1974 FORD CAPRI water pump

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Chapter 2 Cooting system 59
1 I VISCOUS (IPlVC I,m coupling (I,~mpc,alu,e sensitIve 1VIle shown) 2.5 Tuppill\l -lIplhc COlllilll1 h,vel in the c~J)alls,on \;lI\k 27 Checkin U the drive-belt IClls,on (28 hire CIlUulC)
2 Routino Illaintcnanco
Altho ,n1C, ... "ls SPOC""]!! utlhe Rouhnc M .. "UcnanCf! SOChOr! on Ihe 110111 01 the m;uu,a1 c;lrIy oul the lol1oWl!ljl p.occduoes
Check cnoling syslcm lor /c,1k.~ 1 In spe cl Iht! coolin!! sysh),l) hose s 'llcludlll!) the ,adIOiIO' :,"<1 Iwate. hoses for damage. detcriOlllll0n i1nd sccullly If Ihelt) is I'Irly IOulle;1I'01] of swelling 01 p Check coo/tint level 3 Whe r(l Ilrl expanSIon 11lnk 's hlte d (I"te. Illodels) lhc I;oolnnl ICv!:1 can tJC check ed without .enlov,nu the pr Check drivebelt conditioll and tensioll 6 Inspect the complete lenlJth 01 th e tJrovehell(s) for dClello.,llIon which WIIIIlI)f)e,lf ,lS h1lyll1U 0' UlilZinU to the 1)Ulley cUl1t ilC t su.fi\Ccs. 7 Check th(lt the deflec tion 01 the d.ivebclt{s) midway hetween the wate. pump i1nd (litelnntor pulleys is i1pp.ox,,11i1tely 100 111111 (O 4 OIl) under 1ll0de'i1 le thumh p.essule (photo). 8 Whe.e ~Idiustillent is neceSS(I'y. loosen Ihe Ililefllilto. p,vot and adjustment bolts. re l)OSlloon the alternilto. then tighten the b olts. A leve. mill' be used at the pulley end o f the IIlterna tor 10 o b1;lIn Ihe
COf/ec t tension If .equir e d .
9 Run the enuine f o r severlll minutes Ihen rec hec k t he lension.
Renew,1/Jtilreeze 10 O.am i1nd flush Ihe CO(lhng System as descrlhed in Sections 3 and 4 . 11 F,II the coollllg system With Ihe correct solullon of watel and amlf,ccle as desc"hed in SeClions 5 and 6 .
3
Cooling sysl e m -drai"inU
If pOSSIble. ensu,e thilt the engine IS cold belo.t! d.al"i"lJ Ihe cool ant. 10 aVOid the fisk of scalding.
2 Remove Ihe .adlatOf or expanSIon tank IIlIe. cap. If the eflUlnc IS hot. Ih ls must be done vl;lry caul,ously, because a sudden release 0 1
Fig. 2.3 Clltawa y view o f Iho expan sio n tlln k showin g tho plastic lovel indicator -tH rowed (Sec 2)
P'".'·S5U'0 CilIl ,esull II. the cool(lnl !.>oIling i1nd blOWing Oul. On ,1 hot enUlIle. plilce iI cluth ove, the caf} and lurn il ve. y uently. '0 release tim p,ess\lIe slowly. 3 flel110ve the SplilSh shield frOI11 b enomh the ra(II;IIOf. of i1pplrcilble
" Unless !he coolilnt IS beinu discarded and thc ca. 's over (I slilt illJle
d'illl1. ,,'"ce a deiln IWO i1nd a half gallon Conl;1ine. underneath the ,adlaIOl. !) Rel110ve the radlatOl bOllom hose lind allow the coo'al11 10 drili" . 6 If the SyStel1'IS to be completely d,ained. rcmove the cyhnde. block d.;1I1' pluU and draIn oul Iho .emainlng coolant hom tho engine . ThiS d'illf' plug IS locilted all the s,de of the cyl inder block to Ihe rear of the oiliolicr. 7 On 1I10deis wilh all eXJ}ilnSlon tank 'emove the rad.alO' cap as well
4 Cooling systom -ftushing
In IUlIe. !he cooling syStel11 Will lose ils efficiency because o f a bu,ld'lIp 01 .uSI and sedunen t in the radiator. To clean the .adliltol. .emove thc IllIer Cill) i1nd 'he bOllom hose ilnd !lush Ihe radialo" by inse.llng a hose in Iho f,lle. car> neck i1nd funninu Wille. th.ough fOf about tr.m I11mules . 2 If Ihere is a Ilea vy aCCUmuliltlOn 01 sediment. it is betler to .eve.se
flu sh Ihe .adl~tor. by connecting the water supply 10 Ih o boltom of the rilclmof alld allowinu II 10 flow oul of the tOIl. Speclnl hose adapters arc avai lable to enahle thIS to be done w ith the rild.ator In I)OSllion. but It is p,efe.able '0 removc the lad,ato. and tum il upside down.
3 Remove t he thernlos,a, (Section 8) then .eve.se lIush Ihe engine wi,h a W1l1e. hose u n lll clean waler flows from the .ndlat Of bottom h ose connectIon.
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Chapter 2 Cooling system 6 1
8 ThermOSI"t -removal. lor-ling and re fitting
3.0 litre /~n{lIllL' 2 $lilCkclI Ihe clop 0 1 the top 110M) to the ril.loiltor and rcmovc the hoso (photo) 3 UndO ;II,.t ,,:move tho "\4> hnltS ;'Ind Sllr"'!J w,lshers sccUlor'!1 Iho thermO$I,'t h',,,SU'!1 to the q·\·",Io·, heil.l. 4 T,1plh" 1"'''~'''!llIe'ltlv ,','h " pl"Sllc·he.ldcd hiln1l11e •. to h rc,lk th.! g,1sk('1 s".11 Ih"I c".eflilly 1,It fh" hOlls.ng 011. Remove the !J"~k.:l '" one p,,; •. ,, ,11"'~~Ihle. ()Ihe'''''~,' ',1 I"pC hOlh loim Inces 1Oc.lc;rn olllh'l fen,nu's "llh" !Fhket 5 M,,,~ II", fl"'"ulls\;)!!n :,I,,",v whu:h W"v rllund ilnd wlllc.h "";ov up II'S IoI",d, ""'0 u~,) it ~c",wd, ",' III ' fi",ove Il lrOIll Ihe IrOUSII1!1
28 h/le 1:111/1111.' 6 51,u:~'·" II", I l'I's s,.'!;"''''\! II", •.• d.,IIO. holtou. hose and Ihrl hf'.llr;r ho~1't 10 II,,· 111"''''01>1,,1 I"'''~'''!I .ulIl careful Iv remove Iho hose" (ph01<1)
7 Undo .",,1 '''''' II ,11U11,II Ih,: ('{lV"1 ;tw.,v ( ,.1"'1"1 R,'tCove, Ihe ',0111 cuver !Jaskct.1 II.S
unclilr11,\!I".t "11"',wls', ~(:'.II"· .t "II Abo If,mlJVI' Ih" sr';11 !) C;"r;lullv ".I~" Ihe 11""",,"1." (1111 CIt ,,~ how;II'!). """I!! c;""I,,1 10 notc ",1",.11 w.IY '(lund 'I ,~I""·,, (phulo)
All cnyin()s 10 Teslthe Ih",moslill 1o. r"''''<: h,llctIO""'!J hv suspr:llcI ",U 1I Oil a string In" saucep.,n 01 cold ".,1,,, tOHcthe. WIth a !h.). momc1Cr ,,,,"I (he ",nIl!' II they dill.,.
!:on~ldp.ralrlv Ihe Ihe ,mOSlil! mUSI 1.>" "~ncw"d 1 2 If the Ihr:.lllos,... t daM not lully OJlr:!! II. IJO.IIIHI Woll er. or doc s not close dowII ,1~ Ihe water cools. Ihen II ."ust he d, scmded illl(1 il new one frur:d Should Ihe thCrmOSWI he ~Iuck opCO when cold Ih,s w"l IISu.,Uy Iw appil,elll "'hen fcmovmu II from the huusing.
13 Reflllll'!jlhr: the'mOStnl 15 the . everSf'l Sf!ll"Cor.", 10 rClllov.ll AlwilVS
(:"SUIC IIr,)1 11l hOIlS"'!1 .s h",Uv corroded fll " oew hOIl':"'!1 Alw;lvs 1I<:f, il new 1),lSkel .1,,(1 Sf'l.11 II "llphc;lhle (phow) T'!lh",,, II", !,I"'IUUI! 1 holts 10 II,,~ s t)C{:llreci \1>111'''-' wrr:"ch SCllrr'!! (pholo) Rd,tl zh,., coolln!1 svSlem "s d('!>(rrhecl "' 5"ct,on 5
9 Walnr jll""I) _ romO"'11 ilnd refilli,,\)
Dr;,,,, IIr ,· , OJol",!) SVMIIII1 as rlllsc,,).,. d ", S','-I""I 3
3 0 iiiif.' VI/yllw 2 5t.,d"·,, Ih', II .. "" ,,1110'(\;,10' ,1'O"IItll .!! hOJI\~. Jlush Ihe illle,nal!)r low;lIds II .. , "n'I"'O, hit IhH dllvetH,l1 '''''11 lilt· wah" pump twlley ;md ",move .1 3 S tack"n th" lowe. 'ilc1,;.IO' hose d ,p .1 l ilt: ,nt., 1 cunnechon 10 th., 11I,1lt1) Ca ... lr,tiv eilSf) Ihe ho~c hom Ihe W;.I." pu"'p r:lIlOw 4 SI.Ir.k"lI 11r" hosc clrp ,ltthe rCill 01 thc ,,,'mp ;'1111 cilfel"IIV eil:>c the Iro:.c hl)llI Ih,· 1''''''1) !, 5!:10:I0,,,,, tl", IIHld hObO r.hp SIIII" I"d .11 Ih" Inl' of the pump ""d ':;I"'h,IIV ""~,, Iho h oso I,om (he lOp 01 Ihe I'U'''I' G U,"I., Ilro: 11"",0 !toll~ SOC\Jrln\j Ihe walcI pump to the cvl. ,,!! c ' Dloek NOh) III;" ".".h hoi I IS 1,1(0d w,lh;1 sjl ""!J washe, ,111,1111,,1. ,'s Ihe Dol l 's 1.,1l'ped bv II", Iii" pulley. 11 Will hC necessary tu l"ogresslvelV s lncken till) holts alld pilil Ihe W.ltcr ))ump il",ny "0111 Ihe cvlinder blocl.: The )ocm,on 01 Ihe hailS should be "oled, so Ihm Ihey ilre reflued on Iherr 011\)",,,1 POSlllons. 7 Oncc all ItHee boilS hilve been unscrewed hom Ihe cVlrnde , blod the Wille, P""'P m"y he 'emoved ilnd Ihe 0.1sk(:1 se';'ped off
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82 Thermosl"l hOU5111g ilnd lUll hose (3 0 l 'l'c ellUllle)
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8 9 Rcmov,ng Ihe IhefnlOSI .. ,''''' ' A ~ ~ I.-
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86 ThelmOS!,;1 hous;"\) w"h b01\o", hose d isconnected ""d he,1(Cr hose connecled (2 8 hl.e enU IIle)
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8.13A F,n ing a new Ihe,mOSla l hou5'r1U gasket (2.8 loire en[llllc)
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88 Rcmovrng the Ihe.moslnt housing \28 litre engine)
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8 13B TlghlCnrng the thermOS!ill hous,ng L>olts (28 hl.e enu.ne)
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62 Chapter 2 Cooling system
2.8 litre engine 8 Remove the radrator ,lnd Shroud as descrIbed In SectIon 7. 9 Remove the dlll/cbell (Section 10). 10 Remove the ftm and pulley (Section 11) 11 Remove rhe lhcrmosln (Section 8). 12 D,sconnr:c l the hose 110'11 the therm ostat rca r elbow. 1 J Unhoh the wale, pump from the engme, nOlmg the loem'ol] of
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ench IJ0l11'15 they arc of Yil"OUS lengths (phOlos). 14 $OilpC aU the (lasket .
All ellgines 15 Rchumg is 11 reversal 01 removal, bUI elc",'1 the l11m'ng rolCC~ .111< ollw /

Fig. 2.4 Therllloslllt iln d Wil le r pump components on the 3 .0 litH! engine (Sees 8 and 9)
9 1 3A Unbolting the water pump (2.8 li!le eflg inr:) I
Walt"
l)lJtlljJ " I-Iousi"g 2 Bo/( 5 G,lSI 9.138 Waler pump and impeller (2.8 hue engine)
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9 .1 5 Fitt ing the water puml' gaskel (2 8 hire engine)
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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
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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 upholstery and carpets - 17 6 windsCtee n illld windows cleilning - 16 braking system
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
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")256
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Water pump reliuinu -44. 61 removal -61 Weights. vehicle - 6 Wheels care Jod rll )
Index
W indscree n washe r nozzle removal and refitting -219 pump removal and refitting -219 Windsc ree n wipers arms and blades removal and relitting -220 fault tracing -219 motor and lin kage removal and refi1ting -218 mOlor dismantling and roassembly -219 switch (Series II) -225 Wiring diagrams -235 to 249 Working facilit ies -11
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