1974 FORD CAPRI engine oil
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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
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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
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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
Page 39 of 205
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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 h
I,,~t>(:ct Iho !)(:
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
20.7B Cil.d U
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Chapter 1 En gine 39
238 Checkirog the rolor lobe cle
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
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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
2 5 Cr
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~---------------灲潣慲浡湵慬献捯m
Page 43 of 205
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'
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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Page 45 of 205
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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<:;IIIIl
" 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
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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
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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)
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Fi(J 1.7 T iuiltening sequence fo r cylinder he
~4 3A TIl(: dlfferencc hClween the left nmt ','Ilht head gnskets The ""OW mdlcoltes
. oot 3438 CyJrnder head \1,1Skt:1 pOSrilon
rnarkinos
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, I • 1 ... , 345T. h ' , __ ..1 I!., u U lco"I\I 1he cyhnder head bolts 34,7 Guidlfl~J 1he roc ke. ilrm il
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Page 47 of 205
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
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
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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
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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,..,,,
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Page 48 of 205
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
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",
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)
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