oil level FORD CAPRI 1974 Owner's Guide

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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22 2 3G 39
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)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) .
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)84 Chapter 1 1 Bodywork and fitting
3 Remove Ihe lWO h,1ntllc mi.,,,,,,,\! 1I01.s illld Wllhd.llw Ih" hilOldle 4 Rclrlhng IS t he reve.s.: Ollhc ,cUloy;] 1 l"l)l:",h"c. hul ,In "01 lurgel 10 install the hushoS 10' Ihfl link .ods A 1o.lIfll>cl,olcum ]dly on the .od ends 10",11 nSS,Sl w'lh the" "lsWIlIll'/)1l
16 Door lock tlsSClllhly rClllovnl illld refitting
Remove Ihe ct()or HUll p:mel as l"flVlou~IV ,h~5Cflhcd ,1nf! remove the pfilstic sh elHlng 2 Remove thl! Hl!l101(! conlrnl h;]llcth~ ,111(1 Iwn WII\(low ,.;1",e boilS 3 Using " St:rcw(hrv e., Pl15U tlw .;Io,'S tron, Ih" ".111"0' h;uufiu rort ,1,,<1 doweh the ,OIls '''1111 II", Iud il Remove Ill" \,to~s·I'u,1(1 ~,:r"ws ~i:(:"'"\H II,,, I""k .0 Ih" ~h,,11 ;lIld the plnslJc clips SU(;UIIlljl 11,,~ ")""01,, cOlll",1 ", Ih e lock o n IIUl .Ino. ~1":lI. pu~hll'!llhe halllfl lowa.ds Ih.! oul,,, panfil. 10 ennllie Ill" I",:k 10 10" ,;orrm :lly po~'I,or",d 01, II", W;rr sh,,11 , Sucu,,, 11\11 h,, :k w,lh Ihe lto",e S<:"'w~ ,11\11 S()CU'C Ih" ""nOle conllol 'od 10 II", "'''''' parl!:l. w'lh 11m two pl.l~hC clops 8 Rein II", ",xh,um han.llI; ""h '" Ih(", ",~p •. ~:I'v() luck 10";'1'0115 1'0511,on Ih" 1,1.".k I,u~h A IIIId wl"l() Iru~h,,~ IJ .IS ~hnwil III r'!1 11 10.
., ,
,
16. 4 Door lock and reta'l1"IIi screws
Fig. 11 .11 Romoving I h o door bell moulding (Sec 17) 9
The ,emilUldcr 01 I
ho rChllll1!) procedure .s the levelse 01 lhe rcmov~1 prOCedure .
17 Door window glilSS -removal and refining
Remove the door trim pilOel. as previously described. Ihen peel the plas lic sh ee ling away 110m ' he dool panel apertures. 2 Remove Ihe doO! bel l mouldlnU/Wealhf]rsllip assembly (see Fig. 11.11 ). 3 Wind up Ihe w,ndow glass. Ihen lemove 'he pivot plate screws. Remove Ihe four rellulmor lIem plme securrog screws or rivels . Disengage Ihe stu(ls and rOllers of the regulntor mms hom the door glass channel an(1 cmefully hit oul the \jlnss Allow Ihe regulalor 10 fall ilwily. piVOI,ng on Ihe legulmor hnndle shilli.
" When refi llin\j. initially Insert a snlall hloc k 01 wood in Ihe hOllom 01 Ille door assembly. locate Ihl} \)1,155 on Ihl} door panel. so thm il is leSl ,nu on Ih e woodell blo ck 5 locale lh e sluds nnd rolle,s ollhc ICUUI,lIOI ann 11110 ttw door IIlilSS ch~,ulel. I hen ICmpornrlly inswlllhc w,ndow handle and turn ,110 alton
Ihe ueilf pl,lle w'lh Ihe panel flxin!JS . SecIHe Ihe fllal~ 10 Ihe ,nner pnrlel. 6 loosely assmnhle Ihl} p,vOI pia!!!. Ihen Wind up tim UI,lSS ,1m! al'lIn
, I ,n Ihe Irame T,uhlell Ihe p,vOI 111;r1l! SCICWS 7 The remain(l el 01 Ihe rellHmU procedure IS the rev ..... se 01 Ihe .emoval proc(.~lu,e
1
FiU. 11 .1 0 Tho hlack (A) lHld whi:e (0) door lock bushes (Sec16)
Fig . 11 .1 2 Removing Ihe door window g lass (Sec 17)
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