1974 FORD CAPRI engine

washer fluid fuel tank removal radio seats tyre pressure ground clearance

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FORD CAPRI 1974 Workshop Manual 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

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 sheU II "'i'y he nm:; ess,lry to Io1p the mol'" bearing caps with" solt·lacell hnml1lor to releaso Ihem 34 L,lt Ihe C 'Jnk shah oul of thO crankcase and remove Ihe renr 011 seill (pholo).
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.
COll lalfler. When completed relll Ihe plug 'lnd lighlen. 5 Remove the SIMIOr mOIOI as descrlhed In ChilplCr 12 (j Unscrew Ihe nutS 110m hOlh engine mountings 7 Reillovo Ihe i,dilplor plilte 'Jo11 f,oll1 Ihe geilr[}ox. 8 Unscrew Iho sump holts ilnd prise the sump frO"l Ihe cr,lnkCil5o. 9 R 12. 1 The rOCker shJh h,1s a relillning pin at
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 . ,.: , -' /')')')')-" . .
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f iU· 1.2 Exploded view 01 rocker shafl ilsselllhly (Sec 12)
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FORD CAPRI 1974 Workshop Manual o
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-

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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
I , n ed .
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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 101 wr:

JS ncceSSary .
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 2 Remove lilt! valves by comp,ess>llg the valve springs WIth a suiwble v"lve spPlng compressor and loft,ng out the col lets, Relense the v<1lve sprin\j compreSSOI nnd remove the v<1lve sp"ng retainer. spril~,) ami valve (photos). M;llk each valve so that Ihey can be fltled u, the S<1me 10CfltIOn 3 WIth th" v,llves removed. clenn out thC Ci1,lJon Ir{)m the POltS l EXnlllUH! the hearts of the valves nn d ..,;II(:, or nlUll>l fJngmeerini) speCIalist. 5 Check IhE' valves guides lor wear hy "'s(:'II"U the valve on tho (J",de. the valve stem shovkl move eJslly '11 tho gUide withoul SIde
pl t o yOl H 101:,,1 Fo, d de"ler G When !J"ndlnU sllgh11y pIned vnlvcs ,'11d '· .llve se"ts w ,th ca,ho,uIHI"ll) pas1e pro1:eed as fOllows Apply ,I Illtio coalse I) "ndon>! p;,S1C !O tlo" valve seal clean off ,III lr;lC()S of 9,in donu paste . Blow Ihrough the gas pass<1ges With comp",ssed air 7 Check the valve springs for dn!1ln\le and .1lso check the free len\jth. rcler to the Spceo/ lcntions at the beginnong of this ChJpter, Renew II defeclive .
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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,,)
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'('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
.. ----------------------------~, 灲潣慲浡湵慬献捯m

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$FORD CAPRI 1974 Workshop Manual , :: " , .~. , . J I I li . ,, : ) ) Chapter 1 Engine 37 ------------------~~----------------~ 17 8e Tho socond compress,on " 11\1 I~ steppr:d , ., 4 cOI"es out 01 I1S groOvO. ;;Ipp$

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Chapter 1 Engine 37
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17 8e Tho socond compress,on " 11\1 I~ steppr:d
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cOI"es out 01 I1S groOvO. ;;Ippll' sligllt IIpw;;Ird P":SSlJIU SO tlt"t rt ,,:~ts on tllo 1,lrI d ,1bove , It C;;In thon be e<1sed off the pr~ton. wo1h the I,·der u~uge stopping II Irom sl lppllll) 11110 ,1n I:mpll' ~llnov" II It I S ;1rI1' Itut thu tOil pislOn ring thilt It being removed (phO(OS) !l The piston rings must always I>e remov"d trom Ihe tOp 01 Ih"
pi~10n. 10 C heck that the piston ring grooves and ollwal's ,lie IholOl1uhly d CJn Jml unblocked. Piston rings IllUSt ,1lways be hilI,!! (Jv,n Ihe he;){1 01 II,e pis ton and neve r from the bOllom II Th e eilSiest method 10 use when linin\) ,inUS 'S 10 WIHP . ',lrl'llg wnh tho bottom 011 contlol IIIlII. ovor th" lee le' \FI1t\le The 1~'o:Iel (jauUe , complete wilh rlllO. can then he sl1d down thl) piston ov1!r Ih<) Olher p .ston linn groovos tullil the COIlf:Ct (l!Dove IS ,e lB C onnecting ro d s and gudgeoll pins - exami,wtioll ;;Inri f"novation
,
Gudgeon p IllS "ro n sllrlnk fil IIitO the cOl1l1eCllliu wds Netllter 01 lh,,~~ would lIo'1l1~1I1' l1eed .enewal lInl,)ss (he p'stons woro 1J~mq ~h.lnucd. III which case the lIew p'S tOIiS wOlild 0111tol1li$1(;,1I1y h~ ~lIpp"ed Wllh IIew $lJ(IUeoll pillS . .2 C OllllcCtlllU lo(ls are nOI subject 10 wear hut 111 extr<:Ille tnCVIlIS1"IICCS such as ellUlIle se.zure Ihey could he dlstoll~d. Such (OO(I"lons Ina I II h 'I' )~ V'SUi' I' ilppiliOlit but whew doubt e XISIS th"y ~ o uld be checked lor o1l1gn1\\onl ,111d II necessa,1' rellewed or W,l'gh(ened TI " . 01 file )",1.lIlg Caps should ~Iso he ex""I1l1ed lot I!uhcauofls (h I tng ?own whiCh may h~ve been <1ltempted in Iho misl<1ken ,deil .11 heanng slackness could be romed1ed III t hiS wal' If Iher e DIe such !I'Ons (hen (he c F d onllect",u tods <1ntl C<1PS should bo rOllewed hy your 0' ')!lent or locill elluinee'lIlg speci<1hst
19 C r ~c.a ~~~ll1iIlO the malll ho~,illg louillais nne! Cfo1l1kplllS 10' score 1l1.11~S or Oval~ es. Also check thom tor ov,:tltty using <1 micromet"r (pho(o) e,ce~~v~n excess 01 0025 mm (0001 III) should he .c!) 2 CO
llt.;rv I e.c , 0 nOrmal praCtiCe. For d stipulate that undet no , umSIJnces sho II I exces s' U ( tie cranksllillt be .e\)tUund; so tI d,III'J\)e o. cr~nks~a~t.weJr , . <,

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3 II the old C"ll1bhollt 'i b.."nH rel'lI(:tl. ch"t:k ttl,1I tl'" o,lw~ys ,1I1I cle,lI Th cran kshollt 4 Check the ,PI!JOI be,1''''!J III the reil' 0 1 Ihe crJnkshalt and ,f
necessary .ene w It
(photo ·
20 Main <111(1 hiu' Cl1d bearings -e~<1ll1ilH!tio1\ and renovation
W,lh C TtI 'S sympt orn '5 ,1cc on,p~'II':HI!Jy " 1,,11111 0,1 P'l:SSuro). <1lthough th is IS II0t normolllv not.ce<1lJll: ~nluss all 011 p,,,s su. e U~lI\)e IS hlted. M olin be"r.nu la,luI~ IS usu<1111' "d,e<11l -~. ----------------------------procarmanuals.com

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38 Chapter 1 Engine
20.6A Mil,kIl1H S 011 the reverse 01 ,1 hl!1 ClI,t tlP.ilrnlH sh ell (, .... owed) 20.GEl ·S1.1n 2 BCilrll1!j shells 111 (lootl condItIon h,IVC 1)C"fU'O surfaces wllh il smooth. (lyen m.m s,tvcr /u,ey coloUI .111 ave._ Wam hCillln!IS wIll show piuches 01 il d,t(clcnt colour when the hctlring mottll hhMl IS III good cOII(1I110n ,t IS n1(:.cly " qUC!ol10n of "hlilllllllU ,1"0Ihl;l SCI 01 hC.111"!Js th;;! SiUllfl s,~e. A new Oilllksh;,h WIll I1C,,","II1!I c"ps wh,ch wol l he m",ke(1 wnh while piunl I) The oll!)""ll S'l!} 01 Ihe CI heen stnnd;ud a. 0 .25 nun (0.010 .n) unde,s'le. II the lournnis were underS'le Ofty.nally. Ih.s w.1I he ind.cale d hy a ween str,!)e o n Ihe lus l halance weigh I 5 The o"wnal size 01 the bly-end IOUll1:l1 W - , The ,WII II"1I clea.,l"ce 01 [h" hC"""!lS m,ly he ch"cled U~I"!J PI l ,e;IIII1() ~IH:II "n(l C,IP IISSOllliJtr,d . ,lilt! 1110 l)Oits/nulS 11!Jlllcncd 10 Ihe speerllod 10'(lul1 W hen Ihe C 21 T iroin g gOMs -oxailliniltion .1nd renovat;OH
I,,~t>(:ct Iho !)(: muS I nOI exce ed 027 mm (0011 In) .md Ihe bilckl 22 Flywheel _ examinntion and renovatio n
hl~l)t";t Ihe lIywheel lor danln!Je and ch"ck Ih(: ling tical 10.
,1nd d.llll,I!IC 2 If th'l .1I1!1 IIC'" IS h,utiy worn Of has IllISSIl1!J It!clh II shaul. ,e!lew,·d Til" old 11111.1 call ho 'emoved Ironl tile lIywhecl by CU1\1 1l0 lc h 1I.·lwc"n two leeth With 23 Oil "ump -distl1;l!llling. cxarninntion nnd reassembly
II 011 [lU'''1> w~," IS slIspecw(l il is pOSSlhle 1 0 OOIJIIl n 'CpJII Check fVI W("" 11151 li S desc!lbed IlIte! in IhlS Sec llon ilnd II conlun vhlain ,III IIVCI "(lui kil O' il new pump_ The twO f O tors he le·l,s~(1 Its hont f,IC e ,n o,de, to ensu,e cOllecl .e ilssembly 2 Remove Iho u'I"~e PIP(! and 0,1 slfaUle' If flOI ;:rlre ,
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$FORD CAPRI 1974 Workshop Manual Chapter 1 En gine 39 238 Checkirog the rolor lobe cle<lwnce 1 Thoroughly cle"n nil PDflS ,11 petrol or p<l,nlllll nnd wpe dry US!Il\J a IIon.lluify ,ago The neceSslHy clemill1ces nwy now be che$
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",'
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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_
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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
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..-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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44 C hapter 1 Engine
32 11 TUUHU"' !J the !la~~(:1 "(11ll Ihe sump m.ll11'Y face
33 SIII11I ), wal n r 11111111' and cr<1l1ksh "ft pullev _ relil1inU
Ch!all the 1II:11111U I;ICcs or rhe C •• ll1kC<1!;!! ;md sump EII SlUC rh.,1 till! UrooveS III the su.ll C;1IIIa.s ;lIe clc;on .
2 fll1hc ,ubl)Cf sc;')ls mille !JfOOVCS of rhe seal ';.lrrle.s . Apply s<:;IIIIlound hcnC:l1h lila cnd~ 01 the ICar su.,1 (pholos) 3 lOCil!C rhe SId e un~kc's Wllh rhen !;Ihs under Ihe CUI 'ouls III rho rubber s(m ls (photo) 11...,1,1111 lh\: !)"~kl!ls wllh a IUlle scalonU cunlJlO""d If nccnss;u y
" LOI:.llulhn ~1I"'p "" th" !I"~~"I~, "",1-,.""1 S""~ rh,11 Ill" holt h"l!;~ ,"" ~111I ah!Jlllld
~) 1"11 Ill" ~1I"'p s"':"""!1 hullS "".I "lIhl,,,, 11\"", 10 Ih" (;Ollllt:1 r",'1"" " ' IWI) SI'\!I"S .IS ~p",;,I"'d "' Sp"t:,hl.illHms ;11 rhl! I",O''''''''!! of It"" Ch.ll'll"
U 1'111<: .... a n"w \FI.,>klll r)1111HIII111111!1 COV", a n d In th .... Wilt'" p"mp "'1 III .... th",,""o~I,u alit! th'llIlI()~t, lI IlOlI~III!J. lutCI to Chapter 2 Fit Ih'l " "n wahl' ,,'how IU\lII IIH)' Wit II n ne w !J.I~k", ., Coat th .... C ';lIlksll,'lh pulhly wasil .... , wuh ~nahll(J COrllp(Jlllld F it tlU I pulillY. w,.shur illid sUet""'I) holt T,!)lIlun Ille holl to tl)() spn(;tr"'d 10ul"e (phulo)
8 tocate t h e 001 coul .... , Oil til() cylllldu, hl()( :k . IO F'g . 1.5 Correct t im in g geM IllMk alignment where the crllnk shaft ye.., h ;)s two m..,ks (Se c 32)

l
Fig. 1 .6 Oi l cooler fitting angle (Sec 3J)
A RC.lr f.1CC of cylmdCf blOCk
32 2A F'tilllg Ihe rubbef se:!1 to Iho IlIllIng cover 3328 Apply s(:.llul!) compound benenth lhe re.ll rUUb!:1 s!:,,1 333 lOCJIUlg the SIde g;)skct IJbS beneath Ihe seals
-procarmanuals.com

Page 46 of 205
Chapter 1 Engine 45
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)
33 7 ApplylllU se~lInu COIll I)(IUlld to the unnkshnlt pulley wash"r
34 Cylinder hcads. rocker gCM and inlct manifold - rc lin ill(j
Lubricate the valve tnppets wllh cleiln cnUlIle otl ;md Ulse,1 th,,'" It! th o cylindcr block. Ensurc they ille fm"d in thei . OIlDlIlal tOGillrOIl~ 2 EnSIHe tha t the mnllng lilces of thc cylinder hlock ilnd 1he cyllndel h~,lds a.e clean, 3 Position the new cylrnder hCild \I,1skets over 1he \Julde I>ushe~ on the cylinder block. Chec k thm they ilre correc 11y locilled The n!Jht ilod 1, ,11.hnnd gilskets il,e different TIl(: onskets ilrc rn,lrke d FRO NT TOP (pIl Ol0S)
!
.'
/ . .-,,~ .. ~
Fi(J 1.7 T iuiltening sequence fo r cylinder he ,1 C,l rel"lly lower thc cylrndc r hcads 01110 Ill" r:ylorulcr hlock ,'r1d ht lir" h"IIIII'!1 d"wn holts willch should hc !rrr,1 io!Jirliy ollr:d 5 T'Hirlt;1l tl,,: holts. ttl th" ~"qllp.llce shown 'Il r-'!l 17, '1l1he St,l!JCS as ~pe<:tlI"d It) Spf:clhcaltOllS (phOl0) G Luilrr""I" tile plIshrods wIth el1Uine OIl and Insp.rl them til the <:yllluh" hlock 7 I'laen Ill specrfred torque (photo). 9 RelIt the ,nle l l\\al1llold 01<; descrlbell III Ch,lpte' 3 1 0 Adlll~;1 the valve cien,nnces <15 desclllwd In Sect Ion 35.
~4 3A TIl(: dlfferencc hClween the left nmt ','Ilht head gnskets The ""OW mdlcoltes
. oot 3438 CyJrnder head \1,1Skt:1 pOSrilon
rnarkinos
•
r.
/ 1':' .j I
, I • 1 ... , 345T. h ' , __ ..1 I!., u U lco"I\I 1he cyhnder head bolts 34,7 Guidlfl~J 1he roc ke. ilrm il 3 4 8 Tightening the .ock !:! shnit bolts
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