lock FORD CAPRI 1974 Owner's Manual
[x] Cancel search | Manufacturer: FORD, Model Year: 1974, Model line: CAPRI, Model: FORD CAPRI 1974Pages: 205, PDF Size: 43.75 MB
Page 51 of 205

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50 C hapter 1 Engine
51 T llp pcts -removat
Remove the 1
5 2 Crnnksh
4 Wilhdraw Ih~ Wood'uH key hom the end of th(! CllInk5hah and pl,lC,(! " w'lh Ihe pulley. til(! holl alld its washer 5 The C'.1nk~h;)h p"lIey m;oy he ICliloved wilh Ihe eno,,,e III Ihe C:\I. hilt ,I 'S IIIsl tU!Ccss;o,y 10 ,emove Ihe ',ld'illO' :lI1d thc rh'vehelts
53 Flyw heel -remov[ll
P,even llhe flywhcel hum 101m",!) by FHlHllln\J Ihe lin!) !lcal ;ollain~1 ;In imp.ovised SIOI). 2 On nlodels willi nl;lnu:ol 1I;o"$""S5'01i. Icmove Ihe Clulch plessure 1)1;lle and disc :os described in Ch:op!Cr 5. 3 Rele.lse Ihe s,~ bolts secu.in!1 Ihe flywheel 10 Ihe CllInksh;oll .lnd lefl\OVC I,ve of Ihenl.
4 Whilc supporling Ihe tJywheel III pl;ll':e .• emove Ihc Sixlh hoi' ,'11d Iolt Ihe lIywheel otl c;o,elully. so 111:01 Ihe m;lllllg su.lilccs of flywheel [lild c.;onksh;oit ;o.e 1101 dllm,'ged
5 4 Sump -removal
W"h lhe '''1(1'''') oul fli the e,". CII~"'C Ihal Ihe sump has 1o('CIl d,amvd ;ond then lilln the engll1C ()VCI so tl1011 Ihe sump's U l)I)ClmOSI F" wOOr1CII bloc"s tn Slll)lmrl tim en!l'ne 'n Ih,s POSIIiOIl . 2 Remove 11m h()IIS seCUlln( J the oil Sump 10 Ihe CI.1nkColSe o1nd rClllOVO Ihe SUll1p_ 11 the sump IS stuck 10 the c r;ollkcasc . II should be reh;lIsctl hy 1"'SII1\1 olle SIde wllh 11 sClcw drover. 3 To !Cn,ovtl .Ile sump wllh Ihc CIIU"HJ Hl tloe eM. 11151 IcnlUVC Ihe
d'l)S llck :ond d'SCOIlII(!Ct Ihe hatlery 4 Remove Ihe luur holts ;ond lou. Ch,)S ;ond dCI.leh Ihe OIl splash
shIeld.
5 Pl;oce a Con'"lIlcr 01 at lellst 6lttre (106 JlIllI) cal,,-.elly heneath Ihe SUml). remove Ihe d,ain pl\l(l ;ond d,aln Iha sump. Reflilhe d.am plull and (11)hlen II 10 Ihe 10lqUO wrench seilIng gtven In the SIXlClflC;JIIons G Del:och the engme fubl)CI mounllngs, by lemovlng the" nuts an(1 w:oshe!s. 7 Romove the ciampinI) bolt hom the tal) ;oml bOIlOI11 endS 01 the Steellll!.) intellnediate sh(lil. rush Ihe lap end 0 1 Ihe shlilt upwollds unlll Ihe lowcr ell(1 Clin be dlsenga\led 8 PI
55 FrOllt cover -removlll
If Ihe engHle IS In the CM. II wllllnSI he necessaly 10 dlsc()nneC lthe l!allefY. drll'" 11m coolll1\) sys tem ;ond lel110lle Iho radiillor. 2 loosen the alternalol mounllrlg bOilS. SWlrlg the aitemalor downwilids .0w:Olds the cyltnder block and lemove Ihe drive belt
3 Remove the bolt Irom the cenlro of Ihe cooling Ian .. nd pull (
Ian and clutch assembly. 4 Remove Ihc boil an d wilsher from Ihe centre of the cran pulley .. nd I hen use ., claw puller 10 drilw Ihe I)ulley ofllhe sha nOI anempllO lelle, Ihe pulley ott. t)Ccause Ihis may .esull in dllm. t he Irani covcr.
5 Rcmove the si~ bolts secuung Ihe sump 1 0 Ihe honl cover an, t he cleven bolts securing Ihe I ront cover 10 the Cylllldcl block . G lIlt Ihe cover ott ;ond remove Ihe g;oskel.
5 6 Tillling gears -relllov;ol
1 Remove the honl cover 10 e xpose Ihe IImlnu ueo1/S 2 Removc Ihe bolt and washer sccu"I1IJ Ihe fat!Je gear I,
cn,nsIl1'll t. IhCIi pull.he geill ol! and Icmovc tho Woodllll! key. 3 Dlllw the ileal hOI11 Ihe cr;onk!;h:oh am! remove Ihe Wood'utl
57 Carllshaft -r erllov;ol
The camsh:olt nwy be rCUlovfld wllh the cll!JlIle 1<1 Ihe car •• lollowlng p!Cpol.aloIY wo,k IS co1med out. 2 0,,,,,. Ihe cootong syStelll nnd .emove Ihe .ad,mOl 3 Dlsconneci the ballery. 1 Remove Iho sp.1lk pili!! IC.1ds 1,om Ihe spalk 11lugs. 5 D,s':Ol
eCI the le;ods I,ull' Ihe :l lt'!11\.110r. remove Ihc allelllalo·
l i S (hivebell. G Undo "nd rem ovC tho screws S()CIIIII1U Ihe .0dcl covers and It Ihe rocke. covels and Iheir ilaskcls 7 Sincken lhe nulS secullnu the rocker ~"ns unlollhe locke' arm, he swung aside . 8 Remove the pushrods. idenlllylllg each one as .. IS lemoved. so 1 Ciln be rell1l ed in Ihe same position 9 Remove the cylmde. heads,
58 O il pump -r e m oval
Remove Ihe crill1kc:ose sump as ;olleady dcsc"hed 1 2 Remove Ihe boll aUJchmg the 011 scrcen 10 the Illalll 00111.119 (
/ /
Fig. 1.11 Oil pump o n tho 3.0 f itre efluill(l (Se c 58)
F
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Page 52 of 205

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,
l . ,
)
f
)
-• the twO boilS sccurong Ihe 0,1 pump 10 the crankcase and 3 R emov
',.,' . the pump assembly nnd ,ts (roves la I-wllh
drilw
59 P istons, c o nnecting rods and bCilr ings -removal
1/ lhe crankcase sump and the cylinder hC
C,IIl he removed wIthout 'CIllOVlllg the cylInder ca l. tle-ads. 2 B efore removing any COllncCllrIg rod cnp, make sure Ihal the r del number IS mn.kcd all hoth Il
~ssemblv Ollt of the top of thu cyhnder . 6 W,thdrllw Ihe assemhly frorn the cyhntler ,lIld ptace Ihe hCillrnO C,IP
~ck on the connecllrt{J 10(1. 1 If Ihe be.:uinos rue l>CrllO ",newetl. lelnove the uld 1)("""'!15 hy ),,1I1n9 Ihem lound unlrl Ihe nOl ch on Ihe !J(,,,,rnO ~h.,tl rs tlrsenH<10cd
f rom Ihe lecess on Ihe l)e,1r1"U Se,llrnn 'lIlll Ihen hft the IJofI<1rrtlH oul If tho beJrin{Js <11e lemovell ,,,,d the S,lnm ones ,l.e 1":111111 nsctl a!F"n. illS viMlthat Ihey ale .elillcd III Ihe s.lmc scahnH a ... Ihe Olle I.om whIch
thf.'Y WC.C lemoveli.
60 Crankshaft reM oil seal - rellloll,,1
To !emove Ihe 011 sei\1 wllh Ihe ell!J",e In Ihe ca,. Iusl remove Ihe U
(Sec 60)
~ Crank sh aft llnd main
henri nUs -re rnov.r1
, Relnovc" 2 n Ie CIIIl"I" 1'011 Ihe car . 'J, 3 n emovc the ClelC h HSSI~olhly 011 Illllllual transm,ss,on madels ·1 ernove lir", , , ,
L'
·
.... yw lI.le ;lIld Ihe leal 01 sual cal"er. "/-·H. $'i;:.
5 1
Sld e d own. chock It sccu
CilP S all .111(1 lay 1111:111 out'" order NOlll Ihm Ih" c~nlle 111:1111 hcn"ng f.':IP has Ihrll~1 wa~hcfs M;l,k Ihetr POSIIIOIIS hili",,,
62 Ellgiflo Carl\l)Ollelll~ -e~iHllil\1ltiol1 far we"r
nc:lm 10 Soctll)" I 1
63 noct.e r arillS -examination ;ond nmovalion
llll) siuds 011 whIch Ihe locke, arm~ p,vot arc a pless 101 Into the cyhllder he,1I1. ,111(1 II .1 51'<1'0101 cdUO IS Inld aCfOSS all s'x. II cnn be seell whelhtlf ;"'y h,ll1e 1>f:\Jull II) pull oul. II Ihl5 IS Ihu case. Ihe stud w,1I have 10 h e I..,1ll0vt:d. Ihe hole re,lllll!'\! 0111 ,IIId ,Ill overSlie Stud hllll(1 2 Check Ihal Iht.: Itucuds on the sluds a,e!ll Uood conti'IIOI1 anll that ~ \IJ'(juc 01 nllc.1S1 59 N", (
Silil dl:lrCIUIlI. hi a locknul to Ihe mlluslef 3 EX;IIWlln 1hll Illeke. <1111l~ ;IIH) IUit;IUIlI snalS 10' S'~lns 1.11 rrdH'nU. 1.1< I:XCtJSS we,ll 1111 Ih'l Ilc;o,'nu $IIII"I:<.'S II Cllher p.lll shows excessIve W"'II. 1".111 Ihe ,",.k.)! ;",n a"ti ti,e 1\lle'IliH sent '''u~1 IlIl .enowcd If When I;hcr:klll\l lilt"! rI)C~,)lS ;UIIlS. 'C"IOVI) Ih,;", one .11 a l"no \0 ,,"mlll(llo: allY POS).Ihllrly 01 ,urllS ,Iud seals Ilct:lJn l,tlH ullerchan\)cti. or Ilelll(l 1.,!I1Il:d III Ihe W'OIl(j ~IIIrI
GIf Tappets ,HId pushra()s -elWlllin alion ;lIld renoviltian
ncle. 10 Sm;trr)ll I 3
65 CamslHlIt ,\lid ca!l1sh':llt bC(H inos -c~arl\il\"tion and
renovation
UlllhHSI~C camshaft beaflflf)S ;1fC ayml.,tJle. so II IS poss,hlo \0 SOlly,IUIl , I waul c amsh31t by rCtJtlIl(lrnO Ihe 10uII1als. II the call1s . or skew gllar. atll wOln stOllllocallll y. Of arc d':II11.10,,(I. a ncw call1Sh.1h
IllUSt be I'lled and thc tJcallngs should Ihen also be renewed. 2 WOlll or dalllaUed c;m,sha1t bearings can be replaced by ncw ones. hullh,s re'lullt;:s spI)Clal tOOls and should llc om,usted 10 il FOld dC<1lel. 0 ' 10 (1 wa.kshol) wh,ch undertakes carnshafl reclalnl'nu
G G Cylinder horus _ eXHl11irHltio n and re nov(ltion
Reier
til S(:Cllon 1 G
67 P is tons and t)isto n rillUs -ellamilwlioll ,lIld renov(ltion
R e
lcf 10 Sectlo" 11.
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Chapter 1 Engin e 53
-----------------~--~--------------~
@
I
2 5 -
6-
3
7
Fig .1 14 E . ngine IlibriC
) _ d tron sys te m _ description
T he lub, . _ ~ng Jl re,)l'on syslen , IS villually lhe same as lhat for the 2_8 hire $IJP~le rJrJese"hf'd III Section 2<1. except Ih
,
l..j
Fig. 1 .1 3 Ex ploded view of the oil pump (Sec 75)
I 2 3 4 5
Piclc-Ojl (ul)(; i/ml SC/C~'{) G,1$icCI Clips Pump body O"II~f fOlvf 6 ImlL'1 rOl{lr 7 Elld COIIL'r 8 ScM 9 Swing 10 Rc/iL" v,llllc 1)luIl9 ~" II Clip 12 SlI.lf(
Fig . 1.1 5 Cr
CrankC
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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"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~",,, 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"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"":lllI"d IOlllUU , 5 FII ,1 now w;,~h", 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! ,"~,,"t the valves 11110 the \Ju, dc Irom whIch lh ey wele remov(:d 2 To ,WOld d
lhero.s dilnlJC' oltl1<.: ~I""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'l cull":IS hilve seilled properly and t
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
)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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56 Chapter 1 Engine
91 Engine -refilting
Rcf'tlIng the engine is a rCllcrsnl alth e removJI procedure given In Section 44. bUI in addrhon note the following 1)O;I1IS:
(,,) Ugh/I)' 9(0"50 Ihe ycar/)QIC ;npu{ Sh,ll{ (m,lI/v.,1 transmission) (b) Check tlMllhe dlileh fc/c,He .7Im is cOIf(!clly loentcd (m,lllu,)1 (fiJn$miSS;OIl) (e) Adiusl (he clutch cClbfll ,15 (/(!sCllbcri ill Clwp/fN 5 (m,mu,,1 flilMmission) (d) BelOfc COfl/weliny the engine /0 {I!(! ,W{omMIC {MOSl/tllSion check 111M /he /O((/lle con vet/or is fully 01l9,19N/ wilh lite /f,lfI smiSSI()II pump by reh'/(!IICa to CIWp/Of 6 (e) Refll' file ,)II/QIII,llie ("'''lllltHiOIl WillI 1141/11 ,15 dcsCfI/)t'd III Ch,lpWI 6 (/) Ad/usllhe lellsioll 01 the IJowor steeling IIlIfIIll MId .11/emMa. !lnvalid/(s) ,15 d(!scfI/)ml in Ch,?pICIS 10 i/lld 2 f(!SpcC/lv(!/y (!I) Fill Ihc cooJillfl sys/cm (el,.l/'/C' 2) ,md /lOW,!' Slcc/IIIY
SVS/l:tII (ella,'/Cf 10), 1111:11 fIIlllle mlylllc Willi od (SeC/lOll ti~) ("ho/Q)
92 E n £line -initial start-u p after major overlwul or re pair
Hel",
10 Sect Ion 38
PART C, FAULT D IAGNOSIS
93 Faull diagnosis -engine
Sympto m
(n!Jlne f.111s to tllm OVCI whim ~t;llt", IS Opc,;) lcd
Enll"n) lUIIIS ill no.",al ~pced. hili dous not 51,IIt
E"u'ne SlOp s ilnd Will not 'estill t
Enll'Ile
.",slucs, O. lUll S unevenly
L~ck of powc. illlt! poo, comp.esslo ll
91 1 T OPPln! 1 lIl) tile ""'II"") wIth od
ReilSOn(S)
DI~ch.1'Hed 01 delec tlv" 1o:,lle.y
Dilly 01 lI)os" lI.11tc.y le.,ds
O"f '!I:llve sl; IIt", soL"",,,, I. ,II SW'II: " Odl'ctlvl' s lillte. "UIIOf
Dilly 0 ' III"ken e"!I"IC "'''1111''11 SIt;IP
1\I1'"111 ':Ol1lpOlu",ts Will (If ,1;""1) DefectIve low te nSIOIi le"d Detective o. InCOllec,ly :,,, 1 ,:"III"C I h,e;oke. (,I "PI.I,,:a"fe)
Oe f"ctlve condense. (If '11'lllIo,;.,"lc) O'st"hulor cal) defec tIve. or celltral h,ush HI (irs l,,"uto ' cap Ilot m,,~, COfltilf.t w'th th e .otor a"n Ifls.ulhc,em petrol "' tilllk V.1pOOf Iud '11 luel hlle (," hut cOl1{lIuolls)
Fuet pump I:uhlfe E~O:Hs51ve c hoke, caus,,,u spillk pluUs 10 hccolllt) wet
IU"I1I(HI 1,,,IUle result Ill!.! 110111 b.cakdown. or prescncc o t w;'1ler \,Inti w(: 1 cOnthllOIlS l:n:k 1.11 tud. at luel IJlock, l!Je
loose 19111tlon Icads F(luIIV s J)n. k 1)Iuli T'(1ckin£l on d,slllbuto. cnjl IIlsuliltion
InCOIICCll11lxtu'e 'Ullilion 100 telilldcd Dilly con[,lCI blcakc. POlll1S (,I ajlplPcablc). or loose connection'
Faully Of loose condense' ( II ~)JpIPcilblc) Lea kin U ca.hu.eItOJ. o. lII.lll1fold JOlllt
D"lectlve v.,lves Blown cyIP"de . head £lasket
WOlll bo.es OJ dilm ilye
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)
'tz
Chapter 2 Cooting system 59
1 I VISCOUS (IPlVC I,m coupling (I,~mpc,alu,e sensitIve 1VIle shown) 2.5 Tuppill\l -lIplhc COlllilll1 h,vel in the c~J)alls,on \;lI\k 27 Checkin U the drive-belt IClls,on (28 hire CIlUulC)
2 Routino Illaintcnanco
Altho ,n1C, ... "ls SPOC""]!! utlhe Rouhnc M .. "UcnanCf! SOChOr! on Ihe 110111 01 the m;uu,a1 c;lrIy oul the lol1oWl!ljl p.occduoes
Check cnoling syslcm lor /c,1k.~ 1 In spe cl Iht! coolin!! sysh),l) hose s 'llcludlll!) the ,adIOiIO' :,"<1 Iwate. hoses for damage. detcriOlllll0n i1nd sccullly If Ihelt) is I'Irly IOulle;1I'01] of swelling 01 p
COf/ec t tension If .equir e d .
9 Run the enuine f o r severlll minutes Ihen rec hec k t he lension.
Renew,1/Jtilreeze 10 O.am i1nd flush Ihe CO(lhng System as descrlhed in Sections 3 and 4 . 11 F,II the coollllg system With Ihe correct solullon of watel and amlf,ccle as desc"hed in SeClions 5 and 6 .
3
Cooling sysl e m -drai"inU
If pOSSIble. ensu,e thilt the engine IS cold belo.t! d.al"i"lJ Ihe cool ant. 10 aVOid the fisk of scalding.
2 Remove Ihe .adlatOf or expanSIon tank IIlIe. cap. If the eflUlnc IS hot. Ih ls must be done vl;lry caul,ously, because a sudden release 0 1
Fig. 2.3 Clltawa y view o f Iho expan sio n tlln k showin g tho plastic lovel indicator -tH rowed (Sec 2)
P'".'·S5U'0 CilIl ,esull II. the cool(lnl !.>oIling i1nd blOWing Oul. On ,1 hot enUlIle. plilce iI cluth ove, the caf} and lurn il ve. y uently. '0 release tim p,ess\lIe slowly. 3 flel110ve the SplilSh shield frOI11 b enomh the ra(II;IIOf. of i1pplrcilble
" Unless !he coolilnt IS beinu discarded and thc ca. 's over (I slilt illJle
d'illl1. ,,'"ce a deiln IWO i1nd a half gallon Conl;1ine. underneath the ,adlaIOl. !) Rel110ve the radlatOl bOllom hose lind allow the coo'al11 10 drili" . 6 If the SyStel1'IS to be completely d,ained. rcmove the cyhnde. block d.;1I1' pluU and draIn oul Iho .emainlng coolant hom tho engine . ThiS d'illf' plug IS locilted all the s,de of the cyl inder block to Ihe rear of the oiliolicr. 7 On 1I10deis wilh all eXJ}ilnSlon tank 'emove the rad.alO' cap as well
4 Cooling systom -ftushing
In IUlIe. !he cooling syStel11 Will lose ils efficiency because o f a bu,ld'lIp 01 .uSI and sedunen t in the radiator. To clean the .adliltol. .emove thc IllIer Cill) i1nd 'he bOllom hose ilnd !lush Ihe radialo" by inse.llng a hose in Iho f,lle. car> neck i1nd funninu Wille. th.ough fOf about tr.m I11mules . 2 If Ihere is a Ilea vy aCCUmuliltlOn 01 sediment. it is betler to .eve.se
flu sh Ihe .adl~tor. by connecting the water supply 10 Ih o boltom of the rilclmof alld allowinu II 10 flow oul of the tOIl. Speclnl hose adapters arc avai lable to enahle thIS to be done w ith the rild.ator In I)OSllion. but It is p,efe.able '0 removc the lad,ato. and tum il upside down.
3 Remove t he thernlos,a, (Section 8) then .eve.se lIush Ihe engine wi,h a W1l1e. hose u n lll clean waler flows from the .ndlat Of bottom h ose connectIon.
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'.to.
60 C hapter 2 Cooling system
5 Cooling system -fillinu
Ensure 111m the cylinder hlot.k d',1111 pi,,!! IS SCfCWCU "' rumly wl(1 th .. , tlilihe coolll'U system h(')s'~s .1!tl1n POSl t'''1l and secured wIth hose clops. 2 USH1g ~ 1111~IUIC of 45% nnt,hN!IC ilnd b!/)(, wmer. 1,1) the coolll\lI system slowly. 10 nHnlnlise the fisk of "U locks Ellsure IIKIt the hC;'lC' control IS Wined \0 the 'Hor pOSItIon oll"l'W'~: ,10 IIU lock m.ly 101m Ifl the hemer 3 On fl,lIly models w i thou I 01" C'P"II~OOIi t .. llk. hll the liuhnlU ' 10 llHi
hlvel U'llcn III S!:f.rran 2 then ",ht 1110 Itll,·, ,:,,1' Where nil e~Jlan~lIl1l !OInk .s f,[h:d, t.:olllplclCly 1I1I11u; ,;)Ih;no • .11101 ,.,tn the CilP then h.llll,11 the cxp;ms",11 lank and "JI, the hlle . ,'" " (pholO) Notll 1h.11 thl) pressure (:0111 wIlh the Iln"lol" :,..;,1 "'"~, .• tW;II'S be 1111ed 10 Ihe CXI),1IlS,OIl I.,,,k
I) 01 so"'" "1\\I'''es i'" ,II, 1,1",,01 ~"".'" ", .. y I,,, I'"eti Ifl Ih" IW',h:l hose. Loo~"11 Ihe ~,c:rcw boA"", 1,11""111", ' V·.Io'IIl .",d ,cl'\lII",,, ,I wil,'u hubhle I"·,, W,,,",, 110ws 5 nUll Ih.~ ""\I,n<: al,1 I.'~I "tI,· ~'I"',~IIt~ ·~',.· •. ,I "''''ul,,!> Ih,," "lInw ,I 1U tool iHUII,,1' up til') co(,I.", ' I.·v'" '~!lh ,.'t.''''"r.,; 10 SHCl"," 7.
6 A,IIi1f{W/fl milliu re
Ap,lIl I",,,, II,,, p'''I,,''I',,'' .,,, .. ,,,,.1 1""''''''1 .. ",,(I,t'OIlS ",.1,,0:11 II", usc 0 1 ilnld"·,,,.· I',nvules. II, 11'." I, """",,10 .• 1 I" "IUlI""SI) ':''''CI~IO'' "I Ihe ,:oolu'!1 sy:. I",,, 7. Thc (:ou1l1111 ~y:.lcm I:' ""lIdlly 1I1I.~1 wllh .1 sulu'u", "I II!>'". al1lll,cc~c ;lI,d II.s 'CCOIIIll""lIl"d Ih,'1 II,,, l":u.",,t"He ,s 111,11"1.1"",,1
3 Willi 1011\1·111" tvpes olall1,I,,,cl." ""~"""'" '''''''w lhe Cl)o l:")1 "ve,y IWO VCiI'S. W,III ot hel lypCS. d'iI'lI ",,,I ",10" 110" syslcm cv,,'y Iwelv" "lO'lIhs Wh'f.hcver Ivpe.s used, 'I I11\l~1 b" "'llll' ethylclle Ulyr.oll",s" II The lollow".!) l,1ble !)IVe s;o !J'IId., 10 l""I.":I'uu ;l!)aiIl SI l
~
-..-.. -::-' , .
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If
~
Amount 0 1 ilnlilr(l(lzo 45% 40~ 30')(, 25'\', 20'¥, 15'~,
P ro tection to .J2C( 26"F) 25 C ( I3'F) 16 C ( . 3'F) IJC(·!fF) .'JC(·IG'F) IC(tI.'JF)
7 iladialOr rCllloval. inspection, dcaninu and relittinu
1 O,arn Ih" ,:oolll1U S ySICIII as ~h,s ... 'h,·d ,,' S",:I'OI1 3
2 flclllo\" II", :."t;I s h shlcld (,11,"" .. 1) ;011". 'I:III()VIllII.IS fOIH .. "II-. .11" 10", cft l" 3 0" ;,,,I,,!],.II,,, 1,,1nSIllISs,o n 111011,,1-.. 1'1.":,, ., I'.IV 1><·".·,,11, Ill" " . , "ole' """"",. w'l,e till! un ions de.lll ;111,1 '''}!!,' Ih,,,', Oil'! ~ Iv I'''''' II" j"IH! "",h "",I II", '."010:;' 1""0IlS. I .. 1""v""1 110" h,,~ "111,,,,1 .f O'Sf:"""'· •. 1 110.,1<)1' hosf: ,m'I .... I""" "1'1'1" .,1>1" Ih" "~I""'"'''' 1 .,,,1 h"",) I""" II .. , •• ,,10"1110 :, WI",,,, .1",,1,,:.,1>1,]. 'CIllOV!! tl". "',",w~. -."'."''''!! 110" I.", ,tl"",,1 " "w .ati""", IIo"n p"~'I,on Ihc ~h,,,,,,, '''"., II", t.III 1,1."1",, 1,,1"'1"1 l.l Fo< 1:."'" "f ",movnl ;0150 ,,''''''Vo: IIII' troll! •• ,,10,"0' • "' .... 1 .. I"" "''''')\I'''!! th" ·"."'W~ (,)hOlo). I fl"ltmv,· II", I",,, holls. SP"Il!! .• ",1 11 .• 1 w"·.h,,, .. wll".h ,-,. , "". 11 •• , ... It.,101 I" Ih" 1",," ,W(\cllIl1d Iofllll" ,.UIo.IW' Oll( .;,,,,,r,,Uv. ,."." ""t t. '1.1I11"~I" Ih.· ,."1,. ,1,,, "'.IIr,x (phUlo,,) H W'lio II,,· ,."10.,1,,, ,,"I ollhe c.". II,VI:"." tl"'.10 ,I 10 ,,,"'0",, IIII' ·.I",!." .""1 •. 1"",, til" "~I"'"'' ",,,h,1 lei 01 • . ,,,,,,,",,-~,,d .111. '" Will(:,. 10 """"" ,"'v 11", IH """".1" II Ih" 'ild':l!OI ""IUI",~ '''p.II!, ,I ,~ h..,u,', h) 1.1 .11, ..... :h,"'!!'1 ,."1,.*,,. 0 ' havc Ihc 'cp.", do"" hy.1 tiOlIr"to, ~1 ... ~:,.,Ir:.' !) II yuu .u,' "",,:w"'\] iln cady ':0<1'.'101 ;,"d YOll "!l"nd 10 t,t ., I.,:, " ~1"11 lOp 1.11I~ typ". yuu Will nccd Iu fn 111, HXI'.lI1S'OIl contill"'" COil",,, yOll' FCltd oI"ill", lor Ihe COUCCI IYPII all" h""'!1 dt,liliis should Ih,~ .,. 1he C,1~;C. :,~ :0 ~1"":t:'1 se.v,ce kll w,lI il1:.0 .,,' "~IIII!CfI 10 Refllllll!1 , .. iI t(Jv(:,s(ll 0 1 ,cl11oval .• ,,,' t,lIlh" c:l)ohliH SY~I,,'" w .l h ''''e,enl:e 1 0 S,,,;I'OIl 5 On .1ul0"'''I''; ":"'l.'"'~~l(m 1110d"ls IIII' "I' Ih ,· 1';II1"IIHSS'IJII lI",d w,th .et(l.ence lu CIo""I'" G
S 3 F,IhnU Ihe 'ad,;OIO' WIlh coul:",! 75 Fan s h.oud '(:Ii"""}!) sc.ew (.mowed) 7.6 RernovulU Ihe 1<0111 .adlato r cowl
"
"""
, "
7 7A Upper .mlrillOI 'n1JUIlI"'U IJ()II 7 7B Lowe •• ad'nlo, 1ll0un1111U boll ("!lowed) 7.7C ReIllOVII1\J Ihe rJ(MIO'
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Page 65 of 205

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
7 F,t;r new a~lr.'I1S'OIl "Iug 10 Ih e 5h
"', '
-.'. c
'
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)
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'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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Page 66 of 205

15 Fau lt ui(l9"0SiS ~ cooling system
Sympt o m
Overhe
loss of COOI,llll
...
Chapter 2 Cooling systern
Reason{s)
Insuff ic ienl coolant Drivehel t slrppinu R;JdralQr core btockcI .1. or H"lIe rpSI"tled Air lock in cool lnll SySWIl1 W mer hose Coll.1psed, or linked, ''''red",\) flow TherllloSI
65
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Page 71 of 205

70 Chapter 3 Fucl and exhaust systems
liS seatmu Note ,1nd reco.d the number of lurns, so th,11 the screws can be relltted 10 their orjuin~' settings . Unscrew cilch screw fully and remove it and its SPfing . 13 Che<:k the lIoat
Fig. 3 .9 Emulsion t u bes (V) (Sec 9)
Fig, 3.11 Removin!J tho IIlIli'Slilll dillphragm cover (Soc 9)
Refum sWing 8 Cover
the upper body. 18 Adjuslthe flo." level settings, fi,slly w;l h the upper body verlical .md I he needle villve s hut off lithe meilsurerneot is outsIde Ihe IInlllS given in the SpecifiC
Fig. 3.10 Relllovingllie IIccelcrillor pump cover -(lrrowcd (Sec 9)
..
Fig. 3.12 Accelerator pump components (Sec 9)
A B Covcr Diapl/mom c RC/(lfll swing
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