ECU FORD CAPRI 1974 Workshop Manual
[x] Cancel search | Manufacturer: FORD, Model Year: 1974, Model line: CAPRI, Model: FORD CAPRI 1974Pages: 205, PDF Size: 43.75 MB
Page 13 of 205
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Safety first!
Profession;!1 010101 mechanICS Me , .. ,oned in sare working I)'ocedures. H owever cmhusillshC you Olily be "houl gcuin\j on with lhe job In h'lnd. (10 lake the t ime to cnsule thai yOl" safely IS not pul11t ,isk . A rnomcnt"s lac k of attentIon car, resul t on an i1ccidcn!. as can fnollJJC 10 obSOlvQ COlla;n ClemCIlI,l,y precautIons. There will alwilys be new ways 01 h;IVUlU ac c.ttenls. ;111(1 'he following points (10 not p.eICn d 10 he! n cOlllplchcns,vc liS! Or <111 d,lIlge.s; Ihey ,lI C inlt'!I1dcd rathor to milkc you ilW;UC or the ',sks nnd 10 encourage II sn le ly -conSClOus ilpplOilch ,<> ,,11 wall" yOIl C;l"y OUI all YOUI veluelc.
Esscllli,1/ DOs nnd DON'Ts DON'T .cly on a SU1U1c Jack whtn wOlk'''11 undc'tlCil!h the vchlcle Alwilys usc rch
scDlde d by CSC"ll'''U cool»111 DON'T allcmpllO d •• 1Ul 0,1 unt,1 you ;IrC SI"C 'I ha s t;uolcd suUrC'crr lly 10 allo,d scalding you. DON'T yrasp any Il"l! 01 Ihc cngll1c , e~h,l\lSI or "'I; ,lyt 'c r:onll'''IC. w.thoul 11151 aSCe!l""II"~ IhD I II IS su fl,c'ently co1J1 10 avoul hUlllln!1 you. DON'T ,lllow brilkc UUld or anllfr eeze 10 conwct vc hlt.le P
espcci
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IIIlSS ;1IId evcn de,llh ,llIlh;"ed 10 any exlent Pel.ol (!I
h;1\1I:'y II WIn no.",,,lly 1m !JIving 011.1 co.tam al11o"nl of lIyelll'!I'""'<
w h,,; h IS hl\lhly cx, )loSIY c. Alw;.ys dlscon,,!:!;' Ihe hatlc.y e.1.lh (wound) 11:,""11.,1 1,,·1. wo,k,n\) or' Iloe: fuel 01 CI'lctrl~'11 ~ystll"'~ II possl hl() . looson the frller pl"ys or COYer when d,;oQIIl1(1 I
h ntte.y trorn an extern,,1 sou/cc Do n ot chJ'Ue .11 an ()xCCS~'y" .,,1, the Ihllle.y 111,1y hursl Take cal(! when 10PPInU up nnll when cally,nu the h.ltIC'y lh'I.' I:lcctlolvtc. eve n when drlu led .
S plilshes hy wea""y ruhbcr uloves Dnd go~gles Whe" JU"'I) stnlt"'u 01 ca r uSlI1g a booster uatw.y. to. negDllv c l'" (wound) vehicles. connecl Ihe )U"'I) leads in t he follow,ng S(){ll"'''' F"st connec t one ,orn ,) lead belween Ihe posllive ( , ) le"',,,,als 01 1 Iwo hallelieS Th,,11 conneC I Ihe Olhc. jump lend lust 10 Ihe neIFII ' ( ) lelmll1 0l 01 Ihe booster hOllery. ilnd then to 0 good eDrth , (groun(l) pOonl on the lIehiclc t o be starled. 1llleas t 18 in ( " 5 erll) f" Ihe hatte.y If I)(lSs.b lc EnSUIe thot h onds and Jomp leads ".e CI C.1, any mOllln!) P
VIClnlly o f fuel or fuel vnpour
Ignition fiT voltage A seve.e elect"c shock can result from touching certarn parts 01 tl
Iuni lion sySlem. such a s Ihe HT leads, when Ihe eng,n e 's runlli/Hl being cranked. p
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Page 17 of 205
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'6 Routine maintenance
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Every 250 miles (400 lUll) or weekly -whichever comes first
Check the engine 011 level and lOp up " OCCCSSJry (Chapler 1) Check and adlus t lhe IYIC pressures (Chilplcr 10) Clean the windscreen and windows C lean the hcadlamps
Every 6000 miles (10000 km) o r six Illonlhs - whichever comes fir s t
£II[1ille (Clwpter 1) Change engllle 011 and IIher
Cleiln oil flilm c"p Chcck 10 1 ,IllY fluid leaka!)e ,n enUme CO'llp:lnUlCIl1
Cooling syslem (Clwptet 2) Check cool:'lnt level
Fuel syslem (Clmpler 3) Check idh"U mi~lUle (cmiJUiello1 IllUdels onlv) al I"SI se.v,ce ollIe, overhaul C heck idllllg sj)ee d
Ignition sys/Cm (C/I,Wler 4) Clean ,1nd re!)"p Sl)".k plu!)s (.:on!nC ' breilkCl Illudels olllv) Cle an and check d'Shibu\o. C"I). '010'. HT lealls mId co.1 (COllWct
bleaker modcls only) Check elwell angle (cOntact b.e"ke. mo
Bri/king sys/Cm (Ch,1pter 9) Check selva
Che ck hydraulic flu id h,vel
Ch(: ck p"ds :'Illd sho(:s lor wear Check h.ake hllcs and hoses
Suspension .wel stvi'ring (Chi/pICr 10) Check tyres 10' w ear and dam:lge Check steering COmp{lIlCnlS l o r w e:l l "lid d.1nlilue
Bodywork. .111d fittings (Clwptef 11) C lu .. >ek se"t belts fa. we .... damage :lnd secwity
Elvc(ric.11 systcm (Ch,7jJ(ef 12 ) Check Ope.iltoon 01 "Uhts Check wilsher flUId levels Check b.1ltery eleclrolvle lev el
Every 12000 miles (20000 kill) or 12 mOll1hs - whichever comes first
III .1(/(lIlioll 10 Ihe 6000 m/le sciler/Ille
Engine (Ch.1f)ter 1) Check and adlUSI valve clearanc es
r"' .......... ~.~-.... ._ •• -.... __ .... . 3lii1&l •
Cooling system (Chapter 2) Check condition "net tension of 1111011)<1101 dflvehelt
Fllel sys tem (Chapter 3) Tighlcn inlel IIHlnl lold boits/nuts Check vacuum hoses Check e~hiluSI syst em Check ll1r ctonne. temperature cOllllol (,I applicable) Renew fuclllllC ' (fuel injec tion models only)
Ignilion system (Chapler 4) lubricate th e dis'flbulOf (conUlel br eake r models only) Renew the coninCt hu,akcr points (II nppllcJblc) Renew the spMk plugs
Transmission (Chapter 6) Check ool/th"d level Lulmc;ue automatIC 1.,'Insmlss,on IInk:'lue
Rcar axle (C/MplCt 8) Check 011 level
Bli/king system (Chaplet 9) Check v,lcuun' hose
llliJllc:'l1C Ihe handhlake Imk,loe
Suspensioll {//j(J swelill!J (C".1plt~( 10) Check condItIon and hlllSlon o f POWI.II ~I!'tllllli dllvthtl1 (II .1l1pllcal,
Check MlspenSlon 101 we;" ;111(1 d;1Il1.1!)e
Bodywork ,1I)d fillings (Clwpler 11) Check opera lion of all locks Check secu.ity 01 dOOf check sl.aps
LlIl)fIcalC locks. door c heck S\','P5 :'Ind fuel fdler cap flap
Check underbody pr olCctive coalm!)
Electrical system (Chapter 12) Check Opcra1l0n of all eleC111!:al IIcm5
Evcry 2<1 000 llIiles (40000 kill) or 2 yc;u s -\Nhichever comes firsl
III ,1(/111/'011 10 the 12000 111"'1 $d'~'f/u/e
[nyino (CIWpICf 1) f!ell'!W crankC:l $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
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Page 33 of 205
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ClliIpter' Engine
22 Unholt the thcrmOSlilt INlr Woller eillow R()llloVC the ~Jo1~kCl 23 Unboillhe 1II11Ing cover "ml relllove the UaSkCl (photos) 24 Ullscrew Ihe bolt securing the r..~m~h;'lh {le.1. 10 the Cillll$ho1h ;mll pull oHlhl! nCill (photos). 25 Unscrew the fronl ontctnlcrh,lle plil!C {IHllch'llg boilS ':'IIld rel110VI) tllO rn(crnlClhnl C pinto . Remove the \p$kct ,HId ~pnccl (photo~) 26 If the crDr1kshil ft gO;!' nco(ts 10 be removed usc a stand.lld (1UIle. 10 d 'ilW 11 all the CI;mkshilh (phOlO) 27 Unscrew th e camshah thrust pl,lle 50CU''''0 boilS, rcmo"" Ih, ) thrust 1)I.Jle ilnd wi\hdrilw the Cil!l\shatl (ph010S) , 28 Check th,1 tho l)ig-ol1(1 hC.1roll!1 caps Hlld connCCllllU ,ods loll"', ,denl,lic,ltion 11\;1Iks. This IS 10 "n"",,) (h,1I the CUllect CilpS au! [,II,-d (" the COllcc t connecting rods aod nl "',I"""lIlhly 1l1l~ flBed IIl1h"u ~:O"'''.1 cyllndcr hOles NOie thol11 he I)'~IOII'; h,we 1'111 olllOW (0' r\ou;1I1 ma,~"d on Ihe Clown 10 rUdrC,lle Ihe Inrw,r,,1 1",:OIl!1 s ,de (pholOs) 29 flelllove Ihe No 1 cyllnde, I,,!! ,'r,,1 ""IS. Ihen l.1p of! Ih" I,,!! ':Old
cnp I<",.p I"'~ ~h"11 ''''.1fOllgS w'lh Ihe C,1p .1nd COllneCling 'od I, wh,ch lh~,y Me ,eOllIJved . To remove the shell hearings. p,ess "eolllnu on Ihe s,d,) opposilc Ihe g,oovn on hOlh Ihe connCC IUlg ~0(1, Ihe C"I) .• md Ihe h("lllnu w,1I slide 0"1 (photos) 30 W'lhrh.1w Ih" il'~I(ln and co,m(,r:llI1!1 'od "pwards out 0 1 cylind", I,ow hv 1.lpp,ng w'lh lin, h,,,,dl< , 01 " hnmmcr I, 1I,,,le""',1Ih 31 Rtpc:1 II", poo f.·,lwc gIVen ,11 11;'I'''!I',11'105 2!l.1nd 30 10 remove 'C011.1HlH1!1 ,"~IO"~ an, 1 ,:onneclIl1\j fo.b 32 M,,~,) ~II'" Ih,1 II", ,denul'C
:13 U"",, Ih" ""a"'"~lllolts ~mllih 011111" Ill.llt' iJ(!.1tltJU f.nps '''I(I
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9 .2 1 Removinu Ihe enu ine oldaplo, pl.rlC 9 23A Unholr Ihe 11111111\1 cover 923B tll1( retllOV(! lhe {JJskel
9 7.IIA Removc l11e secunnu holl 97.110 ,1rHf ~I"I" "II Ihe t:;1I11~h,"1 un,II [) 25A UI1~Clew Ihe Ilults
;Itld .{!tllOVC the UlICltfled'JIC 925C tlml !JiI!.kt:l
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36 Chap te r 1 Engin e
8 Luh"(;;,,,: lh.) VdtVt! ~1t:m w,1h t!"!l'iI" 011 ;mll UIS",. 01 III 111" yak" !)lIId" Sinh: Oil ,'"ew oil ~I:dl 1110) loUin pla~ttc. ~,:"Is !I\) Urlilip. ,,~h"LI,t v .. lvus (photo) !l F" the v,llve ~PUll!1 ,11111 val",", sP""!J 'CI,lUlI" , 10 Usc .1 ~ul1;ol)h.1 valvll ~P''''Ll (:011111,..,,,$0' lU co"'p'"ss th" \I,11.,c sp"nu unlolthc cOIl<:ls C;lI' In, j'ticd It, p05.II0I1 III ,In, ~lnlS "' IIll) y,11110;: stem Release Ihe v:llve 51)/111\1 f.()UlI)I(l'!>sor. 11 A lter filling ,1111he p,uls. 1011' ti m lOP of the v;,lvl] SP""!1~ 1I\llllly wIth 11 plas llc h,'1111l1ur 10 0.;115""'; CO"CC1 sc;n" ,!! ol'he colll:,s
16 Cylinder borl)s -clIn,nina,ioll and rcnov;ltioll
A oww cylllld", " Iwdculy IOII"d I1l1d Ill" wdll, p.II;oll o:llI"""OIl<)ul liS h!'l!lth Ihe a.; """ 0 1 1111: 1",1,11, '",uls ,,, WI',,, lilt) w"lIs III "!Ihl _"'!llcs to 11m \lonl!I""" II'" ,II,.. "' ~"I" Ih,u,,1 litis w",n I"I\.·~ 1,Iacc
PII''':'I'"lIy 0" Ih,vOl OIl . :on:''''''l'l ulIl ,~ 1!t,O 10 wall! 0' brokc n
p'~I(II' IIII\IS '" 1""IOtl~ :1 11>1 'S po""oI)I'1 W 0111"",, ,11""e IlU';oS,,,,,,U ",,, :/O,,,,,lu •. " 'c,IS,"O Ihe I)IlIC II' Ih., tll'''M plalle bt:low Ihe lop ;,nd aU,I'" ill Ihe bon"", 1>1 tho! .:yllllllc' "I Ih.., """'c pl.",.., II 110" ,1,II""" .. ,c '" IIIU.u Ih,'" 0 076 ,"111 (0003 III) II,ell a ",lxJle 'S IlCC',$S;" y S",,,I;,, Iy .. dolle.encc 01 0 076 """ (0003 ,nl o. ",u'e .'c'oss Ihe holO, (I';IIIIel<;' IS as,!!" 01 oVilhly
1;.,II,no 10' ,l,ci.llJlU
i
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4 Any ho.e whIch is siunlllc~nlly scratched or sCOIed Will re botin g. This symptom usuafly indlcalcs thm IhO piSlon o. rill d;,uII;"Oged. Evcn II only one cyhnder is in need o f .cborlnl1 il w,1I ~ necessnry l or nil cylindcrs 1 0 he bo.ed "nd I'lied w il h new 0 p'Slons .. nd rings. You. Fo .d ;"Ouent O f 10cOl' mala. engin, spec,ahst w,1I be ,,1)le 10 .ebo.e ;"Ond Obl;"o"l lhc necessOI'y m,' pistons II Ih e CI;"Onksh~h IS undergoing le!)lin(!ing .. Iso, iI's .. Iden to lei Ihe S"1I10 111m .enovmo OI"d reassemhle Ihc cr:"lnksha' ll1Slons 10 the block. A rOI)utilble I"m no.mOllly U,ves " Uunr .. nl· suCl1 walk In cnses Wflele enl)ines hnve been ,ebo.ed ""e:"llly I. mOl~lmum. cylondc, loners Me OIvOldahle wh,ch mlly be li1l(.·(1 In cases Ihl! s.,,,,c .ehoflnu I).oeesses have 10 be lollowcd an, se.",ces 0 1 a spec, .. h:;1 cnu,nee!U1U ',rlII :"I,C .eq,lIIcd
1 7 Pistons (lnd piston rings -cxaminmio n nnd renoviltio
WOII! p'stons nrul linus Cilil usunlly hI! (to,1\1!losed whe, ~y"'plo',,s 01 "~C"SSlve od cO"Su"'pl,on nn d low COIllI)'''SSIOIl ;,"11 ;"" SO"lCh"U'S. lhouUh nOI OIlwOlys. assocI,ltcd w'lh WOfll cyl ho,cs Comp'ess,on leSl,"5 Ihal "1 ontO Ihe SI),l, k ph'l) hall.:
Ihe pis tons <15 descllbed l:lI el In Ih ,s Sect.on. Theil place Ihe rin. the cy luuler hores hOIll Ihe lOll. push,ng Ihem down aboul 4 0 lilli' '") wllh !he head 01 Ihe p'slon (100111 wh,ch the 1111\15 hnve ! ",mo,,!:dl so Ihm Ihey !cSl sqll.l,e 11 Ihe cyhntJe. Tho;n ",easuo, !I"I);lllhe "lids ollhe ""!! w,th II leeler !F.u\lc (photo) 11'1 e~ceed ~p·ec",ed m,lxill1um tlmn Ihe IIIIU needs I!:'WW'" 11 The \l!orwcs '" wln,,;h the "n!lS loc,ne It' !he pl~t
eOllllcclmU IOd assclllhhes Shouf(1 be kepi wilhill the hilli l VllllaliO a!) (028 Ot) 10 'l.nlnWIII Cl1glfW balancc () To IClllove Ihe p'SlOn IIIl!)S. shde them cOl.eiuUy over IllC lOP 01 pl~lOll. !akin!) ca,e nOi 10 sClillch lhe aluII"'''''Ul nlloy. nevel shde II oU the h()!iom 0 1 Ihe p'ston sk"l. II IS vc'y ensy 10 !)fc,lk the CIISI
I"SIOll fI:'US " Ihey ,,,e 1IIIIIed 011 fou\lhly. so Ihis ope'auoll shoulI dune wUII e~t,c'"e c ;u c. II 's helplul 10 n"lke lise 0 1 old l\lcle. gall 7 L,II one clld 01 tile p'SlOn nn!J 10 he .e'"ovcd OUI o f liS U'OOVI! "'S\.'I I IIIIde. U Ihe cnd 01 Ihe leele . gilugO 8 TlI'" Ihe Icel e. UIlII\le slowly .ound Ihe IIiSIon lind. as ill/l '
173 Check,nt! Ihe 1)'S lon ""g cnu ~l"P wllh a le"le. uallUC
1 7 8A Remov,ng Ihe lOP comp.esSlon ling 17.8B Remov'ng !he second compress,on IIfl!J
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Chapter 1 En gine 39
238 Checkirog the rolor lobe cle
The p'essed steel 0,1 sump is allDched to Ihe underside 01 Ihe C'~~kcase and aCls as a reservoir 10' Ihe engine all. The 0,1 pump d,,,ws ~~ 'o01lhe sump via an oil SlrDiner and inlake p,pe. Ihen passes 'I uno , t6 lull. flow olll,tler The 1,lte,ed oil 1I0ws hom the cenlre of Ihe oil ;,~e, elenlenl and passes tluough a shari drilling. on Ihe right.hJnd , ,", to the 0, p,essu re switch and 10 the main gallery (on the e 1· Mld side of II -
F Ie C1ankCllse) th,ough " ttansverse d"llIng. Md °h'''' d"lhngs conneCI Ihe main galie,y to the lou, maUl bellflngs be I C camShaft bea"ngs in their turn are connected 10,,11 Ihe Illain d"~I':ngs The b,g-end bea'lIlgs D,e supplied w,lh 0,ltl1l0\lgh d,ayonJI ) 'nys Iro01 the ne,uest rllilill bearing b'U~\,h~rolhec,ankShaft is ,0 tJtlllg. oil ,$ Ihrown irOllllhe hole in each and e~ bea"ng and ensures splash lul)ric"tlon 01 Ihe gudgeon pins lu b ,I HuSt s,(le 01 the cylmder$. The ttllling \)ears
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2310 Checkillg Ihe endflont
Fig. 1.3 Engine lubricalion system for the 2,8 litre engine (Sec 24)
The c r
2 5 Cr
....
~---------------灲潣慲浡湵慬献捯m
Page 41 of 205
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40 Chapter 1 En~Jjne
The system IS known .15 the re v SYSlr.m (positive Uilllk colSC ventilatIon) n n d the il(lv~nt.1(JC 0 1 the sy sleln IS 111;;1( should the 'blow h y' exceed the CtlP
To CIlSU", m,1XIIllUIll life wnh I1\IIHlllurl1 (,oublc I,om im ("",hauled cnume, 110[ o"ly Illllst evcry Pill I Ile cOlfcctly ilsscrllllled Inn """yIl 1m\! 11"'S( he spotl{,s~ly clean. <111 0,lw.1yS m ust he c lCJn, Inckmol w,l~h(!IS nn d 5P''''() wa~he,s O,"st o1lw"ys he Iitted wherc n""d.·,1 .u,,1 illl h'mrlnus ,111(1 Oil "" slld,rlO ~"rlilces must be th o rOU!jllly 1"I"Wd l"d (lUIII1\J asscml,ly
2 Be low ols~"lllhly. ,,~new ... ny hol ls. studs '''H I nu ls wlo"", 11""",,b alt.! Ii) ,Illy w;'V ddllh1\J"rj ,II HI wheneve, poss,hlc 1O~" ", , ~P"IIH w ,lslwls Ohl.H n a compktc so:t o( new !)askets ilnd "II n,', p,"IS.", n"r.ess,',y
3 When ",(,it,,,!) p:,ns "n~"'" I h,11 Ihr,y noe ":('I1<,d on Ih, " "!III)', 1 pos,t,ons il"d d"",CI,ons 0,( ~(J"I lops should h e Slllea",rI " II, !I""'~C befo,e (,IIIII\) A Io'l"ul ,FI, k c t "",1I,"lt should h e "sr,d wh,,,,· "'p"ul",d 10 prevCIlI I""k.,!)"
<1 Ap,"1 from yo", no,m.d tools .• 1 supply o f clean "I!I'" .• " ,,,1 C.II' f,II,)( 1 wnll 0.1":,,, "n!)"h) 0,1 ;"1(( a lo,que W "III(;h ;),e ess"'''t .. ''
27 Crallks h ,d l . rc filt;IlU
W'pe th" ""''''IIH ~h,,11 h":"t,,,"~ "I Ilw c,;" ,kcasOJ wnil." 1"."1 "'!I ,"1(1 fll th" m.II" 1"",,'110 UPI"" h.,11 ,h"lIs,,1 posnuJII 2 "11],,,, 111" Ill;" " h",\I"ltl sh,,1 1 ((":,,t,on5 and lot II,,: h:,I( ~h,·II" II' IIw caps (photo) If I hl] old he:"",!!s a,c IWIIl!! ",I,(wd (oll (l1ou!lh II,,~ 'S.I f,dse eculloll'y "1I1"ss Ihey ;"e p r.lCt,r.,lll y new) m"k e "on. -Ih"y ;'''~ fnl!,(( III (10"" ",,!)uI,,1 POSII,O"S
Fi!l. 1.4 ncar milil) he;!,. .,,\) (;'!(1 " .e " (s h ,Hle d) fo r apply ;, sc;.li"!I compound ( $ cc 27)
3 Apply;, 10111" \I"'il~e 10 ",".11 ""It: 01 II", No : """" lJ",I!niU so '"I",n Ih" 11",,' ,1 W,,~ ll"'~ (" ,Illy """Io:I~ ol,ly) ,1 1: ,1 1110: "PI'''' 1o,llv",s o( I III! Ihl"~1 w,,,h,,,~ "110 II", ,, !)lOove s ",.I" "I 110" "';!'" 1 ":;II ,n'l Till, "10,,,, "''',1 (;oce ""Iwa,ds w'th Ih .
1"".01",1 tt' Ih" 00(,,,,,", /r!,,,ly "It,d.'I~, ""Iy) !J I "1",, .• ,10: lilt, u ,,,,kd,;,1 1 111",,, I""""'~I )ouOI,als ,nid thc 1"""""1 ~I',·lb wl!h ''''!IUH! 0, 1 (1IIIt,to) G I'I,u'" Ill<: ,,,,lI 111,"0 h ca""~1 0,1 """I "' pOS'I'O ll 01) Ihe end 0 ':'dl lk,h,,1 1 AIII"""t'vcly fll II l" lu. ., ",,,,,I,,lIy I"wu, tho cr;,,) ksll.,11 "* , tho (;!iHlk<":ilSC 8 I\pply;) lI"n r O;oIIll( ) o( ~e;oluI!J compound 10 Ille n'ilHng fac , th" ,:,;o""O:iI~" .,,,rI IIlI! ,(:", niilni I'CiI""(l <":,IP (p hu to)
27 2 F'IIIIl~I,1 h~'" "'g shell to Ihc I C'" rllJ") h e;)"I1!) Ci'P 27 [) O,I,, )!! No : ''';I ,n he;,,,,,!) UPI","( shell 278 A pplY"'1I sealtn!) compound t o the ,ea, m,I'" I W;),,,I[J rap
D l]
27.11 T '!Jh1l!'''''H (he "''''') heil"n,) Cilp bolt s 2 7 12 Te'"pO'ilrtly sll~k a d hes,ve tilpe on the 'Cil' of Ihe c'ilnkshilit when f'H in u lilt 'Cil' 001 sUill 10 P'01l!(;1 Ihc seal lops
',,::;;Am p.
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Page 43 of 205
42 Chapter 1 Engine
28 G TempO'i1'y holl 101 IOC;l1inO the mlc""t:thiUo: plale 29 5 0'1111(1 the )l'~10n linUS 29 7 0,11I1{J the cyllnde. hOlo
";; '. '''' . :~ .,
.. : .
..-2 9 8 US'''H (I plSl0n "l1g compressor when uiSerhn!llhc p,ston "110 the hore 30 2 Chet;kln~1 the Sial) washer I)OS'['OIl on the 0,1 pump d""csh"fl 31.3 O,llhe tlywheel holls bel o re ',",ng
(j 1,1 II", two f.t:"11'~ holts ItI1!jl.:r·"!lhl then 101 ;Hlorlm' two holls t'''''IHH""ly 1o. IIU:"I"'!I purposes T'!Jhtcli the CCIllle sec"""!J hails th.·" It''''"Yll the '"ml""'''Y Io,u "d 1000,umU bulh (photo)
29 P istons Hnd COIH1(!cli"g rods -refitting
WI, ... , ('.101,1" the COIU1I;:(.I,n\l ,ad h"U of tll c !l0U·end bO il'lIlll 1111d rh e IInde,sulu ollh(l ~hcll h .... "l1y ;lnd IIIIhe sh ell hc"rlllU "' pO$IIIOn WIth It S Im :, IIUI!llonuuc OIl!"'!I'!!! with the COH CSpo tUhnU CU[-OU1 ",the lad :1 If II", old hC.l.II'!)S 'lrllnea.ly n.;w nlld nrc hell'U re!ltu:d Ih en ensure Ihey inn ,dlll"d III Ih"" cO"I.'Cr 1000.UioilS on the COUOCI ,ods :1 The 1%lOn5 , c:;()n ll'l",,~ With c:;onm;c:;t"'u ,ods. mo f,tted 10 the" IH,::es from th(l lOP 01 Ih'! block
'1 luc ilte the p'stoll ""u Hap s III th e 101i0w inU rllilnnCI .
TOil 1['0' fr Olll Ollt· sir/e of /l,e Oil conl,o l 'IllY "ehc.1/ t'xf/8mle. y,l!) Cellt", 150 /tom lire O/Jilosi/e SI(/e of fire Oil cOII(101 ""Y l,el,cM cx,r.lnr/
Bo/lom or! cOll/,,,1 ""9 HeI,cal eXI',lIIdel' 01l 110s,/ e I/IC /II,lfAed {J,S/OII "on / side
ad cOIl/,OI ''''y, III/':"llrHI',J/c lings 25 film (1 0 ill) c.,,1/ sie/e of tllC /Jchcall;xl1amh'l 9,7/'
5 Well lulJllc~le Ihe pl~lon iln d ring s w il h e ngine oil (phOlo).
6 Fit n unlve.salring compressor Imd I>'epalc 10 insell Ihe fllsl p'Slo n IIItO IIw ho,e. Mnke sure 11 is Ihe corrcct piSlon·conneClinu lod ilSse'l.hly 101 Ihill par',culil' boro. Ihillthe c onnecting lad is Iho COII(.'(:I Wily .ound and th3tthe fron t of Ihe piston (mmkcd with an arro w 01 11 notch) ,s 10 Ihe fronl ollhe engine. 7 Lul )l'Ciltc Ihe Cylmd,:r \)o,e (photo) and inserllhe conncCllIlU ro d a"d p, ston nsse ",!;ly ,nlO Ihe cylinder !loro up 10 Ihe botlom of the pislon IIIllJ com plessor 8 Genlly hUI f,,"'ly Illp Ih~ l/ls!On Ihrough Ihe piston "ng compressor nllu "'I u Ihe cyhnd er 1)(.1'''' uSlI'g Iho shah 01 a hammer (phOtO) 9 G".""nu~ly luh",c"I" 11,,, ,,"ank,),,) 10U"",ls with engllle 0,1 JII{ltu.n Ille ClI,nbh;,lt so 11\1,1 III" e'
30 Oil pump -re fitting
Ensure the l1lillmg lilces 01 Ihe 0,1 pump ;Jnd Ihe clankcase n cle'lIl . 2 Inse.1 the hexilgo nal 0.1 pum p drivesh"fl wilh Ihe pointed en lowil,ds the <1ist"bulor localion. The SlOP washer (photo) must IJ posil ioned 127.5 mm (5.020 in) foom the lounded end 01 t h driveshilll 3 FII th o od pump 10 tho cfankcose and secure wilh t wO boll "9hle llcd to Ihe spec,f,ed 1 0'(lUe N ote: When a flew or overhaoled 0 pump is bl!illY IiI/cd. II should be /illed wilh enyine Olll1l1d lurned . b hand 101 om: comple/e ,evolution before being fil/ed. I his will po"" /he plm.p
3 1 F lywheel and clutch _ refilling
1 Fir Ihe engino IIdap lol pla le on Ihe twO localing dowels 2 Ensure Ihe milling faces of Ihe lIywhc(;1 and crank shaft arc cleal
,lnd fit t he flywh eel 10 tho Cliln kshnll. aliUn",U Ihe nla,ks made ii' (hsrn;Jnthny. unless n ew l>arlS a.e being lilted
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Page 44 of 205
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Ch
4 Chock the secur ing boilS
flywheel 10 "'~1'.111' ,I fro", tll,nlll\J. <1nd tighlen Ihe in il (li<1110I1ill <111(1 plO!i'''~~''VU l11<1ntJer 10 the speclf,ed
IOf~:iil l he clutch (Iosf: ilnd p"'~"'l"" pl.rle iI~s"mbly 10 Ihe flywheel 5 . ,ure Ihe disc ,s I he co"",:1 w.,y lo"nd (see Ch<1plor 5) rTlJk,ng . 6 Secure the pr~ssum pl"h~ "~~I:mhly Wllh the ,ct.1U1Ing boIlS. enl'Jlise Ille clulch dISC "Sill\) .11' old !i,,,"I>OX ,npul slwh 0' sul\ahle ~1Jnd,el Jnd thel1llghten Ih,~ ",I""'II1(II,,,IIS to Ihe sp~clfl()d tOlque III
32 TiOling geMS ilild li,nin(1 COVIH refitting
I Check Ih
';
. ,
. -\.
...
I't'
3 hI Ih'~ c,"n~h
,111(I'"nOIlI with the mark on tho cr,ll1bh.1ft HO
(1'1",1") 10 1 " 1 11,,, f'''111 n,l ~(, .. I tn the 11111111(j .:ov"r .111tl .haw 01 11,10 lh" 1'()~'IIOI\ ,h.I""))II,,,
~ ..
:U 'lA Loc"lo the cr,lnksh<1fl U", II 01 111" e ,.",hhilh
322B ,. ,HId uSO Ihc pull"y In pruss It on 323 Alryn"".",t d01S 0" lhu III\lII1~) \le
~ .. ,
..,
, ,
., ' ,
32 .61 Checklllg Ihe pOS,I'Oli of Ihu old 0,1 se
32 6B OflVII1!j 0111 the ""'lIlg COV(:r 0,1 se<11
32. 10B F,tluU posItion o f Ihe e
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Page 50 of 205
Chapter 1 Engine 49
----------------~--~----------------= anuill transmiSsIOn models, remove foul clops
Ir~nsler it to a WOrk lJench
4 $ Engine disill1lotling -generill
Refer \0 Sec t,on 7
46 Engine illlcillilrics -removi\1
..
1,',lh the engine sep,l rated from th" t r;IIl~:nHS~r()" remove Ihe ~.tcrnally mounted componelliS ;l~ lulluw~
C;J//)Ulello, i.lnd fllcl {lump (C"'1!,lt" 3) IlIlel ,wll exhiwsl tII,wi/a/ris (Chaf!/t't 3) Sp,>r/( plugs and drS/fllmlor (Chaplet 4) AllCllwlor (Chaplet /2) F.w ,7I!d policy (CII,71I1C' 2) W.JICf pump ,wd Ihcffllos/.1I (Clmp/t't 2) C, ,1IIkc,lSC vcn/iliilion lubc 011 {,f/CI (Scc/ion 40) Ol/Icvl!! r/rpsllc/o; and {,/lCf C,?!, [II!1int' 1II01tn/ill.ll h,.1r:kvls Ciulell (Ch,7/I/l'l 5) Powl'r S/Cl'l/IIN 1'(11111' (Ch;lll/Vf 10J
<11 Cylind(Jr heads relllowti with engine in car
I
Q,scunnecllhe IJiltlery le,lds ") ~cmove the splilsh slucld. by renuJVIII
,onneCI the vac\JUnl h"e I
MId I I If . CiI( 10 lie dlSl1i Julor Reillove aile h Xlng bolt 11 0
' I
a Ihe dlst"I>[1I0r ilSsemlily.
'Sconllect Ihe all II 51 halts' , ' ernillOr Cil) es. ilcken the ailelllntor 1110ul1l11lg un(
Fi~,. 1 .10 Turn the rocker (HillS to olle side 10 relllove the pushrods (Sec 47)
15 n,,,,,ove Iwelve lIolts ilnd delilch Ihe exh,lusl I1\,lrlllolds frOI" Ihe cylrrlrtr:f he,lds. 16 Sinckell the cyhmter hend boilS progressively in the revtnSe order to Ih"l shown ill FIll 1.19. IlcrllOVC Ihe bolts nlld hit olt Ihe cylindOf head.
It lile (.Iilsket has stuck and the cylrnder heJd cannot lJe lifted off. wp the cylinder heild wllh n hide·f.1cert. or plnstic·headed hJmmer. 00 nOI try to pri se IlIelil off wllh a screwdrivOf Of rtilillage WIll result.
4 8
Cylinder he,l(ls -rernovfli wilh engine O\lt o f car
Follow Ihe sequence (.I,,·elllll SectIon '17. 51;lItll1g.l1 PillillJl1lph 10. dl$lcoa,d,n!1 leil.!lellCeS to pa'is willch hJve alreildy bcen rcmuved
49 Villve$ _. removal
Rt:rllove the d('POSIlS /'0111 tire corllb\lsl,on chambers ~nd vnlve
h eads by ScrilPIl1!l and W" ~ b'\Ishlll(.l Tilke CJre nOI 10 scratCh the cyllnde, he~d gaskel lilces 2 Lay the CylOl(ier hemt on ,IS sllll) .llld h t the lo,~ed cnd of .1 VJlve spllng compressor ove, the ~plln9 rctiluler ""d ti le head uf the complessor screw in Ihe cenl'e of Ihe v"lve head 3 Compress Ihe sprrng abolll " qUJller 01 an Ulc h 10 Iree Ihl} split colle l hom the top 0 1 the v,llve stelll. If Ihe sPltng ,eliHner "nd collel Slicks. do not screw the co",p,essor down lurlhc< . bec"use IIIIs lII.ly dJr11J\je the valve Slem. bUI lJp the sprong reliluler sha,ply wllh a Ioghl
hammer. 'I When the Iwo halves of Ihe collet h')ve been '(:nloved. onscrew the spllng compressor umrl Ihe spring IS no longe, compressed nnd
remove Ihe compreSSOr . 5 f1Olllove the spltng retnlner. the spflng and the oil seal from Ihe villve Slem. Ihen wrlhdrflw Ihe villve from I he cylinder head. 6 D iscard the valve Slem all senls and plflce Ihe Olher componenls to\jellrCt. identilying them so Ihal they arc refItted III the correC I plnce
III Ihe cylinder head. 7 Remove Ihe sp,11k plugs from Ihe cyhnder hend. II nOI alrendy
removed.
50 Rocker arms -removal
1 Remove the SIIfI nul from Ihe foch" .1'111 Illoullt,n\) stud 2 Lift off the rocker
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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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