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Ford Granada 1985-1994, Руководство пользователя

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Ford Granada 1985-1994 Скачать руководство пользователя страница 156

17 Refit the washer, spring and spring cover.
Compress the spring and refit the circlip, then
release the spring compressor.
18 Lubricate the caliper bore with clean
hydraulic fluid and fit a new piston seal.
19 Reassemble the piston components.
Lubricate the contact face of the adjuster nut
with a little brake grease, then fit the adjuster
nut (with new seal), thrust bearing,
thrustwasher, wave washer and the second
thrustwasher. Secure with the circlip.
20 Fit a new dust boot. The manufacturers
recommend that it be fitted to the caliper
groove and the piston fitted afterwards; it is
also possible to fit the boot to the piston first
and engage it in the caliper groove afterwards.
Either way it is a fiddly business.
21 Refit the piston and screw it into the
caliper, then fit whichever lip of the dust boot
was left free (see illustration).

22 Renew the slide pin gaiters and apply a
little anti-seize compound to the slide pins
when reassembling the caliper to the bracket.

The splash shield is retained by the rear hub

bolts. Proceed as described in Chapter 11 for
removal and refitting of the rear hub.

1 Disconnect the battery negative lead.
2 Depressurise the hydraulic system by
pumping the brake pedal at least 20 times, or
until it becomes hard.
3 Remove the under-dash trim on the driver’s
side.
4 Remove the spring clip which secures the
hydraulic unit pushrod to the brake pedal. Also
remove the clip from the brake pedal shaft
(see illustration).
5 Withdraw the brake pedal shaft towards the
left of the vehicle - through the clutch pedal,
when applicable - until the brake pedal is free.
6 Remove the pedal, noting the fitted
sequence of bushes, spacers and washers.
7 Refit by reversing the removal operations.
Check the correct functioning of the stop-light
and (if applicable) cruise control switches
before refitting the trim. See Chapter 13.

1 Disconnect the battery negative lead.
2 Depressurise the hydraulic system by
pumping the brake pedal at least 20 times, or
until it becomes hard.
3 Disconnect the six multi-plugs from the
hydraulic unit. They are all different, so there is
no need to label them. When a plug has a
spring clip retainer, lift the clip before pulling
out the plug. To release the pump plug, pull
back the rubber boot and the plug sleeve (see
illustrations).
4 Unbolt the earth strap from the unit (see
illustration).
5 Make arrangements to catch spilt hydraulic

15 Hydraulic unit - removal and

refitting

14 Brake pedal - removal and

refitting

13 Rear disc splash shield -

removal and refitting

10•8 Braking system

12.21 Dust boot fitted to caliper and piston

15.3d Disconnecting the pressure switch

multi-plug

15.3e Disconnecting the pump motor plug

15.4 Earth strap (arrowed) bolted to

hydraulic unit

14.4 Pushrod spring clip (A) and brake

pedal shaft clip (B)

15.3a Disconnect the valve block multi-

plug. Lift the clip and pull off the plug

15.3b Disconnecting a fluid level sensor

plug

15.3c Disconnecting the main valve plug

Содержание Granada 1985-1994

Страница 1: ...ire brush small M Funnel medium size Repair and overhaul tool kit These tools are virtually essential for anyone undertaking any major repairs to a motor vehicle and are additional to those given in t...

Страница 2: ...one Vacuum pump and gauge Clutch plate alignment set Brake shoe steady spring cup removal tool Three legged hub and bearing puller Micrometer set Vernier calipers Dial test indicator and magnetic stan...

Страница 3: ...national safety standards If in doubt ask the proprietor or manager of the shop for advice before making a purchase Care and maintenance of tools Having purchased a reasonable tool kit it is necessar...

Страница 4: ...talling the bolt or stud Failure to do this could cause the housing to crack due to the hydraulic action of the bolt or stud as it is screwed in When tightening a castellated nut to accept a split pin...

Страница 5: ...fumes from exhaust system Clutch 4 m m Pedal travels to floor no pressure or very little resistance m m Clutch fails to disengage unable to select gears m m Clutch slips engine speed increases with no...

Страница 6: ...le speed Chapter 4 m m Air filter element clogged Chapter 1 m m Vacuum leak at the throttle body inlet manifold or associated hoses Chapter 4 m m Worn faulty or incorrectly gapped spark plugs Chapter...

Страница 7: ...tching off m m Excessive carbon build up in engine Chapter 2 m m Excessively high engine operating temperature Chapter 3 Engine noises Pre ignition pinking or knocking during acceleration or under loa...

Страница 8: ...corroded or damaged silencers or pipe Chapters 1 and 4 m m Broken mountings causing body or suspension contact Chapter 4 Fault Finding 4 Clutch 5 Manual gearbox Noisy in neutral with engine running m...

Страница 9: ...wheel and pinion Chapter 9 m m Loose or deteriorated final drive mountings Chapter 9 Oil leakage from final drive m m Pinion or output flange oil seal leaking Chapter 9 m m Rear cover leaking Chapter...

Страница 10: ...m Defective shock absorbers Chapters 1 and 11 m m Broken or weak coil spring and or suspension component Chapters 1 and 11 m m Worn or damaged anti roll bar or mountings Chapter 11 Wandering or genera...

Страница 11: ...lown fuse Chapter 13 m m Cable or cable connections loose broken or disconnected Chapter 13 m m Faulty relay Chapter 13 m m Faulty wiper motor Chapter 13 Wiper blades sweep over too large or too small...

Страница 12: ...delivers power from the final drive assembly to the drive wheels Also called a driveshaft or a halfshaft B Ball bearing An anti friction bearing consisting of a hardened inner and outer race with hard...

Страница 13: ...rum to slow or stop the vehicle E EGR valve A valve used to introduce exhaust gases into the intake air stream Electronic control unit ECU A computer which controls for instance ignition and fuel inje...

Страница 14: ...trut an integral coil spring and shock absorber is mounted between the body and the steering knuckle Many modern so called MacPherson strut systems use a conventional lower A arm and don t rely on the...

Страница 15: ...as a release bearing Timing belt A toothed belt which drives the camshaft Serious engine damage may result if it breaks in service Timing chain A chain which drives the camshaft Toe in The amount the...

Страница 16: ...per square X 98 1 Kilopascals kPa centimetre kgf cm2 kg cm2 Millibar mbar X 100 Pascals Pa X 0 01 Millibar mbar Millibar mbar X 0 0145 Pounds force per square inch X 68 947 Millibar mbar psi lbf in2...

Страница 17: ...d motor 3 10 Connecting rods 2A 11 2A 13 2A 15 2B 17 2C 12 2C 14 2C 16 Console light 13 9 Contents 0 2 Control assembly 13 19 Control module 10 13 Control switches 13 19 Control units 13 13 Conversion...

Страница 18: ...gine running REF 11 Ignition starter switch 13 11 Inlet manifold 1 14 4 19 Instrument cluster 13 9 13 10 Instrument illumination dimmer switch 13 11 Instrument panel lights 13 8 Instrument readings in...

Страница 19: ...9 2C 17 Tools and working facilities REF 1 et seq Towing 0 7 Track rod end 11 6 Transmission fluid brown or has burned smell REF 9 Transmission slips shifts roughly is noisy or has no drive in forward...

Страница 20: ...comfortable 70 seat video cinema and one of the most extensive transport book shops in Britain The Pit Stop Cafe serves everything from a cup of tea to wholesome home made meals or if you prefer you c...

Страница 21: ...en We encourage frequent maintenance because it enhances the efficiency performance and resale value of your vehicle If the vehicle is driven in dusty areas used to tow a trailer or driven frequently...

Страница 22: ...rting Section 37 m m Check that automatic choke is fully off with engine hot not fuel injection models Section 36 m m Check power steering fluid level when applicable Section 35 Every 24 000 miles 40...

Страница 23: ...screen washer reservoir 20 Alternator 21 Coolant expansion tank cap 22 Engine mounting 23 Heater hose 24 Automatic transmission fluid dipstick 25 Brake fluid reservoir cap 26 Brake hydraulic unit accu...

Страница 24: ...fuse relay box 28 Wiper motor behind cover 29 Heater blower cover 30 Fuel pressure regulator 31 Distributor screening lid 32 Engine oil dipstick 33 Automatic transmission fluid dipstick Under bonnet...

Страница 25: ...return pipes 19 Rear brake pipes 20 Steering gear feed and return hoses Front underbody view of a 2 0 litre DOHC Granada with automatic transmission 1 Rear silencer 2 Fuel pump fuel injection 3 Fuel f...

Страница 26: ...e and money unless extensive overhaul work is carried out first The following series of operations are those most often required to improve the performance of a generally poor running engine Primary o...

Страница 27: ...rvoir requires repeated replenishment to maintain the proper level this is an indication of a hydraulic leak somewhere in the system which should be investigated immediately Washer fluid 17 When toppi...

Страница 28: ...ictive for many owners 12 Front tyres may wear unevenly as a result of wheel misalignment The front wheels should always be correctly aligned according to the settings specified by the vehicle manufac...

Страница 29: ...sealing washer for condition and renew it if necessary Clean the area around the drain plug opening and refit the plug Tighten the plug to the specified torque 6 Move the container into position under...

Страница 30: ...the vehicle until the necessary repair work has been carried out Renew any damaged sections of hose or pipe 7 Carefully check all rubber hoses and metal fuel lines leading away from the petrol tank Ch...

Страница 31: ...P 3 Wait one minute With the engine still idling withdraw the transmission dipstick see illustration Wipe the dipstick with a clean lint free rag re insert it fully and withdraw it again Read the flui...

Страница 32: ...14 Run the engine to verify that the HT leads have been refitted correctly DOHC engines 15 Proceed as described above whilst noting the following points a Remove the air cleaner as described in Chapte...

Страница 33: ...nd jump starting can be found in Chapter 5 and in the preliminary Sections of this manual SOHC engines 1 Valve clearances are checked with the engine cold 2 On carburettor models remove the air cleane...

Страница 34: ...clearances according to the firing order as follows The cylinders are numbered see illustration and the valves are listed in their correct order working from the front of the engine Valves overlappin...

Страница 35: ...wer arm must be renewed 3 Check the shock absorbers by bouncing the vehicle up and down at each corner in turn When released it should come to rest within one complete oscillation Continued movement o...

Страница 36: ...feel considerably firmer 1 The power steering fluid dipstick is incorporated in the reservoir filler cap The reservoir is mounted on the pump Observe scrupulous cleanliness when checking the level or...

Страница 37: ...curing clips then lift away the air inlet tube plenum chamber and air cleaner lid as an assembly disconnecting the breather hose from the air inlet tube 19 Lift out the air cleaner element then wipe t...

Страница 38: ...It is positively located by a notch or shaped pegs so it cannot be fitted the wrong way round Tighten the securing screws when applicable 15 Refit the distributor cap and secure it with the clips or...

Страница 39: ...rise the system then check the filter unions for leaks Renew the crankcase ventilation vent valve by pulling it from the oil separator and loosening the hose clip see illustration Fit the new valve ti...

Страница 40: ...enewal of the coolant has been neglected or unless plain water has been used as coolant In either case the coolant will appear rusty and dark in colour Flushing is then required and should be carried...

Страница 41: ...2 0 litre Champion LS 09 boxed set 1 8 and 2 0 litre Male distributor fitting Champion LS 10 boxed set The spark plug gap quoted is that recommended by Champion for their specified plugs listed above...

Страница 42: ...1 22 Notes...

Страница 43: ...aul or major repair 51 Major operations possible with the engine in the vehicle 2 Major operations requiring engine removal 3 Methods of engine removal 4 Oil filter renewal 20 Oil pump examination and...

Страница 44: ...010 to 0 064 mm Big end bearing journal diameter Standard 51 980 to 52 000 mm Undersize 0 25 51 730 to 51 750 mm Undersize 0 50 51 480 to 51 500 mm Undersize 0 75 51 230 to 51 250 mm Undersize 1 00 5...

Страница 45: ...entre 44 607 to 44 633 mm Rear 44 987 to 45 013 mm Bearing bush internal diameter Front 42 035 to 42 055 mm Centre 44 655 to 44 675 mm Rear 45 035 to 45 055 mm Valve clearances cold Inlet 0 20 0 03 mm...

Страница 46: ...to 37 Flywheel bolts 64 to 70 47 to 52 Oil pump to cylinder block bolts 17 to 21 13 to 16 Oil pump cover bolts 9 to 13 7 to 10 Sump bolts see text Stage 1 1 to 2 0 7 to 1 5 Stage 2 6 to 8 4 to 6 Stage...

Страница 47: ...g Carburettor stepper motor h Fuel injection system sub harness j Inlet manifold heater 12 Disconnect the HT lead from the coil 13 If an oil level sensor is fitted remove it see illustration 14 Unbolt...

Страница 48: ...em are available from most motor accessory shops and tool factors 10 Another tool which is useful though by no means essential is a valve spring compressor of the type which hooks under the camshaft s...

Страница 49: ...the backplate see illustration 4 Unscrew the bolts and remove the camshaft oil supply tube see illustration 5 Note how the cam follower retaining spring clips are fitted then unhook them from the cam...

Страница 50: ...otor in relation to the rim of the distributor body 4 Slacken the timing belt tensioner retaining bolts then pivot the tensioner pulley away from the belt to obtain maximum drivebelt free play see ill...

Страница 51: ...engine is out of the vehicle start at paragraph 11 If possible remove the sump without inverting the engine so that any sludge in the bottom of the sump stays there 2 Disconnect the battery negative...

Страница 52: ...e oil seal see illustration However it may be possible to remove the oil seal by drilling the outer face and using self tapping screws and a pair of grips 3 Clean the oil seal seating then drive in a...

Страница 53: ...cation marks and if necessary use a centre punch to identify them see illustration 6 Before removing the crankshaft check that the endfloat is within the specified limits by inserting a feeler blade b...

Страница 54: ...f the vehicle must influence the standards applied 3 Gaskets oil seals and O rings must all be renewed as a matter of routine Flywheel and cylinder head bolts must be renewed because of the high stres...

Страница 55: ...ed 4 If new pistons or piston rings are to be fitted to old bores deglaze the bores with abrasive paper or a glaze buster tool The object is to produce a light cross hatch pattern to assist the new ri...

Страница 56: ...ps between the pistons and bores To do this locate two of the pistons at the top of their bores and seal off the remaining bores with paper and masking tape Press a little grease between the two pisto...

Страница 57: ...no tight spots or binding 18 Check that the crankshaft endfloat is within the specified limits by inserting a feeler blade between the centre crankshaft web and the thrustwashers 19 Make sure that the...

Страница 58: ...the rear of the block 2 Wipe the mating faces then locate the flywheel driveplate on the rear of the crankshaft 3 Coat the threads of the bolts with a liquid locking agent before fitting Note that the...

Страница 59: ...car 2 Turn the engine so that No 1 piston is approximately 2 cm 0 8 in before top dead centre This precaution will prevent any damage to open valves 3 Make sure that the faces of the cylinder block a...

Страница 60: ...crankshaft through two full turns clockwise then 60 anti clockwise so it is now at 60 BTDC 11 The belt tension should now ideally be checked by applying Ford tension gauge 21 113 to the longest run D...

Страница 61: ...ck that the torque converter is fully engaged with the transmission oil pump 3 Sling the engine so that it is roughly horizontal Lift it and position it over the engine bay 4 Lower the engine into pla...

Страница 62: ...ed regularly it can give warning of trouble before any other symptoms become apparent 2 The engine must be at operating temperature the battery must be fully charged and the spark plugs must be remove...

Страница 63: ...el driveplate removal inspection and refitting 22 General information 1 Initial start up after overhaul or major repair 34 Major operations possible with the engine in the vehicle 3 Major operations r...

Страница 64: ...service 85 980 to 86 000 mm Oversize 0 15 86 130 to 86 150 mm Oversize 0 50 86 470 to 86 490 mm Piston ring end gap Top 0 300 to 0 600 mm Centre 0 500 to 0 800 mm Bottom oil control 0 400 to 1 500 mm...

Страница 65: ...aft incorporates five main bearings Thrustwashers are fitted to the centre main bearing in order to control crankshaft endfloat The camshafts are driven by a chain from the crankshaft and operate the...

Страница 66: ...disconnecting the union Be prepared for petrol spillage and take adequate fire precautions Disconnect the fuel feed hose and disconnect the fuel return hose from the fuel pressure regulator Plug the e...

Страница 67: ...the vehicle taking care not to damage the components in the engine compartment Note Refer to Part A Section 4 of this Chapter and to the warning that appears at the start of Section 5 before proceedi...

Страница 68: ...ehicle Take care not to damage surrounding components 26 If the vehicle is to be moved with the engine gearbox assembly removed temporarily refit the suspension crossmember and the anti roll bar to th...

Страница 69: ...positioned flush with the engine adapter plate and the transmission housing check that the torque converter is free to move axially a small amount before refitting and tightening the engine to transm...

Страница 70: ...applicable b Exhaust manifold c Alternator d Water pump and thermostat e Water pump alternator drivebelt tensioner f Distributor cap HT leads and spark plugs g Oil pressure warning lamp switch h Cran...

Страница 71: ...ing it free with a screwdriver if necessary then slide the double chain sprocket from the end of the crankshaft and lift the chain from the sprocket see illustration 13 Withdraw the timing chain throu...

Страница 72: ...ts 34 Refit the crankshaft pulley to the end of the crankshaft and draw the pulley onto the crankshaft using the original securing bolt at the same time centering the lower timing chain cover 35 With...

Страница 73: ...r Torx type see illustration 1 With the manifolds removed proceed as follows 2 Unscrew the eleven bolts and four nuts and remove the camshaft cover Recover the gasket 3 Unscrew the four securing bolts...

Страница 74: ...d bolts see illustration progressively loosen the remaining cylinder head bolts and withdraw them from the cylinder head 18 Lift the cylinder head from the block If the cylinder head is stuck tap it f...

Страница 75: ...he following sequence L1 and R1 L5 and R5 L3 and R3 L2 and L4 R2 and R4 34 Fit a new chain tensioner plunger assembly to the housing in the cylinder head with the piston uppermost Before fitting the n...

Страница 76: ...tal tube Make sure that the seal lip faces into the engine Take care not to damage the timing chain cover 52 Fit the upper timing chain cover using a new rubber gasket Great care must be taken to avoi...

Страница 77: ...ting 1 Remove the flywheel driveplate and the engine adapter plate 2 Extract the seal using an oil seal removal tool if available It may also be possible to remove the oil seal by drilling the outer f...

Страница 78: ...ixings to the specified torque where applicable Note A suitable puller will be required to remove the crankshaft pulley A new crankshaft pulley bolt a new lower timing chain cover gasket and a new oil...

Страница 79: ...new connecting rod bolts on reassembly before fitting oil the threads and the contact faces of the bolts Tighten the bolts to the three stages given in the Specifications d Refit the oil baffle and ti...

Страница 80: ...bearing journals 0 25 mm undersize Refer to Part A Section 25 of this Chapter but note that the connecting rod bolts should be renewed on reassembly and when renewing the cylinder head bolts the late...

Страница 81: ...val 4 Oil pump dismantling examination and reassembly 27 Oil pump refitting 34 Oil pump removal 12 Pistons and connecting rods examination and renovation 25 Pistons and connecting rods refitting 33 Pi...

Страница 82: ...unning clearance 0 008 to 0 062 mm No 3 thrust bearing shoulder width standard 26 390 to 26 440 mm No 3 thrust flanged bearing shell width standard 26 240 to 26 290 mm Crankshaft endfloat 0 08 to 0 20...

Страница 83: ...to 42 825 mm Valve clearances cold Inlet 0 35 mm 0 014 in Exhaust 0 40 mm 0 016 in Inlet valves Head diameter 41 85 to 42 24 mm Length 105 25 to 106 95 mm Stem diameter Standard 8 025 to 8 043 mm Over...

Страница 84: ...stated the specifications and torque wrench settings for the 2 4 litre engine are as given for the 2 8 litre engine General Manufacturer s code ARC Bore mm in 84 0 3 307 Stroke mm in 72 0 2 865 Cubic...

Страница 85: ...et pipe to oil pump bolts 9 to 13 7 to 10 Oil pump to block bolts 17 to 21 13 to 15 Sump drain plug 21 to 28 15 to 21 Crankshaft pulley to vibration damper bolts 27 to 33 20 to 24 Crankshaft vibration...

Страница 86: ...ting rods and big end bearings e Renewal of the engine mountings f Removal and refitting of the flywheel g Renewal of the crankshaft front and rear oil seals h Removal and refitting of the camshaft af...

Страница 87: ...0 Take the weight of the engine then remove the single nut on each side which holds engine bearer to its mountings 21 From under the vehicle unbolt the engine adapter plate from the bellhousing 22 Rem...

Страница 88: ...rocker shaft Remove the shafts and pushrods keeping them in order so that they can be refitted in the same locations 6 Unbolt the exhaust pipes from the manifolds 7 Remove the spark plugs 8 Slacken th...

Страница 89: ...ation 30 Withdraw the pushrods and keep them in their originally fitted sequence 31 Disconnect the inlet manifold to timing cover coolant hose from the manifold 32 Unbolt and remove the inlet manifold...

Страница 90: ...This can be verified by removing the distributor cap and checking that the rotor arm is aligned with the No 1 HT lead contact 18 Disconnect the battery negative terminal 19 Unclip the air cleaner cove...

Страница 91: ...marks are aligned at the nearest point to each other see illustration If not turn the crankshaft as necessary 38 Unbolt and remove the timing chain tensioner Take care not to allow the spring loaded t...

Страница 92: ...soft faced mallet if necessary to free them 4 Note that the rear main bearing cap also retains the crankshaft rear oil seal and that the shells for No 3 main bearing have thrust flanges to control cr...

Страница 93: ...ove the carbon deposits from the combustion chambers and valve heads with a scraper or rotary wire brush 2 Remove the valves by compressing the valve springs with a suitable valve spring compressor an...

Страница 94: ...osition of the oil pump cover relative to the body then remove the bolts and spring washers Lift off the cover 4 Mark the rotor faces so that they can be refitted the same way round then remove them f...

Страница 95: ...be expected with new components but there should be no tight spots or binding 12 Press the crankshaft rear oil seal firmly against the rear main bearing 13 Check the crankshaft endfloat levering the c...

Страница 96: ...nsert the first piston into the bore Make sure it is the correct piston connecting rod assembly for that particular bore that the connecting rod is the correct way round and that the front of the pist...

Страница 97: ...ting the shafts slightly if necessary so that the marks on the two gears are aligned Remember that there are two marks on the crankshaft gear 5 Fit the camshaft gear retaining bolt and washer see illu...

Страница 98: ...22 Bolt the tensioner in position at the same time removing the plunger retainer Tighten the bolts to the specified torque 23 Locate a new gasket on the front face of the engine 24 Renew the timing c...

Страница 99: ...see illustration 4 Ensure that the gasket hole lines up with the holes in the gasket crankcase and fit the sump Take care not to dislodge the gasket 5 Fit the 24 securing bolts Tighten them in the seq...

Страница 100: ...equired after the initial running in period 18 Apply jointing compound to the areas where the inlet manifold and cylinder heads meet and locate a new gasket in position Make sure that it is the correc...

Страница 101: ...ghtening slacken one cylinder head bolt a quarter turn then re tighten it to the Stage 4 specified torque Repeat in sequence for all the cylinder head bolts 5 Tighten the inlet manifold bolts 6 Check...

Страница 102: ...2C 22 Notes...

Страница 103: ...removal and refitting 11 General System type Sealed pressurised thermostatically controlled Fan type Mechanical temperature sensitive viscous clutch or electric DOHC Coolant Type See Lubricants and fl...

Страница 104: ...ng Air conditioning is fitted as standard on Scorpio models and is optionally available on some other models In conjunction with the heater the system enables any reasonable air temperature to be achi...

Страница 105: ...adiator has been removed because of suspected blockage reverse flush it 2 Clean dirt and debris from the radiator fins using an air jet or water and a soft brush Be careful not to damage the fins or c...

Страница 106: ...nlet manifold and recover the O ring If it is necessary to prise the thermostat out take care not to damage the surface of the housing in the inlet manifold 16 Refitting is a reversal of removal beari...

Страница 107: ...5 Unscrew the two nuts securing the fan shroud to the top of the radiator then tilt the top of the shroud away from the radiator and lift the shroud to release the lower securing clips Withdraw the as...

Страница 108: ...shown see illustration 20 On models from May 1990 the heater hose A and the expansion tank hose B connections were swapped over 21 If the hoses are disconnected on earlier models such as during engine...

Страница 109: ...the wiring from the sender unit Unscrew and remove it being prepared for some coolant spillage 4 Smear sealant on the sender unit threads before refitting then insert and tighten it Reconnect the wiri...

Страница 110: ...ng clips one screw and one clip for each cable Detach the cables from the heater assembly and withdraw them from the facia whilst noting the correct routing see illustration 20 Refitting is a reverse...

Страница 111: ...aining clips d Use a new gasket when refitting the matrix cover plate e Refill the cooling system 1 Remove the heater assembly as described in the previous Section 2 Remove the two screws which secure...

Страница 112: ...blades removed the motor can be unscrewed from the frame 14 Reassemble and refit in the reverse order of dismantling and removal De ice thermostat 15 Disconnect the battery negative lead 16 Disconnect...

Страница 113: ...rettor dismantling and reassembly 17 Weber 2V carburettor idle speed and mixture adjustments 15 Weber 2V carburettor removal and refitting 16 Weber 2V TLD carburettor automatic choke unit removal refi...

Страница 114: ...5 mm 0 08 0 02 in Float level Not adjustable Automatic choke setting Index Weber 2V carburettor Primary Secondary Barrel diameter 30 mm 34 mm Venturi diameter 85HFCA and DA 25 mm 27 mm 85HFGA HA MA an...

Страница 115: ...e regulator SOHC 15 to 20 11 to 15 2 8 litre 10 to 12 7 to 9 Pressure regulator base nut bolt SOHC 20 to 25 15 to 18 DOHC 9 to 12 7 to 9 V6 2 8 litre 15 to 20 11 to 15 2 4 2 9 litre 9 to 11 7 to 8 Fue...

Страница 116: ...in unburned fuel causing it to overheat when the engine does start see b above e DO NOT switch off the ignition at high engine speeds if the ignition is switched off at anything above idle speed unbur...

Страница 117: ...injection models and carburettor models when fitted with air conditioning have an electric fuel pump The two types of pump are not the same although both are mounted under the vehicle next to the fue...

Страница 118: ...end the float arm see illustration Recover the seal 4 A defective sender unit must be renewed spares are not available Renew the seal in any case 5 Refit by reversing the removal operations 1 Fitted t...

Страница 119: ...hose clips if they are of the crimped type 4 Remove the two securing screws and lift out the separator Remember it is full of fuel 5 Refit by reversing the removal operations Make sure that the diffe...

Страница 120: ...m the ignition coil and then connect the leads of the new loom to the positive terminal of the coil and the end of the disconnected positive feed wire c Connect the loom earth eyelet to one of the ign...

Страница 121: ...mperproof cap where this is required by law then refit the air cleaner Idle speed cannot be adjusted in the usual way on this carburettor as it is controlled by the ESC ll module If mixture adjustment...

Страница 122: ...measure the clearance between the choke valve and the wall of the primary venturi Measure the clearance on the down side of the valve The desired pull down clearance is given in the Specifications 7 I...

Страница 123: ...nlet manifold 9 Slide the float retaining pin from the carburettor top cover tapping it gently if necessary then lift out the float and needle valve 10 If desired the needle valve housing can be unscr...

Страница 124: ...Note the following points a The accelerator pump cover is secured by four screws b The diaphragm return spring is fitted between the pump housing and the diaphragm not between the diaphragm and the co...

Страница 125: ...ct the battery negative lead 2 Remove the air cleaner assembly 3 Disconnect the throttle kicker vacuum hose 4 Withdraw the plastic shield from the throttle kicker see illustration 5 Remove the two sec...

Страница 126: ...he tamperproof plug from the mixture adjusting screw on the underside of the vane airflow meter see illustration 8 On V6 models note that adjustment should first be carried out on the front airflow me...

Страница 127: ...y with the throttle spindle 1 On DOHC models disconnect the battery negative lead 2 Free the throttle position sensor wiring plug from the retaining clip located on the underside of the throttle body...

Страница 128: ...as described above noting that there are two meters instead of one SOHC and 2 8 litre V6 engines 1 Disconnect the battery negative lead 2 On V6 models remove the throttle linkage cover which is secur...

Страница 129: ...the fuel temperature sensor and the fuel injectors noting their locations to assist with refitting 35 Unscrew the two securing bolts and withdraw the fuel rail 36 Lift the fuel injectors from their l...

Страница 130: ...feed union to relieve the pressure in the system Be prepared for fuel spillage and take adequate fire precautions 13 Disconnect the fuel return hose from the pressure regulator see illustration Again...

Страница 131: ...ssist with refitting 15 Disconnect the fuel supply and return hoses from the carburettor Plug their ends to minimise petrol spillage 16 Release the coolant hose from the bracket under the automatic ch...

Страница 132: ...ead Keep dirt out of the ports and other orifices 44 Commence refitting by applying a bead of sealant at least 5 mm 0 2 in wide around the central coolant aperture on both sides of a new gasket 45 Fit...

Страница 133: ...ree Do not apply leverage at the mating faces Recover the gasket 76 Clean all mating faces being careful to keep dirt out of ports and other orifices Obtain new gaskets for both the cylinder head and...

Страница 134: ...joint s 8 On V6 models unbolt the left hand front silencer mounting 9 Release any earth straps 10 With the help of an assistant unhook the system from its mountings and remove it 11 Renew sections as...

Страница 135: ...engines are identified as follows 1 8 litre S stamped adjacent to No 4 spark plug 2 0 litre A L P PP or R stamped adjacent to No 4 spark plug 2 8 litre D or E stamped in centre of cylinder head exhau...

Страница 136: ...4 24 Notes...

Страница 137: ...l 10 Starter motor removal and refitting 9 Starter motor testing on the vehicle 8 Vehicle speed sensor removal and refitting 27 General Electrical system type 12 volt negative earth Ignition system ty...

Страница 138: ...able albeit at reduced power and efficiency in the event of a failure in the module or its sensors Due to the complexity and expense of the test equipment dedicated to the engine management system sus...

Страница 139: ...given the usual course of action is to renew the component concerned The owner whose interest extends beyond mere component renewal should obtain a copy of the Automobile Electrical Electronic Systems...

Страница 140: ...ed by a wire clip 3 Slacken the alternator adjusting and pivot nut s bolt s and washer s see illustration Swing the alternator towards the engine and slip the drivebelt s off the pulley 4 Support the...

Страница 141: ...hicle 5 Refit by reversing the removal operations Check for correct operation on completion 1 Disconnect the motor lead from the solenoid terminal 2 Remove the two screws which secure the armature end...

Страница 142: ...the rotor arm to the point noted in paragraph 7 This will be approximately 20 clockwise from the No 1 firing point paragraph 4 see illustration 10 Make sure that the engine is still positioned at the...

Страница 143: ...lly inserted rotate the distributor body until the rotor arm aligns with mark C on the distributor rim 28 Once the rotor arm cylinder head and distributor alignment marks are all correctly aligned fit...

Страница 144: ...ule is located in the left hand front corner of the engine compartment beside the air cleaner housing 13 To remove the module first disconnect the battery negative lead 14 To improve access remove the...

Страница 145: ...trap marked CARB goes towards the manifold and the end marked DIST towards the module 5 Reconnect the battery ESC II module carburettor models SOHC engines 1 Disconnect the battery negative lead 2 Di...

Страница 146: ...d is earthed temporarily isolate it Make sure that the automatic transmission selector is in the N or P position where applicable 11 Accelerate the engine to a speed greater then 2500 rpm allow it to...

Страница 147: ...nd efficiency will suffer as a result of this adjustment Normal timing should be restored by isolating the adjustment leads when the correct grade of fuel is available 5 If the yellow adjustment lead...

Страница 148: ...Jacking 4 Detach the sensor wiring connector from the bracket and separate the two halves of the connector see illustration 5 Unscrew the securing bolt and withdraw the wiring connector bracket noting...

Страница 149: ...ar caliper overhaul 12 Rear caliper removal and refitting 11 Rear disc splash shield removal and refitting 13 Vacuum servo unit April 1992 on testing removal and refitting 28 Vacuum servo unit check v...

Страница 150: ...t which operates both rear brakes d A G gravity switch is incorporated in the system This is an inertia type switch and informs the control module when the vehicle is decelerating rapidly e A Pedal Tr...

Страница 151: ...on completion Rear brakes 12 Remove the dust cap if fitted from the rear left hand caliper bleed screw Open the bleed screw one full turn 13 Fit the bleed tube over the bleed screw Place the other en...

Страница 152: ...e caliper off the disc and remove the pads see illustration Support the caliper so that the flexible hose is not strained Do not press the brake pedal with the caliper removed 6 Clean the dust and dir...

Страница 153: ...dal at least 20 times or until it becomes hard to depressurise the hydraulic system 2 Slacken the front wheel nuts raise and support the vehicle and remove the relevant front wheel 3 Slacken the flexi...

Страница 154: ...e cable see illustrations Alternatively the two bracket to hub bolts can be removed and the caliper and bracket separated on the bench 6 Refit by reversing the removal operations but before refitting...

Страница 155: ...wool renew the shaft if it is badly corroded The shaft bush in the caliper can also be renewed if necessary Pull out the old bush with an internal puller or slide hammer press in the new bush to 7 5...

Страница 156: ...o the brake pedal Also remove the clip from the brake pedal shaft see illustration 5 Withdraw the brake pedal shaft towards the left of the vehicle through the clutch pedal when applicable until the b...

Страница 157: ...ssure hose from its connections to the pump The hose is secured by a spring clip see illustrations Allow the brake fluid to drain out of the hose 6 Pull the reservoir out of the seals on the hydraulic...

Страница 158: ...the battery Depressurise the hydraulic system by pumping the brake pedal at least 20 times or until it becomes hard Low pressure hose 3 Have ready a container to catch spilt fluid Remove the spring cl...

Страница 159: ...er nut finger tight then tighten a further three to six clicks using self locking pliers or a peg spanner 1 Slacken the rear wheel nuts and chock the front wheels Raise and support the rear of the veh...

Страница 160: ...master cylinder then pull the hoses out from the reservoir see illustration Unscrew the two union nuts and disconnect the brake pipes from master cylinder Plug or tape over the pipe hose ends and mast...

Страница 161: ...orbent rag beneath the valve block then unscrew the three brake pipe outlet unions whilst avoiding getting surplus brake fluid in the wiring plugs Plug the block ports and pipe ends to minimise the lo...

Страница 162: ...ur as that of the original 5 Fit a new O ring to the sensor and apply a smear of clean engine oil to it to ease installation 6 Ease the sensor into position in the servo unit taking care not to displa...

Страница 163: ...mation 32 Steering column removal and refitting 7 Steering column lock removal and refitting 8 Steering gear removal and refitting 3 Steering intermediate shaft and flexible coupling removal and refit...

Страница 164: ...d balljoint nut 25 to 30 18 to 22 Track rod end locknut 57 to 68 42 to 50 Track rod inner balljoint nut 75 55 Intermediate shaft coupling pinch bolts 20 15 Pinion retaining nut manual steering 70 to 1...

Страница 165: ...vel again Refit the filler cap 6 Run the vehicle for a few miles to warm up the fluid and expel any remaining air then stop the engine and make a final fluid level check Manual steering 1 Position the...

Страница 166: ...r grooves Do not tighten the outer clip yet leave it slack until toe has been checked after refitting 5 Refit the track rod end locknut followed by the track rod end itself 6 Repeat on the other side...

Страница 167: ...the bonnet disconnect the intermediate shaft universal joint from the steering column shaft 5 Remove the steering column shrouds and disconnect the switch multi plugs Do not forget the ignition start...

Страница 168: ...ng using a strap wrench which can be improvised using an old drivebelt and a large socket and wrench and unscrew the three pulley securing bolts see illustration Withdraw the pulley 11 Unscrew the thr...

Страница 169: ...hten the locknuts and outer bellows clips 11 Provided the track rods have been adjusted by equal amounts the steering wheel should be central when moving straight ahead The amount of visible thread on...

Страница 170: ...fer the carrier to the stub axle tapping it home if necessary Fit the bearing inner race over the stub axle 15 Refit the ABS rotor dished face uppermost 16 Fit a new hub nut left hand thread on the ri...

Страница 171: ...s and deep dished washers 5 Remove one lower arm pivot nut and bolt Prise the lower arm out of the crossmember and work the anti roll bar free from it 6 Pull the anti roll bar out of the other lower a...

Страница 172: ...Raise the rear of the vehicle and support it securely under the frame rails 2 Remove the exhaust system 3 Remove the propeller shaft 4 Release the handbrake cable from the equaliser yoke by removing...

Страница 173: ...nd the oil seals lips inwards Seat the oil seals with a mallet and the pipe or tube 8 Refit the rear hub 1 This procedure is only specified by the manufacturers as applying to the rear wheels but ther...

Страница 174: ...side by prising them free see illustration 3 Unbolt the two anti roll bar brackets Remove the bar brackets and bushes see illustration 4 Refit by reversing the removal operations Tighten the bracket...

Страница 175: ...secure the compressor to the bracket Withdraw the compressor at the same time disconnecting the suction line and the control multi plug 6 Refit by reversing the removal operations use new O rings on t...

Страница 176: ...11 14 Notes...

Страница 177: ...ch assembly removal and refitting 19 Tailgate lock barrel removal and refitting 17 Tailgate strut removal and refitting 20 Tailgate window mouldings removal and refitting 30 Windscreen and fixed glass...

Страница 178: ...urpose Repairs of minor scratches in bodywork If the scratch is very superficial and does not penetrate to the metal of the bodywork repair is very simple Lightly rub the area of the scratch with a pa...

Страница 179: ...ready for final spraying Paint spraying must be carried out in a warm dry windless and dust free atmosphere This condition can be created artificially if you have access to a large indoor working are...

Страница 180: ...lation panel from the underside of the bonnet to gain access to the windscreen washer hose and washer nozzle heater wiring plugs see illustration 9 Disconnect the wiring plugs and hose and free them f...

Страница 181: ...oom from the retaining clips and tie a suitable length of string to each of the wiring connectors Withdraw the wiring loom from the boot lid until the connectors emerge then untie the string and leave...

Страница 182: ...efully peel away the foam rubber sheet in the area of the door handle operating rod Disconnect the rod from the handle 3 Remove the two screws which secure the handle to the door then remove the handl...

Страница 183: ...el Remove the lock barrel from the lid 4 Undo the four lid lock retaining bolts then withdraw the lock assembly from the boot lid disconnecting the central locking and warning switch wiring plugs see...

Страница 184: ...a riveted fitting carefully cut it free with a sharp knife then glue it back in place afterwards see illustrations 9 Refit by reversing the removal operations Rear door 10 Operations are similar to t...

Страница 185: ...ofed by special adhesives The equipment and skills required to remove and refit this type of window are beyond the scope of this book Consult a Ford dealer or a windscreen specialist 1 Open and prop t...

Страница 186: ...st it and remove it 5 Remove the door mirror 6 Drill out the rivet which secures the front corner moulding Remove the moulding 7 Refit by reversing the removal operations using a new blind rivet to se...

Страница 187: ...fan heater until it is warm to the touch Do not coil the moulding tighter than 300 mm 11 8 in in diameter 6 Peel the backing paper off the moulding Insert one end into the slot at one end of the groov...

Страница 188: ...reen must be at room temperature 20 C 68 F approx 3 Peel off the backing paper from one side of the special adhesive patch Press the sticky side of the patch firmly onto the mirror base 4 Warm the mir...

Страница 189: ...ventilation control panel from the facia panel see illustration 20 Depress the retaining tang situated at the bottom of the control knob and remove the light switch knob from the switch see illustrati...

Страница 190: ...Withdraw the glovebox illumination light and disconnect the wiring connector 41 28 Undo the five right hand lower facia panel retaining screws arrowed 41 31a A pillar trim panel retaining clip 41 31b...

Страница 191: ...heck that all the necessary wiring retaining clips have been released then carefully manoeuvre the facia panel out of position and out from the vehicle 37 Refitting is a reverse of the removal procedu...

Страница 192: ...nge lever trim panel out from the centre console then turn the outer gaiter inside out and unclip the trim panel 17 On models equipped with automatic transmission carefully prise out the outer and inn...

Страница 193: ...om the seat Free the air tube by removing Its two securing screws 3 Separate the backrest from the base of the seat by removing the four retaining bolts 4 Remove the backrest cover by unbending its re...

Страница 194: ...aker see illustration With the nut and washer removed the cushion is then released by prising open the metal tags which secure its bottom wire Pull the bottom of the cushion forwards and upwards to fr...

Страница 195: ...them from the car see illustration 2 Remove the rear speakers 3 Unclip the seven parcel shelf retaining clips four situated along the front edge and three in the centre of the panel then slide the she...

Страница 196: ...12 20 Notes...

Страница 197: ...moval and refitting 28 Speedometer sender unit removal and refitting 21 Switches removal and refitting 15 Window operating motor removal and refitting 18 Windscreen rear window and headlight washer co...

Страница 198: ...n pump Pink 20 Air conditioning cooling fan Yellow 20 Anti lock braking system control circuitry Green 30 Anti lock braking system pump Brown 30 Heated windscreen left hand side Brown 30 Heated windsc...

Страница 199: ...ed for certain tests a self powered test light sometimes known as a continuity tester an ohmmeter to measure resistance a battery and set of test leads and a jumper wire preferably with a circuit brea...

Страница 200: ...ismantle the connection and clean back to bare metal both the bodyshell and the wire terminal or the component s earth connection mating surface Be careful to remove all traces of dirt and corrosion t...

Страница 201: ...f the wing Twist the bulbholder anti clockwise to release it Pull out the old bulb and press in the new one see illustrations 25 Refit the bulbholder then insert the light unit into its hole and press...

Страница 202: ...see illustration Auxiliary driving light 10 This is integral with the headlight unit Rear light cluster Hatchback 11 Remove the rear light cluster bulbholder as described in the previous Section 12 Re...

Страница 203: ...ight off or disconnect the battery negative lead before changing a bulb Courtesy light 2 Carefully prise the light unit from its location If reading spot lights are fitted prise from the middle if not...

Страница 204: ...ured by four screws The bulb is of the wedge base type see illustration Glovebox light 23 Open the glovebox Remove the combined switch light unit which is secured by two screws see illustration 24 Pri...

Страница 205: ...net fitting bulb see illustration Refit the back of the clock then refit the overhead console Models before April 1992 1 Although not essential it is wise to disconnect the battery negative lead 2 Rem...

Страница 206: ...removal operations 1 Two horns are fitted as standard The high tone horn is located to the right of the radiator and is accessible from under the bonnet The low tone horn is located below and to the...

Страница 207: ...e Models up to April 1992 12 On these models remove the four instrument cluster surround retaining screws and remove the surround from the facia Carefully prise the switch out of the aperture and disc...

Страница 208: ...theft systems 35 To avoid damage to other components the battery must be disconnected before the tailgate lock switch is removed 36 Remove the tailgate interior trim panel which is secured by eleven...

Страница 209: ...n a new fuse of the same rating and try the circuit again 6 If the new fuse blows immediately or within a short time do not carry on renewing fuses but look for a short circuit in the wiring to the it...

Страница 210: ...trol unit G Speed control system module H Anti theft alarm module I Warning display lighting K Relay bank 1 Inlet manifold heater relay carburettor 2 Fuel pump relay fuel injection 3 Power hold relay...

Страница 211: ...one motor is being removed free its spade connectors from the common multi plug washer removing the plug shell see illustration It is probably easier to remove both motors and deal with the connectors...

Страница 212: ...es the sender unit the bolt also secures the new earth tag when applicable the radio earth strap and the multi plug retaining bracket 7 Connect the multi plug and fit it to the bracket 8 If any spilla...

Страница 213: ...the ignition and operate the rear wiper control briefly so that the motor stops in the parked position 7 Refit the wiper arm and blade Wet the window and operate the rear wiper control again to check...

Страница 214: ...r other competent specialist Unskilled or uninformed testing may cause further damage When checking wires or sensors for continuity disconnect the control assembly and bulb failure module first otherw...

Страница 215: ...fter removing the air vent grille 30 Pull the module from its bracket Disconnect the multi plug by pressing in the locking lever and pulling the plug Remove the module see illustration 31 Refit by rev...

Страница 216: ...acted 23 Adjust the servo cable so that it is slightly slack then reconnect the battery negative lead Printed circuit board 24 The printed circuit board is located in the steering wheel It can be remo...

Страница 217: ...curely in position by the retaining clips Graphic equaliser 21 When fitted the graphic equaliser is removed in the same way as the radio cassette unit 1 Depending on the level of equipment fitted loud...

Страница 218: ...etaining clip anticlockwise Withdraw it from the facia and disconnect its multi plug 5 Refit by reversing the removal operations 1 Pull the heater control knob off its lever Remove the two retaining s...

Страница 219: ...cken and remove the retaining screws and lower the sensor away from the headlining disconnecting the wiring plug as it becomes accessible 3 Refitting is the reverse of the removal procedure Anti theft...

Страница 220: ...he prefix C indicates a connector or multi plug S a soldered joint and G an earthing point ground The numbers appearing at the break in each wire indicate the circuit number and wire colour Colour cod...

Страница 221: ...Wiring diagrams WD 1 WD Diagram 16 Power operated sliding roof...

Страница 222: ...WD 2 Wiring diagrams Diagram 2 Power distribution...

Страница 223: ...Wiring diagrams WD 3 WD Diagram 2 Power distribution continued...

Страница 224: ...WD 4 Wiring diagrams Diagram 3 Charge start and run Part 1...

Страница 225: ...Wiring diagrams WD 5 WD Diagram 3 Charge start and run Part 1 continued...

Страница 226: ...WD 6 Wiring diagrams Diagram 3A Charge start and run Part 2...

Страница 227: ...Wiring diagrams WD 7 WD Diagram 3A Charge start and run Part 2 continued...

Страница 228: ...WD 8 Wiring diagrams Diagram 4 Engine management 1 8 litre...

Страница 229: ...Wiring diagrams WD 9 WD Diagram 4 Engine management 1 8 litre continued...

Страница 230: ...WD 10 Wiring diagrams Diagram 4A Engine management 2 0 litre carburettor...

Страница 231: ...Wiring diagrams WD 11 WD Diagram 4A Engine management 2 0 litre carburettor continued...

Страница 232: ...WD 12 Wiring diagrams Diagram 5 Engine management 2 0 litre fuel injection...

Страница 233: ...Wiring diagrams WD 13 WD Diagram 5 Engine management 2 0 litre fuel injection continued...

Страница 234: ...WD 14 Wiring diagrams Diagram 5C Engine management 2 8 litre...

Страница 235: ...Wiring diagrams WD 15 WD Diagram 5C Engine management 2 8 litre continued...

Страница 236: ...WD 16 Wiring diagrams Diagram 7A Exterior lighting...

Страница 237: ...Wiring diagrams WD 17 WD Diagram 7A Exterior lighting continued...

Страница 238: ...WD 18 Wiring diagrams Diagram 9 Signalling and warning systems...

Страница 239: ...Wiring diagrams WD 19 WD Diagram 9 Signalling and warning systems continued...

Страница 240: ...WD 20 Wiring diagrams Diagram 10 Interior lighting...

Страница 241: ...Wiring diagrams WD 21 WD Diagram 10 Interior lighting continued...

Страница 242: ...WD 22 Wiring diagrams Diagram 12 Wipers and washers...

Страница 243: ...Wiring diagrams WD 23 WD Diagram 12 Wipers and washers continued...

Страница 244: ...WD 24 Wiring diagrams Diagram 14 Central locking system...

Страница 245: ...Wiring diagrams WD 25 WD Diagram 14 Central locking system continued...

Страница 246: ...WD 26 Wiring diagrams Diagram 15 Power operated windows...

Страница 247: ...Wiring diagrams WD 27 WD Diagram 15 Power operated windows continued...

Страница 248: ...WD 28 Wiring diagrams Diagram 21 ABS...

Страница 249: ...Wiring diagrams WD 29 WD Diagram 21 ABS continued...

Страница 250: ...WD 30 Wiring diagrams Diagram 23 Auxiliary warning system...

Страница 251: ...Wiring diagrams WD 31 WD Diagram 23 Auxiliary warning system continued...

Страница 252: ...WD 32 Wiring diagrams Diagram 29 Radio cassette player and associated circuits typical...

Страница 253: ...Wiring diagrams WD 33 WD Diagram 29 Radio cassette player and associated circuits typical continued...

Страница 254: ...WD 34 Wiring diagrams Diagram 11 Heater blower...

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