1974 FORD CAPRI Workshop Manual

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'6 Routine maintenance
)
Every 250 miles (400 lUll) or weekly -whichever comes first
Check the engine 011 level and lOp up " OCCCSSJry (Chapler 1) Check and adlus t lhe IYIC pressures (Chilplcr 10) Clean the windscreen and windows C lean the hcadlamps
Every 6000 miles (10000 km) o r six Illonlhs - whichever comes fir s t
£II[1ille (Clwpter 1) Change engllle 011 and IIher
Cleiln oil flilm c"p Chcck 10 1 ,IllY fluid leaka!)e ,n enUme CO'llp:lnUlCIl1
Cooling syslem (Clwptet 2) Check cool:'lnt level
Fuel syslem (Clmpler 3) Check idh"U mi~lUle (cmiJUiello1 IllUdels onlv) al I"SI se.v,ce ollIe, overhaul C heck idllllg sj)ee d
Ignition sys/Cm (C/I,Wler 4) Clean ,1nd re!)"p Sl)".k plu!)s (.:on!nC ' breilkCl Illudels olllv) Cle an and check d'Shibu\o. C"I). '010'. HT lealls mId co.1 (COllWct
bleaker modcls only) Check elwell angle (cOntact b.e"ke. mo Cllltch (e/Mllter 5) Check adjuSlmenl
Bri/king sys/Cm (Ch,1pter 9) Check selva
Che ck hydraulic flu id h,vel
Ch(: ck p"ds :'Illd sho(:s lor wear Check h.ake hllcs and hoses
Suspension .wel stvi'ring (Chi/pICr 10) Check tyres 10' w ear and dam:lge Check steering COmp{lIlCnlS l o r w e:l l "lid d.1nlilue
Bodywork. .111d fittings (Clwptef 11) C lu .. >ek se"t belts fa. we .... damage :lnd secwity
Elvc(ric.11 systcm (Ch,7jJ(ef 12 ) Check Ope.iltoon 01 "Uhts Check wilsher flUId levels Check b.1ltery eleclrolvle lev el
Every 12000 miles (20000 kill) or 12 mOll1hs - whichever comes first
III .1(/(lIlioll 10 Ihe 6000 m/le sciler/Ille
Engine (Ch.1f)ter 1) Check and adlUSI valve clearanc es
r"' .......... ~.~-.... ._ •• -.... __ .... . 3lii1&l •
Cooling system (Chapter 2) Check condition "net tension of 1111011)<1101 dflvehelt
Fllel sys tem (Chapter 3) Tighlcn inlel IIHlnl lold boits/nuts Check vacuum hoses Check e~hiluSI syst em Check ll1r ctonne. temperature cOllllol (,I applicable) Renew fuclllllC ' (fuel injec tion models only)
Ignilion system (Chapler 4) lubricate th e dis'flbulOf (conUlel br eake r models only) Renew the coninCt hu,akcr points (II nppllcJblc) Renew the spMk plugs
Transmission (Chapter 6) Check ool/th"d level Lulmc;ue automatIC 1.,'Insmlss,on IInk:'lue
Rcar axle (C/MplCt 8) Check 011 level
Bli/king system (Chaplet 9) Check v,lcuun' hose
llliJllc:'l1C Ihe handhlake Imk,loe
Suspensioll {//j(J swelill!J (C".1plt~( 10) Check condItIon and hlllSlon o f POWI.II ~I!'tllllli dllvthtl1 (II .1l1pllcal,
Check MlspenSlon 101 we;" ;111(1 d;1Il1.1!)e
Bodywork ,1I)d fillings (Clwpler 11) Check opera lion of all locks Check secu.ity 01 dOOf check sl.aps
LlIl)fIcalC locks. door c heck S\','P5 :'Ind fuel fdler cap flap
Check underbody pr olCctive coalm!)
Electrical system (Chapter 12) Check Opcra1l0n of all eleC111!:al IIcm5
Evcry 2<1 000 llIiles (40000 kill) or 2 yc;u s -\Nhichever comes firsl
III ,1(/111/'011 10 the 12000 111"'1 $d'~'f/u/e
[nyino (CIWpICf 1) f!ell'!W crankC:l $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
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7
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5 -
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C ~
1 J
U
i( 8
2 --I-~.'-"'\r__ / II [!CJ.:=J-~
-.... ,I /
i(
• •
Recommended lubricants and fluids
Component or system
Engine (1)
Manual gearbo x (2)
Autolllatic transmission (3) Black dipstick Red dipstick
Rear ade (4)
POwer steering (5)
Br luhricant type or specification
SAE 20W/4Q o r 20W/50 multigrade engine 011
SAE 80 EP 0.1 to Ford spee,flctlllon saM 2C 9008 A
ATF 10 Fonl speclliCil tion SOM 2C 9007 AA ATF 10 Fonl specillcmion SOM 2C 9010 A
SAE 90 ad to Ford specI fiCatiOn SaM 2C 9002 AA
ATF to Ford specd 'C[lllon ESW M 2e. 33E. SCM 2C 9007 AA or DZAZ 19582 A
Hydraulic fluid to Ford SpeCifICation SAM GC 9103 A
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Conversion factors
Length (dis(,1IIce) Inches (Ill) X 254 MIII,mClr(:~ (nun) X o 03!l4 FeCI (h) X 0305 MCI,(l~ (111) X 328 Miles X 1 GO~ Kilolllc(.r,s (kill) X 0621
VOlllflll! (C.~/J.1Cily) Culm: lIu:hcs (eu 111. Ill') X 1 G 367 C,d"c ("nl,met",,; ("c. CII1') X 00131 IIl1PC",llllill1s (hill> pL) X o G68 L'II,-s (I) X 17G ''''(JeIl,11 CltJ,"IS (11111) ILl) X 137 LI''''~; II) X 088 ''''11C'',11 (1,,;'115 (11111l '(1) X 1 lOI uS 'III;"'" (US 'II) X 083) us qlln'ls (US (11) X on·IG L,I11!S II) X 1 057 l"'pe",,1 (pllons (Imp (I~I) X <1 !;4l,) L,I>, -5 (I) X 0" l"'p,,";11 !Iillions (Imp 11011) X 1 ]01 US !j"II"n~ (llS !i.II) X 0833 tiS Bailon,; (US Hal) X 3785 L,',.·s (I) X 026·1
MilH (wl!ighf) Q"nr.cs (OlJ X 7835 G"",,~ WI X 0035 Pnumls (110) X 045·1 K"f"J,."ll~ t~B) X 2205
F()ICI! O"'u: ,,,; I", cn (OIl, (/) X n i'1t!
N''WI'''IS (N) X 36 I'o",ul'; Imr.e (lhl. Ih) X 1 1\.18 N"Wl""~ IN) X On~j
N"wt""s IN) X 0' K'h".: ... m~ I.",:" \~.!11. ~ 'I) X !'lSI
PIt.'SSIIfl- ' l'oun,'~·lnrce 1,1,;1 SIIUil!!! I"dl X 0070 K,lo!!,i"" S 10" ;" i'''' SqUi'''' X 1'1223 (p:.': IIM,n', lbjln') ,:1 ,111'''''''1''' (~!II/c:m'. k!l /cm') I'mll1(ls·lolce IICI lOq";"!! ,"ch X 00G8 Au"" .. phc"" (,,,"'1 X 1.1696 (ps'. 1101/'11'. Ib,"II')
1'0Ilnds ·lo,ce pc. 5'11"',e ",,:h X o OG9 B;,,~ X 1.15
(1'5'. ItJljm'. Ih/m') Pounds· fence I)()' $(I"".e ,,,r:h X G 8% K'I()p"scal~ (!d' .. j X 011\5 (pS I, Ihl /m'. IIl/m'l K"np.1 sr.als (kl'.1) X 00' K""!!'i""'; '''1(;'' I"" Sqll,11C X
'" •. unl,,,,,,I'e (~~,Il.:m:, k!I ,·';"'· M,n,Io,H (mha. ) X 100 1';,,,,',,ls (1',1) X 00' M,I\ot.,u (mh",) X 0011\5 PI,unrb "lOti! 1":' "'III,,,e '''.-\, X 68 !Jllu",e oneil X 0036 (ps'. II,! ",: IIl/,n')
rorqllc (momCllf ollorce) Po"",ls·lo I'nunrls·t o,ce ,nc he,; X 0113 NI'Wh'" ""'I,,,,; (Non) X 8 85 (Ihl 'II. III ",) 1'0"ncl s·IOICe Inches X 0083 Poumb lo'cu ICCI (Ihl h. lb it) X 12
(Ih l '". IIJ 'n) l'olO,,,ls·Io,c\! 11,;,,1 (Ihl h. II! h) X 0138 KoIulI';,,"s·tn,cc "",I"IS X 7233 (kill m. ~\, 111) Pounds·la,ce l e cl (Ih l h. Ih h) X 1356 Nuwlon mel,cs (Nm) X 0738 Newton met.es (Nm) X 0102 K,IO Power Uo,se,}Qw,," (hll) X 745.7 W;IIIS (W) X 00013
VI!/ociry (speed) M, les pe. hou. (1IlIIes /h •. mph) X 1 .609 . Kilometres pc. 110ur (klll/hr. kOhl X 0621
Flwl cOllsumprioll' M,les poll gil1l0l1, Impcllill (mpg) X 0351 K,loon"ucs pc. 10(11) (kill /I) X 2825 M,les pCI 1).111011. US (mpu) X 01\25 K,lolllct«)s II .... lot" .. (kon/I) X 2352
r CII'pcri/fmc
Oey,ec. s F;lhrenhc' l - C ~ 1 8) . 32
.// IS cummon pr;/Clit'l! I U CQIlVl!r l !tOIll miles per y,ll/,J/! (I1IPY) IU IIlres/IOO ~"omelrf!S (1IIOOk l1l). wlletl! "'PY ({"'pl!t/iII) x II 100 Am ... 282 iJnd III/IY (US) ~ If 100 km '" 235
(nchl,~ ('n) FCCI (it) MIl(:s
Cu b,c "H.I",~ (O:u Ill, 'n') 11111)1"",1 poulS (Imp 1,1)
"nile"", '1";,,1 5 (11llp '11) Imp<,,,,11 'l"o1"s (Imp '11) US quaots (US 'II) hUIl""al 1I.1110<1S (lu,p (1.01) IlllpcII.11 U.,lIous Pl11p 11,,1) US ~F'IIOfb (US !1.1IJ
QUilt:",; (U/) f'()"ml~ (Ih)
OlJll<:"S I''',.e (nd. ", ) l'Oun,b lo,r." (H,I, Ih )
Nl!wlon s (N)
Pounds·lo,c!! 1)1;' Stl""'" Inei, (ps'. II,I/m'. Ih /m ")
POllnds· lo,ce pc. 5(1",1.e II".:h
(pS'. Ihl/m'. Ih/'''') I'ounds·lo,cn I)er sq"",,, ",,:1 (pSI. tlli /m'. Ih/m') Pounds·I')lCll pel SlI"ille IIKII
(ps,. Ihl/Ill'. Ill.',,,') K"llpa~cal~ (~I',o)
M.n,t"" (,,,,,;,,)
M,ltoh;" (mh",)
M ,n,I"" (mha,) M ,n, t .... '. (mlom) M,nunet.es ot ",c.cuoy (nHuH!]) Inches 01 W"h" (II1H,O)
Pounds·IOlce 'ncheS (Ih l Ill. III '") Pounds·loocl,; 'ncllUS
(Ib l on. III 'n) I'ounds-Io,ce IIlches
(Ib l in. Ih ,n) POunds ·fo.ce l<,let (Ibl II. III h )
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ounds·lorce Ic.el (Ibl h. Ib h)
NeWlon met.es (Nm)
. 1I0.sel }Qwer (hll)
. M,les pc. hour (rniles/hr: mph)
M, les pe. 1),1110n, Impc.roal (mpg)
M"es pc. »;IItOlt US (mpg)
(F·32jx056
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7
F a ult diagnosis
II)/lodue/ioll The vt!HCI.., ownor who cicIlI s Ills Or he, OWII 'l1;'IIll!:Il;lIl1.;U iu:,;()!(Io IiH 10 Ih o reCOln r11Clldc d schedules should 110 1 h(lv,} to u~e Ilus ~C(,;tIOIl o f Ihe nlCClf'ed ullervals, sudden 1",luIO IS CO"'IIo1I"llvl:ly .;lIC F;'lullS do nOI lISU I,ul " dell"l:lIl1e wOlk w,1I he 1I~'Cess;lIy The OWIlt]! wllo III"kes h,,11 ,I 110/,,11 h,lpll",,,,,1 ildlustmellts 0' ICplaC'IIl'Cllt s II"IV he ~"cce:.sl\ll III
1:"'"';1,1 I""it (or tiS svmplO"'~), hUI he w,1I toe II0lle t ill) W'~H'" 11111 1.11,11 l eC"'I. ,111<1 he m,ly well 1I,llIe ~penlnlOle 1'llIe lind ",olley Ihnll WIIS """"~~;"Y A COdlll ilild IO!JIenl "PIHO,l<.;h w,1I be lound 10 Ix: """e ~,'I'~I;I(.tUlv '" Ihe 10llU lun Alw;IYs I.I~" IIIto ;Iceollllt ,IIIV W,,,""I\l :"!l"S h. ,'IIII11''''15, etc and .cIII(:u,he. thill I,ul\l.e 01 cO"'p0l1clll5 s\lc h ,,~ t\l~'" (J, ~p,"k pluus IlI VellfV Ihe Iilult. Tills IS sII"ply " III,'IICI of hCIIIU SUIC 111,11 you '''''N ".1',11 Ih(l sYlIIl'lOll1s ,lie belolc ~I,IIIIII!I WOII.; T lus IS p;ullcul,IIly ""1"'-"1,1111,1 YOU ille IIIIICSItU"IIIIU i11,1IJ1t 10' SOlllconc else who IIIilV 1101 ha,,, ct(:~c"1r(:d 'I lIe.y acclllately
0011', Ollerlook Ih e obviolls. Fo, e~a",ple, II Ihe IIchlcl!! W01I'1 ~I,'" '~Ih.,,," p(:llol lf'lhe IiInk1 (Ooo't l;1kc anyone t:lsc's word all Ihl$
1).111 'Cul,,, POIII!. ~IId don'l t"l~tlhc luel UilUUC cllhcll) If i1n clCClIlcal 1",,11 I~ ,,,cr,c,lIed. look 10' loose a. bro~ell WIICS belo.e dIUU"'\! OUI the Ic~t !/t;ill
C
U'e tI,e (liscase. n o t th e sym ptom. SuhStltUllng a flilt b.1ltCry ""til il 1"lIy ch;IIW,d olle Will \jt:t you 011 Ihe kUII shouldc., hUI II the \ul(!~dy,,,\) C,IIISC 'S flOt i1Hendel l to. the flew hall", y WIll fJo Ihe SdillC
W"Y S'''"I;nly. Ch,lIlUor,U OII.loulcd spll, k "lu\JS 101 ,] new's\lt W Ill \JCI YOu "'O'·,n!) "11"orl. hUI 'CIIIIIIIII,c' Ihill the .eIlSUIi 10' Ihe lou I",\) (II II ..... ,1~I1 I ~''''!''Y .111 ",colleCI U.;I .
OO'."t t" k l) iH, ythinu fo r g rante d . l'a,"cul 'illll,"U II,ulullllthn hool 10' Illolllhs). "n(1 do,"1 1');I~e compon.'nIS out 01 il 1,1\111 diilUnOSIS ~l:ql""'CC JuSI 1>e(;;I"$C Ih ey ",,1 IIew 0' ,,)cen lly IIll",d WII"" you tio IIIInily d'iI!./nosc a (f,IIIcult lillllt, vou'li ('JrOhllbly .""I,se Illill "lillie cIII(lel1(;c wilS IhelC IrO"'lhc stalt
Elcc(ricall,1!1lls EI.:.'Ctrlc,,1 lilults 1':,1" bc mo,e I)uullnu Ih'lII SI.aIUhlfo,wa,d "'CCIl,11I1CIII lalhucs. hut Ihcy MC 110 less susceptible 10 10Utc;ll "n"IVS'S
II lh!1 haslc pllnclplcs 01 OpClil llon ille 1I1I(lelslOod. Vchlcle clecillcill WII"'!) C~ISIS til c~lIcll1c1y "nl'I\IOIl."lIle condi!t Olls hent, IIlb.atlOIl IIlId chcllllcill ill1l1ck :1ml Ihc 1"51 Ih,,,ys 10 lo,,~ 1o. ,lie 100'>1) 01 ,;OllOIiCI I connecliolls 011,,1 b.oken o. Ch.llc(1 w"es, CS!lCc.I"lIy whcre Ih.) WIll'S I';)SS th'Ollllll holcs "' Ihe bodywork 0' ,lit) suhJ ... :I In IIIII'ilIl011 All '''I.!wl·l,o,hed V .:IHcles III CUllcnt prOdur-IIOn h;lIIc one pole 01 Ihe lI,ule'y 'Cil rl hutl'. Ie connecled 10 Ihu vchlclu hodvwOI~, ilml III
lIe"dy ,111 I"orle'" vehlclcs II IS the neUIlI,v!) ( ) 1e""",,11 Thl) va"OU5
"tU(:lu(:;,1 (:o"'tlOIIenIS mOIO'S, bulh hOI(lll'S elc . ;I.e "Iso cOI"'('''I:I",(1 to e.II III. ellhe. by lIIe,lllS 01 a leild or \1"~'Cllv by tlM}If fIlounllnuS
E I('Ctu(: (:Ullmll flows Ih'ough Ihe CO'I'I)Ol1elll and Ihell hack 10 Ihe b"lIe.y 11':1 Ihc hodywolk " Ihe cO"'I'Ol1ell l mOU1I11I1\) IS l(lOse o. <:olludccl, 0' II il lI'lOci pnth bilC k 10 Ihe IWl1clv IS 1I0t av",!"I)lc. ll1e
CHCIIII WIll be IIICOlllplcl!l "IId m"lhln~l.on WIll le$ul l The e"\)IIIe "lid '0' \)c;IIIKJ O ;lIe "Iso eillthed bv lIIeOlllS 01 flc~,hlc lIIel,,1 ~I,,1I1S to lhe hody Or slll)h,lm(!, II Ihese Sll,lPS .11e !{'osc a. ""5SI11\1, SI;lIlcr mOlo'. !lcllewlOr alld 19",I.on "ouble IlIlly rcsull Assulluny Ihe cil.th .Chlln 10 bc sat,s!xto,y, eleclllCOlllaults WIll he duc ()lIhcr to componellt 11111l1uI1(:I,on 0' to delccls III Ihe CUIIClll ~lIl)l1lv Ind,vldu,ll componentS ,,'C de"lt ""lIh If' Ch;op te. 12 . II supply ""nes "'0 IlIokcn 0' clilcked IIl lerll;lllv IhlS resulls '" iln open,cllcu,!. IIlId Iho eaSleS I w"y 10 check for 11115 IS 10 bypass the SuSpCCI wife lelllPo.allly wllh a Icnuth 01 wi,c hi!lImU (I c rocod,le clil) Or su,wble connCC lor m eilch cnd Altemmillely, 11 12V test lillIlP ColO be used 10
vCltly the p.esence 01 supply lIoltage 011 VilltOUS pomlS along the WIIC
lind Ihe IJle II ;I 1J",e po, lion 0 1 11 hlle WlfC touc hes Ihc bodywolk 01 otl1Cr e;ulhed IIICtal pall. Ih(l cl(:Cloc'tv wIn lale Ihe 10W·fCSlsrance p"th thus fO"II(.-cl bOlck 10 Ihe blllle.y Ilus.s kno",n as il ShOrl ·cifcuil. Hopefully a ShOIl'Clfcull Wilt blow 11 luse, bUI olhClwlse I( may causc bUIO.ng 01 Ihe IIlsulatoon (am! pOSSIbly IU'lhef shall cIrcuits) Of ellen a flfc ThIS IS why 11 .s lIlildlllsable 10 hVPilSS pcrsls telltlv blowtn9 luses wllh silver 10110. wife
Spmcs [II/(I tool kif MoSI IIdllclcs Me supplIed only " 'Ih sutl,clelll 10015 10' whtel chanUII'll, Ihe M,lUl/t:lII111CC iJml millO' "'pi)i, 1001 kll dCWd cd In To()ls a",/ W()'/o:"'Y I.obah!v s .. U'CICIll 10' those .e,)3"S Ih at mOSl n,o!OuSIS would conSldcr atlt~m('JlInu al the ,oildslde In add ,t,on a lew Il\)ms whIch C(ln bc I't\(:cr
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20 Fault diagnosis
Carrying a lew spares eM) :\l1VO you a lono walk!
WHhou t 100 ,ulIeh trouhle in the event o f il hrC S ,Im/( I"uys. dm/JI .1IIri ,:ollt'c/ly Y;'I/ II"(/ III h:;J(/ .~/I{I"III!lI:,lIJ {II"Y .:1H>II1I" to 11).11:/0 /I" .. fllllY '(ltllu.'.\'{ fit"" lin-,/lsllI/w'IIt
DrHII/mim [(JIm, (:lIlIdulI.~VI IIlId C""Ii":II"'HI~'." I'omls (;'s ;,/I/lII(.','I/)/e
IJllv/.'lmll(s) ,.'/I11:II/VJlCY IYl't' m"y suffu;t, SlIill!! {(I,ft'S S •. '/ of //111//:'/1,,1 "ylll bill/,S 1/1/ 0/ ",dlll/Ol 5<:;,11:, ,mil IlOst: '>,md.1UI! t"~II;III.1'1 /),111(1I1!IC Roll OlllllilJIMlt/y IIIl'l' Lf>llylll of sulillflll WIIC Lc"yllt of ci.:cIIlC,llllt·.
rUiC" Of mSIICC/IQIII;III'11 (eilllliot/blt' ;,S II.'S( I;IIIJIJ) OMlt'IY 111111/1 Il'mls Tow" Q/IC Iym(/Oll WJiClllloo/lllY ,ow/osol Llfll! 01 c"Yllle Oil SeMcI I eMI olltyr/wlIll(: /f",d Emeif/CoCY WII/({SCIt'ell W(JIm ({live cl'II$ Tube 01 Idlel IJ,1S((;
II Sllilro IU(l 1 IS Cil",c< I .• 1 Ciln dcs'Ollod for th(l pu'pose should hc uscd 10 m"l",l(~e rrsks of le ohvlOusl y senSible ilems !O carry u addl1ion 10 Ihe nbove When 10urll1g nll,oad 11 mny ue advisnu le 10 carr y nddlllonnl spares
WhiCh, evon 'f you cnnnOi III thcm yowscll, could snve hav'"(J 10 Willi wh,le p Chi/eli {JII( I (/U Ol/it' eab /es Cy/md/H " ",7/ IIPsll:rn AlfclI/MOt /)lIIsiles Fllel (Jump 111/1.11'1 11:11 Tyte va/vI! cote
One of Ihe 111010llng 0'ganlSilll0ns w Engine w ilt no ! starl
Ellgillc taits 10 ((IIf) W/IL'II slilrlc r ()p vra le d 1' 1;11 h~lll.'ry (.ud,;,,!!,!, u~.., rlmlll'uolds, 01 push Sl.1rt) nnllclY 1(:rnllll.,ls Ions!! 01 cntlod,!d BaltelY ll.1,tll to hody dd"cl'vu Enwnc e(utll S I,,1)) 100Sll 01 broken Sl.1rtel 1II0lO r (or so lulloid) "",,,ng loose or IJroken
l\ulOn1 ;II,e II1!11srllr~s,()" seleClor ,n W'OIlIl pos",on, or Inhd)!' sW/lcli fHur,y '11""'Oll/SI (lr lu, sw,'ch folUllY
M i'ror mech:u"C.11 ,,,,lure (Se'lUre)
Sli"!~1 Or sole"ord 'ntorrloll rilul! (seo Chaplllr 12)
A
simple les t lamp is useful fot checking electrical fault s
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Fault diagnosis 21
Starter motor ((/rns cngino slowly Parti ali V disch~rilcd b sian) Ballerv terminals loosc or COli oded Batte.v earlh 10 body delcctrvc Enuine ear th s tr,1p loose Slarle. motor (or solenoid) wiling loose Slaricr mOlr ill1crnlll laull (see Chaple. 12)
Engine ((/"'S normally but 1,1ils ( 0 SIMI Damp or dirlV HT !eads check 10 ' sp regnp) Olher ignilion syslcml",,11 (~ee Chapler II) Olhel luel sySlem 11Ildl (se c Ch"plm J) POOl compression MaJOf mechanic;1 1 l Ellgine lires but will not fUll In su!hcicnl choke (cold flfl!)lIln) Arr le"ks al CilrUurC110. 0' mlill m;1",lolli FuClI sta,vatlon (sec Ch"111C' 3) []"lIast rCSIStor de!ecllvn. or OIlier 'H",II Engine ClltS Ollt ;1nd wilinOI roslinl
fngine culS out suddenly -ignition I,wlt Loose or d'$Conncetcd l T wi.es WCI HT Icads o. d'S I"buiOI C;1P ("lIer tr;1VC'SOll!) w;1'er spl;1sh) Co,1 o . condenser lallulc (cheek 10' SI);lIk) Olhc. ignition laull (see Ch,'plfll 4)
Eflgine mistires belore CUlling oul IlIcll,wlt Fuel I,,"k Cillply Fllel pump dClfecl1vc o. 1,ltcl IIlo .; k(H! (dwck 1m dellvl"V) Fuel tank hllcr vcnl blut;kcd (StII; llon Will II" flV,{Io"'1 Oil lI~h"'~II'H C,11l) C;1llJulCIIor nccdlc v"lvc SIII;klll!J (WIU.'1I1 "ppI1c"hle) C,1lUwellor leiS blocked (ha:l COIII,lIl1ln,Hcll) Othcr lllcl sys!Cm l DISCHARGED
BATTERY
lSin.MIN
POSITIVE
JUfl11) Slart lead conneClions f o r neg!Hive earth vchicles­connect le;1ds in orde r shown
fllgine euls Ol1t -olhor eimses SCIiOliS ovcrhC~ling Mnior mcch Engine ovcrhe Igllitioll (llo-clwrgcj wt1fllillg IigM illuminated SI;1ck o. broken d"vchelt felCn$IOIl 0' Icncw (Ch;1ptr,r 21
Ignitioll warning light /lot illuminBted Coollllll loss .Iuc 10 In!emnl 01 CXierr'JI ICJk NOIC: Do 1101 ,11M coM WMCf 10 ,111 oV~-f/"'.I(C(1 ~·lIy"'., Of d,,,",l[Jf1 m,ly I/)SII/I
l.ow cnuinc oil JlfC!ssuro
G,wge reads low or warning lighl Illuminated wilh engillc
rWllling Olllcvcl low or mCOlfeel 0.,,<10 Deit.'Ctivc gllU!jC 01 sendCI 11111 Wife 10 sendCI UIII' C.1I.hC(1 Engonc ove.hC.1l ing O,lllllcr CIO!19c<1 01 byp,1SS v;1lvc delccllvc O,I ,llcssule lehef v'llve dc!ec tlve Oil pick-up strllll,e. ciomled 0,1 pUIllP WOIil or IllOlllllll1\l~ I\,osc Wo,n Ill,l'" 0' h'!J-cn(i hC.1I1I1!)s NOlO: Luw or! 1"t'HlifU III a IImh III"C"f1~" (.'IIYIIIC .J/ 11l;~()VI.'r I.~ 1101 1II.'I:<.'",.","/y,1 (.",lIlSV {o, CIIII{:"/U Suddel! fJf'~SS!lle {U$S ,11 SlIced IS {M "'/!IC SI{Jl!lflca"l (I! ,my cve/l/. .:In',·j. I/le . Crank engine and chock for Sl)ark. Note use of il)sulated tool 10 hold plug load
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En!J"lO noises
Prc-;f/lli/ioll (plirkiny) Of) ,1Cce/efariOI) IncouCCt W .... de o f fucl '!IIII ,rOn IImonU OIlCOOlCCI
DIMlrbulO1 l,lUIiV or worn
Wnrn 0. IllIlI;1(I,u5tod cil,l)urcnor O. Idling setlrllgs EKCCSSIV(l c;uhon htuld_"I) In cnuulo
Wl!i~'llil/!I or wheeLing nuises Lc,,~onu V,1CUUI11 hose
L""kllllJ Ci'lII),I1(:110 1 0. lIl.ulI/old !FI~.kcl IIlnwlIlH IWild U.1S ~Cl
Fault diagnosis
T,1pping or mUlillg InCOlroC I v:1've clcil,.-.nccs WOIll v.llve flO",
Broken ,)ISlon "no (r,cllm!! nOIse)
Knocking or IIWI/Ipiflf/
Unlnlenllon,'IIll(!ch"'"Cill t.:Orl! I'olll) h o.,,' COllltlOnonl 1,1\11, (HCIU·<.1t{Jr, Will'" !>lItH,) ,-I':) WO", !Jlu-end h(l;u"'!IS ('f)!JUlolf Iw,wy klladuHI jH',h.II' un
de.IO;'1(I)
'A'0'11 Ill.1U) be",",!!S (',"nhhll(1 a'lOl ~n()d''''!1 I''''''''')~ WI'" undcr IOild)
P' Slnn st,lp (mo~t 110!I<:1!;,1>1" when cold)
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Chapter 1 Engine
Contents
Par! A: 2.8 litre engine C;JrllS llaft and CillllShJft be,lrIllgs (;XilOlllllilllon ilnd renovil!"Hl Cnrnslwft and frenl inlCrrned l,1!C pl,ne rcfl1l"l~1 Connecting rods ;lnd gudneon pons c",,,nlO\,lllon "nd
,enovntion
C'nnkcnsc venlll;Jl,on Systelll de~Crlpll("1 C' Englile dlsrnill1tlin9 (IlUmc -ulIlI,,1 SIMI up E"U"'() rehl(ml) [W)lne -rcmova l EnOme nnc,lInries -,ell!I"lU~ E'''9''0 ilnClllarrcs -Wlllov;!1 EnOone componentS -eXi!rlllll.1I'O" lor wear En\)IIlC dtsmant lm9 -goner G"ncr M.llo. operat,ons posSlblc WIlh enWIlf! rr1 car
M "IO. operatIons reqrllJlIl(J enOrrr() ,enloval Mr.:lhmb of cnll'nc '(:l11ov;l1 011 IH"'lp rl'~m.lt)ll'''g. eXil,nrrr"l.oll and ",,,~~c"'lrly all pump 'ufrtlrrlU i'lslo"s and C P;1I1 B . 30 IIlre oily/lie C"",\h,lll ",f,1("UI C;1I"~lrafl ""no·"',1
C.""sl>"fl
and c. ,nrsh;rfl !re,'rr'IO~ 'JX,IIllrrlaHon ,mel 'CIlO""l lun Corr'lectorry ,ods and yud(jeon p illS exa"'"'ill,on Cr, lrr
k
c"se vClrtdm,o;, ~~s·t~nr descJlPtlon ~"lrrhlr.,ft ()x;r'l1Ill,' I'On ,IIHI ,...,novatlon C',1n\;slraft ",I'illlI9
Spcciiic;ltions
P,11/ A · 2 8 li(ro engine
General TI,pc 130<.., St'uk..,
Cul)Ot Cilp " 28
'" 25
'" 27
" 15 :j~ ,
38 37 6 :\G 8
" 7 26 22 3> ,
24 20 3 4
;.>3
30 29
" 12 ,
>0 33 >3
" 32 :J5
70 b7 G5
68 77 GO 80
Cliu,~sh Cylonrle, ho'es " '.'"\1("'11011 ,H,d ,cnoval'o" Cylll"I", heads ,,,as~r""I,ly Cylrnde, h("uh ",f'll""1 CylrlH)." he,ub """"v,,1 wulr "'l!)rr1fl '" ca, Cyl",{i(H he;rds """ovill wllh CUlJrllC o"t 01 car Oec,rrl)on'\II'\J \1"'le",1 E'l EIl;I'"C ilIlCllla"o:s
E'''!JI,t!
,me,I I,IIII:s
[Il!!"'" C"" 'I)O"o.;"ls E"B"'e (1'~Ill"nll,n!J ['"1''''' ',~,'s','''''I,ly Hywh",,1 ,,,,,,,,val
I(;j,wou
""IIov.1 1
\)0)'\1),,11 \1("",,.11
Flywir""lld"""plale f!X ,I!lUnil l(On allli IflnOVill lo n
Front covc, ,cmov.11 Gcm:ral descI,pt,o" lub'lcat,On syslmll (Icsc"pt,o'l
M,1I1l a"d hllj·C"d h"""nys I!x.lrn,nilt,on ,!I,d 'enov~'t,on Ma)o' OJ),,r,rl'OIlS possllJle w'th ""\JIllf! orr C,If MalOr op,,' 001 P"'''fl ",hI I"'!! Od pw"p ",,"ov,,1 f'1~((JI'S ,IIul '.(111''''' :111''1 '0(1,; ,,:I, tl,n!!
1 ",1011'; ,11,(1 P'~lOIl ""llS (,x;r"''''''l,on ,,,,,I ,cnoval,on PI~,1Orrs, ct)"rrr.:~trrro ,,,ds .lIl(f hoal lllO,; removal n,),11 0, 1 s('ill ilrld flywlrcr:1 rcl,tlll'(j !'loclq" Hock", a""s ",,"o"ill nor.k v ' a'IlIS ;rnd C()V,~'S ,e flllll1ll . I~O\lII"V m;r"llell.,nC(!
SU"'P r,1pl)('l __ "ri d plIsI"ods ex.rrnlll.1t'OIl ,rrl(f ,cnovallOll Trn"n(1 Ilc,II'; cx,IIIW,;rl lO'1 ,1(1(! 'ellOV Trn"n\1 I)C,lr'; "Jmov;,)
T",,,,,O
IIC,"~ ,'(ld frO"l plale rcf Valve c.1(;'U,rrlCcs cIrCl!k,n\) and ;ru lustmCII I
Valvcs ValveS arrd valvc SIJ;IIS ex;","nJI,on ,md renOv Part C: Fault ditlljnosis F;rull (f' G ·cylrndc, ollv \II GO V fu,rrrJl,on 9303 mm (3 663 ,n) 6850 mm (2 697 ,n) 2792 cc 92 1
61 52 60 66 86 87
" 48 74 92
" 44 00 46 62 45 78 53 72 55 30 76 70
" ~2 43 7 ~;
82 58 81 67 50 84 63 50 88 40 85 !.>.1 !i l 6,'
" 56 83 59 40 73
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