1974 FORD CAPRI engine oil
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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
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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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) Chapter 1 Engine 27
oint t ighten II ~ further 3/4 l urn ~ Remove the t,l ler C,ll> all the left· hand side of the engine and I,ll the g ine with th e correct quantity and grade 01 od (photo), ;n RemOve the OIllcllcl dipstIc k and wipe it clenn. th en fe -insert'! and emove it Jg
(1.76 p int). 10 CICJfl the 0,11,1101 CilP then refit il .
Check and adjust valve cle
hgMel) inlet manifold bolts 12 Remove the ,111 chamiler and \'oh\on the Inlet 111.11"lold hnlls ({J the spec ified lOrque WIth Icfcll!IlCe t o Ch~ptl!r 3 On compl"I")1I ,(:111 Ihe
JII chnmbcI
R enew (fie crankcase ellli,~sion valve 13 pulithe v(1lvl.' (1Pl(I'hose 1'0111 tlw leM 0 1 Ihe "ohl·l1(1nll locker caver
(photo). 14 [1.clc;lse tile cl'll ill1<1 ",movc the v(1lve foorn the h ose 15 Fit the new valve.n levr:rse ordel
3 Major operations possible with eng inc in car
Thc fol lowrng ma lo r operat,ons Cilrl he C;1
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(It) Rl.'tttOV,ll ollnf ,ellllmg of IIII.' 1".'·(Ofls ilfld cOrlfleelmy rods (,) Rcnewal 01 tI", c ,i/nkslliplt 11(1,,1 Sl'it! rtI IIIIII"y C(lVCI
4 Major operalions requirillg erlgirlo rO!lloval
T he followlllg IHaJOI opernl'OIlS ,,,.IV I", Cill!ICli out ilfl'" 1t'l\1o,",ll of tir e englllC:
(<1) Rcmuvi" iJllr! Id,lllIIY 01 If." ,.,.ttt~Sfti"l .,11(1 II>,1ftl 11,-,tlIIIYS (IJ) !1ellclV,11 ollfw o,wksft,dl II'." .~,.",
5 Methods of engine removal
Althol!OIr It ,~; flo~~lllle to .. ,1)1,,\·,· tI .. , "WIlli': .:Illd U"iU!'vX
o Ellgino rcmovill
II IS t',,-,,.'IIII.-,1 If! h,v" <1 fl
28 E[lO"lc 011 levI;[ d'pstlck ma,kll1gs 2 13 Removing the Cfankc<1se cnHSSIOIl v<1lve
62 Ea'th cable Oil the alte'''''lOl adl"slIllt:l1t u,,,ckel (
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28 Chapter 1 Engine
al1crn;1IOf ,1d,ustmcnl braCket (phot,,)
3 Dr,un the coohnO SY~'cm <'1nd ,emoll" IIw 1,1<1'.1101 ,1S (InSCribed "' ChnplC' 2
6 DisconneCt the h'nkc SCrllO vacuu", h 050 Irom the "" chamber 7 Disconnect t he IIllel duci hom the ""onlc hOusln\) and nH~tUlc control 111111 8 DIsconneCt the IIl.on'e cilhle w.lh ",1.·",,,c(1 to Cha,l le. 3 n Pull the CC"I"~ itT ICil\, lmm the <1",,,1,,",,, C.11> ,l oll PO~I1,on (Oou" s,dn
1 0 D'sc:onnCCl ,hc mirth plUH I.um th., ,1"""'''''01 11 DISCOIllH:CI the W""lO hum th" 1""'I~".ll",e IFllI!)U scnd...,f 111'" (phOlo). lhc.mo!"1111 SWlh:h. Wi"'" "I' "~I"','IOf. i!uxlh;uy ;111 ,r.'VIC' ~ ,1nd coli! Sl.1.1 Vil!VO
12 UIIS, ;I"W Ihc '''11 011 ,,"1 and dl~r.",,,,,', I Ih" O,! lI,eSs,"!! !F'U!JIJ h"" (phQlo) 13 D,sr.UIII'ccllhe IW"h "d,le hOOIlII,,'II,,· h"lkh(:, 1d (I,hnlo) 1'1 rO~lllon ,I ~\lII;IIII" 1:01\1,,,,,,,, 1'''''''.,11, th" I,owe. ske""!1 '''''''I' Ihen <11~(:ollll'~':llhe ilu'd ho~es (CII
: n li,,~, "'w 110" !JI',)lhO~ III .. n" ",. I,,,t ...
:17 n." .... · II ... ""~I"": wh,'" ~I"': '''I I ... • ""'1"'" """,nl""I', It",,, It :.II)lh·1I I",,,~, ... 11'1,,,10) Ii "',' I,.. I .. Iplo" III "'''''I.I",,· ly ''''''OVI: I I
"!II'I h,""I""""'I"", W,lh II,,·, '"I''''' ',lI~"'" I,·,,, ','I I,,, I", .. ~, .... . P' ,I I"'W,IId·,! .. ol""'II""! IC ,I 1«,,, . tl,,· '1··,,,1,,,, ,,,,01 (,,,',"1(,,, dll""'''' :C! Wh,'11 110.· , Io,t, 10 IS ,I",,, "I II,.. '1,·.lIIH" "'p,,1 "Io"! 1 loll tho: "'''111
III"" Ih,' ""'1,1", """I~~'I"'''''I '\',,1,· ."",toll" ,I " .. ~I II", '.""("",,",, , '" "I" "', ''''', i pl" .. o 1
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G 4A fl"nlovlI'g Ihe QXP,IIlS IOlt t.1l1k "'O[l"III' U b,.1Ct..CI ujlpc, ""
,1nd lowc. Sr.ICWS 6 11 TCI""c",t".c U'lUge stJOdCf U
.--~--. ...-,~ .. - -.-... -"',
6.13 Rcmo~'ng Ihc ea,lh Cllb le I.om Ihe bu!khe"d 623 IlcIlIOI"'!)lhc C~I~ns,on b,ac~.et (,'lfowedl trO'1i Ihl' 0<1 COOle,
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Chapter 1 Engine 29
624 Left-hJnd cI1!I'"c i)lO(lI1I"'(ll1l1l 6:12 LIIllll!l Iii\! ''''!)Ull: deal 01 Ihu rnOlllllln!) hr,lCkel~ G 33 L,Illll\) thr, ('''!JI''e hom the engine c()nlp~rtrnr!lll
7 Engine d isl1lil"tling -(Jenerill
\'Vhcn Ihe cn!I"'o I~ lelllovud ['0'" the ':'H. 'I. n"d p;olllc"bdy ,IS aCCCSSOllIJS. are v"llle"IlJle 10 d.lm;I!IC If 1")~~d)lo, 111(""11 the ('''Hill') Ull il stand. or fnlhng thiS. Illnke sUle II IS SUPI!'.)II,,, I In ~(Ich it "'oll'l",r th.ll rt W ill nOI bc dillllJocd whdsl "ndOll'!I t 'jlhl nub ;rrHI hollS . 2 Cleanliness,s ""pollanl wh..,n d, s"""'II,"!) tl,(~ cn!)"H~ to prcvllnt e xposed PMIS from contnm,nnt ,on B(dore ~1:llt'"0 Ih\! (hSIll;lnt lll'(j operJtions. cle;:!n Ihe oulsldc 01 Ihe ell!J1IlC wllh 1';H"Um. 0' a !.food greilSe solvent II 11 IS vcry diriy. Carry outlll1s clc;lIu"\I ,Iway frolll the area in which Ihe [lismilnliino IS to ta ke place_ 3 If an eng ine S1
G Always Ohtalll (;oolll'lele s"ts 01 (la~knls wll,,,, Ihu C"!l'"U 'S IoU'"!! (I,sll'''"tled It IS a !Jood poll(:y to always j,t Ilew \l"skeb III v'ew 01 thc rCI"I'vely 5,,,,,11 CO~t IIwolv!!d l\et.1'" the old !F"knts when (lisIllilllllo"!J the en\J"'e With .1 v,ew to \lSII,\! them as .1 patlCln to ,""ke a rCpl,lcemellt !Ja~ket ,t a new olle 'S 1101 "vallable_ 7 \'\,hun pO%Ihle. "d,t "lOiS. holts illld washe,s III Ih e", loc,ltloll5 liS nu s helps to p,otcct the IlIru,ld5 flom d;u""IJe ""d Will ~Iso b e helpful wh~" t.he enO'"~ 1S to"",\! reilsse"'hled. ;os II uSl
AlthoUIJh the Ilems listed Ill;"ly 1m ,,,moved separ~(o)ly wllh the ''''O",e installed (as tI"scliheci '" III(J ,eh:Volnt Chapters) II IS more ,1pP'Opfiaie 10 lake thclI' oil illter the cnOlllc has hcen removed Irom lhr, f.;11 wh(", e xtensive d iSlllil'l1hllO IS hell'!1 cilifieri 0111. The items .11(1'
Friel init1c/I(Jri svs/I.'II> cOlllponellls (Clmplcr 3) DlS/fibulOf (CII,1/>IN 4) Filn ilnd w.llcr IJUIIIP (Cilill'lL'r 2) Power slccring PUm/' (CII,lp/N 10) IlIkl MI(J cX/)
1 fh,nH)V( ' tloo Oil lev,,1 (hp~t'ck_ 2 UnSClcw the cellire ~Iecve a",1 "!1II0ve tile 011 coolel ilnd g,lske t (pholo) 3 II lIot done prCV'Oll sly. u nscrew tile ~wnp drollll pili\) ;"Inri drJ11l the oll IIlto a Sllolahle conl,,,"c' <1 Unholt the engine mounlings (photos).
5 Unhol t the power steeling pUIllP Idler pulley illld h rilCkel (photo).
6 D,scollncct thc bYPil5S huse 1 '0111 till) tll"ill\) cover ,eill elbow (photo).
1 Hernovc t he rocker covcr secll""\) boilS "nd hit off the covels (photo). DlscGlllle(;t the b,e.llher hose where ,1pplocJble. 8 Undo the rocket shah seClIring holts and remove the ,ocker s hahs Jild 011 splash stllelds (photos). Notc wh,ch Wily the splas h shIelds "re
920,1 cooler show"'!J centre ~Ieeve 9.4A Left·h~nd Side enUlne 1II0Ullt '"0 948 RI\)hl·hand Side enU11le moul11lng
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30 Ch[lptc r 1 Engin e
!l 5 Pow." ~1o'''''n!J JUIIlljl,dlolr rlUlley :111(1 I,,;ldi:;t! ' (."",,,, ... 1 96 D'$l:IIUII,·,:I"'(1 til" hy !l;ISS I,n~fl hum the ,"nUl1l U,II", w;u dhow
9.SA Unsc .. ;w lil., bolts 9.8H .. ,,,,,I '(:I\1OY') ( h " roc ke r ~1,;,11S 9 8e . . lrlli oil ~pl,l~h slll!:lds
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99 Remove the push,otls 9 .1 0 RcmovlrI!) the cylinder he"d boils 9.11 RCmOVUln the "Ohl himd sIde c,(hud". head
tilled. M,uk the locke. Sh,llI S so (h,ll they C
coneCI rcllltlllU 15 Inv(;.t Ihe engine "nd unbOlt the sump (photo). Remove Ih(l
Uas kets 1 G Unholt the plck·up p'pe from Ihe OIl pump. Dnd !CllIove the \.Iaskel (photos) 17 Unb011 the ort PVIl1P and w,thd,aw the (
lveshalt. notlnlJ whIch wny fOun(1 II IS lIlted (I)hotos). 18 R(;l11o\(! lhe crankshaft pulley S{-cIIIUI!1 boll and lake the pulley ot! the cranksh;l ft (photOs) Reslr,"11 the c,ank~hnfl I.orn lurnlllfj I,y
ch ockrn\) thc II~whccl 19 Indc>l mark lh(; pOSItIon 01 III
& co
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ClliIpter' Engine
22 Unholt the thcrmOSlilt INlr Woller eillow R()llloVC the ~Jo1~kCl 23 Unboillhe 1II11Ing cover "ml relllove the UaSkCl (photos) 24 Ullscrew Ihe bolt securing the r..~m~h;'lh {le.1. 10 the Cillll$ho1h ;mll pull oHlhl! nCill (photos). 25 Unscrew the fronl ontctnlcrh,lle plil!C {IHllch'llg boilS ':'IIld rel110VI) tllO rn(crnlClhnl C pinto . Remove the \p$kct ,HId ~pnccl (photo~) 26 If the crDr1kshil ft gO;!' nco(ts 10 be removed usc a stand.lld (1UIle. 10 d 'ilW 11 all the CI;mkshilh (phOlO) 27 Unscrew th e camshah thrust pl,lle 50CU''''0 boilS, rcmo"" Ih, ) thrust 1)I.Jle ilnd wi\hdrilw the Cil!l\shatl (ph010S) , 28 Check th,1 tho l)ig-ol1(1 hC.1roll!1 caps Hlld connCCllllU ,ods loll"', ,denl,lic,ltion 11\;1Iks. This IS 10 "n"",,) (h,1I the CUllect CilpS au! [,II,-d (" the COllcc t connecting rods aod nl "',I"""lIlhly 1l1l~ flBed IIl1h"u ~:O"'''.1 cyllndcr hOles NOie thol11 he I)'~IOII'; h,we 1'111 olllOW (0' r\ou;1I1 ma,~"d on Ihe Clown 10 rUdrC,lle Ihe Inrw,r,,1 1",:OIl!1 s ,de (pholOs) 29 flelllove Ihe No 1 cyllnde, I,,!! ,'r,,1 ""IS. Ihen l.1p of! Ih" I,,!! ':Old
cnp I<",.p I"'~ ~h"11 ''''.1fOllgS w'lh Ihe C,1p .1nd COllneCling 'od I, wh,ch lh~,y Me ,eOllIJved . To remove the shell hearings. p,ess "eolllnu on Ihe s,d,) opposilc Ihe g,oovn on hOlh Ihe connCC IUlg ~0(1, Ihe C"I) .• md Ihe h("lllnu w,1I slide 0"1 (photos) 30 W'lhrh.1w Ih" il'~I(ln and co,m(,r:llI1!1 'od "pwards out 0 1 cylind", I,ow hv 1.lpp,ng w'lh lin, h,,,,dl< , 01 " hnmmcr I, 1I,,,le""',1Ih 31 Rtpc:1 II", poo f.·,lwc gIVen ,11 11;'I'''!I',11'105 2!l.1nd 30 10 remove 'C011.1HlH1!1 ,"~IO"~ an, 1 ,:onneclIl1\j fo.b 32 M,,~,) ~II'" Ih,1 II", ,denul'C
:13 U"",, Ih" ""a"'"~lllolts ~mllih 011111" Ill.llt' iJ(!.1tltJU f.nps '''I(I
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9 .2 1 Removinu Ihe enu ine oldaplo, pl.rlC 9 23A Unholr Ihe 11111111\1 cover 923B tll1( retllOV(! lhe {JJskel
9 7.IIA Removc l11e secunnu holl 97.110 ,1rHf ~I"I" "II Ihe t:;1I11~h,"1 un,II [) 25A UI1~Clew Ihe Ilults
;Itld .{!tllOVC the UlICltfled'JIC 925C tlml !JiI!.kt:l
,
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34 Chapter 1 Engine
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9 .33A flerllovlllU n m,l'" /)(:,lrrl1g h011 934 flemovinu Iho crnl1kshah 9 35A n"movino In upper rnolill henrillO 5oh(:11
935U flernovrllU the llppe. hil!f 01 No 3 mJrl1 bCilrrng shell
liu(iom half of ench i>CIIIIIlU shr,lI. Iilk"'11 I:"rr) 10 kccp Ihe hea"ll
35 Removc Ihe upper hnlvos 01 the m,un Iw.nrtrlg shells ;lIlt! thll upper hillf 01 tho No 3 hc:um!j Ih,ust wilshers (whe.e illlphcnlJle) "am lire crilnkcnso ilnll Illacc them wI,h the lespectlve m,lln h en""ll C.lpS (photos )
1 0 SUnIl) -rClllovl.1 and refitting with enuine in c;or
1 Disconnect thO hillhlry neU ,lIlve leJd.
2 RomOve the d,Slrrhuto. enl) (Chilpte. 4) Jnd the rad'ilIO' silloud (Chapte. 2).
3
App'y Ihe hil'l('h.ake Ihen l ilCk u', Ihe fronl 01 I he C,1' ilnd suppori on axlo Slo1nds.
I;ilc h end (arrowed)
11 EnUino eOlllpollent:; -(!x ,1Il1i nation fo r WCilr
Whcn Ihe enUIIlc hil~ heen siripped down ilnd all Ihe pilrts h 'mr~n cleilned. Illey should be exarllinc(t fo r w car. In cases where delrllile we", hn1l1 IS !IIv,~n. II ",ust be a mailer of ,udgmenl on whe: or IIOt J PM I IS 10 be ICllcwe(1 o. relilled. Iilklng inlO conSIdClatlon 'urthel "'e expeCled hom Ihe engine. Ihe degree 01 reliabllily reqlJl' Iho COSI ollhe new pilrt ilntl Iho:! nmount of diSfllillltlrng which wII, necess.1fy 10 renew Ihe pilrt lat e •.
12 Rocker ilssemlJly -dismantling. examination ilnd reassembly
Tilp o u, 'he rotl pin !rom one end 0' ' he rocker shall and removo spllng w,'she. (phO IO) . 2 Shde the rocker amlS. rocker Suppor,s and springs 011 Ihe '0(, Shill!. Keep Ihem in Ihe COllecl Older so thaI they can be reassemble r the same pOSition It il rocker support sticks it can be removed 'ilpping " with a solt·lilced hal11mer.
ID ~~t:, rL'O'~COO' f0 .: . . , -111'" . . , . II . ,.: , -' /')')')')-" . .
'. :", o n . , .,
f iU· 1.2 Exploded view 01 rocker shafl ilsselllhly (Sec 12)
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Chapter 1 Engine 35
3 Examine the rocker shah ,md ,oc ker il,ms for we~r, II the rod", alill rl tha t conwcts the valve stem IS conSiderably worn. n,new the " ."'"nl I f it is worn shqhlly step-shnped it may be cleaned up wIth rOc e r ". . a fi ne oil stone. . , commencing Jalluary 1984. modolled ,oc ker shah sp"nOs have ~een fi n ed. Where wppet no,se IS evident 011 e~rlier models hl'lw",en e n g ine speeds of 1500 ,111d 2000 'p'll. the later type 01 SP,,,llIS nl.1Y he
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5 Od t he parts and reas~r)!llhle them on therr shahs III thO) n"lI,n;.1 or der With both rockel shafts f,tled the 001 holes must face downw.l,ds to th e cylindel heads Th.s po~"tlon IS lIl(hcated by a notch 011 Oil" "nd
lace of th e rocker shaft
13 Tappets and pushrod s - eXill11inalion 1It HI renova tion
I Examine the v
14 Can,shaft ilnd ciln ls h Hft b earings -cxmninatio n "" d
rCll ovntion
II there is excessIve WO),11 III lhe camsh;lft thp.y will h,lVl! t" lJ" lunc wed. As the 1'1lI1'11 ul '''"1'11 Iwarrll\lS w!(lI"es speel,lI [(",I, thl~ ~houtd be left 10 your 10c,, 1 FOI(! dealer. 2 The camshaft n1;IY show SI\II1S of wear Of) tlH! I)(:''''''!I 1""""'1s 00 C;In lobes. The main d(:elsloll to lake IS what de!)",,, "I I'll"," n ec e ssitaleS renewIng the camshaft. which IS e xpensIve S<:'H"'!IOI da",~ge to t he bearIng 10",()"ls cannO I he ren'OVNI hy ''''I,,,,,I'''!I. runew,)1 0 1 the camshnft IS the only so lutioll J The CJm lobes mny show SlUns of ridgIng or piltmg on Ill" I"U" poin ts . II ridging IS sllghl then It may be pOSSIble 10 rel\\OVC It woth "
lonc oil stone or emery clOlh. The cnm lobes. however. ;"" ~urf;It:e hau Jencd nnd once the h
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15 Cylinde r heads -dismantling . renova tion and rCils sembly
Clenn the d "t nnd oil off the cylinder he
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t5 2A Comp' ess the SP'Ii") woth II valvlJ
! ' Il "nU comp,esso, . 1
5 .2£1 thu" """ove the collets (n'il\l'lellC 15 2C. followe(1 by the ,elnmer
1520 ... an d valve SP"Il\!
p,ohe show,,)
t;. "" &' '
'('ii" " 18 ... ,,,
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15 2E RlInlov,nU nil 'nlel valve 15 2F Inltl valve (top) and cxhnust v<1lvU {bot 10m) COlllpo"ents
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