1974 FORD CAPRI engine
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About this manual
Its aim The OIUll 01111'$ 111,11111;,1 IS 10 hel l} you lid the l}cS I v~llIe from yOl" vchicl.:!. 11 Cilll do SO III seve.;)1 ways II eml hOllp you dccllh~ wh,,! work Illust be done (eyell should YOIi chou$u 10 III!! 1 duno by OJ IF"Il\lu). pro v ide ulfo'Ill.1100tl 011 touiU1C Il"HIlICIl;UICU ;)lId SCfVIC"\~. "lid give 11 lo Uic .. 1 f01USC u l :'C I'OII nlld d"'!J"OSIS whe n ,,1Ildom f
SCCtlons. numuClcd wllh slll\lle IlyUles. eg 5. and the Sec tion s "ltO p",ag'ilphs (01 sub·seCllons). wllh Occll11,,1 numbels following 011 110111 Ihe Sociion Ih ey nlc III . <)1.1 5 1. 5 2. 5 3 elc . h IS froely illusltnted. espccl"lIy III those paris where Ihele is il delalled sequcnce of opel allons 10 be carricd ou1. Thelo ilre Iwo fo rm s
of IILUS";I\IOII 1r!IUfeS ;111f1 ph(lt
1'1>010g'"ph 5 C,lllY Ihe s,"lle ",""llO' (ell hOI rrld ,v l{h lollly 01 III 'el"led Uroups) '"S Ihc Sec lion 0' $1I1I,s(lCIIO" 10 which Ihey rel"I". There IS (III illph(lllcllCillllidex ;lllhe h.lr.k of Ihe I11"nuill;1S well , 's il COl1lell iS Irs t ill Ihe !r OIll E.1Ch Chilplel IS ilho 1}leceded hy liS own rn(lrl/rdu(ll coments IrSI Rclerence~ 10 the ·Ie ft· or 'tI~h" 01 Ihe III;h ,r;le arc III Ihe sensc 01 n person In Ihe (Irll/er's scm filCIIIO lorw,lrds. Unless olhclwlsc stilted. nulS ilrld holls ;lIe rcrllow,d hv '<11111119 nntl·clockwlse. "lid lighlclled hy l",n"'\1 r;i {){ :kwls,) Vehicle 1lI11Iwl" clu.ers conllnually 1Il., ke chilll!Jcs to spcr;lloco1llUIIS ~lId reCO IIIIllCl1d lltloIiS. (l1I(t Ihese. wiron notified. ,,'e IIlCO rPOI(lI"d 11110 our rll""Uills ill Ihc eilrlrest oppOllunlly Whils t el/ery care is la ken to ensure Ihnl the in lorrnillion in this mant"'! is correct. no liilbility can be ilecelHed by Ihe auth ors o r publishers fo r loss. dam~ge o r injury cilused by any errors in. or omissions from. the inlorma tion gil/en.
Proje ct veh icle The vehic le u se d In the prep,lfillion aflhis mo1nu~l . and ilppcnrinu in Illilny of Ihe phO IOIJr"phiC sequences. \V,lS a Ford Cilj)ri 2.8 InJeCllon.
Introduction to the Capri V6
Tile C(lpri It mode ls wcrc lirs t Introduccd '" Ihe UK in February 1974 uSing il Wide rilflUC of engrncs prcl/iously used on olher Ford I/chicles. T he mod(lls cOl/ered III Ihls ","llu,,1 usclhe V6 3.0 hlrc Esse~ alld V6 2 8 litre Cologne engines The restyled Sories III models were Introduced in Marc h 1978 W,lh a Ironl spoll!;:r (Ind 10Ul headlilnlps. and lollowrng Ihls Ih e 2.8InJCCIIOfl vers.on was launchcd on July 1981. Seplernl»e r 1984 saw Ihe Inlroductloll 0 1 the high pcrlolJ.l1(1nce 28 Injection Special which
leatwed a IrnHwd shp d,f!elcI1tlal. lockilble spoked alloy whecls (Ind il higher lel/el 01 Inlellor III'" In 1987 Ihe lilS I CilprrS w ere mildo .. Ihe limiled edllrOI) 280 The Cilr 1$ conl/cnilonai III IlIcch"nlCilllayoul. dlil/e from Ihe ellgille being trnnstllilled 10 Ihe re"r ilxle IhrOllgh iI II or 5·speed nl;111Uill gearbox or alternatll/ely Oil S(llies II JIIodels. a 3 ~Jlecd (Iulomat>c IransmlSSlon
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Safety first!
Profession;!1 010101 mechanICS Me , .. ,oned in sare working I)'ocedures. H owever cmhusillshC you Olily be "houl gcuin\j on with lhe job In h'lnd. (10 lake the t ime to cnsule thai yOl" safely IS not pul11t ,isk . A rnomcnt"s lac k of attentIon car, resul t on an i1ccidcn!. as can fnollJJC 10 obSOlvQ COlla;n ClemCIlI,l,y precautIons. There will alwilys be new ways 01 h;IVUlU ac c.ttenls. ;111(1 'he following points (10 not p.eICn d 10 he! n cOlllplchcns,vc liS! Or <111 d,lIlge.s; Ihey ,lI C inlt'!I1dcd rathor to milkc you ilW;UC or the ',sks nnd 10 encourage II sn le ly -conSClOus ilpplOilch ,<> ,,11 wall" yOIl C;l"y OUI all YOUI veluelc.
Esscllli,1/ DOs nnd DON'Ts DON'T .cly on a SU1U1c Jack whtn wOlk'''11 undc'tlCil!h the vchlcle Alwilys usc rch
scDlde d by CSC"ll'''U cool»111 DON'T allcmpllO d •• 1Ul 0,1 unt,1 you ;IrC SI"C 'I ha s t;uolcd suUrC'crr lly 10 allo,d scalding you. DON'T yrasp any Il"l! 01 Ihc cngll1c , e~h,l\lSI or "'I; ,lyt 'c r:onll'''IC. w.thoul 11151 aSCe!l""II"~ IhD I II IS su fl,c'ently co1J1 10 avoul hUlllln!1 you. DON'T ,lllow brilkc UUld or anllfr eeze 10 conwct vc hlt.le P
espcci
sp
IIIlSS ;1IId evcn de,llh ,llIlh;"ed 10 any exlent Pel.ol (!I
h;1\1I:'y II WIn no.",,,lly 1m !JIving 011.1 co.tam al11o"nl of lIyelll'!I'""'<
w h,,; h IS hl\lhly cx, )loSIY c. Alw;.ys dlscon,,!:!;' Ihe hatlc.y e.1.lh (wound) 11:,""11.,1 1,,·1. wo,k,n\) or' Iloe: fuel 01 CI'lctrl~'11 ~ystll"'~ II possl hl() . looson the frller pl"ys or COYer when d,;oQIIl1(1 I
h ntte.y trorn an extern,,1 sou/cc Do n ot chJ'Ue .11 an ()xCCS~'y" .,,1, the Ihllle.y 111,1y hursl Take cal(! when 10PPInU up nnll when cally,nu the h.ltIC'y lh'I.' I:lcctlolvtc. eve n when drlu led .
S plilshes hy wea""y ruhbcr uloves Dnd go~gles Whe" JU"'I) stnlt"'u 01 ca r uSlI1g a booster uatw.y. to. negDllv c l'" (wound) vehicles. connecl Ihe )U"'I) leads in t he follow,ng S(){ll"'''' F"st connec t one ,orn ,) lead belween Ihe posllive ( , ) le"',,,,als 01 1 Iwo hallelieS Th,,11 conneC I Ihe Olhc. jump lend lust 10 Ihe neIFII ' ( ) lelmll1 0l 01 Ihe booster hOllery. ilnd then to 0 good eDrth , (groun(l) pOonl on the lIehiclc t o be starled. 1llleas t 18 in ( " 5 erll) f" Ihe hatte.y If I)(lSs.b lc EnSUIe thot h onds and Jomp leads ".e CI C.1, any mOllln!) P
VIClnlly o f fuel or fuel vnpour
Ignition fiT voltage A seve.e elect"c shock can result from touching certarn parts 01 tl
Iuni lion sySlem. such a s Ihe HT leads, when Ihe eng,n e 's runlli/Hl being cranked. p
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Routine maintenance
Maintenance is essential tOI C"~l"'Il\J sal"I\,.
The 1"II<)wII'~1 Sr:r",,:,~ schedules ,"lJ ol I rS I of the maintenance req
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I Br,lke St'fVO uni/ 12 A" mIN duct 21 f/,ld'o,IOI l"lm c:,/, 31 Coohng sys/em pressure 2 Slarl v
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'6 Routine maintenance
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Every 250 miles (400 lUll) or weekly -whichever comes first
Check the engine 011 level and lOp up " OCCCSSJry (Chapler 1) Check and adlus t lhe IYIC pressures (Chilplcr 10) Clean the windscreen and windows C lean the hcadlamps
Every 6000 miles (10000 km) o r six Illonlhs - whichever comes fir s t
£II[1ille (Clwpter 1) Change engllle 011 and IIher
Cleiln oil flilm c"p Chcck 10 1 ,IllY fluid leaka!)e ,n enUme CO'llp:lnUlCIl1
Cooling syslem (Clwptet 2) Check cool:'lnt level
Fuel syslem (Clmpler 3) Check idh"U mi~lUle (cmiJUiello1 IllUdels onlv) al I"SI se.v,ce ollIe, overhaul C heck idllllg sj)ee d
Ignition sys/Cm (C/I,Wler 4) Clean ,1nd re!)"p Sl)".k plu!)s (.:on!nC ' breilkCl Illudels olllv) Cle an and check d'Shibu\o. C"I). '010'. HT lealls mId co.1 (COllWct
bleaker modcls only) Check elwell angle (cOntact b.e"ke. mo
Bri/king sys/Cm (Ch,1pter 9) Check selva
Che ck hydraulic flu id h,vel
Ch(: ck p"ds :'Illd sho(:s lor wear Check h.ake hllcs and hoses
Suspension .wel stvi'ring (Chi/pICr 10) Check tyres 10' w ear and dam:lge Check steering COmp{lIlCnlS l o r w e:l l "lid d.1nlilue
Bodywork. .111d fittings (Clwptef 11) C lu .. >ek se"t belts fa. we .... damage :lnd secwity
Elvc(ric.11 systcm (Ch,7jJ(ef 12 ) Check Ope.iltoon 01 "Uhts Check wilsher flUId levels Check b.1ltery eleclrolvle lev el
Every 12000 miles (20000 kill) or 12 mOll1hs - whichever comes first
III .1(/(lIlioll 10 Ihe 6000 m/le sciler/Ille
Engine (Ch.1f)ter 1) Check and adlUSI valve clearanc es
r"' .......... ~.~-.... ._ •• -.... __ .... . 3lii1&l •
Cooling system (Chapter 2) Check condition "net tension of 1111011)<1101 dflvehelt
Fllel sys tem (Chapter 3) Tighlcn inlel IIHlnl lold boits/nuts Check vacuum hoses Check e~hiluSI syst em Check ll1r ctonne. temperature cOllllol (,I applicable) Renew fuclllllC ' (fuel injec tion models only)
Ignilion system (Chapler 4) lubricate th e dis'flbulOf (conUlel br eake r models only) Renew the coninCt hu,akcr points (II nppllcJblc) Renew the spMk plugs
Transmission (Chapter 6) Check ool/th"d level Lulmc;ue automatIC 1.,'Insmlss,on IInk:'lue
Rcar axle (C/MplCt 8) Check 011 level
Bli/king system (Chaplet 9) Check v,lcuun' hose
llliJllc:'l1C Ihe handhlake Imk,loe
Suspensioll {//j(J swelill!J (C".1plt~( 10) Check condItIon and hlllSlon o f POWI.II ~I!'tllllli dllvthtl1 (II .1l1pllcal,
Check MlspenSlon 101 we;" ;111(1 d;1Il1.1!)e
Bodywork ,1I)d fillings (Clwpler 11) Check opera lion of all locks Check secu.ity 01 dOOf check sl.aps
LlIl)fIcalC locks. door c heck S\','P5 :'Ind fuel fdler cap flap
Check underbody pr olCctive coalm!)
Electrical system (Chapter 12) Check Opcra1l0n of all eleC111!:al IIcm5
Evcry 2<1 000 llIiles (40000 kill) or 2 yc;u s -\Nhichever comes firsl
III ,1(/111/'011 10 the 12000 111"'1 $d'~'f/u/e
[nyino (CIWpICf 1) f!ell'!W crankC:l $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
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1 J
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i( 8
2 --I-~.'-"'\r__ / II [!CJ.:=J-~
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Recommended lubricants and fluids
Component or system
Engine (1)
Manual gearbo x (2)
Autolllatic transmission (3) Black dipstick Red dipstick
Rear ade (4)
POwer steering (5)
Br
SAE 20W/4Q o r 20W/50 multigrade engine 011
SAE 80 EP 0.1 to Ford spee,flctlllon saM 2C 9008 A
ATF 10 Fonl speclliCil tion SOM 2C 9007 AA ATF 10 Fonl specillcmion SOM 2C 9010 A
SAE 90 ad to Ford specI fiCatiOn SaM 2C 9002 AA
ATF to Ford specd 'C[lllon ESW M 2e. 33E. SCM 2C 9007 AA or DZAZ 19582 A
Hydraulic fluid to Ford SpeCifICation SAM GC 9103 A
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a
20 Fault diagnosis
Carrying a lew spares eM) :\l1VO you a lono walk!
WHhou t 100 ,ulIeh trouhle in the event o f il hrC
DrHII/mim [(JIm, (:lIlIdulI.~VI IIlId C""Ii":II"'HI~'." I'omls (;'s ;,/I/lII(.','I/)/e
IJllv/.'lmll(s) ,.'/I11:II/VJlCY IYl't' m"y suffu;t, SlIill!! {(I,ft'S S •. '/ of //111//:'/1,,1 "ylll bill/,S 1/1/ 0/ ",dlll/Ol 5<:;,11:, ,mil IlOst: '>,md.1UI! t"~II;III.1'1 /),111(1I1!IC Roll OlllllilJIMlt/y IIIl'l' Lf>llylll of sulillflll WIIC Lc"yllt of ci.:cIIlC,llllt·.
rUiC" Of mSIICC/IQIII;III'11 (eilllliot/blt' ;,S II.'S( I;IIIJIJ) OMlt'IY 111111/1 Il'mls Tow" Q/IC Iym(/Oll WJiClllloo/lllY ,ow/osol Llfll! 01 c"Yllle Oil SeMcI I eMI olltyr/wlIll(: /f",d Emeif/CoCY WII/({SCIt'ell W(JIm ({live cl'II$ Tube 01 Idlel IJ,1S((;
II Sllilro IU(l 1 IS Cil",c< I .• 1 Ciln dcs'Ollod for th(l pu'pose should hc uscd 10 m"l",l(~e rrsks of le
WhiCh, evon 'f you cnnnOi III thcm yowscll, could snve hav'"(J 10 Willi wh,le p
One of Ihe 111010llng 0'ganlSilll0ns w
Ellgillc taits 10 ((IIf) W/IL'II slilrlc r ()p vra le d 1' 1;11 h~lll.'ry (.ud,;,,!!,!, u~.., rlmlll'uolds, 01 push Sl.1rt) nnllclY 1(:rnllll.,ls Ions!! 01 cntlod,!d BaltelY ll.1,tll to hody dd"cl'vu Enwnc e(utll S I,,1)) 100Sll 01 broken Sl.1rtel 1II0lO r (or so lulloid) "",,,ng loose or IJroken
l\ulOn1 ;II,e II1!11srllr~s,()" seleClor ,n W'OIlIl pos",on, or Inhd)!' sW/lcli fHur,y '11""'Oll/SI (lr lu, sw,'ch folUllY
M i'ror mech:u"C.11 ,,,,lure (Se'lUre)
Sli"!~1 Or sole"ord 'ntorrloll rilul! (seo Chaplllr 12)
A
simple les t lamp is useful fot checking electrical fault s
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Fault diagnosis 21
Starter motor ((/rns cngino slowly Parti ali V disch~rilcd b
Engine ((/"'S normally but 1,1ils ( 0 SIMI Damp or dirlV HT !eads
Engine ClltS Ollt ;1nd wilinOI roslinl
fngine culS out suddenly -ignition I,wlt Loose or d'$Conncetcd l T wi.es WCI HT Icads o. d'S I"buiOI C;1P ("lIer tr;1VC'SOll!) w;1'er spl;1sh) Co,1 o . condenser lallulc (cheek 10' SI);lIk) Olhc. ignition laull (see Ch,'plfll 4)
Eflgine mistires belore CUlling oul IlIcll,wlt Fuel I,,"k Cillply Fllel pump dClfecl1vc o. 1,ltcl IIlo .; k(H! (dwck 1m dellvl"V) Fuel tank hllcr vcnl blut;kcd (StII; llon Will II" flV,{Io"'1 Oil lI~h"'~II'H C,11l) C;1llJulCIIor nccdlc v"lvc SIII;klll!J (WIU.'1I1 "ppI1c"hle) C,1lUwellor leiS blocked (ha:l COIII,lIl1ln,Hcll) Othcr lllcl sys!Cm l
BATTERY
lSin.MIN
POSITIVE
JUfl11) Slart lead conneClions f o r neg!Hive earth vchiclesconnect le;1ds in orde r shown
fllgine euls Ol1t -olhor eimses SCIiOliS ovcrhC~ling Mnior mcch
Ignitioll warning light /lot illuminBted Coollllll loss .Iuc 10 In!emnl 01 CXierr'JI ICJk
l.ow cnuinc oil JlfC!ssuro
G,wge reads low or warning lighl Illuminated wilh engillc
rWllling Olllcvcl low or mCOlfeel 0.,,<10 Deit.'Ctivc gllU!jC 01 sendCI 11111 Wife 10 sendCI UIII' C.1I.hC(1 Engonc ove.hC.1l ing O,lllllcr CIO!19c<1 01 byp,1SS v;1lvc delccllvc O,I ,llcssule lehef v'llve dc!ec tlve Oil pick-up strllll,e. ciomled 0,1 pUIllP WOIil or IllOlllllll1\l~ I\,osc Wo,n Ill,l'" 0' h'!J-cn(i hC.1I1I1!)s NOlO: Luw or! 1"t'HlifU III a IImh III"C"f1~" (.'IIYIIIC .J/ 11l;~()VI.'r I.~ 1101 1II.'I:<.'",.","/y,1 (.",lIlSV {o, CIIII{:"/U Suddel! fJf'~SS!lle {U$S ,11 SlIced IS {M "'/!IC SI{Jl!lflca"l (I! ,my cve/l/. .:In',·j. I/le .
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Chapter 1 Engine
Contents
Par! A: 2.8 litre engine C;JrllS llaft and CillllShJft be,lrIllgs (;XilOlllllilllon ilnd renovil!"Hl Cnrnslwft and frenl inlCrrned l,1!C pl,ne rcfl1l"l~1 Connecting rods ;lnd gudneon pons c",,,nlO\,lllon "nd
,enovntion
C'nnkcnsc venlll;Jl,on Systelll de~Crlpll("1 C'
M "IO. operatIons reqrllJlIl(J enOrrr() ,enloval Mr.:lhmb of cnll'nc '(:l11ov;l1 011 IH"'lp rl'~m.lt)ll'''g. eXil,nrrr"l.oll and ",,,~~c"'lrly all pump 'ufrtlrrlU i'lslo"s and C
C.""sl>"fl
and c. ,nrsh;rfl !re,'rr'IO~ 'JX,IIllrrlaHon ,mel 'CIlO""l lun Corr'lectorry ,ods and yud(jeon p illS exa"'"'ill,on
k
c"se vClrtdm,o;, ~~s·t~nr descJlPtlon ~"lrrhlr.,ft ()x;r'l1Ill,' I'On ,IIHI ,...,novatlon C',1n\;slraft ",I'illlI9
Spcciiic;ltions
P,11/ A · 2 8 li(ro engine
General TI,pc 130<.., St'uk..,
Cul)Ot Cilp
'" 25
'" 27
" 15 :j~ ,
38 37 6 :\G 8
" 7 26 22 3> ,
24 20 3 4
;.>3
30 29
" 12 ,
>0 33 >3
" 32 :J5
70 b7 G5
68 77 GO 80
Cliu,~sh
E'''!JI,t!
,me,I I,IIII:s
[Il!!"'" C"" 'I)O"o.;"ls E"B"'e (1'~Ill"nll,n!J ['"1''''' ',~,'s','''''I,ly Hywh",,1 ,,,,,,,,val
I(;j,wou
""IIov.1 1
\)0)'\1),,11 \1("",,.11
Flywir""lld"""plale f!X ,I!lUnil l(On allli IflnOVill lo n
Front covc, ,cmov.11 Gcm:ral descI,pt,o" lub'lcat,On syslmll (Icsc"pt,o'l
M,1I1l a"d hllj·C"d h"""nys I!x.lrn,nilt,on ,!I,d 'enov~'t,on Ma)o' OJ),,r,rl'OIlS possllJle w'th ""\JIllf! orr C,If MalOr op,,'
1 ",1011'; ,11,(1 P'~lOIl ""llS (,x;r"''''''l,on ,,,,,I ,cnoval,on PI~,1Orrs, ct)"rrr.:~trrro ,,,ds .lIl(f hoal lllO,; removal n,),11 0, 1 s('ill ilrld flywlrcr:1 rcl,tlll'(j !'loclq"
SU"'P
T",,,,,O
IIC,"~ ,'(ld frO"l plale rcf
Valvcs
61 52 60 66 86 87
" 48 74 92
" 44 00 46 62 45 78 53 72 55 30 76 70
" ~2 43 7 ~;
82 58 81 67 50 84 63 50 88 40 85 !.>.1 !i l 6,'
" 56 83 59 40 73
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