wheel 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 13 of 205
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:ansa
Safety first!
Profession;!1 010101 mechanICS Me , .. ,oned in sare working I)'ocedures. H owever cmhusillshC you Olily be "houl gcuin\j on with lhe job In h'lnd. (10 lake the t ime to cnsule thai yOl" safely IS not pul11t ,isk . A rnomcnt"s lac k of attentIon car, resul t on an i1ccidcn!. as can fnollJJC 10 obSOlvQ COlla;n ClemCIlI,l,y precautIons. There will alwilys be new ways 01 h;IVUlU ac c.ttenls. ;111(1 'he following points (10 not p.eICn d 10 he! n cOlllplchcns,vc liS! Or <111 d,lIlge.s; Ihey ,lI C inlt'!I1dcd rathor to milkc you ilW;UC or the ',sks nnd 10 encourage II sn le ly -conSClOus ilpplOilch ,<> ,,11 wall" yOIl C;l"y OUI all YOUI veluelc.
Esscllli,1/ DOs nnd DON'Ts DON'T .cly on a SU1U1c Jack whtn wOlk'''11 undc'tlCil!h the vchlcle Alwilys usc rch
scDlde d by CSC"ll'''U cool»111 DON'T allcmpllO d •• 1Ul 0,1 unt,1 you ;IrC SI"C 'I ha s t;uolcd suUrC'crr lly 10 allo,d scalding you. DON'T yrasp any Il"l! 01 Ihc cngll1c , e~h,l\lSI or "'I; ,lyt 'c r:onll'''IC. w.thoul 11151 aSCe!l""II"~ IhD I II IS su fl,c'ently co1J1 10 avoul hUlllln!1 you. DON'T ,lllow brilkc UUld or anllfr eeze 10 conwct vc hlt.le P
espcci
sp
IIIlSS ;1IId evcn de,llh ,llIlh;"ed 10 any exlent Pel.ol (!I
h;1\1I:'y II WIn no.",,,lly 1m !JIving 011.1 co.tam al11o"nl of lIyelll'!I'""'<
w h,,; h IS hl\lhly cx, )loSIY c. Alw;.ys dlscon,,!:!;' Ihe hatlc.y e.1.lh (wound) 11:,""11.,1 1,,·1. wo,k,n\) or' Iloe: fuel 01 CI'lctrl~'11 ~ystll"'~ II possl hl() . looson the frller pl"ys or COYer when d,;oQIIl1(1 I
h ntte.y trorn an extern,,1 sou/cc Do n ot chJ'Ue .11 an ()xCCS~'y" .,,1, the Ihllle.y 111,1y hursl Take cal(! when 10PPInU up nnll when cally,nu the h.ltIC'y lh'I.' I:lcctlolvtc. eve n when drlu led .
S plilshes hy wea""y ruhbcr uloves Dnd go~gles Whe" JU"'I) stnlt"'u 01 ca r uSlI1g a booster uatw.y. to. negDllv c l'" (wound) vehicles. connecl Ihe )U"'I) leads in t he follow,ng S(){ll"'''' F"st connec t one ,orn ,) lead belween Ihe posllive ( , ) le"',,,,als 01 1 Iwo hallelieS Th,,11 conneC I Ihe Olhc. jump lend lust 10 Ihe neIFII ' ( ) lelmll1 0l 01 Ihe booster hOllery. ilnd then to 0 good eDrth , (groun(l) pOonl on the lIehiclc t o be starled. 1llleas t 18 in ( " 5 erll) f" Ihe hatte.y If I)(lSs.b lc EnSUIe thot h onds and Jomp leads ".e CI C.1, any mOllln!) P
VIClnlly o f fuel or fuel vnpour
Ignition fiT voltage A seve.e elect"c shock can result from touching certarn parts 01 tl
Iuni lion sySlem. such a s Ihe HT leads, when Ihe eng,n e 's runlli/Hl being cranked. p
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Page 23 of 205
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En!J"lO noises
Prc-;f/lli/ioll (plirkiny) Of) ,1Cce/efariOI) IncouCCt W .... de o f fucl '!IIII ,rOn IImonU OIlCOOlCCI
DIMlrbulO1 l,lUIiV or worn
Wnrn 0. IllIlI;1(I,u5tod cil,l)urcnor O. Idling setlrllgs EKCCSSIV(l c;uhon htuld_"I) In cnuulo
Wl!i~'llil/!I or wheeLing nuises Lc,,~onu V,1CUUI11 hose
L""kllllJ Ci'lII),I1(:110 1 0. lIl.ulI/old !FI~.kcl IIlnwlIlH IWild U.1S ~Cl
Fault diagnosis
T,1pping or mUlillg InCOlroC I v:1've clcil,.-.nccs WOIll v.llve flO",
Broken ,)ISlon "no (r,cllm!! nOIse)
Knocking or IIWI/Ipiflf/
Unlnlenllon,'IIll(!ch"'"Cill t.:Orl!
de.IO;'1(I)
'A'0'11 Ill.1U) be",",!!S (',"nhhll(1 a'lOl ~n()d''''!1 I''''''''')~ WI'" undcr IOild)
P' Slnn st,lp (mo~t 110!I<:1!;,1>1" when cold)
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Chapter 1 Engine
Contents
Par! A: 2.8 litre engine C;JrllS llaft and CillllShJft be,lrIllgs (;XilOlllllilllon ilnd renovil!"Hl Cnrnslwft and frenl inlCrrned l,1!C pl,ne rcfl1l"l~1 Connecting rods ;lnd gudneon pons c",,,nlO\,lllon "nd
,enovntion
C'nnkcnsc venlll;Jl,on Systelll de~Crlpll("1 C'
M "IO. operatIons reqrllJlIl(J enOrrr() ,enloval Mr.:lhmb of cnll'nc '(:l11ov;l1 011 IH"'lp rl'~m.lt)ll'''g. eXil,nrrr"l.oll and ",,,~~c"'lrly all pump 'ufrtlrrlU i'lslo"s and C
C.""sl>"fl
and c. ,nrsh;rfl !re,'rr'IO~ 'JX,IIllrrlaHon ,mel 'CIlO""l lun Corr'lectorry ,ods and yud(jeon p illS exa"'"'ill,on
k
c"se vClrtdm,o;, ~~s·t~nr descJlPtlon ~"lrrhlr.,ft ()x;r'l1Ill,' I'On ,IIHI ,...,novatlon C',1n\;slraft ",I'illlI9
Spcciiic;ltions
P,11/ A · 2 8 li(ro engine
General TI,pc 130<.., St'uk..,
Cul)Ot Cilp
'" 25
'" 27
" 15 :j~ ,
38 37 6 :\G 8
" 7 26 22 3> ,
24 20 3 4
;.>3
30 29
" 12 ,
>0 33 >3
" 32 :J5
70 b7 G5
68 77 GO 80
Cliu,~sh
E'''!JI,t!
,me,I I,IIII:s
[Il!!"'" C"" 'I)O"o.;"ls E"B"'e (1'~Ill"nll,n!J ['"1''''' ',~,'s','''''I,ly Hywh",,1 ,,,,,,,,val
I(;j,wou
""IIov.1 1
\)0)'\1),,11 \1("",,.11
Flywir""lld"""plale f!X ,I!lUnil l(On allli IflnOVill lo n
Front covc, ,cmov.11 Gcm:ral descI,pt,o" lub'lcat,On syslmll (Icsc"pt,o'l
M,1I1l a"d hllj·C"d h"""nys I!x.lrn,nilt,on ,!I,d 'enov~'t,on Ma)o' OJ),,r,rl'OIlS possllJle w'th ""\JIllf! orr C,If MalOr op,,'
1 ",1011'; ,11,(1 P'~lOIl ""llS (,x;r"''''''l,on ,,,,,I ,cnoval,on PI~,1Orrs, ct)"rrr.:~trrro ,,,ds .lIl(f hoal lllO,; removal n,),11 0, 1 s('ill ilrld flywlrcr:1 rcl,tlll'(j !'loclq"
SU"'P
T",,,,,O
IIC,"~ ,'(ld frO"l plale rcf
Valvcs
61 52 60 66 86 87
" 48 74 92
" 44 00 46 62 45 78 53 72 55 30 76 70
" ~2 43 7 ~;
82 58 81 67 50 84 63 50 88 40 85 !.>.1 !i l 6,'
" 56 83 59 40 73
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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
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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
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38 Chapter 1 Engine
20.6A Mil,kIl1H S 011 the reverse 01 ,1 hl!1 ClI,t tlP.ilrnlH sh ell (, .... owed) 20.GEl ·S1.1n
2 BCilrll1!j shells 111 (lootl condItIon h,IVC 1)C"fU'O surfaces wllh il smooth. (lyen m.m s,tvcr /u,ey coloUI .111 ave._ Wam hCillln!IS wIll show piuches 01 il d,t(clcnt colour when the hctlring mottll h
I,,~t>(:ct Iho !)(:
hl~l)t";t Ihe lIywheel lor danln!Je and ch"ck Ih(: ling tical 10.
,1nd d.llll,I!IC 2 If th'l .1I1!1 IIC'" IS h,utiy worn Of has IllISSIl1!J It!clh II shaul. ,e!lew,·d Til" old 11111.1 call ho 'emoved Ironl tile lIywhecl by CU1\1 1l0 lc h 1I.·lwc"n two leeth With
23 Oil "ump -distl1;l!llling. cxarninntion nnd reassembly
II 011 [lU'''1> w~," IS slIspecw(l il is pOSSlhle 1 0 OOIJIIl n 'CpJII Check fVI W("" 11151 li S desc!lbed IlIte! in IhlS Sec llon ilnd II conlun vhlain ,III IIVCI "(lui kil O' il new pump_ The twO f O tors
20.7B Cil.d U
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42 Chapter 1 Engine
28 G TempO'i1'y holl 101 IOC;l1inO the mlc""t:thiUo: plale 29 5 0'1111(1 the )l'~10n linUS 29 7 0,11I1{J the cyllnde. hOlo
";; '. '''' . :~ .,
.. : .
..-2 9 8 US'''H (I plSl0n "l1g compressor when uiSerhn!llhc p,ston "110 the hore 30 2 Chet;kln~1 the Sial) washer I)OS'['OIl on the 0,1 pump d""csh"fl 31.3 O,llhe tlywheel holls bel o re ',",ng
(j 1,1 II", two f.t:"11'~ holts ItI1!jl.:r·"!lhl then 101 ;Hlorlm' two holls t'''''IHH""ly 1o. IIU:"I"'!I purposes T'!Jhtcli the CCIllle sec"""!J hails th.·" It''''"Yll the '"ml""'''Y Io,u "d 1000,umU bulh (photo)
29 P istons Hnd COIH1(!cli"g rods -refitting
WI, ... , ('.101,1" the COIU1I;:(.I,n\l ,ad h"U of tll c !l0U·end bO il'lIlll 1111d rh e IInde,sulu ollh(l ~hcll h .... "l1y ;lnd IIIIhe sh ell hc"rlllU "' pO$IIIOn WIth It S Im :, IIUI!llonuuc OIl!"'!I'!!! with the COH CSpo tUhnU CU[-OU1 ",the lad :1 If II", old hC.l.II'!)S 'lrllnea.ly n.;w nlld nrc hell'U re!ltu:d Ih en ensure Ihey inn ,dlll"d III Ih"" cO"I.'Cr 1000.UioilS on the COUOCI ,ods :1 The 1%lOn5 , c:;()n ll'l",,~ With c:;onm;c:;t"'u ,ods. mo f,tted 10 the" IH,::es from th(l lOP 01 Ih'! block
'1 luc ilte the p'stoll ""u Hap s III th e 101i0w inU rllilnnCI .
TOil 1['0' fr Olll Ollt· sir/e of /l,e Oil conl,o l 'IllY "ehc.1/ t'xf/8mle. y,l!) Cellt", 150 /tom lire O/Jilosi/e SI(/e of fire Oil cOII(101 ""Y l,el,cM cx,r.lnr/
Bo/lom or! cOll/,,,1 ""9 HeI,cal eXI',lIIdel' 01l 110s,/ e I/IC /II,lfAed {J,S/OII "on / side
ad cOIl/,OI ''''y, III/':"llrHI',J/c lings 25 film (1 0 ill) c.,,1/ sie/e of tllC /Jchcall;xl1amh'l 9,7/'
5 Well lulJllc~le Ihe pl~lon iln d ring s w il h e ngine oil (phOlo).
6 Fit n unlve.salring compressor Imd I>'epalc 10 insell Ihe fllsl p'Slo n IIItO IIw ho,e. Mnke sure 11 is Ihe corrcct piSlon·conneClinu lod ilSse'l.hly 101 Ihill par',culil' boro. Ihillthe c onnecting lad is Iho COII(.'(:I Wily .ound and th3tthe fron t of Ihe piston (mmkcd with an arro w 01 11 notch) ,s 10 Ihe fronl ollhe engine. 7 Lul )l'Ciltc Ihe Cylmd,:r \)o,e (photo) and inserllhe conncCllIlU ro d a"d p, ston nsse ",!;ly ,nlO Ihe cylinder !loro up 10 Ihe botlom of the pislon IIIllJ com plessor 8 Genlly hUI f,,"'ly Illp Ih~ l/ls!On Ihrough Ihe piston "ng compressor nllu "'I u Ihe cyhnd er 1)(.1'''' uSlI'g Iho shah 01 a hammer (phOtO) 9 G".""nu~ly luh",c"I" 11,,, ,,"ank,),,) 10U"",ls with engllle 0,1 JII{ltu.n Ille ClI,nbh;,lt so 11\1,1 III" e'
30 Oil pump -re fitting
Ensure the l1lillmg lilces 01 Ihe 0,1 pump ;Jnd Ihe clankcase n cle'lIl . 2 Inse.1 the hexilgo nal 0.1 pum p drivesh"fl wilh Ihe pointed en lowil,ds the <1ist"bulor localion. The SlOP washer (photo) must IJ posil ioned 127.5 mm (5.020 in) foom the lounded end 01 t h driveshilll 3 FII th o od pump 10 tho cfankcose and secure wilh t wO boll "9hle llcd to Ihe spec,f,ed 1 0'(lUe N ote: When a flew or overhaoled 0 pump is bl!illY IiI/cd. II should be /illed wilh enyine Olll1l1d lurned . b hand 101 om: comple/e ,evolution before being fil/ed. I his will po"" /he plm.p
3 1 F lywheel and clutch _ refilling
1 Fir Ihe engino IIdap lol pla le on Ihe twO localing dowels 2 Ensure Ihe milling faces of Ihe lIywhc(;1 and crank shaft arc cleal
,lnd fit t he flywh eel 10 tho Cliln kshnll. aliUn",U Ihe nla,ks made ii' (hsrn;Jnthny. unless n ew l>arlS a.e being lilted
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Page 44 of 205
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Ch
4 Chock the secur ing boilS
flywheel 10 "'~1'.111' ,I fro", tll,nlll\J. <1nd tighlen Ihe in il (li<1110I1ill <111(1 plO!i'''~~''VU l11<1ntJer 10 the speclf,ed
IOf~:iil l he clutch (Iosf: ilnd p"'~"'l"" pl.rle iI~s"mbly 10 Ihe flywheel 5 . ,ure Ihe disc ,s I he co"",:1 w.,y lo"nd (see Ch<1plor 5) rTlJk,ng . 6 Secure the pr~ssum pl"h~ "~~I:mhly Wllh the ,ct.1U1Ing boIlS. enl'Jlise Ille clulch dISC "Sill\) .11' old !i,,,"I>OX ,npul slwh 0' sul\ahle ~1Jnd,el Jnd thel1llghten Ih,~ ",I""'II1(II,,,IIS to Ihe sp~clfl()d tOlque III
32 TiOling geMS ilild li,nin(1 COVIH refitting
I Check Ih
';
. ,
. -\.
...
I't'
3 hI Ih'~ c,"n~h
,111(I'"nOIlI with the mark on tho cr,ll1bh.1ft HO
(1'1",1") 10 1 " 1 11,,, f'''111 n,l ~(, .. I tn the 11111111(j .:ov"r .111tl .haw 01 11,10 lh" 1'()~'IIOI\ ,h.I""))II,,,
~ ..
:U 'lA Loc"lo the cr,lnksh<1fl U", II 01 111" e ,.",hhilh
322B ,. ,HId uSO Ihc pull"y In pruss It on 323 Alryn"".",t d01S 0" lhu III\lII1~) \le
~ .. ,
..,
, ,
., ' ,
32 .61 Checklllg Ihe pOS,I'Oli of Ihu old 0,1 se
32 6B OflVII1!j 0111 the ""'lIlg COV(:r 0,1 se<11
32. 10B F,tluU posItion o f Ihe e
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Page 51 of 205
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50 C hapter 1 Engine
51 T llp pcts -removat
Remove the 1
5 2 Crnnksh
4 Wilhdraw Ih~ Wood'uH key hom the end of th(! CllInk5hah and pl,lC,(! " w'lh Ihe pulley. til(! holl alld its washer 5 The C'.1nk~h;)h p"lIey m;oy he ICliloved wilh Ihe eno,,,e III Ihe C:\I. hilt ,I 'S IIIsl tU!Ccss;o,y 10 ,emove Ihe ',ld'illO' :lI1d thc rh'vehelts
53 Flyw heel -remov[ll
P,even llhe flywhcel hum 101m",!) by FHlHllln\J Ihe lin!) !lcal ;ollain~1 ;In imp.ovised SIOI). 2 On nlodels willi nl;lnu:ol 1I;o"$""S5'01i. Icmove Ihe Clulch plessure 1)1;lle and disc :os described in Ch:op!Cr 5. 3 Rele.lse Ihe s,~ bolts secu.in!1 Ihe flywheel 10 Ihe CllInksh;oll .lnd lefl\OVC I,ve of Ihenl.
4 Whilc supporling Ihe tJywheel III pl;ll':e .• emove Ihc Sixlh hoi' ,'11d Iolt Ihe lIywheel otl c;o,elully. so 111:01 Ihe m;lllllg su.lilccs of flywheel [lild c.;onksh;oit ;o.e 1101 dllm,'ged
5 4 Sump -removal
W"h lhe '''1(1'''') oul fli the e,". CII~"'C Ihal Ihe sump has 1o('CIl d,amvd ;ond then lilln the engll1C ()VCI so tl1011 Ihe sump's U l)I)ClmOSI F" wOOr1CII bloc"s tn Slll)lmrl tim en!l'ne 'n Ih,s POSIIiOIl . 2 Remove 11m h()IIS seCUlln( J the oil Sump 10 Ihe CI.1nkColSe o1nd rClllOVO Ihe SUll1p_ 11 the sump IS stuck 10 the c r;ollkcasc . II should be reh;lIsctl hy 1"'SII1\1 olle SIde wllh 11 sClcw drover. 3 To !Cn,ovtl .Ile sump wllh Ihc CIIU"HJ Hl tloe eM. 11151 IcnlUVC Ihe
d'l)S llck :ond d'SCOIlII(!Ct Ihe hatlery 4 Remove Ihe luur holts ;ond lou. Ch,)S ;ond dCI.leh Ihe OIl splash
shIeld.
5 Pl;oce a Con'"lIlcr 01 at lellst 6lttre (106 JlIllI) cal,,-.elly heneath Ihe SUml). remove Ihe d,ain pl\l(l ;ond d,aln Iha sump. Reflilhe d.am plull and (11)hlen II 10 Ihe 10lqUO wrench seilIng gtven In the SIXlClflC;JIIons G Del:och the engme fubl)CI mounllngs, by lemovlng the" nuts an(1 w:oshe!s. 7 Romove the ciampinI) bolt hom the tal) ;oml bOIlOI11 endS 01 the Steellll!.) intellnediate sh(lil. rush Ihe lap end 0 1 Ihe shlilt upwollds unlll Ihe lowcr ell(1 Clin be dlsenga\led 8 PI
55 FrOllt cover -removlll
If Ihe engHle IS In the CM. II wllllnSI he necessaly 10 dlsc()nneC lthe l!allefY. drll'" 11m coolll1\) sys tem ;ond lel110lle Iho radiillor. 2 loosen the alternalol mounllrlg bOilS. SWlrlg the aitemalor downwilids .0w:Olds the cyltnder block and lemove Ihe drive belt
3 Remove the bolt Irom the cenlro of Ihe cooling Ian .. nd pull (
Ian and clutch assembly. 4 Remove Ihc boil an d wilsher from Ihe centre of the cran pulley .. nd I hen use ., claw puller 10 drilw Ihe I)ulley ofllhe sha nOI anempllO lelle, Ihe pulley ott. t)Ccause Ihis may .esull in dllm. t he Irani covcr.
5 Rcmove the si~ bolts secuung Ihe sump 1 0 Ihe honl cover an, t he cleven bolts securing Ihe I ront cover 10 the Cylllldcl block . G lIlt Ihe cover ott ;ond remove Ihe g;oskel.
5 6 Tillling gears -relllov;ol
1 Remove the honl cover 10 e xpose Ihe IImlnu ueo1/S 2 Removc Ihe bolt and washer sccu"I1IJ Ihe fat!Je gear I,
cn,nsIl1'll t. IhCIi pull.he geill ol! and Icmovc tho Woodllll! key. 3 Dlllw the ileal hOI11 Ihe cr;onk!;h:oh am! remove Ihe Wood'utl
57 Carllshaft -r erllov;ol
The camsh:olt nwy be rCUlovfld wllh the cll!JlIle 1<1 Ihe car •• lollowlng p!Cpol.aloIY wo,k IS co1med out. 2 0,,,,,. Ihe cootong syStelll nnd .emove Ihe .ad,mOl 3 Dlsconneci the ballery. 1 Remove Iho sp.1lk pili!! IC.1ds 1,om Ihe spalk 11lugs. 5 D,s':Ol
eCI the le;ods I,ull' Ihe :l lt'!11\.110r. remove Ihc allelllalo·
l i S (hivebell. G Undo "nd rem ovC tho screws S()CIIIII1U Ihe .0dcl covers and It Ihe rocke. covels and Iheir ilaskcls 7 Sincken lhe nulS secullnu the rocker ~"ns unlollhe locke' arm, he swung aside . 8 Remove the pushrods. idenlllylllg each one as .. IS lemoved. so 1 Ciln be rell1l ed in Ihe same position 9 Remove the cylmde. heads,
58 O il pump -r e m oval
Remove Ihe crill1kc:ose sump as ;olleady dcsc"hed 1 2 Remove Ihe boll aUJchmg the 011 scrcen 10 the Illalll 00111.119 (
/ /
Fig. 1.11 Oil pump o n tho 3.0 f itre efluill(l (Se c 58)
F
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Page 52 of 205
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-• the twO boilS sccurong Ihe 0,1 pump 10 the crankcase and 3 R emov
',.,' . the pump assembly nnd ,ts (roves la I-wllh
drilw
59 P istons, c o nnecting rods and bCilr ings -removal
1/ lhe crankcase sump and the cylinder hC
~ssemblv Ollt of the top of thu cyhnder . 6 W,thdrllw Ihe assemhly frorn the cyhntler ,lIld ptace Ihe hCillrnO C,IP
~ck on the connecllrt{J 10(1. 1 If Ihe be.:uinos rue l>CrllO ",newetl. lelnove the uld 1)("""'!15 hy ),,1I1n9 Ihem lound unlrl Ihe nOl ch on Ihe !J(,,,,rnO ~h.,tl rs tlrsenH<10cd
f rom Ihe lecess on Ihe l)e,1r1"U Se,llrnn 'lIlll Ihen hft the IJofI<1rrtlH oul If tho beJrin{Js <11e lemovell ,,,,d the S,lnm ones ,l.e 1":111111 nsctl a!F"n. illS viMlthat Ihey ale .elillcd III Ihe s.lmc scahnH a ... Ihe Olle I.om whIch
thf.'Y WC.C lemoveli.
60 Crankshaft reM oil seal - rellloll,,1
To !emove Ihe 011 sei\1 wllh Ihe ell!J",e In Ihe ca,. Iusl remove Ihe U
(Sec 60)
~ Crank sh aft llnd main
henri nUs -re rnov.r1
, Relnovc" 2 n Ie CIIIl"I" 1'011 Ihe car . 'J, 3 n emovc the ClelC h HSSI~olhly 011 Illllllual transm,ss,on madels ·1 ernove lir", , , ,
L'
·
.... yw lI.le ;lIld Ihe leal 01 sual cal"er. "/-·H. $'i;:.
5 1
Sld e d own. chock It sccu
CilP S all .111(1 lay 1111:111 out'" order NOlll Ihm Ih" c~nlle 111:1111 hcn"ng f.':IP has Ihrll~1 wa~hcfs M;l,k Ihetr POSIIIOIIS hili",,,
62 Ellgiflo Carl\l)Ollelll~ -e~iHllil\1ltiol1 far we"r
nc:lm 10 Soctll)" I 1
63 noct.e r arillS -examination ;ond nmovalion
llll) siuds 011 whIch Ihe locke, arm~ p,vot arc a pless 101 Into the cyhllder he,1I1. ,111(1 II .1 51'<1'0101 cdUO IS Inld aCfOSS all s'x. II cnn be seell whelhtlf ;"'y h,ll1e 1>f:\Jull II) pull oul. II Ihl5 IS Ihu case. Ihe stud w,1I have 10 h e I..,1ll0vt:d. Ihe hole re,lllll!'\! 0111 ,IIId ,Ill overSlie Stud hllll(1 2 Check Ihal Iht.: Itucuds on the sluds a,e!ll Uood conti'IIOI1 anll that ~ \IJ'(juc 01 nllc.1S1 59 N", (
Silil dl:lrCIUIlI. hi a locknul to Ihe mlluslef 3 EX;IIWlln 1hll Illeke. <1111l~ ;IIH) IUit;IUIlI snalS 10' S'~lns 1.11 rrdH'nU. 1.1< I:XCtJSS we,ll 1111 Ih'l Ilc;o,'nu $IIII"I:<.'S II Cllher p.lll shows excessIve W"'II. 1".111 Ihe ,",.k.)! ;",n a"ti ti,e 1\lle'IliH sent '''u~1 IlIl .enowcd If When I;hcr:klll\l lilt"! rI)C~,)lS ;UIIlS. 'C"IOVI) Ih,;", one .11 a l"no \0 ,,"mlll(llo: allY POS).Ihllrly 01 ,urllS ,Iud seals Ilct:lJn l,tlH ullerchan\)cti. or Ilelll(l 1.,!I1Il:d III Ihe W'OIl(j ~IIIrI
GIf Tappets ,HId pushra()s -elWlllin alion ;lIld renoviltian
ncle. 10 Sm;trr)ll I 3
65 CamslHlIt ,\lid ca!l1sh':llt bC(H inos -c~arl\il\"tion and
renovation
UlllhHSI~C camshaft beaflflf)S ;1fC ayml.,tJle. so II IS poss,hlo \0 SOlly,IUIl , I waul c amsh31t by rCtJtlIl(lrnO Ihe 10uII1als. II the call1s . or skew gllar. atll wOln stOllllocallll y. Of arc d':II11.10,,(I. a ncw call1Sh.1h
IllUSt be I'lled and thc tJcallngs should Ihen also be renewed. 2 WOlll or dalllaUed c;m,sha1t bearings can be replaced by ncw ones. hullh,s re'lullt;:s spI)Clal tOOls and should llc om,usted 10 il FOld dC<1lel. 0 ' 10 (1 wa.kshol) wh,ch undertakes carnshafl reclalnl'nu
G G Cylinder horus _ eXHl11irHltio n and re nov(ltion
Reier
til S(:Cllon 1 G
67 P is tons and t)isto n rillUs -ellamilwlioll ,lIld renov(ltion
R e
lcf 10 Sectlo" 11.
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