1974 FORD CAPRI Workshop Manual

80 Chapter 3 ~lIel and exhaust systems
24 Ai r cloanor -removal and re filling
1 Remove Iho elomerll as dllsc"hed III Sect,on 23. 2 Work,nn under Iht! left ·hand honl wheel arch. unboll the illr clenne, hOdy f,om Ih e s,de of the engmo compnl1lllen\. 3 Rohuil1g IS n rove rsal 01 tho lomova l I)rocodule wl lh relelence 10 $(1(;11011 23,
25 Main system compono n ts -rellloval "l1d rofitling
Fllel p /llllP 1 Thn hll)1 pump IS loc.lwd "' " lI,hlw.. 1ll011111111U .lUflchod 10 Ihe "!Ihl h"n{1 51th! 01 lhe 11I/,llal1k (phnIO) ') D,sC:OllllCCI Ihe h le"l1 line IIIlIon on Ih e lu«1 dlSlllhul cl;lIllp l hl) 111(:1 IIIIUI hose IIC1W,,':1I1he ludl;lllk ,1ml th « 11111111) uSlnH ,1 h",ke hose cl,IOUjl or sHlIII;" If Ih oro ,s only ve.v hnle 11101111 I ho 1IInk. illl 11"lIl<1llvO 10 cl,1mplI'!l1hc ho~() IS 10 dram Ihe Innk onCIl Ihe mlOI hose 10; ,h~c:ol1nCClu" !". OIs.:nrUlI){:I IIlI! Iud ",Ie! ,llId uIIII" 1 IIIIJoI:S I.nUl Iho pump G Cn,"'ully ut",llily Ihf! dm:I"c:al C:("UH~C1l00S 10 IllI! pump nil"
'''~t:un'''~.1 11",," 7 I ,.,,.,~'''' the 1I!l11l hoilid Illd 1'lIlk SUPI)(Jl IIII(f Sl'ilP Illell unh(lll ll,,~ lul,I)". mOlllllll'H ami 111,,1 JlUlll!' 8 !'IISf) the pllmll "("n the "'OIull"'!! !) Ilcfllllll!j 's il IUliers,, 1 01 ,emOVi.1
FiU. 3 .34 R Oilr viow o f
A Ink'1 pi,ll}
fuel,HIIl'I) (Soc 25)
8 Fucl'WIII/'
..
) 2~ 1 Fllel pump showing Wlflflg ond oul'el pipe
~ .. . . ~ ~ ... ,
2510 Fuel accumulatO'
Fuel accumulator 10 The fuel accumulatO I is bolted to the Ical 11001 above Iho lear "Klc (phOIO). 11 Disconnect the bflltCly . 12 Releaso the preSSIJle in the system as descllbed in PfllfltJlilph 3, 13 I'lilCO the leal of th e car ovel ,1n inspection pit o. lilise il on ' ilmps O. fldo·stands. 1 4 D,sconnectlhe fucl pipes I,om the lu el accumul,110r and catch Ihe s Fuel filler 17 The luel 1IIICr 's locmed 011 th e wheel olfch in Ihe lelt hand side of Ihe .mU"'o COIllI)"' ln,elll (1IhOto).
Fi U. 3.35 ConeCI 10Ciliion o f fuel filler oullel pipe (Sec 25)
A B Fuel "'ICf Ou/lelll'lle c Engine comporlmenl side p,wel
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Chapter 3 Fuel and exhilust sys tems 81
1 8 Disco"nect the hllllmy 1 9 Relc,,~e tl", .. ,e5~II.e In t he system "s described in palaglaph 3 22 P lace some cluth hcnc,llh the luel flhel then disconnect the mlet ilnd outlet ", lions 2 1 Rcmollc tht) mOIlI1lIlI11 sc.cws ,1od withl1,,,w Lhe fuel f,ltc ,. Remove
the bl:lclwt II 'ltICIlS$:I'y 22 RchulI1U IS a .ellcls:l1 01 ,emoval. but m"ke sure tha t the 1,ltel is
pQs. t.onnd thll I:Olfe ct W,ly 10un(l. "n(1 Locate tile OUIICI plj'JC:I~ snown
io FiH. 33!)
Fucl tlisfllbu{(}r 23 The f""t d'~L"I"'lor .~ IOr.i'to(1 on top 0 1 the "" flltl'!'. 24 DISCOnl"" .t thu !o:m",y 25 n,;L""~,,, thO! L''''',~II''~ III (hI'! system:ls d"sl:"lmd in piull u,a"h :I"" t compL"L"ly 11,111"11" tho I,,,, d 111111 ",Hon 26 DI~r."'UII". t tl,,, """,11'1'1111 f,,(:II'"C$ 1,<)ul til(! llis t,d,utOI 27 UIIS'~":W ,I", nll"l1 """m'"'n sc",ws alld hit Ihe IIISIIIIJlIIOI away 28 RHhll""1 ".,' ",v':I~,,1 "I rr""OvilIIJlJ IIISC a IIIiW coppe, w"~.h,,, r:ach ~,de of Iht: '1',"'1" IIIIIW'~ ",,(I dO not OVf!rI'UII1I:rllhe llIliol Imils 9 Hall" Ih" :.y·.1t:1I1 I""",u'li t: heckr.d by yo"r dllatCr: 30 I\dl"~t th" "II" "I~:I"t :II\l IIIHXIIlIfl as ,leScII",,1I III SectIons 73 ,IIld 26.
W"",,·/I/I/I.'ylll;/fOf 31 The w."'" "I' "'!I"I"tl1l 's loc ;llt,d on till! hunt of the ""!I"'" ""xtlO t he c(X,l"'H ~y~t"l11 nuth, t I:lhow 32 D,sco",,, • .: ! tl", lhlllCI" 33 Flcleasc Ihe prcssllfc In the sySlcm as desc"hed in parag'''I)h 3 34 Discount: GI Ihc lIacuum hose ilud wi"uy plllg (photo) 35 D'SCOI1"I:CI the fuel hiles (l)holO) 36 Unsc,ew the Iwo sockcl·he;lded uolts ;lnll wllhd';lw thll 'C!jUI;ltol . 37 Ref,(lln\1 IS ,1 ,cve.sa' o t ,emOIl"' . hut lise a new copp .. " wa~hcr eilch Si(lc 01 tim h,ll1l0 \llllons (phOIO) 00 nOl ove,l>ghtcil lh" I"'''on cenlre hol ts
Fuel S f"ff v:llvc 38 T hc luel stMI 1I:llve is located on thc ligl1l ·hand s,de of the lIir ch"mhel. 39 DIsconnect the bmlory . 40 Disconnect the elcctlic p lug and fuel supply pipc from th e lIalve (pholo) 41 Unscrew tho twO socke t·headed mount,ng bolts uSlllg an Allen
key .
42 Ref,,,,,,!) IS .1 'ellcrS:l1 of ,ernOllal. but u~e II ncw moullting flange !lasket Use" new copper w"shel all each SIde of the """10 union lind do nOI ovnlllllhien the Centrc holt.
A!lxih~1I"Y "i,. r/(!vicc 1\3 Thc i",x,h.n y "" rlcvice is 10C"II,1I On the IIU"t hal1d flOllI of thu lIir cha",!,,", 1\4 O lsc0I1"", .1 Ihe hallerI'. 1\5 D.scr"'''.,ct tl,(, eleCt,ic p l11\1 ;,ml IWO illf hoses IrOI11 the ""vice (phoIOS) 116 Unsc",w tl", two 'UO"nIl119 holts .11,,1 hit tl"l ;rss",,,t,ly i!Wlly. 1 7 Fl"f,It'''H .s ;1 HIIIC,s,,1 of 'elllolllli
Foel injocrurs 48 D, sclI"""'.t Ihe h;lll",y. 1\9 O, sr. 25.3 4 D,sconncct'no Ihe wII'no plug . 25.35 ... "nd fuel hncs from the W""'H'P !egulato! 25.37 Re new tho copper wilshcrs each side 01 the banjo union
25 .4 0 A DisconnectIng Iho tuel slart valve
wiring plug
, "-
2 5 .4 06 ... and fuel supply pipe
•
25.4 5A Au xilia,y air dcvice w ifin g plug.
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,
~ Chilpter 3 Fuel and exhaust systems
~5 4513 ,111<1 "'f hose s 2550A D",conneclinu the maUl "" supply t.unkul!! 1.011 the 1111~hue cont.ol 111111 25501l mid th'OI1I C houslIlU
"",'
25 53A UnsCII)w the holts. 255311 ,,,"U)IIC the ~'" chal11bcr ~5 53C ;11111 'cmoY(: the Haskct
,
25 5 4A UlIsc'ew the 11101l1lt;IIU bolts. 2554 U ,lIld remove the UIIL'CtOrs 2556 The "'Jecto, Q·rinU seal (a"owed)
56 Rcl,llll.g IS 11 reve rsal 01 rcmoval. hut mtlke SUiO Iha l til.., "l)OC Iors .IIC clea n and III new O'lIng seals (pholo). Also rencw the;IU chamber gtlskel.
26 I( H o mixture -adjustment
Noto: 11!e miJllllfe s"/liIl9 is preset during (!for/actiOIl of II", eM ,'nd shOll1ll 1101 "ofllwll~ require "djIISlment. If I!~'W r:QfIIl'O"Cllf.~ l)f 'he sys({)m ""VI! bccn flllCd. IlOwever. tile mix/IIII! (;,1/1 be mi,l/steil as lollows "Silly /II) cxlwlls/ y,l$ Slandard equlplllcnt) III iI(;COnlDncc with tIn: nH!llul;I(;WH"'s 111-SIIUCllons
3 Incroase the enyulC speed 10 3000 'pm and hold it the,e 10' 30 seconds to Sl Idle speed .
5 Break oft the lalllpl:q)lOol cap 110111 the mj~ture conlrol screw on lap 01 Ihe fuel uistllbulOi. 6 S tabilise the cxhausl Ua ses as dcscllhc·d ,n paragraph 3. 7 In sert 11 3 r1\I AUcn key onto Ihe heau 01 the mixture SCfew and tum the SCfew urlld the COlfeCI CO re -
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·s
Chapter 3 Fuel and exhaust sys tems 83
1.6 7 I\dJ"~IIII!J II", n"~h"" ~ t:"'w
27 F"HII;Hlk. $1)I"ll)r ,Uli( and Idll)r pipr. -Ufm() r(ll
The 1(,11101.',.1 ,11111 "dlu",U pH.II.",hJlf:S ;1Ii! SII"II,II III Ihose !I'V"'I III
Sec lions 13 10 16 Ilow'IV<:f. Ih., ~.:",h:r "nlt.s 1 ... :;.1.,,1 o n ti,e letl h"tHl side 01 lhe "ml tank (phOIO) "lid Ihl) luel I'UIIII' 'S ~l'C"" .. d 10 lh(: righl·h"ml $ 1110 .
28 ACGelerilto r c;thlO -removl.1 "nu relitling
27.1 F tHlll(1l1k ~'!tldef "nil
29 Inlel manifold -rcmoval and re li inU
Ilclm In S')(:tlon 19. bUI Irl sJ(w d 01 ,.,((\01.'11'(1 thc cilllnllc1l0f,
" ,movc Ihe "'I"I:IOIS (Inti iii. chilmhef as dc-sc"hed in SeC t.on 25. N Ole th,,1 the.c IS one nul ill eilch end of Ihe m(ln,Iol(l. ;md 111m the bOltS (lIe of d,ife.enl Icn(jlhs (phow). 2 Also unbolt Ihe oUlle t elbOW and will/n·U)) .e(jul"lo, 1ll0unlin(j hlilckct hOIll I he "onl of the inlet nI(lIl ,lold (phOl0S). 3 Follow the I'ghtening seQuence uiven III Fig. 3.36 w hich d,lIels IrOIll the 3 ,0 hIr e engine (photo)
28.1/ llel110vlll\l the sleeve hom Ihe end 0 1 the (lCceh:r.lI0r c"hle 28,1 B Plisinn O\'! til " 11,1,,11\I0 chp 2a.le Removmg tile ilccclcrmOI cntJle 110111 Ihe IT,oull ting bracko l
---,
I
~ =-~==) ,
~. ,
,
'1,'
29 1 A Un~(.:r1:w the Inh,t m,llulol( l ho lls
J
29 10 (emove tilt) IW!IS
r " ' , , '~;
29, I C ... 1If1(11,/t off the ma(\, Iold
I
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~9.1D Tn~ Inrel m "
-'. I.: .,
I
:
29 2A Unscre w Ihe holts ...
) "Ig 3.361n101 m - z-.~,.......------...-.
,
29 1 E Se,~hn!J !;oIllJ)ound locJlIon 1l"IOIc fo1lU1!J the O,ls~"t
,
292B . ;md rClilOve the outlet elbow alld WllPlll·Up rcuu l,1\or mOunt",\) Ilr;1Gk..,t
293 TlulllcnUl!) tho IIIle l mnn "old IHIIS nnd botls
,
d
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Chapter 3 Fuel and exhaust systems
30 E~haust manifold -rOllloval nnd r e fitting
Rcle . \0 Section 20. but not that 1,11C' models do nOI have n downpipo scaling ring (photos)
~ ..
y
" ..:
';.
__ +.,,",l
31 E~haust system -removal and ro fitting
Reier to Section 21 (pholO).
85
3" ,A TI!Jhlenrrl!J Iho O~hilUSI mnnilold nuts 30.1 BRight hnnd e~hnust rn.1nilold ·to­downpipc connection 30.1 C Dl sconnec tirrg the lell hnnd e~hnusl downp;,Je hom Ihe manIfOld
. ;/~}":"~"":'. ,
\"~'"
} ·':t-­
i
31.1A hhnust system ,ubbe. mountIng (;,,,owed) 31.1 B Irnermed'ilttl oxhilu st system-to-honl pIpe clamp
RT C , FAULT D IAGNOSIS
32 Fault diagnosis -fuel sys tem (CMuurottor)
Symptom
Fuel COlls!ll11ption e~cesslve
Insu llicienl fuel detrvery or weak mi~lure
33 Fault diagnosis -fuel system (fuol injection)
Symptom
~ngine will no t starl (cold 0' hot)
Reason(s)
Ai . 1,ltel clement choked Fuel lenk flom cmbulellor. fuel pump Of luellrlles Gene.ally waUl ca,bu,ettor Needle vnlve StickIng open Incorrec t idling speed Clogged fuel Irne
o. hiler
F R
llason(s)
Ai. !tow sensa. plale incorroctly sel FauilY fu el pump Fuel lank omply
'J
----------------------------......
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Symptom
Engine will nOt Slnr1 (HOT)
Engine will not stal! (COLO )
Engine mIsfires on rond
Unsatisfacto,y ,oad p edomlilnce
Rough Idling (ilIWilYS)
Rough rdllng (during warm -up)
Excessive fuel consumptIon
nglne fUns on
I
C hapte r 3 Fuel and exha ust systems
Reason(s)
AuxiT inry air device not clOSing
Auxilimy ai, dev ice nOl opening SImI villve filulty Thermotime switch nOt closing
L oose fuel pump elec trical connections
System fuel presswe incoflec!
M,xture adjustment incorrect
AUKlhilr y ili, deVIce nOt OllC,ahng cOflec tly
Mixture M1ts utment incolleci leak in system fuel lines
Airtlow sensor plate or cont/otplunger not moving "eely Injector villves leakinU or then OJ)Cnlng pressure too low
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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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