FORD GRANADA 1985 Service Owners Manual

panel. Disconnect the wiring connectors from
the heated window switches and fuel
computer (where fitted) and remove the panel
from the car.
14Undo the two retaining screws then
manoeuvre the control panel out of the facia
and disconnect the wiring connector (see
illustration).
15Unclip the central fan switch from the
panel then, using a small flat-bladed
screwdriver, bend back the retaining tabs and
remove the cover from the panel base plate
(see illustration).
16Cut the cable retaining clips then release
the cables from the toothed guides and
remove the base plate.
17Refitting is a reversal of the removal
procedure securing the cables to the base
plate using new retaining clips.
Models before April 1992
Front
1Remove the heater controls as described in
the previous Section.
2Remove the centre console as described in
Chapter 12. Also remove the console bracket
and the gear lever inner gaiter.
3Unclip the under-dash trim on both sides.
Remove the glovebox lid.
4Remove the radio (Chapter 13).
5Remove the ABS and (when applicable) the
EEC IV modules (Chapters 10 and 13).
6Remove the remaining lower trim on the
passenger side to expose the heater casing.
7Remove the two securing screws and
release the cables from the heater.
8When refitting, place the air distribution and
temperature control valve levers in their
uppermost positions, then connect the cables.
9The remainder of refitting is a reversal of the
removal procedure.
Rear
10Remove the centre console (Chapter 12).
11Remove the front seat on the side
concerned. Also remove the rear seat cushion. 12Remove the front seat belt lower anchor bolt.
13Remove the front scuff plate, which is
secured by three screws. Remove the front
screw from the rear scuff plate.
14Roll back the front carpet from the scuff
plates to expose the heater cable. Release the
cable from its ties and disconnect it from the
control unit and the nozzle (see illustration).
15Refit by reversing the removal operations.
Models from April 1992
16Remove the facia undercovers, the right-
hand lower facia panel and the glovebox .
17Undo the two retaining nuts, then release
the retaining clips and remove the trim panel
from the glovebox aperture.
18Remove the heater control panel.
19Slacken and remove the control cable
retaining screws then release the retaining
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).
20Refitting is a reverse of the removal
procedure noting the following points.
a)Ensure that the cables are correctly routed
prior to connecting them to the heater
housing.
b)Prior to refitting the glovebox aperture trim
panel, check that the panel controls
function correctly and that the cables
move the relevant operating lever
smoothly from the fully open to the fully
closed position without any trace of undue
friction.
Models before April 1992
1Disconnect the battery negative lead.
2Depressurise the cooling system by
slackening the expansion tank cap. Take
precautions against scalding if the system is
hot.3Disconnect the two heater hoses from the
stubs on the bulkhead. Be prepared for some
coolant spillage: catch the coolant in a clean
container if it is fit for re-use. Plug the hoses,
or tie them up with their open ends raised.
4Expel as much coolant as possible from the
heater matrix by blowing through it.
5Remove the matrix connector plate and
gasket from the bulkhead.
6Working inside the vehicle, remove the
centre console and other trim as described for
access to the heater control cables .
7Remove the instrument cluster surround,
which is secured by four screws. Also pull out
the heater louvre panel.
8Remove the facia panel top, which is
secured by five screws and four clips.
9Detach the air trunking from the heater
casing. Release the trunking from the
bulkhead when necessary.
10Remove the two nuts which secure the
heater unit. Pull the unit into the vehicle until
the pipe stubs are clear of the bulkhead, then
remove it sideways. Be prepared for coolant
spillage.
11Check the condition of the foam gasket on
the bulkhead and renew it if necessary.
12Refit by reversing the removal operations.
13Top-up the cooling system on completion,
and check the level again after the engine has
been run.
Models from April 1992
14Disconnect the battery negative terminal.
15Drain the cooling system.
19Heater assembly - removal
and refitting
18Heater control cables -
removal and refitting
3•8Cooling, heating and ventilation systems
17.14 Heater control panel retaining screws
(arrowed)
18.19 Heater control cable retaining screw
and clip (arrowed)
17.15 Exploded view of the heater control
panel
A Control cable retaining clips
B Cover
C Fan switch
D Base plate18.14 Rear heater control cable at nozzle
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16Locate the heater matrix feed and return
hoses on the engine compartment bulkhead.
Slacken the retaining clips and disconnect
both hoses from the matrix unions. Be
prepared for some coolant spillage. Plug the
matrix unions to prevent residual coolant
being spilt as the assembly is removed.
17Slacken and remove the two retaining
screws then remove the matrix cover plate
and gasket from the bulkhead; discard the
gasket as a new one should be used on
refitting.
18Remove the facia panel.
19Release the facia wiring loom from the
bulkhead to gain access to the demister
nozzle fasteners (see illustration).
20Remove the retaining nut and screw then
detach each windscreen demister nozzle from
the heater assembly. Undo the two retaining
nuts and detach the centre face level nozzle
from the heater.
21Slacken and remove the two retaining nuts
then detach the right-hand face level nozzle
from the heater and remove it from the vehicle.
Repeat the procedure for the left-hand nozzle.
22To detach each rear footwell nozzle from
the heater unit, remove the pin from the nozzle
retaining clip whilst supporting the outer part
of the retaining clip from the rear (see
illustration). Note: If the rear of the clip is not
supported when the pin is removed it will drop
down into the nozzle. To retrieve the clip will
require the removal of the vent which first
requires the front seat to be removed and
carpet lifted.
23Disconnect the wiring connector from the
heater control panel.
24Undo the two nuts securing the heater
assembly to the bulkhead then carefully
manoeuvre the assembly out of the vehicle
whilst being prepared for the possibility of
coolant spillage from the matrix unions.
25Refitting is a reverse of the removal
procedure noting the following points.
a)Tighten all retaining nuts and screws
securely and ensure that all nozzles are
securely connected to the heater
assembly so that there are no air gaps or
leaks.b)Check the operation of all heater cables
before refitting the facia, ensuring that the
relevant component moves smoothly from
the fully open to the fully closed position.
c)Ensure that the heater hoses are correctly
reconnected and are securely held by the
retaining clips.
d)Use a new gasket when refitting the matrix
cover plate.
e)Refill the cooling system.
1Remove the heater assembly as described
in the previous Section.
2Remove the two screws which secure the
heater matrix. Withdraw the matrix.
3If the matrix is leaking it is best to obtain a
new or reconditioned unit; home repairs are
seldom successful.4To dismantle, release the clips which secure
the casing halves together by using a
screwdriver. Carefully prise the halves apart
and separate them.
5Remove the flap valves and operating levers
from the casing halves, noting how they are
fitted for reference when reassembling.
6Flush the matrix with clean water to remove
any debris.
7Reassembly is a reversal of dismantling.
Additional clips may be needed to secure the
casing halves once they have been separated.
1Drain the cooling system.
2Noting the correct fitted positions, slacken
the retaining clips and disconnect the coolant
hoses from the valve.
3Disconnect the vacuum pipe from the top of
the valve then unclip the valve and remove it
from the retaining bracket.
4Refitting is a reverse of the removal
procedure ensuring that the coolant hoses are
reconnected to their original unions on the
valve and are securely held in position with the
retaining clips.
1Only those items which can be renewed
without discharging the system are described
here. Other items must be dealt with by a Ford
dealer or air conditioning specialist (see
illustration).
Compressor drivebelt
2Disconnect the battery earth lead.
3On OHC engines, remove the radiator
cooling fan.
4Slacken the compressor strap and pivot
bolts (see illustration),move the compressor
22Air conditioning system -
component renewal
21Heater coolant valve -
removal and refitting
20Heater matrix - dismantling
and reassembly
Cooling, heating and ventilation systems 3•9
3
19.19 Release the facia wiring loom from
the bulkhead to gain access to the
demister nozzle retaining nut and screw
(arrowed)19.22 Detach the rear footwell nozzles from
the heater assembly
If the heater matrix is blocked
it can sometimes be cleared
by reverse-flushing using a
garden hose and a proprietary
radiator cleaning product if necessary.
22.1 Air conditioning system
component locations
1 De-ice thermostat
2 Evaporator
3 Expansion valve
4 Compressor
5 Compressor clutch
6 Pressure switch
7 Sight glass
8 Dehydrator
9 Cooling fan
10 Condenser
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towards the engine and remove the old
drivebelt.
5Fit the new drivebelt, position the
compressor to achieve the correct belt tension
and tighten the strap and pivot bolts.
6Refit and secure the fan, when applicable,
and reconnect the battery.
7Recheck the belt tension after it has run for
at least 10 minutes under load.
Condenser fan and motor
8Disconnect the battery earth lead and
remove the radiator grille.
9Disconnect the fan wiring connector at the
right-hand side of the condenser.
10Remove the three securing bolts andremove the fan and motor(see illustration).
Turn the frame to position the fan wiring on the
dehydrator side to avoid damaging the wiring.
Take care also not to damage the condenser
fins or tube.
11Unclip the fan guard from the top of the
frame.
12To remove the fan blades from the motor,
remove the retaining nut and circlip. The nut
has a left-hand threadie it is undone
clockwise.
13With the blades removed, the motor can
be unscrewed from the frame.
14Reassemble and refit in the reverse order
of dismantling and removal.
De-ice thermostat
15Disconnect the battery negative lead.
16Disconnect the vacuum hoses from the
plenum chamber cover. Pull off the rubber seal
and remove the plenum chamber cover; it is
secured by four screws and one nut.
17Disconnect the thermostat from the
evaporator casing and remove it. Also remove
the thermostat probe.
18Refit by reversing the removal operations.
Heater water valve
19The heater water valve used with air
conditioning is vacuum-operated. It is located
on the right-hand side of the engine bay, near
the bulkhead. 20Drain the cooling system.
21Slacken the hose clips and detach the
coolant hoses from the valve, noting how they
are connected.
22Disconnect the vacuum hose from the top
of the valve.
23Unclip the valve from its bracket and
remove it.
24Refit by reversing the removal operations.
Refill the cooling system.
3•10Cooling, heating and ventilation systems
22.4 Air conditioning compressor adjuster
strap bolts (arrowed)22.10 Condenser fan securing bolts
(arrowed)
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Chapter 4
Fuel and exhaust systems
Air cleaner and element - removal and refitting . . . . . . . . . . . . . . . . .2
Air cleaner temperature control - description and testing . . . . . . . . .3
Carbon canister - removal and refitting . . . . . . . . . . . . . . . . . . . . . .44
Carbon canister purge solenoid - removal and refitting . . . . . . . . . .45
Exhaust gas oxygen (HEGO) sensor - removal and refitting . . . . . .43
Exhaust manifold(s) - removal and refitting . . . . . . . . . . . . . . . . . . .41
Exhaust system - inspection, repair and renewal . . . . . . . . . . . . . .42
Fuel cut-off inertia switch - removal and refitting . . . . . . . . . . . . . . . .7
Fuel filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Fuel gauge sender unit - removal and refitting . . . . . . . . . . . . . . . . . .6
Fuel-injection system - depressurisation . . . . . . . . . . . . . . . . . . . . .28
Fuel-injection system - idle speed and mixture adjustments . . . . . .31
Fuel-injection system relays - location . . . . . . . . . . . . . . . . . . . . . . .29
Fuel-injectors - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .36
Fuel pressure regulator - removal and refitting . . . . . . . . . . . . . . . .37
Fuel pump - testing, removal and refitting . . . . . . . . . . . . . . . . . . . . .4
Fuel rail temperature switch - removal and refitting . . . . . . . . . . . . .39
Fuel tank - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . .1
Idle speed control valve - removal and refitting . . . . . . . . . . . . . . . .34
Inlet manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .40
Mixture adjustment potentiometer - removal and refitting . . . . . . . .38
Pierburg 2V carburettor - dismantling and reassembly . . . . . . . . . .13
Pierburg 2V carburettor - fast idle adjustment . . . . . . . . . . . . . . . . .14
Pierburg 2V carburettor - idle speed and mixture adjustments . . . .11
Pierburg 2V carburettor - removal and refitting . . . . . . . . . . . . . . . .12Throttle body - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .33
Throttle cable - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .9
Throttle pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .8
Throttle position sensor - removal and refitting . . . . . . . . . . . . . . . .32
Unleaded fuel - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Vane airflow meter(s) - removal and refitting . . . . . . . . . . . . . . . . . .35
Vapour separator - removal and refitting . . . . . . . . . . . . . . . . . . . . .10
Weber 2V carburettor - automatic choke adjustment . . . . . . . . . . .18
Weber 2V carburettor - 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,
refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Weber 2V TLD carburettor - accelerator pump diapragm renewal .25
Weber 2V TLD carburettor - idle speed and mixture adjustments . .19
Weber 2V TLD carburettor - low vacuum enrichment
diaphragm renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Weber 2V TLD carburettor - needle valve and float removal,
refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Weber 2V TLD carburettor - power valve diaphragm renewal . . . . .23
Weber 2V TLD carburettor - removal and refitting . . . . . . . . . . . . .20
Weber 2V TLD carburettor - secondary throttle valve vacuum
diaphragm renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Weber 2V TLD carburettor - throttle kicker removal, refitting
and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
General
System type:
1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin choke Pierburg carburettor
2.0 litre carburettor:
SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin choke Weber 2V carburettor
DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin choke Weber 2V TLD carburettor
All models with fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-point fuel-injection system controlled by EEC IV engine
management system
Fuel tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 litres (15.4 gallons) approx
Fuel grade*:
Leaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 octane RON (UK 4-star)
Unleaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 octane RON (Premium)
* Models fitted with a catalytic converter must be operated on unleaded fuel at all times. Do notuse leaded fuel as the catalyst will be destroyed.
Idle speed:
1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 20 rpm
2.0 litre carburettor:
SOHC* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 or 875 rpm
DOHC:
Manual gearbox* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ± 25 rpm
Automatic transmission* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 875 ± 25 rpm
2.0 litre fuel-injection:
SOHC* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 or 875 rpm
DOHC* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 875 ± 50 rpm
4•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty
Specifications Contents
4
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4•2Fuel and exhaust systems
Idle speed (continued):
2.4 litre*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .850 ±50 rpm
2.8 litre* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .850 rpm
2.9 litre* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .850 ±50 rpm
Idle mixture (CO) level:
1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3%
2.0 litre carburettor:
SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.75 to 1.50%
DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 ±0.25%
2.0 litre fuel-injection:
SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 to 1.0%
DOHC - models without catalytic converter . . . . . . . . . . . . . . . . . .1.0 to 1.5%
2.4 litre - models without a catalytic converter . . . . . . . . . . . . . . . . . .0.5 to 1.0 %
2.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 to 1.0%
2.9 litre - models without a catalytic converter . . . . . . . . . . . . . . . . . .0.5 to 1.0 %
*Electronically controlled
Pierburg 2V carburettor
Venturi diameter:
Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 mm
Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 mm
Jet sizes:
Idle (fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Idle (air bleed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Primary main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107.5
Secondary main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Adjustments:
Fast idle speed (engine warm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1800 ±100 rpm (on second highest step of cam)
Choke pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 mm (0.12 in)
Throttle damper setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 ±0.5 mm (0.08 ±0.02 in)
Float level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Not adjustable
Automatic choke setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Index
Weber 2V carburettorPrimarySecondary
Barrel diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 mm34 mm
Venturi diameter:
85HFCA and -DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 mm27 mm
85HFGA, -HA, -MA and -NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 mm25 mm
Jet sizes - 85HFCA:
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112135
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165150
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F22F22
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4545
Jet sizes - 85HFDA:
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110135
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160150
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F22F22
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4545
Jet sizes - 85HFGA and -HA:
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107125
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180160
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F59F59
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4550
Jet sizes - 85HFMA:
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105130
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200160
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F59F59
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4550
Jet sizes - 85HFNA:
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110125
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180160
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F59F59
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4550
Adjustments:
Choke pull-down (maximum):
85HFCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.0 mm (0.35 in)
85HFDA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 mm (0.32 in)
All others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5 mm (0.30 in)
Bi-metal housing setting:
85 HFCA, -DA, -HA and -MA . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Index
85HFGA and -NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 mm (0.12 in) lean
Float level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5 to 8.5 mm (0.30 to 0.34 in)
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Fuel and exhaust systems 4•3
4
Weber 2V TLD carburettorPrimarySecondary
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.0 mm25.0 mm
Main jet:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115157
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112157
Air correction jet:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175145
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210145
Emulsion tube:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F114F3
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210145
Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1800 ±50 rpm
Float level (with gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29.0 ±0.5 mm
Automatic choke vacuum pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . .5.0 ±0.5 mm
Throttle kicker speed (see text):
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000 ±50 rpm
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2200 ±50 rpm
Fuel-injection system
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bosch
Fuel pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Roller cell, electric
Fuel pump output pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greater than 5 bar at 12 volts, no flow
System control pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 bar
Torque wrench settingsNmlbf ft
Inlet manifold:
SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2113 to 16
DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 2415 to 18
V6:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 to 83 to 6
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 156 to 11
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 to 2111 to 16
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2516 to 18
Stage 5 (after warm-up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2516 to 18
Exhaust manifold:
OHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2516 to 18
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 to 3018 to 22
Plenum chamber to inlet manifold:
2.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 to 105 to 7
2.4 & 2.9 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 2515 to 18
Carburettor bolts (DOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 106 to 7
Fuel pump bolts (mechanical pump) . . . . . . . . . . . . . . . . . . . . . . . . . . .14 to 1810 to 13
Fuel pipe to fuel-injection pressure regulator:
SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 to 2011 to 15
2.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 to 127 to 9
Pressure regulator base nut/bolt:
SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 2515 to 18
DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 127 to 9
V6:
2.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 to 2011 to 15
2.4 & 2.9 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 117 to 8
Fuel rail bolts:
SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 117 to 8
DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2615 to 19
Exhaust downpipe flange nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 to 4026 to 30
Exhaust clamps and U-bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 to 4528 to 33
Exhaust gas oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 7037 to 52
Throttle body bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 117 to 8
Idle speed control valve bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 117 to 8
Fuel filter unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 to 2010 to 15
Fuel rail temperature sensor (DOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 116 to 8
Fuel rail temperature switch (2.4 & 2.9 litre) . . . . . . . . . . . . . . . . . . . . . .20 to 2515 to 18
HEGO sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 7037 to 52
All models are fitted with a rear-mounted fuel
tank. Fuel is conveyed from the tank by a
mechanical or electrical fuel pump, according tomodel and equipment, to the carburettor or fuel-
injection system. The delivery capacity of the
fuel pump exceeds the maximum demands of
the system, so excess fuel is constantly returned
to the tank. This helps to avoid the problems of
vapour locks in the fuel lines.
Carburettor models have a twin venturidowndraught carburettor of Pierburg
manufacture on 1.8 litre models and Weber on
2.0 litre models. Both makes of carburettor
have an automatic choke.
Fuel-injection, when fitted, is of the Bosch
L-Jetronic type. This system is under the
control of the EEC IV module.
1General information and
precautions
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The exhaust system fitted in production is
made of aluminised steel, with stainless steel
used in the endplates and baffles of the rear
silencer. Individual sections of the system are
easily renewed in service.
Emission control for the UK market is
achieved largely by the inherent efficiency of
the fuel, ignition and engine management
systems. A welcome spin-off from such
efficiency is remarkably good fuel economy for
a vehicle of such size and weight.
Precautions
Fuel
Many of the procedures in this Chapter
require the removal of fuel lines and
connections which may result in some fuel
spillage. Residual pressure in fuel-injection
systems will remain in the fuel lines long after
the vehicle was last used, therefore extra care
must be taken when disconnecting a fuel line
hose. Loosen any fuel hose slowly to avoid a
sudden release of pressure which may cause
fuel spray. As an added precaution place a rag
over each union as it is disconnected to catch
any fuel which is forcibly expelled. Before
carrying out any operation on the fuel system
refer to the precautions given in “Safety first!”
at the beginning of this Manual and follow
them implicitly. Petrol is a highly dangerous
and volatile liquid and the precautions
necessary when handling it cannot be
overstressed
Tamperproof adjustment screws
Certain adjustment points in the fuel system
(and elsewhere) are protected by tamperproof
caps, plugs or seals. The purpose of such
tamperproofing is to discourage, and to deter,
adjustment by unqualified operators.
In some EU countries (though not yet in the
UK) it is an offence to drive a vehicle with
missing or broken tamperproof seals. Before
disturbing a tamperproof seal, satisfy yourself
that you will not be breaking local or national
anti-pollution regulations by doing so. Fit a
new seal when adjustment is complete when
this is required by law.
Do not break tamperproof seals on a vehicle
which is still under warranty.
Catalytic converter
The catalytic converter is a reliable and
simple device which needs no maintenance in
itself, but there are some facts of which an
owner should be aware if the converter is to
function properly for the full service life.
a)DO NOT use leaded petrol in a car
equipped with a catalytic converter the
lead will coat the precious metals,
reducing their converting efficiency and
will eventually destroy the converter.
b)Always keep the ignition and fuel systems
well-maintained in accordance with the
manufacturer’s schedule - particularly,
ensure that the air cleaner filter element,
the fuel filter and the spark plugs are
renewed at the correct interval - if the inletair/fuel mixture is allowed to become too
rich due to neglect, the unburned surplus
will enter and burn in the catalytic
converter, overheating the element and
eventually destroying the converter.
c)If the engine develops a misfire, do not
drive the car at all (or at least as little as
possible) until the fault is cured - the
misfire will allow unburned fuel to enter
the converter, which will result in
overheating, as noted above.
d)DO NOT push- or tow-start the car - this
will soak the catalytic converter 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,
unburnedfuel will enter the (very hot)
catalytic converter, with the possible risk
of igniting on the element and damaging
the converter.
f)DO NOT use fuel or engine oil additives -
these may contain substances harmful to
the catalytic converter.
g)DO NOT continue to use the car if the
engine burns oil to the extent of leaving a
visible trail of blue smoke - the unburned
carbon deposits will clog the converter
passages and reduce the efficiency; in
severe cases the element will overheat.
h)Remember that the catalytic converter
operates at very high temperatures -
hence the heat shields on the car’s
underbody and the casing will become hot
enough to ignite combustible materials
which brush against it - DO NOT,
therefore, park the car in dry undergrowth,
over long grass or piles of dead leaves.
i)Remember that the catalytic converter is
FRAGILE, do not strike it with tools during
servicing work, take great care when
working on the exhaust system, ensure
that the converter is well clear of any jacks
or other lifting gear used to raise the car
and do not drive the car over rough
ground, road humps, etc, in such a way as
to “ground” the exhaust system.
j)In some cases, particularly when the car is
new and/or is used for stop/start driving, a
sulphurous smell (like that of rotten eggs)may be noticed from the exhaust. This is
common to many catalytic converter-
equipped cars and seems to be due to the
small amount of sulphur found in some
petrols reacting with hydrogen in the
exhaust to produce hydrogen sulphide
(H
2S) gas; while this gas is toxic, it is not
produced in sufficient amounts to be a
problem. Once the car has covered a few
thousand miles the problem should
disappear - in the meanwhile a change of
driving style or of the brand of petrol used
may effect a solution.
k)The catalytic converter, used on a well-
maintained and well-driven car, should
last for between 50 000 and 100 000 miles
- from this point on, careful checks should
be made at all specified service intervals
of the CO level to ensure that the
converter is still operating efficiently - if
the converter is no longer effective it must
be renewed.
See Chapter 1, Section 38.
1On carburettor models only, the air cleaner
can take in both hot and cold air. Hot air is
obtained from a shroud bolted to the exhaust
manifold.
2A flap valve in the air cleaner spout
determines the mix of hot and cold air. The
valve is operated by a vacuum diaphragm.
Vacuum is obtained from the inlet manifold
and is applied via a heat-sensing valve, which
cuts off the vacuum as the temperature of the
incoming air rises. Thus the air cleaner takes in
only hot air on starting from cold, changing
progressively to cold air as the engine warms
up (see illustrations).
3If the system fails, either the engine will take
a long time to warm up (flap stuck in “cold”
position), or it may run roughly and not
develop full power when warm (flap stuck in
“hot” position). Check it as follows.
3Air cleaner temperature control
- description and testing
2Air cleaner and element -
removal and refitting
4•4Fuel and exhaust systems
3.2b Air cleaner heat sensor3.2a Air cleaner vacuum diaphragm unit
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4With the engine cold, disconnect the cold
air inlet trunking from the spout. Look into the
spout and check that the flap valve is covering
the hot air inlet.
5Start the engine and allow it to idle. Check
that the flap moves to cover the cold air inlet. If
the flap does not move, check the diaphragm
and heat sensor as follows.
6Stop the engine. Disconnect the diaphragm
vacuum pipe from the heat sensor. Apply
vacuum to the diaphragm, using a vacuum
head pump or by connecting the pipe directly
to manifold vacuum. If the flap now moves, the
heat sensor or vacuum line was faulty. If the
flap still does not move, the diaphragm is
faulty or the flap is jammed.
7On completion reconnect the vacuum pipe
and the cold air trunking.
Mechanical
1Carburettor models without air conditioning
are fitted with a mechanical fuel pump, located
on the left-hand side of the engine block.
2To test the pump, disconnect the ignition
coil LT lead. Disconnect the outlet hose from
the pump and place a wad of rag next to the
pump outlet. Take appropriate fire
precautions.
3Have an assistant crank the engine on the
starter. Well-defined spurts of fuel must beejected from the pump outlet - if not, the pump
is probably faulty (or the tank is empty).
Dispose of the fuel-soaked rag safely.
4To remove the fuel pump, first disconnect
the battery negative lead.
5Disconnect and plug the pump inlet and
outlet hoses. Be prepared for fuel spillage.
6Unscrew the two bolts and withdraw the
pump from the cylinder block. Remove the
gasket. If necessary extract the pushrod (see
illustrations).
7Clean the exterior of the pump in paraffin
and wipe dry. Clean all traces of gasket from
the cylinder block and pump flange.
8If the fuel pump has a removable cover,
remove the screw and withdraw the cover and
nylon mesh filter with seal (see illustrations).
Clean the filter, cover and pump in fuel. Locate
the filter in the cover and fit the cover to the
pump so that the pipe and indentation are
aligned. Tighten the screw.
9Refitting is a reversal of removal, but fit a
new gasket and tighten the bolts to the
specified torque. If necessary discard the
crimped type hose clips and fit screw type
clips.
Electrical
SOHC and 2.8 litre V6 engines
10All fuel-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 fuel tank.11If the fuel pump appears to have failed
completely, check the appropriate fuse and
relay. On fuel-injection models, also check the
inertia switch (when fitted).
12To test the carburettor type pump,
disconnect the fuel supply hose from the
pressure regulator or vapour separator in the
engine compartment. Lead the hose into a
measuring cylinder.
13Take appropriate fire precautions. Switch
on the ignition for 30 seconds and measure
the quantity of fuel delivered: it should be at
least 400 cc (0.7 pint).
14To test the fuel-injection type pump,
special equipment is required. Consult a Ford
dealer or other fuel-injection specialist. The
problem may be due to a clogged filter.
15To remove a pump, first disconnect the
battery negative lead. Take appropriate fire
precautions.
16Raise and support the rear of the vehicle.
Clean the fuel pump and its surroundings.
17Clamp the tank-to-pump hose, or make
arrangements to collect the contents of the
fuel tank which will otherwise be released.
18Place a drain pan beneath the pump.
Disconnect the inlet and outlet hoses; be
prepared for fuel spillage. Caution: Fuel under
pressure may spray out of the outlet hose
union as it is slackened.
19Disconnect the wiring plug from the pump.
20Slacken the pump bracket clamp bolt and
slide the pump out of the bracket.
21Refit by reversing the removal operations.
Make sure that all hoses and unions are in
good condition.
22On2.4 & 2.9 litre V6 engines up to mid-
1990, switch the ignition on and off five times,
without cranking the engine, to pressurise the
fuel system then check the pump unions for
signs of leakage.
23Run the engine and check for leaks.
DOHC engine
24On these models the fuel pump is
mounted in the fuel tank, on the same
mounting as the fuel level sender unit(see
illustration).To test the pump specialist
equipment is required, therefore this task must
be entrusted to a Ford dealer.
4Fuel pump - testing, removal
and refitting
Fuel and exhaust systems 4•5
4
4.6a Removing the mechanical fuel pump4.6b Fuel pump pushrod
4.8a Removing the fuel pump cover - note
alignment indentations4.8b Fuel pump cover and filter screenA Fuel pumpB Fuel level sender unit
4.24 Combined fuel pump/fuel level sender
unit
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25To remove the pump, first remove the fuel
tank.
26Unscrew the fuel pump/fuel level sender
unit by engaging two crossed screwdrivers in
the slots on either side of the unit mounting
flange. Recover the seal.
27Refitting is a reversal of removal. It is
necessary to fit a new seal.
1Run the fuel level as low as possible before
removing the tank.
2Disconnect the battery negative lead.
3Remove the fuel filler cap. Siphon or pump
the remaining fuel out of the tank. Store the
fuel in a suitable sealed container.
4Remove the two screws on either side of the
filler neck.
5Raise and support the rear of the vehicle.
6Remove the shield from the right-hand rear
inner wheel arch. Also remove the rear bumper
undershield. which is secured by six screws.
7Disconnect the fuel supply and return lines
from the tank (see illustration). Drain the fuel
in the lines into a suitable container and
remove it.
8Support the fuel tank. Remove the two bolts
which secure the rear ends of the fuel tank
supporting straps.
9Lower the tank and supporting straps,unhooking the front ends of the straps from
their locations. Disconnect the wiring and the
vent hose from the tank. Remove the tank with
filler pipe attached.
10Fuel tank repairs including soldering or
welding must be left to specialists. Even when
empty, the tank may contain explosive vapour.
Proprietary compounds are available for
making temporary “cold” repairs.
11Refit the fuel tank in the reverse order to
removal. Check for leaks on completion.
1Remove the fuel tank.
2Unscrew the sender unit from the tank.
There is a Ford tool (No 23-014) which
engages with the lugs on the unit, but with
patience a pair of crossed screwdrivers or
similar items can be used instead.
3Remove the sender unit, taking care not to
damage the float or bend the float arm(see
illustration).Recover the seal.
4A defective sender unit must be renewed;
spares are not available. Renew the seal in any
case.
5Refit by reversing the removal operations.
1Fitted to DOHC and 2.4 & 2.9 litre V6
engined models, this device is designed to cutoff pressurised fuel to the fuel-injection system
in the event of an accident. It does this by
interrupting the electrical supply to the fuel
pump.
2To remove the switch, first disconnect the
battery negative lead.
3Open up the tailgate and locate the switch
which is mounted near the tailgate lock striker.
On Estate models the switch is located behind
a trim panel in the rear right-hand corner of the
luggage compartment (see illustration).
4Remove the trim panel and disconnect the
switch wiring connector (see illustrations).
5Extract the two retaining screws and
remove the switch.
6Refitting is a reverse of the removal
procedure. On completion, depress the switch
button to ensure that the switch has been
reset.
1Disconnect the battery negative lead.
2Unclip the under-dash insulation on the
driver’s side.
3Disconnect the cable from the pedal. The
cable may be secured by a clip, or it may slot
into a “keyhole” fitting (see illustration).
4Remove the two nuts which secure the
throttle pedal bracket to the bulkhead.
Remove the pedal and bracket.
5Refit by reversing the removal operations.
8Throttle pedal - removal and
refitting
7Fuel cut-off inertia switch -
removal and refitting
6Fuel gauge sender unit -
removal and refitting
5Fuel tank - removal and refitting
4•6Fuel and exhaust systems
5.7 Fuel tank supply (left) and return hoses
7.4a On early models it will be necessary to
remove the luggage compartment rear trim
panel to gain access to the fuel cut-off
inertia switch . . .
7.4b . . . on later models an access cover in
the trim panel is provided8.3 Throttle pedal showing “keyhole” cable
fitting (arrowed)
6.3 Removing the fuel gauge sender unit7.3 Fuel cut-off inertia switch location -
Estate models
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1Disconnect the battery negative lead.
2Disconnect the cable from the pedal.
3Working under the bonnet, free the cable
outer from the bulkhead and pull the cable into
the engine bay.
4On carburettor models, remove the air cleaner.5On V6 models, remove the throttle linkage
cover, which is secured by three screws (see
illustrations).
6Disconnect the cable inner from the throttle
lever on the carburettor or fuel-injection linkage.
The cable may be secured by a spring clip, or by
a simple barrel and slot arrangement (see
illustration).
7Disconnect the cable outer from its bracket.
It may be secured by a spring clip, or by four
plastic lugs. The lugs are most easily released
with a tool (see illustration).
8Refit by reversing the removal operations.
Adjust the threaded sleeve on the cable outer
so that there is a small amount of slack with
the pedal released; have an assistant operate
the throttle pedal and check that the throttle
lever moves over its full range of travel.
9On automatic transmission models, check
the adjustment of the kickdown cable.
1All carburettor models are fitted with a
vapour separator, mounted on the left-hand
inner wing. On 1.8 litre models the separator
incorporates a pressure regulator (see
illustrations).2Disconnect the battery negative lead.
3Identify the three hoses connected to the
separator. Disconnect the hoses, cutting off
the hose clips if they are of the crimped type.
4Remove the two securing screws and lift out
the separator. Remember it is full of fuel.
5Refit by reversing the removal operations.
Make sure that the different hoses are
connected to the correct stubs on the
regulator. Use new hose clips when
necessary.
See Chapter 1, Sections 15 and 16.
1Disconnect the battery negative lead.
2Remove the air cleaner.
3Disconnect the automatic choke electrical
lead from the manifold thermo-switch.
4Unclip the throttle arm from the throttle lever
(see illustration).
5Disconnect the fuel hose from the
carburettor and plug it. If a crimped hose clip
is fitted, cut it off and use a worm drive clip
when refitting (see illustration).
6Depressurise the cooling system by
removing the expansion tank filler cap. Take
precautions against scalding if the system is
hot.
12Pierburg 2V carburettor -
removal and refitting
11Pierburg 2V carburettor - idle
speed and mixture adjustments
10Vapour separator - removal
and refitting9Throttle cable - removal and
refitting
Fuel and exhaust systems 4•7
4
9.5a Three screws (arrowed) secure the
throttle linkage cover9.5b Throttle linkage with cover removed9.6 Removing a throttle cable inner - barrel
and slot type
12.4 Throttle arm-to-lever clip (arrowed)
9.7 Tool for releasing accelerator cable
lugs
A 25 mm (1 in)
B Centrepunch indentsC 16 mm (0.63 in)
10.1a Fuel vapour separator without
pressure regulator
A Fuel return
B Fuel supplyC Carburettor supply
10.1b Fuel vapour separator and pressure
regulator
A Fuel supply
B Carburettor supplyC Fuel return
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