lock 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 6 of 205
)
-
About this manual
Its aim The OIUll 01111'$ 111,11111;,1 IS 10 hel l} you lid the l}cS I v~llIe from yOl" vchicl.:!. 11 Cilll do SO III seve.;)1 ways II eml hOllp you dccllh~ wh,,! work Illust be done (eyell should YOIi chou$u 10 III!! 1 duno by OJ IF"Il\lu). pro v ide ulfo'Ill.1100tl 011 touiU1C Il"HIlICIl;UICU ;)lId SCfVIC"\~. "lid give 11 lo Uic .. 1 f01USC u l :'C I'OII nlld d"'!J"OSIS whe n ,,1Ildom f
SCCtlons. numuClcd wllh slll\lle IlyUles. eg 5. and the Sec tion s "ltO p",ag'ilphs (01 sub·seCllons). wllh Occll11,,1 numbels following 011 110111 Ihe Sociion Ih ey nlc III . <)1.1 5 1. 5 2. 5 3 elc . h IS froely illusltnted. espccl"lIy III those paris where Ihele is il delalled sequcnce of opel allons 10 be carricd ou1. Thelo ilre Iwo fo rm s
of IILUS";I\IOII 1r!IUfeS ;111f1 ph(lt
1'1>010g'"ph 5 C,lllY Ihe s,"lle ",""llO' (ell hOI rrld ,v l{h lollly 01 III 'el"led Uroups) '"S Ihc Sec lion 0' $1I1I,s(lCIIO" 10 which Ihey rel"I". There IS (III illph(lllcllCillllidex ;lllhe h.lr.k of Ihe I11"nuill;1S well , 's il COl1lell iS Irs t ill Ihe !r OIll E.1Ch Chilplel IS ilho 1}leceded hy liS own rn(lrl/rdu(ll coments IrSI Rclerence~ 10 the ·Ie ft· or 'tI~h" 01 Ihe III;h ,r;le arc III Ihe sensc 01 n person In Ihe (Irll/er's scm filCIIIO lorw,lrds. Unless olhclwlsc stilted. nulS ilrld holls ;lIe rcrllow,d hv '<11111119 nntl·clockwlse. "lid lighlclled hy l",n"'\1 r;i {){ :kwls,) Vehicle 1lI11Iwl" clu.ers conllnually 1Il., ke chilll!Jcs to spcr;lloco1llUIIS ~lId reCO IIIIllCl1d lltloIiS. (l1I(t Ihese. wiron notified. ,,'e IIlCO rPOI(lI"d 11110 our rll""Uills ill Ihc eilrlrest oppOllunlly Whils t el/ery care is la ken to ensure Ihnl the in lorrnillion in this mant"'! is correct. no liilbility can be ilecelHed by Ihe auth ors o r publishers fo r loss. dam~ge o r injury cilused by any errors in. or omissions from. the inlorma tion gil/en.
Proje ct veh icle The vehic le u se d In the prep,lfillion aflhis mo1nu~l . and ilppcnrinu in Illilny of Ihe phO IOIJr"phiC sequences. \V,lS a Ford Cilj)ri 2.8 InJeCllon.
Introduction to the Capri V6
Tile C(lpri It mode ls wcrc lirs t Introduccd '" Ihe UK in February 1974 uSing il Wide rilflUC of engrncs prcl/iously used on olher Ford I/chicles. T he mod(lls cOl/ered III Ihls ","llu,,1 usclhe V6 3.0 hlrc Esse~ alld V6 2 8 litre Cologne engines The restyled Sories III models were Introduced in Marc h 1978 W,lh a Ironl spoll!;:r (Ind 10Ul headlilnlps. and lollowrng Ihls Ih e 2.8InJCCIIOfl vers.on was launchcd on July 1981. Seplernl»e r 1984 saw Ihe Inlroductloll 0 1 the high pcrlolJ.l1(1nce 28 Injection Special which
leatwed a IrnHwd shp d,f!elcI1tlal. lockilble spoked alloy whecls (Ind il higher lel/el 01 Inlellor III'" In 1987 Ihe lilS I CilprrS w ere mildo .. Ihe limiled edllrOI) 280 The Cilr 1$ conl/cnilonai III IlIcch"nlCilllayoul. dlil/e from Ihe ellgille being trnnstllilled 10 Ihe re"r ilxle IhrOllgh iI II or 5·speed nl;111Uill gearbox or alternatll/ely Oil S(llies II JIIodels. a 3 ~Jlecd (Iulomat>c IransmlSSlon
procarmanuals.com
Page 8 of 205
![FORD CAPRI 1974 Workshop Manual Jacking and towing
Jilckillg poillls To chan!IC ,I WhUt:1 111 ,11 ,-,"W!ICIICY. usc the t:]ck slIpplled wilh the velIe!!.!. Ensurf! 1hal the Hhldwh,:cl nuIS;OH! ,ciC;lSCd Imlole Ii, cklll\j up thO](/img/11/56932/w960_56932-7.png "FORD CAPRI 1974 Workshop Manual Jacking and towing
Jilckillg poillls To chan!IC ,I WhUt:1 111 ,11 ,-,\"W!ICIICY. usc the t:]ck slIpplled wilh the velIe!!.!. Ensurf! 1hal the Hhldwh,:cl nuIS;OH! ,ciC;lSCd Imlole Ii, cklll\j up thO")
Jacking and towing
Jilckillg poillls To chan!IC ,I WhUt:1 111 ,11 ,-,"W'!ICIICY. usc the t:]ck slIpplled wilh the ve'lIe!!.!. Ensurf! 1hal the Hhldwh,:cl nuIS;OH! ,ciC;lSCd Imlole Ii, cklll\j up thO ca. and make SlUe Ih;u the .lOIn of the 1,1Ck IS luU.,. cnua\Jcd wI,h the body bracket and thatlhe hase allhe Jilek IS st;lIldlt '!J on a 111111 surface. The Jilek supplied w!lh lhe vehIcle IS 1101 $",,;,l)le lor lISC when laislflg the ve!.iclc lor U\;J",l()II;IIlCC or 'Cp,1If up,:r;J110ns. For this walk, use a trol ley. hyd'ilui,c Of screw-Iype tad IOCille(1 und!:. thO f,OIll crOSSlllcmbcr. bodylrame s,(ic-mcmbcls 01 ,ea, il~le cnsing, .1$ ,UuSlr
Fronl IOwin9 pain I S (ll • • owed )
Towing poillls II you/ vehIcle ,s bCIIl9 IOWl;d, m,lke SUfe lhal the lOw rope IS auached to Iho 110111 cmssmembcr or, where Ilued. the towlog eye auachcd 10 Iho 11001 ClOssmember II Ihe vehicle IS equipped wilh atilOma llC Iraosrlllsslon, the d.slanCe lowed rnuSI nOI exceed 15 miles (24 km). 00' Ihe speed 30 mph (48 km/h), olhe.wise sefious damage 10 Ihe Ir
10Wlflg eye.
, 'I I -J ' ,;
~)
'J
: .. ': .... 111"'"' ..... _-.___ •• _...:. __ ... ,
Jacking l)oinl S
Rear towing I)oio \s (arrowe d )
procarmanuals.com
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 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 $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
procarmanuals.com
Page 22 of 205
)
T
Fault diagnosis 21
Starter motor ((/rns cngino slowly Parti ali V disch~rilcd b
Engine ((/"'S normally but 1,1ils ( 0 SIMI Damp or dirlV HT !eads
Engine ClltS Ollt ;1nd wilinOI roslinl
fngine culS out suddenly -ignition I,wlt Loose or d'$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 25 of 205
I.
)
24
Cylinder block Bore d'iJrllCIC ' mm (.n). SI;'1ncli'll(t {j.,1CICS ,
2.3and4 .. OverSIze UI,lcics. A ... Il and C
Crankshaft Endfl0i1 1 mill (OIl) .
Camshaft nUllS! plme Illtcknc~s 111111 (m). Red Blue Endflo;'1 illm (m)
Pisto ns elc.uance III bo.e ""11 (Ill) Rm!J !J'~P mm (m) Top. CClille BUliom
Connecting rods BO!I "lid IHJ.IIUI!IIUn'UHU r, h: ;,. ;uu";C m ... (m)
V
E'h,"'~I
Lubricatio n systmn e"p.1';' ly W,t h t,llc' W,thout hll(:' 0,1 p,eS~I"e (111111111,,,11' 1ll 80 C) 750 'PIII 7000 .pm
Torque w re nch sctlings Malll hea.",u CalIS B'g·cnd ClIPS C .,II.kshalt pulley boll C;.III sh;.lt Oem Call1shilit th'ust vlme Flywhcel
TUlII"\) cove' To hlock To .1(111pt(II I)I;II C 0,1 pump 0,1 pUll',. covel Rocke. ~hall Slimp
Staue 1 SI:lge 2 0" dUlln pllill CyIUI(I,,;, heild bolb SI1I\Jf! 1 S I; 'UI , 2
S Ing.., 3 (;dlCI 10 1020 nUllul(lS WilH)
Chapter 1 Engine
93.0 10 1093020 (3 6618 10 36(22) InCr(!mcnlS of I 0010 (e.ClO04 )
935201093530 (3 .68 19 10 3 (823) I ncrements 01 0010 (0.0004 )
0080100280(000311000110)
3.960 10 3 985 (0 1559 10 0 15(9) 3986 to <1 011 (0 1569 to 0 1579) 002 to 0 10 (00008 (000039)
0028100048 (00011 (000019)
038 10058 (00150 to 0027.8) 038 !O 0 58 (001 50 100 0228) 038 to 1 110 (00150 10 00551 )
0006 10 0 064 (00002 10 0 0025)
46"
035 (0014)
0 40(0016)
24 -oroc 72 ' ABOC
73 ' OBOC
25 ' ATDe
0023 10 a aGO co 0009 10 a 0024 ) 525 (2 06(9)
a
020 I n 0 063 (0 0008 to 0 0025) a 046 to 0 089 (0 0018 to 00035)
1 25 h ilC (7 5 Pilot) 400 litre ("l0 IJIIlI)
1 a kol/cm' ( 14 2 II>IIIIl' , 28 kul/clII' (398 Ihf:,n')
Nfll 90 to 104 29 to 34
4 2 to 50 42 to 50 17 to 21 65 to 7 1
17
t o 2 1
1 3 to 1 7 141017 91013 59 10 67
4 107 7 10 10 2 1 1028
39 to 5 4 54 10 69
Ihf It 6610 77 21 to 25 3 1 1037 31 10 37 13 to 15 48 1 0 52
13 10 1 5 101013 10 to 13 71010 44 1049
3105 5 10 7 15 to 21
29 10 4 0 40 10 5 1 70 to 85 S I;'lle 4 (:,Itt" '",,",nU enumc to , 15 .llIl)Ules ill 1000 fpm)
Ror;kl1' cow:! ...... ..............•..
95 t o 1 15 Bilek 011 1/2 "to 7 IU'I) and .elolQuc one bOlt al a l'I11C 10 Stagc 3 valu<] 310 5
procarmanuals.com
Page 26 of 205
Chapter 1 Engine
: Part B: 3.0 litre engine
General
)
rr
T ype .. Bore Slroke
Cubic capacoly .... Compression 111100
cylinde r block Bo,e dlnmCler mrn (In): $wndMd urnelcs. A B.CllndD DverSilC {)Inel!} A
Cranksh aft Endllonl mrll (III) ..
Camshaft ThruSI plate tlllckness mm (III) EnclllO;1! 111m (In) .
Piston s Clearances III bore mm (111) nlllg gap mm (tn) Top .. Cenue BOllom ..
Connecting rods Blg·end hea,ony running clearance mm (In)
Valves Seill :myle . V,llve clearance (cold) mm (m) Inlel .. E~h
Torque wrench settings Ma,,.. be",IOO C.IIl S ..... . B'o -end Cill)S .... CrMllsh
Cvlind e, l1e,l(1 boit s .. SI
n",), 0.1 senl cill/ie ,
6·cytonder ohv in 60' V 'o,mallon 9367 rum (3688 in) 72 .42 nun (2851 In) 2993 cc 89· ,
936·17 10 93 658 (3 68o!) 10 3 6873) Illcrements of I 0010 (0 0004) 9 4036 10 !"I4091 (37022 to 3 70" 4)
0080100780(000311000110)
533'\105384 (0210 10 0 212) 0153100254 (0006\ 10)
0036100051 (000141000020)
0254100508 (0010 100020) 025· 100508 (0010100020) 025·1 10 0 38 1 (0.010 10 0 015)
0006 \0 0.064 (00002 \0 0.0025)
032(0013) 055 (0022)
79 B mc 67 ABDC 70 UaDC 14 ' ATOC 0013 10 0 05 1 (00005 to 0 0020) 47955 (1.8880)
0020100063 (00008 10 0 0025) 0048100050 (00019 10 00020)
500 hue (88 prill) 1 25 hIre (75 pml)
10 kUf!cm' (14 .2Ibl"n') 2 8 kuf/cm' (398 lbl/in')
Nm 68 \0 76
53 \0 59
55
10 62 551061 69 to 76 1510 18 17 10 2 1 8 \0 12 8 1011
10 301050 82 10 92 110\0 1 17 11010117 3105 27 10 34 16 \0 20
Ibf ft 50 10 56
39 10 44 41 1 046 4 1 1045 51 1056 11 \0 13 13 1015 6\09 6\08
7
22 1 0 37 61 10 68
8 1 1086 81 to 86 2 10 4 20 to 25 121015
25
procarmanuals.com
Page 27 of 205
a
26 Chapter 1 Engine
PART A, 2.8 LITRE ENGINE
General dcscril>liOIl
The 2.8 !lIte cnnlne IS of GC,Il1;l1l V(l Qve.hctld v
the d'SI"hutOf ,m(t 0,1 pump is located in flont 01 the 'Oil! Cilm bC;1rIog lub"cation IS by means of a bi-rotor 011 pump
2 Routine lll;lintelHlnco
I\llho inlo.vals sj)ecilio( in 1110 Routine M~"'lcn,1ncc $CCllon II from 01 Ihe m~nll;ll carry 0111 the 'ollowlng p.ocedu.es.
Change engine oil. renew otl tiller olld clean oil filler c. 1 Apply Ihe hil"clb.~kc Ihon jack III) Ihe lrolll 0 1 Ihe Cill and Sil l on ilKlc Sliln(\s. Alle'nnlively pOSll10n Ihe Cill ovc. ,111 ",~pcCtl(ln I 2 rlace a SUlliluh:1 cont~Ule. beneillh Ihn sum1) Ihen tlns.;."w dHun ph.!) (photos) ~nd (If""' the 001 3 Wh.le the o,l.s cI.,}lninu unserew Ih" 0,11.110. '-:;111,,<190 USII'H a' wl()nch ., Clean Ihe d.;IIn plug and Sltllllllhen ,elll Ihe pili!) and IIUhl"!! 5 CtCill1lhc IllIer COlllil(:1 mea 01 11i(, CXlenSIOII blackc. 6 Sme:1f a fIlm 01 enUlnc 011 011 Ihe now 0111.1Ir,. ",hhe. u,'~k(" I screw lion IImoi " JlISI CO(l\;1CIS the t"n~k"l 1 ,1(:(, (photo) 1'",111
Fig. 1.1 EKptoded v iow of tho 2 .8 titro engine Illain c0I11I)ononl5 (Sec 1 )
I T!,ellliostnl hUl/slII!) 5 U y poss /Just! /l,J/Jyc
"
Cr;III.sllllll gear 13 Od pump dflVOS/l,l/l
2 'h':III.ostn/ 6 Ifl/.:1 " ... ",ilold 10 Flywheel 14 M{J;n b e{Jflng CilP
3 W,J/er PUJllP , C{J/lJS/",/I/llfI/SI/J/OJ//! /I Cr{Jnbh
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 31 of 205
I
I
I
I
30 Ch[lptc r 1 Engin e
!l 5 Pow." ~1o'''''n!J JUIIlljl,dlolr rlUlley :111(1 I,,;ldi:;t! ' (."",,,, ... 1 96 D'$l:IIUII,·,:I"'(1 til" hy !l;ISS I,n~fl hum the ,"nUl1l U,II", w;u dhow
9.SA Unsc .. ;w lil., bolts 9.8H .. ,,,,,I '(:I\1OY') ( h " roc ke r ~1,;,11S 9 8e . . lrlli oil ~pl,l~h slll!:lds
'-'.
,-:~~q!~"
, " . i.
99 Remove the push,otls 9 .1 0 RcmovlrI!) the cylinder he"d boils 9.11 RCmOVUln the "Ohl himd sIde c,(hud". head
tilled. M,uk the locke. Sh,llI S so (h,ll they C
coneCI rcllltlllU 15 Inv(;.t Ihe engine "nd unbOlt the sump (photo). Remove Ih(l
Uas kets 1 G Unholt the plck·up p'pe from Ihe OIl pump. Dnd !CllIove the \.Iaskel (photos) 17 Unb011 the ort PVIl1P and w,thd,aw the (
lveshalt. notlnlJ whIch wny fOun(1 II IS lIlted (I)hotos). 18 R(;l11o\(! lhe crankshaft pulley S{-cIIIUI!1 boll and lake the pulley ot! the cranksh;l ft (photOs) Reslr,"11 the c,ank~hnfl I.orn lurnlllfj I,y
ch ockrn\) thc II~whccl 19 Indc>l mark lh(; pOSItIon 01 III
& co
procarmanuals.com