engine FORD GRANADA 1985 Service Manual Online
[x] Cancel search | Manufacturer: FORD, Model Year: 1985, Model line: GRANADA, Model: FORD GRANADA 1985Pages: 255, PDF Size: 14.98 MB
Page 87 of 255
Make sure that the thermostat is the right way
round - the wax capsule fits into the cylinder
head, with the direction of flow arrow facing
forwards (see illustration).
8Refill the cooling system.
DOHC engines
9Disconnect the battery negative lead.
10Drain the cooling system.
11On fuel-injection models, for access to the
thermostat housing, loosen the clips and
remove the air inlet tube which connects the
plenum chamber to the inlet manifold.
12Disconnect the coolant hoses from the
thermostat housing (see illustrations).
13Disconnect the wiring plug from the
cooling fan switch mounted in the thermostat
housing (see illustration).
14Unscrew the three securing bolts, andwithdraw the thermostat housing (see
illustration).
15Manoeuvre the thermostat away from the
inlet manifold and recover the O-ring. If it is
necessary to prise the thermostat out, take
care not to damage the surface of the housing
in the inlet manifold.
16Refitting is a reversal of removal, bearing
in mind the following points:
a)Ensure that the O-ring seal is correctly
fitted around the edge of the thermostat.
b)When fitting the thermostat to the inlet
manifold ensure that the relief valve is
located in the 12 o’clock position (see
illustration).
c)Tighten the thermostat housing bolts to
the specified torque.
d)Refill the cooling system.
3•4Cooling, heating and ventilation systems
7.3 Top hose attachment to the thermostat
housing
7.12b . . . from the thermostat housing
7.5b . . . extract the thermostat . . .7.5c . . . and the sealing ring7.7 Thermostat direction of flow arrow
7.12a Disconnecting the coolant hoses . . .
7.13 Disconnect the cooling fan switch
wiring plug . . .7.14 . . . and remove the thermostat
housing
7.4 Removing the thermostat housing7.5a Remove the retaining clip . . .
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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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Page 89 of 255
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
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Page 90 of 255
See Chapter 1, Section 21.
1On 2.0 litre DOHC engines only, remove the
water pump/alternator drivebelt as described
in the previous Section.
2Loosen the alternator lower mounting
through-bolt, then remove the alternator upper
mounting bolt, and swing the alternator away
from the engine.
3Unscrew the central securing bolt, and
withdraw the drivebelt tensioner assembly.
4Commence refitting by positioning the
tensioner on the cylinder block, ensuring that
the lug on the rear of the tensioner bracket
engages with the corresponding hole in the
cylinder block (see illustration). Tighten the
securing bolt.
5Swing the alternator into position to align
the upper mounting bolt hole with the
corresponding hole in the drivebelt tensioner
assembly, then refit and tighten the upper
mounting bolt, then the lower throughbolt.
6Check the full length of the drivebelt for cracks
and deterioration and renew if necessary.
7Fit the drivebelt using a reversal of the
removal procedure, and release the tensioner
to tension the drivebelt.
1Disconnect the battery negative lead.
2Depressurize the cooling system by
unscrewing the expansion tank cap. Take
precautions against scalding if the system
is hot.
3Slacken the hose clips on all the hoses
which are connected to the tank. Pull off and
plug those hoses which are above the
waterline.4Remove the two screws which secure the
tank. Tilt the tank so that the coolant lies away
from the outlets, then disconnect and plug the
remaining hose.
5Disconnect the coolant level sensor, when
fitted, and remove the tank.
6Refit by reversing the removal operations.
Top-up the cooling system on completion.
1The temperature gauge sender is located
towards the front of the engine. On SOHC
models it is just below the inlet manifold (see
illustration); on V6 models it is just below the
top hose connection on the front of the left-
hand cylinder head, and on DOHC models it is
located at the front of the inlet manifold (see
illustration).
2Slacken the expansion tank cap to release
pressure in the cooling system, taking
precautions against scalding if the system
is hot.Tighten the cap again to minimise
coolant loss.
3Disconnect the wiring from the sender unit.
Unscrew and remove it, being prepared for
some coolant spillage.
4Smear sealant on the sender unit threads
before refitting, then insert and tighten it.
Reconnect the wiring.
5Top-up the cooling system if necessary,
then run the engine and check the operation of
the temperature gauge.The cooling fan switch is located in the end
of the thermostat housing.
Removal and refitting of the switch is as
described for the temperature gauge sender in
the previous Section.
Models before April 1992
Front
1Disconnect the battery negative lead.
2Remove the instrument cluster (Chapter 13).
3Remove the facia top (Chapter 12).
4Unclip the two control cables from the
control levers (see illustration).
5On air conditioned models, disconnect the
hoses from the vacuum switch.
6Remove the four screws which secure the
heater control assembly. Withdraw the
assembly from the facia.
7When refitting, secure the control assembly
with the four screws. Reconnect the vacuum
switch (when applicable) and the control
cables. Adjust the control cables if necessary
by altering the positions of the cable clips.
8When satisfied with the operation of the
cables, refit the other disturbed components.
Rear
9Remove the centre console (Chapter 12).
10Unclip the control cables and remove the
control unit.
11Refit in the reverse order to removal.
Models from April 1992
12Undo the two instrument panel surround
retaining screws, then carefully release the
retaining clips and remove the surround from
the facia.
13Pull off the three knobs from the heater
and ventilation controls to gain access to the
two hidden central vent panel retaining
screws. Slacken and remove the four panel
retaining screws and partially withdraw the
17Heater controls - removal and
refitting
16Cooling fan switch - removal
and refitting
15Temperature gauge sender -
removal and refitting
14Expansion tank - removal and
refitting
13Water pump/alternator
drivebelt tensioner - removal
and refitting
12Water pump/alternator
drivebelt(s) - inspection,
renewal and adjustment
Cooling, heating and ventilation systems 3•7
3
13.4 On refitting, ensure the drivebelt
tensioner lug (A) engages with hole in the
mounting bracket (B)15.1a Temperature gauge sender (manifold
removed)15.1b Temperature gauge sender unit
location (arrowed)
17.4 Heater control cable clip (arrowed)
viewed through windscreen
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Page 91 of 255
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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Page 92 of 255
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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Page 93 of 255
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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Page 94 of 255
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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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
procarmanuals.com