1974 FORD CAPRI horn

72 Chapter 3 Fuel and exhaust systems
3 Unsc.cw the cenlle bolt and .emovc the cove •. T o p VtlCllllm pul/-down 6 FII Choke phasillg 7 Hold tho Ih'O Hlo 1),1.tly open IJ(mdlllU Ihe tau. S Rn"t Ihe intelnal hcal stueld eIlS''''"\1 Ih,lt Ihl! hole ,n the COve'
locmes COrfeclly 01110 Ihe t :le\] CkOt. and t'yhten the C"n\'1) bolt. Top up I he coohng s y Slem ,I Ilccess: llY 12 Reconnect!hc h;")lle'y . run thc ell!l'"c :",d Mllu~t Ihe 1,IStldle spccd ;,s d"sCllhed III Ihe 101l0winU Pil';'!I.;lph
Filsl idlv speL'd 1 3 hlc;IlIy" tachomcte. wlIII,c .eq,,"ed !lllmlc. 10 sellhu t,'~1111l1! 'P'" 10 lhe ~peclllncl v.1Iuc . nUll lhc CnnUlc lip to no.,,,al opc.at"I!1 t,:'Upe."lu,e. then ~wO\ch oil ;Jml COllllect Ihn tachomete. (whe.e .wn"a"h,) OpCl1t he Iluollie pal\lally. hnhllhc chokc pl.1\(.)5 lully closed tI'"" 'ele,lse tht.! th,ollie $0 Ih.111he cho~e 1""ch.1111$I11 IS held 'n the fast "II" fK151\10" Relc"$c the cho~1"l pl.ltCS . d" . .:ckllll! lh;lllhcy .cmaln lully olwn (II they ".c not open. Ihe ,lsse rnlJly IS I"ully 01 Ihe cnU"lc ' S 1101 al 01Ie .,11111IJ len'I/C,,'lurc) Wlthoul louchl"H the ;lc c"le."to. ved"I. Sliltl
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Fig. 3.1 9 Choke phasing adjuSlme'lI (Sec 11)
A 0,,/1 8 AUjus/my'"y
Fig. 3 .17 Checking the Vllc .. "m pull·down with l' drill {Scc 111
A t:lils/lc Im",' C V;//:1I11111 ('I'~'f,~lmllull B DIJII
Fig. 3.18 AdjtlslinU the vacullm pull- down (Sec 11)
A 8
Fig. 3 .20 linkage SCI fo r checking fast idle adjustment (Secl1)
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74 Chapter 3 Fuel and exhaust systems
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Fig. 3 .23 F el ' onenlS (Sec 13)
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Se.ll Ruhbcl ill,W/,lIQI S SI!IIIJ..'f lIoil
14 Fuel lank -cronning DrHI rcpl1ir
D SImps E , COllflcetiu"
W,lh IlI1m 11 I~ likely Ihal scd'lllcnl .... .11 COIiC(;1 1f1 the IJOIiUlIl u l the ruel wnk. Con 15 Fuct lank sender unil _ remov;11 nlld refilliny
Check Ihe h01l1 whL'{)ls Ihen J;lc k ufllhe le;lr of Ihe 17;11 ;'Ind supporl ,1 ilxle sr,llids . 2 SYI/hon Ihe fllel hom Ih e tllcllim k. Wherc ;lpphcilhle d,scol,,'ecl Ihe fuel line hOIll the scnder unll.
" Discormoci Ihe wiring 5 USlllljlWO SC!(lw(i!lvers III Ihe 51015 inlhe sendcr unit ,e lirmlng 1111\1. unsr;'ew Ih o sender (mil loom Ihe tucllilnk Lilt ilW;lY Ihe scaling ling iln d Ihe sender unit. nO llng Ihill Ihe 110.11 must hilng downw;'IrrJs. G Re fill ing is a rever snl of .e moval . bUI clea n lile milling !;lces ;'Inel I II ;'I new sealing ring .
1 6
Fuel lank filler pipe -removal "nel refitting
I Remove the cap horn Ihe hiler pipe. 2 Re movo Ihe .ighl·twnd siele lIim p;'lllei. 3 Peel back Ih e in sul alion clear 0 1 Ih e pipe (:Over fliln cl (Ghia only). 4 Lift outlhe pimel coverinU Ihe spore wheel. 5 Unbolt Ihe IllIer pipe covor panel. 6 Lo osen th e clips and releilse Ihe rubl>C1 oail er from Ih e floor and f,llel pipo (phOIO) 7 Remove Ihe screw al Ihe lO P of Ih e pipo nexl 10 Iho filter cap (photo). 8 Disconnect the hoso and withdra w the I.ller pipe I rom in si de Ih e
car.
o Relill ing
is a rever sal 01 romov;lI,
A
cceleralor cabl o - removal and relining
Removo Ihe
lowe. lac.a panel inSide Ihe ca'.
166 Rull"'" !F"1I1';'I1 "otlom " I I"". la llk flU", l"llll
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1(; 7 Fuel lank flUc. Pll~ UppCI 1II0UIIIIII\I SClew (.lIwwL't I)
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: : i;. "j -' , ,' .... :r: , :'y~ it. ; '., :
Fig. 3.24 Disconnecling Ihe innor cabla from the pedal (Sec17)
Pusll M 11 ,mrl rcfc,uc ill IJ
2 Disconn(:cI Ihe cahle 1<0111 Ihe I)OOal hy unhookoug Ihe clip and rcleasing Ihe ""II:! cal,le 3 Rem oye Ihe IHal:.e servo un:1 a~ dcscfLb c(1 11 Ch;lll lcr 9. Ihen remove the SClew securrn~J Ih(: Oulcr cable to Ihe iJulkhc;'ld
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78 Chapter 3 FlIer and exhaust systems
TIlls system, when comp1lrcd with conventlon,lI c.Jrhwctlo, ~rrilngemen1s. oncms of tho fuel inrcclton system lall into three
tI'(lllPS
A FI/ef Milk Fuef Plllllf! F/lel .?CCIIIIW/<1IOI Fuel filler F/lel ,IISltihular ,w(/ millime con/rol l11ralllc MIlllll/ce/Of "',1/1'115 AI( ch.ll11/"1(
B W C Wilil/[I Hd,.ys SMt'ly SWitch
The fuel pump IS 0 1 eh,CIIICtllly operated. ,aile. cell Iyp" A .",SS (IIC rchd ..,:,1..,0 'S mco,p[)I;oh~(1 III the pwnp 10 preY",l! f:XCOSSlvn
p"'SSUIC la"ld III) '" tho event of ,1 ,,)Sl"Ctlon III th e pipelollf!s The fuel ,I(:c\llllula lor ha~ 'wo lunf.luItlS. (t) In 4'ill1I,)(:I1 llll! IIIII,,;,'U)!l 0 1 lhe luclllow. HHlu.:.iI ,ml hy Ihe I)\I"'P ;IIIf' (II) 10 11I;""t,"" Iud I"'"'~''''' ,,1";1 .h" .:o,!.m" h;os Iom,n sw"dn,,' "If TillS p.r.v"rlls .• v; 'po", IIH:1o; .lo.:vel"I'III!1 w,th t:'Hlf.O:'I""nt 100' ~t,' OIlS""l1g .h'lI each cylrndo. fCCOlves Ihe same ;lII1OtUlI. TIlt! mlxhlW COIII.ol aSSemhly ,ncorpo'illes ,III IIi, senso. pl, 1le ;m d cOlllml plllll(le •.
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9
The iI" sen~or 1)1"le is locilled in 'he main nIl Stlealll be.ween the iI'r clr:wller ,1nd the Ih'Ol\Io bullerfly. Du'ing idling. the ~irflow hits Ihe sensor plate which in tu.n ' Fig. 3.32 Fue' injOCliOrl system flow diagralll (Soc 22)
1 Flle/lall/(
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Mu;/ulc CUIIIIOI ,mif 6 IIIIOlfic pla/c assembly 10 S/;II/ villve 2 Fuel PIIII/I' 5., Fucl (Iistllbutor 7 Inicc/or valvc /I 'hell1JOlimc sw,lch 3 Fuel i'CC/IIIIUI"tul 50 Alf SCIISOI 8 WiJllII·Up regula/or 4 Fuel '"10:1
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Plcssule regtllillQI 9 AU~IIt"aIY air device
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94 Chapter 4 Ignition system
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. --8 2A Removill{J the IllnSlre dust COve, (28 hl'c Cllume)
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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\( check IhJllhc rOl0' ;lIm IS PO"1I1119 to the No 1 cylmdc. scgmon!.n the Cill) rndlcmed by the sial on the 11m. 3 On the 3.0 lUre engIne the cont,le l poullS ll\u~1 he ,ust SCI)ilril\U'!J Tho e~ilCt Instant C,1" he checked by connect"'u il 12 vol1 lest lamp between the contilC, brcilke r low tenSIon Iemur),,1 iUl(t O,"lh, W,th the iUnilion Oil, tho d is trlbuto. ShOllld be turn ed nrl\,·clockwisc unlol lho bulb luSlligh(s. " On (he 28 li(re enuule the ("gger arms and stator ;HIllS must bc aligned It not. (um I he (hst"bulOr as necessary . !:i Tighten the (hSI"buto. clamp boll and .ehl the cap 6 Set In thIS way the lUlling WIll be alll)'Olmalely co , ..
8 2B UtJlle. vIew 01 the l.imJer Mrn .lrld Call (28 lIt Ie enU"Wj
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8 20 Vacuum un.1 sC(:u"ng screw WIth e')Hh lead termmal
10 W,lh Ihe enij1l1e I(lIrng pornt thc \fmlng hgh( at the cr",lksholl1 pulley The wh,le 1),1mte hne
12 To check the mechanrcat adv.1nce. Increase the engIne speed and note whelher the wh,te malk on the pulley moves away Irom the mark on th e pOInter . 11 It docs the mechanical advance is lunctioning 13 W,th the enOlile Idlmu the vnCU\ Jm advance can be checked by suc kIng the oldv~ncu pIpe that W.1S removed from the carburellOI o r air box ThIS should also c.Juse the while rnark on the pulley to move away horn the mar k on the pointer 14 On completIon remove Ihe timlllU hght and rC(:onnec lthe v.1CUUIll pIpe
10 Ignition illlllllifier module (2.8 l i tre enuine) -removal and rClittinu
Thc Iunitlon illl\J}l lflcr module is locmed on Ihe left· hand SIde of the engIne COnlpar tment. tUSI behind Ihe hOnt suspenSIon strut upper mounting.
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"00 Chapter 5 Clutch
53 Locmlll\J the (flCllon disc on the
f lywheel 5 .6 Cent,.,l ising the friction disc 5.7 TI\)htIJnlll!) 111" ,: 1,,[, h cover holls
6.4 The plilSllC wlls which .cWin the fclcJSC hcnrinl] in the lever (""owed) G 5 nt:lcas(l levor IOC,11;01) 011 the 1"1101 stud
5 The f"~lI()n rt.!;c must now be Cclltrilloscd SO Ihill when the (IllUme imd !Jci"loo~ .1<0 milled Ihe input shall splmes Will pass 1I110uUll the splines III Ihe )HCIIO!) diSC Id(!,lIly a wlille.s;,' dUh;h (;C!l!r()" Inpul ~h"fl shuuld be u~cd. hlJt ,rlh.'IIHI(,vcly a woodull 'lIilnd,!:i G,II1 h.., Ill.1 6 Clutch release bcnring removal 1Hl(1 rcfitting
Remove thc gcarbox "s dcscflbed in Chaptcr 6. Alternal,vely. illhe cngi ne is to bc removed for repairs. acccss 10 the rclcilse bcminy ,s possible leaving lhe gearbox in position. 2 loosen and back oil the cable adjustmcnl milS. 3 Whcre npplicable. plisc lhe ciulCh cnble fuhhel gaitcr flOm the bell housing nnd unhook thc cahle end lotting from the release fevel. <1 Puilihe release I)ealing hom the \Juide tube. Whcre necessary use a scrcwdrlver to pflse the f)Caring flom the Icvcr and lelease the pfas\lC
tabs (photo).
5 Pull t he rclease IiNCI sldcways to d,sengage it from t he pivot retaining stud (photo). thcn withdraw ,t ovcr thc IJuide tube ,1nd input shah
6 The rele ase beann\) is supplied completc w ith lhe huh (photo). If fC(luired. thc two componenlS can be scparated usinU a VICC and soh metal drill.
)Before relltllng (hc releasc bcariny. apply a lillie molybdcnum "."ase 10 the \llude tubc and contact laces of the release lever 8 flefl!1lng is a ((,versal of remov~l. butllnally chcck the clutch pedal and cable ndlUsllllenl JS descflbed in Seclion 2_
7 Clutch c;lllic -Icnewnl
Apply tlol) Io.",dl!<"k" llien lilCk "I' lilt: j'onl of 11"1 Gil o1l1d suppor( on ax il! ~!and~ 2 PIIS" th" dUlch callie whlJel (jilll'" horn lh" h'·lIhou~u'(j. lousel! the ati,US111l'JllI nul(s). ;IIHI unhook the c;,I,I" ,·nrl IlIllllB hOIll lhe release h,v,,, Pull off the !Jalter (phOlUS) 3 Ikmuv" ti,,) c,lhle frorn lhe hole II) lh., 1,,·lIh"u~"l\J. nUlo)\) lhe posltlun of lhe slccve (phOIO) <1 WOlkln\l illS Ide (hC Cilf. remove the luw,,, I,,,",,, pallel lor , '. ,
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7.2A Prisc all the rubber Ualtef
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·06 Chapter 6 Manual gearbox and automatic transmiss io n
disengilge the gearbox inpu t Shill! hom ,ho clutch p,Iot bearing ,111(1 clu tc h friction disc. I, is imporlanllhal,hc engine and transmi ssion <'lre kept in lino while this is being done. 14 When the gearbox shaft is cleDr of the clutch, remove th e
tran smissio n assembly from bCn(!illh the car.
15 When refiuing, ensure 1il1 the clut ch pilot h earing in the end althe tfilnksha h is ill plilce Jncl is scrviceDble. Tic the clutch lever 10 the clutch housing, 1 0 pr(!venllhe release le.rertrolll slipping out while the ,Wnsmission assembly is being lined. 16 Smear some molybdenum-based grease OntO the end and splines 0' the gearbox input s!mh lind refit the gearbox by reversing the fcmovili p.ocedure. 17 II is impO.IMll when offering up the {jOMOO)(. th,lt il is e~ th e clutch ffiction drsc i1nd the Cfankshnft. Ifthe.e.s d.iilcul1y Inlnatinn th e splrnes 01 the gea.box shillt ,1no the frrctio n oisc. select iI \)em to 'CSlrain the movemcnt of the gc,lrbox shillt nnd turn the gearbox
slightly until the splines enter Do not iluempltO lo.ce the tfilllsmisslOn
ontO thO enlJlnO ThiS Illay (i ImpOSSible
'8 Ahe •• el,uinn has been completed. chuck the 011 level Ifl t he .r Gearbox (4 'S II001l) -dismantling
Romoye the lou. bolts hom the 1011 cove. 01 the t.ansm.sslon c~t()"sion housin!J ilnd f.om the lri"'snHs~ir)Ol eo'S<' Ilcmovflthc \:oye. s.
t.1king c from th e seloclOl shalt. 4 Remove tho twO bolts from the selectol sh 5 Remove the Ih.ee bolts from the selector hOUSing COVCI. Remove the cove. with the shaft. then ro tate the selec tor sh th c 15t/2nd. 3!d/top and .cve.se oe,1'5 suiliClently to rele plullger ill th o 3.d/top selecto. '<1'1. Remoy e Iho th.ee selecto. lorks. J Remoye the plug hom the side 01 the c rca •. Allow tho laygeal cluste. to drop into the ho ltom 01 the box. out 0 1 mesh wilh tho lIl<1inshalt gea.s. 15 Withd.aw the mainshalt and elflension assembly from the ge tho '.ont 01 the gembox and slide the retainel 011 the input shalt. 17 Remov e the circlip hom the outside 0 1 the fronl bearing and tap the outer raco of the bearing to d.ive the inpu t shillt and bea.ing assembly into the gea rbox. then lilt them out olthe box . 18 Remoye Ihe laysha lt geaf cluste •. Ihe two th.ust washe.s and any I"'o se needle 'OIiOfS.
R emoYo the .eyerse idle , shah by sc.ewing a suitable bolt into Ihe end of Iho shah and then leye.ing the Sh;'lit Out uSing Iw o open ·ended spanne.s. Fi\)
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6.6 Removing the seleclor 10lk rolillins (Sec 4)
A CIfC/'11
Fin. 6 .7 Revorso gear interlock nnd light swil c h (Sec 11)
A Ravelse liyh, switch 8 Swing C Plf/ngcr
o h!/ellocl< ball E Sc,ew IJlug
Rct.1ininy bolt F
5 M Remoye 3rd/top gear s yn chron ise. hub ci.clip Ense the hub amf
thud gear lotwald lly lel/erinu the,n gently wrth a p th e mainshah nUl and lemoye it 4 R emove the loc kpli/te . speedometer dfivegem. ilS d.ive ball and Ihen level 011 the reaf bea.ing. complcte With bearing IClaine •. Separate the bea.ing and its lelainel. 5 Remove the 011 scoop ring and lils i gear . 6 Removo 1 sl/2nd gear synchronisc. ci.clip and pull 011 the hub with the bi/ulk .ings and second gear. 7 Check thallhere is a mark to align the selec to. sleeve in .elation to the hub. II no malk can be seen. make one with a dab of paint ~nd then dismantle the synch.oniser hubs. 8 8010/0 sta.ting .eassembly. Clean all parts thoroughly 3nd check
their condition. Smear all Pi/ItS wilh tr3nsmission 011 befo.e fitting .
9 Reassemble the synchroniser sleeve and hub so that the nlafks on thorn align . Inse.t the sliding keys and 1IIIhe shdrn\) key sp"ngs so Ihat Ihei. open ends afe stagge.ed re lat ive 10 each other
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