oil FORD CAPRI 1974 User Guide

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I
7
F a ult diagnosis
II)/lodue/ioll The vt!HCI.., ownor who cicIlI s Ills Or he, OWII 'l1;'IIll!:Il;lIl1.;U iu:,;()!(Io IiH 10 Ih o reCOln r11Clldc d schedules should 110 1 h(lv,} to u~e Ilus ~C(,;tIOIl o f Ihe nlCClf'ed ullervals, sudden 1",luIO IS CO"'IIo1I"llvl:ly .;lIC F;'lullS do nOI lISU I,ul " dell"l:lIl1e wOlk w,1I he 1I~'Cess;lIy The OWIlt]! wllo III"kes h,,11 ,I 110/,,11 h,lpll",,,,,1 ildlustmellts 0' ICplaC'IIl'Cllt s II"IV he ~"cce:.sl\ll III
1:"'"';1,1 I""it (or tiS svmplO"'~), hUI he w,1I toe II0lle t ill) W'~H'" 11111 1.11,11 l eC"'I. ,111<1 he m,ly well 1I,llIe ~penlnlOle 1'llIe lind ",olley Ihnll WIIS """"~~;"Y A COdlll ilild IO!JIenl "PIHO,l<.;h w,1I be lound 10 Ix: """e ~,'I'~I;I(.tUlv '" Ihe 10llU lun Alw;IYs I.I~" IIIto ;Iceollllt ,IIIV W,,,""I\l :"!l"S h. ,'IIII11''''15, etc and .cIII(:u,he. thill I,ul\l.e 01 cO"'p0l1clll5 s\lc h ,,~ t\l~'" (J, ~p,"k pluus IlI VellfV Ihe Iilult. Tills IS sII"ply " III,'IICI of hCIIIU SUIC 111,11 you '''''N ".1',11 Ih(l sYlIIl'lOll1s ,lie belolc ~I,IIIIII!I WOII.; T lus IS p;ullcul,IIly ""1"'-"1,1111,1 YOU ille IIIIICSItU"IIIIU i11,1IJ1t 10' SOlllconc else who IIIilV 1101 ha,,, ct(:~c"1r(:d 'I lIe.y acclllately
0011', Ollerlook Ih e obviolls. Fo, e~a",ple, II Ihe IIchlcl!! W01I'1 ~I,'" '~Ih.,,," p(:llol lf'lhe IiInk1 (Ooo't l;1kc anyone t:lsc's word all Ihl$
1).111 'Cul,,, POIII!. ~IId don'l t"l~tlhc luel UilUUC cllhcll) If i1n clCClIlcal 1",,11 I~ ,,,cr,c,lIed. look 10' loose a. bro~ell WIICS belo.e dIUU"'\! OUI the Ic~t !/t;ill
C
U'e tI,e (liscase. n o t th e sym ptom. SuhStltUllng a flilt b.1ltCry ""til il 1"lIy ch;IIW,d olle Will \jt:t you 011 Ihe kUII shouldc., hUI II the \ul(!~dy,,,\) C,IIISC 'S flOt i1Hendel l to. the flew hall", y WIll fJo Ihe SdillC
W"Y S'''"I;nly. Ch,lIlUor,U OII.loulcd spll, k "lu\JS 101 ,] new's\lt W Ill \JCI YOu "'O'·,n!) "11"orl. hUI 'CIIIIIIIII,c' Ihill the .eIlSUIi 10' Ihe lou I",\) (II II ..... ,1~I1 I ~''''!''Y .111 ",colleCI U.;I .
OO'."t t" k l) iH, ythinu fo r g rante d . l'a,"cul 'illll,"U II,ulullllthn hool 10' Illolllhs). "n(1 do,"1 1');I~e compon.'nIS out 01 il 1,1\111 diilUnOSIS ~l:ql""'CC JuSI 1>e(;;I"$C Ih ey ",,1 IIew 0' ,,)cen lly IIll",d WII"" you tio IIIInily d'iI!./nosc a (f,IIIcult lillllt, vou'li ('JrOhllbly .""I,se Illill "lillie cIII(lel1(;c wilS IhelC IrO"'lhc stalt
Elcc(ricall,1!1lls EI.:.'Ctrlc,,1 lilults 1':,1" bc mo,e I)uullnu Ih'lII SI.aIUhlfo,wa,d "'CCIl,11I1CIII lalhucs. hut Ihcy MC 110 less susceptible 10 10Utc;ll "n"IVS'S
II lh!1 haslc pllnclplcs 01 OpClil llon ille 1I1I(lelslOod. Vchlcle clecillcill WII"'!) C~ISIS til c~lIcll1c1y "nl'I\IOIl."lIle condi!t Olls hent, IIlb.atlOIl IIlId chcllllcill ill1l1ck :1ml Ihc 1"51 Ih,,,ys 10 lo,,~ 1o. ,lie 100'>1) 01 ,;OllOIiCI I connecliolls 011,,1 b.oken o. Ch.llc(1 w"es, CS!lCc.I"lIy whcre Ih.) WIll'S I';)SS th'Ollllll holcs "' Ihe bodywork 0' ,lit) suhJ ... :I In IIIII'ilIl011 All '''I.!wl·l,o,hed V .:IHcles III CUllcnt prOdur-IIOn h;lIIc one pole 01 Ihe lI,ule'y 'Cil rl hutl'. Ie connecled 10 Ihu vchlclu hodvwOI~, ilml III
lIe"dy ,111 I"orle'" vehlclcs II IS the neUIlI,v!) ( ) 1e""",,11 Thl) va"OU5
"tU(:lu(:;,1 (:o"'tlOIIenIS mOIO'S, bulh hOI(lll'S elc . ;I.e "Iso cOI"'('''I:I",(1 to e.II III. ellhe. by lIIe,lllS 01 a leild or \1"~'Cllv by tlM}If fIlounllnuS
E I('Ctu(: (:Ullmll flows Ih'ough Ihe CO'I'I)Ol1elll and Ihell hack 10 Ihe b"lIe.y 11':1 Ihc hodywolk " Ihe cO"'I'Ol1ell l mOU1I11I1\) IS l(lOse o. <:olludccl, 0' II il lI'lOci pnth bilC k 10 Ihe IWl1clv IS 1I0t av",!"I)lc. ll1e
CHCIIII WIll be IIICOlllplcl!l "IId m"lhln~l.on WIll le$ul l The e"\)IIIe "lid '0' \)c;IIIKJ O ;lIe "Iso eillthed bv lIIeOlllS 01 flc~,hlc lIIel,,1 ~I,,1I1S to lhe hody Or slll)h,lm(!, II Ihese Sll,lPS .11e !{'osc a. ""5SI11\1, SI;lIlcr mOlo'. !lcllewlOr alld 19",I.on "ouble IlIlly rcsull Assulluny Ihe cil.th .Chlln 10 bc sat,s!xto,y, eleclllCOlllaults WIll he duc ()lIhcr to componellt 11111l1uI1(:I,on 0' to delccls III Ihe CUIIClll ~lIl)l1lv Ind,vldu,ll componentS ,,'C de"lt ""lIh If' Ch;op te. 12 . II supply ""nes "'0 IlIokcn 0' clilcked IIl lerll;lllv IhlS resulls '" iln open,cllcu,!. IIlId Iho eaSleS I w"y 10 check for 11115 IS 10 bypass the SuSpCCI wife lelllPo.allly wllh a Icnuth 01 wi,c hi!lImU (I c rocod,le clil) Or su,wble connCC lor m eilch cnd Altemmillely, 11 12V test lillIlP ColO be used 10
vCltly the p.esence 01 supply lIoltage 011 VilltOUS pomlS along the WIIC
lind Ihe IJle II ;I 1J",e po, lion 0 1 11 hlle WlfC touc hes Ihc bodywolk 01 otl1Cr e;ulhed IIICtal pall. Ih(l cl(:Cloc'tv wIn lale Ihe 10W·fCSlsrance p"th thus fO"II(.-cl bOlck 10 Ihe blllle.y Ilus.s kno",n as il ShOrl ·cifcuil. Hopefully a ShOIl'Clfcull Wilt blow 11 luse, bUI olhClwlse I( may causc bUIO.ng 01 Ihe IIlsulatoon (am! pOSSIbly IU'lhef shall cIrcuits) Of ellen a flfc ThIS IS why 11 .s lIlildlllsable 10 hVPilSS pcrsls telltlv blowtn9 luses wllh silver 10110. wife
Spmcs [II/(I tool kif MoSI IIdllclcs Me supplIed only " 'Ih sutl,clelll 10015 10' whtel chanUII'll, Ihe M,lUl/t:lII111CC iJml millO' "'pi)i, 1001 kll dCWd cd In To()ls a",/ W()'/o:"'Y I.obah!v s .. U'CICIll 10' those .e,)3"S Ih at mOSl n,o!OuSIS would conSldcr atlt~m('JlInu al the ,oildslde In add ,t,on a lew Il\)ms whIch C(ln bc I't\(:cr
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20 Fault diagnosis
Carrying a lew spares eM) :\l1VO you a lono walk!
WHhou t 100 ,ulIeh trouhle in the event o f il hrC S ,Im/( I"uys. dm/JI .1IIri ,:ollt'c/ly Y;'I/ II"(/ III h:;J(/ .~/I{I"III!lI:,lIJ {II"Y .:1H>II1I" to 11).11:/0 /I" .. fllllY '(ltllu.'.\'{ fit"" lin-,/lsllI/w'IIt
DrHII/mim [(JIm, (:lIlIdulI.~VI IIlId C""Ii":II"'HI~'." I'omls (;'s ;,/I/lII(.','I/)/e
IJllv/.'lmll(s) ,.'/I11:II/VJlCY IYl't' m"y suffu;t, SlIill!! {(I,ft'S S •. '/ of //111//:'/1,,1 "ylll bill/,S 1/1/ 0/ ",dlll/Ol 5<:;,11:, ,mil IlOst: '>,md.1UI! t"~II;III.1'1 /),111(1I1!IC Roll OlllllilJIMlt/y IIIl'l' Lf>llylll of sulillflll WIIC Lc"yllt of ci.:cIIlC,llllt·.
rUiC" Of mSIICC/IQIII;III'11 (eilllliot/blt' ;,S II.'S( I;IIIJIJ) OMlt'IY 111111/1 Il'mls Tow" Q/IC Iym(/Oll WJiClllloo/lllY ,ow/osol Llfll! 01 c"Yllle Oil SeMcI I eMI olltyr/wlIll(: /f",d Emeif/CoCY WII/({SCIt'ell W(JIm ({live cl'II$ Tube 01 Idlel IJ,1S((;
II Sllilro IU(l 1 IS Cil",c< I .• 1 Ciln dcs'Ollod for th(l pu'pose should hc uscd 10 m"l",l(~e rrsks of le ohvlOusl y senSible ilems !O carry u addl1ion 10 Ihe nbove When 10urll1g nll,oad 11 mny ue advisnu le 10 carr y nddlllonnl spares
WhiCh, evon 'f you cnnnOi III thcm yowscll, could snve hav'"(J 10 Willi wh,le p Chi/eli {JII( I (/U Ol/it' eab /es Cy/md/H " ",7/ IIPsll:rn AlfclI/MOt /)lIIsiles Fllel (Jump 111/1.11'1 11:11 Tyte va/vI! cote
One of Ihe 111010llng 0'ganlSilll0ns w Engine w ilt no ! starl
Ellgillc taits 10 ((IIf) W/IL'II slilrlc r ()p vra le d 1' 1;11 h~lll.'ry (.ud,;,,!!,!, u~.., rlmlll'uolds, 01 push Sl.1rt) nnllclY 1(:rnllll.,ls Ions!! 01 cntlod,!d BaltelY ll.1,tll to hody dd"cl'vu Enwnc e(utll S I,,1)) 100Sll 01 broken Sl.1rtel 1II0lO r (or so lulloid) "",,,ng loose or IJroken
l\ulOn1 ;II,e II1!11srllr~s,()" seleClor ,n W'OIlIl pos",on, or Inhd)!' sW/lcli fHur,y '11""'Oll/SI (lr lu, sw,'ch folUllY
M i'ror mech:u"C.11 ,,,,lure (Se'lUre)
Sli"!~1 Or sole"ord 'ntorrloll rilul! (seo Chaplllr 12)
A
simple les t lamp is useful fot checking electrical fault s
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T
Fault diagnosis 21
Starter motor ((/rns cngino slowly Parti ali V disch~rilcd b sian) Ballerv terminals loosc or COli oded Batte.v earlh 10 body delcctrvc Enuine ear th s tr,1p loose Slarle. motor (or solenoid) wiling loose Slaricr mOlr ill1crnlll laull (see Chaple. 12)
Engine ((/"'S normally but 1,1ils ( 0 SIMI Damp or dirlV HT !eads check 10 ' sp regnp) Olher ignilion syslcml",,11 (~ee Chapler II) Olhel luel sySlem 11Ildl (se c Ch"plm J) POOl compression MaJOf mechanic;1 1 l Ellgine lires but will not fUll In su!hcicnl choke (cold flfl!)lIln) Arr le"ks al CilrUurC110. 0' mlill m;1",lolli FuClI sta,vatlon (sec Ch"111C' 3) []"lIast rCSIStor de!ecllvn. or OIlier 'H",II Engine ClltS Ollt ;1nd wilinOI roslinl
fngine culS out suddenly -ignition I,wlt Loose or d'$Conncetcd l T wi.es WCI HT Icads o. d'S I"buiOI C;1P ("lIer tr;1VC'SOll!) w;1'er spl;1sh) Co,1 o . condenser lallulc (cheek 10' SI);lIk) Olhc. ignition laull (see Ch,'plfll 4)
Eflgine mistires belore CUlling oul IlIcll,wlt Fuel I,,"k Cillply Fllel pump dClfecl1vc o. 1,ltcl IIlo .; k(H! (dwck 1m dellvl"V) Fuel tank hllcr vcnl blut;kcd (StII; llon Will II" flV,{Io"'1 Oil lI~h"'~II'H C,11l) C;1llJulCIIor nccdlc v"lvc SIII;klll!J (WIU.'1I1 "ppI1c"hle) C,1lUwellor leiS blocked (ha:l COIII,lIl1ln,Hcll) Othcr lllcl sys!Cm l DISCHARGED
BATTERY
lSin.MIN
POSITIVE
JUfl11) Slart lead conneClions f o r neg!Hive earth vchicles­connect le;1ds in orde r shown
fllgine euls Ol1t -olhor eimses SCIiOliS ovcrhC~ling Mnior mcch Engine ovcrhe Igllitioll (llo-clwrgcj wt1fllillg IigM illuminated SI;1ck o. broken d"vchelt felCn$IOIl 0' Icncw (Ch;1ptr,r 21
Ignitioll warning light /lot illuminBted Coollllll loss .Iuc 10 In!emnl 01 CXierr'JI ICJk NOIC: Do 1101 ,11M coM WMCf 10 ,111 oV~-f/"'.I(C(1 ~·lIy"'., Of d,,,",l[Jf1 m,ly I/)SII/I
l.ow cnuinc oil JlfC!ssuro
G,wge reads low or warning lighl Illuminated wilh engillc
rWllling Olllcvcl low or mCOlfeel 0.,,<10 Deit.'Ctivc gllU!jC 01 sendCI 11111 Wife 10 sendCI UIII' C.1I.hC(1 Engonc ove.hC.1l ing O,lllllcr CIO!19c<1 01 byp,1SS v;1lvc delccllvc O,I ,llcssule lehef v'llve dc!ec tlve Oil pick-up strllll,e. ciomled 0,1 pUIllP WOIil or IllOlllllll1\l~ I\,osc Wo,n Ill,l'" 0' h'!J-cn(i hC.1I1I1!)s NOlO: Luw or! 1"t'HlifU III a IImh III"C"f1~" (.'IIYIIIC .J/ 11l;~()VI.'r I.~ 1101 1II.'I:<.'",.","/y,1 (.",lIlSV {o, CIIII{:"/U Suddel! fJf'~SS!lle {U$S ,11 SlIced IS {M "'/!IC SI{Jl!lflca"l (I! ,my cve/l/. .:In',·j. I/le . Crank engine and chock for Sl)ark. Note use of il)sulated tool 10 hold plug load
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En!J"lO noises
Prc-;f/lli/ioll (plirkiny) Of) ,1Cce/efariOI) IncouCCt W .... de o f fucl '!IIII ,rOn IImonU OIlCOOlCCI
DIMlrbulO1 l,lUIiV or worn
Wnrn 0. IllIlI;1(I,u5tod cil,l)urcnor O. Idling setlrllgs EKCCSSIV(l c;uhon htuld_"I) In cnuulo
Wl!i~'llil/!I or wheeLing nuises Lc,,~onu V,1CUUI11 hose
L""kllllJ Ci'lII),I1(:110 1 0. lIl.ulI/old !FI~.kcl IIlnwlIlH IWild U.1S ~Cl
Fault diagnosis
T,1pping or mUlillg InCOlroC I v:1've clcil,.-.nccs WOIll v.llve flO",
Broken ,)ISlon "no (r,cllm!! nOIse)
Knocking or IIWI/Ipiflf/
Unlnlenllon,'IIll(!ch"'"Cill t.:Orl! I'olll) h o.,,' COllltlOnonl 1,1\11, (HCIU·<.1t{Jr, Will'" !>lItH,) ,-I':) WO", !Jlu-end h(l;u"'!IS ('f)!JUlolf Iw,wy klladuHI jH',h.II' un
de.IO;'1(I)
'A'0'11 Ill.1U) be",",!!S (',"nhhll(1 a'lOl ~n()d''''!1 I''''''''')~ WI'" undcr IOild)
P' Slnn st,lp (mo~t 110!I<:1!;,1>1" when cold)
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Chapter 1 Engine
Contents
Par! A: 2.8 litre engine C;JrllS llaft and CillllShJft be,lrIllgs (;XilOlllllilllon ilnd renovil!"Hl Cnrnslwft and frenl inlCrrned l,1!C pl,ne rcfl1l"l~1 Connecting rods ;lnd gudneon pons c",,,nlO\,lllon "nd
,enovntion
C'nnkcnsc venlll;Jl,on Systelll de~Crlpll("1 C' Englile dlsrnill1tlin9 (IlUmc -ulIlI,,1 SIMI up E"U"'() rehl(ml) [W)lne -rcmova l EnOme nnc,lInries -,ell!I"lU~ E'''9''0 ilnClllarrcs -Wlllov;!1 EnOone componentS -eXi!rlllll.1I'O" lor wear En\)IIlC dtsmant lm9 -goner G"ncr M.llo. operat,ons posSlblc WIlh enWIlf! rr1 car
M "IO. operatIons reqrllJlIl(J enOrrr() ,enloval Mr.:lhmb of cnll'nc '(:l11ov;l1 011 IH"'lp rl'~m.lt)ll'''g. eXil,nrrr"l.oll and ",,,~~c"'lrly all pump 'ufrtlrrlU i'lslo"s and C P;1I1 B . 30 IIlre oily/lie C"",\h,lll ",f,1("UI C;1I"~lrafl ""no·"',1
C.""sl>"fl
and c. ,nrsh;rfl !re,'rr'IO~ 'JX,IIllrrlaHon ,mel 'CIlO""l lun Corr'lectorry ,ods and yud(jeon p illS exa"'"'ill,on Cr, lrr
k
c"se vClrtdm,o;, ~~s·t~nr descJlPtlon ~"lrrhlr.,ft ()x;r'l1Ill,' I'On ,IIHI ,...,novatlon C',1n\;slraft ",I'illlI9
Spcciiic;ltions
P,11/ A · 2 8 li(ro engine
General TI,pc 130<.., St'uk..,
Cul)Ot Cilp " 28
'" 25
'" 27
" 15 :j~ ,
38 37 6 :\G 8
" 7 26 22 3> ,
24 20 3 4
;.>3
30 29
" 12 ,
>0 33 >3
" 32 :J5
70 b7 G5
68 77 GO 80
Cliu,~sh Cylonrle, ho'es " '.'"\1("'11011 ,H,d ,cnoval'o" Cylll"I", heads ,,,as~r""I,ly Cylrnde, h("uh ",f'll""1 CylrlH)." he,ub """"v,,1 wulr "'l!)rr1fl '" ca, Cyl",{i(H he;rds """ovill wllh CUlJrllC o"t 01 car Oec,rrl)on'\II'\J \1"'le",1 E'l EIl;I'"C ilIlCllla"o:s
E'''!JI,t!
,me,I I,IIII:s
[Il!!"'" C"" 'I)O"o.;"ls E"B"'e (1'~Ill"nll,n!J ['"1''''' ',~,'s','''''I,ly Hywh",,1 ,,,,,,,,val
I(;j,wou
""IIov.1 1
\)0)'\1),,11 \1("",,.11
Flywir""lld"""plale f!X ,I!lUnil l(On allli IflnOVill lo n
Front covc, ,cmov.11 Gcm:ral descI,pt,o" lub'lcat,On syslmll (Icsc"pt,o'l
M,1I1l a"d hllj·C"d h"""nys I!x.lrn,nilt,on ,!I,d 'enov~'t,on Ma)o' OJ),,r,rl'OIlS possllJle w'th ""\JIllf! orr C,If MalOr op,,' 001 P"'''fl ",hI I"'!! Od pw"p ",,"ov,,1 f'1~((JI'S ,IIul '.(111''''' :111''1 '0(1,; ,,:I, tl,n!!
1 ",1011'; ,11,(1 P'~lOIl ""llS (,x;r"''''''l,on ,,,,,I ,cnoval,on PI~,1Orrs, ct)"rrr.:~trrro ,,,ds .lIl(f hoal lllO,; removal n,),11 0, 1 s('ill ilrld flywlrcr:1 rcl,tlll'(j !'loclq" Hock", a""s ",,"o"ill nor.k v ' a'IlIS ;rnd C()V,~'S ,e flllll1ll . I~O\lII"V m;r"llell.,nC(!
SU"'P r,1pl)('l __ "ri d plIsI"ods ex.rrnlll.1t'OIl ,rrl(f ,cnovallOll Trn"n(1 Ilc,II'; cx,IIIW,;rl lO'1 ,1(1(! 'ellOV Trn"n\1 I)C,lr'; "Jmov;,)
T",,,,,O
IIC,"~ ,'(ld frO"l plale rcf Valve c.1(;'U,rrlCcs cIrCl!k,n\) and ;ru lustmCII I
Valvcs ValveS arrd valvc SIJ;IIS ex;","nJI,on ,md renOv Part C: Fault ditlljnosis F;rull (f' G ·cylrndc, ollv \II GO V fu,rrrJl,on 9303 mm (3 663 ,n) 6850 mm (2 697 ,n) 2792 cc 92 1
61 52 60 66 86 87
" 48 74 92
" 44 00 46 62 45 78 53 72 55 30 76 70
" ~2 43 7 ~;
82 58 81 67 50 84 63 50 88 40 85 !.>.1 !i l 6,'
" 56 83 59 40 73
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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'~P mm (m) Top. CClille BUliom
Connecting rods BO!I "lid IHJ.IIUI!IIUn'UHU r, h: ;,. ;uu";C m ... (m)
V V"lvI! ~1I11"!J (11)1] 1''''WI, "'III (,,,) SlcIII III !lIIId" CI0.);1I"'1I:1) ,,,'" (II') 1,,1,,1
E'h,"'~I
Lubricatio n systmn e"p.1';' ly W,t h t,llc' W,thout hll(:' 0,1 p,eS~I"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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26 Chapter 1 Engine
PART A, 2.8 LITRE ENGINE
General dcscril>liOIl
The 2.8 !lIte cnnlne IS of GC,Il1;l1l V(l Qve.hctld v01l0'11 ollhe clankcl'ISC IS a pressed steel sump whIch ,lets ns a "'~"\lOIl fa. the cnWllc 011 I\hlll1l1l1lll11 ,1110y p'Sl0ns illC conl1CClcd 10 lhe Clanksho1l' hy ~I !.1·C"OII 10lucd s'l~1 COllnCChng lods ,1n(l glld\Joon pillS Two I:Olllp'f'SSIOII 111'\)5 a/HI onc 0.1 (:onllol Illig, ,,11 101:;111,,1 al,ov(! lhe !llulgtJon 1)111. alo Io110d. Till) la'lIed c."nksh"'1 ""'s in lOll' ilia", iJca'lI1gs. and en(lIioal 's (:Olll.ollcll hy II110M w;lshc.s 00 No 3 1I1;lIn bO~'IIl!J. The dllv(! 00'" IOf
the d'SI"hutOf ,m(t 0,1 pump is located in flont 01 the 'Oil! Cilm bC;1rIog lub"cation IS by means of a bi-rotor 011 pump
2 Routine lll;lintelHlnco
I\llho inlo.vals sj)ecilio( in 1110 Routine M~"'lcn,1ncc $CCllon II from 01 Ihe m~nll;ll carry 0111 the 'ollowlng p.ocedu.es.
Change engine oil. renew otl tiller olld clean oil filler c. 1 Apply Ihe hil"clb.~kc Ihon jack III) Ihe lrolll 0 1 Ihe Cill and Sil l on ilKlc Sliln(\s. Alle'nnlively pOSll10n Ihe Cill ovc. ,111 ",~pcCtl(ln I 2 rlace a SUlliluh:1 cont~Ule. beneillh Ihn sum1) Ihen tlns.;."w dHun ph.!) (photos) ~nd (If""' the 001 3 Wh.le the o,l.s cI.,}lninu unserew Ih" 0,11.110. '-:;111,,<190 USII'H a' wl()nch ., Clean Ihe d.;IIn plug and Sltllllllhen ,elll Ihe pili!) and IIUhl"!! 5 CtCill1lhc IllIer COlllil(:1 mea 01 11i(, CXlenSIOII blackc. 6 Sme:1f a fIlm 01 enUlnc 011 011 Ihe now 0111.1Ir,. ",hhe. u,'~k(" I screw lion IImoi " JlISI CO(l\;1CIS the t"n~k"l 1 ,1(:(, (photo) 1'",111
Fig. 1.1 EKptoded v iow of tho 2 .8 titro engine Illain c0I11I)ononl5 (Sec 1 )
I T!,ellliostnl hUl/slII!) 5 U y poss /Just! /l,J/Jyc
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Cr;III.sllllll gear 13 Od pump dflVOS/l,l/l
2 'h':III.ostn/ 6 Ifl/.:1 " ... ",ilold 10 Flywheel 14 M{J;n b e{Jflng CilP
3 W,J/er PUJllP , C{J/lJS/",/I/llfI/SI/J/OJ//! /I Cr{Jnbh procarmanuals.com

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) Chapter 1 Engine 27
oint t ighten II ~ further 3/4 l urn ~ Remove the t,l ler C,ll> all the left· hand side of the engine and I,ll the g ine with th e correct quantity and grade 01 od (photo), ;n RemOve the OIllcllcl dipstIc k and wipe it clenn. th en fe -insert'! and emove it Jg grourod. 9 If neCeSSary. lOp up the level nOI1l19 thaI the diSlnncc between the minimum and 1l1.1X"mHll level marks rep rescms ,1pprox imil\cly 1.0 hIre
(1.76 p int). 10 CICJfl the 0,11,1101 CilP then refit il .
Check and adjust valve cle 11 Refe r 10 SeClian 35
hgMel) inlet manifold bolts 12 Remove the ,111 chamiler and \'oh\on the Inlet 111.11"lold hnlls ({J the spec ified lOrque WIth Icfcll!IlCe t o Ch~ptl!r 3 On compl"I")1I ,(:111 Ihe
JII chnmbcI
R enew (fie crankcase ellli,~sion valve 13 pulithe v(1lvl.' (1Pl(I'hose 1'0111 tlw leM 0 1 Ihe "ohl·l1(1nll locker caver
(photo). 14 [1.clc;lse tile cl'll ill1<1 ",movc the v(1lve foorn the h ose 15 Fit the new valve.n levr:rse ordel
3 Major operations possible with eng inc in car
Thc fol lowrng ma lo r operat,ons Cilrl he C;1 (,1) Removal al>d rufilliny ollfl~' cyh,,(h,r heiufs (h) Removal ami rehlllilg 01 rocker shall aml/lllslliods (e) Rcmov,11 ,m(/ ,elilllilg of {'Or!( elwine mOllnlings (rf) R/,fIIov,rI ,11[(/ reliltirry 01 (lie flywlleel (geillbo>< lI:muved) (t') Remov,ll amI rufl/liny olille Slimp 011(1 oil f)(!fIIP (I) Re/IJov,)1 ,11111 rehltiny of Ilw liming yl."ilf$ (y) RCIlIOvo1l ,mil relilliny ollhe biy-crlflln',llinys
,
(It) Rl.'tttOV,ll ollnf ,ellllmg of IIII.' 1".'·(Ofls ilfld cOrlfleelmy rods (,) Rcnewal 01 tI", c ,i/nkslliplt 11(1,,1 Sl'it! rtI IIIIII"y C(lVCI
4 Major operalions requirillg erlgirlo rO!lloval
T he followlllg IHaJOI opernl'OIlS ,,,.IV I", Cill!ICli out ilfl'" 1t'l\1o,",ll of tir e englllC:
(<1) Rcmuvi" iJllr! Id,lllIIY 01 If." ,.,.ttt~Sfti"l .,11(1 II>,1ftl 11,-,tlIIIYS (IJ) !1ellclV,11 ollfw o,wksft,dl II'." .~,.",
5 Methods of engine removal
Althol!OIr It ,~; flo~~lllle to .. ,1)1,,\·,· tI .. , "WIlli': .:Illd U"iU!'vX ')IIlg \IIldCllilkcn 'C'I"''''~ Ih ... 1(,IIIl ),,)1 of tl .. , \i,),IIbo~ ,IS well as the (:1l!1" 1" ,t 's l ecomnH:lld,'pJ 11\,11 tip,) O",Hho x 'S ,,,,OlI<.)v()(1 fr'~l (nil"r to Chap('" 0)
o Ellgino rcmovill
II IS t',,-,,.'IIII.-,1 If! h,v" <1 fl ,. '~ , I\; , .,
28 E[lO"lc 011 levI;[ d'pstlck ma,kll1gs 2 13 Removing the Cfankc<1se cnHSSIOIl v<1lve
62 Ea'th cable Oil the alte'''''lOl adl"slIllt:l1t u,,,ckel ( ... ---------------------------------procarmanuals.com

28 Chapter 1 Engine
al1crn;1IOf ,1d,ustmcnl braCket (phot,,)
3 Dr,un the coohnO SY~'cm <'1nd ,emoll" IIw 1,1<1'.1101 ,1S (InSCribed "' ChnplC' 2 6 DisconneCt the h'nkc SCrllO vacuu", h 050 Irom the "" chamber 7 Disconnect t he IIllel duci hom the ""onlc hOusln\) and nH~tUlc control 111111 8 DIsconneCt the IIl.on'e cilhle w.lh ",1.·",,,c(1 to Cha,l le. 3 n Pull the CC"I"~ itT ICil\, lmm the <1",,,1,,",,, C.11> ,l oll PO~I1,on (Oou" s,dn
1 0 D'sc:onnCCl ,hc mirth plUH I.um th., ,1"""'''''01 11 DISCOIllH:CI the W""lO hum th" 1""'I~".ll",e IFllI!)U scnd...,f 111'" (phOlo). lhc.mo!"1111 SWlh:h. Wi"'" "I' "~I"','IOf. i!uxlh;uy ;111 ,r.'VIC' ~ ,1nd coli! Sl.1.1 Vil!VO
12 UIIS, ;I"W Ihc '''11 011 ,,"1 and dl~r.",,,,,', I Ih" O,! lI,eSs,"!! !F'U!JIJ h"" (phQlo) 13 D,sr.UIII'ccllhe IW"h "d,le hOOIlII,,'II,,· h"lkh(:, 1d (I,hnlo) 1'1 rO~lllon ,I ~\lII;IIII" 1:01\1,,,,,,,, 1'''''''.,11, th" I,owe. ske""!1 '''''''I' Ihen <11~(:ollll'~':llhe ilu'd ho~es (CII0 17 fl,mIDv" Ih" 1 8 AIIl'ly Ih" h,~"dlJ,,'ke tlll '"I, ••. k "II Ihe 110111 0 1 the c", alld s"PI' 011 il~lc ~1,II,ds 19 A .m'ovo: Ih" s.,~llcr mow, ;,~ d,.:, ... ,hcd III Ch"",c, 1 '} 20 R","ov" Ih.] clu lC h c"t,le 1"JlI' Ih,~ \I";"b()~ wllh ,.,1'''I'I'CI; ChnplC' 5 2 1 U .. 0>1 .... w , .. , d ",'novc Ih" 0,1 r,h,·, <;."!II,I!lc ($1:(:11011 21 22 OI~,"("'''''':1 II", hoses "011 II,,· " .. ,,,,,Ic. 23 U~"I!I .1 '/7 ",," sll;mn,,, "" .... I .. W II,,: ~,occI.11 nul "",:"IIn(1 1 IlxIClls"'" h',II.k',1 II) Ihe 0,1 c(,,,I"1 H","m'c thc h",o,:kcl. 101Io.:!I"" w III UIII,ull th,· !w;"I)O~ !1Il'" 11"" "!I"'" "d,'I,T(JI 1'10110: '}7 Lm'''' 110,· ,;," 10 Ihc WOlIn"~ 78 51'1'1''''1 II." !I,·,uhOx willi" 1",11,,\' I." I 29 All."" " 1.""'1 10 II", "n!I"'" , .. "I i"',1 I "~,, ",. W"''1J'1 I" ''',11101, ';I'!I"'" ".,1 .. ", "." ~",t.1hlc "I.~ ,. I", "II,,,·, I ,I~: hlll si cll., , ... '" .""UI th" h""1 " I II,,· ,:.h,'"~1 ",.",,1..',,·, :I() T" P"""'" d, .. II.tUC 10 II" , ,~., h,I" .. ,,, "'I' ,"" . ,hI", .""'. "'m" 110<:111 ""I" :,.1,·,,,,,,:,, '0 Ch,'pl'" I
: n li,,~, "'w 110" !JI',)lhO~ III .. n" ",. I,,,t ...
:17 n." .... · II ... ""~I"": wh,'" ~I"': '''I I ... • ""'1"'" """,nl""I', It",,, It :.II)lh·1I I",,,~, ... 11'1,,,10) Ii "',' I,.. I .. Iplo" III "'''''I.I",,· ly ''''''OVI: I I
"!II'I h,""I""""'I"", W,lh II,,·, '"I''''' ',lI~"'" I,·,,, ','I I,,, I", .. ~, .... . P' ,I I"'W,IId·,! .. ol""'II""! IC ,I 1«,,, . tl,,· '1··,,,1,,,, ,,,,01 (,,,',"1(,,, dll""'''' :C! Wh,'11 110.· , Io,t, 10 IS ,I",,, "I II,.. '1,·.lIIH" "'p,,1 "Io"! 1 loll tho: "'''111
III"" Ih,' ""'1,1", """I~~'I"'''''I '\',,1,· ."",toll" ,I " .. ~I II", '.""("",,",, , '" "I" "', ''''', i pl" .. o 1
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G 4A fl"nlovlI'g Ihe QXP,IIlS IOlt t.1l1k "'O[l"III' U b,.1Ct..CI ujlpc, ""
,1nd lowc. Sr.ICWS 6 11 TCI""c",t".c U'lUge stJOdCf U 6 12 0,1 P'~SS'"C gauge IInc (llo0wcd)
.--~--. ...-,~ .. - -.-... -"',
6.13 Rcmo~'ng Ihc ea,lh Cllb le I.om Ihe bu!khe"d 623 IlcIlIOI"'!)lhc C~I~ns,on b,ac~.et (,'lfowedl trO'1i Ihl' 0<1 COOle,
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