FORD CAPRI 1974 Manual PDF

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 COlleCtIOn Icts Hi Rein tho power valve dlo'Jlhr"gm nssembly ~s follows. Loosely fIt Ihe Ihree rtrnplungm ret"iIlIIlO screws. comp.ess the return spfln!! ensu"o!) tl>;)t the dl"phr"W11IS 001 IwislP.d Or dlSlorted Ihenl;\Jhlen Ihe scrells ,'mf Ide,lse Ihe SP'1I1!). Check lor correcl IUllc lloomo !ly push Ing Ihe rtl,ll )hr"IJlll down nnd ,hen blockllig the:m hleed holll w,lh ;J f,nue, I1cfcnse the d'ilphr;JUI11 whde 51111 keeplll!J the ,lIf holo blocked [I the fhilPlu"~Jm sl,'ys down. II hns Willed j)rope.ly to Its housing 17 RefIt the Ileedle v"lve hOIJSIII\j, ncedle v;Jlve nnd 110,11 nssemhlv 10
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 SpecifiCcnd Ihe Ing umll Ihe SCltll1g IS correct ,,,ul recheck. Far bOlll 11m flam leve l ild!lIstmCIllS Ihl! lIJlflCf body g,~~k'" muSI be remove<1 . 20 Refit Ihe fuel inwke "Iwr ilnd loc.11if1{1 11111. 21 Posilion Ihe Uilsket (lnd relIt the c(llbu.ellor UP1Xi' hody M,lke SUII' Ihill the choke link loc;(1\es through Ihe upper hody correClly 22 Recorlllecl the choke link Mid secure II wllh IIIIl U·clrp 23 AdjuSI Ihe Ih,o\lle 1)1(lleS lor synch,onrlilIIOIi. Wme! h"ck Ihl! .. II" screw unlll II,s r.le,1r ot Ihe IhrOllle mcr.hmliSI11 ilnd Ih{:n 101)5'''' Ill" synchronililllOn "dlust,nu sc.ew. Hold Ihe "ulo·chole pl"tes '" ,m open POSItIon, flIck Ihe Ihrollle ilnd ,,1I0w hOlh pl,1les to r.1o~e IIIlIy T"p bOlh pliltes 10 flnSilre Ih.11 Ihey h,we clnsml r.nl1lph~I{:ly ;111(1 liI(:" ll!Jhlcn the synchrorll~il1l0n sc.ew. To chHck. j)a,lmfly open IhH Ih,nllll! uSll1g the 1(110 sr.rew, SO Ih~1 IllIlre IS n clealanCe! of 0 5111111 (002 HI) betweeo olle of the Ih.011le j)l alL's (lnd li S holC ChHck Iha l the mh,·, plnle hns Ihe s~l11e open;lI\j
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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) Chapter 3 Fuel and exhaust systems
FiU _ 3.13 Components to he checked (Sec 9)
A
8
C/u':(:A fur wP.olf alJd (/illlli'f/I.l Clwck '(If .~/I"lIitJfJ
C CI)(xk for hd,ill{J {) Check (Of spfrlling
10 Weller cnrhurettor ""tom,lIie choke - rcmov,]L overhaul
and refitlinu
1 DlsconlH!~1 Ihe i)illicry nC\j 3 UnscI!;w the contlC hoi! ""d remove the cover. 1 Remove the three SCfClWS. dewell the housing 5 Detach Ihe interna l hCill shield . 6 Remove the smgle U· clip and disconnect the choke plote OpCfilting link, 7 Remove the three screws, disconnect the choke link ,It lhe opefiHing lever nnd dctilCh the chokl:! assembly . 8 Remove the three screws ric"nts dlllinU
le"sselllhly. 11 Ik"ssemhle the choke meCh'1I11SI11. 12 Relit ll1e v"CUUIll til"phl1'lI)lIl alld hOUSII1,). enslllinu th"t lhe (hilphl,l()fIl IS lIolt before lile housing IS fllted. 13 Ensure thm the O-IIllg is correctly locmed in the choke housinU then reCOllnect the lower choke I",k Position the assembly and secure il WIth the thr ee sClews . ensure thnt the upper choke link loc"tes
cOlrectly tluouUh the c"rlJlJretlOf body 111 RecOllllec t the upper choke Imk to the choke Sp"l(tie. 15 Check the V"CUUIll pull· down Sect ion 11 1 G RelIt Ihe mlern,,1 heat shield enSlllinu that the hole in the cover loculCs correctly onto the peg C[lst III the housing. 17 Conllect the bi·mewl Sp"llg to the choke lever. position the housing and loosely lit lhe Ihree relnining screws. 18 ROlnte the houstng untIl Ihe marks ,lre "Iigned. then light en Ihe three screws. 19 Refll lhe cover logether WIth [l new g 11 Weber carbur e l tor automnt ic choke -adjustment
Note: lile pfOccc/ bccn rcmoved 1 D 'scOllncct Ihe bn(lcty canh lead . 2 Rcmove the illf cleaner. ilS deSCribed in Seclion 3.
.l.I. .... , •• ,. ••. • .. .• . ,,~ ......... , •• , •• .;..,.: .•• ' •.•••• 1 . ;."
.,.', .,1,,/. 1,,' .. 1 . .. . , 1.,.: .. 1,.1.1,.1 .•. : ...
J
Fig. 3.1 4 F loat level adjustment t Fit!. 3.15 Automatic choke housing re taining screws­ilrrowed (Sec 10)
.------
./ /' (
Fig.
/
3 .16 Automatic c hoke h ousing alignment (Sec 10)
A Rich c B Normal scl/lllg
marks
71
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72 Chapter 3 Fuel and exhaust systems
3 Unsc.cw the cenlle bolt and .emovc the cove •. T o p VtlCllllm pul/-down 6 FII Choke phasillg 7 Hold tho Ih'O Hlo 1),1.tly open IJ(mdlllU Ihe tau. S Rn"t Ihe intelnal hcal stueld eIlS''''"\1 Ih,lt Ihl! hole ,n the COve'
locmes COrfeclly 01110 Ihe t :le\] CkOt. and t'yhten the C"n\'1) bolt. Top up I he coohng s y Slem ,I Ilccess: llY 12 Reconnect!hc h;")lle'y . run thc ell!l'"c :",d Mllu~t Ihe 1,IStldle spccd ;,s d"sCllhed III Ihe 101l0winU Pil';'!I.;lph
Filsl idlv speL'd 1 3 hlc;IlIy" tachomcte. wlIII,c .eq,,"ed !lllmlc. 10 sellhu t,'~1111l1! 'P'" 10 lhe ~peclllncl v.1Iuc . nUll lhc CnnUlc lip to no.,,,al opc.at"I!1 t,:'Upe."lu,e. then ~wO\ch oil ;Jml COllllect Ihn tachomete. (whe.e .wn"a"h,) OpCl1t he Iluollie pal\lally. hnhllhc chokc pl.1\(.)5 lully closed tI'"" 'ele,lse tht.! th,ollie $0 Ih.111he cho~e 1""ch.1111$I11 IS held 'n the fast "II" fK151\10" Relc"$c the cho~1"l pl.ltCS . d" . .:ckllll! lh;lllhcy .cmaln lully olwn (II they ".c not open. Ihe ,lsse rnlJly IS I"ully 01 Ihe cnU"lc ' S 1101 al 01Ie .,11111IJ len'I/C,,'lurc) Wlthoul louchl"H the ;lc c"le."to. ved"I. Sliltl
, ,
~A
Fig. 3.1 9 Choke phasing adjuSlme'lI (Sec 11)
A 0,,/1 8 AUjus/my'"y
Fig. 3 .17 Checking the Vllc .. "m pull·down with l' drill {Scc 111
A t:lils/lc Im",' C V;//:1I11111 ('I'~'f,~lmllull B DIJII
Fig. 3.18 AdjtlslinU the vacullm pull- down (Sec 11)
A 8
Fig. 3 .20 linkage SCI fo r checking fast idle adjustment (Secl1)
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Chapter 3 Fuel and exhaust systems 73
Fig 3.21 Adjusting the fast idle speed (Sec 11)
A Clloke f(llly Olwn ()
the 1:1l!)1I1" alld ;HI)"~;1 lhe lasl ,die s<:rew as llecess;uy 10 ohlain lhe COlleCI la~l I(llf~ 'Ilill 11 Finally felll lhe ,\(I cif,.1ne,.
1 2 Weber carburettor ~ id lilllJ ndjustment
N ote: III view of lfoe illcfem;illg ,1WmeIJeSS ollile d,lI/flefS of exh.lflsl pol/ulioll olml Ihe vefY low levels of cmbol! //Ionuxirle (CO) emission fOI which Ihis e,,,burel/o, is dcsiW!N/. IIIe: slow fUnlling mix/ute: se:l/ill9 ,wd tin' b,lsie idle svlling all WCbt'f e,ltborcl/OfS shoufllllu/lw "djus/cd Wililoll! OW (ISO of a {!fop!"!, CO flfv/ef (c·Xll,lOS! fI"s iflf'lfyser). Bdum CUfluHencillY work ,1150 f(;o1(/ /he flO/t' .11 til<: IW9innilly of Sl'CltOn 9 1 Walm LIp lh(l (ll1gU)(l 10 ilS nounal operalinu If:l1lpCrailH(l 2 COlIIlCCl .1 CO nleler ilnd " lolchol1l(llel. ,I lhe Iilller ,s nOl aireCilllons .11 lhe IJCU>flninu 01 tillS Ch,lplN . 5 Adlust the Idle speed scrcw 10 give the COIfCCt rpm. (j DlHlllO nornlnl rout>nc m~>lltcnnIlCC serv'CIfl!I. norll1<1lly no ,1d·
IUSlrnent of lho mixture (CO levol) w,lIb(l requll(ld. It howevel the CO levcl is lound to be II1COHCCt thc 10110willII p locedwe should be ,ulnp!Cd 7 Rcmove lhe plast,c Cn(1 In lhe two nllxtwe SClCWS lInlil thcy stop 111ld lhc n wi"d Olll lhwe full turns on e~ch sClew. Tum e.1ch screw both III cl1ch ll1ne. This wllf give nn l1pproxirnntl} St:ltinU lor lhc rlllxlure. Now clC.1r thl} cnginc cxhiltiSl g<1ses by IlInnmu the enUlne ~1 3000 rpm lor ilpproximJtcly 30 scconds !
corr(lCl readings me ohwined. 9 Whe,e applicable f it new plas tic cnps 10 the mixture sc,ews. Remove th(l taChOmeler .1nd CO meter.
)13 Fuel tilnk ~ removill .lIld re fittin g
Gn;at cs n~ccssary when wOlkmg on 3"y parI 0 1 th(l luel system FiB . 3.22 C A fI /dlc Spt'cil SC".,V MHIIIII.' SCII.'WS
2 O,sr.onnuct tho !Jallf)ry I,·"ds
c S,.',l/,·" /J/IIY rd,) ,wI lemow.')
3 Syphon o1"y petlOl Ii,,,,a"u!)!) III Ihl"! t,lnk min a 1",,1<11 conwu'"r sUltiawd plar.e 1 Choke lhe trolll whe"ls S"culI~ty Jack up lhe Ie"" 01 lhl"! CM ~nd ~;IJPpOfl II on htocks. or Il(mty h;'~(ld slnnds. 5 DlsCO""ccI1he luet leerl p>pe <11 Ihe lank and III,e 11 from the clips alonu lhc IIOnl edge 01 the liwk. AI~o (hsco"ncct the return pipe where litted. G Remove thc WIfIIlO conneCl0,S 1 10m lhe tnnk sllnder til"!. nOllllg lheir pOSlllon$ so lhs ,md dI Sr.Olllll"!t:t the lJr();\lher pipe ~t lh(l T ·COlloccllon 8 Loose" the t.1nk shaps (pholo). ~"ppo'l the 1;II,k Ul pos,t"m and. whole slin suppOlll"'I the tilllk. "'IllOVC lhe Strill'" C"rf)lully WIlHlve ltll, lo1nk .1%clllbly ilnd i,,"k \lLI ;IId. 11 lolled . leilv>lI\I II", r",·1 I ,ll", pipe I" posit>on. [) Belooe rel'lllll!) tlill lallk. (lIlSIlIC 110011 lho ftHIl "'sut,lItH p"d~ (B "I FlU. 3 23) nle sluck 10 Ih" lank III lhc pOS'I>OIIS shown 10 Smea( Ilrease IOlind lhe exlerlor IJllhe 1011,,( pqw h,,~e. to I"c,hlate liS ent ry >IllO the fUl;l lo1nk se;,1 1'0"lllon the lallk ;IIld ~lIppl)<1 ,1. tl"", relll the twO (Dilk dips i,Itl:l rc,:onnf)i:lul(l the lu,,1 ilnd vCIll p'pcs 11 Ensure t.llJl lhe vent p>pc 's cirpp"d 11110 po~,>l,on ,'!HI IS nOl klllked or u.1pped 12 Tlulotcn the tJnk stlap nulS lInnl 35 to 110 ,HIll {I ' 10 1 (j Ill) 01 lh,end IS prOlrudlilU lhrouuh the nlll
~.* ..... ·0 ~'.~',":L: :~ .. ~" :".~ r~r· .. '.~ . . ' . -
.... ', . ~ , . .
iil~);-< .~:a
1 3 .8 F uel tank StrllP lInd 1!OIt
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74 Chapter 3 Fuel and exhaust systems
, ;
1)'>­
,
Fig. 3 .23 F el ' onenlS (Sec 13)
A
" C
Se.ll Ruhbcl ill,W/,lIQI S SI!IIIJ..'f lIoil
14 Fuel lank -cronning DrHI rcpl1ir
D SImps E , COllflcetiu"
W,lh IlI1m 11 I~ likely Ihal scd'lllcnl .... .11 COIiC(;1 1f1 the IJOIiUlIl u l the ruel wnk. Con 15 Fuct lank sender unil _ remov;11 nlld refilliny
Check Ihe h01l1 whL'{)ls Ihen J;lc k ufllhe le;lr of Ihe 17;11 ;'Ind supporl ,1 ilxle sr,llids . 2 SYI/hon Ihe fllel hom Ih e tllcllim k. Wherc ;lpphcilhle d,scol,,'ecl Ihe fuel line hOIll the scnder unll.
" Discormoci Ihe wiring 5 USlllljlWO SC!(lw(i!lvers III Ihe 51015 inlhe sendcr unit ,e lirmlng 1111\1. unsr;'ew Ih o sender (mil loom Ihe tucllilnk Lilt ilW;lY Ihe scaling ling iln d Ihe sender unit. nO llng Ihill Ihe 110.11 must hilng downw;'IrrJs. G Re fill ing is a rever snl of .e moval . bUI clea n lile milling !;lces ;'Inel I II ;'I new sealing ring .
1 6
Fuel lank filler pipe -removal "nel refitting
I Remove the cap horn Ihe hiler pipe. 2 Re movo Ihe .ighl·twnd siele lIim p;'lllei. 3 Peel back Ih e in sul alion clear 0 1 Ih e pipe (:Over fliln cl (Ghia only). 4 Lift outlhe pimel coverinU Ihe spore wheel. 5 Unbolt Ihe IllIer pipe covor panel. 6 Lo osen th e clips and releilse Ihe rubl>C1 oail er from Ih e floor and f,llel pipo (phOIO) 7 Remove Ihe screw al Ihe lO P of Ih e pipo nexl 10 Iho filter cap (photo). 8 Disconnect the hoso and withdra w the I.ller pipe I rom in si de Ih e
car.
o Relill ing
is a rever sal 01 romov;lI,
A
cceleralor cabl o - removal and relining
Removo Ihe
lowe. lac.a panel inSide Ihe ca'.
166 Rull"'" !F"1I1';'I1 "otlom " I I"". la llk flU", l"llll
(
. ,'l
--.
. ~
1(; 7 Fuel lank flUc. Pll~ UppCI 1II0UIIIIII\I SClew (.lIwwL't I)
"
, I;'.' . :~, \;.;
: : i;. "j -' , ,' .... :r: , :'y~ it. ; '., :
Fig. 3.24 Disconnecling Ihe innor cabla from the pedal (Sec17)
Pusll M 11 ,mrl rcfc,uc ill IJ
2 Disconn(:cI Ihe cahle 1<0111 Ihe I)OOal hy unhookoug Ihe clip and rcleasing Ihe ""II:! cal,le 3 Rem oye Ihe IHal:.e servo un:1 a~ dcscfLb c(1 11 Ch;lll lcr 9. Ihen remove the SClew securrn~J Ih(: Oulcr cable to Ihe iJulkhc;'ld
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)
Chapter 3 Fuel and exhaust systems 75
;\1.325 Prisillll oul tho re l ~ fl""",V<: Ilw au eli!.",u. ;IS d .. ,~r."'J(:d III Sf·etlan 3 5 1',,11 011 tlo" ~I""VH ,,,HI d,s<:OlUI'!Cl 111" I""~II<: sock", 110m 110"
cOlll,,,1 IIIIK"!I" G I'll'." Ih" ",,,,,,1 '''','UHrI!l <:lIp hom the IlIi,,;k"l 7 U~"'!I a ~,:",wd"v"r. d"I"CSS tile pl 111 Accelerato r Sl,,'fl and ped,, ' -rc "'ov;,1 ;,nd relilti"u
'o le: If /I" ., IU:(/"I ",!ly ,.~ to "(~ /f.'/!/oVI:1I /("1,:, (0 1""""1';'1"" 12 [)I~.,:,,,,,,,'cl (h" 1",lle,y lea(ls ? r",," liNd" t lw C,II lemove Ihe 1;)(;';1 It""", 1';,,,,,1 II I, '''WII\l:d hy ,,<'I(:W~ (IlHO) OIII""e S{;WWS (LHD) "IIIII!I Ihe ''',II "dUI! ami C;1Il tJ" IUH:lopp"d l,ulll lhe hont l~d\)c 3 n"lllove th" ,u;cole'''lot cilhlc hom Ihe p"dal sha h olS ((e~""h"d III
Secll"" 113
RI-IO variilnls 4 DI~(u"ncct Ihe IHake ope',IiIl1\J IOd ill Ihe b'ake ped;rl. thcn 'enluve tio" I"aslcr cylinder ,lilt! sc,vo lllHI nell" to Ch,lpl!!' 9 101 lUll lol'l
'nl')lll1alI1111
5 WO,kllll) I I"OIl\)h (he ,e,l' bulkhead III the C "IJ"'C vo"'p,"t""!1I1. pull Ollt lire sh;rft "nd S"CUI1I1() chp () Rotate Ihe I1\)ht·h,,,,d Shil l I IIIO'"ltlll\) bush Ih,ou\)h 45' ,n e'lhe' d1lCC1l011 ;)nd pull II Out 7 DetaCh Ihe LHD vmi,!IIls 8 Loosen Ill" clamp illHI dewch Ihe sh;rlt exlClls,on ,oct. 9 C;uefully rlllve Out the ,,\)Ilt·hand 1110unlll\\) bush 'ewln, n\) clop 110111 Ihe sh;)h, thcn slide Out Ihe sh;)h ulll,1 ,t louches the hCitlC! IJOx 10 Detach thc "U1l1 h,H\d mount'n\) bush I,om thc ped;)1 1J0~ by 'Olilllll\) tlHolIUh 4 5' 11 ellhe, ducctlon, (hen pulhng It oul The ilccelera!{), slHlit [l5seml;l), Cilll 'lOW be removed
AI/models 11 Oetach II", 'em;lIl\ll\Y bush ;rm] clIp hOIll lire shalt. ) To re11l0V" the pedill, pl1se the f!;ln\Je ilway Irom the SPIYO( on lire snail. lhell ,emove the p"dal and sp"ng 13 WI,en ,eflll"'!! tire pedal. locilte the sp''''U on Ihe SPIUOI shall, lilr,, clop th" 11""\)"$ 01110 Ihe SP'\JOIS ilnt! check lhilt Ihe pcd;)1 I"vots
cO"lIetl),
Fig. 3.26 Accele ra to r cable rc moval 1001 (Sec 1 7 )
A _ 250",,,,(10,,,)
() ~ Cell(fe IlUlidl /11 /J!Uv;d" ',1,SL'd -'''ullld ... ,
14 ncllll"'() the pud.ll shilft ,s Ihe ,eve,su 01 Ihc lelllov,,1 IHocerhllC, lolinwlllU whIch It w ,lI he 'H!CUssa,y to ;ullllS I It,,) cailic. "5 d"scllt)IJ d 11 Si,(.t'OIl 16 OIL Rill) v;",allts. dlcck lh;ot the I)(:d;oll"'$ 6 tn 14 ",m (02" 1{) 0 55 'Il) I,ft 110'" the nflu posit 'on If IIo,,"ss.u y ild)"st Ih!! pedal
Iofl up ~!Op !O ach'"ve I h,s
19 1"lc t Ill[l"il o ld -rClllov;l1 ilnd rcfitting
1 DIsconnect (he biltlc,y ne(),1Ilve IUild. 2 D'illli Ihe coolm\) syslem (Chapter 2). ,emovc Ihe d'StllIJU1{)I (Chapl", 4), and remove the C.llilll'et!O' (SectIon 8) ] DI~<:OIlI,,:ct til!! rl!m,IIIiUlI) hoses ;rlld Willi'\) <1 UllSV,P.W the 'nlet m;r,ulold holl~ p'ouress,vd), III II", ",v,,'~r: oldl)I 10 that lflvell II, 1"1) 327 5 LIft 11'1) II,let Ill;H"lold frum tlH! o:yhlHit;, hr:;lds ;",(1 II''''10(:k 8 LUCil(e il lIew \)Jsk\lI Oil lh" Il(lild~ ;",(( block :J Fll the Ullet '11;UlIlo ld then II'S"II II,e holts olml i<\)ir(ell them 11Iou,ess lvcly ,n Ihe scqllencu shown In F,U 327 alld ,n lire sw\)es
\)IVCll '" the Spec,fr~.lt'ons 10 The '''lllillll'''\) proced",e IS" 'eve,s,,1 01 ,elHoval rlefrlllhc cool",'J s)'stem WIth Icfe'cnce 10 CI"lpte, 2
Fig. 3.27 Inlet III,mifold bolt tightening sequcnce fo r 3.0 litre engines (Sec 19)
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76 Chap~r 3 Fuel and exhaust syste m s
20 E~huust nlllnifold -removalllnd refitting
1 Disconnect the hallelY negillive h}ild. 2 Apply the h,lndl,)',li<.e then lilCi<. up Ihe Iront o[ Ihe Cill ilnd suppo,t on axle stands 3 Unsc,ew the nulS ilnd d,scontlect th c exh;!ust pipe alld U;lIl!) C 110m Ihe edl;!ust tIIiln"old. Rctllove the sc;!hnH tlllt!. 4 Unsc.ew the nulS p,ou,ess,vcly ;!lIff ,cmove the tIIOlrllfold from IhC
cy lrnd c. heOlct. Removc Ihe gaskels . 5 Refrllrnn IS;! Icvers;! 1 01 renIOV;!!, hUI cleOllllhe millrnlJ 1,1COS "rul Irl new n,1$kClS Tr\Jhlon Iho nuts prowossrvoly
_.-/-
-'
1
2 1 E~rH1usl s ystem -removul ilnd refitting
Posi ,ion Ihe COl' ovcr;!n in~pcction I)rl. O. 100ci<. ,hc CM Hnd suppa., II securely on blocks o. stands. 2 DrsconnC CI Iho bllttcry. 3 lrfl up the rosonmo. hox ;!nc! pull the ,ubbe, rtlsulato. off each srd e b,;!ckel. 1 50111",1IC ,111 Ihe Clmlll) nutS wrlh p<:nClfmrng all. or II jl'OPtlCI,',y
COfl05,on inillbrto • . 5 Disconn ect lhc f!Onl pipe f,om ,he milltlroid. d e tilr.h the sOOlhnu lin!] and lower the ,.onl section 01 ,he lIxhaust
F ig .
3.28 Exhaust system coml)onetllS (Sec 21 )
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Chapter 3 Fuel and exhaust systems 77
Fig. 3.29 CUlling the reM o f tho exhaust system to facilitate its removal (Sec 21 )
6 Usu a hadsa w 10 CII I II"Ul'!lh Ihe .e:!. Cxh:!ust p'pe ilhoul 240 mm (94 .n) ItOm Iho! ''';]' ollho I.onl tI:S(HlilIO' (r.O 329) 7 Removtlihe IHII sl:(:IIIIIl!llhe I.:a. sllrm cm hlolt:kel clamp. SWU1!llhc hl"ck,,1 ell,;" ot 1111, sol"nc", :tni! ,,",I ,lcll lit" ",n, e xhausl ~(,CII"n. 8 Ot.lt.1Ch ,1", 11"'110VI) Iho I"a. IIIOUnlll'!IIIIIIlw. :tnd IIIa(.k,,1 clallip 9 Rell1uve Iho hont P'P" LJ r:lallip and dill I oH 1111) Iron I pipe . D"t;tcll Ihe f(:sonn lo' 1I100mlll'!! h.ack", and Ih" wll plpt: 111111. If filled 10 Slilll 1e!11!1Il!j hy SCllhlll\j il nlo"k 115 I'"'' (1 8 III) 1,0m Ih', CIII ends ollhe ,csonnto. 10 Silence. pipe I I POSition Ihc .csonnlOl and ltont II'IX! ilSS(lmhly. loosely SUCIIIC ,110 the hr,'CkC I and man,Iold connCCIoOIi 12 Slide a se.vice sleeve (FlU. 3.30) 01110 Ihe .eson ;IIOf I"I)C. pos,"on,nu lI S end In Ime with Ihe s O lhed ma.k m,llle p.eviously. 13 F'llhe Silence. l)lpe mlO Ihe sleeve up 10 lI S sCli hed ma.k and .ehl Ihe .e:!. StiOIlCt" c l."up ItJo~ly Wilcil hlhll!llhe clamp. ensutc Ihm liS
;IIlUlet! end .s IIpp • .:tlnn~1 111 1\l1!II'lhe I!xhatls l syst"m sn Ih;11 .. I tin 1IOilit IS 'I Ile;u,,' Ih;)l 1 25 "'''' (1 III) 10 "lty i:Oll'pOllelll. o. 1',111 01 Ihe t,,,dywn,k TI!lilteli th\)
• J. ,
.) '. ,
FiU . 3.30 F itting the service sleeve to Ihe eKhausl system -arrowod (Sec 21)
II1n n llol(1 conn(:(:tlon and Ihen screw on Ihe nUlS of Ihe .esonnIO' clnlllflllll111 13 mm (0. 5 m) of Ih.end Pfotrudes Ih,ough Ihe nulS. 15 1'0SIlion Ihe IWO U·dmllps on Iho service steeve and li!Jhlen the n\llS 10 thu IO'IIIHl w.ench sc1ttng Uiven in lite SPCClhC,ltions 1 G [1"" 1 lit,) 1;111 pIpe 111m of "pP'OP".1W thon reconnect Ihe b.ll\e'y. M:ttllhe OllOine and chock 10' 10,lk 5 17 Low,,, the c," 10 Ihe Wound.
PART B, FUEL INJECTION SYSTEM
22 Goneril! description
The 111,,1 "'1"Cllon sySlem fitted 10 Ihe 2 .8 hIre engIne IS o f the COllltlllHlIlS '''IL'Cllon Iype ;tnd sttppltes " p.ecisely conuolled (IUnllllly (II ;I\()lII,":d hll:1 10 "nch c ylt1lde. undo. fill Ollo.nttng condItions.
A U C
Fllel plllllJl FII~·1.1C'·''''IUI •• tul '''mUIr) IWlls",!}
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3.31 Locations o f the fuel illjection system compo non IS
Fuel "'WI G rhemlolime switch
(Sec 22)
K
L Relays ilnd line (lise Im,lu'se module OrstllbulQr/mixture cO/wol "",I W,l. m·up leguliltol H Allxrfi,lfV illf device J Stilll valve
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78 Chapter 3 FlIer and exhaust systems
TIlls system, when comp1lrcd with conventlon,lI c.Jrhwctlo, ~rrilngemen1s. oncms of tho fuel inrcclton system lall into three
tI'(lllPS
A FI/ef Milk Fuef Plllllf! F/lel .?CCIIIIW/<1IOI Fuel filler F/lel ,IISltihular ,w(/ millime con/rol l11ralllc MIlllll/ce/Of "',1/1'115 AI( ch.ll11/"1(
B W C Wilil/[I Hd,.ys SMt'ly SWitch
The fuel pump IS 0 1 eh,CIIICtllly operated. ,aile. cell Iyp" A .",SS (IIC rchd ..,:,1..,0 'S mco,p[)I;oh~(1 III the pwnp 10 preY",l! f:XCOSSlvn
p"'SSUIC la"ld III) '" tho event of ,1 ,,)Sl"Ctlon III th e pipelollf!s The fuel ,I(:c\llllula lor ha~ 'wo lunf.luItlS. (t) In 4'ill1I,)(:I1 llll! IIIII,,;,'U)!l 0 1 lhe luclllow. HHlu.:.iI ,ml hy Ihe I)\I"'P ;IIIf' (II) 10 11I;""t,"" Iud I"'"'~''''' ,,1";1 .h" .:o,!.m" h;os Iom,n sw"dn,,' "If TillS p.r.v"rlls .• v; 'po", IIH:1o; .lo.:vel"I'III!1 w,th t:'Hlf.O:'I""nt 100' ~t,' OIlS""l1g .h'lI each cylrndo. fCCOlves Ihe same ;lII1OtUlI. TIlt! mlxhlW COIII.ol aSSemhly ,ncorpo'illes ,III IIi, senso. pl, 1le ;m d cOlllml plllll(le •.
6
9
The iI" sen~or 1)1"le is locilled in 'he main nIl Stlealll be.ween the iI'r clr:wller ,1nd the Ih'Ol\Io bullerfly. Du'ing idling. the ~irflow hits Ihe sensor plate which in tu.n ' Fig. 3.32 Fue' injOCliOrl system flow diagralll (Soc 22)
1 Flle/lall/(
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Mu;/ulc CUIIIIOI ,mif 6 IIIIOlfic pla/c assembly 10 S/;II/ villve 2 Fuel PIIII/I' 5., Fucl (Iistllbutor 7 Inicc/or valvc /I 'hell1JOlimc sw,lch 3 Fuel i'CC/IIIIUI"tul 50 Alf SCIISOI 8 WiJllII·Up regula/or 4 Fuel '"10:1
"'
Plcssule regtllillQI 9 AU~IIt"aIY air device
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Chapte r 3 Fu el an d exhau st systems 79
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Fig. 3.33 Fuel injuctiOIl system circuit di 1 /J,1I1C 1V C W"lflll (If! luyu/',lor plMC
2 Sialicr I/Iolor /) Axll/,-"y ,1i, device G Theo1lO/lmc switch
3 fgnitioll switch E FIII;I/Iump H St,lfl valve
A M,lin con(Iol r(;/,)y F S 8 Power supply rcl.1Y
Tho safety switch is provided to cut olf illl power !O the fuel injection sySl(!m if the air sensor plJIC (mixt\HC COlllrol assemhly) IS il the rest position even if the ignition switch IS all. The s[lfcly switch would ell! off the power to the fuel pump for oillllpic ,I il fllOJllmu W 23 Aoutino maintenance
AI the IntelV Check (Jnd adiusl idfing spoed 1 COllnecl11 11Ichomeler to Iho engine then rlJll the enVine to 110rmal Oper ., '
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n fr.X l
the engllle 10 'die.
3 Check Ihill I he idle speed is lIS given in the Specificmions ilnd il nccnssary "dlust the idle speed screw 10cllted heneillh Ihe Ihrottle housinv {photo).
Check conditiorl o f fuel hoses " Reier to SeClion 2.
Tighte/l the inlel manifold boilS and /luis 5 Refur 10 Section 29 and lighten the inlel rll Reflew Ihe fuel filter 6 Refel to Sec tion 25.
Renew the air filter element 7 Disconnect the h assembly, ,1rld hit out the air filler element {photo). 10 Cle 23.3 Idle speed ildjustrnellt sc rew (arrowed) 238 Releasing the .. II cleane l spring Clip 23.9 Removing t he air filter element
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