1974 FORD CAPRI check engine

Chapter 1 En gine 39
238 Checkirog the rolor lobe cle 1 Thoroughly cle"n nil PDflS ,11 petrol or p and between bOlh rotors olnd Ihe end cover pl"le. 8 The rotor lobe cle (phOIO). 9 The cleal3nce between tile outer r010r ,lnt! pump body should IJC w,thin Ihe limits 0.1510 0,30 mm (O.006 to 0012 'n) (photo). 10 The endltoal clear"nce n1ay be lllC"SlUCd hy plnc,ng n slecl t. !r.l II,em by removing t he rotors and l overcome wilh ol new unil. 12 W,lh JII P"I!S scrupulously cle !.p.ojl!l ilnd IInhlly luhuCJIC w,lh eng;ne VII. 13 Us,ng a SUltilble dl"nu.:ler d"fl. drove in il new se Ihn 0,1 pump cover all(1 secure Wllh Ihe holls t l\Jhtcned In iI (('Juon,,1 .1n Spr'Crl,c,1t,ons . 15 f'lthe d"veshilft ",to Ihe !Olor dllvesh 24 Lubric"tion system ~ description
The p'essed steel 0,1 sump is allDched to Ihe underside 01 Ihe C'~~kcase and aCls as a reservoir 10' Ihe engine all. The 0,1 pump d,,,ws ~~ 'o01lhe sump via an oil SlrDiner and inlake p,pe. Ihen passes 'I uno , t6 lull. flow olll,tler The 1,lte,ed oil 1I0ws hom the cenlre of Ihe oil ;,~e, elenlenl and passes tluough a shari drilling. on Ihe right.hJnd , ,", to the 0, p,essu re switch and 10 the main gallery (on the e 1· Mld side of II -
F Ie C1ankCllse) th,ough " ttansverse d"llIng. Md °h'''' d"lhngs conneCI Ihe main galie,y to the lou, maUl bellflngs be I C camShaft bea"ngs in their turn are connected 10,,11 Ihe Illain d"~I':ngs The b,g-end bea'lIlgs D,e supplied w,lh 0,ltl1l0\lgh d,ayonJI ) 'nys Iro01 the ne,uest rllilill bearing b'U~\,h~rolhec,ankShaft is ,0 tJtlllg. oil ,$ Ihrown irOllllhe hole in each and e~ bea"ng and ensures splash lul)ric"tlon 01 Ihe gudgeon pins lu b ,I HuSt s,(le 01 the cylmder$. The ttllling \)ears ~:.;. ' "cilled Ihrough lln 0,1 d"IIon\) . ,J",'
•
2310 Checkillg Ihe endflont
Fig. 1.3 Engine lubricalion system for the 2,8 litre engine (Sec 24)
The c r large dllilings in Ihe cylinder block "nd cylinder he"d_
2 5 Cr The closed crilnkc vent valve_
....
~---------------灲潣慲浡湵慬献捯m

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' POSIIUHl 10' Ihe CO'"1(JI:I"'(I .ods 10 il(! dr l.w n \)lIto" 10 WOlle !:In,l n rhe cOIl''''CIi''U ,ad heillOflU Cilp ilild hack 01 the 5 1 he 10llHue ill lh e b Ihe cO""OClmg rod Cill) 11 Gcn e.ouSly lulmc,lI e Ihe shell h,)IHIlIU ,lIld oller up lhe conncct' .od bCil''''U cal> 10 Ihe connect,n n rod 12 Ret,n,nu the cU'U1eCtlf'H lod lillIS, 13 Tluhten the nulS w.lh a 10f(lue wrench 10 the sllCc,hed SClling 14 When "II Ihe p'Slons i1nd conneCI",u ,uds h,we b(lcn filled. rO I,' the Cf.1l1ks hillt 10 check Ih"l eve'yl""'u 'S Ilec. :Ind Ihill Ihere are' hiUh SI.>OIS cauSi ng bUl(llIIg
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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46 Chapter 1 Engine
35 Vnlvo clearances -checking lind adjustment
Adll'S 1 the inle t Jnd c~h"ust villvc clcnrnnce s when lho engine is cold, he lween 20 th e valves 01 N o 1 or 5 cy lll1(le l Will he seen to be rocking (the two lOCker .1.ms movlI1(J '" oppOS'to tlireCt,ons). If thc vlllvcs 0 1 N o 1 cylinde • .1IC lockll1~J. ,Ol:lhl the CI:lllksllol ft th.ough 360' so thl1l those 011 No 5 cylinde. ,lie ,ock"'!J 5 W hen the vlllves oj No 5 cVhnd':I :lre In thiS position. check the v:llve cle.1 .. lOlces 01 No 1 cyhndc, by IIlseillng a leder gnugc 01 the
S llcclfled thickness hetween Ihe lock e ' ,'1111 :lnri the vnlve stem. ArlluSt the cl("II:lncc. It necess,"Y. hy hlmong the lOCkCf null ndJushn!,l screw 1011111 the speCified cfenlnnce IS obtained (1Ih010) Inle t nnd edlo1u~t v;,lv'~ cle;IIances a.e rh(/.!.ell\. 6 II the engine IS now IOt,~tcrl '/301 II hun the v.1lv .... s 01 N o 3 cvlll"l!":r w,1I he rockul~J ,111<1 the v;olv"s 01 No ,I CVlll,!s,!r r..1I' he checked ,lnd I1dJus t()d .
7 Proceed to ;"Idlust Ihe cf":II:II'CCS .1I:COrdrn\1 1 0 th" '''rnO o!(ler ;"IS lollows. F,U 1 .8 shows the cvlOildel IHHllhe.s "nd valves Irsl .... d OIl tllell eou eer o.rlcr. wo,k",U Ilorn Ihe llOlIt 01 the engone .
Valves rocking No 5 Cldimler No 3 cylm(lcr No 6 cylmticr No 1 cylll/tier Nu 4 CylllltilH Nil 2 cylll/tie,
Villves to ndjust No 1 cyltll(lef (ill. ,'x) No" cyllmler (III. ,'x) No 2 cylm(lcr (ill. ex) No 5 cylilltier (cx. ill) No 3 cylmdcr (ex. IiI) No 6 cylimft'r (ex, ;n)
8 r-11 the rock er COV~!' U,1skcIS ;IIHI rockc. covers (photo). T 'Uh ten the S(!C'''rI1 !) holts to Ihe speCi fied twqllc
~:j?0
ex-0
(;\G-in
~G-E'X
r:\G-in
0G-E'X
ex---{) 8 4 G-in
. n 1
in--v FRONT "'""
of
Engine
Fig. 1.8localio n of inlet " .
l
I
36 Engine anciIiMies·· ref itting
Rcle' 10 SCClrOIl 8 "ud rul,t the Irsted COllllJor""'t~ \Vllh rele,erlce to Ihe Chaple,s mtl'C,lh)(!
37 Engino -refitting
Rcf,wn!) the cngrne '$ D reve,sDI 01 the ,emoval procedure given or Section 6 . hili III Ddd,uon note Ihe lol/owing pOin ls
(,l) (b) ,oj (II)
(c)
Llyfuly (frc,lSC fhc yembox illfml shaft Ch~'ck 111,11 /h,· clulch rcle,'se ,11m IS correctly loca/cd AdIIlS/ Ihe CfffU;h C,l"'C as (Iescfibed til Chilpler 5
Ad,US/ Ifle tcnSfo n of Ihe powef sleell;IY pump ilnd ,,1/emilIO ' "nvd1ell(s) ,IS (/eSt'nlwtilll CII,lplefS 10 alld 2 respcc/ively Fill Ille COQIIIUI sySlem (Ch.lp/er 2) "1/(1 powcr stecling SYS/VIII (ell"!!I,.:, 1 0). Illen I,II/lic Cflgine w,III 011 (Scc/ioil 2)
38 Engine -in,t;"l stMt 'lIl) ,,/ter major overhaul or rcpnir
M"ke su,e thai th.:: h:l1tc1y ,$ fuliV cha,u.::O '!IId Ib,"" alliub rrcafl tS coolant and lucl ,lie '''III''''',sl,..,,,
.... ~ __________ .................................. r
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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

:as::.w.'q
48 Chapter 1 Engine
110 Routine '!lain!cnanc!!
At the 1I11Clv"ts specifIed III Ihl! ROutlll!! M"inlcni'lnce sectIon in thO !rom althe mil"l).11 cnlfy out the followmg procedures.
ClwlIgc ollgiflO oil. reflew oi/Ii/fer t/lld clean oil filler cap 1 Rdo, 10 S()C\'OIl 2
Check illld <1r/jllsl vMvc c/c,7f<1nccs 2 Rcfe. 10 Scellon 89
TigMt'lI mll;( IlliIlldold hollS 3 RP.1110VU Ihe ;", Llr:"llcr ;unl lI!Jh1cn the Inlet rlIi'1ll,fotd holts 10 Ill" spccll",d ,ollluO wIlh .oleumc!! to Chapter 3. On comple\lon re lu the au deane.
R(JIII.'w Ihe cmllkc'ISf! l.'mission v,Jlve " Ad", In SIl<:\lUIl 7
41 Major operations \lOssi!>lo with (lilgine in car
T 10" lollow,n!) ""'1111 Ot",,;otlOIlS Illay he r.'If.icd Ollt wlthou, ""''''VIII!lllw';!)!luH!
(.,) /r,·", .. vmy .1",1 "'/'/flll!! III!! ,:ylmd ... , "1.'01(1", (II) {,"'IIIIJVIlIf/ tllld "d'I/IIIO (/1<: /ltmll!l 1I,·.ItS (i:) 11,:IIIIIVIII.'I.IIItI,dll/III!/ /IIt] I!II{/IIIL' 11II1I/11!""I1/III!I~ (II) III'II"'~IIIY .",,1 "-'''/lilly/he Im!lIll~'I!It];,,""" ",;" "'111"'/"'.'1 (,') /{"/IIIIVHI!I .mlf ,,-,"II"'II,IIt] (;;/II'S/l."1
42 M" jot Ollcra lio ns requiring engine removnl
The followll1~lll1alm ope"II'OIiS may be c,lIIlI~d OUI allC! ,cmoval of Ih" !!II!I"W
(01' /r,''''''''''''! ,mlf ,,:III/my llit] fly"'/md (b) 1,'I;"""'III!I ;lIId 1I:"lIiII!! lIlt] II.'''' "';1111 '''.·;IIIIIY vII sl~.ll (,;) f,',:/lWVIII!1 11",1 ,,:hl/myllll" ,:,.mAr:;,.w stlll'p· (,I) 11,·wIIV"'!1 .md It"/tflmyl/t,) 1.-"/II,,.t:I"'!1 tOri 1t~·;"'''!1 (,.) /1,.",,,,.,,,.'1 .md II-,!t/lmylll,) ,,,sl,"'.~ .1111/ ,;ullltL'd"'!1 IUds II) ".,.""",,,,.'1 .lIId tdll/myll"-' "II /lllillfl (.'/) f'"'·"'''V''''f ,11101 td'IIIII,,'''t] (I.mAsh .. ", ;/lul",;,,,, ht];mllYS fli) J,',·IIU1V'It!l .1111111.'1t1/1II!I fl,t, C,lll/.f/"dl 1141.<111."5
A lth""!lh 'I'~ 1)(,·.~d,le 10 1(~II1()~clhe SUI"P W'lh lhc C"gllHlII' the ca'. I! IS 1(":o""",·,,~I,,d thai 101 ,Illy ope"u,olls wh'ch .elt""e Ihe .emov,d 01 IIH: ~""'P. ~,,<:h ;,~ the ,eOllov,ll nf Ihe CI,'nksh;lfl alllll"o c!l(II)c tl,,: ""!)"'" ,~ '''''''IV'·!!
43 Mctho(ls of engine removal
The ""!I""~ 'n"V he hfWd oul e'the. 0'1 us own u. III u."t wuh Ihe I""'~""!>~'{)" On I1lo.I\lIS l'I1t.' 44 Engi"e -rcmoval
Open imd p.O)) up Ihe bonnet lhen covel Ihe w'ngs w'lh CIOlhs. o~ <:n.(l11O.1,d. 10 Il,olecl Ihcm hom scr II", IJ.,U",v oul <1 fle,l/oyu lhv ,II' cle 5 flc"'ovu 111,· ~pl.'~h ~h,(;ld hy "''''<1VU'H II", hlllt~ ,1,,<1 cI'p~ 6 PI,lce ... ~:Il"I.I·nf" of 10 lot", 11"16 JI"'I) r:,'I),II·, tv ,,,,,Iu.,,, !,
'iI(I' Ihem
8 flc"'"~,, Ih., I",,, hllll~ ...... · '"II'!I th", """.11',, til Ih" '''UII Ila" hfl Ihc "1(10,,10, ""t
\) D,sc""''',,:1 Ih,· ',,11 w",.·, hm,,, 1"111' Ih" w"tt·, 1"""11 ;",.t a"I, cho~e
10 fle"",,,,, tht! -l.lI"·' ""'10' h,·;11 ~h,,'ld .11,,1 II"·,, ,I,,, '''''''·'·1 tho I,om Ih" ,,11"""'\0 " t'·IIIt"·'."'"'' '.""d,·, 111"1. "1"'''"11 1./,,1 ;111,* mOIO'
II R"IIl'l"" Ih,· ...... " huh ... "''' ~""'!I th.· 11""nl,· h"k"!IU I,
aSS(lmhly to Ih" .1\1<'1 ",.",,1,,101 .lIlfl "·"If"·,, It Ipl'Il.IIt 1 2 fl''''' vnCll"Ill hn,." I",,,, Ih,· ,"1,·1 " .. ",,1,,101 .",,1,1,,· "oJ )."· ... ~II"· I",,, fll. conn,-ct", .11111 , .. I.· ... t I""" tl,,· .,,1 IW""";'" '" .... ,,,,, 13 R""",,,,, tl", •...• , 1",l b ""·"""'!I Ih" '.1.",,·, "",r,,, .""t ",,,,(,,. 14 flell1""" Ih,· I.\() """ 10, 01 ..... ·"'''''·''1 II,., ,,,hi,,·, """I.'I"'~ III, en(Jllh1 """,,'I"'!I' 15 RII"'(J~" tt,,· I.'." ~"'I~ f""" '·.11 h ,·~h.""t n.",,),· ,11,,1 ,II".,,,,,,, e~h,'"~1 il'l"'S ),'"'' III" ,·~I,.".,t ",.""f',lel
114 12 Fuel j)1""p ". d 1,,0;1 I,"t;
I;" ,
1:-,
!
~ ,
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