roof FORD CAPRI 1974 Workshop Manual

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General dimensions, weights and capacities
Dimensio ns (t y pic .. )) Ov"",11 lo'I1(llh Ov,,,,,11 wIdth Ov",;,11 IlI:!!lill Wh""IIJo1S() Tlack F,on1-30 h(I(!. 28 hire. ReiH. 3.0 !olle 2 .8 litre TlJJnOll(J circle (he1wccll ke,l>s) 30 hire 28 litre
Weights (typical ) 30 S Manl!~1 IIo1I1SI11;%IOI1 . Autulll"j,{; llimsmj~s'on 30 Gill;] . Mallual 1,~nsrnISSIOll Automm,e tl""Slllission 2 8 IllJCClio 'l Roof ",d 10<1d
Ca pilcities (typiCill) EIlB"l(), 3 0 htH) . With tiller
Wrthout filter 28 litre : Wrth frller . Without frlter . COOI"l\1 system 3 0 li tre , 2 8 litre
Fuel sys tem . TrJnsrlllssion
M'III(rJI. 4·speed .
5 ·speed .
Automatic (JPprox)
Rear Jxle. Stee ring geM: MJrlU.11 Power·Jssistcd.
GeJr 001 Fluid Sr:p.lrate rese rvoir Imellr,, 1 reservoir
Series II 4340mm (1709 in). 1698 Illll) «(}(;,9 in) 1357 Ilun (53.4 in) 2559 ""11 (100.7 in)
1353 IlUll (53.3 in)
1384 mOl (54 5 in)
100m(32811)
1155 kg (2546 Ib) 11 <15 kU (2524 Ib)
1185kg (2612 11)) 1174 kg (2588 Ih) 1190 kg (2623 Ib) 75 kg (165 Ib) max
5.0 Irtre
(8.8 pint) 4.25 htre (7.5 pin1)
4.25 litre (7.5 pint) 4 .0 l i tre (7.0 pint)
9 .3 htre (16.4 pin1) 8 .7lotre (15.3 pin1) 58 litre (1 2.7 gal)
2 .0 litre (3. 5 pim) 1.9 Iotre (3.3 pim) 7 .5 litre (13 .2 pim) 1.1 litr e (1. 9 pint)
0.15 litle (0.26 pint)
0 .20 litre (0.35 p int)
2.2 litre (3 .87 Plllt) 0 .50 litre (0.88 pin1)
Series III 4439 mm (174.810) 11398 111m (66.9 in) 1323 mm(521 in) 2563 mill (1009 in)
1353 mm (53.5 in) 1400 mm (55.1 in)
1384 mm (54.5 in) 1431 mm (56.3 in)
98 m (32.2 II) 99111 (325 It)
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Chapter 11 Bodywork and fittings
Contents
i'ldIUS\Oy,ll and luhlllnq 25 ~ 'PCIS ,,:~mO\l.11 and reassembly.... .... ........ ..... ..... 45 HCillcr controls ~ ildluSlmenl . 40
Specifications
Torque w rench settings Se.llbel ls :
) pillar .\ lIoor .............. ............. .......... _ ._ ..... .. . Openlnu rcar qUilrter glass tougle 10 C pIllar.
Heal"r cOlllrols removill im(1 rchUrn!! lIemcr Willer villve (heilvy dull' he;II'~r) rcrnoval and rel,ttrng I"tc"or m ,,,or -remov,,1 and refrtllng . LOild spnce I"", pifflel -refl1ov~1 and refillmu M,l,nten;mcc bodywork ,1nd underfr;lflle M;r,nICnnnce • upholstery imd C;Hpets Millo r body dilm SeillS -remov,,1 ilnd refilling Sunroof -rcmoval an(1 ref ininu. Sunroof bracket an(1 dnve ilssernbly _. removal and refitting SUrlrool PJnel - T;rilgJte -removal "nd refilting Tailgnte p"vale lock -removal "nd refillinu Tailgate striker plate -removal "nd refilling Tailgate window glass -removnl and relittin(1 Window frame moulding "nd door weatherstrips -rcmov,,1 refitting Wrndscreen -removal ilnd rellllltlg
NIH
2010 30 35 10 42 4.5
Ib l It
15 to 22 26 1 0 31 33
41
" 38
" 3 4 G 5 23 ,
22 2 3G 39
" 35
33
27 28
" 11
"nd 19 10
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) Chapter 11 Bodywork and fitting 187
16mm ~ 0.5 -1.0
( 0.63," t 0.0
19 ) -O.O~
Fin. 11 .1 5 [30l1 ,1f!1 lock;,, !) ~p"iI1U ~(llling dimensi o n {Sec 26 }
OP"I) II", t."I!!,,!!, ;ond <1<:1;1(,11 Ih.: OIl hne COIHlCClOrs IWIll the d;;Jlllpcr(s)hlllll(S) (llh(l\OSj 2 SUppOI! the lilll!late. tIH!!l d'~<;'''lI1''cl the d;lIl1pc,S hy 11"5111(1 out the p11'l511(; w(!(IU',s w ith a sIu;,1I se:lcWdllVCI (photo). 3 With hulp foam an assI stan t. ~UPPOlt tile taIlgate and lumovu It I,y removlno the hmgc holls (photo) 4 When Ulstalilng. nh\jn the tnit~ID1C so thnt t he ed\jl.'s nrc flush wllh the ,ea, of the roof nnd the C 'p llla, s.des. nnd the \jnp hetween the l ,// ,
700mm( 275,n )
.200rnm( 078,n)
-OOOmm(OOO,n
Fig .l1.16 Ta ilgate-to-roof eduo illiglllllf! llt (Sec 27)
f-Ol,H)rs of tho body. with the Sillkm plaH, III th,! lippe, ec,H",1 pos'tlon G Pints C,111 he used hcnC 28 Tailga!C privnte lock -relllov,,1 n n d refitting
Open the wilgate ilnd prise oft the trml. then ,,,Illove the Inleh (th,ee Loolts and wash&rs) (flhotoj. 2 Remove tl)() lock cylinder ,etninin\! nul. then tlUn thu lock spIder. to
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27.1A Tnilg~te dampe, connl.'ctlon to body 27 .1 B Tailgate (fnmpe, con"cc\'orl to \ailgmc 272 Method of d,SCOllncC t."u the l .' .' ,",
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27.6 Tadgate bumper pad 28.1 Tailgate l • _____________________________ J~I
灲潣慲浡湵慬献捯m

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) Chapter 11 Bodywork and fitting 189
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32 8A I',,~c 0111 Ihe alp 32 an ali(I ,(,mo .. c the console screw 329 Removing the hnndbrake lever boot find be~el
Fig.n.la C lock ro:.,,"ov 1 () "'I!! (0 If; "') /J IOO",m (()/I() III)
32 Centre cOIl~ole·· fUIllUV,,1 ,,,,d refiUinu
IJasic tYlle '.111 Ihe caqll:l 110m ;!lolllni the r'OIlI of t im t:()Il~()lo, thun push the " .J Gfli,1 type (also Il((ed fa I(I/ef nVI)-Glli" modrds) 6 Lift the Cil'PCl hom ;"oulld the IrOll1 oj the console 7 F,.brIC 17 As appliCill)le. remove lhe eleeuical connector from Ihe base 01 cilch senlhelt s(;llk and rcmove the stn lk ".lI1g boll th,ouOh the top of thc consolc. Rcmove the stnlk ilssell1hly thrOuoh tlHl II1SIdc console suppo,!. 18 Pull the cMpet awny hom the SIdes of the 5UPPO,1 assen,bly. then detilch the support hy removIng (he eluht S!)CUW1!J screws. 19 Hefil!lnU is bilS'C,1I1y Ihe reV«($e ollhe !«Illoval procedlHe. hUI Illst ensure lh,11 illl Ihe splle nuts ilre corrCClly loenled on Ihe brflCke(s. Tluhten tile sefllhelt SliIlks to the specilied IOlque.
33 Sunroof piln el -ndjustments
Gap adjustment 1 When closed. a Unp of 5 8 10 6.9 mm (0.2310 027 "') should eXI~t hetwecn thc slIn(oof and (h e CM rool. II;) vmyl roof cover IS lilted. Ih,s gap should he reduced by 1 .78 mm (0.07 Ill). If adlllst'!\(Jnl IS requued. pwceed ns detaIled below. 2 With the sunrool hall open. remove (he sunrool heildhlunll hnlne 3 Close the sUllfool. then pull Ihe hei!dhnll1H hOIll (he Ie." and remove ,I. 1 To ndlust the hOnl 01 the sumoo!. loosen the front Uu,de relillnu1U screws. then whIlst p,essu1!J (he Uuitles IIlwilrds. lighten thc screws. 5 To ;)d,ustthe rear. loosen (he twa h.II1!) screws nt eneh Side of the ,1dlustinU hnsc. thcn p,ess (he reilr shdes mw,uds ,1"d t'Uh!Cn . 6 F,t the hCildllmn(J and hemU",,,,U h,,,ne 7 lithe ild)lIsunenl is slill Incorrect. ,emove (he we,l\hel$I"p from Ille rool panel ;)11(1 hend ,IS mountll1g lIange as necessary
.,.,.'~ ..... ,,--...... ;;
• · .. ···"'·' -·0 . .'--
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FiU 11.19 Sunroof controllllechanism (Secs 33. 34 and 35)
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Chapter 11 Bodywork and fitting
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Fig 11.20 Sunroof front g ' I ', Fig. 11 .21 Sunroof reM U FiU .1'.22 Sunroof heiullt adjustment (Sec 33)
Neighl adjustment 8 lhll lIont edge 01 the SlUllool should he lIu~h with. o r 1 nUn (004 Ill) heluw. the edUe 01 the Cill loul Th" W 9 Proceed 34 Sunroof -removal ;:H1d refitting
Open the sumool. then m,uk the pOSItion of uoth guide pm assemblies Remove the Uuide pins !',",sition.
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llft the hom 01 the sumoo! Olll 01 liS opening. whIlst tu'ning Ihe handle unlil the screws l acceSSIble .
4 Unsc,ew the cable and hit Ollt the complete Slln,oo/. uldudlll\J the b,lse ~ssemhly. 5 Unsclew the hnndle assen1bly. pllil out the handle Jnd escutcheon then ,emove the button conllol RenlQve the cup. G Unsc,ew the gem beming. then remove il. 10geth(1< with lhe plllJon_ 7 Move the cable so th;]t the g,ooved dowel pin ~ppe (a) Pull t/le bullOtJ clown ,md lum Ihe h.un/le fully clockwise. which sho!llcloow be ,lpptoxim.;(ely 30 degrees ahead of ils original POSilioJ) opposite the cup of the h 11 Insert the Sunroof IntO the opening mId ~tl"ch th(l c procarmanuals.com

) Chapter 11 Bodywork ar\d fitting 191
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FilJ. 11.23 elweki"\) the sunroof hHndle nlignment (Sec 3 4 )
wllh th" ",.IIk-, " •• "I,~ whO:1l "",,",vt:d NOh! th.,t tile lelt ,lnd "oht·h1lnd gUltit,s .",' ,,,.( "'I,,"cil.LI'!I.,,,I,I,, 13 A,il'''1 II,., ,,",1 , .1<; d"~<-"I""I '" 11", I""V'()US Soctlon
35 Sunloof h',"ckcl M"t d .. ivH n%l)mhly rClllov ' f ilti"lJ
til" cr .• Ilk to.lt,dh: til" p"I,on dllv" and the hu"",,!) tl,,, ""V''''''') '.1"1'. II"", ""'IIIV" 11't: m irror, f.()"'t,:~v IIUht ove Ihe ""d,lI" 01 11m win" a<:lu;'t'''u cilhJ(, and ,hsGlfd il.
6 Pull bold, Oil Ihe cabl" ~h!lhlly. to (;1",,, 110" d"ve ir~;~,,"'I,ly 01 Ihe cable 7 Reillove Ihe tulle \JlJld'~ S(;"'W ("!)hr·h,u,,l s'de) ,l"d clop (Idr-hand side), ;]Ild remOVO Ihe tull,,~ 8 Ren,ovr~ the screws, 10 rele,lSe the b'ilcket ;]nd dJ1ve ilsse",hly. 9 RehwII!) the ur,1t;kcl il'1(1 drive ,lssembly 's Ihe reV'IIse of the ,emov;,1 p'ocndwe, US"'!! a ""w u,ooved dowel pin. Check 110" h;,ndle
POS'I,oll. ;'S rl,,~cr,lJed ,n I"";'()'ilph 1001 Iho prev,ous Sc,;I,O" and ;]dJu~1 Ih!) "'01. 01 necess,,,y. as de~c"l>ed III Seelion 33.
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FiU 11,24 Tuhe guid e screw ilnd clip a llow"d (S".: 35)
36 S!la t helts -IJener .. 1
All ",,,dels ;H(J hllud with OI1Clt", 1(,(,1 S(!.!I 1,,,11:; In, 110" 1"'''1 """h n",,, ",,;01 ho:llS 01 ,1 s",ul,,. type ,Ire also ilvntl;1I,1,~ 2 I '!I 11 2~ shows Ihe 1I00r -rllo,u'h,(1 hunl S,,"1 1",11 '.I.rl~ Ikn",v.d of II", I>,'~I(: Iype hxu)!1 r~ Sirilitlhlfo,w;"d, IHlIIor GIII,r ;r"d L,("r """Ids II", C""I", console m"SI be parlly removed, ol~ descrrh"d "' S'·,·I,,'" ]2 3 ro ""nove Ihe frOni ~eill belt rn",I,;] re,,1. u~m()ve IhO! "',,, '1","1", III'" POI""', i'S descllbed in SeClion 22. Ihcn relllovc Il>e Ih",!: "ub I,,,,,,
Ihc ,,,,chu, plillC ;rnd lowcr thc nssemtJly Ihrou()h Ihe ;rp"'I\"". whtl~1 feed",!! Ihn hel l Ihrough Ihe sial "' Ihe "ull,r jJ''''ul (ph()I"~l 1 Tu ,emove Ihe ,eilr seill belts remove Ihe cushrun ,,,,,I "",., ",w II",
anchrll holls The "'erlra reels Ciln ue lI"hulted I'om tIH~".II ,.,,10, 1"""'1-. (pholos)
36.3A F,ont S(!ilt belt ilnchor pl;,tc ilnd nuts 36.38 Feedlll\l Ihe honl seill belt IJuouUh
Ihe slOI III Ihl! inner pilllel
36.3C Front seill bell 1llP.,I'il ,eel ;]nrl
;]Ilchor pl,lIe
36.4A Reil! scm belt outer ,lIlehor 36.46 Rear seal belt m,ddle anchor 36.4 C Rear SCJt bell inC'l'a u:(;1
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Index
A
Accelerator cilble removal ilnd refining -14 shnft ilnd pedal removal and refining -75 Air cleaner removill Jnd ref,nrng cal buren or mod cis -68 fuel injecllon models -80
P rnator .,rushes inspecllon. removal and refilling Bosch -202 Femsa -203 Lucas - 202
dismantling and rcassembly -203
removal and refining -201 Antifreeze mixture -60 Automatic transmission descrip tion -122
B
downshift cable removal. refi11ing and adjustment -121 extension housing oil seal renewal -121 faull diagnosis -127
maintenance. routine -123
removal and refOlting -123
selector mechanism ildjustment - 126 rcmovill. overhaul ilnd refl11lng -125 speclflf:iltions -103 SI.1r1er IIlh'bilm/reVerse lamp switch remov Bilttery clrilrgmg _ 201 description and testing -200 removal and rcfll\lng -201 Big-end bearings -37. 52 Bleeding the hydr centre console -189
demister
noules reOlov description _ 174
doms-178.180. 18210 185 face level vents removal and refItting -197 facia panel -188 fuel filler flap -188 heater -192 to 194. 196 10 ) bodywork and under/rame _ 176 routine _ 116
uphOISlCry
and carpets -176 mirrors
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192 open rem quarter glass assembly
removal and refitting -186
re~r qllMlcr trim panel removal and refitting -185 repi'lir millor damaue -178 minor damage -176 sent belts -191 seats -192 sunroof-189la 191 lailgate -180. 187. 188 torque wrench scuings -173 windscreen -180 Bodywork repair sequence (colour) -174, 175 Bonnet release c p ipes c
Camshaft (3.0 litre engine) retitting -54 removal -50 Camshaft and camshaf t bearings examination and renovation 2 _8 litre engine -35
3 .0 litre engine -51 Camshah and front intermediate plate (2.8 litre engine) refilling -41 Capacities. general -6 Carburetlor (Weber) aulomat ic choke
adjustment -71 removal. overhaul and retitting -71
dismantling and reassembly -69 general -68 idling adjustment -73
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fault diagnosis -172 leaf spling .emoval. bush renewal and refitting -165 maintllnance. louline -161 shock absorber remoyal and refitting -165 stabiliser bar removal and refitting -165 lorque wrenCh settings -158 R"ays -225 Rep.ir procedures, general - 9
Rocker e rms (3.0 litre engine) examinat ion and renovation -51 removal - 49 Rocker arms and coverl (3.0 litre engine) ref itting -55 Rocker assembly (2.8 litre engine) dismantling. examina tion and reassembly -34 Routine maintenance stt Maintenance. routine
5
Safety precautions - 12 Seat belts -191 Seats .emoval and refining -192 Sidelight bulb renewal -213 Spare parta buying -8
to carry in ca. - 19 Spark p lugs conditions (colour) -91 lemoval. servicing and .elilling -95 Speedometer cable renewal - 226 Stabiliur bar Iront -163 rear -165 Starter moto r
description -207
d ismant ling and reassembly -207
removal and refi tting -207 testing on engine -207 Steering column removal. overhaul and refitt ino -170 desc.iption -158 faull diagnosis -172 f,on t wheel alignmenl ~nd steering angles -171 gear (manual)
ove,haul and adjustment -166 removal and refittin g -166 maintenance. rouline -161 power steering bleeding -168 gear removal and refitting -168
pump femoval and refining - 168
specifications _ 157 torque wlench senings -158 track rod end balljoint renewal-167
whea' removal and refitt ing -168 Sump 2.8 litra engine
refining -44
removal and refining with engine in car -34 3.0 litre engine refitting -55 removal -50 Sunroof bracket and dr ive assembly lemoval and refitting -191 panel adjustments -189 removal and refining _ 190 Suspension lfnd steering _ 15 7 tl seq Suspension see Front suspension Imd Re ar suspension jtches removal and relining
Index
T
central facia - 225
door p illar - 224 handbrake warning light _ 225 hazard warning -223
ignition -224
instr um
ent cluster illum ination _ 224 light and windscreen wiper (Series II) -225 load sp':)ce lamp -225 steerin g column multi-Iunction -224
s top lamp - 152
Tailgate priv ate lock removal and relining -187 .emoval and refilling -187 striker plate removal and relin ing - 188 wnsher
nozzle removal and refitting -217
pump rllmov31 and refitting -217 window glass removal and relitting -180 wiper mOlOr and linkage remoyal and refitting -217 Tappets (3.0 litre engine) remoyal -50 Tappets and push rods el u
care and maintenance -171 presswes -158 size -15 8
Underframe
maintenance -16. 176 Upholstery maintenance -176
v
Vacuum servo unit (braking system) description -156 lemov~! and refining -156 Valves clearances checking and adjustment -46 . 55 Valves (3.0 titre engine) removat -49 Valves and va lv e seats (3.0 litre engine) examination and renovation -52 Vehicle identification numbers - 8
255
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