torque FORD CAPRI 1974 Workshop Manual

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 V"lvI! ~1I11"!J (11)1] 1''''WI, "'III (,,,) SlcIII III !lIIId" CI0.);1I"'1I:1) ,,,'" (II') 1,,1,,1
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
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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 Lubric W'lh 1,ller W'lhoUI "iter ..... " .. 0, prCSSllle (nllillmum

Chapter 1 Engine 45
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)
33 7 ApplylllU se~lInu COIll I)(IUlld to the unnkshnlt pulley wash"r
34 Cylinder hcads. rocker gCM and inlct manifold - rc lin ill(j
Lubricate the valve tnppets wllh cleiln cnUlIle otl ;md Ulse,1 th,,'" It! th o cylindcr block. Ensurc they ille fm"d in thei . OIlDlIlal tOGillrOIl~ 2 EnSIHe tha t the mnllng lilces of thc cylinder hlock ilnd 1he cyllndel h~,lds a.e clean, 3 Position the new cylrnder hCild \I,1skets over 1he \Julde I>ushe~ on the cylinder block. Chec k thm they ilre correc 11y locilled The n!Jht ilod 1, ,11.hnnd gilskets il,e different TIl(: onskets ilrc rn,lrke d FRO NT TOP (pIl Ol0S)
!
.'
/ . .-,,~ .. ~
Fi(J 1.7 T iuiltening sequence fo r cylinder he ,1 C,l rel"lly lower thc cylrndc r hcads 01110 Ill" r:ylorulcr hlock ,'r1d ht lir" h"IIIII'!1 d"wn holts willch should hc !rrr,1 io!Jirliy ollr:d 5 T'Hirlt;1l tl,,: holts. ttl th" ~"qllp.llce shown 'Il r-'!l 17, '1l1he St,l!JCS as ~pe<:tlI"d It) Spf:clhcaltOllS (phOl0) G Luilrr""I" tile plIshrods wIth el1Uine OIl and Insp.rl them til the <:yllluh" hlock 7 I'laen Ill specrfred torque (photo). 9 RelIt the ,nle l l\\al1llold 01<; descrlbell III Ch,lpte' 3 1 0 Adlll~;1 the valve cien,nnces <15 desclllwd In Sect Ion 35.
~4 3A TIl(: dlfferencc hClween the left nmt ','Ilht head gnskets The ""OW mdlcoltes
. oot 3438 CyJrnder head \1,1Skt:1 pOSrilon
rnarkinos
•
r.
/ 1':' .j I
, I • 1 ... , 345T. h ' , __ ..1 I!., u U lco"I\I 1he cyhnder head bolts 34,7 Guidlfl~J 1he roc ke. ilrm il 3 4 8 Tightening the .ock !:! shnit bolts
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Chapter 1 Engin e 47
--;; ble chec k ~II littings nnd elcct"cill connections. Ensu,e thnt the 2 .,",or is correctly lilted ilnd Ihil t Ihe IUnil,on tlmmg StJtlC Selllll\) 's distrlU
I CI , t II in doubt Ie el 10 1npler . eorr~~ ~10VO 1110 SPJlk plugs nnd the '- ' conneC lion from Ihe 1\)111110n 3 '1 Turn Ihe engine over on Ihe st~rler motor unlil Ihe 011 pres~!II{! co'· . light is e~til1gu,shed or unlIt 01' pres sure IS .ccorded on IIl{!
warnu"lg . d I This witt ensure Ihill Ihe engme ,s no l Slarve 0 0,1 dU"I1!11he g~~ge,. I,w minules running alte. IflIlJ.1t SI.:lrl·Up. The l uel syslulll W Ill ,,,toea . I· • be p!"iOled dunng IllS ope.atlon.
: SOReconne<:llhe '_ ' conneclion on the 'IIn'tlon co,1 and ,elll th e sp.:llk
lugs and loads .
Stilrl .Ihe ~ngme .. ~ AS soon as Ihe engme Ilfes and .uns. keel) ,t gOll1g ill il lilst \lckov(;.
nl (no las te,) and bring it up 10 nOlll1nl wo.kong ICmpernturc ~ ~s the engine WilflllS up there WIll lie (){I(I smelts nnd SOfll~ "mol Il
hom pariS getting hOI and uUI.l1Ing olf all (leposIl5. The Signs IU luok
10' arc l eilks 01 w i•
exact gos liUht position unlil lhe w:1I1l11h ;oml vlh!al'On hiwU ;I(;t,," on Ihem, and il is almos t CllrWU1 th.11 th(ly WIlt ncrHI I'Hhw1l1l1H hllth". Tills should be done. of course. wllh Ihe C"( ,,nc slopped 7 When nOrmal running lefllJ}Coallll e hilS hecn .cnch", (lnuine -il new bemings and/or pistons "nve hcen lIlted II shollid he
I' !.tilled as a new engine and run IIl.1t.1 .cducc(1 spcud tor Ih~ IUS I 1000 miles (1600 km).
PART B: 3.0 LITRE ENG INE
39 Gener;!1 description
ThC !lcne'il' conl,uu'illion 0 1 the 3 0 hue enuine is sil11l'nr 10 the 2 8
( \:\.~ ,..d r •• -~~ .. ; ~
389 Recloeck,,'u Ihe Iluhlness 0 1 Ihe cyhnder head bolts afte. ,,,,,.loIlU lhe enu")e fOf 20 'I1In ul('"5
hire nllu""1 d(:~c"hed III Sec(,on 1. Thc Slunillcan t dltferences iI.e .1S follows
(i') FI,'I •. yllll(/vr ht',1(/$ ",'III the combustion cl.,1mba,s itl lila I".~I()IIS (b) Imhvr(/",llly IIIOUlIlCd rOC~t'f ,Jrms illstead of a lockct sitaft (c) W"lvr pump 10C,11cd 011 Ihe ,i!llu of the allgine ((f) DiSlfllmto' ,WI/ orf ,,"1/11' (I,ivell f,om thc front of thc c,lrmllllft (e) ML'ch,mic.1llllcl,Jl/flfP ollcfMed by ,1f1 ccccntric on tllC frolll vllhc c,lmshMt (f) /rr.';" (Ill sC;llloCMCII '" ,1 S':l'olfall: c,ltric, (y) OJ! trltvr IOt';llvl/ on tlw "I}fI1 lef(-h,mrf sidc (If tlw clI{Jlln'
Fig. 1.9 Sectional view o f tho 3.0 litre engine ( Sec 39)
i
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~ .... ------------------------------.. ~; 灲潣慲浡湵慬献捯m

Chapter 1 Engine 49
----------------~--~----------------= anuill transmiSsIOn models, remove foul clops bolt~ n automatic 1.,J;lsmission .models. drilm the torque conve!ler ,\Ild 18 Ihe drivep l . odelS make s"re Ih,lt the torqlle converter ,em,,!!)s lilly 1f1 1he $lOI1 m transmission . 20 When the engine hilS been SCpM,lICd from 11l(l 11.,11$1111551011, 1,lllh!.! . ,lowly chccklll9 j,equently to see (hMllle CflUllle does not loul " ng,ne . ~nv part of the bo?ywork. 21 W hen the engUle 's cle,lr of the iJody . lower it to the ~lfOun(i. Of
Ir~nsler it to a WOrk lJench
4 $ Engine disill1lotling -generill
Refer \0 Sec t,on 7
46 Engine illlcillilrics -removi\1
..
1,',lh the engine sep,l rated from th" t r;IIl~:nHS~r()" remove Ihe ~.tcrnally mounted componelliS ;l~ lulluw~
C;J//)Ulello, i.lnd fllcl {lump (C"'1!,lt" 3) IlIlel ,wll exhiwsl tII,wi/a/ris (Chaf!/t't 3) Sp,>r/( plugs and drS/fllmlor (Chaplet 4) AllCllwlor (Chaplet /2) F.w ,7I!d policy (CII,71I1C' 2) W.JICf pump ,wd Ihcffllos/.1I (Clmp/t't 2) C, ,1IIkc,lSC vcn/iliilion lubc 011 {,f/CI (Scc/ion 40) Ol/Icvl!! r/rpsllc/o; and {,/lCf C,?!, [II!1int' 1II01tn/ill.ll h,.1r:kvls Ciulell (Ch,7/I/l'l 5) Powl'r S/Cl'l/IIN 1'(11111' (Ch;lll/Vf 10J
<11 Cylind(Jr heads relllowti with engine in car
I
Q,scunnecllhe IJiltlery le,lds ") ~cmove the splilsh slucld. by renuJVIII , R ernove the servo V,lCUlUl1 hose I ~ DI~conrlccl Ihe rilll,.llul hose from Ihe ilulomallC choke D,s·
,onneCI the vac\JUnl h"e I • D,sconnect" I I I 10 0 le ea( co I I~con"ecllhe HT ICilds Irom the spark plugs and IrOlillhe Ign'llon I ,1od remove Jlw L T I I I I .
MId I I If . CiI( 10 lie dlSl1i Julor Reillove aile h Xlng bolt 11 0
' I
a Ihe dlst"I>[1I0r ilSsemlily.
'Sconllect Ihe all II 51 halts' , ' ernillOr Cil) es. ilcken the ailelllntor 1110ul1l11lg un( Pusil rod . C,II1)e "Oled. 11 IS very Imporl "IOC>! "
Fi~,. 1 .10 Turn the rocker (HillS to olle side 10 relllove the pushrods (Sec 47)
15 n,,,,,ove Iwelve lIolts ilnd delilch Ihe exh,lusl I1\,lrlllolds frOI" Ihe cylrrlrtr:f he,lds. 16 Sinckell the cyhmter hend boilS progressively in the revtnSe order to Ih"l shown ill FIll 1.19. IlcrllOVC Ihe bolts nlld hit olt Ihe cylindOf head.
It lile (.Iilsket has stuck and the cylrnder heJd cannot lJe lifted off. wp the cylinder heild wllh n hide·f.1cert. or plnstic·headed hJmmer. 00 nOI try to pri se IlIelil off wllh a screwdrivOf Of rtilillage WIll result.
4 8
Cylinder he,l(ls -rernovfli wilh engine O\lt o f car
Follow Ihe sequence (.I,,·elllll SectIon '17. 51;lItll1g.l1 PillillJl1lph 10. dl$lcoa,d,n!1 leil.!lellCeS to pa'is willch hJve alreildy bcen rcmuved
49 Villve$ _. removal
Rt:rllove the d('POSIlS /'0111 tire corllb\lsl,on chambers ~nd vnlve
h eads by ScrilPIl1!l and W" ~ b'\Ishlll(.l Tilke CJre nOI 10 scratCh the cyllnde, he~d gaskel lilces 2 Lay the CylOl(ier hemt on ,IS sllll) .llld h t the lo,~ed cnd of .1 VJlve spllng compressor ove, the ~plln9 rctiluler ""d ti le head uf the complessor screw in Ihe cenl'e of Ihe v"lve head 3 Compress Ihe sprrng abolll " qUJller 01 an Ulc h 10 Iree Ihl} split colle l hom the top 0 1 the v,llve stelll. If Ihe sPltng ,eliHner "nd collel Slicks. do not screw the co",p,essor down lurlhc< . bec"use IIIIs lII.ly dJr11J\je the valve Slem. bUI lJp the sprong reliluler sha,ply wllh a Ioghl
hammer. 'I When the Iwo halves of Ihe collet h')ve been '(:nloved. onscrew the spllng compressor umrl Ihe spring IS no longe, compressed nnd
remove Ihe compreSSOr . 5 f1Olllove the spltng retnlner. the spflng and the oil seal from Ihe villve Slem. Ihen wrlhdrflw Ihe villve from I he cylinder head. 6 D iscard the valve Slem all senls and plflce Ihe Olher componenls to\jellrCt. identilying them so Ihal they arc refItted III the correC I plnce
III Ihe cylinder head. 7 Remove Ihe sp,11k plugs from Ihe cyhnder hend. II nOI alrendy
removed.
50 Rocker arms -removal
1 Remove the SIIfI nul from Ihe foch" .1'111 Illoullt,n\) stud 2 Lift off the rocker re moved.
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7
Chapter 1 Engine
Fig . 1.1 8 R ear oil sen I ilnd ildaptcr pliltc (Sec 84)
84 Renr oil se;1i ,,,,(I lIywheel - rc fitti"u
1 I'll the ()n!J"I(~ .r,," ,,(1"1'10' pla1<:1 and s(:clIre ,I wllh 'I S IIv(: holls. 2 Smenr en\J1ne (ld OlltO the CI,mkshah '''". Smear 0,1 on the lip 01 the sea l tlnd pos(( lon tlon ';".11 on th e cran hha ll. 3 Align the seil l c;""er holos wllh Ihose 011 the cylrnd(:, hlock . Insell the loul bolts and 11!lhlCll Ihem 10 the SpeCifIed 10lqUfl 4 F it the flywher.:l . or dllveplalc on au lOlllallC lwnsrnis sion Illodels.
InSerll h e six holl S ;",d u\llole rllhem 10 Ihe 10 lque w rench sell"'U Uiven in lhe Speclllcm'olls
8 5 Sump -rciiuill!)
En~",,, lh;ol Ill" ru,rI "'!) ',u.l,u :e s 01 hoth IllI.! Slimp a"d t h e c(,1nkcilsc ,lie cl ea" ,mol IIi,1I n", '.""I",!) SlIrJ ,u;e 01 the Sli mp IS not d'S lo lte d. 2 Apply IO" ,I,,,!! c"'''pollnd 1 0 the pOUltS wllel(~ Ihe l"llllll) cover ablilS lhu ,;yir r"lr" 1,Io ck .lIId where Ihe rea' 001 $u,,1 carr.(:r "dIOIllS II 3 Pln ce tloo \J,,~k"l '" fJo~.t.on, lIt tlo" SlIm l} ,'Ild IIlS(). 1 lhe r0Io1111il1l)
bolts ImUO I tl!lhl 4 PrO!lres~lvely 1I!llIt,," llw sump holt s 011 opposIte I'ilr ts lIllt,1 all 0 1
t
hem ,H" il l tl", ~ 1"":lllI"d IOlllUU , 5 FII ,1 now w;,~h", 10 Ihe ~Ul1lp II"'UI pili!) , IIlscrl lhe dl,lIll pllll) and
t ,uhlen ,t
8 6 Cylinder h e"ds re;rssernbly
L~y the cylrnd" r h",.\! on .IS s Ide. luhrrcnt e cvcry valve Uu ide with eng;l1(! oil. ,lilt! ,"~,,"t the valves 11110 the \Ju, dc Irom whIch lh ey wele remov(:d 2 To ,WOld d sprlll\). 5 US1ll\J a vnlve ~prul!) compresso r. com press lhe splln\) lus t enou\)h 10 inse,t the IWO Splil COIl,,15 If lhe vnlvc spml(j is compressed 100 filr.
lhero.s dilnlJC' oltl1<.: ~I""IU rcW""C' dillllil\)IIlU tllC villve SHlm 011 sen l
G Ahcr "lsert")!J tit" ~pllt collets. r eleilSo the spllny compressor (111(1
rcmove II 7 C hcc k th"t lh..: ~pl'l cull":IS hilve seilled properly and t t he v"lve S1C1lI hUhl1y w llh a plJstrc headed hJmrne, to ensure 1I11S,
Fi g. 1.1 9 Tightening sequenc e for cylinde r head bolts on the 3.0 litre enuine (Sec 8 7)
a Repe"l liln pruccdwn orven III p;ua!Jrnphs 1 to 7 o n the (CmJlnlllU
v,llv"s
87 Cylinder heads - re fitt;nu
11 the tappels w ere rcmoved. luiJricnle lhe lilppets nnd I heu hores wnh enoine orl nnd insor t thOlll wilh lhc;, d Ished cnds uppermost Ensule lha l every tappet ,s rclltlcd Into lhe hore hom whIch II wns
t nkcl1
2 Mak e sure tha t Ihe rna t"'!1 surlaccs o f lhe cylinder block. cyl lndor henrJs ;Uld 1111,,1 Ill,lIlIlold ;lIe de;"l. then plnce new cyhndcr head \Ja~kets ove, the Wildes un thn cylrmh" block. Tho cyirnder head \I,,~k ~IS beilr thO malkln\! TOP f:nON T ilnd nced to h e pOSII,oned
cOII(:ct ly .
3 Low ul Ille cyl ""lcr he,1ds ov"r the" posl tlonrngst u(!s, Although t he cyhlld\~r headS ,"0 Id entlc;,I, they should h,lVe been Illtlrke d when remuved ilnd should be lehllUd III thcrr ()IIUinal positions t1 Inse rt the cyirndcf 11I)"d boilS f"'!I(:r t.!Jh l then tIghten lhelll prUglC SSlv(: ty OIl the olde, shown III r,U I l!J and III llle stnucs",s U iven
m the SpcelirC;lt'OnS
88 Rocker arms and cover
s -refiUing
Ensure Ihm "II Ihe puslllOlls ,lie ,nselwd I!ltO the" p'llpor placos ;II1 l
)olt S nntl lighten them t o the spec ,f led torque.
89 Valve clearnnees -checking nnd adjustment
R eier
to SeC!lon 3 5
90 Engine ancillaries -refitting
R eier 10 Sec tIon 46 and ref, t lhe I. ste d componenlS w,th refercnce
to th e Chaptels ind,cilte(f
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)
Chapter 3 Fuel and exhaust systems 67
Torque wrenc h setting s Fuel P\JlllP Inlet n' Pari R Fue! iniaclion syslem
G ene ra l SyS1c'" Iype Idl e sp ce d CO "o,![ ull" Fu el p"mp rfelov(!ry (nHrHrl1lJlll)
SyS1cn, P")~"'''U Fvcll,mk Co1P,lC '(y
Torque wrenc h settings Fue l ,11,>1,,1.,,101
W",m "p "'~11I1;,1O' 51<1,1 V,llvt: A\J~'h;"y i'" duvlC(! Air eh.""I>", Bal1)o I>ull~ Fuel d'SI"hu\or W",nl up '«!lul,l1or (MIO) W,llln·up rC(jul PART A: CARBURETTOR SYSTEM
Gener,,1 description
TI", 1",,1 sy'>I<'1ll <;onSIS1$ of " reM moulI1ed fuel wl1k. il {hilpluo1\Jn1 type 1",,1 1l"'''P d"v(JIl I,om the C,lIllSh eJr.h COII~'Stll'!I 01 ,I hont pIpe nnd leson S omn models !"ay he hlled wIth a p,llted vacuum switch (PVS) to p'eVUl1t fI"1 SpulS aud nllsl"'"0 OCCll""'\) when the enllllle is cold "lid flll"""'1 WIth hJlI or pMllJI choke. When the enuine IS cold (below 71 C I i GO F» the I'VS IS closcd. In tillS cond,I'Oll. c;lIhurenor v,lClIllln IS ,'Pl'hed directly to Ihe d,st"lnilor V'J the Ilon·return v;)lvc. whIch "lIow~ (he va ClJllI1I Jdv,lIlee to IJc milll1lolll1e( 1 lIntier <1cccieIJt.on.
prc .. en ('''Uliat spots or mlsf""'\J .... ·ho)lI the eng"'e h<1s re<1ched liS norm;ll ope,mll1\J lemperJtllle Ihe PV S I, open In tillS condltloll lhe C<1rbUle1l0' '5 connected 10 Ihe
d ,s t"hu!Or v.a lhe PVS.
2 Rouline lll AI the IIlIclv Check and adjust the idling speed find mixture 1 Refel to Sect.on 12.
Check condilion of fuel hoses 2 E>.n''''lle illl Ihc fuef hoses on the eng ine compartment and on the fu!:1 ""'k. for SIgns 01 leilkJge or eletellowt,on. 3 Che ck the secullty 01 holtS 4 Rel"r to Sect,on 19 Jnel t.ghlcn tile IIllet I11J",101d bolts III the
)
s!:q uence (jlvcn
Renew the ilir filler element 5 D'$ coruWct lhe hauery. G Remove lhe twO nuts secullng the air cleaner lid nnd remov e tile
N rn 16 to 20
4 to 8 8!O 15
'8 to 2 2
1 8 to 2 2 20 to 27 38 to 45 20 to 2 4
Ibl It 12 to 15
3 to 6 6 to 11 13 to 16
13 to 16 15w20 28 to 33 15 to 18
1305<:h K ·JetfOnic COlltonnous inlCCllon !JOO .1. 25 rpm 1 25 I 0.2 930 a cc cvcry 30 scconds 5 f)5 I 0.25 kUI/crn' (789 I 36 11l1/on') 580 hlrc ( 12.7U Nm Ih l It 32 to 38 24 10 28 7 to 10 5 to 7
7 to 10 5w7 7 to 10 5 10 7 7w!l 5 10 7
18 to 20 13 10 15 11 to 15 810 11 5 to 8 4 \0 6
5 10 8 4 to 6 181020 13 t o 15
hd . 0" I;>ter models the ltd rnily be secuted with sprong IJSleners. 7 LIlt Out the paper clement 8 Cillelllily clc Check air cleaner IClllpcril{(lrc control (whcrc (i{{cd) 11 By looking through thc main ,101 cle,llle' spout. nOle the pos'tlon 01 lhe 1I"1l v F ig . 3 .1
Air tamper A 8 C
VaC(I(lm mUlor FIlip valve I-IC<1I sensor
o 1-101 all in",ke E Culd illl U!wh,
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Chapter 4 Ignition system
Contents
"'ondcnsc! (30 Iotre cnUIIlC) teslI llU . removal and rc h1!ln g .... 5 '"tact b.ellkc . POIllIS (3 .0 litre CIlUIIlC) ,lI 11us1mC lll 3 ConlilC ! brCi.ke< POintS (30 lIue cnumc) -Hlllloval fllIIl rclr ninH . " f" '~lnb\llo, (1111 CIl\ Ji llCS) lema",,1 .lIlt! .cll1l1n\) (j nhlllOr (28 lilre Cilomo) -overhalll.. 8 D,stributor (30 h\le cnuinc) overhaul . 7 Faull diagnos is -iUm\loll system. 12
S rICcificin ion s
System ty pe
3.0 lit.e engine 2.8 litre engine
Convent ional ignition
Distributor
ROIDlion Condense, cnp Iqnition timing
c 1 !H6 model yC Jil
I',im Spark plugs
Type Elect. ode U .
8reaker/ess igllilion
Distributor
Rotation .. HT lead rCSlstn llCe .
Firing order
Ignition timing
Coil
Primary rcs,sWnce
Secondary resis lan ce ............... .
Spark plugs
Type Electrode {jap .
,1/ systems
Torque w rench settings SpD,k p lugs (3.0 litl(l CIl!JUlC) SPD,k plug s (2 8 hl,e engine)
Geller,11 dCSCfll>, ioll 19r1lllon tnnphlicr Inodule (2 8 hire engine) -. emov,l l and 'Ch1tmO ... ......... .............. . IUrlltlon timinlJ -ndJuslmcnl . flOulUl!) Ill;untenancc . Spark plugs -rem Oval, servicing an d .cl'!lu \g ,
ConvcmiOllill. with cantilCl tu cilke. Br eake rlcss. clCCltOnic
Clockwbe 0 2110025 mid
0 .61 mm (002510) 36" t o <10 · 30000 ohm mOlX"U,uU 1 <1 2 5 3 6
10"' B1 DC 11\· BTDC
0!l5 10 1.60 ohm 50001 0 !l300 o h m
M ot
o,,,,,lt AGR 22 o. Ch;lIllp lon RN 9Y C 060 IlHIl (0024 in)
Cl ockw,se 30000 ohm Il1 12 *
BTOC
0 .
75100.85 o hm 5000 to 6000 ohm
Moto"ra" Super AGR O .GO mill (0024 in)
N rn 30 to GO 25 to 38
22C 0' ChJlllplon RN 7YC
Ibl It 22 to 30 1 8 to 28
10
9
2 11
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,6 Chapter 4 Ignition system
9 The spark plug gaf} is 01 conside rable impor1~e. as. if it is too lilrge or too small. the size of the spark ilnd its efficiency will be seriously impilired. The spilrk plug should be set to the ligure given in thl} Specifications ill the beginning of this Chapter; IOTa sel it, measure the gilp with a/cere, gauge. and then bend open. or close. the outer plug electrode untillhe correct gap is achieved. The centre electrode should never be benl as this may crack the insulation ilnd cause plug fAilure if nothing worse. 11 Relit the plugs, and re/ilthe leads from the distr ibu tor in the correct I"ing order. which is given in the Specifications. Screw the plugs in by hilnd initiilily then tighten them to the specified torque using the plug spilnnel.
12 Fault diagnosis -ignition system
By lar (he nlo1jori (y 01 brCJkdown and running troubles ilre caused by InUits In the igrlOlron system er(her in (he low (enSlon or high tens ion circuns There LJratlon or fuel Injec tion Setlln(Js, ilre normally tllle to faults in the d,strrllulOr Or 10 Incorrect I(Jrlltion tlllllrl!J .
Engine fails 10 staft 1 If the engine falls to StM( and t he cal was IIJnning norll1t1l1y when.t wns IJst used, first check ther e is fuel in the petrol wnk. If (he engille tums ovel normally on (he starter 1I10tor and the bilHery is evidently well chmged. then the lault mny be in either the high or low tension circuits. Firs( check Ihe HT circuit. Note: If lire hal/cry is known 10 hI! {(Illy ch,}lged, Ihe ignilion liglll cOllies on, ,1I)d Ihe s/arler 1II010r {,lils /() tum IIIe ongine check the tightness o f the le'lds on the biltlely terillinilis ,1I)d <1Iso (lte seCUIIHWSS oflhe e,l,th leold (0 irs cOllllec/ion 10 tire body It is qui(e common for tlie le,1(ls /0 Ii,}ve wOlked loose. l.'vc'1I If Ihey look ,1n(/ lecl seclI,e. /I one 01 the boll/my ((:{minM {Josts [11.'1.1' vC'IV liot wi".." (Iyiny (0 wOlk Ihe s/mler 1II0tOl (his is ;/ sUie IIId'C,7/IUI/ 0/ ;/ I;wlty COllllel;('On 1(1 1h.11Ie"lIillal. 2 One of tile commonest rOilsons lor bad stmtln!J IS wet or d;UllP sp,uk plug lead~ and dlstribu(or. Hemove (he distllblltor cap. H "JOdenSil(Ion is v iSIble IIlte!llillly dry the CJp With il rag and also wIpe ;lCf the leads nelu the cap_ 3 If (he enUiue sull fmls 1 0 St.l.t. check that cunent IS reachlllg (he JUS, by dlscounectln!1 ench plug le,l<1 in turn ilt the sp1Hk plllU end, .. ,ld holdlllg Ihe end olthe callie about 5 mm (0.2 Ill) aWilY from the cylillder block. Spin the enu'ne all the sta rter motor. 1 Spa,klllg between the end of the cable ilnd Ihe block should he fa"ly strong With J strong leuulm blue spark_ (Hold (he lead WI(h wbber to ilvold elec(IIc shocks) If Clluelll is reilching (he plugs. then rel110Ve them and clean and reg,lp them. Tho engine should now SWrt 5 If there is no spilrk ilt the plug leilds. wke of! the HT lead from the cenlre of the d'sltibutor C 6 If Ihere me no spmks Irom the end of the lend 110m the coil check the connections atlhe coil end of the lead. If il is in order 5(31 1 checking (he low tension circuit. 7 Use iI 12V voltmeler or a 12V bulb ilnd two leng(hs of w ire. On conventional distributors switch on the ignilion i1nd ensure tha t the points arc open. On breakerless dlstlibulOlS ensure thilt Ihe segments on the rOlor are nOt adJilcenl to (he triggel coil. Make a tes t between the low tension wire to the COil ( + ) terminal nnd eilrth. A leading of 7 (0 8 'lollS should be obtained. N o reJding indiCiites a break in the supply from the ignition swilCh or il f,1UIl in the ballast resiswnce wire. A correct rending indicn(es a faulty cojl or condensel, or n blok en lend between the coil ilnd the distrIbutor. On breokedess ignition systems the (rigger coil and ilmplificr module are suspect . H~ve (hem checked by a Ford dealer. . 8 Take the condenser wire off the points assembly Jnd with the points open test between the moving point ilnd eMth. If there is now a leildrng then the tault is in (he condenser. Fit a new one as dcsclibed in this Chapter, Section 5 9 W,th no reilding from the moving point to eilrth, wke ,1 reildrng between eil/th ,1nd the ell or negiltive ( - ) teminal ot (he COIl. A rendm(J here shows a broken wire which will need to be renewed hetween (he COil ilnd dis(rihutor. No retlding confirms thil1the coil hilS failed ilnd must be renewed, afler which the eno"te wdl run once more Rcmtmher (0 rel,t tho condenser wire 10 the pomt$ ilssemhly.
Engine misfires 10 If the enOlnr. mlsfues re!Julariy. run It ilt a f~st irllrng speed. Pull off eilch 01 the plu(! C,lpS III hUll nnd hsten t o (he note 01 the engrne. Hold the phl(J cnp In il dry cloth or with a rubber g love other Pollt of the dlstllhu(or. These lilles J,e p,lths which now conduct electllcit y Jcross the CJp lhus lewng it run to e,,'th. Tile only answer IS a new distllbutor CilP_ 16 APilit frorn the Ignition tll1l1ng being Incorrect. other Ciluses of rlllsl,,,ng hilve already been denl( w l(h under Ihe section dealrng with the f,lriUre of Ihe enuine to star I. To reCi!p - these 0110 Ih,lt:
(,J) The cOllm.lV be {,lufly giving ,111 iniNmil/elll mislile (b) Thele limy he ,1 (/iJmiJged wile or loose cOrlflee/ioll in till! low (eflsion circuil (c) The condensel /II,lY I;e shOll circuiling (i{ filled) (d) There nwy be a meehanic,lllolUI! IiI Ihe dis/flbll/or (bfOken dliving spindle or eOlllac/bleaker spring. if filled)
17 If the ignition (iming is too far reto1lded, it should be noted thallhe engine will tend to overheat. and there will he a quite no(iceable drop in powel. If the engine is overheating and Ihe power is down, and Ihe ,oni(ion tim in!) is correct. then Ihe carburenor or fuel injection should be checked, i1S ,I is likely that this is where the Iilult lies.
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