check oil 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 10 of 205
General repair procedures
Whenever scrvie,,,U. repair or overhaul work ,$ c;nric
Joinl mating ftlces ,7l1d gaskets Where 1'1 gasket IS lIsed tmlwl:CIl the ",,,,ill\1 [
Make SUfi) lh,,[ tnppcd holes nrc ciedncd WIth il pI pc clcilncr, and kcep thcm flcc 01 101l1llng compound If tillS IS helll\) used unless
speCIfIcally Instructed otherWIse Ensure that "II ollfrtes. (:hannels 0 1 pIpes ,lie Clt'ill ilnd blow thlough Ihelll. p,eleriluly llsing compressed ill(
ai/ seal s
Wheneve, nn od sCill is removed flom its wOlkll1\1 10Ciliion, eIther mdlvidu"lly or "s p"rt of iln assemhly, It should be lencwcd The very finc sc"lIng IIp of the sei'll IS e"slly dama\Jcd and WIll not seal If the surface it COI11<1(:15 IS not completely c lean and free frOlll
SCHl\ches, nicks 0' grooves. If the o'iginal scaling surfi'lce of the COlnponern cannOI he restorCd, Ihe component shoul d he renewed, PrOlect lhe lips of the scal from any surlace which mi'lY damage them in the course of fmlng. Usc wpe or a conical sleeve where POSSIble, LUb ricate the senl lips WIth 011 befole fruing and, on dual lipped se"ls, fill the space be twcen the hps With grease. Unless otherwise stated. all seills must be hlled with then sealing hps toward the lubricilrH to he seillcd Use iI\ubuli'l' <111ft 01 block 01 wood 01 the npploprime sIze to II1sta ll
) I he scal ilnd, lithe sCi,1 housing IS ~houldeleu. drive the seill down to the shoulue,. If the scal hOUSIng is unshouldcred, the seal Should be fItted with its lace flush W ith the hou$lIlg top face,
Screw IhrCiU/s and lasleoings Always cnsurc that a blind t"pped hole is completely free from orl. U
reilSe,
wilte, or other flUId hcfore instatllng the hott a' stud. Fililu'e 10 do tillS could C,luse thc housm\) to c"lck due to the hydrilulic <1ction of the bolt or slud ilS It IS sc,ewed '" When tluhtenlllU ,1 cilswllilled nut to ilCCCpt iI spht pin, tIghten the nut to the speCIfIed torque, whele ilpphcilh le, and then lIghten furthe, to the next split pin hole Ncver slilckenlhe nulla "lrgn a spirt pin hole unless ~t
SOllle Inswnces, where no a lterniltlve IS poss ible. II hilS been necessary 10 resort to the use of a manufilclurer"S tool and thIS has been done for reilsons of safety as well as Ihe eHlcien! completion of the repair
operation. Unless you are highly Skilled ilnd hilve a thorough unde,standlng of the procedure desc(lbed, neve, " tWlllpl to bypass the use of any specl,,1 tool when the procedure descrIbed specllies ils use, Not only IS I here a ve,y great risk of pe,sonal Injury, but expensive dillllage could be causJd 10 Ihe components involved
procarmanuals.com
Page 13 of 205
" .
:ansa
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
sp
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
"
procarmanuals.com
Page 17 of 205
" ,
'6 Routine maintenance
)
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 $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
procarmanuals.com
Page 20 of 205
" .'
I
7
F a ult diagnosis
II)/lodue/ioll The vt!HCI.., ownor who cicIlI s Ills Or he, OWII 'l1;'IIll!:Il;lIl1.;U iu:,;()!(Io IiH 10 Ih o reCOln r11Clldc d schedules should 110 1 h(lv,} to u~e Ilus ~C(,;tIOIl o f Ihe nl
1:"'"';1,1 I""it (or tiS svmplO"'~), hUI he w,1I toe II0lle t ill) W'~H'" 11111 1.11,11 l eC"'I. ,111<1 he m,ly well 1I,llIe ~penlnlOle 1'llIe lind ",olley Ihnll WIIS """"~~;"Y A COdlll ilild IO!JIenl "PIHO,l<.;h w,1I be lound 10 Ix: """e ~,'I'~I;I(.tUlv '" Ihe 10llU lun Alw;IYs I.I~" IIIto ;Iceollllt ,IIIV W,,,""I\l :"!l"S h. ,'IIII
0011', Ollerlook Ih e obviolls. Fo, e~a",ple, II Ihe IIchlcl!! W01I'1 ~I,'" '~Ih.,,," p(:llol lf'lhe IiInk1 (Ooo't l;1kc anyone t:lsc's word all Ihl$
1).111 'Cul,,, POIII!. ~IId don'l t"l~tlhc luel UilUUC cllhcll) If i1n clCClIlcal 1",,11 I~ ,,,cr,c,lIed. look 10' loose a. bro~ell WIICS belo.e dIUU"'\! OUI the Ic~t !/t;ill
C
U'e tI,e (liscase. n o t th e sym ptom. SuhStltUllng a flilt b.1ltCry ""til il 1"lIy ch;IIW,d olle Will \jt:t you 011 Ihe kUII shouldc., hUI II the \ul(!~dy,,,\) C,IIISC 'S flOt i1Hendel l to. the flew hall", y WIll fJo Ihe SdillC
W"Y S'''"I;nly. Ch,lIlUor,U OII.loulcd spll, k "lu\JS 101 ,] new's\lt W Ill \JCI YOu "'O'·,n!) "11"orl. hUI 'CIIIIIIIII,c' Ihill the .eIlSUIi 10' Ihe lou I",\) (II II ..... ,1~I1 I ~''''!''Y .111 ",colleCI U.;I
OO'."t t" k l) iH, ythinu fo r g rante d . l'a,"cul
Elcc(ricall,1!1lls EI.:.'Ctrlc,,1 lilults 1':,1" bc mo,e I)uullnu Ih'lII SI.aIUhlfo,wa,d "'CCIl,11I1CIII lalhucs. hut Ihcy MC 110 less susceptible 10 10Utc;ll "n"IVS'S
II lh!1 haslc pllnclplcs 01 OpClil llon ille 1I1I(lelslOod. Vchlcle clecillcill WII"'!) C~ISIS til c~lIcll1c1y "nl'I\IOIl."lIle condi!t Olls hent, IIlb.atlOIl IIlId chcllllcill ill1l1ck :1ml Ihc 1"51 Ih,,,ys 10 lo,,~ 1o. ,lie 100'>1) 01 ,;OllOIiCI I connecliolls 011,,1 b.oken o. Ch.llc(1 w"es, CS!lCc.I"lIy whcre Ih.) WIll'S I';)SS th'Ollllll holcs "' Ihe bodywork 0' ,lit) suhJ ... :I In IIIII'ilIl011 All '''I.!wl·l,o,hed V .:IHcles III CUllcnt prOdur-IIOn h;lIIc one pole 01 Ihe lI,ule'y 'Cil rl hutl'. Ie connecled 10 Ihu vchlclu hodvwOI~, ilml III
lIe"dy ,111 I"orle'" vehlclcs II IS the neUIlI,v!) ( ) 1e""",,11 Thl) va"OU5
"tU(:lu(:;,1 (:o"'tlOIIenIS mOIO'S, bulh hOI(lll'S elc . ;I.e "Iso cOI"'('''I:I",(1 to e.II III. ellhe. by lIIe,lllS 01 a leild or \1"~'Cllv by tlM}If fIlounllnuS
E I('Ctu(: (:Ullmll flows Ih'ough Ihe CO'I'I)Ol1elll and Ihell hack 10 Ihe b"lIe.y 11':1 Ihc hodywolk " Ihe cO"'I'Ol1ell l mOU1I11I1\) IS l(lOse o. <:olludccl, 0' II il lI'lOci pnth bilC k 10 Ihe IWl1clv IS 1I0t av",!"I)lc. ll1e
CHCIIII WIll be IIICOlllplcl!l "IId m"lhln~l.on WIll le$ul l The e"\)IIIe "lid '0' \)c;IIIKJ O ;lIe "Iso eillthed bv lIIeOlllS 01 flc~,hlc lIIel,,1 ~I,,1I1S to lhe hody Or slll)h,lm(!, II Ihese Sll,lPS .11e !{'osc a. ""5SI11\1, SI;lIlcr mOlo'. !lcllewlOr alld 19",I.on "ouble IlIlly rcsull Assulluny Ihe cil.th .Chlln 10 bc sat,s!xto,y, eleclllCOlllaults WIll he duc ()lIhcr to componellt 11111l1uI1(:I,on 0' to delccls III Ihe CUIIClll ~lIl)l1lv Ind,vldu,ll componentS ,,'C de"lt ""lIh If' Ch;op te. 12 . II supply ""nes "'0 IlIokcn 0' clilcked IIl lerll;lllv IhlS resulls '" iln open,cllcu,!. IIlId Iho eaSleS I w"y 10 check for 11115 IS 10 bypass the SuSpCCI wife lelllPo.allly wllh a Icnuth 01 wi,c hi!lImU (I c rocod,le clil) Or su,wble connCC lor m eilch cnd Altemmillely, 11 12V test lillIlP ColO be used 10
vCltly the p.esence 01 supply lIoltage 011 VilltOUS pomlS along the WIIC
lind Ihe IJle
Spmcs [II/(I tool kif MoSI IIdllclcs Me supplIed only " 'Ih sutl,clelll 10015 10' whtel chanUII'll, Ihe M,lUl/t:lII111CC iJml millO' "'pi)i, 1001 kll dCWd cd In To()ls a",/ W()'/o:"'Y I
procarmanuals.com
Page 21 of 205
a
20 Fault diagnosis
Carrying a lew spares eM) :\l1VO you a lono walk!
WHhou t 100 ,ulIeh trouhle in the event o f il hrC
DrHII/mim [(JIm, (:lIlIdulI.~VI IIlId C""Ii":II"'HI~'." I'omls (;'s ;,/I/lII(.','I/)/e
IJllv/.'lmll(s) ,.'/I11:II/VJlCY IYl't' m"y suffu;t, SlIill!! {(I,ft'S S •. '/ of //111//:'/1,,1 "ylll bill/,S 1/1/ 0/ ",dlll/Ol 5<:;,11:, ,mil IlOst: '>,md.1UI! t"~II;III.1'1 /),111(1I1!IC Roll OlllllilJIMlt/y IIIl'l' Lf>llylll of sulillflll WIIC Lc"yllt of ci.:cIIlC,llllt·.
rUiC" Of mSIICC/IQIII;III'11 (eilllliot/blt' ;,S II.'S( I;IIIJIJ) OMlt'IY 111111/1 Il'mls Tow" Q/IC Iym(/Oll WJiClllloo/lllY ,ow/osol Llfll! 01 c"Yllle Oil SeMcI I eMI olltyr/wlIll(: /f",d Emeif/CoCY WII/({SCIt'ell W(JIm ({live cl'II$ Tube 01 Idlel IJ,1S((;
II Sllilro IU(l 1 IS Cil",c< I .• 1 Ciln dcs'Ollod for th(l pu'pose should hc uscd 10 m"l",l(~e rrsks of le
WhiCh, evon 'f you cnnnOi III thcm yowscll, could snve hav'"(J 10 Willi wh,le p
One of Ihe 111010llng 0'ganlSilll0ns w
Ellgillc taits 10 ((IIf) W/IL'II slilrlc r ()p vra le d 1' 1;11 h~lll.'ry (.ud,;,,!!,!, u~.., rlmlll'uolds, 01 push Sl.1rt) nnllclY 1(:rnllll.,ls Ions!! 01 cntlod,!d BaltelY ll.1,tll to hody dd"cl'vu Enwnc e(utll S I,,1)) 100Sll 01 broken Sl.1rtel 1II0lO r (or so lulloid) "",,,ng loose or IJroken
l\ulOn1 ;II,e II1!11srllr~s,()" seleClor ,n W'OIlIl pos",on, or Inhd)!' sW/lcli fHur,y '11""'Oll/SI (lr lu, sw,'ch folUllY
M i'ror mech:u"C.11 ,,,,lure (Se'lUre)
Sli"!~1 Or sole"ord 'ntorrloll rilul! (seo Chaplllr 12)
A
simple les t lamp is useful fot checking electrical fault s
procarmanuals.com
Page 22 of 205
)
T
Fault diagnosis 21
Starter motor ((/rns cngino slowly Parti ali V disch~rilcd b
Engine ((/"'S normally but 1,1ils ( 0 SIMI Damp or dirlV HT !eads
Engine ClltS Ollt ;1nd wilinOI roslinl
fngine culS out suddenly -ignition I,wlt Loose or d'$Conncetcd l T wi.es WCI HT Icads o. d'S I"buiOI C;1P ("lIer tr;1VC'SOll!) w;1'er spl;1sh) Co,1 o . condenser lallulc (cheek 10' SI);lIk) Olhc. ignition laull (see Ch,'plfll 4)
Eflgine mistires belore CUlling oul IlIcll,wlt Fuel I,,"k Cillply Fllel pump dClfecl1vc o. 1,ltcl IIlo .; k(H! (dwck 1m dellvl"V) Fuel tank hllcr vcnl blut;kcd (StII; llon Will II" flV,{Io"'1 Oil lI~h"'~II'H C,11l) C;1llJulCIIor nccdlc v"lvc SIII;klll!J (WIU.'1I1 "ppI1c"hle) C,1lUwellor leiS blocked (ha:l COIII,lIl1ln,Hcll) Othcr lllcl sys!Cm l
BATTERY
lSin.MIN
POSITIVE
JUfl11) Slart lead conneClions f o r neg!Hive earth vchiclesconnect le;1ds in orde r shown
fllgine euls Ol1t -olhor eimses SCIiOliS ovcrhC~ling Mnior mcch
Ignitioll warning light /lot illuminBted Coollllll loss .Iuc 10 In!emnl 01 CXierr'JI ICJk
l.ow cnuinc oil JlfC!ssuro
G,wge reads low or warning lighl Illuminated wilh engillc
rWllling Olllcvcl low or mCOlfeel 0.,,<10 Deit.'Ctivc gllU!jC 01 sendCI 11111 Wife 10 sendCI UIII' C.1I.hC(1 Engonc ove.hC.1l ing O,lllllcr CIO!19c<1 01 byp,1SS v;1lvc delccllvc O,I ,llcssule lehef v'llve dc!ec tlve Oil pick-up strllll,e. ciomled 0,1 pUIllP WOIil or IllOlllllll1\l~ I\,osc Wo,n Ill,l'" 0' h'!J-cn(i hC.1I1I1!)s NOlO: Luw or! 1"t'HlifU III a IImh III"C"f1~" (.'IIYIIIC .J/ 11l;~()VI.'r I.~ 1101 1II.'I:<.'",.","/y,1 (.",lIlSV {o, CIIII{:"/U Suddel! fJf'~SS!lle {U$S ,11 SlIced IS {M "'/!IC SI{Jl!lflca"l (I! ,my cve/l/. .:In',·j. I/le .
procarmanuals.com
Page 28 of 205
)
) Chapter 1 Engine 27
oint t ighten II ~ further 3/4 l urn ~ Remove the t,l ler C,ll> all the left· hand side of the engine and I,ll the g ine with th e correct quantity and grade 01 od (photo), ;n RemOve the OIllcllcl dipstIc k and wipe it clenn. th en fe -insert'! and emove it Jg
(1.76 p int). 10 CICJfl the 0,11,1101 CilP then refit il .
Check and adjust valve cle
hgMel) inlet manifold bolts 12 Remove the ,111 chamiler and \'oh\on the Inlet 111.11"lold hnlls ({J the spec ified lOrque WIth Icfcll!IlCe t o Ch~ptl!r 3 On compl"I")1I ,(:111 Ihe
JII chnmbcI
R enew (fie crankcase ellli,~sion valve 13 pulithe v(1lvl.' (1Pl(I'hose 1'0111 tlw leM 0 1 Ihe "ohl·l1(1nll locker caver
(photo). 14 [1.clc;lse tile cl'll ill1<1 ",movc the v(1lve foorn the h ose 15 Fit the new valve.n levr:rse ordel
3 Major operations possible with eng inc in car
Thc fol lowrng ma lo r operat,ons Cilrl he C;1
,
(It) Rl.'tttOV,ll ollnf ,ellllmg of IIII.' 1".'·(Ofls ilfld cOrlfleelmy rods (,) Rcnewal 01 tI", c ,i/nkslliplt 11(1,,1 Sl'it! rtI IIIIII"y C(lVCI
4 Major operalions requirillg erlgirlo rO!lloval
T he followlllg IHaJOI opernl'OIlS ,,,.IV I", Cill!ICli out ilfl'" 1t'l\1o,",ll of tir e englllC:
(<1) Rcmuvi" iJllr! Id,lllIIY 01 If." ,.,.ttt~Sfti"l .,11(1 II>,1ftl 11,-,tlIIIYS (IJ) !1ellclV,11 ollfw o,wksft,dl II'." .~,.",
5 Methods of engine removal
Althol!OIr It ,~; flo~~lllle to .. ,1)1,,\·,· tI .. , "WIlli': .:Illd U"iU!'vX
o Ellgino rcmovill
II IS t',,-,,.'IIII.-,1 If! h,v" <1 fl
28 E[lO"lc 011 levI;[ d'pstlck ma,kll1gs 2 13 Removing the Cfankc<1se cnHSSIOIl v<1lve
62 Ea'th cable Oil the alte'''''lOl adl"slIllt:l1t u,,,ckel (
Page 33 of 205
, ,
)
.'
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
-, "
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
,
procarmanuals.com
Page 36 of 205
o
Chapter 1 Engine 35
3 Examine the rocker shah ,md ,oc ker il,ms for we~r, II the rod", alill rl tha t conwcts the valve stem IS conSiderably worn. n,new the " ."'"nl I f it is worn shqhlly step-shnped it may be cleaned up wIth rOc e r ". . a fi ne oil stone. . , commencing Jalluary 1984. modolled ,oc ker shah sp"nOs have ~een fi n ed. Where wppet no,se IS evident 011 e~rlier models hl'lw",en e n g ine speeds of 1500 ,111d 2000 'p'll. the later type 01 SP,,,llIS nl.1Y he
I , n ed .
.
5 Od t he parts and reas~r)!llhle them on therr shahs III thO) n"lI,n;.1 or der With both rockel shafts f,tled the 001 holes must face downw.l,ds to th e cylindel heads Th.s po~"tlon IS lIl(hcated by a notch 011 Oil" "nd
lace of th e rocker shaft
13 Tappets and pushrod s - eXill11inalion 1It HI renova tion
I Examine the v
14 Can,shaft ilnd ciln ls h Hft b earings -cxmninatio n "" d
rCll ovntion
II there is excessIve WO),11 III lhe camsh;lft thp.y will h,lVl! t" lJ" lunc wed. As the 1'1lI1'11 ul '''"1'11 Iwarrll\lS w!(lI"es speel,lI [(",I, thl~ ~houtd be left 10 your 10c,, 1 FOI(! dealer. 2 The camshaft n1;IY show SI\II1S of wear Of) tlH! I)(:''''''!I 1""""'1s 00 C;In lobes. The main d(:elsloll to lake IS what de!)",,, "I I'll"," n ec e ssitaleS renewIng the camshaft. which IS e xpensIve S<:'H"'!IOI da",~ge to t he bearIng 10",()"ls cannO I he ren'OVNI hy ''''I,,,,,I'''!I. runew,)1 0 1 the camshnft IS the only so lutioll J The CJm lobes mny show SlUns of ridgIng or piltmg on Ill" I"U" poin ts . II ridging IS sllghl then It may be pOSSIble 10 rel\\OVC It woth "
lonc oil stone or emery clOlh. The cnm lobes. however. ;"" ~urf;It:e hau Jencd nnd once the h
,
15 Cylinde r heads -dismantling . renova tion and rCils sembly
Clenn the d "t nnd oil off the cylinder he
pl
.. ··'1:
. ,
•
,r· ' .
t5 2A Comp' ess the SP'Ii") woth II valvlJ
! ' Il "nU comp,esso, . 1
5 .2£1 thu" """ove the collets (n'il\l'lellC 15 2C. followe(1 by the ,elnmer
1520 ... an d valve SP"Il\!
p,ohe show,,)
t;. "" &' '
'('ii" " 18 ... ,,,
'" ' .
. '
15 2E RlInlov,nU nil 'nlel valve 15 2F Inltl valve (top) and cxhnust v<1lvU {bot 10m) COlllpo"ents
.. ----------------------------~, 灲潣慲浡湵慬献捯m
Page 37 of 205
)
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
~~.~-'"'~
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
procarmanuals.com