1974 FORD CAPRI Workshop Manual

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40 Chapter 1 En~Jjne
The system IS known .15 the re v SYSlr.m (positive Uilllk colSC ventilatIon) n n d the il(lv~nt.1(JC 0 1 the sy sleln IS 111;;1( should the 'blow h y' exceed the CtlP 26 £:nuine r C ilssell1bly -generill
To CIlSU", m,1XIIllUIll life wnh I1\IIHlllurl1 (,oublc I,om im ("",hauled cnume, 110[ o"ly Illllst evcry Pill I Ile cOlfcctly ilsscrllllled Inn """yIl 1m\! 11"'S( he spotl{,s~ly clean. <111 0,lw.1yS m ust he c lCJn, Inckmol w,l~h(!IS nn d 5P''''() wa~he,s O,"st o1lw"ys he Iitted wherc n""d.·,1 .u,,1 illl h'mrlnus ,111(1 Oil "" slld,rlO ~"rlilces must be th o rOU!jllly 1"I"Wd l"d (lUIII1\J asscml,ly
2 Be low ols~"lllhly. ,,~new ... ny hol ls. studs '''H I nu ls wlo"", 11""",,b alt.! Ii) ,Illy w;'V ddllh1\J"rj ,II HI wheneve, poss,hlc 1O~" ", , ~P"IIH w ,lslwls Ohl.H n a compktc so:t o( new !)askets ilnd "II n,', p,"IS.", n"r.ess,',y
3 When ",(,it,,,!) p:,ns "n~"'" I h,11 Ihr,y noe ":('I1<,d on Ih, " "!III)', 1 pos,t,ons il"d d"",CI,ons 0,( ~(J"I lops should h e Slllea",rI " II, !I""'~C befo,e (,IIIII\) A Io'l"ul ,FI, k c t "",1I,"lt should h e "sr,d wh,,,,· "'p"ul",d 10 prevCIlI I""k.,!)"
<1 Ap,"1 from yo", no,m.d tools .• 1 supply o f clean "I!I'" .• " ,,,1 C.II' f,II,)( 1 wnll 0.1":,,, "n!)"h) 0,1 ;"1(( a lo,que W "III(;h ;),e ess"'''t .. ''
27 Crallks h ,d l . rc filt;IlU
W'pe th" ""''''IIH ~h,,11 h":"t,,,"~ "I Ilw c,;" ,kcasOJ wnil." 1"."1 "'!I ,"1(1 fll th" m.II" 1"",,'110 UPI"" h.,11 ,h"lIs,,1 posnuJII 2 "11],,,, 111" Ill;" " h",\I"ltl sh,,1 1 ((":,,t,on5 and lot II,,: h:,I( ~h,·II" II' IIw caps (photo) If I hl] old he:"",!!s a,c IWIIl!! ",I,(wd (oll (l1ou!lh II,,~ 'S.I f,dse eculloll'y "1I1"ss Ihey ;"e p r.lCt,r.,lll y new) m"k e "on. -Ih"y ;'''~ fnl!,(( III (10"" ",,!)uI,,1 POSII,O"S

Fi!l. 1.4 ncar milil) he;!,. .,,\) (;'!(1 " .e " (s h ,Hle d) fo r apply ;, sc;.li"!I compound ( $ cc 27)
3 Apply;, 10111" \I"'il~e 10 ",".11 ""It: 01 II", No : """" lJ",I!niU so '"I",n Ih" 11",,' ,1 W,,~ ll"'~ (" ,Illy """Io:I~ ol,ly) ,1 1: ,1 1110: "PI'''' 1o,llv",s o( I III! Ihl"~1 w,,,h,,,~ "110 II", ,, !)lOove s ",.I" "I 110" "';!'" 1 ":;II ,n'l Till, "10,,,, "''',1 (;oce ""Iwa,ds w'th Ih .
1"".01",1 tt' Ih" 00(,,,,,", /r!,,,ly "It,d.'I~, ""Iy) !J I "1",, .• ,10: lilt, u ,,,,kd,;,1 1 111",,, I""""'~I )ouOI,als ,nid thc 1"""""1 ~I',·lb wl!h ''''!IUH! 0, 1 (1IIIt,to) G I'I,u'" Ill<: ,,,,lI 111,"0 h ca""~1 0,1 """I "' pOS'I'O ll 01) Ihe end 0 ':'dl lk,h,,1 1 AIII"""t'vcly fll II l" lu. ., ",,,,,I,,lIy I"wu, tho cr;,,) ksll.,11 "* , tho (;!iHlk<":ilSC 8 I\pply;) lI"n r O;oIIll( ) o( ~e;oluI!J compound 10 Ille n'ilHng fac , th" ,:,;o""O:iI~" .,,,rI IIlI! ,(:", niilni I'CiI""(l <":,IP (p hu to)
27 2 F'IIIIl~I,1 h~'" "'g shell to Ihc I C'" rllJ") h e;)"I1!) Ci'P 27 [) O,I,, )!! No : ''';I ,n he;,,,,,!) UPI","( shell 278 A pplY"'1I sealtn!) compound t o the ,ea, m,I'" I W;),,,I[J rap
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27.11 T '!Jh1l!'''''H (he "''''') heil"n,) Cilp bolt s 2 7 12 Te'"pO'ilrtly sll~k a d hes,ve tilpe on the 'Cil' of Ihe c'ilnkshilit when f'H in u lilt 'Cil' 001 sUill 10 P'01l!(;1 Ihc seal lops
',,::;;Am p.
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Chapter 1 En Hine 41
27.1 3A Crankshaft cndfl,,"t r:,Ul he ct",cko:d
w
Ith fee ler gauges
V" ,
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.:,;~" ~ .... ::.~.;
2" I!3A Lrll;,lhl Ihe dow!;1 ~".;lo; WI III" "'.I1n
I)e,',"]!! <;;'1'
n .I50 ... ~nd press lully 111 wllh a ~(."·wdrivcr
28 1 A FII Ihe ch;IIl\lclct! Sjhlcer 28W ,lIld k e y on lhc Cil,,'~hdlt
!l Apply n :;'\\1),11 01 II'"a~rl 10 bolh suh,~; "f Ihl' No 3 1\\"111 bU,lIlIlIJ C;]P ,.0 !IS W lelnll] thu th"", W:ISIII:IS FIt 11"1 llrlllsl w;,~hur~ wrlh lllC 1;llf 10C,'tNI 11 lhu 1J'OUVI] ,,,,,f lire slul S I;'<;"'IJ uulw!llds (u~dy moticls nllly) . 10 FIt lhe 111,'''' hU;""\11 caps wnll thu ,II lOWS Oil Ihe C,lpS pOI1lI 13 US"'!J I<-eter \J;'Iu\1es. check Ihe cr,lnksh!l1t clltllloai by luse'ton\! Ihe t,.utl":< u,luue belwt.'e" Ihe e.,lnkshalt IOtHnal sldc and Ihe IhlUSI ~,'~hCIS The elc;"al)ce musl 110 e xcet'(! Ihe "gUle u,ven Ul the
( O('e",entoons lhe check call nlso he made IISlnU a dIal IJilugc 011(1105). ~: Rot
ale the crankshafr to enswe tll:ll II'S nOI hlndmg or stlekln\!
I,,'ould It he v Ory SI,I! to t"", 01 have I m)h 0;1)015 ,t must be fCrHoved and Oloughly Checked . IS CO;'llhe rea. ilia." hC!lrlllIJ CliP dowd su~ls wilh seallllg compound ,'nd "Ion t)OSIl 0 U
1 II I n. se a 1,Iunt soew(hlvcr or suml,:" 1001\0 press Ihem IU V 'n (phOlo s) They should be tItled WIth Ihe rounded face pomong ow,l,ds th e beann\.] cap
28 Cam!;hld, ( ( ant rOllt inlermedill\e pl,II o -refitting
1 Shde lhe . 41lrJ I I SI);'I<;cr onlO th e camshafJ with Ihe chJmlered sIde II1sl 2 ,II Ie key (photos) 3 ~UIJI;cnle lhe camshah beil"ngs. Ihe camshafl and Ihe tluust plalC illC ullV Inseltlhl.l cilmshah !rom lhe lront and III the IhfU SI plale
;""t sell.I<,,:k"'\1 M,CI,'IIl!J ""'1" TI\jI't\:1l Ilw II [()lillie.
" ~'I lhu 1111""\1 , ;OVUI \JII"k ~,I,'''v,'s and 0 IIn\1 o;.,;lb CI"nkc,1$() , lin ,:h;Hll"~lud end 01 11m Ulnde sl(]eve~ muSI k,cl) oulwa,d
I()w;"d~ III" llIlllnU r ;(}ve' 5 [nsulc 111" m"Wl\1 f;lcl.Is Ilf llll! 1: .;",~c;15e ~nd thu hOfllllllenncdlalc plalC an, clean ;"" lhen apply ~""""\I compound 10 holh lac,-,s rO~'lIon lhu nd"kt;1 on Ihe ct""kcase ,mlllhen I.llhe IlIlern,ulh all' plate
(phOlO)
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/ \.
285 F,urnll Ihe Interllled.ate pl"te
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42 Chapter 1 Engine
28 G TempO'i1'y holl 101 IOC;l1inO the mlc""t:thiUo: plale 29 5 0'1111(1 the )l'~10n linUS 29 7 0,11I1{J the cyllnde. hOlo
";; '. '''' . :~ .,
.. : .
..-2 9 8 US'''H (I plSl0n "l1g compressor when uiSerhn!llhc p,ston "110 the hore 30 2 Chet;kln~1 the Sial) washer I)OS'['OIl on the 0,1 pump d""csh"fl 31.3 O,llhe tlywheel holls bel o re ',",ng
(j 1,1 II", two f.t:"11'~ holts ItI1!jl.:r·"!lhl then 101 ;Hlorlm' two holls t'''''IHH""ly 1o. IIU:"I"'!I purposes T'!Jhtcli the CCIllle sec"""!J hails th.·" It''''"Yll the '"ml""'''Y Io,u "d 1000,umU bulh (photo)
29 P istons Hnd COIH1(!cli"g rods -refitting
WI, ... , ('.101,1" the COIU1I;:(.I,n\l ,ad h"U of tll c !l0U·end bO il'lIlll 1111d rh e IInde,sulu ollh(l ~hcll h .... "l1y ;lnd IIIIhe sh ell hc"rlllU "' pO$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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Ch ---3 Fit Ih e si~ flywheel sec"""\1 11()1I~ (n, t"dl (phOto ).
4 Chock the secur ing boilS
flywheel 10 "'~1'.111' ,I fro", tll,nlll\J. <1nd tighlen Ihe in il (li<1110I1ill <111(1 plO!i'''~~''VU l11<1ntJer 10 the speclf,ed
IOf~:iil l he clutch (Iosf: ilnd p"'~"'l"" pl.rle iI~s"mbly 10 Ihe flywheel 5 . ,ure Ihe disc ,s I he co"",:1 w.,y lo"nd (see Ch<1plor 5) rTlJk,ng . 6 Secure the pr~ssum pl"h~ "~~I:mhly Wllh the ,ct.1U1Ing boIlS. enl'Jlise Ille clulch dISC "Sill\) .11' old !i,,,"I>OX ,npul slwh 0' sul\ahle ~1Jnd,el Jnd thel1llghten Ih,~ ",I""'II1(II,,,IIS to Ihe sp~clfl()d tOlque III diagonal Jnd pr09,esS1ve m;II'"<.;1
32 TiOling geMS ilild li,nin(1 COVIH refitting
I Check Ih Ihe keyS ;110 f,ee I,on' hili'" III II,,, I.,y'> ",(" II,,, k<.;yw;IYs 2 If Ihe c' u~c 1 M pulley Jnd boll to P""'S ,I "" (pll"I"~)
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I't'


3 hI Ih'~ c,"n~h';h,,1( wIth Ihe punch ""Ilk III
,111(I'"nOIlI with the mark on tho cr,ll1bh.1ft HOI!) use a dl (pholo) 6 Oel~'lllllln th" pO~lIlon of Ihe OIl sedllll lI,c l"llIlly C()V('I, Ih'-:II d"vc Oll( Ille old su,,1 (ph010S) . 7 0,·.011 1110 100111 i."rIOO of Ihe 1111"",1("Io;no plate ;",.1 the I.ICe of Ille 111""'0 f:OVI". nll,l IOO(1 COlllpOIHH I fI f'''~lt''''\'' IIIJW !!'I,.kl,1 all Ihe Illlr:fIl",(ilil(n plall' "lid Irl lire ,,,,,,n(l ('I)V", 10 lire cyirnd,,, hlock Inserl Ihe I,,,II~ f'II\IOI l'Uln D C.,III,,, Ih" ("'''II!) cover ~rolilid II", nuse of IIw (.,.II,k~h.lft USnl\) v"",,'" C,oI'I"'"s .11 I'JII' dl~mCI!lc pO'"I~. 11",,1 fully 1'\lhIo:II 111" hailS
(1'1",1") 10 1 " 1 11,,, f'''111 n,l ~(, .. I tn the 11111111(j .:ov"r .111tl .haw 01 11,10 lh" 1'()~'IIOI\ ,h.I""))II,,, ~ ..
:U 'lA Loc"lo the cr,lnksh<1fl U", II 01 111" e ,.",hhilh
322B ,. ,HId uSO Ihc pull"y In pruss It on 323 Alryn"".",t d01S 0" lhu III\lII1~) \le lh"l
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..,
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32 .61 Checklllg Ihe pOS,I'Oli of Ihu old 0,1 se 32.10A Fi11lllg the c,,,nkshJfl fronl 0,1 se<11 using a sockut ~nd 11011
32 6B OflVII1!j 0111 the ""'lIlg COV(:r 0,1 se<11
32. 10B F,tluU posItion o f Ihe e f ,ol1l orl ~",~I III Ihe 1Ir1I11ly cove,
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