FORD CAPRI 1974 Workshop Manual

" .... Index
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Engine -23 cl $cq Engine (2 .8 litro) lmcillllries -29. 36 camshaft -35, 41 components e~aminlltion for wear -34 connecting rods -37. 42 crankcase ventilation system -39 crankshllft -37, 40 crankshaft pulley -44 cylinder bores -36 cylinder heads -35. 45 description -26 dismantling -29 fault dingnOSlS -20. 56 flywheel -38. 42 front interm!.lt hate plme -41 gudgeon pins -37 lubriClllion system·-39 main Il!ld big·end bellrings -37 rll(lintenance, routine -26 OIl pump -38. 42 operations possible with eng :ne in car -22 op(!r;lIions rC'quiring engine remov,,' -22 iSlOn rings -36 pistons -36. 42 rC(lssembly -40 refining -46 removal -22 removal methods -22
rocker asscmbly -34. 45 spec ifications -23 start· up after overhau l-4 6 sump -34, 44 lappets ;:and pushrods -35 timing covcr -43 timing gears - 38. 43
l orque wrench senings -24 valvcs -46 Engino (3.0 litro) ilO)cill:lr ies • 49. 55 camshalt •. 50. 51. 54 componcnlS e~.-.minlllion lor WC:lr -34. 51 connecting rods -37. 42. 51. 52. 54 cr.-.nkshMt ventoilltion system --53 Crank~hllh -52. 54 Crtlnkshllh pulley -50
c .t1nkshaft rear oil seal -51. 55 cylillde. bores -36. 51 ylinde. hoad s -49. 55 decarbonising -52 descrif)1ion _ 47 dism.-.ntling -29. 49 faull dingnosis -20. 56 lIywhecl/d.ivepl(lte -50. 52 . 55 Iront covc. -50 hOn! plate -54 gudgeon pins -37. 52 IUbricntion system -53 main and big·end bcarings -37, 52 mainten(lnce. routine -48 oil pump -50. 52. 54 operations possible with engine in ca. -48 operations requiring engine .emov,)1 _ 48
piston rings -36. 51 pistons -36. 42. 51, 54 push.ods -35. 51 reassembly -40. 54
refining -56
removal _ 48
removn! methods -48
rocker arms - 49. 51. 55
specifications -25
sump -
50. 55 pppels -35. 50. 51 !lming gears -38. 50. 52. 54 torquo wrcnch sellings -25
.
villvcs -46. 49. 52. 55 Exhaus t syste m remova l and refining -76 EMpnfls ion tank ( coolin g sys tem) removal and refilling -64
F
Facia pilnel t(!mov,)1 and rcfining -188 Fan hub bearing (3.0 lit r e models) .encwal -64
Fan. viscous d rive remov,,1 and refinmg -63 Fnllli (Jingnosis -19 et seq Fault di,)gnosis
lIulOtl1allC lrnnsmrssion -127 tJ,nkmg system -156 Clutch -101 coolmg system -65 clectf1clll system -19. 233 cnlline -20. 56 fuel system cilrbure uor - 85 lucl inlCCho n -85 IHn,hon system -96 mllnu .. 1 !Je.l,hox 122 p.npeller shaft -131 1f!.1f FrOIl! cover (3.0 l i lre engino) reftlovnl 50 FrOllt dir oc tion indicator l c; ,hper
oved'lIul -
145 remov r emoval and retnung -215 F ront log lamp ')nd bu lb
rcmoval ilnd rcfilling -2 I 5 Front suspen sio n COIl sprinU removal and refIning -162 duscnp tlon -158 fault dIagnosis -172 h\,bs-161.162 milintenance. routine -161 stabiliscr bar removal and rcfming -163 Strut removal and refilling -162 lorque wrench sellings - 158 track control arm removal and .elilling -164 Fuel (/lid exhaust systems -66 el $eq Fuel filler cap .cmoval and refining -188 Fuo l injection syste m ')CCclcflltor cable -74. 83
air Cleilller -80 deSCri ption - 77 exhaust manifold - 85 fault diagnosis -85 fuel lank. s&nder unit and filler pipe -83 idle mixture ,)djustment -82
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inlet manifold - 83
main system components remova l and refilling -80 m~intenilnce, routine -79
specificiltions -67 to rque wrench settings -67 Fuel pump carburettor system cleaning - 68 re moval and refilling - 68
testing -68
fuel inject ion system removal and refining -80 Fuel system (carbureUor) accelera tor cable -74
accelerator shah and pedal - 75 air cleaner - 68
carburetlor -66, 68 to 73
description -67 e~ haust manifold - 76 lault diagnosis -85 luel pump -68 fu el wnk -73, 74 fu el lan k fille r pipe -74 fuel tank sender unit -74 inle l manifold -75 mainte nance, routine -67 specifiCiltions -66 torque wrench senings - 67 Fue l tank cleaning and repai r -74
filler pipe removal and re fi\ling .-74 remova l and refilling -73
sender uni t removal and ref il\in g -74 Fuel tank sender unit (fuel injection models) -83 Fuses
G
general -220 specifica tio ns - 199
Gearbo~ see Manual gearbO K Gudgeon pins - 37. 52
pdbrake adjus tment -153 cable(s} and rod removal and refilling 155 lever removal and refitting -154
warnin g hght switc h -225 Headlights alignment - 212 assembl y: removal and refilling ~ 211 bulbs renewal-2 13 Heater assembly: diSI11(lntting and reassembly 8ehr - 19 4 Smiths standard and heavy duty -196 assembly: removal and ret.tting -193 contlols
adjustmen t -192 removal and refilling ~ 1 93 water valve (heavy dUly heater)
removal and re fitting - 193 History o f tho nlodal-5 Horn faul t tra cing . remova l and refilling -220 Hubs, front
bearings renewal -162 removal. ret lu in g and bearing adjustment -16 1 Iraulic systam (brakes) bleed ing - 152 pipes and hoses removal and refilling -151
Index
Ignition switch and lock -224 Ignition system -87 el seq Ignition sys tem amplrlier module (2 .8 l i\(e mode ls)
r emova l and refilling - 94
condenser (3. 0 litre models) -90 COntact bre aker points (3.0 litre models) - 89
description -88
dis tributo r -
90. 92. 93 fau lt diagnosis -96
firing order -87 mainteMnce. routine -88
spare plugs - 91. 95 speci fications -87
t im ing -94
torque wrench settings -87 In strument cluster ill umina tion switch -224 removal and refitting _ 221 Instrument voltage regulator removal and refilling -226 Interior lamp and bulb
removal and refilling -217
J
Jacking -7
L
lubricants and fluids recommended - 17 lubrication chart - 17 lubrication system
M
2.8 litre engine -39 3.0 litre engi ne -53
Main and big·eOld bO(lrings e~amination and renovation -37, 52 Main bearings (3.0 litro engine) removal - 51 Maintenanco , routine bodywork and fillings d oor ch ec k straps security check - 16 locks, door chec k Straps. tuellilte r C upholstery and carpets - 17 6 windsCtee n illld windows cleilning - 16 braking system
h andbrake linkage lubricat ion -16, 144
h ydraulic fluid levul check /lap up - 16 . 143 hydraulic flu id renewal -16. 144
line s and hoses check -16
pads ilnd shoes we." check -16 , 14 3 servo check -16 . 144 vacuum hose check -16 Clutch adjustment chock -16, 98 cooling syslem
coolan l leve l chec k/top up -16, 59 coolant renewal -16, 59 drivebelt condl tion/wnsion check -16, 59 leaks check - 59 electrical system
ballery elec tro lyt e leve l cheek /top up - 16. 200 equ ipmen t opera tio n check -16. 200 headlamps cleaning -16
253
'i
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2"4 Index
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ligh\s operation check -16 w~she( fluid levels check/lop up - 16, 217, 219
engine
crankcase emission valve renewal -16, 27
fluid leaks check -16 oil i1nd filter change -16, 26 oil filler cap clClIning -16. 26 oil level check/lop up -16 1I;llvo clearances check/adjust -16. 46
exhaust system condition check -16
fuel sySlCm exhaust -85 Inlet 83 M ,lIlua l g e o
removlll and relltting lldjustllble exter ior -192 interior -192
Oil pump
p
28 Iotre engine dismantling. examination and re~sselllhly -38 ref in in 9 -42 3 0 li tre englllc dismantling. eX~lllinmion ilnd reass embly .-52 [elit\lng -54 removill 50
Pedal ,1cceler,ltOr 75 bra k e · 152 clutch -101 Pisto n an d connec ting rods ref,nin\j -42. 51 Pistons and pisto n rin\js exanllna\lon ,1nd rcoova\lon 36,51 Pi sto ns. connecting rod s il11d bearin\js (3.0 litre cngine) [lmlov,11 51 Propeller shaft 128 d s, .'r/ Prop elle r shaft cenlre bcarln!J r()"l]w~1 12!J
descrip1l011 28 I"ul l (i iaunosis - 131 removat and rel,UlI1U -128 10rque wrench seHlIlgs -128 univers~1 10lllts inspection 130 Pushrods 35< 51
R
Rndi,lto r rel11ov~I, Inspcctoon, cie rear hilckpl~te removal and rclluin(J -148 shoes renewal - 14 6 wheel cylinder removal, overhilul ~nd ref'lllllg - 14 7
Rear lamp and b ulb removal and refttling - 216 Rear number plilte lamp and bulb removal ilnd relilling -216 R ear su spension description - 158
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fault diagnosis -172 leaf spling .emoval. bush renewal and refitting -165 maintllnance. louline -161 shock absorber remoyal and refitting -165 stabiliser bar removal and refitting -165 lorque wrenCh settings -158 R"ays -225 Rep.ir procedures, general - 9
Rocker e rms (3.0 litre engine) examinat ion and renovation -51 removal - 49 Rocker arms and coverl (3.0 litre engine) ref itting -55 Rocker assembly (2.8 litre engine) dismantling. examina tion and reassembly -34 Routine maintenance stt Maintenance. routine
5
Safety precautions - 12 Seat belts -191 Seats .emoval and refining -192 Sidelight bulb renewal -213 Spare parta buying -8
to carry in ca. - 19 Spark p lugs conditions (colour) -91 lemoval. servicing and .elilling -95 Speedometer cable renewal - 226 Stabiliur bar Iront -163 rear -165 Starter moto r
description -207
d ismant ling and reassembly -207
removal and refi tting -207 testing on engine -207 Steering column removal. overhaul and refitt ino -170 desc.iption -158 faull diagnosis -172 f,on t wheel alignmenl ~nd steering angles -171 gear (manual)
ove,haul and adjustment -166 removal and refittin g -166 maintenance. rouline -161 power steering bleeding -168 gear removal and refitting -168
pump femoval and refining - 168
specifications _ 157 torque wlench senings -158 track rod end balljoint renewal-167
whea' removal and refitt ing -168 Sump 2.8 litra engine
refining -44
removal and refining with engine in car -34 3.0 litre engine refitting -55 removal -50 Sunroof bracket and dr ive assembly lemoval and refitting -191 panel adjustments -189 removal and refining _ 190 Suspension lfnd steering _ 15 7 tl seq Suspension see Front suspension Imd Re ar suspension jtches removal and relining
Index
T
central facia - 225
door p illar - 224 handbrake warning light _ 225 hazard warning -223
ignition -224
instr um
ent cluster illum ination _ 224 light and windscreen wiper (Series II) -225 load sp':)ce lamp -225 steerin g column multi-Iunction -224
s top lamp - 152
Tailgate priv ate lock removal and relining -187 .emoval and refilling -187 striker plate removal and relin ing - 188 wnsher
nozzle removal and refitting -217
pump rllmov31 and refitting -217 window glass removal and relitting -180 wiper mOlOr and linkage remoyal and refitting -217 Tappets (3.0 litre engine) remoyal -50 Tappets and push rods el u
care and maintenance -171 presswes -158 size -15 8
Underframe
maintenance -16. 176 Upholstery maintenance -176
v
Vacuum servo unit (braking system) description -156 lemov~! and refining -156 Valves clearances checking and adjustment -46 . 55 Valves (3.0 titre engine) removat -49 Valves and va lv e seats (3.0 litre engine) examination and renovation -52 Vehicle identification numbers - 8
255
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")256
W
Water pump reliuinu -44. 61 removal -61 Weights. vehicle - 6 Wheels care Jod rll )
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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