
94 Chapter 4 Ignition system
i ' .
. --8 2A Removill{J the IllnSlre dust COve, (28 hl'c Cllume)
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, , ,
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J 2C W'''I1!j connector i'Uld seCUJlIlg screw (lHOwS)
9 Ignitio n timing -adjustment
Wnh the (.lIs\"OuIO' III!Cd ilS dcscllbed OIl SectIon 6, check Ihilt 1Ill! COHCCt llllllng m;l!ks "'0 ;1119110d. 2 To check the ;1111,,11 (5 t;1I,e) setting, .emovc the (I'51"lIu I0' c;lll [11l\( check IhJllhc rOl0' ;lIm IS PO"1I1119 to the No 1 cylmdc. scgmon!.n the Cill) rndlcmed by the sial on the 11m. 3 On the 3.0 lUre engIne the cont,le l poullS ll\u~1 he ,ust SCI)ilril\U'!J Tho e~ilCt Instant C,1" he checked by connect"'u il 12 vol1 lest lamp between the contilC, brcilke r low tenSIon Iemur),,1 iUl(t O,"lh, W,th the iUnilion Oil, tho d is trlbuto. ShOllld be turn ed nrl\,·clockwisc unlol lho bulb luSlligh(s. " On (he 28 li(re enuule the ("gger arms and stator ;HIllS must bc aligned It not. (um I he (hst"bulOr as necessary . !:i Tighten the (hSI"buto. clamp boll and .ehl the cap 6 Set In thIS way the lUlling WIll be alll)'Olmalely co
8 2B UtJlle. vIew 01 the l.imJer Mrn .lrld Call (28 lIt Ie enU"Wj
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,I,
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8 20 Vacuum un.1 sC(:u"ng screw WIth e')Hh lead termmal
10 W,lh Ihe enij1l1e I(lIrng pornt thc \fmlng hgh( at the cr",lksholl1 pulley The wh,le 1),1mte
12 To check the mechanrcat adv.1nce. Increase the engIne speed and note whelher the wh,te malk on the pulley moves away Irom the mark on th e pOInter . 11 It docs the mechanical advance is lunctioning 13 W,th the enOlile Idlmu the vnCU\ Jm advance can be checked by suc kIng the oldv~ncu pIpe that W.1S removed from the carburellOI o r air box ThIS should also c.Juse the while rnark on the pulley to move away horn the mar k on the pointer 14 On completIon remove Ihe timlllU hght and rC(:onnec lthe v.1CUUIll pIpe
10 Ignition illlllllifier module (2.8 l i tre enuine) -removal and rClittinu
Thc Iunitlon illl\J}l lflcr module is locmed on Ihe left· hand SIde of the engIne COnlpar tment. tUSI behind Ihe hOnt suspenSIon strut upper mounting.
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,6 Chapter 4 Ignition system
9 The spark plug gaf} is 01 conside rable impor1~e. as. if it is too lilrge or too small. the size of the spark ilnd its efficiency will be seriously impilired. The spilrk plug should be set to the ligure given in thl} Specifications ill the beginning of this Chapter; IOTa sel it, measure the gilp with a/cere, gauge. and then bend open. or close. the outer plug electrode untillhe correct gap is achieved. The centre electrode should never be benl as this may crack the insulation ilnd cause plug fAilure if nothing worse. 11 Relit the plugs, and re/ilthe leads from the distr ibu tor in the correct I"ing order. which is given in the Specifications. Screw the plugs in by hilnd initiilily then tighten them to the specified torque using the plug spilnnel.
12 Fault diagnosis -ignition system
By lar (he nlo1jori (y 01 brCJkdown and running troubles ilre caused by InUits In the igrlOlron system er(her in (he low (enSlon or high tens ion circuns There
Engine fails 10 staft 1 If the engine falls to StM( and t he cal was IIJnning norll1t1l1y when.t wns IJst used, first check ther e is fuel in the petrol wnk. If (he engille tums ovel normally on (he starter 1I10tor and the bilHery is evidently well chmged. then the lault mny be in either the high or low tension circuits. Firs( check Ihe HT circuit. Note: If lire hal/cry is known 10 hI! {(Illy ch,}lged, Ihe ignilion liglll cOllies on, ,1I)d Ihe s/arler 1II010r {,lils /() tum IIIe ongine check the tightness o f the le'lds on the biltlely terillinilis ,1I)d <1Iso (lte seCUIIHWSS oflhe e,l,th leold (0 irs cOllllec/ion 10 tire body It is qui(e common for tlie le,1(ls /0 Ii,}ve wOlked loose. l.'vc'1I If Ihey look ,1n(/ lecl seclI,e. /I one 01 the boll/my ((:{minM {Josts [11.'1.1' vC'IV liot wi".." (Iyiny (0 wOlk Ihe s/mler 1II0tOl (his is ;/ sUie IIId'C,7/IUI/ 0/ ;/ I;wlty COllllel;('On 1(1 1h.11Ie"lIillal. 2 One of tile commonest rOilsons lor bad stmtln!J IS wet or d;UllP sp,uk plug lead~ and dlstribu(or. Hemove (he distllblltor cap. H "JOdenSil(Ion is v iSIble IIlte!llillly dry the CJp With il rag and also wIpe ;lCf the leads nelu the cap_ 3 If (he enUiue sull fmls 1 0 St.l.t. check that cunent IS reachlllg (he JUS, by dlscounectln!1 ench plug le,l<1 in turn ilt the sp1Hk plllU end, .. ,ld holdlllg Ihe end olthe callie about 5 mm (0.2 Ill) aWilY from the cylillder block. Spin the enu'ne all the sta rter motor. 1 Spa,klllg between the end of the cable ilnd Ihe block should he fa"ly strong With J strong leuulm blue spark_ (Hold (he lead WI(h wbber to ilvold elec(IIc shocks) If Clluelll is reilching (he plugs. then rel110Ve them and clean and reg,lp them. Tho engine should now SWrt 5 If there is no spilrk ilt the plug leilds. wke of! the HT lead from the cenlre of the d'sltibutor C
Engine misfires 10 If the enOlnr. mlsfues re!Julariy. run It ilt a f~st irllrng speed. Pull off eilch 01 the plu(! C,lpS III hUll nnd hsten t o (he note 01 the engrne. Hold the phl(J cnp In il dry cloth or with a rubber g love
(,J) The cOllm.lV be {,lufly giving ,111 iniNmil/elll mislile (b) Thele limy he ,1 (/iJmiJged wile or loose cOrlflee/ioll in till! low (eflsion circuil (c) The condensel /II,lY I;e shOll circuiling (i{ filled) (d) There nwy be a meehanic,lllolUI! IiI Ihe dis/flbll/or (bfOken dliving spindle or eOlllac/bleaker spring. if filled)
17 If the ignition (iming is too far reto1lded, it should be noted thallhe engine will tend to overheat. and there will he a quite no(iceable drop in powel. If the engine is overheating and Ihe power is down, and Ihe ,oni(ion tim in!) is correct. then Ihe carburenor or fuel injection should be checked, i1S ,I is likely that this is where the Iilult lies.
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) Chapter 9 Braking syste m 143
2
Fig. 9.1 DU

)
Index
A
Accelerator cilble removal ilnd refining -14 shnft ilnd pedal removal and refining -75 Air cleaner removill Jnd ref,nrng cal buren or mod cis -68 fuel injecllon models -80
P rnator .,rushes inspecllon. removal and refilling Bosch -202 Femsa -203 Lucas - 202
dismantling and rcassembly -203
removal and refining -201 Antifreeze mixture -60 Automatic transmission descrip tion -122
B
downshift cable removal. refi11ing and adjustment -121 extension housing oil seal renewal -121 faull diagnosis -127
maintenance. routine -123
removal and refOlting -123
selector mechanism ildjustment - 126 rcmovill. overhaul ilnd refl11lng -125 speclflf:iltions -103 SI.1r1er IIlh'bilm/reVerse lamp switch remov
demister
noules reOlov
doms-178.180. 18210 185 face level vents removal and refItting -197 facia panel -188 fuel filler flap -188 heater -192 to 194. 196 10
uphOISlCry
and carpets -176 mirrors
-
192 open rem quarter glass assembly
removal and refitting -186
re~r qllMlcr trim panel removal and refitting -185 repi'lir millor damaue -178 minor damage -176 sent belts -191 seats -192 sunroof-189la 191 lailgate -180. 187. 188 torque wrench scuings -173 windscreen -180 Bodywork repair sequence (colour) -174, 175 Bonnet release c
Camshaft (3.0 litre engine) retitting -54 removal -50 Camshaft and camshaf t bearings examination and renovation 2 _8 litre engine -35
3 .0 litre engine -51 Camshah and front intermediate plate (2.8 litre engine) refilling -41 Capacities. general -6 Carburetlor (Weber) aulomat ic choke
adjustment -71 removal. overhaul and retitting -71
dismantling and reassembly -69 general -68 idling adjustment -73
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)
rernoy .. ' and refl Uing -69 spcc,'iC
(IlIvchells
G3 e~p:mSloll I nnk 6<1 Ian hub l)()nllllH (30 hilI] 1110<1111,;) 64 f~ull (II;)Ul1osl~ 65
flll".U -
60 lIush"'9 59
",nmlen,lncc. roullllC 59
'ild,nlOr
GO speclficn llon5 57 lem,)er;!lurc unuuc Sf:n(Ie. unil -134 IhcrmOSl<11 -61 10Htlle wrench selll ngs 57 VISCOUS drlv\! 11'111 -63 W1)ler IWIllP 61 Crankca se ventiln tion system 2.8 tol'c engine -39 3.0 rillC engine 53 Cranksh1)ft 2.8 li l.e engine examinat ion nnd rcnoviuion -37 refilling -<10
3 .0 til.e cn gine examination lind renOV1'l110n -52 Crankshilft and main bearings (3.0 litr o engino) removal -51 Crankshllft pulley refitting (2.8 hIre engine) -44
removal ( 3 .0 litre engine) -50 Crankshaft r ear oil seal (3.0 litre engine) .efllling - 55 .emova l -51 Cylinder bores ~xaminalion and .enovation -36. 51 Indo r heads 2.8 titre engine dismanll ing .• cnova lion and .eassembl y -35
Index
D
refining - 45
3.0 litre engin e
. eassembly -55 refining -55 .emoval wilh engIne -49
removal wil h engine in car -49
Decarhonising -52 Dimensions. vehicle _ 6 Dim-dip lighting system _ 226 Disc br1lke s scc Front disc brakes Distributor overhaul 2.8 hlle engIne -93 3 a !r1l0 cng,ne -92 rcmoval and r efIlling _ 90 Doors eXle.io. hllndle ,emoval and refilling - 183 lock 1Issernbly removal and .efilling -184 pillar swi lc h -224
priVill e lock ,ernovill and ref'lIing -185 fnllics tracing nnd feCllik al ion -178 remOle conlroi hnndle removal and refilling -180 Hlmoval and rell\1l11g _ 185 Irim j>ilnel removal and ,efi ning _ 182 window Irnm c
moul(II ng nnd door wealhcrSlrips
removal and refining -185 rcmoval and relining -185 wmdow glass removal and retilling - 184 window regulnlor nssembly
r emoval and relilling -183 Drivebelt s .emov,,1 ilnd refil ling -63 Drum brakes sce Renl drum brakes
E
Eloc triclIl.system -198 e/ seq Electrical systcm altell11110, -201 10 203
ilu xiha.y driving "ghl -212 bmlery -200. 201 bulbs -199.21310217 ciga. IighlOf -225
clock -223
d escrip llon -200 dim-dip ligh ling syslem -226 laull diilgnOSIS -19. 233 ""sher unils and rel1lys -225
fuse s -199. 220
headligllls -211 10213 horn -220
inSI.ument clUSler -22 1 inSI.ument vollage .egula lor - 226 Inmp5 -21410217 mninlenance. fOUline w 200 mobite r"dio equIpment - 226
precautions - 200
rildio /casse tte player -226 specif ications - 198
speedomeler cab le -226 Slmte . mOlOr -207 swi tches -223 10 22 5 lailgall) wash er -217 laHgme wipef -217 to.que wrench sell ings -199
w indscree n washer -219 windscreen wiper -21810 220 wi.ing diagrams -235 10 249
25'
Ii
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" .... Index
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Engine -23 cl $cq Engine (2 .8 litro) lmcillllries -29. 36 camshaft -35, 41 components e~aminlltion for wear -34 connecting rods -37. 42 crankcase ventilation system -39 crankshllft -37, 40 crankshaft pulley -44 cylinder bores -36 cylinder heads -35. 45 description -26 dismantling -29 fault dingnOSlS -20. 56 flywheel -38. 42 front interm!.lt hate plme -41 gudgeon pins -37 lubriClllion system·-39 main Il!ld big·end bellrings -37 rll(lintenance, routine -26 OIl pump -38. 42 operations possible with eng :ne in car -22 op(!r;lIions rC'quiring engine remov,,' -22 iSlOn rings -36 pistons -36. 42 rC(lssembly -40 refining -46 removal -22 removal methods -22
rocker asscmbly -34. 45 spec ifications -23 start· up after overhau l-4 6 sump -34, 44 lappets ;:and pushrods -35 timing covcr -43 timing gears - 38. 43
l orque wrench senings -24 valvcs -46 Engino (3.0 litro) ilO)cill:lr ies • 49. 55 camshalt •. 50. 51. 54 componcnlS e~.-.minlllion lor WC:lr -34. 51 connecting rods -37. 42. 51. 52. 54 cr.-.nkshMt ventoilltion system --53 Crank~hllh -52. 54 Crtlnkshllh pulley -50
c .t1nkshaft rear oil seal -51. 55 cylillde. bores -36. 51 ylinde. hoad s -49. 55 decarbonising -52 descrif)1ion _ 47 dism.-.ntling -29. 49 faull dingnosis -20. 56 lIywhecl/d.ivepl(lte -50. 52 . 55 Iront covc. -50 hOn! plate -54 gudgeon pins -37. 52 IUbricntion system -53 main and big·end bcarings -37, 52 mainten(lnce. routine -48 oil pump -50. 52. 54 operations possible with engine in ca. -48 operations requiring engine .emov,)1 _ 48
piston rings -36. 51 pistons -36. 42. 51, 54 push.ods -35. 51 reassembly -40. 54
refining -56
removal _ 48
removn! methods -48
rocker arms - 49. 51. 55
specifications -25
sump -
50. 55 pppels -35. 50. 51 !lming gears -38. 50. 52. 54 torquo wrcnch sellings -25
.
villvcs -46. 49. 52. 55 Exhaus t syste m remova l and refining -76 EMpnfls ion tank ( coolin g sys tem) removal and refilling -64
F
Facia pilnel t(!mov,)1 and rcfining -188 Fan hub bearing (3.0 lit r e models) .encwal -64
Fan. viscous d rive remov,,1 and refinmg -63 Fnllli (Jingnosis -19 et seq Fault di,)gnosis
lIulOtl1allC lrnnsmrssion -127 tJ,nkmg system -156 Clutch -101 coolmg system -65 clectf1clll system -19. 233 cnlline -20. 56 fuel system cilrbure uor - 85 lucl inlCCho n -85 IHn,hon system -96 mllnu .. 1 !Je.l,hox 122 p.npeller shaft -131 1f!.1f
oved'lIul -
145 remov
rcmoval ilnd rcfilling -2 I 5 Front suspen sio n COIl sprinU removal and refIning -162 duscnp tlon -158 fault dIagnosis -172 h\,bs-161.162 milintenance. routine -161 stabiliscr bar removal and rcfming -163 Strut removal and refilling -162 lorque wrench sellings - 158 track control arm removal and .elilling -164 Fuel (/lid exhaust systems -66 el $eq Fuel filler cap .cmoval and refining -188 Fuo l injection syste m ')CCclcflltor cable -74. 83
air Cleilller -80 deSCri ption - 77 exhaust manifold - 85 fault diagnosis -85 fuel lank. s&nder unit and filler pipe -83 idle mixture ,)djustment -82
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inlet manifold - 83
main system components remova l and refilling -80 m~intenilnce, routine -79
specificiltions -67 to rque wrench settings -67 Fuel pump carburettor system cleaning - 68 re moval and refilling - 68
testing -68
fuel inject ion system removal and refining -80 Fuel system (carbureUor) accelera tor cable -74
accelerator shah and pedal - 75 air cleaner - 68
carburetlor -66, 68 to 73
description -67 e~ haust manifold - 76 lault diagnosis -85 luel pump -68 fu el wnk -73, 74 fu el lan k fille r pipe -74 fuel tank sender unit -74 inle l manifold -75 mainte nance, routine -67 specifiCiltions -66 torque wrench senings - 67 Fue l tank cleaning and repai r -74
filler pipe removal and re fi\ling .-74 remova l and refilling -73
sender uni t removal and ref il\in g -74 Fuel tank sender unit (fuel injection models) -83 Fuses
G
general -220 specifica tio ns - 199
Gearbo~ see Manual gearbO K Gudgeon pins - 37. 52
pdbrake adjus tment -153 cable(s} and rod removal and refilling 155 lever removal and refitting -154
warnin g hght switc h -225 Headlights alignment - 212 assembl y: removal and refilling ~ 211 bulbs renewal-2 13 Heater assembly: diSI11(lntting and reassembly 8ehr - 19 4 Smiths standard and heavy duty -196 assembly: removal and ret.tting -193 contlols
adjustmen t -192 removal and refilling ~ 1 93 water valve (heavy dUly heater)
removal and re fitting - 193 History o f tho nlodal-5 Horn faul t tra cing . remova l and refilling -220 Hubs, front
bearings renewal -162 removal. ret lu in g and bearing adjustment -16 1 Iraulic systam (brakes) bleed ing - 152 pipes and hoses removal and refilling -151
Index
Ignition switch and lock -224 Ignition system -87 el seq Ignition sys tem amplrlier module (2 .8 l i\(e mode ls)
r emova l and refilling - 94
condenser (3. 0 litre models) -90 COntact bre aker points (3.0 litre models) - 89
description -88
dis tributo r -
90. 92. 93 fau lt diagnosis -96
firing order -87 mainteMnce. routine -88
spare plugs - 91. 95 speci fications -87
t im ing -94
torque wrench settings -87 In strument cluster ill umina tion switch -224 removal and refitting _ 221 Instrument voltage regulator removal and refilling -226 Interior lamp and bulb
removal and refilling -217
J
Jacking -7
L
lubricants and fluids recommended - 17 lubrication chart - 17 lubrication system
M
2.8 litre engine -39 3.0 litre engi ne -53
Main and big·eOld bO(lrings e~amination and renovation -37, 52 Main bearings (3.0 litro engine) removal - 51 Maintenanco , routine bodywork and fillings d oor ch ec k straps security check - 16 locks, door chec k Straps. tuellilte r C
h andbrake linkage lubricat ion -16, 144
h ydraulic fluid levul check /lap up - 16 . 143 hydraulic flu id renewal -16. 144
line s and hoses check -16
pads ilnd shoes we." check -16 , 14 3 servo check -16 . 144 vacuum hose check -16 Clutch adjustment chock -16, 98 cooling syslem
coolan l leve l chec k/top up -16, 59 coolant renewal -16, 59 drivebelt condl tion/wnsion check -16, 59 leaks check - 59 electrical system
ballery elec tro lyt e leve l cheek /top up - 16. 200 equ ipmen t opera tio n check -16. 200 headlamps cleaning -16
253
'i
'" , '.;.l
•
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2"4 Index
",-----------------------------------------------------------------1 -
ligh\s operation check -16 w~she( fluid levels check/lop up - 16, 217, 219
engine
crankcase emission valve renewal -16, 27
fluid leaks check -16 oil i1nd filter change -16, 26 oil filler cap clClIning -16. 26 oil level check/lop up -16 1I;llvo clearances check/adjust -16. 46
exhaust system condition check -16
fuel sySlCm
removlll and relltting lldjustllble exter ior -192 interior -192
Oil pump
p
28 Iotre engine dismantling. examination and re~sselllhly -38 ref in in 9 -42 3 0 li tre englllc dismantling. eX~lllinmion ilnd reass embly .-52 [elit\lng -54 removill 50
Pedal ,1cceler,ltOr 75 bra k e · 152 clutch -101 Pisto n an d connec ting rods ref,nin\j -42. 51 Pistons and pisto n rin\js exanllna\lon ,1nd rcoova\lon 36,51 Pi sto ns. connecting rod s il11d bearin\js (3.0 litre cngine) [lmlov,11 51 Propeller shaft 128 d s, .'r/ Prop elle r shaft cenlre bcarln!J r()"l]w~1 12!J
descrip1l011 28 I"ul l (i iaunosis - 131 removat and rel,UlI1U -128 10rque wrench seHlIlgs -128 univers~1 10lllts inspection 130 Pushrods 35< 51
R
Rndi,lto r rel11ov~I, Inspcctoon, cie
Rear lamp and b ulb removal and refttling - 216 Rear number plilte lamp and bulb removal ilnd relilling -216 R ear su spension description - 158
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