siroker POSI ,lnd cheding Its hergllt n!tar gently closll1g the doo •. The striker plale call be reposnroned verlrC d lmensron. bw t~ke Colle 10 not to dislurb any prevrous milral se1\lI1gs 01 Ihe pl,lte.
8 Bumper s -removal nnd refitlin g
FrOIll bumpN 1 D,sconnect the u<.rttery earth lend. Also where necessary dis connect the IIldrC 3 Renlove the fOI" bumper rewining screws (pholo) nnd hit away the bumper. On Imer models drser1!lage the bumper corner sectiOns f,om the body side clips as the I)umper IS wnhdrJwn. <1 Refrl1ing r$ the reverse 01 the removal p.ocedure. but do nOI fully truhlCn Ihe uolts unlrl tire bumper is correclly aliUned .
Rear bUll/pel 5 Open the lJ.tgate. Ihen rernOve the mal ilnd the sub·floor. G Remove the Jack ilnd washer water reservOIr (where applrcable) . 7 Remove the two nuts. Sp",l(J wilsher and 11m wilshers. procarmanuals.com