
74 Chapter 3 Fuel and exhaust systems
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Fig. 3 .23 F el '
A
" C
Se.ll Ruhbcl ill,W/,lIQI S SI!IIIJ..'f lIoil
14 Fuel lank -cronning DrHI rcpl1ir
D SImps E , COllflcetiu"
W,lh IlI1m 11 I~ likely Ihal scd'lllcnl .... .11 COIiC(;1 1f1 the IJOIiUlIl u l the ruel wnk. Con
Check Ihe h01l1 whL'{)ls Ihen J;lc k ufllhe le;lr of Ihe 17;11 ;'Ind supporl ,1 ilxle sr,llids . 2 SYI/hon Ihe fllel hom Ih e tllcllim k. Wherc ;lpphcilhle d,scol,,'ecl Ihe fuel line hOIll the scnder unll.
" Discormoci Ihe wiring 5 USlllljlWO SC!(lw(i!lvers III Ihe 51015 inlhe sendcr unit ,e lirmlng 1111\1. unsr;'ew Ih o sender (mil loom Ihe tucllilnk Lilt ilW;lY Ihe scaling ling iln d Ihe sender unit. nO llng Ihill Ihe 110.11 must hilng downw;'IrrJs. G Re fill ing is a rever snl of .e moval . bUI clea n lile milling !;lces ;'Inel I II ;'I new sealing ring .
1 6
Fuel lank filler pipe -removal "nel refitting
I Remove the cap horn Ihe hiler pipe. 2 Re movo Ihe .ighl·twnd siele lIim p;'lllei. 3 Peel back Ih e in sul alion clear 0 1 Ih e pipe (:Over fliln cl (Ghia only). 4 Lift outlhe pimel coverinU Ihe spore wheel. 5 Unbolt Ihe IllIer pipe covor panel. 6 Lo osen th e clips and releilse Ihe rubl>C1 oail er from Ih e floor and f,llel pipo (phOIO) 7 Remove Ihe screw al Ihe lO P of Ih e pipo nexl 10 Iho filter cap (photo). 8 Disconnect the hoso and withdra w the I.ller pipe I rom in si de Ih e
car.
o Relill ing
is a rever sal 01 romov;lI,
A
cceleralor cabl o - removal and relining
Removo Ihe
lowe. lac.a panel inSide Ihe ca'.
166 Rull"'" !F"1I1';'I1 "otlom " I I"". la llk flU", l"llll
(
. ,'l
--.
. ~
1(; 7 Fuel lank flUc. Pll~ UppCI 1II0UIIIIII\I SClew (.lIwwL't I)
"
, I;'.' . :~, \;.;
: : i;. "j -' , ,' .... :r: , :'y~ it. ; '., :
Fig. 3.24 Disconnecling Ihe innor cabla from the pedal (Sec17)
Pusll M 11 ,mrl rcfc,uc ill IJ
2 Disconn(:cI Ihe cahle 1<0111 Ihe I)OOal hy unhookoug Ihe clip and rcleasing Ihe ""II:! cal,le 3 Rem oye Ihe IHal:.e servo un:1 a~ dcscfLb c(1 11 Ch;lll lcr 9. Ihen remove the SClew securrn~J Ih(: Oulcr cable to Ihe iJulkhc;'ld
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![FORD CAPRI 1974 Workshop Manual )
Chapter 3 Fuel and exhaust systems 75
;\1.325 Prisillll oul tho re l<lin in\] clip (A) when removing IIIH acceluralOr callie (n) (Sec 1 7 )
~ fl""",V<: Ilw au eli!.",u. ;IS d .. ,~r."'J( FORD CAPRI 1974 Workshop Manual )
Chapter 3 Fuel and exhaust systems 75
;\1.325 Prisillll oul tho re l<lin in\] clip (A) when removing IIIH acceluralOr callie (n) (Sec 1 7 )
~ fl""",V<: Ilw au eli!.",u. ;IS d .. ,~r."'J(](/manual-img/11/56932/w960_56932-75.png)
)
Chapter 3 Fuel and exhaust systems 75
;\1.325 Prisillll oul tho re l
cOlll,,,1 IIIIK"!I" G I'll'." Ih" ",,,,,,1 '''','UHrI!l <:lIp hom the IlIi,,;k"l 7 U~"'!I a ~,:",wd"v"r. d"I"CSS tile pl
'o le: If /I" ., IU:(/"I ",!ly ,.~ to "(~ /f.'/!/oVI:1I /("1,:, (0 1""""1';'1"" 12 [)I~.,:,,,,,,,'cl (h" 1",lle,y lea(ls ? r",," liNd" t lw C,II lemove Ihe 1;)(;';1 It""", 1';,,,,,1 II I, '''WII\l:d hy ,,<'I(:W~ (IlHO) OIII""e S{;WWS (LHD) "IIIII!I Ihe ''',II "dUI! ami C;1Il tJ" IUH:lopp"d l,ulll lhe hont l~d\)c 3 n"lllove th" ,u;cole'''lot cilhlc hom Ihe p"dal sha h olS ((e~""h"d III
Secll"" 113
RI-IO variilnls 4 DI~(u"ncct Ihe IHake ope',IiIl1\J IOd ill Ihe b'ake ped;rl. thcn 'enluve tio" I"aslcr cylinder ,lilt! sc,vo lllHI nell" to Ch,lpl!!' 9 101 lUll lol'l
'nl')lll1alI1111
5 WO,kllll) I I"OIl\)h (he ,e,l' bulkhead III the C "IJ"'C vo"'p,"t""!1I1. pull Ollt lire sh;rft "nd S"CUI1I1() chp () Rotate Ihe I1\)ht·h,,,,d Shil l I IIIO'"ltlll\) bush Ih,ou\)h 45' ,n e'lhe' d1lCC1l011 ;)nd pull II Out 7 DetaCh Ihe
AI/models 11 Oetach II", 'em;lIl\ll\Y bush ;rm] clIp hOIll lire shalt. ) To re11l0V" the pedill, pl1se the f!;ln\Je ilway Irom the SPIYO( on lire snail. lhell ,emove the p"dal and sp"ng 13 WI,en ,eflll"'!! tire pedal. locilte the sp''''U on Ihe SPIUOI shall, lilr,, clop th" 11""\)"$ 01110 Ihe SP'\JOIS ilnt! check lhilt Ihe pcd;)1 I"vots
cO"lIetl),
Fig. 3.26 Accele ra to r cable rc moval 1001 (Sec 1 7 )
A _ 250",,,,(10,,,)
() ~ Cell(fe IlUlidl /11 /J!Uv;d" ',1,SL'd -'''ullld ... ,
14 ncllll"'() the pud.ll shilft ,s Ihe ,eve,su 01 Ihc lelllov,,1 IHocerhllC, lolinwlllU whIch It w ,lI he 'H!CUssa,y to ;ullllS I It,,) cailic. "5 d"scllt)IJ d 11 Si,(.t'OIl 16 OIL Rill) v;",allts. dlcck lh;ot the I)(:d;oll"'$ 6 tn 14 ",m (02" 1{) 0 55 'Il) I,ft 110'" the nflu posit 'on If IIo,,"ss.u y ild)"st Ih!! pedal
Iofl up ~!Op !O ach'"ve I h,s
19 1"lc t Ill[l"il o ld -rClllov;l1 ilnd rcfitting
1 DIsconnect (he biltlc,y ne(),1Ilve IUild. 2 D'illli Ihe coolm\) syslem (Chapter 2). ,emovc Ihe d'StllIJU1{)I (Chapl", 4), and remove the C.llilll'et!O' (SectIon 8) ] DI~<:OIlI,,:ct til!! rl!m,IIIiUlI) hoses ;rlld Willi'\) <1 UllSV,P.W the 'nlet m;r,ulold holl~ p'ouress,vd), III II", ",v,,'~r: oldl)I 10 that lflvell II, 1"1) 327 5 LIft 11'1) II,let Ill;H"lold frum tlH! o:yhlHit;, hr:;lds ;",(1 II''''
\)IVCll '" the Spec,fr~.lt'ons 10 The '''lllillll'''\) proced",e IS" 'eve,s,,1 01 ,elHoval rlefrlllhc cool",'J s)'stem WIth Icfe'cnce 10 CI"lpte, 2
Fig. 3.27 Inlet III,mifold bolt tightening sequcnce fo r 3.0 litre engines (Sec 19)
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76 Chap~r 3 Fuel and exhaust syste m s
20 E~huust nlllnifold -removalllnd refitting
1 Disconnect the hallelY negillive h}ild. 2 Apply the h,lndl,)',li<.e then lilCi<. up Ihe Iront o[ Ihe Cill ilnd suppo,t on axle stands 3 Unsc,ew the nulS ilnd d,scontlect th c exh;!ust pipe alld U;lIl!) C 110m Ihe edl;!ust tIIiln"old. Rctllove the sc;!hnH tlllt!. 4 Unsc.ew the nulS p,ou,ess,vcly ;!lIff ,cmove the tIIOlrllfold from IhC
cy lrnd c. heOlct. Removc Ihe gaskels . 5 Refrllrnn IS;! Icvers;! 1 01 renIOV;!!, hUI cleOllllhe millrnlJ 1,1COS "rul Irl new n,1$kClS Tr\Jhlon Iho nuts prowossrvoly
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1
2 1 E~rH1usl s ystem -removul ilnd refitting
Posi ,ion Ihe COl' ovcr;!n in~pcction I)rl. O. 100ci<. ,hc CM Hnd suppa., II securely on blocks o. stands. 2 DrsconnC CI Iho bllttcry. 3 lrfl up the rosonmo. hox ;!nc! pull the ,ubbe, rtlsulato. off each srd e b,;!ckel. 1 50111",1IC ,111 Ihe Clmlll) nutS wrlh p<:nClfmrng all. or II jl'OPtlCI,',y
COfl05,on inillbrto • . 5 Disconn ect lhc f!Onl pipe f,om ,he milltlroid. d e tilr.h the sOOlhnu lin!] and lower the ,.onl section 01 ,he lIxhaust
F ig .
3.28 Exhaust system coml)onetllS (Sec 21 )
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Chapter 3 Fuel and exhaust systems 77
Fig. 3.29 CUlling the reM o f tho exhaust system to facilitate its removal (Sec 21 )
6 Usu a hadsa w 10 CII I II"Ul'!lh Ihe .e:!. Cxh:!ust p'pe ilhoul 240 mm (94 .n) ItOm Iho! ''';]' ollho I.onl tI:S(HlilIO' (r.O 329) 7 Removtlihe IHII sl:(:IIIIIl!llhe I.:a. sllrm cm hlolt:kel clamp. SWU1!llhc hl"ck,,1 ell,;" ot 1111, sol"nc", :tni! ,,",I ,lcll lit" ",n, e xhausl ~(,CII"n. 8 Ot.lt.1Ch ,1", 11"'110VI) Iho I"a. IIIOUnlll'!IIIIIIlw. :tnd IIIa(.k,,1 clallip 9 Rell1uve Iho hont P'P" LJ r:lallip and dill I oH 1111) Iron I pipe . D"t;tcll Ihe f(:sonn lo' 1I100mlll'!! h.ack", and Ih" wll plpt: 111111. If filled 10 Slilll 1e!11!1Il!j hy SCllhlll\j il nlo"k 115 I'"'' (1 8 III) 1,0m Ih', CIII ends ollhe ,csonnto. 10 Silence. pipe I I POSition Ihc .csonnlOl and ltont II'IX! ilSS(lmhly. loosely SUCIIIC ,110 the hr,'CkC I and man,Iold connCCIoOIi 12 Slide a se.vice sleeve (FlU. 3.30) 01110 Ihe .eson ;IIOf I"I)C. pos,"on,nu lI S end In Ime with Ihe s O lhed ma.k m,llle p.eviously. 13 F'llhe Silence. l)lpe mlO Ihe sleeve up 10 lI S sCli hed ma.k and .ehl Ihe .e:!. StiOIlCt" c l."up ItJo~ly Wilcil hlhll!llhe clamp. ensutc Ihm liS
;IIlUlet! end .s IIpp • .:tlnn~1 111 1\l1!II'lhe I!xhatls l syst"m sn Ih;11 .. I tin 1IOilit IS 'I Ile;u,,' Ih;)l 1 25 "'''' (1 III) 10 "lty i:Oll'pOllelll. o. 1',111 01 Ihe t,,,dywn,k TI!lilteli th\)
• J. ,
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FiU . 3.30 F itting the service sleeve to Ihe eKhausl system -arrowod (Sec 21)
II1n n llol(1 conn(:(:tlon and Ihen screw on Ihe nUlS of Ihe .esonnIO' clnlllflllll111 13 mm (0. 5 m) of Ih.end Pfotrudes Ih,ough Ihe nulS. 15 1'0SIlion Ihe IWO U·dmllps on Iho service steeve and li!Jhlen the n\llS 10 thu IO'IIIHl w.ench sc1ttng Uiven in lite SPCClhC,ltions 1 G [1"" 1 lit,) 1;111 pIpe 111m of "pP'OP".1W thon reconnect Ihe b.ll\e'y. M:ttllhe OllOine and chock 10' 10,lk 5 17 Low,,, the c," 10 Ihe Wound.
PART B, FUEL INJECTION SYSTEM
22 Goneril! description
The 111,,1 "'1"Cllon sySlem fitted 10 Ihe 2 .8 hIre engIne IS o f the COllltlllHlIlS '''IL'Cllon Iype ;tnd sttppltes " p.ecisely conuolled (IUnllllly (II ;I\()lII,":d hll:1 10 "nch c ylt1lde. undo. fill Ollo.nttng condItions.
A U C
Fllel plllllJl FII~·1.1C'·''''IUI •• tul '''mUIr) IWlls",!}
Fi g.
D f F
3.31 Locations o f the fuel illjection system compo non IS
Fuel "'WI G rhemlolime switch
(Sec 22)
K
L Relays ilnd line (lise Im,lu'se module OrstllbulQr/mixture cO/wol "",I W,l. m·up leguliltol H Allxrfi,lfV illf device J Stilll valve
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78 Chapter 3 FlIer and exhaust systems
TIlls system, when comp1lrcd with conventlon,lI c.Jrhwctlo, ~rrilngemen1s.
tI'(lllPS
A FI/ef Milk Fuef Plllllf! F/lel .?CCIIIIW/<1IOI Fuel filler F/lel ,IISltihular ,w(/ millime con/rol l11ralllc MIlllll/ce/Of "',1/1'115 AI( ch.ll11/"1(
B W
The fuel pump IS 0 1 eh,CIIICtllly operated. ,aile. cell Iyp" A .",SS (IIC rchd ..,:,1..,0 'S mco,p[)I;oh~(1 III the pwnp 10 preY",l! f:XCOSSlvn
p"'SSUIC la"ld III) '" tho event of ,1 ,,)Sl"Ctlon III th e pipelollf!s The fuel ,I(:c\llllula lor ha~ 'wo lunf.luItlS. (t) In 4'ill1I,)(:I1 llll! IIIII,,;,'U)!l 0 1 lhe luclllow. HHlu.:.iI ,ml hy Ihe I)\I"'P ;IIIf' (II) 10 11I;""t,"" Iud I"'"'~''''' ,,1";1 .h" .:o,!.m" h;os Iom,n sw"dn,,' "If TillS p.r.v"rlls .• v; 'po", IIH:1o; .lo.:vel"I'III!1 w,th t:'Hlf.O:'I""nt 100' ~t,'
6
9
The iI" sen~or 1)1"le is locilled in 'he main nIl Stlealll be.ween the iI'r clr:wller ,1nd the Ih'Ol\Io bullerfly. Du'ing idling. the ~irflow hits Ihe sensor plate which in tu.n '
1 Flle/lall/(
"
Mu;/ulc CUIIIIOI ,mif 6 IIIIOlfic pla/c assembly 10 S/;II/ villve 2 Fuel PIIII/I' 5., Fucl (Iistllbutor 7 Inicc/or valvc /I 'hell1JOlimc sw,lch 3 Fuel i'CC/IIIIUI"tul 50 Alf SCIISOI 8 WiJllII·Up regula/or 4 Fuel '"10:1
"'
Plcssule regtllillQI 9 AU~IIt"aIY air device
·.i
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Chapte r 3 Fu el an d exhau st systems 79
Ii
0) G
\E )
' .. ~ ee)
Fig. 3.33 Fuel injuctiOIl system circuit di
2 Sialicr I/Iolor /) Axll/,-"y ,1i, device G Theo1lO/lmc switch
3 fgnitioll switch E FIII;I/Iump H St,lfl valve
A M,lin con(Iol r(;/,)y F S
8 Power supply rcl.1Y
Tho safety switch is provided to cut olf illl power !O the fuel injection sySl(!m if the air sensor plJIC (mixt\HC COlllrol assemhly) IS il the rest position even if the ignition switch IS all. The s[lfcly switch would ell! off the power to the fuel pump for oillllpic ,I il fllOJllmu W
AI the IntelV
,. ,
< '(:,,~ , • . . ;::~t,·· . , ,
.' ) . ;~ ~~;:;: ~iJ" .. ,
n fr.X l
the engllle 10 'die.
3 Check Ihill I he idle speed is lIS given in the Specificmions ilnd il nccnssary "dlust the idle speed screw 10cllted heneillh Ihe Ihrottle housinv {photo).
Check conditiorl o f fuel hoses " Reier to SeClion 2.
Tighte/l the inlel manifold boilS and /luis 5 Refur 10 Section 29 and lighten the inlel rll
Renew the air filter element 7 Disconnect the h
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!
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! 1 I'
: 1'1 1 . ,
I
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I
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80 Chapter 3 ~lIel and exhaust systems
24 Ai r cloanor -removal and re filling
1 Remove Iho elomerll as dllsc"hed III Sect,on 23. 2 Work,nn under Iht! left ·hand honl wheel arch. unboll the illr clenne, hOdy f,om Ih e s,de of the engmo compnl1lllen\. 3 Rohuil1g IS n rove rsal 01 tho lomova l I)rocodule wl lh relelence 10 $(1(;11011 23,
25 Main system compono n ts -rellloval "l1d rofitling
Fllel p /llllP 1 Thn hll)1 pump IS loc.lwd "' " lI,hlw.. 1ll011111111U .lUflchod 10 Ihe "!Ihl h"n{1 51th! 01 lhe 11I/,llal1k (phnIO) ') D,sC:OllllCCI Ihe h
'''~t:un'''~.1 11",," 7 I ,.,,.,~'''' the 1I!l11l hoilid Illd 1'lIlk SUPI)(Jl IIII(f Sl'ilP Illell unh(lll ll,,~ lul,I)". mOlllllll'H ami 111,,1 JlUlll!' 8 !'IISf) the pllmll "("n the "'OIull"'!! !) Ilcfllllll!j 's il IUliers,, 1 01 ,emOVi.1
FiU. 3 .34 R Oilr viow o f
A Ink'1 pi,ll}
fuel,HIIl'I) (Soc 25)
8 Fucl'WIII/'
..
) 2~ 1 Fllel pump showing Wlflflg ond oul'el pipe
~ .. . . ~ ~ ... ,
2510 Fuel accumulatO'
Fuel accumulator 10 The fuel accumulatO I is bolted to the Ical 11001 above Iho lear "Klc (phOIO). 11 Disconnect the bflltCly . 12 Releaso the preSSIJle in the system as descllbed in PfllfltJlilph 3, 13 I'lilCO the leal of th e car ovel ,1n inspection pit o. lilise il on ' ilmps O. fldo·stands. 1 4 D,sconnectlhe fucl pipes I,om the lu el accumul,110r and catch Ihe s
Fi U. 3.35 ConeCI 10Ciliion o f fuel filler oullel pipe (Sec 25)
A B Fuel "'ICf Ou/lelll'lle c Engine comporlmenl side p,wel
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Chapter 3 Fuel and exhilust sys tems 81
1 8 Disco"nect the hllllmy 1 9 Relc,,~e tl", .. ,e5~II.e In t he system "s described in palaglaph 3 22 P lace some cluth hcnc,llh the luel flhel then disconnect the mlet ilnd outlet ", lions 2 1 Rcmollc tht) mOIlI1lIlI11 sc.cws ,1od withl1,,,w Lhe fuel f,ltc ,. Remove
the bl:lclwt II 'ltICIlS$:I'y 22 RchulI1U IS a .ellcls:l1 01 ,emoval. but m"ke sure tha t the 1,ltel is
pQs. t.onnd thll I:Olfe ct W,ly 10un(l. "n(1 Locate tile OUIICI plj'JC:I~ snown
io FiH. 33!)
Fucl tlisfllbu{(}r 23 The f""t d'~L"I"'lor .~ IOr.i'to(1 on top 0 1 the "" flltl'!'. 24 DISCOnl"" .t thu !o:m",y 25 n,;L""~,,, thO! L''''',~II''~ III (hI'! system:ls d"sl:"lmd in piull u,a"h :I"" t compL"L"ly 11,111"11" tho I,,,, d 111111 ",Hon 26 DI~r."'UII". t tl,,, """,11'1'1111 f,,(:II'"C$ 1,<)ul til(! llis t,d,utOI 27 UIIS'~":W ,I", nll"l1 """m'"'n sc",ws alld hit Ihe IIISIIIIJlIIOI away 28 RHhll""1 ".,' ",v':I~,,1 "I rr""OvilIIJlJ IIISC a IIIiW coppe, w"~.h,,, r:ach ~,de of Iht: '1',"'1" IIIIIW'~ ",,(I dO not OVf!rI'UII1I:rllhe llIliol Imils 9 Hall" Ih" :.y·.1t:1I1 I""",u'li t: heckr.d by yo"r dllatCr: 30 I\dl"~t th" "II" "I~:I"t :II\l IIIHXIIlIfl as ,leScII",,1I III SectIons 73 ,IIld 26.
W"",,·/I/I/I.'ylll;/fOf 31 The w."'" "I' "'!I"I"tl1l 's loc ;llt,d on till! hunt of the ""!I"'" ""xtlO t he c(X,l"'H ~y~t"l11 nuth, t I:lhow 32 D,sco",,, • .: ! tl", lhlllCI" 33 Flcleasc Ihe prcssllfc In the sySlcm as desc"hed in parag'''I)h 3 34 Discount: GI Ihc lIacuum hose ilud wi"uy plllg (photo) 35 D'SCOI1"I:CI the fuel hiles (l)holO) 36 Unsc,ew the Iwo sockcl·he;lded uolts ;lnll wllhd';lw thll 'C!jUI;ltol . 37 Ref,(lln\1 IS ,1 ,cve.sa' o t ,emOIl"' . hut lise a new copp .. " wa~hcr eilch Si(lc 01 tim h,ll1l0 \llllons (phOIO) 00 nOl ove,l>ghtcil lh" I"'''on cenlre hol ts
Fuel S f"ff v:llvc 38 T hc luel stMI 1I:llve is located on thc ligl1l ·hand s,de of the lIir ch"mhel. 39 DIsconnect the bmlory . 40 Disconnect the elcctlic p lug and fuel supply pipc from th e lIalve (pholo) 41 Unscrew tho twO socke t·headed mount,ng bolts uSlllg an Allen
key .
42 Ref,,,,,,!) IS .1 'ellcrS:l1 of ,ernOllal. but u~e II ncw moullting flange !lasket Use" new copper w"shel all each SIde of the """10 union lind do nOI ovnlllllhien the Centrc holt.
A!lxih~1I"Y "i,. r/(!vicc 1\3 Thc i",x,h.n y "" rlcvice is 10C"II,1I On the IIU"t hal1d flOllI of thu lIir cha",!,,", 1\4 O lsc0I1"", .1 Ihe hallerI'. 1\5 D.scr"'''.,ct tl,(, eleCt,ic p l11\1 ;,ml IWO illf hoses IrOI11 the ""vice (phoIOS) 116 Unsc",w tl", two 'UO"nIl119 holts .11,,1 hit tl"l ;rss",,,t,ly i!Wlly. 1 7 Fl"f,It'''H .s ;1 HIIIC,s,,1 of 'elllolllli
Foel injocrurs 48 D, sclI"""'.t Ihe h;lll",y. 1\9 O, sr.
25 .4 0 A DisconnectIng Iho tuel slart valve
wiring plug
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2 5 .4 06 ... and fuel supply pipe
•
25.4 5A Au xilia,y air dcvice w ifin g plug.
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