Page 21
Valve guides:
46.65 mm
Length
LJUL1
1Z
UiIIIL1
fl/fl
1Z
fiLl
I
liii
Bore for valve guides in
cylinder head, diameter
13.000-13.018 mm
Valve springs:
1975 model
As from 1976 model
Installed length
Free length
Length at full elevation
Load at full elevation
39.5 mm
44.3 mm
29.5 mm
795-880 N (178-198 Ib,
81-90 kg)
39.5 mm
43.1 mm
29.5 mm
755-815 N (170-183 lb.,
77-83 kg)
(N.B This valve spring
(83 58 467) must only
be fitted in combina
tion with camshaft
83 58 186 (carbureted
engines as from 1976
model and camshaft
83 56 057 (injection
engine as from 1975
model.
Valve depressors:
Diameter
Height
Bore in cylinder head
for valve depressors
(camshaft bearing assy.)
37.87-37.98 mm
33 mm
38.000-38.016 mm
Pallets for valve adjustmen t:
Diameter
Thickness
.15.5 mm
1.77-2.89 mm
There are 23 pallets of different
thicknesses at intervals of 0.050 mm
Materials:
Exhaust valve
Stellited steel
Sodium-cooled exhaust valve are
fitted in 1977 model cars with fuel
injection engines, as from engine Nos.
BI 20 P01006201, BI 20 P02002615
BI 20 P04003376, Bl 20 P05001556
BI 20 P07001001 (and P07000604P0700062 5
N.B.
Sodium-cooled valves for scrapping
must under no circumstances be mixed
with ordinary scrap before they have
been specially treated, owing to the
risk of explosion. Refer to Section 214
under
‘Scrapping of sodium-cooled
valves”.
Engine model 1975—81
020—5
Page 22
Inlet valve
Valve guides
Valve seats
Valve clearances, cold
engine (30 minutes after
running the engine warm:
Inspection tolerance
zone:
Inlet
Exhaust
Adjustment tolerance
zone:
Inlet
Exhaust
Idler shaft axial play
Steel
(Valve spindles are chromium plated)
Cast iron
Sintered metal
0.006-0.012” (0.15-0.30 mm)
0.014-0.020” (0.35-0.50 mm)
Turbo 0.016-0.020 (0.40-0.50 mm)
0.008-0.010” (0.20-0.25 mm)
0.016-0.018” (0.40-0.45 mm)
Turbo 0.018-0.020” (0.45-0.50 mm)
0.002-0.005” (0.05-0.13 mm)
Lubrication system
Type
Pressure-lubricated
points
Splash-lubricated
points
Oil filter
Crankcase ventilation,
fully enclosed
Lubricating oil, grade:
SAE 10 W 30, 10 W 40 or 5 W 30.
If no oil meeting these speci
fications is available, oil with
a viscosity or SAE 10 W 50 may
be used.
Service SE in API-system or
Ford spec. ESE-M2C-1O1C
Oil volume md. filter
Oil pump pressure-reducing
valve opens at
Oil pressure warning light comes
on at
Oil pressure at 2000
r/min (oil SAE 10 W 40 at 80°C)
Oil pump:
Axial clearance between rotor and
housing
Oil cooler air (Turbo) opening
temp. of thermostatic valve
020—6
Forced-flow circulating oil
system
Dual-rotor type oil pump
Camshaft, crankshaft, idler shaft,
connecting rods, transmission chain
Cudgeon journals, cylinder walls, valve
depressors and valve stems
Full-flow type
From crankcase through valve cover
restriction to inlet manifold. Valve
cover is connected to atmospheric
pressure via the air cleaner.
6 Imp. pints (3.5 litres)
4.0-5.0 bar (kgf/cm
0.3-0.5 bar (kgf/cm
2
2
Mm. 3.0 bar (kgf/cm
57-71 lb/in
,
4.2-7.1 lb/in
2
,
43 lb/in
0.002-0.003” (0.05-0.09 mm)
approx. 75°C
Engine model 1975—81
2
,
2
.)
.)
2
.)
-
Page 23
Fuel system
Sinqle—carburetor
As from 1975 model
Make
Model
Diameter
Metering needle
Float setting
Modifications as from
1977 model
Zenith
175 CD-2S(E)
175 CDSEVX
1 3/4”
BiDS
0.63-0.67 in (16-17 mm)
between the highest point
on the float and the seal
of the carburetor body.
0.08 in (2.0 mm)
Automatic transmission oil
to Ford specification M2C.33F
or equivalent
Mm. of 0.040 in (10 mm) be
low top of damper
Float valve
Oil type in carburetor damper
Level or oil in carburetor damper
Clearance between fast idling cam
and adjusting screw (choke in)
Normal idling speed
(engine warmed up and
headlights dipped)
CO content
0.04 in (1.0 mm)
850 ÷ 50 rpm
Up to and md. 1976 model:
As from 1977 model Europe
As from 1977 model Sweden
max 3.5 % at 850 r/min
1.5 + 1 O/ at 850 r/min
1.75+ 0.25 O/ at 2000 r/min
(check value: max. 4.5 %
at idling speed)
On setting at 2000 r/min:
Vacuum pipe to distributor, crankcase
ventilation hose and, where applicable,
vacuum pipe to the EOR valve disconnected.
Fuel jet setting (adjustable up to and
mcI 1976 model
0.098 ÷ 0.008 in (2.5 +
0.2 mm) between upper sur
face of fuel jet jet bridge
surface in carburetor
housing
Fuel jet setting (fixed as from 1977
model
Inserted to a distance of
0.098 in (2.5 mm) from jet
bridge surface
Fuel needle setting in vacuum piston
(initial setting for adjustment)
Lower part of groove for
plastic washer level with
the underside of vacuum
piston
Initial setting for adjustment of fuel
needle as from 1977 model
Shoulder of needle level
with bottom edge of vacuum
piston
Ternperature compensaor, opening at
room temperature (+68 F/f 20 C)
0.004-0.012 in (0.1-0.3 mm)
Colour coding of vacuum piston return
spring
Red
Engine model 1975—81
020—7
I
Page 24
Twin-carburetor
As from 1975 model
Modifications as from
1977 model
Make
Model
Diameter
Metering needle
Zenith
150 CD-2S(E)
1 1/2”
BiDS
Float setting
0.63-0.67 in (16-17 mm)
between the highest point
of the float and the ma
ting surface at the car
buretor housing
0.08 in (2.0 mm)
Automatic transmission oil
to Ford specification M2C.33F
or equivalent
Mm. 0.39 in (10 mm) under
the upper part of the damper
cylinder
Float valve
Oil type in carburetor damper
Level or oil in carburetor damper
Clearance between fast idling cam
and adjusting screw (choke in)
Normal idling speed
(engine warmed up and
headlights dipped)
CO content
Model 1975:
As from 1977 model Europe
As from 1977 model Sweden
150 CDSEVX
B5EJ (as from 1980 model
B5EQ
0.04 in (1.0 mm)
850
-
50 rpm
max 3.5 % at 850 r/min
1.5 + 1 % at 850 r/min
1.0 + 0.25 % at 2000
r/mfn (check value: max.
4.5 % at idling speed)
On setting at 2000 r/min:
Vacuum pipe to distributor, crankcase
ventilation hose and, where applicable,
vacuum pipe to the EGR valve disconnected.
Fuel jet setting (adjustable up to and
0.098 + 0.008 in (2.5 +
md 1976 model
0.2 mm) between upper sur
face of fuel jet jet bridge
surface in carburetor
housing
1977
from
as
Fuel jet setting (fixed
Inserted to a distance of
model
0.098 in (2.5 mm) from jet
bridge surface
Fuel needle setting in vacuum piston
Lower part of groove for
(initial setting for adjustment)
plastic washer approx.
0.016 in (0.4 mm) below
bottom of vacuum piston
fuel
of
Shoulder of needle level
Initial setting for adjustment
needle as from 1977 model
with bottom edge of vacuum
piston
Temperature compensator, opening at
0.004-0.012 in (0.1-0.3 mm)
room temperature (+68 F/+20°C)
piston,
vacuum
Return spring for
Blue
color
Others
0
Fuel pump (mechanical) type
Static fuel pressure at starter
speed
Fuel tank capacity
020—8
AC Delco No. 7990045
)
lb/in
2
, 2.4-3.6 .
(kg/cm
0.17-0.25 bar 2
liters)
(55
gal.
12.1 Imp.
Engine model 1975—81
Page 25
Fuel system, injection engine
I
Components
Injection valve
•
o
‘Cold start valve
Mixture control unit:
Up to and mcI. 1976 model
1977 model
As from 1978 model
Air flow sensor:
Up to and mcI. 1976 model
1977 model
As from 1978 model
Fuel distributor:
Lip to and mc!. 1977 model
As from 1978 model
Warm up regulator, up to and md.
1976 model
Warm up regulator, up to and md.
1977 model
437 502 004
0 280 170 401
0 438 040 004
0 438 040 034
0 438 120 049
Turbo 0 438 040 041
0 438 120 013
0 438 120 046
0 438 120 071
Turbo 0 438 120 087
0 438 100 005
0 438 100 023
Turbo 0 438 100 057
0 438 140 013
0 438 140 020
Auxiliary air valve
Fuel filter, up to and mcI. 1978
model
Fuel filter, as from 1977 model
Fuel accumulator:
Up to and mcI. 1977 model
1978 model
As from 1979 model
0 438 170 001
0 438 170 014
0 438 170 010
Fuel pump
Up to and inch 1977 model
As from 1978 model
0 580 254 994
0 580 245 978
Temperature-sensing
Up to and mcI. 1977* model
As from 1977** model
0 280 130 214
0 280 130 217
*
As from 1980 model
0 437 502 012
Turbo up to and md. ‘mo
del 1979: 0 438 140 051
Turbo as from 1980 model
0 438 140 070
0 280 140 107
0 450 905 005
0 450 905 021
Up to and md. engine number:
As from engine number:
P120 P01-8201, B120 P02-3301, B120 P07-1626
P120 P01-8202, B120 P02-3302, B120 P07-1627
**
Test values
1.
Fuel pump, capacity. (minimum flow
against system pressure, ie. measured
in the return pipe)
Up to a,d including 1977 model
750cm /30s
As from 1978 model 900 cm 3 /30 s
2.
Control pressure, cold engine
Up to and mcI. 1976 model
bar
kpfcrrr
-
II9
2.5
tZILE
2.0
1.5
1,0
0.5
0
10
20
30
40
°C
S 5200
Up to and mcI. 1976
bar
_ch 0 438 14d 020
Bosch 0438 140 013
-
2.5
25
20
2,0
1.5
1,5
Bosch 0 438 140 070
BocI 0438 100 032
L
,.t
J
!‘L
2,5
‘0
L
-
7’V’’
10
j=
---“i
1.0
10
20
30
40
C
As from 1977 model
-r
05
“
:I Y
1.0
‘--H
0,5
‘
10
20
30
40
C
Turbo as from 1980 model
Engine model 1975—81
0
--HHH =
0
CLI
20
30
40
°C
S 6244
020—9
Page 26
2 48.5-54.0
,
3.4_328 bar ( kg/cm
lb/in
3.
Control pressure, warm engine
4
Control pressure, full-laden Turbo
1978-1979 models:
0
62 or speed above 130 km/h
5.
6.
7.
2 35.6-41.2
,
2.5-9 bar ( kg/cm
lb/in )
1980 model
Simulated charging pressure in excess
2 35.6-41.2
,
2.5-9 bar ( kg/cm
of 0.33-0.40 bar
lb/in )
Line pressure:
kg/cm 64.0-72.5
2
Test value
4.5521 bar ( ,
lb/in )
2
Turbo 5.2_5.82 bar ( kg/cm
74-82.5 lb/in )
2
cm
9
k
4.7-4.9 bar ( /
Setting value
66.9-69.7 lb/in
Turbo 5.4-5.6 r ( kg/cmL,
76.8-79.7 lb/in )
Leakage check:
Minimum pressure af
1.0 bar ( kg/cm 14.2 1b/in)
ter 20 minutes
1.5 bar ( kg/cm 21.3 lb/in )
As from 1978 model
Injection valve:
Opening pressure as from date
2 35.6-49.8
,
code 828 L978)
2.5326 bar ( kg/cm
lb/in )
Opening pressure as from date
kg/cm 38.4-54
2
code 829 (1979 model)
2.7328 bar ( ,
lb/in
2
3.0-41 bar ( kg/cm , 42.6-58.3
Opening pressure 1980 model
lb/in
Maximum variation between injection
)
lb/in
2 8.5 2
,
0.6 bar ( kg/cm
valves in same engine
8.
Leakage check, injection valve
9.
Idling speed setting (warm
engine and cars to swedish
specification: day warning
lights on.
CO content:
Up to and including 1976 model
Europe as from 1977 model
Sweden as from 1977 model
Test system should maintain 2
a pressurof 2.4 bar ( kg/cm
34.1 lb/in ) for 15 S
850 ± 50 r/min
Max. 3.5 % at 850 r/min
1.5 ± 1 % at 850 r/min
1.5 + 0.5 % at 850 r/min
Tightening torques
Air flow sensor:
Stop bracket retaining bolts
Counterweight retaining bolts
Air flow sensor plate retaining screw
Fuel distributor retaining bolts
Line pressure regulator screw plug
M 8 bolt
M 10 bolt
M 12 bolt
M 14 bolt
M 12 cap nut
M 14 cap nut
020—10
0
4.7-5.3 Nm (3.4-8.8 ftlb, 47-53 kgcm)
4.7-5.3 Nm (3.4-3.8 ftlb, 47-53 kgcm)
5.0-5.5 Nm (3.6-4.0 ftlb, 50-55 kgcm)
3.2-3.8 Nm (2.3-2.7 ftlb, 32-38 kgcm)
13-15 Nm (9.4-10.8 ftlb, 130-150 kgcm)
10-12 Nm (7.2-8.7 ftlb, 100-120 kgcm)
13-15 Nm (9.4-10.8 ftlb, 130-150 kgcm)
20-24 Nm (14.4-17.4 ftlb, 200-240 kgcm)
15-20 Nm (10.8-14.4 ftlb, 150-200 kgcm)
15-20 Nm (10.8-14.4 ftlb, 150-200 kgcm)
25-30 Nm (18.1-21.8 ftlb, 250-300 kgcm)
Engine model 1975—81
.
Page 27
Turbo system
Turbo compressor make
Maximum charing pressure (see
Measuring the charging pressure)
Approximate length of spring in
charge pressure regulator (basic
setting)
Pressure switch actuating pressure
Clearance, turbo shaft bearings:
End float
Radial clearance
Garrett AiResearch
0.70 ± 0.05 bar kg/cm
2
,
12.8 ÷ 1.4 lb/in
2
Approx. 18 mm (0.79 in)
2
0.9 + 0.1 bar (kg/cm , 12.8 + 1.4 lb/in
0.025-0.10 mm
0.075-0.18 mm
Fuel boosting device, 1979 model:
Type
Full-load enrichment dependent on speed
and throttle valve position
Throttle valve switch (throttle
opening when swich closes)
Speed transmitter (closing speed)
Pressure regulator (reduced control
pressure)
CO value with throttle valve switch
depressed (CO value at idling speed
set at 1.0-2.0 %)
Fuel boosting device as from 1980
model
Type
620
80 ± 3 mph (130 ± 5 km/h)
2.5-2.9 bar (kg/cm
2
,
35-41.2 lb/in
2
4-6 % CO approx
Charging pressure controlled full-load
boosting. Warm-up regulator and special
control system)
Warm-up regulator
Simulated charging pressure when the
control pressure is reduced
0.33-0.40 bar kg/cm
Reduced control pressure (wit[carging
pressure over 0.4 bar (5.7 lb/in )
2.5-2.9 bar (kg/cm
Throttle valve switch (throttle
opening when contact closes)
CO value at idling speed with
simulated charging prssure
over 0.4 bar (5.7 lb/in )
2
,
2
,
4.7-5.7 lb/in
35-41.2 lb/in
2
2
620 approx.
4-6 % CO approx.
Exhaust emission control system
EGR system
EGR cut-in speed
(fast idling)
Vacuum necessary to
open EGR valve
Opening temperature of
PVS valve
Restriction diameter at
EGR outlet in exhaust
manifold
On-off
Two port (Injection engine with
automatic transmission), as
from 1978 model
Around 1 900 u/mm
2 600 +300 u/mm
2.36 ÷ 0.20 in
(60÷5 mm)Hg
2.36 + 0.2 in
(2.36÷5 mm)Hg
Approx. 100°F (38°C)
Approx. 100°F (38°C)
0.16 in (4 mm)
No restriction
Engine model 1975—81
020—11
Page 28
Deceleration valve, carbureted engines
(up to and mcI. 1977 model
Setting:
1.
Turn the valve screw clockwise until en
gine speed ceases to increase.
2.
Turn the valve screw counter-clockwise un
til the engine has returned to idling speed
and then turn the screw a further 1/2-3/4
turn clockwise from this position.
Checking:
Rev up the engine and release the throttle.
Check that the engine speed after slight
delay returns smoothly and distinctly to
idling speed.
-
-
Electrically controlled deceleration device
Speed transmitter
Deceleration solenoid,
adjusting
Energizes the solenoid when the
speed of the car exceeds 19-22
mnh/30-35 km/h.
Increases the idling speed to 1 550
÷ 50 r/min (Turbo 1978-1979 model:
1 400 ± 50 r/m in) when the throttle
is closed and the solenoid connected
to battery voltage (at speeds above
19-22 mph/30-35 km/h)
N.B.
The solenoid cannot open the throttle
valve but merely functions as a stop to
prevent the throttle closing complete
ly during engine overrun at speeds
exceeding 19-22 mph/30-35 km/h.
Deceleration valve, injection engine
Time for engine to drop
from 3 000 r/min to
idling speed
Up to and mcI. 1976
model
As from 1977 model
4-5 5
3-6 5
Delay valve
Delay of vacuum signal to
vacuum regulator in distri
butor
6 ± 2 s (Turbo Sweden as from 1979 model:
20 + 4 s)
Dashpot
Check. Deceleration time from 3000
r/min to idling speed
Setting: r/min when the dashpot rod
hits the stop on the throttle spindle.
(Vacuum pipe disconnect from the distri
butor, engine warm)
020—12
3-6 s
1979 model: 2600 + 100
As from 1980 model: 2000 + 100
Engine model 1975—81
.
Page 29
Exhaust system
Exhaust pipe inner
diameter
1.73? (44 mm)
Cooling system
Type
Liquid capacity of
cooling system md.
heating system
Thermostat opens at
Radiator pressure cap
opens at
Pressurized
7 lrnp.iarts (8 1)
89
2
-
0.9-1.2 bar (kg/cm
2
,
12.8-17.0 lb/in
2
)
Water pump
Clearance between pump shaft and pump
cover
No. adjustment needed. Original
gasket gives correct clearance.
Hammers must never be used when re
moving or fitting the later version
of water pump (impeller retained by
nut). As from 1977 model, the thread
on the water pump shaft is only used
during removal of the pump.
Se Group 2.
Engine model 1975—81
020—13
Page 30
Tightening torques
Dimension
Main bearings
Big-end bearing bolts
Camshaft bearing caps
Valve cover
Crankshaft belt pulley
Seal end (flywheel
side)
Cylinder head screw
Flywheel
Water pump impeller
(earlier version, bolt
Water pump impeller
(later version, nut)
Oil pump
Spark plugs
Idler shaft keeper
plate
Chain sprocket idler
shaft
Chain sprocket camshaft
Inlet manifold
Thermostat housing
Throttle valve housing
Exhaust manifold 1975
model
Exhaust manifold 1976
model
Torque
kgm
ftlb
M 12
M 10
MB
M 6 (M 8)
M 16
MB
108
54
18
2.0
190
20
11
5.5
1.8
0.2
19
2.0
79
40
13
1.4
137
14
M 12
M 10
93
59
9.5
6.0
69
43
M B (lefthand thread)
M 12 (lefthand thread)
M8
M 14 x 1.25
M8
25
2.5
18
15
1.5
11
18
28
20
1.8
2.8
2.0
13
20
14
M 10
M8
MB
MB
MB
25
20
18
18
18
2.5
2.0
1.8
1.8
1.8
18
.14
13
13
13
M10
25
2.5
18
MB
20
2.0
14
For other bolts, use general tightening
torques:
Dimensions Nm
M 5
M 6
M 8
M 10
020—14
Tiqhtening_torque
ftlb
kgm
4.9
9.8
19.6
39.2
0.5
1.0
2.0
4.0
3.6
7.2
14.4
28.9
Engine model 1975—81
.