1974 FORD CAPRI Workshop Manual

19 2 Chapter" Bodywork and fitting
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FiU.ll.25 Front sen 1 h e l! ;,IIchorilu e points (Sec 36 )
!; Wlu,,, ",!oWIl!) Ihe se a t hcll~. rn," " ,."'fl thai lin: .l1H:hor pl.,u,s ;H() "n~'t(()lu,d n! Ihe co"eCI an!ll,,~ a"d 1'!lilll,n IllI! h()lt~ 10 11m sp,,(:,I',~d
"'J'lI!
) Adju slilhle exterio r .n ir ror HlInovnl ilnd refittinu
1l,,,,,OV'!
Ih~ doo< 1"1ll panel "~ ,lo:~,-"lJr:d .. , S"C\ ,orl 13 ? Un~c'cw Ihl) mOunllll!) nul,; ... ,of wllhd,aw 110" 'lHllll! f""" IIor: ()ul~"le 01 111() doo,. ill Ihe S,Hll<: I """ I""(!")~I 1Il1' (,,,hies I Io",u,)h liln hole (),holO). 3 fkllltlllg ,s n ,eve'slli 01 ,ellloval
38 Interior m ir ror -remova l ,mel relittinu
P"se Ihe p!nstic cover 110m the nlllio r bilsc (photo)
2 Un!":" .w the C«)~~·heillj scr~wS nnd ,r.move the IlHr fO' and bilse
/,om thp. ,o"f (photo) 3 Rd,tI'fln 'S n ,e"crsal of remo",,1
39 S eilt s - .e lllovill illle! relittin\!
Fronl scals 1 Hef,1 tllp. seat fully In Ihp. len, Ihl'" \ll\sc,ew Ill(! ",ount,n\! hails from the f,ont "I tl", ~fode 'ilil$ (photo) 2 Adlust Ih" seat fully to the fran I. unsc'ew Ihe r~m [nOwllong boits. th~" ,e'nn"" th" SI,,11 frail' the eil' 3 R(,f'II"'~1 os a ,cvllosill of 1I;1110V,oI
Rcnr sl.'als 4 RCIIl"V", lilt) ~';'"ws hom the 10",,, "I th" ~e,ll cosh,on. nnd 1011 the cush,on f",m Ill" cn, (pholo) 5 n"l"a~" 110" s,';l1 from 11m LlPP'" l:oIch«; s). 11«,,, ,,"bolt the hmUes nlHl ",n,,,v., 11<" S""I i>;)cklr:s l
6 n"roIIO!l!! o~ a ",v,~os"l of removal
4 0 Huatflr (;onU'ols D'~{:{"HH:';1 th" iM ll(l'y (l,lOlh I".,d. lhan [Ilnlova Ihe ulova COIll!>;"IO",,,1 by U(\~"'''W''lO 7 ~""'WS ,11 lill) lop <1m! 2 nuts ,1t Iha llot1 Slil ndard hei/ler 3 Child thm the (h~lldJ\llor nnll le~J"I;tIO' Jlap favers 3 ', 2 Adjustahle cxlclio, millOI c;i/)I() cOl1ltol 381 namove the pillstic cover. 382 and lJ"SC'~W the mirro' base
) 39.1 F,ont seat fron t nlounting bolt
39_4 RernovlllU ,ear seat cushion rnoulllIng sClews
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Chapter 11 B odywork an d fitting 1 93
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Fig . 11 .2 6 Heilter control cil blc 1Hljus tm ent
on SlHn (IMd heilter (S ec 40)
A (),.\·/"UlI/Ot flajl COII/ro//aVllr 8 I/Cgll/;I/O( Il.7p con/fo/h'vt'f
"'!ovy dilly IIfHltOf Chl.-r.k thilt Ihe d'Slflhutor 1I"p levc. ,HId WilIC, cont.ollcve. (FlU 11 28) we 011 Ihc cnd ollhl)" Ir,"vel ilnd clamp Ihe oulC, cablcs "I \IllS lIon.
AlllwMCfS 5 On complct ion. reconrWC I Ihe ulove comp;lr llllent liUhtinU leads.
Ihen lelil Ihe Ulove COllll)nltrllell1 nnd reconnet;1 Ihe hnllelY emlh len {1
41 H OMe r controls - removal and refittinu
1 Disconnect Ihe ballery eimh lend. 2 Rcmove Ihe s teer ing column shroud (2 screws D tthe bOliO",. then pull oul .lIlhe lOp). Lo wer thc stee.ing column (lel\Ving Ihe twO bOltS in position) sufficiently to ullow t he inst.umenl cluster I rim to be remOve d. 3 DIsconnect Ihc switch 10MIs ;lnd remove the instruments cluSIO' t"m. COllll)lot e with cowl "im (11 screws). Rcmovc the instrumont clusle r l!clOI (3 scrcws). 4 Pull oil Ihe hOiltor control knobs. II t his IS 1I0t possIble I> sWItch illI(1 light i"'1 leild5 . D,sconncct the cilhles 110111 tho hCiller COl1lrols Rcll1tlllU IS the .evcrse 01 Ihe rcmovi,l p.ocoduro. du"ng whIch It
.. hc neccssmy 10 adjust th e callies. as dl.'SCfllled III the p.evlous ::. .on Also it w,1I be necessary to obtall1 new hCille. control knobs where npphcable.
42 HCHte r
water villve (hellvy duty heater) -IC lll oval an( 1
refittin g
Drilin
the engine coolant ilnd dlsconncct tho lowe. hosc !rom th c ,aulato. (,efe. to Chapter 2. II necessary). 2 Disconnect Ihe th.ee water hoses f,olll tho Wille. valve. 3 Removo the OUWr cilble from the clip on the WilWr v~lve bracket.
Ihen lenlOve the assembly from the bulkhead (2 screws). 4 Twis t the wate r valve. to disconnect the cable IrOI11 the operilt ing
l ever .
S Relilling is Ihe reve'so of the removal p.occdure. during which ~dJustl\lcnt should be m~do. as described in Section 40 fOf the heavy duty healCf On completion. re li t the rudiutor hose and fililhe cooling SYSt(:rll . us described in Chapler 2 .
43 Heater assembly -re mova l and re fillin u
1 DlsconnOCl lhc tJiltH:ry ea.th ICild. 2 -,,,in the COOIIlI1l. rei!;fliny 10 Chllpte. 2. II neCCSSilry. 3 sconnect th e Wiltcr hoscs from the hoale. he;!t e.chanuc. (phOtO). II I> 2111111
- ' = 1 --·-~··""I c,
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F ig .
11 .27 Heale r COl\trol cilhle ncJju stm ont on heilvy cJllty hl"latot (Sec 40)
A /),., ·{n/w/III If,}!, CQII/lo/ft'vct
Il"'·I·"1>.1 VU[ CO""'OL U·OL(
".."Tt"CO""'OL -NIL\[
Fig. 11.28 Willer varv e o n heavy duty heilter (Sec 40)
43.3 H eiltel water hoses
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~'l4 Chilpter 11 Bodywork and fitting
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complessnd ~" to IcmOVI! ,OIly I.nolar ,,,",,,"1111)11 Alh,,,)attv,,lv pl;)c" clothS JII,l/or I1CW~I)ilP'''S 1)(!I\!;o1th In ,11",,, 1, al'V SI"lld!!" 11 Remov" thc (.over pan,,1. tn!I"lh," wllh II", lw,'t nxch'''''Ie! 10 watel cOI"'~~(:IIOIl \J,;~k...r. f,om th,~ IlLII~I"',1,J (2 ~r:tI~WS) 5 SlackclI till! !1"o1ll~N'" l(l(.k"(li. 111,·" ""''''Vl) Ihl) !)"oI,I,~vf)f The locknut IClIlIlICS a 5p,,(;'al p"!J Sp""""'. ,IV,HI.lhl" hOIll Foul. hllt It IS lIot
d,fficult to 1;)10'11:;\1" ,1 10,, 1 wh'<.-II which wIll do Ih" 1010 6 Rcmove til.., I'n,r,d I';IV (1 ~':II!WS) WI""" til",,, IS a celli'" fOI1S<)t.i. this must hc ICmOVl!ri "Iso (lcfcl to SC,.t'Oll 32 ) 7 Remove Ihe strJ(!IIllli coll,"m sl"olld (2 ~n"ws al tl", hOllUm. th(!n
pull out CO'lneCI'Olls (1 '01""W ",II.h) 11 D'SI:OII'H,,:t 110" I,ll.'" ""IIt h"~",, h",,, 110" 1"'011," TI"·,,, ,',,:") '''' tI'" 'lilnrt;)ld lHloll<;r .",<1.1 "" II", 1 .. ,,,vV d"IV 1,,·.110" ? Rel\\o"" tlo" IIIw,,, d.l~h 1'.,"0:1 ~"I'I""t ~I"y (1 ~""w) 13 O,s",,,,,,,,,,t II", C,,,,I,,,I (""1,1,,,, (,'"'' 11,,· 1",.,1", .",,1 11", 10",,10"
J.se Rel\\ov,n\! lire il~ht")V
hlowef If!a 1111 Heatcr ass(l'lIhlv (Behr) dismantling Runl""" Ih" d",\I,I",IOI 1I"I'~hol(1 (1 clop) NOI" th,lt Ihe fl.1p ""ll;)UlS II) Ihe 1"""'1 SI,,:tl"') "f the IU)lISI"!! ? R"",ov" tlw ,: I.IInps ~"r.""n!1 Ih,~ IWO h"lv"s 01 the IIm,s,n!j, "srn!) c"ciop pi"",. Iklll"'" 11\" "I'P'" ~"r:I""', ~'Ol"pl"jll w llh tilt, m01o,.from tlw low"" ~""trOI\ 3 Rem,,,,,, tI,!! 1",.11 !!~d'."HJ'" ""tI I",m Ih" I"rn,,, Ihe low!!' SCCllnn
43.16 He,ltcI tnounilng holt (a,rowed)
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Fig .1129S . tilndard Beh r heater (5 1 ec44)
2 Mowr ,1nd f"n 3 Upper housing 4 Lower housillg Deli/isle, " 5 Helll CXChaosc connection 6 Neil l crl /lye( COVIN plale 7 C ... liJllger 8 Oll/rol {hll' 9 ;,001l011/,1fJ shaN cal CXC hiW 10 Dis/rib I ger sC =
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)96 Chapter 11 Bodywork an d fittings
of the housing, then remOlle the heal exchanger from the 1ramc and lake ott the fOilm pilcking. 4 To remove the distributor flap from the housing. remove the clip and withdraw the conlrollcvcr sideways. 5 Remove the rcgul<110r flap from the lower section of the housing, Bend bJck the 2 claillping straps sulticicnlly \0 enable the conlrollCIICI 10 be withdrawn (liter i, hilS been turned tow;1rds the side, then remove the regulating flilp. 6 Remove the retaining straps for the blower mOlor cap. by pressing outwards from the inside uSing 11 screwdriver. 7 Deweh the mOlOr from the upper sectioll. Disconnect the motor leads, remove til(! <1 rewining clumps and remove the motor and filiI inw,uds. a When reassembling. positIon thc blower mOlOr so that the clectric control lever from the si(lc.
11
11 The remainder 01 the reassembl y procedure is the reverse 01 the
r emova l procedure.
45 Heate r nssenlbly (Smiths standard and heavy duty) -dismantl ing and reassem bly
Standard he,1ler I Remove clips A and B (Fig. 11.32) ilnd remove lhe heater housing
sidc cover complete with flaps (15 screws) .
Heavy duty healer 2 Remove clip A (FIg . 11.32) olnd remove thc hcater housing SIde cover complete WIth flaps (15 screws)
All he,lIers 3 Remove thc heat e~chnnger nnd 10,1111 sen I. <1 Prise off the c"clip nnd remove the Ian I.om the blower motor shall. 5 Detach the blowe r motor from the support (3 nuts and holts). 6 Reassemhly is the reverse of the dismantl ing procedure.
Fig .
11.30 Stilndllrd Smiths h eater (Sec 4 5 )
1 M%r assembly
2 COVt·( and black!:t assembly 3 Control valve operatillg le vel
4 Righr·hand housing cover 5 Dis/ributor flap 6 Fan
7 Control v 10 Heal eXChanger seal 11 Plenum cflambe! cover
-------------------------------~ 灲潣慲浡湵慬献捯m

7
) Chapte r 11 Bodyw ork an d f ittings 197
Fig. 11 .3 1 H eavy duty Smith s h eate r (Sec 4 5)
1 Housing 6 Plenum chamber covel
2 Hot ai, supply /0 laciil 7 Ois/fibulor flap
connec tion 8 Right·hand hOllsing cover
3 OrlniSlef hos e connectioll 9 Cover ,ltld bfackel assembfy
4 F.ln 10 MOIOI .lSscmlJly
5 HeM exclllmgcr scM
4 6 Dcmister nOlzle s -remova l alld refiuing
r :cngcr's side rtcnlOve thc glove COlllpiUll1lCllt by Ullscrcw"'9 the 7 screws iI the to · 'ld 2 nuts (ll lhe hall()m. Also discoIH'oG I the glovo compJrlrllCIl h\, ,19 Icads. 2 WIthdraw lhe hose frorll\he dCnllSlC . noale (lnd remove the noule (I sClew ). 3 RefItting is Ihe rev erse 01 the .cmovill Il' occ du.e .
Driver'S side 4 Initially proceed a s descullnd in palagr,lphs I , 2 and 3 0 1 SectIo n 41. Additionally remove th O ashu".,. and CIgar Irgluer .
o
Fig. 11.32 He ate r d istributo r flap (A ) and regulator flap (S ) clips (Sec 45)
5 Remove the inSllumen l cluster (4 screws ). disconne<:ling Ihe speedomele . d.ive cable and elect.ical conneClio ns . If lhere is any doubl about Ihe position 01 ~my 01 Ih e ele<:trical connec tions, make a nOle of them fn SI 0' ,111. 6 Withdraw the d ernis te . noale hose i1nd remove the demiste r noule (1 scre w), turning it upward and ou twards so thililhe inlet side 01 Ihe nonle can come ou t first from th e in strument cluste. opening. 7 R efiuing is th e reverse of Ihe removil ' procedure .
47 Fac e level vonts -removal an d re litting
Passengers side 1 Hcmove Ihe gl ove comparlment by unsc!ew 'ng 7 SCfcwS at t he lOp ;Uld 2 !llltS ,11 th e bottom . Also drsconnec t Ihc glove compar tmen l Irghlrng leads. 2 Wrlhclraw I he hose( s) h om th e vent. 3 Remove the vent by unscrewing the 2 flu lS which a rc access ible from the reilr of th e pan el. 4 Rcliu in\j is lhe reverse 0 1 the relllovill procedulC.
Driver's side 5 Inil iall y p'oceed as described rn paragr aphs I, 2 ilnd 3 0 1 Secti on 41. Addrlionally remove Ihe 9 screws at the lO p ollhe rnstrumenl pilnel tllm. 6 W,lh the hose(s) Irom the vent .
7 Remove the ven l by usncrewlIlg the 2 nuts which i1re ,1ccesslble from the reM o f the p.,lnel. 8 Relru.ng is the reverse of the remova l procedure .
••
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Index
A
Accelerator cilble removal ilnd refining -14 shnft ilnd pedal removal and refining -75 Air cleaner removill Jnd ref,nrng cal buren or mod cis -68 fuel injecllon models -80
P rnator .,rushes inspecllon. removal and refilling Bosch -202 Femsa -203 Lucas - 202
dismantling and rcassembly -203
removal and refining -201 Antifreeze mixture -60 Automatic transmission descrip tion -122
B
downshift cable removal. refi11ing and adjustment -121 extension housing oil seal renewal -121 faull diagnosis -127
maintenance. routine -123
removal and refOlting -123
selector mechanism ildjustment - 126 rcmovill. overhaul ilnd refl11lng -125 speclflf:iltions -103 SI.1r1er IIlh'bilm/reVerse lamp switch remov Bilttery clrilrgmg _ 201 description and testing -200 removal and rcfll\lng -201 Big-end bearings -37. 52 Bleeding the hydr centre console -189
demister
noules reOlov description _ 174
doms-178.180. 18210 185 face level vents removal and refItting -197 facia panel -188 fuel filler flap -188 heater -192 to 194. 196 10 ) bodywork and under/rame _ 176 routine _ 116
uphOISlCry
and carpets -176 mirrors
-
192 open rem quarter glass assembly
removal and refitting -186
re~r qllMlcr trim panel removal and refitting -185 repi'lir millor damaue -178 minor damage -176 sent belts -191 seats -192 sunroof-189la 191 lailgate -180. 187. 188 torque wrench scuings -173 windscreen -180 Bodywork repair sequence (colour) -174, 175 Bonnet release c p ipes c
Camshaft (3.0 litre engine) retitting -54 removal -50 Camshaft and camshaf t bearings examination and renovation 2 _8 litre engine -35
3 .0 litre engine -51 Camshah and front intermediate plate (2.8 litre engine) refilling -41 Capacities. general -6 Carburetlor (Weber) aulomat ic choke
adjustment -71 removal. overhaul and retitting -71
dismantling and reassembly -69 general -68 idling adjustment -73
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rernoy .. ' and refl Uing -69 spcc,'iC d'ilUlinU 59
(IlIvchells
G3 e~p:mSloll I nnk 6<1 Ian hub l)()nllllH (30 hilI] 1110<1111,;) 64 f~ull (II;)Ul1osl~ 65
flll".U -
60 lIush"'9 59
",nmlen,lncc. roullllC 59
'ild,nlOr
GO speclficn llon5 57 lem,)er;!lurc unuuc Sf:n(Ie. unil -134 IhcrmOSl<11 -61 10Htlle wrench selll ngs 57 VISCOUS drlv\! 11'111 -63 W1)ler IWIllP 61 Crankca se ventiln tion system 2.8 tol'c engine -39 3.0 rillC engine 53 Cranksh1)ft 2.8 li l.e engine examinat ion nnd rcnoviuion -37 refilling -<10
3 .0 til.e cn gine examination lind renOV1'l110n -52 Crankshilft and main bearings (3.0 litr o engino) removal -51 Crankshllft pulley refitting (2.8 hIre engine) -44
removal ( 3 .0 litre engine) -50 Crankshaft r ear oil seal (3.0 litre engine) .efllling - 55 .emova l -51 Cylinder bores ~xaminalion and .enovation -36. 51 Indo r heads 2.8 titre engine dismanll ing .• cnova lion and .eassembl y -35
Index
D
refining - 45
3.0 litre engin e
. eassembly -55 refining -55 .emoval wilh engIne -49
removal wil h engine in car -49
Decarhonising -52 Dimensions. vehicle _ 6 Dim-dip lighting system _ 226 Disc br1lke s scc Front disc brakes Distributor overhaul 2.8 hlle engIne -93 3 a !r1l0 cng,ne -92 rcmoval and r efIlling _ 90 Doors eXle.io. hllndle ,emoval and refilling - 183 lock 1Issernbly removal and .efilling -184 pillar swi lc h -224
priVill e lock ,ernovill and ref'lIing -185 fnllics tracing nnd feCllik al ion -178 remOle conlroi hnndle removal and refilling -180 Hlmoval and rell\1l11g _ 185 Irim j>ilnel removal and ,efi ning _ 182 window Irnm c
moul(II ng nnd door wealhcrSlrips
removal and refining -185 rcmoval and relining -185 wmdow glass removal and retilling - 184 window regulnlor nssembly
r emoval and relilling -183 Drivebelt s .emov,,1 ilnd refil ling -63 Drum brakes sce Renl drum brakes
E
Eloc triclIl.system -198 e/ seq Electrical systcm altell11110, -201 10 203
ilu xiha.y driving "ghl -212 bmlery -200. 201 bulbs -199.21310217 ciga. IighlOf -225
clock -223
d escrip llon -200 dim-dip ligh ling syslem -226 laull diilgnOSIS -19. 233 ""sher unils and rel1lys -225
fuse s -199. 220
headligllls -211 10213 horn -220
inSI.ument clUSler -22 1 inSI.ument vollage .egula lor - 226 Inmp5 -21410217 mninlenance. fOUline w 200 mobite r"dio equIpment - 226
precautions - 200
rildio /casse tte player -226 specif ications - 198
speedomeler cab le -226 Slmte . mOlOr -207 swi tches -223 10 22 5 lailgall) wash er -217 laHgme wipef -217 to.que wrench sell ings -199
w indscree n washer -219 windscreen wiper -21810 220 wi.ing diagrams -235 10 249
25'
Ii
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