service 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 53 of 205
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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
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:
[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
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
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
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
Page 78 of 205
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Chapter 3 Fuel and exhaust systems 77
Fig. 3.29 CUlling the reM o f tho exhaust system to facilitate its removal (Sec 21 )
6 Usu a hadsa w 10 CII I II"Ul'!lh Ihe .e:!. Cxh:!ust p'pe ilhoul 240 mm (94 .n) ItOm Iho! ''';]' ollho I.onl tI:S(HlilIO' (r.O 329) 7 Removtlihe IHII sl:(:IIIIIl!llhe I.:a. sllrm cm hlolt:kel clamp. SWU1!llhc hl"ck,,1 ell,;" ot 1111, sol"nc", :tni! ,,",I ,lcll lit" ",n, e xhausl ~(,CII"n. 8 Ot.lt.1Ch ,1", 11"'110VI) Iho I"a. IIIOUnlll'!IIIIIIlw. :tnd IIIa(.k,,1 clallip 9 Rell1uve Iho hont P'P" LJ r:lallip and dill I oH 1111) Iron I pipe . D"t;tcll Ihe f(:sonn lo' 1I100mlll'!! h.ack", and Ih" wll plpt: 111111. If filled 10 Slilll 1e!11!1Il!j hy SCllhlll\j il nlo"k 115 I'"'' (1 8 III) 1,0m Ih', CIII ends ollhe ,csonnto. 10 Silence. pipe I I POSition Ihc .csonnlOl and ltont II'IX! ilSS(lmhly. loosely SUCIIIC ,110 the hr,'CkC I and man,Iold connCCIoOIi 12 Slide a se.vice sleeve (FlU. 3.30) 01110 Ihe .eson ;IIOf I"I)C. pos,"on,nu lI S end In Ime with Ihe s O lhed ma.k m,llle p.eviously. 13 F'llhe Silence. l)lpe mlO Ihe sleeve up 10 lI S sCli hed ma.k and .ehl Ihe .e:!. StiOIlCt" c l."up ItJo~ly Wilcil hlhll!llhe clamp. ensutc Ihm liS
;IIlUlet! end .s IIpp • .:tlnn~1 111 1\l1!II'lhe I!xhatls l syst"m sn Ih;11 .. I tin 1IOilit IS 'I Ile;u,,' Ih;)l 1 25 "'''' (1 III) 10 "lty i:Oll'pOllelll. o. 1',111 01 Ihe t,,,dywn,k TI!lilteli th\)
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FiU . 3.30 F itting the service sleeve to Ihe eKhausl system -arrowod (Sec 21)
II1n n llol(1 conn(:(:tlon and Ihen screw on Ihe nUlS of Ihe .esonnIO' clnlllflllll111 13 mm (0. 5 m) of Ih.end Pfotrudes Ih,ough Ihe nulS. 15 1'0SIlion Ihe IWO U·dmllps on Iho service steeve and li!Jhlen the n\llS 10 thu IO'IIIHl w.ench sc1ttng Uiven in lite SPCClhC,ltions 1 G [1"" 1 lit,) 1;111 pIpe 111m of "pP'OP".1W thon reconnect Ihe b.ll\e'y. M:ttllhe OllOine and chock 10' 10,lk 5 17 Low,,, the c," 10 Ihe Wound.
PART B, FUEL INJECTION SYSTEM
22 Goneril! description
The 111,,1 "'1"Cllon sySlem fitted 10 Ihe 2 .8 hIre engIne IS o f the COllltlllHlIlS '''IL'Cllon Iype ;tnd sttppltes " p.ecisely conuolled (IUnllllly (II ;I\()lII,":d hll:1 10 "nch c ylt1lde. undo. fill Ollo.nttng condItions.
A U C
Fllel plllllJl FII~·1.1C'·''''IUI •• tul '''mUIr) IWlls",!}
Fi g.
D f F
3.31 Locations o f the fuel illjection system compo non IS
Fuel "'WI G rhemlolime switch
(Sec 22)
K
L Relays ilnd line (lise Im,lu'se module OrstllbulQr/mixture cO/wol "",I W,l. m·up leguliltol H Allxrfi,lfV illf device J Stilll valve
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Page 100 of 205
Chapter 5 Clutch 99
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3 I V,,'W 01 Ihe clutch wIth the Ue,IIbox r~movcd
1 If IH,<:~SS;lIy. ill'" Ihe
I Remove the ~Jenrbox .. 5 described in Chapter G (photo). 2 Ma,k Ihe chltd, cove,
II", ~1'''I'·r ""!I Uoar (photo).
1 Cili lch assemhly -inspectioll
Ex;"nIlIO IllI] 1", :lio n dISC lor we,ll ollhe In<:lIon 1ll'lIe"al. for bwkell .j ,;pllilUS. (ilSlull rOll of the rilll "ml we;lr all the splmos Unless the
. 1I:h plate IS In ve'y \Jood condlliull II is ;I false "cono"'y not 10 hi J
II""" ono ? The I"ctron d,sc should he ren ewed as as "ssemhly II IS adviscd Ih.ll th,s co\m;r~ IS prelelahle to lIymB 10 1'1 .. IIew I"ctlon IIIHIlU· :3 Chec k tho tnJchlned Iilces 01 Ihe flywheel "nd p'essure plate . lithe Ilywheells scoled. II should he relllove<1 "lid m~ch",cd Illhe preSSIJle pl.lIe IS scored.
cluic h nnd II si9nS 01 le"ks "re found. rec t,ly Ihe le"ks be/Ole hlling Ihe
clutch.
5 E x nmlllC Ihe diapl""9fll sprinu lor wear ,lIld <1
., Ch eck Ihe comt.tion ollhe dolCh spigol be .. ring in Ihe end 01 Ihe o""kshillt. Further inlorlllillion on this is given in Ch;lpICr 1.
5 Clu tc h assembly _ relitting
Note: A chI/eli CCII(r,l/ising roo/ is required in (his See (ion. I IllS IInpOllanllhal no od or gre.lse gelS onlO th(l friction mated,,1 01 h,c t,on diSC 01 on 10 the laces of Ihe lIywheel find pressure plalc. It ,~advisi,llle to have clean hands when rel'lIing the dolCh and 10 w ipe lho lIywheel ;lIld pressure [lla\\! surfaces wilh clean rag belore
I~assernhly IS s1
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'.
33 One method 01 10cklllH the Slarter lin!) \lo"r wlHle \II1SCleWll1U
the clulCh cover hailS
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Fig . 5.3 Clulc h centr" lising nHllldrel dimellsio ns ISec 5 )
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1626 111111 (061 ill) 25101ll11! (100 1ft) 3175 mill (125 1ft)
)
.. , . I .. ~ .
rI .• 44.15 mm (I 75 ill) IIImil!l(IfII (: ~ 15210111111 (6.00 ill)
.l/lf!f(!X
./J?f1. ' ,
.?!<'. , , ..... /
~/ r .... :./ .:..1('":'
'''r' ....... , .
. )i";; , i ,
. . ~:.. • j • ,
/'" , , -..
··E
"
.. . -
5.2 Friction disc FLYWHEEL SIDE marking
2 The friClion disc is Il,arkcd flvwlwcl shit· (photo) and il i$ impol1anl Ihal th is face . which can 11150 be idenl,lled by ils haVing the longe, cenllal boss. ;s plnced againSI Ihe lIywheel. The cushion springs and reJaining pl"te muSI b(l ollsel away hom lhe Ilywheei. 3 Loca te the Inctlon disc "nd cover "ssembly on t he lIywheel with the cover cOlleclly positioned on J he loc .. ting dowels (phOto) . If lhe oliginal assembly is being , efllled .. lIgn Ihe previously made marks .
<1 Insell Ihe reta,ning boilS I"'ger Ilghl.
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Page 124 of 205
Chapter 6 Manual gearbox and automatic transmission 123
When towing a vehic le wIth automl11ic uansmission it is impoltllllt to observe the precautIons gIven til ,he 'Jading and Towing' se<:,ion at the Iront 01 the manual. Due to the complexity of the au'oma',c tran smission unit. If performance IS not up 10 s tandard, or overhaul is necessary, it IS impera tive that this be left to the locallllain agents who will have the special equipment for fault diagnosis and rectiflcallon. The content of the following sections is thereforc confined to supplying gener", Informl11ion 1'Ind any service information and ins t.uc tion tha i cnn be used by the owner.
19 Routine Illilinte,wno
At the i!lle.vnls SI)CClfiecllll Iho ROllllne Milintennnce seCIlOll in the I.onl 01 th e Illanllal cnllY Oul Ihe follOWIng p'ocp.dwe
Luuricow selector link'1[}() , Applv the h;rrldh.,lke th(:n J,lck \lp the front of Ihc Cill ,'lid Support
,n nxle Slnnds
2 Orlthe Irnkn!JCs at cndl end 01 Ihe genrsh ,h rml on the Icfl·hnnd "le 01 Ihe Iransnll~s,on lowel the cnr \0 Iho wound,
Check /mn.Wllissioll fluid level 4 Elrlll!! the engIne and trnnsnllSSlon to nOllllal ope.IlIUl!IIp.llIperillllfe
and I)alk tho vehlchl on le vel grOllnd 5 Wi,h Ihe engIne idllll(l. move tht: 1.,lnsnllSj"on St:leclt>r lev!]r through ill! pOSlllons 1!lIee lImes. Ihen onuaue '1" ,11111 wall for ;rt lea~t one minute. 6 With ,he engine 51111 idling, wllhd.ilW Ihe lr.1nSnllSSIOll d,psllck.
Wipe it dean, reinsert II, wilhd •• 1W 11 for Ihe second !line nnd read off the levol. 7 Two tv pes 01 automatic transnllssion fluid a.e nvarlilblc (sec SpccifiCiltions 10' tv,>c numbe.s) .1nd It is ImpO,I,ln , Ihilt IheV 'lIe nOI mixed. The colour 01 the dipstick. 10' flUId level checklllg denotes which fluid tvpe to use , 8 If a tlr1nsnllssion requlII"U 1,1ter tvpe fluid IS I'lled 10 " to'
adjus'or screw n lew h,fIlS . 13 Tlghlolllhe adJuslo, sOcw to 14 Nm (10 Ihl II) IISIilU a SUItable lo,que wrcnch From Ih,s poSlllon slaCken the adJusle r screw bv exact Iv I'll \Urns (pre·1983 models) or 2 Iwns ( 1983 and late,
model), Ihen tighten Ihe locknut Wllhoul diSlUrblllg Ihe pOsition of Ihe adjuster sc,ow .
14 R econnec t the downshift cable and lowe' Ihe car 10 Ihe ground.
20 Automalic transmission -removal (HId refining
If l)Osslble, ,aise the car on a hOlsl o. place it over an inspectIon pit. Alternatively, it WIll ho necessary 10 Jack up Ihe car to obtain the Illaximum possible amount of wOlking room undernealh. 2 Place a large d.ain pan benealh the transmiss.on sump (011 pan)
Ihen. working horll the ,car, loosen the a!laching boilS and allow ,he lIuld to drain. nemove all thO bohs excep t tho two I.onl ones to draIn as mIlch fluid as pOSSIble, th on temporarilV .efit Iwo bolls at th e re,1I 10 hold it in place . 3 Remove tho Slilrte. moto. as desc.ibed in Chapter 12 . • jWhero apphcable, rernove the access cover Dnd ad3pto, plale bolts,
Ie the engine untrl the to.qu e converter drain plug is visible, then
unsc.ew Iho plug and d.ain Iho Ihud Into a suit3ble con winer. Refl! and l'Uh ten Iho plug.
Fig. 6 .25 Checkill{J tho au tomatic transmission lIuid lovel (Soc 19)
Fig. 6.2 6 FrQ,1 bn'ko band adjustment (Sec 19)
A Arllf/SICI sc/t'w a Locknut
C Downslu/t Icvel D Downs/u/t c.lblc
Fig. 6.27 Torquo convorter to driveplato boll -arrowod (Sec 20)
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Page 157 of 205
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156 Chapter 9 Brakin g syste m
Secondary cc1ble (early models) 5 Loosen 1I1c lock.nut ~nd unscrew the adju stment ferrule from the right-hand rear clevis.
6 Remove the split pin and clevis pin securing the secanda.v caulo \0 the left-hand Icar operating le ve l. 7 htrac the clip, remove the clovis pin. and withdraw the pullcy wheel from the lever on the Ical a~le. 8 Remove Ihe cable from the lever.
Transverse rod (later models) 9 Disconne ct the cable from the righi-hand rear opCfating Icvcr by
removing the split pin and clovis pin. to Uncl.p the cable hom the 'Hlnsvcrse rod . 11 Remove Iho spli, pin and clevis pin securing the fod 10 the Icft·h~nd le;!1 operating lever . 12 Slide the transverse rod Irom the guide on the rOM axle . 13 Check thO {luide bush lor wear and dama ge and renew It il necessary by prising il oul and pressing a new bush irllo POSilioll.
All models 14 Refining is a r e versa' of removal. but lubr icllto the lin kage as )scflhed in Section 2, and atljl' stthe cable as (fescri bed in Section 18.
21 VilCUUrll sorvo unit -dosCrilHion
A vacuum servo unit is linod Into the lir,lk e hydrallirc cil cu il. 111 series with I he 111,1S ler cylinde f. to provide assiswnco to the dllver whlln Ihe brake pedal is depressed . Thi s reduces the eHolI le{luired try the driller to oper,lIe the brakes, under all brak ing condi tions .
This unit operates by vacuum, obtained from Ihe indu ction mnni rold and comprises basicall y iI booster diilphragnl and check lIallle . The servo unit and hydraulic master cylinder are connected
t o gether so that th e serllO unit piston rod acts as the master cylrnder pUShrod. The driller's b rilking ellon is trilnsmitted through allot her PIi ShlOd 10 the serllO unit piston and ils built-in COmrol system . The scrllo unll pislon docs not fit tightly inro the cylinder. but has a strong ,lltl flhril!Jlllto ke el) liS edges in COllst ilnt COntaCI with I he cylinder Willi_
23 rilult diagnosis -hrilking system
~ylllptom
-'ceSSllle ped,,1 u;tllel
nrakcs pull 10 ono Side
Or;tke ludder
E~cessive eHor l to stop car
so ensuring an i1inigh t seal between the two parts, The fo rward
chamber is held undelllaCUUm condi tions cleilted in the inle t manifold of the engine and during periods when the brake pedill is not in use, the controls open a passtlge 10 the rear ch ambe ., so placing it under lIacuum conditions as well. When the b.ake pedal is dep.essed. the lIacuum pass.Jge to the rear chamber is CUI oH and the chamber expos ed to atmospheric pressure. The consequent rush 01 ail pushes
the servo piston lorward in tile lIacuum chamber and operates the main push rod to the m.Jster cylindcl. The controls are designed so that assistance is given under all condllions. When the brakes are 1'101 requ ired, vacuum in the rear chamuer i s .e -es tabl ished when the br.Jke ped.J1 is released . All air Irom the atmosphe.e entering tho rear ch.Jmbe. is passed through II sma ll air trlter. Und er normal opcr.Jting cond itions tho IIflC(IUm serllO unit is lIery relraule and does not require ollerhaul e~cepl at IIcry high mile,1geS. In this case it is far bcner 1 0 o bta in a serllice e~hange uni l. r,1the, than rcp;ti . the o,igi'lo11 unit . Although inlernal components we,e once .Jv'lIlaule 10 ' ovcrhauling purposes this service has no w been
d,scont,nue(t .
22 Vacuulll servo unit _ remOlla l MId re filtillg
I RemOIlO the master cylinder as desc.ihed In Section 10. 2 D,scolllwc l thc vacuum hose from the non·return lIalve on the serllo \lI1it. 3 Work i,,!) insido thc cal. remOlle th e lower l;t cia panel below the stccring column. 4 E~tractlhc clip and l)ul1 outlho clellis pin attaching Ihe push.od to the l ootu .ake ped;t!. 5 Unsc.ew the nuts securing thc mount ing b.ack.et to the bulkhead.
then withdraw thc serllo unit and bracket from the engine COlllp,lJtlnen t, 6 UnSClew th e nuts ar1(1 serlar,lle the braket 110m the SCIIIO uni, . 7 netrning IS;t rell e.sal 0 1 remOllal w ith leference .Jlso 10 Section 1 0 when retrumg Ihe master cylrnder.
Renson(s)
RC.Jr blake self adju sting mechanism faulty All i n hydrilulic system
WOIll or cont,llllina led /rnin{Js Seized Caliper or wheel cy linde r
E~cessille run-out or distortion of discs o. drums
Worn Of cont aminated linings Brake backplate or caliper l oose WOIll suspensio n bailloints
SerllO unit faulty
Worn or conwmin.Jted linings
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