1974 FORD CAPRI lock

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 ,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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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 th e valves 01 N o 1 or 5 cy lll1(le l Will he seen to be rocking (the two lOCker .1.ms movlI1(J '" oppOS'to tlireCt,ons). If thc vlllvcs 0 1 N o 1 cylinde • .1IC lockll1~J. ,Ol:lhl the CI:lllksllol ft th.ough 360' so thl1l those 011 No 5 cylinde. ,lie ,ock"'!J 5 W hen the vlllves oj No 5 cVhnd':I :lre In thiS position. check the v:llve cle.1 .. lOlces 01 No 1 cyhndc, by IIlseillng a leder gnugc 01 the
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
~:j?0
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 " .
l
I
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,..,,,
.... ~ __________ .................................. r
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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 i•
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", (lnuine -il new bemings and/or pistons "nve hcen lIlted II shollid he
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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~ .... ------------------------------.. ~; 灲潣慲浡湵慬献捯m

Chapter 1 Engine 49
----------------~--~----------------= anuill transmiSsIOn models, remove foul clops bolt~ n automatic 1.,J;lsmission .models. drilm the torque conve!ler ,\Ild 18 Ihe drivep l . odelS make s"re Ih,lt the torqlle converter ,em,,!!)s lilly 1f1 1he $lOI1 m transmission . 20 When the engine hilS been SCpM,lICd from 11l(l 11.,11$1111551011, 1,lllh!.! . ,lowly chccklll9 j,equently to see (hMllle CflUllle does not loul " ng,ne . ~nv part of the bo?ywork. 21 W hen the engUle 's cle,lr of the iJody . lower it to the ~lfOun(i. Of
Ir~nsler it to a WOrk lJench
4 $ Engine disill1lotling -generill
Refer \0 Sec t,on 7
46 Engine illlcillilrics -removi\1
..
1,',lh the engine sep,l rated from th" t r;IIl~:nHS~r()" remove Ihe ~.tcrnally mounted componelliS ;l~ lulluw~
C;J//)Ulello, i.lnd fllcl {lump (C"'1!,lt" 3) IlIlel ,wll exhiwsl tII,wi/a/ris (Chaf!/t't 3) Sp,>r/( plugs and drS/fllmlor (Chaplet 4) AllCllwlor (Chaplet /2) F.w ,7I!d policy (CII,71I1C' 2) W.JICf pump ,wd Ihcffllos/.1I (Clmp/t't 2) C, ,1IIkc,lSC vcn/iliilion lubc 011 {,f/CI (Scc/ion 40) Ol/Icvl!! r/rpsllc/o; and {,/lCf C,?!, [II!1int' 1II01tn/ill.ll h,.1r:kvls Ciulell (Ch,7/I/l'l 5) Powl'r S/Cl'l/IIN 1'(11111' (Ch;lll/Vf 10J
<11 Cylind(Jr heads relllowti with engine in car
I
Q,scunnecllhe IJiltlery le,lds ") ~cmove the splilsh slucld. by renuJVIII , R ernove the servo V,lCUlUl1 hose I ~ DI~conrlccl Ihe rilll,.llul hose from Ihe ilulomallC choke D,s·
,onneCI the vac\JUnl h"e I • D,sconnect" I I I 10 0 le ea( co I I~con"ecllhe HT ICilds Irom the spark plugs and IrOlillhe Ign'llon I ,1od remove Jlw L T I I I I .
MId I I If . CiI( 10 lie dlSl1i Julor Reillove aile h Xlng bolt 11 0
' I
a Ihe dlst"I>[1I0r ilSsemlily.
'Sconllect Ihe all II 51 halts' , ' ernillOr Cil) es. ilcken the ailelllntor 1110ul1l11lg un( Pusil rod . C,II1)e "Oled. 11 IS very Imporl "IOC>! "
Fi~,. 1 .10 Turn the rocker (HillS to olle side 10 relllove the pushrods (Sec 47)
15 n,,,,,ove Iwelve lIolts ilnd delilch Ihe exh,lusl I1\,lrlllolds frOI" Ihe cylrrlrtr:f he,lds. 16 Sinckell the cyhmter hend boilS progressively in the revtnSe order to Ih"l shown ill FIll 1.19. IlcrllOVC Ihe bolts nlld hit olt Ihe cylindOf head.
It lile (.Iilsket has stuck and the cylrnder heJd cannot lJe lifted off. wp the cylinder heild wllh n hide·f.1cert. or plnstic·headed hJmmer. 00 nOI try to pri se IlIelil off wllh a screwdrivOf Of rtilillage WIll result.
4 8
Cylinder he,l(ls -rernovfli wilh engine O\lt o f car
Follow Ihe sequence (.I,,·elllll SectIon '17. 51;lItll1g.l1 PillillJl1lph 10. dl$lcoa,d,n!1 leil.!lellCeS to pa'is willch hJve alreildy bcen rcmuved
49 Villve$ _. removal
Rt:rllove the d('POSIlS /'0111 tire corllb\lsl,on chambers ~nd vnlve
h eads by ScrilPIl1!l and W" ~ b'\Ishlll(.l Tilke CJre nOI 10 scratCh the cyllnde, he~d gaskel lilces 2 Lay the CylOl(ier hemt on ,IS sllll) .llld h t the lo,~ed cnd of .1 VJlve spllng compressor ove, the ~plln9 rctiluler ""d ti le head uf the complessor screw in Ihe cenl'e of Ihe v"lve head 3 Compress Ihe sprrng abolll " qUJller 01 an Ulc h 10 Iree Ihl} split colle l hom the top 0 1 the v,llve stelll. If Ihe sPltng ,eliHner "nd collel Slicks. do not screw the co",p,essor down lurlhc< . bec"use IIIIs lII.ly dJr11J\je the valve Slem. bUI lJp the sprong reliluler sha,ply wllh a Ioghl
hammer. 'I When the Iwo halves of Ihe collet h')ve been '(:nloved. onscrew the spllng compressor umrl Ihe spring IS no longe, compressed nnd
remove Ihe compreSSOr . 5 f1Olllove the spltng retnlner. the spflng and the oil seal from Ihe villve Slem. Ihen wrlhdrflw Ihe villve from I he cylinder head. 6 D iscard the valve Slem all senls and plflce Ihe Olher componenls to\jellrCt. identilying them so Ihal they arc refItted III the correC I plnce
III Ihe cylinder head. 7 Remove Ihe sp,11k plugs from Ihe cyhnder hend. II nOI alrendy
removed.
50 Rocker arms -removal
1 Remove the SIIfI nul from Ihe foch" .1'111 Illoullt,n\) stud 2 Lift off the rocker re moved.
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50 C hapter 1 Engine
51 T llp pcts -removat
Remove the 1 !.111m "' thell bores.
5 2 Crnnksh Prel/cntlho CJ,lIlkshilf l hom 'Ot:ll111(J. by lillllmUl!J the flywheel,' the (jl1nin.! 'S 0111 01 the C;1I, o' hy 10ckll1\1 Ihe transmIssion ,I the cnOllle IS 51,11 III the Cill . 2 Rclcilsc the p"lIny boll hy l,oUlU 1l '111\1 511.11111C. ;'Ind rapptl1\J the sp,lnnc. ShiH ply, thon remove Iho holl ;1I\d washer 3 Usc il S I).ockcl pllile. 10 (h"w the pulley olllhe Cfilnkshall. Do not ilUOl1lpl 10 lever II oH, bC(:.lIlSl; the engllle [,onl COV(II IS j,aulle ;111(1 Icvcrn'H ilU1l1l1S1 11 Ill;)y (11510'1. or even InC.11; II.
4 Wilhdraw Ih~ Wood'uH key hom the end of th(! CllInk5hah and pl,lC,(! " w'lh Ihe pulley. til(! holl alld its washer 5 The C'.1nk~h;)h p"lIey m;oy he ICliloved wilh Ihe eno,,,e III Ihe C:\I. hilt ,I 'S IIIsl tU!Ccss;o,y 10 ,emove Ihe ',ld'illO' :lI1d thc rh'vehelts
53 Flyw heel -remov[ll
P,even llhe flywhcel hum 101m",!) by FHlHllln\J Ihe lin!) !lcal ;ollain~1 ;In imp.ovised SIOI). 2 On nlodels willi nl;lnu:ol 1I;o"$""S5'01i. Icmove Ihe Clulch plessure 1)1;lle and disc :os described in Ch:op!Cr 5. 3 Rele.lse Ihe s,~ bolts secu.in!1 Ihe flywheel 10 Ihe CllInksh;oll .lnd lefl\OVC I,ve of Ihenl.
4 Whilc supporling Ihe tJywheel III pl;ll':e .• emove Ihc Sixlh hoi' ,'11d Iolt Ihe lIywheel otl c;o,elully. so 111:01 Ihe m;lllllg su.lilccs of flywheel [lild c.;onksh;oit ;o.e 1101 dllm,'ged
5 4 Sump -removal
W"h lhe '''1(1'''') oul fli the e,". CII~"'C Ihal Ihe sump has 1o('CIl d,amvd ;ond then lilln the engll1C ()VCI so tl1011 Ihe sump's U l)I)ClmOSI F" wOOr1CII bloc"s tn Slll)lmrl tim en!l'ne 'n Ih,s POSIIiOIl . 2 Remove 11m h()IIS seCUlln( J the oil Sump 10 Ihe CI.1nkColSe o1nd rClllOVO Ihe SUll1p_ 11 the sump IS stuck 10 the c r;ollkcasc . II should be reh;lIsctl hy 1"'SII1\1 olle SIde wllh 11 sClcw drover. 3 To !Cn,ovtl .Ile sump wllh Ihc CIIU"HJ Hl tloe eM. 11151 IcnlUVC Ihe
d'l)S llck :ond d'SCOIlII(!Ct Ihe hatlery 4 Remove Ihe luur holts ;ond lou. Ch,)S ;ond dCI.leh Ihe OIl splash
shIeld.
5 Pl;oce a Con'"lIlcr 01 at lellst 6lttre (106 JlIllI) cal,,-.elly heneath Ihe SUml). remove Ihe d,ain pl\l(l ;ond d,aln Iha sump. Reflilhe d.am plull and (11)hlen II 10 Ihe 10lqUO wrench seilIng gtven In the SIXlClflC;JIIons G Del:och the engme fubl)CI mounllngs, by lemovlng the" nuts an(1 w:oshe!s. 7 Romove the ciampinI) bolt hom the tal) ;oml bOIlOI11 endS 01 the Steellll!.) intellnediate sh(lil. rush Ihe lap end 0 1 Ihe shlilt upwollds unlll Ihe lowcr ell(1 Clin be dlsenga\led 8 PI 9 Remolle I he Inur boilS securing Ihe fronl anlj·roll har to the Slde·membei (lnd the l()ul boilS securing each engHle mounling blllckel to .lIe sidenlCmber. 10 Remove the 011 sump Imlts lind I I the sump hns sluck to the crilnkc;ose .• elellse the sump by press ing 'I sideways wilh a screwdriver.
55 FrOllt cover -removlll
If Ihe engHle IS In the CM. II wllllnSI he necessaly 10 dlsc()nneC lthe l!allefY. drll'" 11m coolll1\) sys tem ;ond lel110lle Iho radiillor. 2 loosen the alternalol mounllrlg bOilS. SWlrlg the aitemalor downwilids .0w:Olds the cyltnder block and lemove Ihe drive belt
3 Remove the bolt Irom the cenlro of Ihe cooling Ian .. nd pull (
Ian and clutch assembly. 4 Remove Ihc boil an d wilsher from Ihe centre of the cran pulley .. nd I hen use ., claw puller 10 drilw Ihe I)ulley ofllhe sha nOI anempllO lelle, Ihe pulley ott. t)Ccause Ihis may .esull in dllm. t he Irani covcr.
5 Rcmove the si~ bolts secuung Ihe sump 1 0 Ihe honl cover an, t he cleven bolts securing Ihe I ront cover 10 the Cylllldcl block . G lIlt Ihe cover ott ;ond remove Ihe g;oskel.
5 6 Tillling gears -relllov;ol
1 Remove the honl cover 10 e xpose Ihe IImlnu ueo1/S 2 Removc Ihe bolt and washer sccu"I1IJ Ihe fat!Je gear I,
cn,nsIl1'll t. IhCIi pull.he geill ol! and Icmovc tho Woodllll! key. 3 Dlllw the ileal hOI11 Ihe cr;onk!;h:oh am! remove Ihe Wood'utl
57 Carllshaft -r erllov;ol
The camsh:olt nwy be rCUlovfld wllh the cll!JlIle 1<1 Ihe car •• lollowlng p!Cpol.aloIY wo,k IS co1med out. 2 0,,,,,. Ihe cootong syStelll nnd .emove Ihe .ad,mOl 3 Dlsconneci the ballery. 1 Remove Iho sp.1lk pili!! IC.1ds 1,om Ihe spalk 11lugs. 5 D,s':Ol
eCI the le;ods I,ull' Ihe :l lt'!11\.110r. remove Ihc allelllalo·
l i S (hivebell. G Undo "nd rem ovC tho screws S()CIIIII1U Ihe .0dcl covers and It Ihe rocke. covels and Iheir ilaskcls 7 Sincken lhe nulS secullnu the rocker ~"ns unlollhe locke' arm, he swung aside . 8 Remove the pushrods. idenlllylllg each one as .. IS lemoved. so 1 Ciln be rell1l ed in Ihe same position 9 Remove the cylmde. heads, screws. These cannOt be removed wI,h an oldm;OlY screwdliver ,lily nllempt 1 0 do so WIll resull OIl Ihe sc,ews bemU d",na\.l<:d. I Impact SCfeW(!IIver is nOI ilva,lnl)lo. the SCIOWS m;o¥ he Icmoved w sui l:oblc key lInd the urace 01 a sockel scI 12 Remove t he c.1m5ho1ll IhllJS I !)lolW 011\(1 the space. hclund II 13 Pull the c;omsh;oll lo.ward to wllhdl,1W 'I. 100f 111\1 Cil!e 10 ~ee" Sh,'lllfl Ime. 50 Ih;ollhe edges ullhe cams do nOl rt,1mnge Ihe cam~ beilllllUs_
58 O il pump -r e m oval
Remove Ihe crill1kc:ose sump as ;olleady dcsc"hed 1 2 Remove Ihe boll aUJchmg the 011 scrcen 10 the Illalll 00111.119 (
/ /

Fig. 1.11 Oil pump o n tho 3.0 f itre efluill(l (Se c 58)
F
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)
f
)
-• the twO boilS sccurong Ihe 0,1 pump 10 the crankcase and 3 R emov
',.,' . the pump assembly nnd ,ts (roves la I-wllh
drilw
59 P istons, c o nnecting rods and bCilr ings -removal
1/ lhe crankcase sump and the cylinder hC C,IIl he removed wIthout 'CIllOVlllg the cylInder ca l. tle-ads. 2 B efore removing any COllncCllrIg rod cnp, make sure Ihal the r del number IS mn.kcd all hoth Il lowest position . . ., Remove the COI1l1CCIIl1\1 ,ud nuts ilnd pull (lit the [)(lalln!) Cilp 5 Rotate ,he crnllkshafl \liH,llhe connCCllrl!l rod 1)"'11(1 removed IS 111 it s h ighes t positio n thon u~() Ihe h,lndle of ~ hanHller to plr~h \Il"
~ssemblv Ollt of the top of thu cyhnder . 6 W,thdrllw Ihe assemhly frorn the cyhntler ,lIld ptace Ihe hCillrnO C,IP
~ck on the connecllrt{J 10(1. 1 If Ihe be.:uinos rue l>CrllO ",newetl. lelnove the uld 1)("""'!15 hy ),,1I1n9 Ihem lound unlrl Ihe nOl ch on Ihe !J(,,,,rnO ~h.,tl rs tlrsenH<10cd
f rom Ihe lecess on Ihe l)e,1r1"U Se,llrnn 'lIlll Ihen hft the IJofI<1rrtlH oul If tho beJrin{Js <11e lemovell ,,,,d the S,lnm ones ,l.e 1":111111 nsctl a!F"n. illS viMlthat Ihey ale .elillcd III Ihe s.lmc scahnH a ... Ihe Olle I.om whIch
thf.'Y WC.C lemoveli.
60 Crankshaft reM oil seal - rellloll,,1
To !emove Ihe 011 sei\1 wllh Ihe ell!J",e In Ihe ca,. Iusl remove Ihe U 2 Releilse Ihe SIX holts S"",,"IO Ihe tlywheel lI11d remOlle I,ve 01 Ihem Wh ,l o holding Ihe flywheel. fCmove thc slxlh bolt and hll ,Iway Ihc lIywheel. 3 n emove the lour hOlts SCI;""IIU Ihe Orl se;rl C Fig.l.1 2 R ernovinu the rear oil se al from Ihe carrier
(Sec 60)
~ Crank sh aft llnd main
henri nUs -re rnov.r1
, Relnovc" 2 n Ie CIIIl"I" 1'011 Ihe car . 'J, 3 n emovc the ClelC h HSSI~olhly 011 Illllllual transm,ss,on madels ·1 ernove lir", , , ,
L'
·
.... yw lI.le ;lIld Ihe leal 01 sual cal"er. "/-·H. $'i;:.
5 1
Sld e d own. chock It sccu "' 111111 ,1n(1 Illy I")ul Ihe he.1""\) cnps In ord~r. 10 nemove the IWO boilS Irom eadl ollhe malll b(:;IIIIIIJ c"ps. hit lilt)
CilP S all .111(1 lay 1111:111 out'" order NOlll Ihm Ih" c~nlle 111:1111 hcn"ng f.':IP has Ihrll~1 wa~hcfs M;l,k Ihetr POSIIIOIIS hili",,, .., 01 lire IWO th,us t wi\~hels We'e ""Hovod
62 Ellgiflo Carl\l)Ollelll~ -e~iHllil\1ltiol1 far we"r
nc:lm 10 Soctll)" I 1
63 noct.e r arillS -examination ;ond nmovalion
llll) siuds 011 whIch Ihe locke, arm~ p,vot arc a pless 101 Into the cyhllder he,1I1. ,111(1 II .1 51'<1'0101 cdUO IS Inld aCfOSS all s'x. II cnn be seell whelhtlf ;"'y h,ll1e 1>f:\Jull II) pull oul. II Ihl5 IS Ihu case. Ihe stud w,1I have 10 h e I..,1ll0vt:d. Ihe hole re,lllll!'\! 0111 ,IIId ,Ill overSlie Stud hllll(1 2 Check Ihal Iht.: Itucuds on the sluds a,e!ll Uood conti'IIOI1 anll that ~ \IJ'(juc 01 nllc.1S1 59 N", ( Silil dl:lrCIUIlI. hi a locknul to Ihe mlluslef 3 EX;IIWlln 1hll Illeke. <1111l~ ;IIH) IUit;IUIlI snalS 10' S'~lns 1.11 rrdH'nU. 1.1< I:XCtJSS we,ll 1111 Ih'l Ilc;o,'nu $IIII"I:<.'S II Cllher p.lll shows excessIve W"'II. 1".111 Ihe ,",.k.)! ;",n a"ti ti,e 1\lle'IliH sent '''u~1 IlIl .enowcd If When I;hcr:klll\l lilt"! rI)C~,)lS ;UIIlS. 'C"IOVI) Ih,;", one .11 a l"no \0 ,,"mlll(llo: allY POS).Ihllrly 01 ,urllS ,Iud seals Ilct:lJn l,tlH ullerchan\)cti. or Ilelll(l 1.,!I1Il:d III Ihe W'OIl(j ~IIIrI
GIf Tappets ,HId pushra()s -elWlllin alion ;lIld renoviltian
ncle. 10 Sm;trr)ll I 3
65 CamslHlIt ,\lid ca!l1sh':llt bC(H inos -c~arl\il\"tion and
renovation
UlllhHSI~C camshaft beaflflf)S ;1fC ayml.,tJle. so II IS poss,hlo \0 SOlly,IUIl , I waul c amsh31t by rCtJtlIl(lrnO Ihe 10uII1als. II the call1s . or skew gllar. atll wOln stOllllocallll y. Of arc d':II11.10,,(I. a ncw call1Sh.1h
IllUSt be I'lled and thc tJcallngs should Ihen also be renewed. 2 WOlll or dalllaUed c;m,sha1t bearings can be replaced by ncw ones. hullh,s re'lullt;:s spI)Clal tOOls and should llc om,usted 10 il FOld dC<1lel. 0 ' 10 (1 wa.kshol) wh,ch undertakes carnshafl reclalnl'nu
G G Cylinder horus _ eXHl11irHltio n and re nov(ltion
Reier
til S(:Cllon 1 G
67 P is tons and t)isto n rillUs -ellamilwlioll ,lIld renov(ltion
R e
lcf 10 Sectlo" 11.
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