1974 FORD CAPRI Workshop Manual
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Buying spare parts and
vehicle identification numbers
Bllyillg spare parts Sp;'1rc p"rlS ;lre ilwul.1!Jlc from momy sources. Jo. exam ple FOHI uar"gcs. oliler gil':lgCS ,-mtl ncccssu.y shOIIS. im(i mOlor ';.elms 0", a
I lOSII.ve idenlil leallol1, Bumcml)C. ,h;'1 .,,;,ny p;rrlS illt) ;'Yirrl;.hle on a InelOry exclHlnge schelllC illly PililS .elurne(1 should nlw,1ys he clennl II obviously makes oood snnse 10 go S\""Uhl \0 Ihn SIICel.1hsts on you. CM lor this Iype 01 PMI as Ihey n.e besl equipped Il) supply you O/hef yM,'yes Im.1 m:cesSOlr shops These a.e ollen ye'Y goot! plnces 10 buy Illate".lls al1
ileccssoflcs, uSlIillly l \.lye conyenlent opcnUlU hours, Ch.11Ue I, prices and can often be lound nOI la. hom home MOlor 1,7C(0IS ~ Good lacto.s will stock illl Ihe mOle Illlp,,, comllOnen lS which wea. oul .elilhycly qUI ckly ((..'9 Clutch COIllI,cm. PISIOI1S. villyes. e~hilusl systems. IJr;lku cyhnlie
Vehicle itlenlificc1l;OIl numbers Altholl!lh milny uuhviduill pa.ls. 1md ill some cases sub-ass/:mlo III a lIU1nlJm 01 dlflerent models II IS dallge,ou$ 10 a ssUllle tll;1 \JCCilU5e they look the 5,lIn e, Ihey a.e the same. Dillelences n.e nlwilys e.1sy 10 detect excepl l.Iy serial numtJCrs Make su.e the.e th;otille ilPI),op"ale identify number for the mode! or suh-asseml.lt known .1n(l Quoled when a spare PMt is obtained. '"c v(!/m;fc irlCl!lrfrc.lfioll "IMe is mounted on the rIght-hand tr Will\! ilpron on SCries II models or on the righl·hand Side of Ihe f, Cfossmemher on Selles III models.
Vehiclo ident ifictltion philO location (Series III)
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General repair procedures
Whenever scrvie,,,U. repair or overhaul work ,$ c;nric
Joinl mating ftlces ,7l1d gaskets Where 1'1 gasket IS lIsed tmlwl:CIl the ",,,,ill\1 [
Make SUfi) lh,,[ tnppcd holes nrc ciedncd WIth il pI pc clcilncr, and kcep thcm flcc 01 101l1llng compound If tillS IS helll\) used unless
speCIfIcally Instructed otherWIse Ensure that "II ollfrtes. (:hannels 0 1 pIpes ,lie Clt'ill ilnd blow thlough Ihelll. p,eleriluly llsing compressed ill(
ai/ seal s
Wheneve, nn od sCill is removed flom its wOlkll1\1 10Ciliion, eIther mdlvidu"lly or "s p"rt of iln assemhly, It should be lencwcd The very finc sc"lIng IIp of the sei'll IS e"slly dama\Jcd and WIll not seal If the surface it COI11<1(:15 IS not completely c lean and free frOlll
SCHl\ches, nicks 0' grooves. If the o'iginal scaling surfi'lce of the COlnponern cannOI he restorCd, Ihe component shoul d he renewed, PrOlect lhe lips of the scal from any surlace which mi'lY damage them in the course of fmlng. Usc wpe or a conical sleeve where POSSIble, LUb ricate the senl lips WIth 011 befole fruing and, on dual lipped se"ls, fill the space be twcen the hps With grease. Unless otherwise stated. all seills must be hlled with then sealing hps toward the lubricilrH to he seillcd Use iI\ubuli'l' <111ft 01 block 01 wood 01 the npploprime sIze to II1sta ll
) I he scal ilnd, lithe sCi,1 housing IS ~houldeleu. drive the seill down to the shoulue,. If the scal hOUSIng is unshouldcred, the seal Should be fItted with its lace flush W ith the hou$lIlg top face,
Screw IhrCiU/s and lasleoings Always cnsurc that a blind t"pped hole is completely free from orl. U
reilSe,
wilte, or other flUId hcfore instatllng the hott a' stud. Fililu'e 10 do tillS could C,luse thc housm\) to c"lck due to the hydrilulic <1ction of the bolt or slud ilS It IS sc,ewed '" When tluhtenlllU ,1 cilswllilled nut to ilCCCpt iI spht pin, tIghten the nut to the speCIfIed torque, whele ilpphcilh le, and then lIghten furthe, to the next split pin hole Ncver slilckenlhe nulla "lrgn a spirt pin hole unless ~t
SOllle Inswnces, where no a lterniltlve IS poss ible. II hilS been necessary 10 resort to the use of a manufilclurer"S tool and thIS has been done for reilsons of safety as well as Ihe eHlcien! completion of the repair
operation. Unless you are highly Skilled ilnd hilve a thorough unde,standlng of the procedure desc(lbed, neve, " tWlllpl to bypass the use of any specl,,1 tool when the procedure descrIbed specllies ils use, Not only IS I here a ve,y great risk of pe,sonal Injury, but expensive dillllage could be causJd 10 Ihe components involved
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Tools and working facilities
Intra d!le I iOIl
A ~CICC1101l of good 100ls IS il fUlldillll! :lllill (C(j""Clllcnt Jor ''''yOIlD cOlllcmplilllO\llhc l1lilUHenilllCli
ce. S«IVIC"'U ,1I1d ""11 or repa " Oper"llons illC 10 he unde!l
SCfilwdflver -4 in long x '/ 4 ill dm (flil( bla(le) SCfewdriver -4 in /ollg x '/4 in {kl (cross bl,lde) CombinaliOIl pliers -6 inch H,lCks.1W (juniOf) Tvrc IWrl/I) TYfC preSSUfC gauge GrC,HC gun 011 C,?/! Fine elllufY c/ulh (I sheet) WIfC urush (slll.?!l) Funnel (IIIt'dium sile)
Repair nnd overhallllool kif Th(:~c 100iS ,1/(: vlllu;rlly eS~~"ll'o1llor anyOlle llnd(:rlirklno nlly 111,) rcp""s 10 " 111(110, vel"cln,
f)""lw[JI "',mmcr Soll-I,lced I!;""tllcr. I,lasllc or rflUbl.'f Sc,cwrliivCt 6", /ooy x 5/
16 m ({,;, (1101/ "'ilde) SCf(.·IVdIlV"f -2 m lony X ~/f6 m squme (lIolI blilde) SClel",(/riv(J1 112 til lony x 1'4 /f/ di,) (ClOSS bl"de) Scrl.iovdllver . 3 II! fOllY x '/8 III dri, (c/uclflei,ll1s) Pliers deelllei,ll1S srdl.' CllllelS P/i(JIS IICI!llIe nosed PI,e,s c/lclip (mlefm" mllle,,-!,'''',)/} Cold eillse{· 1 '2 tlfel! SCllbe r
SCt.l/'(Jr
C(JII/le
l!Unch Pm {Jllneh Hacks,)w V"lv(J yrmr/mg 1001 SlCe/ mlelslfo1lghl·edge AI/ell A'eys Se/eclion of fries Wife brush (Io1fg(J) Axle, sl.1nds Jack (sirong Ifol/ey Of hyrlr,;ubc Iype)
Special IDOls
The lools III lh ls Irsl ;rre Ihose which arc no! used reuulo1r1y. 1\,. (:xpel1slvc 10 huy. 01 whIc h need 10 be uscd In accordililce wllh Ilor: manul
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Tools and workin g facilities
vehicle Ill,Ulur"Clu,C' spc'CIhcally fOf its deolc. network. You "",II hnd ()(;c(lsiOllal references 10 these manufac turcrs' s,) cciallools in the lCKt of this manu;!!. Generally, an allcrna live met hod of doing rhe lob w ithoul the IIchictc rn.1nufac h.Jlcrs· special 1001 is given . However, sometirnes. there is no allcm;l1ivc 10 using them. Where this is the case and the relcvanllOol CiinnOI be bought Of bo"owcd. you w,lI have 10 enlfuSI the woll" 10 11 franchised gaHige.
Vil/ve SfJllir[} com{Jfcssof (where ,1{JfI/ic.lb'e)
Pis/oil riny cOIIIII/esso! Ball/oim SCI/,llfllOI UniVCls.,ll1ulJlbCillill(J pI/litH Imp"el 5Cr(]W(lrtVl)f MicromClcf and/or vel Iller tpu{Jc
Diaf fllmye
5110/)OS(;01IlC lillliny ligh' Dwell ,1IIy/',' Int'ICI/I;,ciloll!c/cr Uni1lf!fsM e/c'·/IIC ,1/ III(II/i ·melef Cyli(l(f~'f CI/III/If<.'ssioo yml.lJc Lil/illy 1,1Clr.fL' TfOllcy;,1cJ< Ligl!l WI/II CII/t'llsion 1<.',1(/
Buying lools For prilctlcally all tools. a \OollaClOr IS the best source since he Will have a vCly COllll)lchenSlvc r,lnye COUlI);lfcd with the ,Wela!Jc U,l.ayc o. accessory shop. HavIIlU s;lld th"t. accessolY shops olten aile< eXCI:II..,nt quality tOOls at discount pllces. so It I>'"lys to shop aloulld. Remcmoo •. you dOIl ·t have t o buy the most e~I)()IISIVC ItelllS on the shell, but it is alwayS ildvisilhlc 10 steer cleil' 0 1 the vely cheap 1001s. The.e i1IC plenty 01 good 10015 alGund ilt .eilsonilhlc III ices. so .1sk the j>fop.ie\O. o. nl."lnilne. 01 thO shop 101 ildvico belo.e lllilklll\J tI Iltllchilse.
Care and f/1,1inrenc1flcc of lools Hilving I>urchilsed iI reilsonilble 100 1 kil. il IS nccess.1fy 10 k eel> Ihe lools in a clciln S()fViCCilblc condition. Allc. lise. illwilyS wipe all ,IllY dll" grc/IS(! illid Illcwl pilrticles \Ising ,1 clCiln. dlY cloth. belorc puu.ng Ihe lools aw"y. Ncvel le,wc thcm lYing alound alte. they have been used A sm,plc tool rtlck on .he l)ill;1\)e o. wo.kshop Willi. Imuelns such as screwdllve.s illHl pllels IS i1 uood idc,l. SlO lC ;111 "OIm,,1 w/{lllchcs ilnd soc kets II, i1 metal bo~. Any meilS\llu'\j 1115l1l1n1cnls. 1),lu\Jes.
metCIS. etc. IIH1S t ho c;rlehilly s taled whe.o they calmO! he d
Workillg facililil.' s NO! 10 lie lo.gonen when dISCUSSII\\J lools. IS the wo.kshO$lltself. If ilnylhing mo.c Ihal' .outll10 !IIi1lnlCllancc os to be Cil.flt.'"il oul. somc 10'0ll of sUlwhle wo.king "'Cil becomes esscn"ill .
It IS al>PlcC'
JilW gal) (in)
0250 0.276 0 .3 13
0 .3 15
0 .31\4 0.3 54
0 .315
0.391
0.'133
0
.'138 o 4il5 04?:? o !l00 0512 0525 0551 0563 0591 0600 06'5 0630 0669 068. 0709 0 :110
0 .7"8 0'/50 0 .813 0820 0 .866 0875 0920
0938
09il!) 1000 1.010 102 4 1063 I 100 I 125 I 181 1.200 1.250 1 260 1.300
1 .313
1 .390
1.417 1 1138 1480 1500 \.575 1614 1625 1 .610 1.688 1 811 1.813 1 .860 1 875 1969 2000 2050 2.165
2 .362
Spilnner si~e
11~ in AF 7 mnl 5 1 16 in AF 8 111m !lIn 111 AF. 1/8 III Whnwo.lh 9mm 3/1;1 ill AF 1 0 I1ml 11111111 '/ Hi III AF 3/Hi in WhilwOlth: I .~ 111 BSF 12 mill 'n 111 AF 13 nll11 1/
4 in WhllwOllh, $/16 In BSF 14 mm 9116 in AF 15mm 5/
16 in Whitwo.th. J 8 in BSF $/s in AF 16 mm
17 nlln I ' /Hi In AF 1 8 Illlll 31 8 III Whitwonh; 1i16 on BSF 19 mn, 3 /
4 in AF 13/16 ill AF 7/1 6 ;n Whilwollh. 1
/ 2 in BSF 22 Illm ·"8 in AF 1/1. in Whi,wonh; 9" 6 in nSF 15/
16 in AF 2
4 nlln 1 in AF 9/16 ill Whitworth. 5/
8 OIl BSF
26 """ 11/16 OIl AF: 27 mm 5:
6 i,l Whitwollh. 1 1/ 16 in BSF II/a in AF 30 111111 111 161n WI"lwO'lh. 3/_ 111 I3SF 1 1
/4 III AF 32 Illlll 3 ; 4 III Wh,twonh. 1 a In I3SF 15/16 OIl AF 13/16 ;n WhltWorlh. 1~/16 In BSF 361ll1ll 1
'/16 in AF 1/ 8 in Whitwolth; I in BSF 11/7inAF 40 mm. 15
/16 in Whltwo.,h 41 nun 15/a in AF 1 III WhilwOflh. 11. 8 i n BSF
111/16 in AF 46 111m 113/16 III AF II/a In Whi,woflh. III~ \1 nSF
1 1
/8 in AF 50 nun 2 irl AF 1'/~ in Wh,lworth; 1 3
/8 in BSF 55 mill 60 Illm
11
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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 14 of 205
Routine maintenance
Maintenance is essential tOI C"~l"'Il\J sal"I\,.
The 1"II<)wII'~1 Sr:r",,:,~ schedules ,"lJ ol I rS I of the maintenance req
.
,
. . c;~
~--------------------'--~~~~'~
I Br,lke St'fVO uni/ 12 A" mIN duct 21 f/,ld'o,IOI l"lm c:,/, 31 Coohng sys/em pressure 2 Slarl v
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14,-------------------------------------------------------------
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-. . . { .' ~I ~ " : . ',\' ,.~ ~ . . -,. ','. ;,:! ---. , ." .. ~
View o f frOll t undo. body (2 _8 injection)
,
1
3 4 ,
Exhilllsl sys/t'''' {,uIII II'Pol Clutch c.,hI,· ,w'/mi!lJt'f g.li/l:( Od /rU,H Cd,llIdy" Brake c.l/,/uN OWkt· fie.d)l" "yllt,IIII,,; hese
6
7 8 9
F,QII! SIl$/lellSIOII {""Ie t 'ollitolmm Tr,lt'1!. (0(/ emf IMII/mlll RulJ/"" IJdfows Pt)Wf!( s/f!f!,lIIg !leal
'0 Fam l SI",,,II.\I." " .l(
" f)1II d}d{.~
" r.", .., Sump "" ,h,,,,, Iduy , ., U!lIIOIII 1m,,...
'" " S(.JI/"', 11/(1/01' lV/,'/w/11
16 SMile, "'''IQI 17 Fuel !ct-" ,1m/te/llm ,)'pes /8 M,1"'1.1I,!",,,v ox 19 Plopell,·, _,,,,,11
20 MUI"'('''', ("IIYllle IC,ll) 21 511<:1:1/"""
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7
__ ---------------------------------------------------------------------------------------------------------1 5
.' J .,
!,
!,'",., s,lenCl" (Jm/ /.1'/ J"In' He,)1 spOlIg R"'
IlIIt"IIIerlt"I" Stl,·", ,', 10 Re,)1 .nl(J cilsioy .111d 1~lfJlw/lUf sh.dl th"l''''''lml um/ Ire." sr;""".~,,, /,." 11 F,,<'I,n'cllfllu/,1IQ' !'lId fI''''Y'' ,\",.".1,,/ ""'1/ "
U,1IIr1hri,A c lillk,lye 13 (11('/1,.",*
. '
_'f"!!": •• , •
~f:.'~"., " ........ 'H,""':
,
, ...... " .. ~ .• y.: \ /:'"'' "
... _ ....
~-----'._----
14 Ou/lcYl /III/I)" 15 {"I,.'( II/J~
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