radiator FORD GRANADA 1985 Service Owner's Manual

Chapter 3
Cooling, heating and ventilation systems
Air conditioning system - component renewal . . . . . . . . . . . . . . . . .22
Cooling fan switch - removal and refitting . . . . . . . . . . . . . . . . . . . .16
Cooling system - draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Cooling system - filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Cooling system - flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Electric cooling fan(s) - removal and refitting . . . . . . . . . . . . . . . . . .10
Expansion tank - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .14
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . .1
Heater assembly - removal and refitting . . . . . . . . . . . . . . . . . . . . .19
Heater control cables - removal and refitting . . . . . . . . . . . . . . . . . .18
Heater controls - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .17
Heater coolant valve - removal and refitting . . . . . . . . . . . . . . . . . .21Heater matrix - dismantling and reassembly . . . . . . . . . . . . . . . . . .20
Radiator - inspection and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Radiator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Temperature gauge sender - removal and refitting . . . . . . . . . . . . .15
Thermostat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Thermostat - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Viscous-coupled fan - removal and refitting . . . . . . . . . . . . . . . . . . .9
Water pump/alternator drivebelt(s) - inspection, renewal and
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Water pump/alternator drivebelt tensioner - removal and refitting .13
Water pump - 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 fluids”
Capacity:
SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 litres (14.1 pints) approx
DOHC:
Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 litres (13.9 pints) approx
Fuel injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 litres (12.8 pints) approx
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 litres (15.0 pints) approx
Specific gravity at 45 to 50% antifreeze concentration . . . . . . . . . . . . . 1.069 to 1.077
Expansion tank cap
Opening pressure:
SOHC and V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 to 1.10 bar
DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.4 bar
Thermostat
Nominal rating:.
SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88°C (190°F)
DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102°C (216°F)
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F)
Actual opening temperature:
SOHC and DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° to 89°C (185° to 192°F)
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79° to 83°C (174° to 181°F)
Water pump drivebelt
Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm (0.4 in) approx under normal fingertip pressure at mid-
point of longest run
3•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
3
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Cooling system
The cooling system is of pressurised type
and includes a front mounted crossflow
radiator, belt-driven water pump, temperature-
sensitive thermo-viscous fan (on DOHC
models, an electrically-operated cooling fan is
fitted, operated by a switch in the thermostat
housing), wax type thermostat, and an
expansion and degas tank.
The radiator matrix is of copper and brass
construction and the end tanks are of plastic.
On automatic transmission models the right-
hand side end tank incorporates the
transmission oil cooler.
The thermostat is located behind the water
outlet elbow at the front of the cylinder head
on OHCmodels, and on the front of the water
pump on V6 models. Its purpose is to ensure
rapid engine warm-up by restricting the flow of
coolant in the engine when cold, and also to
assist in regulating the normal operating
temperature of the engine.
The expansion tank incorporates a pressure
cap which effectively pressurises the cooling
system as the coolant temperature rises,
thereby increasing the boiling point of the
coolant. The tank also has a further degas
function. Any accumulation of air bubbles in
the coolant, in particular in the thermostat
housing and the radiator, is returned to the
tank and released in the air space thus
maintaining the efficiency of the coolant.
On models fitted with the auxiliary warning
system, the expansion tank contains a level
sensor which operates a warning light if the
coolant level falls significantly.
When the engine is started from cold, the
water pump circulates coolant around the
cylinder block, cylinder head(s) and inlet
manifold. The warm coolant passes through
the automatic choke housing (when
applicable) and through the heater matrix
before returning to the engine. As the coolant
expands, the level in the expansion tank rises.
Circulation of coolant through the radiator is
prevented while the thermostat is shut. When
the coolant reaches the predeterminedtemperature the thermostat opens and hot
water passes through the top hose to the top
of the radiator. As the water circulates down
through the radiator, it is cooled by the
passage of air past the radiator when the car is
in forward motion, supplemented by the action
of the thermo-viscous fan when necessary.
Having reached the bottom of the radiator, the
water is now cool and the cycle is repeated.
Circulation of water continues through the
expansion tank, inlet manifold and heater at all
times; the heater temperature control being by
an air flap.
The thermo-viscous fan is controlled by the
temperature of air behind the radiator. When
the air temperature reaches a predetermined
level, a bi-metallic coil commences to open a
valve within the unit and silicon fluid is fed
through a system of vanes. Half of the vanes
are driven directly by the water pump and the
remaining half are connected to the fan blades.
The vanes are arranged so that drive is
transmitted to the fan blades in relation to the
drag or viscosity of the fluid, and this in turn
depends on ambient temperature and engine
speed. The fan is therefore only operated when
required, and compared with direct drive type
fan represents a considerable improvement in
fuel economy, drivebelt wear and fan noise.
Air conditioning
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 achieved inside the car, it
also reduces the humidity of the incoming air,
aiding demisting even when cooling is not
required.
The refrigeration side of the air conditioning
system functions in a similar way to a
domestic refrigerator. A compressor, belt-
driven from the crankshaft pulley, draws
refrigerant in its gaseous phase from an
evaporator. The compressed refrigerant
passes through a condenser where it loses
heat and enters its liquid phase. After
dehydration the refrigerant returns to the
evaporator where it absorbs heat from air
passing over the evaporator fins. The
refrigerant becomes a gas again and the cycle
is repeated.Various subsidiary controls and sensors
protect the system against excessive
temperature and pressures. Additionally,
engine idle speed is increased when the
system is in use to compensate for the
additional load imposed by the compressor.
Precautions
Antifreeze mixture
Antifreeze mixture is poisonous. Keep it out
of reach of children and pets. Wash splashes
off skin and clothing with plenty of water.
Wash splashes off vehicle paintwork to avoid
discolouration.
Antifreeze/water mixture must be renewed
every two years to preserve its anti-corrosive
properties. In climates where antifreeze
protection is unnecessary, a corrosion
inhibitor may be used instead - consult a Ford
dealer. Never run the engine for long periods
with plain water as coolant. Only use the
specified antifreeze, as inferior brands may not
contain the necessary corrosion inhibitors, or
may break down at high temperatures.
Antifreeze containing methanol is particularly
to be avoided, as the methanol evaporates.
The specified mixture is 45 to 50%
antifreeze and 50 to 55% clean soft water (by
volume). Mix the required quantity in a clean
container.
Air conditioning refrigerant
Although the refrigerant is not itself toxic, in
the presence of a naked flame (or a lighted
cigarette) it forms a highly toxic gas. Liquid
refrigerant spilled on the skin will cause
frostbite. If refrigerant enters the eyes, rinse
them with a dilute solution of boric acid and
seek medical advice immediately.
In view of the above points, and of the need
for specialised equipment for evacuating and
recharging the system, any work which
requires the disconnection of a refrigerant line
must be left to a specialist.
Do not allow refrigerant lines to be exposed
to temperatures above 110°C (230°F) - eg
during welding or paint drying operations and
do not operate the air conditioning system if it
is known to be short of refrigerant, or further
damage may result.
1General information and
precautions
3•2Cooling, heating and ventilation systems
Torque wrench settingsNmlbf ft
Radiator lower mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 126 to 9
Thermostat housing bolts:
SOHC, DOHC and 2.8 litre V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2013 to 15
2.4 & 2.9 litre V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 to 105 to 7
Water pump bolts:
SOHC, M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2113 to 16
SOHC, M10 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 to 4226 to 31
DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2816 to 21
2.8 litre V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 137 to 10
2.4 & 2.9 litre V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 to 105 to 7
Water pump pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2616 to 19
Water pump/alternator drivebelt tensioner bolt (DOHC) . . . . . . . . . . . .70 to 9752 to 72
Fan-to-viscous clutch bolts:
SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 106 to 7
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2313 to 17
Fan shroud bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 to 116 to 8
Cylinder block drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2516 to 18
procarmanuals.com

See Chapter 1, Section 46.
See Chapter 1, Section 46.
See Chapter 1, Section 46.
1Drain the radiator. There is no need to drain
the cylinder block. On DOHC engines the
electric cooling fan assembly must be removed
to gain the clearance to remove the radiator.
2Disconnect the top and bottom hoses from
the radiator by slackening the hose clips and
pulling off the hoses with a twisting motion
(see illustrations). Do not use excessive force
- the radiator side tanks are made of plastic.
3On OHCmodels, disconnect the small hose
running from the expansion tank to the radiator.
4On automatic transmission models, clean
around the transmission fluid cooler unions on
the radiator and disconnect them (seeillustration). Be prepared for fluid spillage;
plug or cap the cooler lines to keep dirt out.
5On models with air conditioning, disconnect
the auxiliary fan thermo-switch. If the thermo-
switch is mounted in the radiator, remove It.
6Remove the upper half of the fan shroud by
removing the two bolts and two clips (see
illustration), and the lower half which is
secured by two bolts.
7Release the two radiator top mounting clips
by pulling out the plastic plugs (see illustration).
8Raise and support the front of the vehicle.
Support the radiator and remove the two
bottom mounting bolts (see illustration).
9Carefully lower the radiator slightly to free
the top mountings, then remove it from under
the vehicle.
10If a new radiator is being fitted, transfer the
fan shrouds and mountings from the old one.
11Refit by reversing the removal operations,
then refill the cooling system.
12On automatic transmission models, check
the transmission fluid level.
1If the radiator has been removed because of
suspected blockage, reverse-flush it.
2Clean 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 cut your
fingers. 3A radiator specialist can perform a “flow
test” on the radiator to establish whether an
internal blockage exists.
4A leaking radiator must be referred to a
specialist for permanent repair. Do not attempt
to weld or solder a leaking radiator, as
damage to the plastic parts may result.
5In an emergency, minor leaks from the
radiator can be cured by using a radiator
sealant while the radiator is in situ.
SOHC engines
1Disconnect the battery negative lead.
2Drain the cooling system. As it is not
necessary to completely drain the radiator, the
bottom hose can be disconnected from the
water pump.
3Disconnect the top hose from the
thermostat housing at the front of the cylinder
head (see illustration).
4Unscrew the bolts and remove the housing
and gasket (see illustration).
5Using a screwdriver, prise the retaining clip
from the housing, and extract the thermostat
and sealing ring (see illustrations).
6Clean the thermostat housing and cylinder
head mating surfaces. Obtain a new gasket for
reassembly, and if necessary a new sealing
ring too.
7Refit by reversing the removal operations.
7Thermostat - removal and
refitting
6Radiator - inspection and repair
5Radiator - removal and refitting
4Cooling system - filling
3Cooling system - flushing
2Cooling system - draining
Cooling, heating and ventilation systems 3•3
3
5.2a Radiator top hose5.2b Radiator bottom hose (A)
Also shown are automatic transmission fluid
cooler lower union (B) and hose to expansion
tank (C)5.4 Transmission fluid cooler upper union
5.6 Fan shroud clip5.7 Pull out the plug to release the radiator
top mounting5.8 One of the radiator bottom mounting
bolts (arrowed)
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V6 engines
17The thermostat is removed in the course
of water pump removal.
1A rough test of the thermostat may be made
by suspending it with a piece of string in a
saucepan full of water(see illustration).Bring
the water to the boil. The thermostat most
open by the time the water boils. If not, renew
it.
2If a thermometer is available, the precise
opening temperature of the thermostat may be
determined and compared with that given in
the Specifications.
3A thermostat which fails to close as the
water cools must also be renewed.
1Disconnect the battery negative lead.
2Remove the upper half of the fan shroud
(two bolts, four clips).
3Undo the nut which secures the fan clutch
to the water pump.This nut has a left-hand
thread, ie it is undone in a clockwise direction.
A thin cranked spanner, 32 mm (OHC) or 36
mm (V6) AF is needed(see illustration);
alternatively, if two of the pulley bolts are
removed, a normal thickness or even anadjustable spanner can be used (see
illustrations). Tap the spanner with a mallet if
need be to release the nut.
4The fan can now be unbolted from the
viscous clutch if required. Do not overtighten
the bolts when refitting.
5Refit by reversing the removal operations.
1Disconnect the battery negative lead.
2To provide additional clearance when
removing the cooling fan shroud assembly
(which is removed from below the vehicle),
apply the handbrake, then jack up the front of
the vehicle and support it securely on axle
stands (see “Jacking”).
3Disconnect the wiring plug(s) from the
motor(s), and where applicable, unclip the
wiring from the fan shroud.
4Unclip the expansion tank hose from the fan
shroud.
5Unscrew the two nuts securing the fan shroud
to the top of the radiator, then tilt the top of theshroud away from the radiator, and lift the
shroud to release the lower securing clips.
Withdraw the assembly from below the vehicle.
6To remove the fan blades, prise the
securing clip from the end of the motor shaft.
7The motor can be separated from the fan
shroud by unscrewing the three securing nuts
and bolts.
8Note that two cooling fans may be fitted,
depending on model. Both fans are secured to
the shroud in the same manner.
9Refitting is a reversal of removal, but when
fitting the fan blades, ensure that the drive dog
on the motor shaft engages with the slot in the
rear of the fan blades.
SOHC engines
1Disconnect the battery negative lead.
2Drain the cooling system.
3Remove the fan and viscous coupling.
4If not already done, remove the pump
drivebelt(s), then unbolt and remove the water
pump pulley (see illustration).
5Disconnect the radiator bottom hose and
the heater return hose from the pump.
6Remove the timing belt cover, which is
secured by three bolts.
11Water pump - removal and
refitting
10Electric cooling fan(s) -
removal and refitting
9Viscous-coupled fan - removal
and refitting
8Thermostat - testing
Cooling, heating and ventilation systems 3•5
3
7.16 Thermostat relief valve (arrowed)
positioned in the 12 o’clock position8.1 Checking the thermostat opening
temperature9.3a Dimensions of spanner for undoing
fan clutch nut. Spanner thickness must not
exceed 5 mm (0.2 in)
9.3b Undoing the viscous fan clutch nut9.3c Removing the fan and clutch11.4 Undoing a water pump pulley bolt
X = 10 mm (0.4 in)
Y = 10 mm (0.4 in)Z = 50 mm (2.0 in)
If problems are experienced
with the pulley turning as the
nut is undone, remove the
drivebelt and clamp an old
drivebelt round the pulley to restrain it,
using self-locking pliers.
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7Remove the three securing bolts and
withdraw the water pump (see illustrations).
8A leaking, noisy or otherwise defective
pump must be renewed.
9Clean the mating faces and obtain a new
gasket for reassembly (see illustration).
10Refit by reversing the removal operation,
tightening all fastenings to the correct torque
(where specified).
11Refill the cooling system.
DOHC engines
12Disconnect the battery negative lead.
13On fuel-injection models, for access to the
water pump, remove the air inlet hose, plenum
chamber, and air cleaner lid as an assembly.
14Drain the cooling system.
15Remove the water pump/alternator
drivebelt.16If the pump pulley is to be removed, it is
easiest to do this with the pump in position as
follows. Prevent the pulley from rotating using
a strap wrench (which can be improvised
using an old drivebelt and a large socket and
wrench), and unscrew the four pulley securing
bolts. Withdraw the pulley.
17Position a suitable container beneath the
water pump to catch the coolant which will be
released as the pump is removed, then
unscrew the five securing bolts and withdraw
the pump from the housing in the cylinder
block (see illustration). Recover the O-ring
seal and discard it; a new one must be used
on refitting.
18Refitting is a reversal of removal, bearing
in mind the following points:
a)Ensure that the mating faces of the water
pump and cylinder block are clean and fit
a new O-ring to the pump (see
illustration).
b)Tighten the water pump bolts and where
applicable the pump pulley bolts to the
specified torque.
c)On completion refill the cooling system.
19Note that on models up to May 1990, the
coolant hoses were connected to the water
pump housing as shown(see illustration).
20On models from May 1990, the heater
hose (A) and the expansion tank hose (B)
connections were swapped over.21If the hoses are disconnected on earlier
models, such as during engine removal, they
should be reconnected as on later models, ie
connect the heater hose to connection B and
connect the expansion tank hose to connection
A. This will reduce the possibility of noises from
the heater matrix due to air in the system.
V6 engines
22Disconnect the battery negative lead.
23Drain the cooling system.
24Remove the fan and viscous coupling.
25If not already done, remove the pump
drivebelt(s), then unbolt and remove the water
pump pulley.
26Disconnect the radiator bottom hose and the
heater return hose from the thermostat housing.
27Remove the three bolts which secure the
thermostat housing to the water pump.
Remove the housing and the thermostat.
28Remove the twelve securing bolts and
withdraw the water pump. Note that on some
models it will be necessary to remove the
crankshaft pulley and damper to gain access
to the lower water pump bolts (see
illustration).
29A leaking, noisy or otherwise defective
pump must be renewed.
30Clean the mating faces and obtain a new
gasket for reassembly. Use a new thermostat
housing gasket also.
31Refit by reversing the removal operation,
tightening all fastenings to the correct torque
(where specified).
32Refill the cooling system.
3•6Cooling, heating and ventilation systems
11.7a This water pump bolt also secures
the alternator strap
11.18 On refitting, renew the water pump
O-ring (arrowed)
11.17 Withdrawing the water pump from
the cylinder block (engine removed)
11.19 Water pump housing hose
connections
A Heater hose connection - up to May 1990
B Expansion tank hose connection - up to
May 1990
C Bottom radiator hose
11.28 Removing the water pump
11.7b Water pump removed11.9 Fitting a new gasket to the water
pump
procarmanuals.com

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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55Release the throttle position sensor wiring
connector from the clip under the throttle
body, and separate the two halves of the
connector.
56Remove the fuel-injectors.
57Check that all relevant wiring, hoses and
pipes have been disconnected to facilitate
removal of the manifold.
58Unscrew the ten bolts and two nuts
securing the inlet manifold to the cylinder
head, and carefully withdraw the manifold.
Recover the gasket.
59Recover the two plastic spark plug
spacers from the recesses in the cylinder head
(see illustration).
60If desired, the manifold can be dismantled
with reference to the relevant paragraphs of
this Chapter.
61Refitting is a reversal of removal, bearing
in mind the following points.
a)Ensure that the spark plug spacers are in
position in the cylinder head recesses
before refitting the manifold.
b)Ensure manifold and cylinder head mating
surfaces are clean and dry and fit a new
gasket.
c)Tighten the manifold retaining nuts and
bolts evenly and progressively to the
specified torque.
d)Refit the fuel-injectors.
e)Make sure that all hoses, pipes and wires
are securely reconnected in their original
positions.
f)On completion, refill the cooling system.
g)Check the adjustment of the throttle cable
and where necessary, adjust the speed
control cable so that only a small amount
of slack is present in the cable.
h)Where applicable, check and if necessary
adjust the idle speed and mixture.
V6 engines
62Disconnect the battery negative lead.
63Drain the cooling system.
64Remove the throttle linkage cover.
65Release the hose clips and move the
airflow meter-to-manifold trunking aside.
Unclip or remove the crankcase ventilation
hose.
66Disconnect the radiator top hose and the
heater hose from the outlet at the front of the
manifold. Be prepared for some coolant spillage.67Disconnect the multi-plugs from the idle
speed control valve, the temperature gauge
sender unit; the coolant temperature sensor
and the throttle position sensor. Also
disconnect the injector wiring harness.
68Disconnect the throttle cable from the
linkage, unclip it and move it aside. On
automatic transmission models, also
disconnect the downshift cable or multi-plug,
as applicable.
69Disconnect the fuel feed and return pipes.
Be prepared for fuel spillage.
70Remove the HT leads and the distributor.
71Remove the plenum chamber, which is
secured by eight bolts.
72Remove the rocker covers, which are each
secured by seven bolts.
73Disconnect the water pump bypass hose
from the inlet manifold.
74Remove the eight bolts which secure the
inlet manifold to the cylinder heads.
75Lift off the manifold complete with fuel
pressure regulator, fuel rail, throttle body
housing etc. If it is stuck, carefully lever it free.
Do not apply leverage at the mating faces.
Recover the gasket.
76Clean all mating faces, being careful to
keep dirt out of ports and other orifices.
Obtain new gaskets for both the cylinder head
and plenum chamber sides of the manifold,
and for the rocker covers.
77Commence refitting by applying sealant
(Ford part No A70X-19554-BA, or equivalent)
around the ports and coolant passages on the
cylinder head.
78Apply sealant around the apertures on
both sides of the gasket. then fit the gasket to
the cylinder heads.
79Refit the manifold and insert the securing
bolts. Tighten the bolts, in the order shown
(see illustration),through the first four stages
given in the Specifications.
80Refit the water pump bypass hose.
81Refit the rocker covers, using new
gaskets. The adhesive sides of the gaskets
must face the covers.
82Reverse the remaining removal
operations, but do not refit the throttle linkage
cover yet.
83When the cooling system has beenrefilled, reconnect the battery and start the
engine. Check for fuel and other leaks.
84Bring the engine to operating temperature,
then stop it and carry out the final tightening of
the inlet manifold bolts as follows.
85Release the air inlet trunking. Unplug the
idle speed control valve and the throttle
position sensor. Unbolt the plenum chamber
and move it aside, disconnecting vacuum and
breather hoses as necessary.
86Slacken, but do not remove, the two bolts
which secure the fuel rail to the manifold.
87Tighten the inlet manifold bolts to the
Stage 5 specified torque, again following the
sequence shown. A special cranked spanner
(Ford tool No 21-079, or equivalent)(see
illustration)will be needed to tighten No 4
bolt when the distributor is fitted. In the
absence of such a spanner, remove the
distributor again.
88Tighten the fuel rail securing bolts.
89Refit the disturbed components. Run the
engine again and check the ignition timing and
the exhaust CO level .
90Refit the throttle linkage cover.
SOHC and all V6 engines
1Disconnect the battery negative lead.
2Apply copious quantities of penetrating oil
to the manifold and exhaust pipe flange nuts
and bolts.
3On carburettor models, remove the air
cleaner and the hot air pick-up pipe.
4Unbolt any heat shields or shrouds from the
manifold.
5Unbolt the exhaust pipe(s) from the manifold
flange. Support the exhaust system if
necessary.
6Unbolt the manifold from the cylinder head
and remove it. Recover the gasket.
7Refit by reversing the removal operations.
Use a new gasket, and apply anti-seize
compound to the various nuts and bolts.
Tighten the manifold fastenings to the
specified torque.
41Exhaust manifold(s) - removal
and refitting
Fuel and exhaust systems 4•21
4
40.59 Removing a spark plug spacer from
the cylinder head recess40.79 Inlet manifold bolt tightening
sequence
Arrow points to front of engine40.87 Cranked spanner needed for
tightening V6 inlet manifold bolt with
distributor fitted
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Chapter 12
Bodywork and fittings
Bonnet - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Bonnet insulation panel - removal and refitting . . . . . . . . . . . . . . . .26
Bonnet release cable - removal and refitting . . . . . . . . . . . . . . . . . .11
Boot lid lock barrel - removal and refitting . . . . . . . . . . . . . . . . . . . .18
Boot lid - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . .9
Bumper mouldings - removal and refitting . . . . . . . . . . . . . . . . . . . .36
Bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Centre console - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .42
Door - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Door exterior handle - removal and refitting . . . . . . . . . . . . . . . . . .13
Door interior trim panel - removal and refitting . . . . . . . . . . . . . . . .22
Door latch assembly - removal and refitting . . . . . . . . . . . . . . . . . .15
Door lock barrel - removal and refitting . . . . . . . . . . . . . . . . . . . . . .14
Door striker plate - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Door weatherstrip - removal and refitting . . . . . . . . . . . . . . . . . . . .16
Door window frame mouldings - removal and refitting . . . . . . . . . .31
Door window glass - removal and refitting . . . . . . . . . . . . . . . . . . . .23
Door window regulator mechanism - removal and refitting . . . . . . .24
Exterior mirror - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .39
Facia panels and trim - removal and refitting . . . . . . . . . . . . . . . . . .41
Front bumper - height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .34
Front seat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Front seat air cushion - removal and refitting . . . . . . . . . . . . . . . . .45
Front seat belts - removal and refitting . . . . . . . . . . . . . . . . . . . . . .47
Front spoiler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .37Fuel filler lock barrel - removal and refitting . . . . . . . . . . . . . . . . . . .21
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Headlining - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .38
Interior mirror - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .40
Maintenance - bodywork and underframe . . . . . . . . . . . . . . . . . . . . .2
Maintenance - upholstery and carpets . . . . . . . . . . . . . . . . . . . . . . . .3
Major body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Minor body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Motifs and emblems - removal and refitting . . . . . . . . . . . . . . . . . .33
Overhead console - removal and refitting . . . . . . . . . . . . . . . . . . . .43
Radiator grille - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .27
Rear parcel shelf - removal and refitting . . . . . . . . . . . . . . . . . . . . .50
Rear quarter window moulding - removal and refitting . . . . . . . . . .32
Rear seat belts - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .48
Rear seat components - removal and refitting . . . . . . . . . . . . . . . . .49
Seat belts - care and maintenance . . . . . . . . . . . . . . . . . . . . . . . . .46
Side mouldings - removal and refitting . . . . . . . . . . . . . . . . . . . . . .28
Sliding roof - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .10
Tailgate - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Tailgate latch 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 - removal and refitting . . . . . . . . . . . . .25
Windscreen mouldings - removal and refitting . . . . . . . . . . . . . . . .29
Torque wrench settingsNm lbf ft
Front seat belt buckle to seat frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 to 64 38 to 47
Seat belt retractor bolts (front and rear) . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 45 18 to 33
Other seat belt anchorages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 45 18 to 33
Rear seat back hinge to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 to 25 16 to 18
Rear seat back latch striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 to 60 30 to 44
Front seat retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 32 18 to 24
Front seat frame-to-slide bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 32 18 to 24
Rear bumper mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 16
Front bumper adjuster lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 16
12•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
12
The bodyshell and floorpan are of pressed
steel, and form an integral part of the vehicle’s
structure. Various reinforcing and mounting
components beneath the floorpan are made of
HSLA (High Strength Low Alloy) and REPHOS
(rephosphorised) steels, which have superiorstrength-to-weight characteristics when
compared with conventional steels.
Extensive use is made of plastic for
peripheral components such as the radiator
grille, bumpers and wheel trims, and for much
of the interior trim.
Interior fittings are to the high standard
expected in a vehicle of this class, with even
the basic level models well equipped. A wide
range of options is available, including air
conditioning and leather upholstery.The general condition of a vehicle’s
bodywork is the one thing that significantly
affects its value. Maintenance is easy, but
needs to be regular. Neglect, particularly after
minor damage, can lead quickly to further
deterioration and costly repair bills. It is
2 Maintenance - bodywork and
underframe1 General information
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5Free the glass from the channels. Carefully
remove the glass upwards through the
window aperture.
6Refit by reversing the removal operations.
Note that the channels are adjustable: wind
the window up and down after securing the
channels and adjust them if necessary for
smooth operation. The regulator mechanism
can also be adjusted (see illustration).
Rear door
7Remove the two screws which secure the
window channel (see illustration).
8Remove the two screws which secure the
glass to the regulator mechanism. Free the
glass from the channel and carefully lift it out
through the window aperture.9When refitting, secure the glass and the
channel, then make sure that the window can
wind up and down smoothly before
proceeding further. Adjust the channel or
regulator if necessary.
10Refit the weatherstrip and trim panel.
1The window regulator mechanism is riveted
to the door skin. A blind rivet gun will therefore
be needed for successful refitting.
2Remove the door interior trim panel and
peel back the foam rubber sheet.
3Support the glass and remove the two
screws which secure it to the regulator
mechanism. Wedge or tape the glass in the
raised position.
4When applicable, disconnect the window
motor multi-plug (see illustration).
5Remove the two slide screws and drill out
the four rivets which secure the regulator (see
illustrations). Remove the regulator through
the large lower aperture in the door.
6When refitting, secure the regulator with the
two slide screws, then fit four new rivets in the
rivet holes.
7The remainder of refitting is a reversal of
removal.The windscreen, the rear (tailgate) window
and the rear quarter windows are all secured
and weatherproofed 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.
1Open and prop the bonnet.
2When an under-bonnet light is fitted,
disconnect its wire. Remove the screw which
secures the light, pull the wire through the
insulation panel and remove it.
3Remove the centre screws from the plastic
fittings which secure the insulation. Prise the
outer parts of the fittings out of the bonnet and
remove the insulation panel.
4Refit by reversing the removal operations.
Feed the under-bonnet light wire into place
before finally securing the insulation panel.
Early models
1Open and prop the bonnet.
2Remove the two screws which secure the
centre section of the grille.
3When fitted, remove the headlight washer
jets by pulling them out of their fittings.
4Release one end of the grille side section
from its fixing next to the direction indicator
lens (see illustration). Carefully pull the side
section away from its mountings until it can be
separated from the grille centre section.
5The centre section can now be released
from the other side section by raising the tang
on the catch which holds the sections
together, then twisting them apart (see
illustration).
6Refit by reversing the removal operations.
27Radiator grille - removal and
refitting
26Bonnet insulation panel -
removal and refitting
25Windscreen and fixed glass -
removal and refitting
24Door window regulator
mechanism - removal and
refitting
Bodywork and fittings 12•9
12
23.6 Window regulator adjustment screws
(C)
A Front doorB Rear door
23.7 Rear door window channel screws (A)
24.5a The two regulator slide screws
(arrowed)
24.4 Window motor multi-plug
24.5b Two of the rivets (arrowed) which
secure the regulator
Two other rivets are out of shot to right
27.4 Removing a grille side section
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