belt FORD CAPRI 1974 Workshop Manual

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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 Cllltch (e/Mllter 5) Check adjuSlmenl
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 $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
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50 C hapter 1 Engine
51 T llp pcts -removat
Remove the 1 !.111m "' thell bores.
5 2 Crnnksh Prel/cntlho CJ,lIlkshilf l hom 'Ot:ll111(J. by lillllmUl!J the flywheel,' the (jl1nin.! 'S 0111 01 the C;1I, o' hy 10ckll1\1 Ihe transmIssion ,I the cnOllle IS 51,11 III the Cill . 2 Rclcilsc the p"lIny boll hy l,oUlU 1l '111\1 511.11111C. ;'Ind rapptl1\J the sp,lnnc. ShiH ply, thon remove Iho holl ;1I\d washer 3 Usc il S I).ockcl pllile. 10 (h"w the pulley olllhe Cfilnkshall. Do not ilUOl1lpl 10 lever II oH, bC(:.lIlSl; the engllle [,onl COV(II IS j,aulle ;111(1 Icvcrn'H ilU1l1l1S1 11 Ill;)y (11510'1. or even InC.11; II.
4 Wilhdraw Ih~ Wood'uH key hom the end of th(! CllInk5hah and pl,lC,(! " w'lh Ihe pulley. til(! holl alld its washer 5 The C'.1nk~h;)h p"lIey m;oy he ICliloved wilh Ihe eno,,,e III Ihe C:\I. hilt ,I 'S IIIsl tU!Ccss;o,y 10 ,emove Ihe ',ld'illO' :lI1d thc rh'vehelts
53 Flyw heel -remov[ll
P,even llhe flywhcel hum 101m",!) by FHlHllln\J Ihe lin!) !lcal ;ollain~1 ;In imp.ovised SIOI). 2 On nlodels willi nl;lnu:ol 1I;o"$""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 9 Remolle I he Inur boilS securing Ihe fronl anlj·roll har to the Slde·membei (lnd the l()ul boilS securing each engHle mounling blllckel to .lIe sidenlCmber. 10 Remove the 011 sump Imlts lind I I the sump hns sluck to the crilnkc;ose .• elellse the sump by press ing 'I sideways wilh a screwdriver.
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, screws. These cannOt be removed wI,h an oldm;OlY screwdliver ,lily nllempt 1 0 do so WIll resull OIl Ihe sc,ews bemU d",na\.l<:d. I Impact SCfeW(!IIver is nOI ilva,lnl)lo. the SCIOWS m;o¥ he Icmoved w sui l:oblc key lInd the urace 01 a sockel scI 12 Remove t he c.1m5ho1ll IhllJS I !)lolW 011\(1 the space. hclund II 13 Pull the c;omsh;oll lo.ward to wllhdl,1W 'I. 100f 111\1 Cil!e 10 ~ee" Sh,'lllfl Ime. 50 Ih;ollhe edges ullhe cams do nOl rt,1mnge Ihe cam~ beilllllUs_
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)
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,. Chapter 2 Cooling system
Cont ents
AntIfreeze mixture Cool ing system -draining, Cooling system -filhng Coo ling system -flushing " D,ivcbcllS -femoy~1 and refilling Expansion lank -removal and reflllmg F;)n hub be,Hing (3 .0 lit re eng ine) -renewal . Fault diagnosis -cooling system
Sp(lcifiCiltions
System type
Thermostat
Opening lempel F ully open lernpcln1 ulc. 30 hlle engines , ... . _._ .. .... 2.8 hlle eng1ll es .. , ..... . _._ .. _
M'ninlllnl IhennO SWI Havel _
Orivebelt tension
O()lleCI,on JlHOwily between pulleys (longeSI run)
Prossure cnp setting
3 0 lure engines -._ .. ,. "._ 2 8 hire engin es _
System capncit y
30 htle eng ines .. , .... 2 8 lille engines
Ioorque Wrench settings "lIe fHlgil)( :s
'" ~JI~;·;~~;~'·." _ ... , .. " , e"noSl~t 110[151119
G 3 5 4 10
" 12 15
Gene',,' description RmhalOr -.ellloy;,I, inspection, clCilning imd refllting RO\ J\inc rn TcrnpC' Thc'1ll0SW I -removal, testing and !(~fl1llllg . Viscous drive fan -removal and refilling. Willer pump -,cmevn l and refilling
1 7 2 13 8 11 9
P,cssu"scd. With beil ·drlven pump ,1"d larl (VISCOUS (hive type on 1.1u:, moduls). IhcrrnoSWI ... nd expansion \,lflk on I"W' Illodels
85 to 9S ·C (185 to 208'F) 79 to 83" C ( 1 74 to lSl'F)
9910 10TC (21010 2Hi"F)
9 T C (207'F) 7.0 nun (028 Ill)
100nll)1 (0.4 in)
091 klll/enl' ( 12 .9 Ibljin') 0 .8510 1.10 klli /elll' (12110 15.6 Ibf!m')
931111e (16.4 pinl) 8.71111e (15 3 p inl)
No.
710 10 710 10 161020
81011 17 10 20 9 to 13 810 11 20 to 25 201025
Ibf ft
5 to ., 5 to ., 12 10 15
6 108 13 to 15
7 10 1 0 6108 151018 1510 18
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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 Check coo/tint level 3 Whe r(l Ilrl expanSIon 11lnk 's hlte d (I"te. Illodels) lhc I;oolnnl ICv!:1 can tJC check ed without .enlov,nu the pr Check drivebelt conditioll and tensioll 6 Inspect the complete lenlJth 01 th e tJrovehell(s) for dClello.,llIon which WIIIIlI)f)e,lf ,lS h1lyll1U 0' UlilZinU to the 1)Ulley cUl1t ilC t su.fi\Ccs. 7 Check th(lt the deflec tion 01 the d.ivebclt{s) midway hetween the wate. pump i1nd (litelnntor pulleys is i1pp.ox,,11i1tely 100 111111 (O 4 OIl) under 1ll0de'i1 le thumh p.essule (photo). 8 Whe.e ~Idiustillent is neceSS(I'y. loosen Ihe Ililefllilto. p,vot and adjustment bolts. re l)OSlloon the alternilto. then tighten the b olts. A leve. mill' be used at the pulley end o f the IIlterna tor 10 o b1;lIn Ihe
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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Chapter 2 Cooling system 63
10 Orivcbelts -rcmoval .. nd refitting
Where ilpphcilhle. remove the power slecrinl] pump d rive b elt w Ith refe rence to Ch 11 Viscous drive fan -rcmovllt ilnd refitting
Fm hest acce~s to th e fan. 1"~1 ,,:(l10VH th e ""hatol "s dc~c"hcd Ifl
y
SectIon 7 2 Remove the drivcbel\{s) (Section 10) 3 Wlwlc the filn hils ,1 centrill bolt unscrew Ihis ilnd wllhdrnw the fan from the extension Shilh. 4 If the Ian IS secured by It is possdlle 10 Ullscrew two 01 the pulley boil S so Ihm il spilnner 01 nor m G II necess t _
~~-~~,==========~)
I( t-ix~
(0
Fig. 2.5 Manifold spanner lor removal of the viscolls drive Inn (Sec 11)
x -2[j 0 "'''' (I 0111) Y -1201ll1ll(05ill)
e
11.5 80l1s securing filn 10 viscous cuupling 11.6 Unholting the w procarmanuals.com

Chapter 4 Ignition sys te m 95
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. 2 1!11"I'On ampllf,er mod"l~ .1m1 mull< .pluu eOllllecto,s
2 With til() l~pll!lOn sw'tehud off rhsconner.1 thO two llIulu·plu!) comW(:I 11 Spark 1)lugs -re m oval, servicing and retitling
l' Rem ove the ilir clea ner or inl et duCling ilS rC{luuC tl. 2 Identify Ih c HT leads for posi lion \hen c11Se 0I1I1CCI them from thc sp.,.k I)I!I!J$ hy plllhn!) on the IC'fl,i",11 ends. not Ihc tIIilin leilds (photo) 3 US'''!! a sp;"k pluy Sl)ilnnrlr. unscrew tllf! pluUs 1'0111 the cyhnder
h
Ci'ld s (ph"lo~1 4 H Ih'l IIl',,,laIOl no~ of Ilw sp",k pl"H IS dean i'lnd wh,te. wl1h 110 (ICPO$115 tlw;.~ ".dlCo1l1ve of a w,~;,k n"~IUH1. 0' 100 h o t .1 plug (,1 hot plug II;'n~h:ts 1",.11 aWily fWIl' t he I)h.~:I.odc slowly il cold I lhl!1 triHl sle.s ,I ;rw.lY "",dly) <; lhl! IIltl!JS f'l1l:d ilS stimrJi"d a'c ilS hSICd IIllhoJ S pccifleallol1s!lt Ilic ha. d black look",U depos.ls. th..,,, Ih .s .s ,mheilhve Ihilt Ihe m'~I\I.e IS o "eh Should Ihe plllg he h l"ek amI Oily. Ihen II IS lik ely thaI the .I U ine IS fairly W Olfl. (IS well il~ Ihe mixilne benlU 100 Itch 6 If th c lllSuliltor nose '5 cove.ed wnh I I\Jll t Ian 10 glcY ls h blown (ICI>oSIIS. Ihen Ihe mlxllue's CO"I..'CI ,lnd II '5 h kely Ihallhe eng"'e IS ill good condurOll 7 "the.c ilfC illly Iraces of lo"g b.ow n tnpC""1J stilU'S onlhe OUlslde 0 1 Iho wh'le pOl lion ollhe plug. the n th O pl\l\: 1 W ill h,1V(l1O be renewed.
as Ihis shows Ihiltlhere .s il filulty Jom l helween Ihe plug ilnd body and Ihe insulilIO '. and comp. ess.on .s beltlU ilflowed co IC 3
4 \)6
Fig. 4 .6 HT I Cild l)osilion5 o n the 3.0 l i tro C "~Jine (Soc 11)
AllOW III'''(;,lICS ,,,,,,1 ul "'''UtllC
Fig. 4 .7 HT lead posit io ns 011 Iho 2.8 lilro engino (Sec 11)
AllOW imilc,lles I'UII ! 01 ell!}"''''
8 Plugs should be clCilned by.1 So,,,(1 hlilsung n'achme w hich w.lIl.ce thcll' from cil.bon mo.e Iho f
enewcd.
~. . -,,' ;-------
..... -.,.""I'~ -, .. C"
-C~i < , ','" , ,., :.."
.---.
. ~~ ' . ." , _ t~ .
,
I • I 2 DlSCOllllCC I thO lIT leild . 11.3A ... unsc.ew the spa.k plug I I 38 and remove 11
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Chapter 10 Suspension and steering 161
fig. 10.11 Drivebelt [ldjustlllent pulley holts on 3.0 litre models -arrowed (Sec 2)
2 Routine maintenance
At the "*',vals spec ,f,ed III the Routine MainhHlance $()(;t,on in the front of til() manunl c,lIIy out the 101l0wlIl\j p,o(;cdures.
Check lyres for illflalioll, wear and conditioll 1 Check [lnd If necessary adjust the tyre pressures .
2 Check [III t yres for WC[lr and condition with referenc e to Section 21
Check power steering pump drive belt tensiof) 3 Check thm the deflection of the drivebelt m,dway ulon!) its lonyest nlll between upper pulleys is approxirn 1110tler;lle th"'''h pressure . 1 If "dl"~t"'e"l ,s necuss;uy. loosen the ,dler pulley bracket bolt~. re'posll'o" tlH~ IIIilcket then rc·t'Uhten the bolts On 30 htre llIodels the III[lck"t t"u~t he pivott:!! .1tound the end holt. whmeas on 2.8 litre ,,'odds the b';'eket mllst I", ,"oved wllh"l Ihe elonu"t<:d bolt holes
(photo).
Clwck puwer steering fluid levef (lnd hydraulic huses II pOSStble the level should be checked w,th the Buid [It nOll1lal
uper,\!mg tClIll)Cr[lture . 6 On c;lrly modcls unscrcw the wing nut nnd relnove Ihe rese,voir cover ilild uaskel. The flu,d should be up 10 Ihe MAX level mark on the
reservo". 7 On later models, wrn tht! hiler C lll.Jrk on the d'pstick.Js applicable (photo).
Fig. 10. 5 Topping·up the power steering reservoir on early models (Sec 2)
8 Whele nec.ess.1'y ~dd Ihe ~pccilled lIU1d to bring Ihe level up to the
correct ,nilrk. 9 ChC(;k the hydr[luhc hoses for comJit,on and security.
Check steerinfj ,-md suspension components 10 n,ll$O tilt) front ilno reM 01 the Cill or position over an inspeclion pn. 11 Check the SleetinlJ wck and t'e 'rods for d[lm3ge und weM. Also check the wek HJbber bellows and track rod end rubber bOOIS for spfilS
ilnd leilk[lge. 12 Chec k the front ,md reilr suspension components lor d"m.Jge [lnd wear. In particuf;lr check the front suspension tr.Jck control Mm ilrod stahiliwr r"bber mounling bushes. Usc a lever to check that there is no excessive we[lr III the Iron I slispenSlon lower IJ[ll lJoints which Me
"'\()\JIill wnh the track conlrol ilflllS . 13 Check the operat,on of the I,ont ;IIHt rear shock absorbers This is
be st ilchievcd with thO} Cilr on the \lfOlind by depressing euch corner of the ca' 1111\I1. On 'ele[lsil\ljthe C()"H~r helllU checked Ihe body should ,,~c thell s"llie IIlIl11ed,mely on ,t~ way down. II there nrc sever.J1 ()sclll;ot'ons the sho(;k absorber IS weilk nnd should be renewed.
3 Front hub _ removal. refitliny and bearing adjustillent
Apply the h[llldhr[lke then Jilek tip the front 01 the cm ilnd support
on axlt! standS Remove til(! rOildwhecl 2 Rernove the front ul;lke CJllper With ,elerence 10 Ch.Jpter 9. Whele the flex,ble br[lke host! is connecte(t dueclly to the cililper ther e IS no need 10 disconnect the hose i1S thO} caliper can be suspcnded by wire
aWily from the diSC. 3 By calelul 1 centre of the huu (phOIO).
" :<>,:,~,.
Adjusting the power Sleering pump drivebelt tension on the 2.8 litre engine
2.7 Powcr steeling filler c.Jp/d,pstlck for the 2.8 hIre engine
3.3 Removing the dUSI cap from the front
hob
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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) .
procarmanuals.com

) Chapter 11 Bodywork and fitting 185
18 Door window 'ramo -re moval and re litting
Remove the door !fUll pimo' as previously desclibed, Ihen paollho plas tic sheeting away from the lowe. door p;lnel apertures 2 RClllove Ihe door belt mouldinO/wCiJlherst,ip assembly. 3 lower Ihe window glllss, then peel back the lower front corne. of 1110 plastic shee tIng ilild remove Ihe felicclO' (where ilpplicablc) \0 g1\1n access 10 the I rOl1land rOil' lower fixing bolls. hes t o the reilt of Iho fitSI Illouldm!l chp 7 S,)tinn Ihe real of the h;'lme 11110 the shell. so Ih.lt Ihe hame lies hdwcon Ihe 1.11.155 ,ltld Ihe outer p.l0,, 1. whIlst spml!J"'g the frame fr Ont eltlcal len pasl Ihe mouldln!! chi). so Ih,11 Ihls framo and the l\,p,II,lr (fore and aft) 01 8 to 1 2 nUll (03 10 05 10)
TI\lhtrm Ihe holts 10 The .elnalnde. of t he fI:hlllllg plor-edur!.! IS II", IOVOIS" o f Iho removall)rocedure.
19 Window frame moulding ,md door weathers trips -removal and refitting
Where armlrc 2 When rehl1inu. corrCClly 1)OSltion Ihe weOlthCf StflJl over liS U.oov!.! . W,th Ihe thumhs. cOlrclutly I)IIse lire st"l) lully 11110 th!.! !JlOove J W",d Ihe WIndow up (wl""e ilpplrc '1:0 Door _ r!.!llloval (lnd fl.lfitti"u
Wllh Ihe doo. Ol)!.!". remove Ihe dip IrOIll 'he bOliom ollh!.! check ... rn 1)lvot l)lfl Ihen relllove tho .)Ul \I}holoj 2 SUllIlOtI the door on blocks of \'1/00<1. 3 Where doo. speOlkers Olre fIlled relllove Ih!.! Irllll !)OInel (Sec' ion 1 J) Ihen remove Ihe WirlllU from tire frolll etlu!.! of Ihe doOt.
4 Where rull pin typo hlllUfis ,lie hlled (eOlrly models) use ('
'A ,
FiU. 11.13 Window frame relaining bolts - arrowed (Sec 18)
Prisc out rcllec/or (or ,1CCCSS to A "fld Imlf bock pli/stic slleel over B
5 Remove Ihe scuff "Iilte Itont sCrow and locally Irftlhe wOilther stllp (j Remove Iho lowor I~cia p~nel. 7 On Ihe lI(jhl·hnnd side. rOlllove Ihe instrument p,mel ilS describ ed
III Chilpter 12. On Ihe lelt·hOlnd sid!.! remOve Ihe glove compartment a Remove the Inco lovel vont. 9 UnsCtew the nu's OInd remove the plmes hom Ihe inner sidos of tire
l unges. Ihen Irlt Iho dOOf from t he Cill. 10 Reflllin(j is n reversal of tcmovOlI. but check the <100' striker adJustllwnt [IS desc ,ibed in Section 7.
2 1
Door privDte lock -removnl ilnd refitting
I Remove the doo. 111m panel DS desCtl bed in Secllon I J. 2 P rise the clip hom the control rod ;md d,sconnect It from the m,llll dOOf lock (pho.o).
3 Slide Ihe . e .arninu chp down th!.!n Wllhd.,lW Ihe pllva.e lock frOlll lire outsid!.! of the door 4 Rehllinu IS ,1 .everS 22 Rear quarter trim p(lnel -relllovill OIml relining
Remove the screws rel'llnlrlU Ihe wrndow thet""'. 2 Remove t he B 'Plllar vertlcOlI \I11 Olnd th!.! seatbelt screw (whe.e
OIpp
ciltJle) 3 Remove Ihe twO screws [Inti remove Ille r!.!Dt seat cush ion Whele Jpplrc opel\ln!J "I tire cuslHon.
4 Remove Ihe three 1Iim panel screws !llld the SIOI) 1)lilI!.! Wlre.e
, 20. 1 Door check Ollln (arrow!.!dj 20.4 Door hlnye on , I
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