1974 FORD CAPRI Workshop Manual

15 Fau lt ui(l9"0SiS ~ cooling system
Sympt o m
Overhe En\lIlHl !!ms too cool
loss of COOI,llll
...
Chapter 2 Cooling systern
Reason{s)
Insuff ic ienl coolant Drivehel t slrppinu R;JdralQr core btockcI .1. or H"lIe rpSI"tled Air lock in cool lnll SySWIl1 W mer hose Coll.1psed, or linked, ''''red",\) flow TherllloSI T hernlostat dtlf.!ct,ve , (), 110 Ih,:flnosut W,ol1n Ihe"Il Dcfe~llve p,ess",e cap l,:akln\l hos,!s leak 111 ,ad,mOl. 01 hen"" tOI() TherrllOsl,lt or 111111111 11~I~l~1 In,l k Blown cylinder h'~ild O.l~l." Crn ck(!(1 cy"nd~( bfock, 0, h(:"d
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I II
Chapter 3 Fuel and exhaust systems
Contents
Pari A: C,UbufCIIQr system AccchmllOf cable -removal .1n( rerilling , ........... , ...... . Accclm SI}ecifications
PMf A: Cilfborettor system
Gctwrctl System 'Y lloC
Fuel pump delivery l)reSS\lrc .
Fuc l I,ln k c,lpnc,'Y .
Cilrhurcttor lytle Tluol1le baf!el dranwtcr
Vcnlull d"ll'ICICI
Mainjct: 1 !I71\/1975 1976 onwards Idlong speed: 1971\/1975 1976 .............. .. 1977onwilfd5 FilSI idle speed: 1976 1974/1975 ilnd HI77 onwilr(ls
Floal leveL: 6111SS lIoal
PlaStic float
Floill Iravel ...
CO %
111 idle: 197<1/1975 1976 1977 oowards ......... ........ , .................... . Maximum choke vacuum p ull down. 1974/1975 .......... ....... .. 1976 1977 onwards ............... . Choke phasing: 1974/1975 1976 .......... .. 1977 onwards,
17 18 3 7 8 20 21 5 6 4 14 13
16
15
1 19 ,
9 12
Weber calburellor P.1rt 8: Fuel injection system Accelerator cahle -removal and wfl1l1n!J ' Au cleaner -Icmoval ilnd lellll,O!! E~h.1USI maOifold Icmov,ll and whllm!j
Exh,luSt system .. lemoval ,1nd rnf,ttin!1 Fuel l:lnk. sCIld el utUt and follel l"floC !!fmc.,,1 Gene.;,1 descflpt,on
Irlle nuxture • ,1d/l' Slmenl ..
Inle t man,fold .• emoval and 'ef,nn,!]
Ma,n systcm compo nents .emoval and rd,ll'n!) nouline m.1jnlcn,lnce .
P.1r( C: F.1l1ff di,1gnosis Fintlt d,n!]l1osis .. fuel syslem (cadJll,ello,) Faull d'agnosis -fuel system (fuel injeCI,on) ,
11
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:12 33
Dual vcnlu.i downcfoa"llhl carh,",cl1or. m~IHI"'Ci,lIv Or.cHnlcd (hap'" .agm luel pump. tempcrilh rrc cOllI/oiled air clenne, on sallHl "'0111:15 02510 0.35 kgl/cm' (3.7 1 0 50 1I,l/ln') 580 Il1re (I2 7 1)011)
Weber (Iunl venturi wilh autorn;rt,c choke 3801111 27 nun
1450101 or 1<12 mill 142 mm
800 J. 25 rpm 825 1. 25 'pm 850 l 25 rpm
noo ,., 100 rpm 2000 ± 100 rpm
40.0 mm (1.575 in)
3 4 .3 mm (1.350 in) 12.5 1. 0 .49 mOl (0.492 L 0 .02 in)
2.8:l. 0 .2 1.75 10
5 .0 1 0 .25 nun (0.197 7.0 J . 0 .25 mm (0.276 5.5 :t 0 .25 mill (0.217
2.3 ± 0.25 mm (0091
, 0,01 , 001 , 0.01
± 0 .01
3 .0 :t. 0 .25 nun (0 118 ± 0.01 2 .8 :l: O .25mm{0.110 J. 0 .01
in)
in)
,n)
in)
in)
III)
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Chapter 3 Fuel and exhaust systems 67
Torque wrenc h setting s Fuel P\JlllP Inlet n' Pari R Fue! iniaclion syslem
G ene ra l SyS1c'" Iype Idl e sp ce d CO "o,![ ull" Fu el p"mp rfelov(!ry (nHrHrl1lJlll)
SyS1cn, P")~"'''U Fvcll,mk Co1P,lC '(y
Torque wrenc h settings Fue l ,11,>1,,1.,,101
W",m "p "'~11I1;,1O' 51<1,1 V,llvt: A\J~'h;"y i'" duvlC(! Air eh.""I>", Bal1)o I>ull~ Fuel d'SI"hu\or W",nl up '«!lul,l1or (MIO) W,llln·up rC(jul PART A: CARBURETTOR SYSTEM
Gener,,1 description
TI", 1",,1 sy'>I<'1ll <;onSIS1$ of " reM moulI1ed fuel wl1k. il {hilpluo1\Jn1 type 1",,1 1l"'''P d"v(JIl I,om the C,lIllSh eJr.h COII~'Stll'!I 01 ,I hont pIpe nnd leson S omn models !"ay he hlled wIth a p,llted vacuum switch (PVS) to p'eVUl1t fI"1 SpulS aud nllsl"'"0 OCCll""'\) when the enllllle is cold "lid flll"""'1 WIth hJlI or pMllJI choke. When the enuine IS cold (below 71 C I i GO F» the I'VS IS closcd. In tillS cond,I'Oll. c;lIhurenor v,lClIllln IS ,'Pl'hed directly to Ihe d,st"lnilor V'J the Ilon·return v;)lvc. whIch "lIow~ (he va ClJllI1I Jdv,lIlee to IJc milll1lolll1e( 1 lIntier <1cccieIJt.on.
prc .. en ('''Uliat spots or mlsf""'\J .... ·ho)lI the eng"'e h<1s re<1ched liS norm;ll ope,mll1\J lemperJtllle Ihe PV S I, open In tillS condltloll lhe C<1rbUle1l0' '5 connected 10 Ihe
d ,s t"hu!Or v.a lhe PVS.
2 Rouline lll AI the IIlIclv Check and adjust the idling speed find mixture 1 Refel to Sect.on 12.
Check condilion of fuel hoses 2 E>.n''''lle illl Ihc fuef hoses on the eng ine compartment and on the fu!:1 ""'k. for SIgns 01 leilkJge or eletellowt,on. 3 Che ck the secullty 01 holtS 4 Rel"r to Sect,on 19 Jnel t.ghlcn tile IIllet I11J",101d bolts III the
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s!:q uence (jlvcn
Renew the ilir filler element 5 D'$ coruWct lhe hauery. G Remove lhe twO nuts secullng the air cleaner lid nnd remov e tile
N rn 16 to 20
4 to 8 8!O 15
'8 to 2 2
1 8 to 2 2 20 to 27 38 to 45 20 to 2 4
Ibl It 12 to 15
3 to 6 6 to 11 13 to 16
13 to 16 15w20 28 to 33 15 to 18
1305<:h K ·JetfOnic COlltonnous inlCCllon !JOO .1. 25 rpm 1 25 I 0.2 930 a cc cvcry 30 scconds 5 f)5 I 0.25 kUI/crn' (789 I 36 11l1/on') 580 hlrc ( 12.7U Nm Ih l It 32 to 38 24 10 28 7 to 10 5 to 7
7 to 10 5w7 7 to 10 5 10 7 7w!l 5 10 7
18 to 20 13 10 15 11 to 15 810 11 5 to 8 4 \0 6
5 10 8 4 to 6 181020 13 t o 15
hd . 0" I;>ter models the ltd rnily be secuted with sprong IJSleners. 7 LIlt Out the paper clement 8 Cillelllily clc Check air cleaner IClllpcril{(lrc control (whcrc (i{{cd) 11 By looking through thc main ,101 cle,llle' spout. nOle the pos'tlon 01 lhe 1I"1l v F ig . 3 .1
Air tamper A 8 C
VaC(I(lm mUlor FIlip valve I-IC<1I sensor
o 1-101 all in",ke E Culd illl U!wh,
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68 Chapter 3 Fuel and ClChau st systems
14 Dlsco""C(:t lhl) V;1CllUlll ~lIprly IUPC (10111 th,: h<:.11 ~Cllsor Oh~r.rv'J Ihe O,) CI; ,hOil Olillc U;1,) villvi) whll!) ,'Ilhe s,.,mc hn~c ;)PpIY"l!1 SUCtIo n 10 Illu cnd 01 lhc ~"ppIV plpn It Ihe 11;111 v,llve 'C~1"'S closed then CI!lu:r tlw (i .dplu;)!l11l or 1110 flap V"IV~l IS 1 ,I\Jlly If thl) I lilP now opf;n~. Ihe f;lUII 1":$ III Ih,~ hea l ~(:n ~o(
3 Air clear -rCllloval nml le fittinu
1 Q,seol1ll(;f:l lhe 1I,,1h !IY 2 Remove tli' l two n"l~ '<:t:lII,n!l 111".111 (,"'.III,,, lid "nt! ",m""" II,,, hd. til ... " I,ll" OUI 11", "" 1.1,',,,,.., 0;1,,11\,,111 3 Kuuc.k '>.ILk lh" I"", Iud. l"hs _mel 'CIIlU"" Ihe toUl Ilul:> so'' tuH1!! lh,);oll ch',IIlt" if) !he r.;Hhu"·lw, lu> 4 Funl III "lIP Inst "'\1
H Ih.·", .11" .. II ""Y'"'''' 1",,1..~ " 1",·I"",,,,,,y •. h d).. .. I 1111"1 I""" P "I~",'I"'" ':,111 I" , ",.,11" I,V ot"".""" .. ,.I"I~1 110" ",,11"1 1"11" "I II ... It ... 1 1"""1' .,,'U I '.(""","'I",!) II", 11111"1' OI,lh' l I,y., I''''!III, (,I 1"1,,, I"" ~II.,~" I." :' Cr.,,,1.. 111" ""!I"'" .",,' /,h~",\"" ..... 1"·. 1"" _, "'''''1 .. 1 p,'III,1 '''''''', .... I",,,, .h" '''''''I' .",,1"1 .,11111" I''''''''y .. , .. ... ,,,' :1 To c.h""k 111.11 II,,! I''''''P ,<; w.II"" 'h ~p""oI" .'IIUIl. ,,,,,,,,,,, ,1 .' p.e"~",,, !la,,!!,! 1 0 th,! IU""p outkl D'M·,"''' ... '. t III" II r ","", hom 11", co,l. c,;ulk th" ""!)"l{, ;11111 UhM"V" wh",h'" Ih" 1>\1,1,,1 1''''';''''111 " ." SllCCd'e d
5 Fucl purlll) dc,,,,illg
D"I,'I:II (h .) 1",,11111'" 10",,, II,,· 1"""1> ,,,I ... lui", 2 Umlo ,IIlIt """("'" lh,' ( •. ".", '~" ...... _ .. "t 0 ""'1 .""t t.!1 "tt lh,· .... ~III".· .. 1 "''1'. 1,lk' '''Ht ,.",,1 :l 1 t""oU~II,ly (.1""" 11", ·,,-ltll"':I'1 "tl'. 1,110;' ,11,,1 III''''t''''\) ,.1,.11,,1,,·, U~"'H a 1);ou'tl>l,,·,11 ,tlHI ( .11"", 1";h"II() '",n<) "" "ny ",·,111"(:1'1 ,I In ,,,,,,,,,,,,,,101,- " tt", "'''''','! ""qll"IlI;" !to ,h"m.IIIIIII'H Dn " .. 1 UVI""!tl'I"" II,,, '.""1", '.,.,.,,\' .• ,; '( (",,1<1 (h~t'''1 tlon ~.,(t llw,"1 ("'t>
6 Fuel P""'tl ,emovnl ,md .uliuiny
L()U~"II II", h""l! ,.ht ... Io<)l1l Ille IWO C(Jlln," (1011:; ')" It\!! P""' P ;,,,,1 ''''"0~C Ihl! ho~" If "'''"1)<,<1 IVp" d, .. ~ ,,,e I'lh .. '<:I cu, Ih,-m Iol'(' .",d H'lti.,e.C lh"m w'lh ).C'l'W lH'" • . ht> .. 2 Undo ,lnd "'!II(We (h" [<\0 nul~ ""d ~fI"'l!1 wn"h,,,~ senor'''!! II", jllllnp to (li e 1"11"'\1 rI"'" H!ull'(11Ih' I,uml' nil nCIll()'" II", !I"~~~I 3 n(:l.tinlH lhe 1""111' 'S the '(:YI:'~ 0' '(:11101';11 . hUl de,H' lhe ,,,.,,\11\1 ',lC",S ,lIld 1'1 " r"' ..... 'I,l~kc(
7 C;orbllrnU or · gCnc'ill
'Th" c,,,hu .. ,uu< IS nllh" \Vclx.r ci .. ,,1 "CIll,,1I (lownd';1uuhl lVI)C Willi ;111 .1II1UI\1;.U<: ('ho~ (~ 10 (:nsur" C;1Sy S.,\lIII1\1 100'" cold The m,un ;Ultl
IItim U sy~",,,,s ;IIe dup"t;~ I1 ... '(I. p;,ch b.1 .. cl h<1Y1I\9 S('j).lf<11e SVS1(:II1S supplied Irom 11 (;0"'111011 110<11 ch,lI1'u." A S'"(JtC ,'lcd':f<110' pump 01 Ih~ dJi)ph"lYIll lVt)C supphes hOlh b;lr! Ih'Oltl(l hnrrch, trl.1m YenlU" ,1nd ;lceel,,"IiO' pump ""dy ThC,e ;lJe two tl"01l1" ~p'nt!l,,~ ...... hoch ;"tI IIIU!rconnc cled I)y U .
3 2 O,; ,ur;om 0 1 nir tcmpcr;ohorc contro llC d ilir clcnn.] r (Suc 2) V.I<: IIII11! /",.1,·
f)""d".IfltJJ lllUl f),.II""_"''''
(A j
()
1 1"1:'1' V;,'~!! I/ul ;'" /I"IV
FiU . 3.3 Air c lcm'er (A) (Sec 3)
(c ' ..
Fig_ 3.4 Fuel pump filter rcmo",,1 (Scc 5)
8 c Pump body
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Clwpter 3 Fuel The fully ~u!OnHIIIC choke system IS lor.olle(l 011 lh'~ "oill-hami side 01 t he Cn'UUlCltor hody a Carburcltor -rClllovill 1 Disco nnect the Iwltery . 2 nc",ovc Iho) "" cle 5 Disconnect the fu,,1 f"ed ilnd ,(:t",,, plp"S I,o'n til" C ... I"'H-tt,,, If •• cl, ,,,pf,, IIYI' " hose dan,p IS l'ltr~d, CUI II,e ,: 1""'1' II> ""n,w" ,t .",,1 "·'''·W II wLlh SpeC ifiCatiOnS and wlrt ,III the 1r0$CS Top u p til" ",,,,I"'!I ~y~!t:m II necessa.y. Adjust the ,die ,;p,;Old ;0111 IIlIxtuw a,; d"·,,.,,lred II, 5",.1 ,,, " 12 .
Fig. 3,5 U·circlip 011 the choke operatil\g link (Sec: 9)
A /I
Fi9 3_7 Upper body components (Sec 9)
Flo,lI telaininy pm Ftll.'t c o NlJcdto V;I/V(!
POWCI v.1lvc
9 Weber Cilrhurettor -dismilntlinu [lnd reas~ernhly
Note: On 1977 mod(!/s onw,lf(II /lIP. cmlll/id/ot 11,15 ,1 '/Jy PilIS' tdle IIdIItS/IIIY SP~'W willch IS sc,l/r:iI //I l!lodl/cllOn wl/h <1 willie (}f ljlCY 1,/,'sIIC (:,11' UlI(ler /10 CItC(ff!!s/a/lces should {/II.~ SCI('"W h e /,)t!J/JlNl'd wi/h (Fly 322) 1 R(!II1Ov(! the C.1,h"n;llor I! O"l th e ':Ol!)""' . ,1~ dr;w,lp.oI ,n Section 8. an d cl(!,lIl th.) f:ilrl""etlor extC"Of w'lh 1'.,['01 or a walt' soluhle t"OI",,:l;\,y 1'/,,;)11(:1 J. C;, rdully I"'S" 0,,1 Ihe U'CIIClrp w,th a hC,(lWII"v" •• lIul ,h~COIUlo:cl til" '.ilok" pl"w oj)l:(allnulrnk :I 1\""10\"" tire ~I X ·,,:,,'ws ;'"It ,i,-(;" .h II" , GIl1"""llor "Ill"" body. ·1 Uns';",w llr,) h'n~s nul locnl"d:ot th" ((",I ,nwk,) .'nd d el.1cll Ihe flU'l
Iolt"1 (; T"II Ollt tlo" lIo;i! ,,,t.1"lII'!J pm. ;,nd dd.1{,1r II,,) 110;11 ,Hl d needh~
v:otv" I, R"",,,v,, tlon th,c" ~c,,:ws and d"t.u:1r tlw po","", valvc d';lpl"a!)1ll .'~h,,"'tJly 7 U"hl:",W thn ncedle ~"Iv" ho,,~,nu 8 U"suo:w the It)( and Io:t pt"\Js I. o r" til" c."jJ\""l1m Imdy. not"l\) th .. , p"~.'I'o"s III wh",h 11,,;y ;0,(, f'lll:d ~) I~l"ll()v" (h" two cn ,"b,on luhes ;011'" ,,,'IIOVIII\) the two lll,lIn "" l"II rt<.:t,on t,;ts 10 1l<:!lIUVC lorn sr.'l:ws. t;JkC nil II", ,1co:"I,;r.lto , j)"Il'P co"", ,,,,d ,,,,,,,-.vOl ttl<, d',Ij,lua!l1l> ;Hld 5P(in'l SUlul,, "11,,1<;1, ','rI"'v\! tile '11'tl·~tall d,.lt>lua~I'" 1 1 CIo';j1l .,ll ttlC compontnt s ;oml Ih,,' (.:n,;w" Ihat the lets ,\10 ,u",I".t,,,. :t"III,y I,tow",!) t IHOI,!)11 Ilw'I' I J. Ca,ciully ';C,(,W ", Ih e moxtu,e sc.ews Ul\lI( (,aeh 01 Ih cm con1.1cts
Fi\j. 3.6 Removing the upper h ody -nrrowed (Sec 9)
A II
Fig. 3,8 Jet locatiolls (Sec 9)
Mwn ICIS C Idlc ICIS Air COtt~'CIIOIl ;"IS
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