fuel pump FORD CAPRI 1974 Workshop Manual

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Page 22 of 205

FORD CAPRI 1974 Workshop Manual )
T
Fault diagnosis 21
Starter motor ((/rns cngino slowly Parti ali V disch~rilcd b<ltlcry (rClch"!le. usc Jump INlds. or push
sian) Ballerv terminals loosc or COli oded Batte.v earlh 10 body de

)
T
Fault diagnosis 21
Starter motor ((/rns cngino slowly Parti ali V disch~rilcd b sian) Ballerv terminals loosc or COli oded Batte.v earlh 10 body delcctrvc Enuine ear th s tr,1p loose Slarle. motor (or solenoid) wiling loose Slaricr mOlr ill1crnlll laull (see Chaple. 12)
Engine ((/"'S normally but 1,1ils ( 0 SIMI Damp or dirlV HT !eads check 10 ' sp regnp) Olher ignilion syslcml",,11 (~ee Chapler II) Olhel luel sySlem 11Ildl (se c Ch"plm J) POOl compression MaJOf mechanic;1 1 l Ellgine lires but will not fUll In su!hcicnl choke (cold flfl!)lIln) Arr le"ks al CilrUurC110. 0' mlill m;1",lolli FuClI sta,vatlon (sec Ch"111C' 3) []"lIast rCSIStor de!ecllvn. or OIlier 'H",II Engine ClltS Ollt ;1nd wilinOI roslinl
fngine culS out suddenly -ignition I,wlt Loose or d'$Conncetcd l T wi.es WCI HT Icads o. d'S I"buiOI C;1P ("lIer tr;1VC'SOll!) w;1'er spl;1sh) Co,1 o . condenser lallulc (cheek 10' SI);lIk) Olhc. ignition laull (see Ch,'plfll 4)
Eflgine mistires belore CUlling oul IlIcll,wlt Fuel I,,"k Cillply Fllel pump dClfecl1vc o. 1,ltcl IIlo .; k(H! (dwck 1m dellvl"V) Fuel tank hllcr vcnl blut;kcd (StII; llon Will II" flV,{Io"'1 Oil lI~h"'~II'H C,11l) C;1llJulCIIor nccdlc v"lvc SIII;klll!J (WIU.'1I1 "ppI1c"hle) C,1lUwellor leiS blocked (ha:l COIII,lIl1ln,Hcll) Othcr lllcl sys!Cm l DISCHARGED
BATTERY
lSin.MIN
POSITIVE
JUfl11) Slart lead conneClions f o r neg!Hive earth vchiclesconnect le;1ds in orde r shown
fllgine euls Ol1t -olhor eimses SCIiOliS ovcrhC~ling Mnior mcch Engine ovcrhe Igllitioll (llo-clwrgcj wt1fllillg IigM illuminated SI;1ck o. broken d"vchelt felCn$IOIl 0' Icncw (Ch;1ptr,r 21
Ignitioll warning light /lot illuminBted Coollllll loss .Iuc 10 In!emnl 01 CXierr'JI ICJk NOIC: Do 1101 ,11M coM WMCf 10 ,111 oV~-f/"'.I(C(1 ~·lIy"'., Of d,,,",l[Jf1 m,ly I/)SII/I
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 . Crank engine and chock for Sl)ark. Note use of il)sulated tool 10 hold plug load
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Page 53 of 205

FORD CAPRI 1974 Workshop Manual , ,
52 Chapter 1 Engin e
68 Connecting rods and gudgeon pins -Il~nmination a nd renovation
Refer 10 Sccuo n 18.
69 Cr,lIlkshnft -e~(lrl1in<ltion and renOV;ltion
E~amUle the four lIil;" l>e ..

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52 Chapter 1 Engin e
68 Connecting rods and gudgeon pins -Il~nmination a nd renovation
Refer 10 Sccuo n 18.
69 Cr,lIlkshnft -e~(lrl1in E~amUle the four 'lIil;" l>e .. "n9 Journals and the s,~ Cfanlq>nls. whIch should illl be smooth Iln(1 IHlJhly polIshed II there arc any dllCP Ulooves. 01 deep scratches ;mo lhe.e ,s a sirn,l,lr " Check the spiuol bu,1"n!) III Ihe .ea. 0 1 the Cfankshall on manual l.ans.mSSlon m()(lels :mllil necess;uy .enew II
70 Mail' and biu·end heafinUs -olwillinmion and H)!1ovation
Ilelo,r to Seo.:lIOIl 20
71 TilninU oellrs -e~i1miniltion find renOVlltio n
Re f
el to Sec t,on 21.
72 Flywhee l/ d riveplale -Okamitliltiotl lind ronovtttion
Inspf:CI lhu ffywhf)l)I 0 ' ([ttvl'pl,,": fOI (!;U";'\lC ilnd 1:I".1I:k Ih;'1 Ihe ""!I H".u docs uol have .IIlY \)Iok"n o. l);Idly wOtn teeth. :1 On ''''''''';11 I'''"''''US~IO'' mnd"b ,I IS pOSSII.Il) 10 'CHew the I"'!l \]C,II .'S Ilesl: 73 Valves (",d v"lvo sO,,1S -tJkiu"illHtion lind renovation
[xallutle Ihl} v,tlves 101 IlIls "lid !l,ooves lind the valve SIems to. e~c,'SslV') we,l' III d'~loIIIOII' 2 Ek,""l1ltJ Ihe v,oIVil hf)"d 10' SI!.!"S 01 hu",u,U of the vOllvo seillS lind ch .. !ck Ihe ht 01 Ihl) villves III Iho v,llve UUldes . 10 SCl) II Ihe villve uu,des il,e WO!ll
3 We"" valve U",dcs c;'" be r l),lIned O\It lind vlIlves w'th overs.~e Siems lilted II iI v " Villves illld v~Ivo se .. ts whlc" show JollIe s,on 01 wear. call he lilpped in.
S To 1,1P the valves. In tt s u ction Iype gnmlonu 1001 to Ihe villvc hettd. smeil' a lu tle COil.se c;ubo.unllulll urmdmu pOIste on to I he sealing I~c e 01 Ihe vnlve ond inserllhe valve 11110 the cyJonder he"d. Rub Ihe stern of the v al ve gundlng 1001 hetween the palms 0 1 the hands. so Ihal Ihe valve,s ,otllle(l hHckwards 1I11d lo.wa.ds When II IS lelt lhOlI culling has
ceased. loft Ihe villvc. rotate It th.ough 90·, lowe. 1 and fepCill the u"n(llnu o.:.e.atlon . • e dlslllbulill9 the g"nd,ng pas!O on Ihe seal if necessilry. Conlinue Ihe process unlll a mllll gwy bOlnd IS pfoduced OIloun d the complete pe"phclY of hoth the vlllvc and t he valve seil l G RepoiJl Ihe opcrilllO" US" 'U fine o""d,nU I).Jsle. 10 ohtil'" IInlsh. then clean lJoth Ihe valvcs and Ille v alve seals 10 ,emove IIU \llIces 01 u"ndlno pash:! 7 II 'I IS convenl,,1lI 10 liIke Ihe eyhndc. he 74 Dccarbonising -go notal
When Ihe cyllnde. heilds (li e removed. eilhe. in Ihe Course ovelhJul Of for inspection 01 bows 0. villve condllion when the e IS in Ihe CM . il IS nO'''1 2 Th is is hesl done wilh 0 cup shilped wire hruSh ilnd iln elect." and is laorly slriliuhlforw,!,d when Ihe engine IS d'S p,slOns removed Somel,,"es h.l. d SPOIS 01 ca.bon iI.e nOI , .emoved exc e)) t by iI SCf,'pCI . When cleanln!) Ihe p'Slons wllh a SCI IiIke care nOllO dam.lge Ihe sudace 01 the ,)iSlolI.,n (lilY WlJy . 3 When Ihe en!l",e IS in Ihe car. ceria", prCCau tlons mUSt be t whe", dcca.OOrllSIno the pistons' c.owns in o.del 10 p.evenl dislo, pieces 01 carbon 1.111;110 into Ihe inlerior 0 1 the ellgme which c cause dillllilgC to Cylindcr hores. pis Ion .10d lings 01. 01 allowed the Woller jl.1sSolues. llilrllilOC 10 'he Willer pun.,). Turn the engine so Ihe p'S lOn lleinU Wal ked on IS Mlhe top 01 lIS slIoke and then mas l Ihe a(llttcen l cy'",der bores ilnd ilil sU!roundl",g wttt(" l"cket alii wllh papel and .1!!hes,ve 1ape Press !lwasf) ,nto Ihe gil(l illI .ound pislon 10 keep Cilrbon pa,lIcles alit ,,"d Ih(ln SClilpe 1111 c,lfllon awa hand Do not usc iI power thin and wile hntsh when Ihc enguI(lls II, ettr as II WIt! virlUillly be 1Il1posslhie 10 kcop alf the cal ball dUSI clc, the engine. When compleled. c.1wlully c'ear OUI the OH,,,se moun(I ",II 01 Ihe (liS lon With ,1 mlllc h SlIck or somelhl"U Sllm 'iI • . bringing ciI.bon palhcles wllh It. R c,lellt the p(()r,e~s onlho o the. p,slon C'OIol II IS nOllecormllended Ih.lll1 "'ljJ 01 "uhon IS leit .ound Ihe edge 01 p,slon on I h(l Iheory Ih"t ,I Will ,11(1 all consumplion. ThiS WilS valli
Ihe eiliite. dilys 01 10nU stroke low .eVYlnO en!)lIles tJUllllodern enUil fuels ilnd Itrb"canlS C,1use less cOIIOOn deposils OInyway and any. b ehind lend merely 10 cause h O I .SpO IS.
75 Oil PU"',) -disnwntlino. eknmin"liOil ,,"d reOlssembly
The Oil pump mm"Itt;"S a I)ressure 0 1 ilbout 2 8 kgl/cm' (3 Ihf/in') lInd unless Ihere is ,1 sIo",IIcanl (hop In 001 P'(lSsuro willel ,)loved to he due 10 the Pllln,). rillhn. Ih;", 10 wo", heil'm!)s. 11 IS be .
t o le"ve Ihe 011 pump und'S hilhed. 2 To d'smanlle Ihe pump. fll:.1 ,emove II hOln the en!l'ne ns desc,,1 III SUClion 58 3 Remove Ihe IWO bolts seCulII1!J Ihe en d cover 10 the body 1 'emove the covel ilnd 1he .ehel v;" ve "sscmhly. Ihen Ihe Iwo P"
fOIOI assembly.
" Remove ,he IWO bolts lind ,,,ke Ihe p,ck·up w he lind SCIl' lIssembly oft Ihe pump housin!1 S Wilsh all lhe pilrlS In petlo'. usc iI hlllsh 10 cleol" Ihe Inside 01 1 pump ho usinu ilnd lhe p.cssu,.., .elle' vil've eh'!lnbel. ilnd milke 5' Ihilt ,111 p,tltlClcs 01 dill ilnd mewl n,e ,emoved Allow the pttrlS 10'~ n;IIUf,lllyor blow them d.y G Check Ihe Illslde ollho Puml) houSII'9. Ihe OilIer .;w:e ilnd Ihe 101 101 dilfllilUe and e~cesSIve weill 7 E~ll'''Ule the I111lling su.lace 01 lhe I)Ump cove. 101 we,lr It Ihe CO' IS sco,ed. o rooved. a. shows ilny s'g ns o f wea •. a new covef must I hlled 8 W,lh the ,otor assembly filted in the hOuSing. place a straighl·ed!. over Ihe end 0 1 the housing .012 in) OInd Ihe Inner 10 oute. rOlor gap. which should b 'oss IhOln 0.020 mOl (0008 i n ) II oulside these dimenSions. a ne" pun,,) Should be fitled 10 Check that Ihe leroel vollve and its sea Illig ,Ire Iree of dan'ilge all' thaI the .elief vOl've sp.ing ha s nOt collapsed. 01 is damaged. and 1 new paIlS ,f necessil rv. 11 Reassemble Ihe pump by IUSI lilting the lillie. IJnd outer rOIOr) Ihen lubric.11inU them wllh enUOne OIl. '2 Apply e ngine 011 to Iho rehcl vlllve plunuer r hOUSing Relll the Sjll1llU cal) and Ihe pump covel '3 Refit t he cov e. allolchrnenl sc.ews 1111d IlghlenIhelll1 0 the to.qu' wrench sen ing giv chec k thOlI Ihe 1010r moves freely 14 Refil the PlCk·up lUhe procarmanuals.com

Page 67 of 205
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i
I II
Chapter 3 Fuel and exhaust systems
Contents
Pari A: C,UbufCIIQr system AccchmllOf cable -removal .1n( rerilling , ........... , ...... . Accclm SI}ecifications
PMf A: Cilfborettor system
Gctwrctl System 'Y lloC
Fuel pump delivery l)reSS\lrc .
Fuc l I,ln k c,lpnc,'Y .
Cilrhurcttor lytle Tluol1le baf!el dranwtcr
Vcnlull d"ll'ICICI
Mainjct: 1 !I71\/1975 1976 onwards Idlong speed: 1971\/1975 1976 .............. .. 1977onwilfd5 FilSI idle speed: 1976 1974/1975 ilnd HI77 onwilr(ls
Floal leveL: 6111SS lIoal
PlaStic float
Floill Iravel ...
CO %
111 idle: 197<1/1975 1976 1977 oowards ......... ........ , .................... . Maximum choke vacuum p ull down. 1974/1975 .......... ....... .. 1976 1977 onwards ............... . Choke phasing: 1974/1975 1976 .......... .. 1977 onwards,
17 18 3 7 8 20 21 5 6 4 14 13
16
15
1 19 ,
9 12
Weber calburellor P.1rt 8: Fuel injection system Accelerator cahle -removal and wfl1l1n!J ' Au cleaner -Icmoval ilnd lellll,O!! E~h.1USI maOifold Icmov,ll and whllm!j
Exh,luSt system .. lemoval ,1nd rnf,ttin!1 Fuel l:lnk. sCIld el utUt and follel l"floC !!fmc.,,1 Gene.;,1 descflpt,on
Irlle nuxture • ,1d/l' Slmenl ..
Inle t man,fold .• emoval and 'ef,nn,!]
Ma,n systcm compo nents .emoval and rd,ll'n!) nouline m.1jnlcn,lnce .
P.1r( C: F.1l1ff di,1gnosis Fintlt d,n!]l1osis .. fuel syslem (cadJll,ello,) Faull d'agnosis -fuel system (fuel injeCI,on) ,
11
"
:12 33
Dual vcnlu.i downcfoa"llhl carh,",cl1or. m~IHI"'Ci,lIv Or.cHnlcd (hap'" .agm luel pump. tempcrilh rrc cOllI/oiled air clenne, on sallHl "'0111:15 02510 0.35 kgl/cm' (3.7 1 0 50 1I,l/ln') 580 Il1re (I2 7 1)011)
Weber (Iunl venturi wilh autorn;rt,c choke 3801111 27 nun
1450101 or 1<12 mill 142 mm
800 J. 25 rpm 825 1. 25 'pm 850 l 25 rpm
noo ,., 100 rpm 2000 ± 100 rpm
40.0 mm (1.575 in)
3 4 .3 mm (1.350 in) 12.5 1. 0 .49 mOl (0.492 L 0 .02 in)
2.8:l. 0 .2 1.75 10
5 .0 1 0 .25 nun (0.197 7.0 J . 0 .25 mm (0.276 5.5 :t 0 .25 mill (0.217
2.3 ± 0.25 mm (0091
, 0,01 , 001 , 0.01
± 0 .01
3 .0 :t. 0 .25 nun (0 118 ± 0.01 2 .8 :l: O .25mm{0.110 J. 0 .01
in)
in)
,n)
in)
in)
III)
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Page 69 of 205
I,
68 Chapter 3 Fuel and ClChau st systems
14 Dlsco""C(:t lhl) V;1CllUlll ~lIprly IUPC (10111 th,: h<:.11 ~Cllsor Oh~r.rv'J Ihe O,) CI; ,hOil Olillc U;1,) villvi) whll!) ,'Ilhe s,.,mc hn~c ;)PpIY"l!1 SUCtIo n 10 Illu cnd 01 lhc ~"ppIV plpn It Ihe 11;111 v,llve 'C~1"'S closed then CI!lu:r tlw (i .dplu;)!l11l or 1110 flap V"IV~l IS 1 ,I\Jlly If thl) I lilP now opf;n~. Ihe f;lUII 1":$ III Ih,~ hea l ~(:n ~o(
3 Air clear -rCllloval nml le fittinu
1 Q,seol1ll(;f:l lhe 1I,,1h !IY 2 Remove tli' l two n"l~ '<:t:lII,n!l 111".111 (,"'.III,,, lid "nt! ",m""" II,,, hd. til ... " I,ll" OUI 11", "" 1.1,',,,,.., 0;1,,11\,,111 3 Kuuc.k '>.ILk lh" I"", Iud. l"hs _mel 'CIIlU"" Ihe toUl Ilul:> so'' tuH1!! lh,);oll ch',IIlt" if) !he r.;Hhu"·lw, lu> 4 Funl III "lIP Inst "'\1
H Ih.·", .11" .. II ""Y'"'''' 1",,1..~ " 1",·I"",,,,,,y •. h d).. .. I 1111"1 I""" P "I~",'I"'" ':,111 I" , ",.,11" I,V ot"".""" .. ,.I"I~1 110" ",,11"1 1"11" "I II ... It ... 1 1"""1' .,,'U I '.(""","'I",!) II", 11111"1' OI,lh' l I,y., I''''!III, (,I 1"1,,, I"" ~II.,~" I." :' Cr.,,,1.. 111" ""!I"'" .",,' /,h~",\"" ..... 1"·. 1"" _, "'''''1 .. 1 p,'III,1 '''''''', .... I",,,, .h" '''''''I' .",,1"1 .,11111" I''''''''y .. , .. ... ,,,' :1 To c.h""k 111.11 II,,! I''''''P ,<; w.II"" 'h ~p""oI" .'IIUIl. ,,,,,,,,,,, ,1 .' p.e"~",,, !la,,!!,! 1 0 th,! IU""p outkl D'M·,"''' ... '. t III" II r ","", hom 11", co,l. c,;ulk th" ""!)"l{, ;11111 UhM"V" wh",h'" Ih" 1>\1,1,,1 1''''';''''111 " ." SllCCd'e d
5 Fucl purlll) dc,,,,illg
D"I,'I:II (h .) 1",,11111'" 10",,, II,,· 1"""1> ,,,I ... lui", 2 Umlo ,IIlIt """("'" lh,' ( •. ".", '~" ...... _ .. "t 0 ""'1 .""t t.!1 "tt lh,· .... ~III".· .. 1 "''1'. 1,lk' '''Ht ,.",,1 :l 1 t""oU~II,ly (.1""" 11", ·,,-ltll"':I'1 "tl'. 1,110;' ,11,,1 III''''t''''\) ,.1,.11,,1,,·, U~"'H a 1);ou'tl>l,,·,11 ,tlHI ( .11"", 1";h"II() '",n<) "" "ny ",·,111"(:1'1 ,I In ,,,,,,,,,,,,,,101,- " tt", "'''''','! ""qll"IlI;" !to ,h"m.IIIIIII'H Dn " .. 1 UVI""!tl'I"" II,,, '.""1", '.,.,.,,\' .• ,; '( (",,1<1 (h~t'''1 tlon ~.,(t llw,"1 ("'t>
6 Fuel P""'tl ,emovnl ,md .uliuiny
L()U~"II II", h""l! ,.ht ... Io<)l1l Ille IWO C(Jlln," (1011:; ')" It\!! P""' P ;,,,,1 ''''"0~C Ihl! ho~" If "'''"1)<,<1 IVp" d, .. ~ ,,,e I'lh .. '<:I cu, Ih,-m Iol'(' .",d H'lti.,e.C lh"m w'lh ).C'l'W lH'" • . ht> .. 2 Undo ,lnd "'!II(We (h" [<\0 nul~ ""d ~fI"'l!1 wn"h,,,~ senor'''!! II", jllllnp to (li e 1"11"'\1 rI"'" H!ull'(11Ih' I,uml' nil nCIll()'" II", !I"~~~I 3 n(:l.tinlH lhe 1""111' 'S the '(:YI:'~ 0' '(:11101';11 . hUl de,H' lhe ,,,.,,\11\1 ',lC",S ,lIld 1'1 " r"' ..... 'I,l~kc(
7 C;orbllrnU or · gCnc'ill
'Th" c,,,hu .. ,uu< IS nllh" \Vclx.r ci .. ,,1 "CIll,,1I (lownd';1uuhl lVI)C Willi ;111 .1II1UI\1;.U<: ('ho~ (~ 10 (:nsur" C;1Sy S.,\lIII1\1 100'" cold The m,un ;Ultl
IItim U sy~",,,,s ;IIe dup"t;~ I1 ... '(I. p;,ch b.1 .. cl h<1Y1I\9 S('j).lf<11e SVS1(:II1S supplied Irom 11 (;0"'111011 110<11 ch,lI1'u." A S'"(JtC ,'lcd':f<110' pump 01 Ih~ dJi)ph"lYIll lVt)C supphes hOlh b;lr! Ih'Oltl(l hnrrch, trl.1m YenlU" ,1nd ;lceel,,"IiO' pump ""dy ThC,e ;lJe two tl"01l1" ~p'nt!l,,~ ...... hoch ;"tI IIIU!rconnc cled I)y U .
3 2 O,; ,ur;om 0 1 nir tcmpcr;ohorc contro llC d ilir clcnn.] r (Suc 2) V.I<: IIII11! /",.1,·
f)""d".IfltJJ lllUl f),.II""_"''''
(A j
()
1 1"1:'1' V;,'~!! I/ul ;'" /I"IV
FiU . 3.3 Air c lcm'er (A) (Sec 3)
(c ' ..
Fig_ 3.4 Fuel pump filter rcmo",,1 (Scc 5)
8 c Pump body
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Page 71 of 205
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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$FORD CAPRI 1974 Workshop Manual , . , I , ~. ! 78 Chapter 3 FlIer and exhaust systems TIlls system, when comp1lrcd with conventlon,lI c.Jrhwctlo, ~rrilngemen1s. <lchicves <l mOIO IlccUl.1te control 01 lho <Jil/fuel mi~l\l,e re$
,
. ,
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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/(
"
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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Page 80 of 205
$FORD CAPRI 1974 Workshop Manual ) Chapte r 3 Fu el an d exhau st systems 79 Ii 0) G \E ) .. ~ ee) Fig. 3.33 Fuel injuctiOIl system circuit di<lUrnrn (Sec 22) 1 /J,1I1C 1V C W"lflll (If! luyu/,lor plMC 2 Sialicr I/Iolor /)$
)
Chapte r 3 Fu el an d exhau st systems 79
Ii
0) G
\E )
' .. ~ ee)
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 ., '
,. ,
< '(:,,~ , • . . ;::~t,·· . , ,
.' ) . ;~ ~~;:;: ~iJ" .. ,
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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: 1'1 1 . ,
I
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Page 81 of 205
80 Chapter 3 ~lIel and exhaust systems
24 Ai r cloanor -removal and re filling
1 Remove Iho elomerll as dllsc"hed III Sect,on 23. 2 Work,nn under Iht! left ·hand honl wheel arch. unboll the illr clenne, hOdy f,om Ih e s,de of the engmo compnl1lllen\. 3 Rohuil1g IS n rove rsal 01 tho lomova l I)rocodule wl lh relelence 10 $(1(;11011 23,
25 Main system compono n ts -rellloval "l1d rofitling
Fllel p /llllP 1 Thn hll)1 pump IS loc.lwd "' " lI,hlw.. 1ll011111111U .lUflchod 10 Ihe "!Ihl h"n{1 51th! 01 lhe 11I/,llal1k (phnIO) ') D,sC:OllllCCI Ihe h le"l1 line IIIlIon on Ih e lu«1 dlSlllhul cl;lIllp l hl) 111(:1 IIIIUI hose IIC1W,,':1I1he ludl;lllk ,1ml th « 11111111) uSlnH ,1 h",ke hose cl,IOUjl or sHlIII;" If Ih oro ,s only ve.v hnle 11101111 I ho 1IInk. illl 11"lIl<1llvO 10 cl,1mplI'!l1hc ho~() IS 10 dram Ihe Innk onCIl Ihe mlOI hose 10; ,h~c:ol1nCClu" !". OIs.:nrUlI){:I IIlI! Iud ",Ie! ,llId uIIII" 1 IIIIJoI:S I.nUl Iho pump G Cn,"'ully ut",llily Ihf! dm:I"c:al C:("UH~C1l00S 10 IllI! pump nil"
'''~t:un'''~.1 11",," 7 I ,.,,.,~'''' the 1I!l11l hoilid Illd 1'lIlk SUPI)(Jl IIII(f Sl'ilP Illell unh(lll ll,,~ lul,I)". mOlllllll'H ami 111,,1 JlUlll!' 8 !'IISf) the pllmll "("n the "'OIull"'!! !) Ilcfllllll!j 's il IUliers,, 1 01 ,emOVi.1
FiU. 3 .34 R Oilr viow o f
A Ink'1 pi,ll}
fuel,HIIl'I) (Soc 25)
8 Fucl'WIII/'
..
) 2~ 1 Fllel pump showing Wlflflg ond oul'el pipe
~ .. . . ~ ~ ... ,
2510 Fuel accumulatO'
Fuel accumulator 10 The fuel accumulatO I is bolted to the Ical 11001 above Iho lear "Klc (phOIO). 11 Disconnect the bflltCly . 12 Releaso the preSSIJle in the system as descllbed in PfllfltJlilph 3, 13 I'lilCO the leal of th e car ovel ,1n inspection pit o. lilise il on ' ilmps O. fldo·stands. 1 4 D,sconnectlhe fucl pipes I,om the lu el accumul,110r and catch Ihe s Fuel filler 17 The luel 1IIICr 's locmed 011 th e wheel olfch in Ihe lelt hand side of Ihe .mU"'o COIllI)"' ln,elll (1IhOto).
Fi U. 3.35 ConeCI 10Ciliion o f fuel filler oullel pipe (Sec 25)
A B Fuel "'ICf Ou/lelll'lle c Engine comporlmenl side p,wel
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Page 86 of 205
$FORD CAPRI 1974 Workshop Manual Chapter 3 Fuel and exhaust systems 30 E~haust manifold -rOllloval nnd r e fitting Rcle . \0 Section 20. but not that 1,11C models do nOI have n downpipo scaling ring (photos) ~ .. y " ..: ;.$
Chapter 3 Fuel and exhaust systems
30 E~haust manifold -rOllloval nnd r e fitting
Rcle . \0 Section 20. but not that 1,11C' models do nOI have n downpipo scaling ring (photos)
~ ..
y
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31 E~haust system -removal and ro fitting
Reier to Section 21 (pholO).
85
3" ,A TI!Jhlenrrl!J Iho O~hilUSI mnnilold nuts 30.1 BRight hnnd e~hnust rn.1nilold ·todownpipc connection 30.1 C Dl sconnec tirrg the lell hnnd e~hnusl downp;,Je hom Ihe manIfOld
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31.1A hhnust system ,ubbe. mountIng (;,,,owed) 31.1 B Irnermed'ilttl oxhilu st system-to-honl pIpe clamp
RT C , FAULT D IAGNOSIS
32 Fault diagnosis -fuel sys tem (CMuurottor)
Symptom
Fuel COlls!ll11ption e~cesslve
Insu llicienl fuel detrvery or weak mi~lure
33 Fault diagnosis -fuel system (fuol injection)
Symptom
~ngine will no t starl (cold 0' hot)
Reason(s)
Ai . 1,ltel clement choked Fuel lenk flom cmbulellor. fuel pump Of luellrlles Gene.ally waUl ca,bu,ettor Needle vnlve StickIng open Incorrec t idling speed Clogged fuel Irne
o. hiler
F R
llason(s)
Ai. !tow sensa. plale incorroctly sel FauilY fu el pump Fuel lank omply
'J
----------------------------......
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Page 87 of 205
Symptom
Engine will nOt Slnr1 (HOT)
Engine will not stal! (COLO )
Engine mIsfires on rond
Unsatisfacto,y ,oad p edomlilnce
Rough Idling (ilIWilYS)
Rough rdllng (during warm -up)
Excessive fuel consumptIon
nglne fUns on
I
C hapte r 3 Fuel and exha ust systems
Reason(s)
AuxiT inry air device not clOSing
Auxilimy ai, dev ice nOl opening SImI villve filulty Thermotime switch nOt closing
L oose fuel pump elec trical connections
System fuel presswe incoflec!
M,xture adjustment incorrect
AUKlhilr y ili, deVIce nOt OllC,ahng cOflec tly
Mixture M1ts utment incolleci leak in system fuel lines
Airtlow sensor plate or cont/otplunger not moving "eely Injector villves leakinU or then OJ)Cnlng pressure too low
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