– SOLUTIONS INFO. This Manual cover all years: Ford Companion 1990 1991 1992 1993 1994 1995 1996 1997 Solution Repair service Guidebook – EXHAUST CONTROL INFO. Downloading this solution guidebook will certainly assist you to repair your issue in the most affordable method. Ford Repair 1990 1991 1992 1993 1994 1995 1996 1997 Solution Guidebook Repair service.

This is a total Solution Fixing Handbook. It includes details as well as detalis you should assist you not just repair your car issues, yet likewise preserve your automobile great operating for future usage. This handbook is additionally a really reliable source of details that will certainly make you, in time recognize a growing number of regarding your automobile as well as the best ways to stop future troubles from occurring. Ford Fusion First generation (2006,2007,2008,2009,2010,2011,2012) Powertrain Engine 2.3 L Duratec 23 I4 3.0 L Duratec 30 V6 Transmission 5-speed Mazda G5M manual (I4) 5-speed Mazda FNR5 automatic (I4) 6-speed Aisin TF-80 automatic in October 2012 under the 2013 design.

Sales in Europe as well as Asia, as Ford Mondeo, are anticipated to start in 2015, in addition to South Africa, where the Combination name will certainly be made use of. Distributions of the Combination Energi started in the United States in February 2013. The whole 2013 Ford Combination line-up was granted with the 2013 Eco-friendly Auto of the Year at the 2012. This Manual Covers Models: 2000, 2001, 2002, 2003, 2004 Covers all versions & all repairs a-z: This a total solution handbook. It covers nearly every detail on your car.

Jan 18, 2009 Hi i am trying to find some where that i can download Haynes manuals for free. Ford Escort/Lynx 1981-1990 Ford Escort/Tracer 1991-1999. Ford Escort Repair Manual Online. Ford Escort repair manuals are available at the click of a mouse! Chilton’s Ford Escort online manuals provide.

All versions, and all engines are consisted of! This guidebook coincides handbook that is provided to your regional service/repair shop. The pdf permit you to focus for to check out Detailed parts and afterwards publish out any type of web pages you need Without Getting oil on any web pages. Covers thoroughly, countless pages all. For easy, thorough watching. Works on all computers – computer & mac. Ford Mustang Cobra 2001-2002-2003 Service Repair Manual I have actually here the primary classifications that can be found in our guidebooks.

You could expect lots of more sub groups in any sort of manual we offer! * engine overhaul as well as reconstructing * brakes * sunroof. * timing belt substitute * problem codes. * electrical wiring diagrams * fixing and also diagnostics. * engine performance * front end procedures and also. Specs * suspension. * transmission details * cooling service.

And abilities. * computer system analysis codes. * firing orders * described specs covered.

* manufacturing facility upkeep schedules and also charts. * serpentine belt routings with layouts * timing belt. Solution procedures. * driving issues. * complete torque requirements. * u-joint and also cv-joint service procedures. * repair treatments * complete electrical wiring diagrams.

* numerous images. And also a lot more Format: pdf. Language: english.

Suitable: win/mac/linux.

• 1•1 Chapter 1 Routine maintenance and servicing Contents Air cleaner element renewal.34 Fuel filter renewal - fuel injection engines. • 1•2 Servicing Specifications Engine Oil filter type.Champion C104 Valve clearances (cold): OHV engines. • Automatic transmission.7.9 litres (13.9 pints) Ford Escort maintenance schedule The maintenance intervals in this manual are provided with the If the vehicle is driven in dusty areas, used to tow a trailer, or driven assumption that you, not the dealer, will be carrying out the work.

• 1•4 Maintenance schedule Every 12 000 miles (20 000 km) or 12 months - whichever comes first Every 250 miles (400 km) or weekly In addition to all the items in the 6000 mile (10 000 km) service, carry out the following: See 'Weekly checks'. • Maintenance - Component location 1•5 Engine and under bonnet component location on 1986 1.4 litre models (air cleaner removed for clarity) 1 Fuse and relay box 2 Windscreen wiper motor 3 Engine oil dipstick 4 Carburettor 5 Fuel pump 6 Battery negative terminal 7 Brake master cylinder reservoir 8 Distributor 9 Ignition coil. • 1•6 Maintenance - Component location Engine and underbonnet components location on 1989 1.3 litre HCS model (air cleaner removed for clarity) 1 Ventilation air inlet duct 2 Battery 3 Bonnet hinge 4 Suspension strut upper mounting 5 Brake system fluid reservoir 6 Ignition system ESC module 7 Windscreen washer reservoir filler cap 8 Transmission housing.

• Maintenance procedures 1•7 Rear underbody view of a 1986 1.4 litre Saloon model 1 Fuel filler pipe 2 Suspension lower arm 3 Tie-bar 4 Tie-bar front mounting 5 Fuel tank 6 Handbrake cable adjuster 7 Exhaust mounting 8 Exhaust intermediate silencer 9 Exhaust rear silencer 10 Rear towing eye another. • 1•8 Maintenance procedures Weekly checks 3 Fluid level checks 4 Tyre checks 5 Battery check See “Weekly checks” starting on Page 0•10.

See “Weekly checks” starting on Page 0•10. See “Weekly checks” starting on Page 0•10. Every 6000 miles or 6 months 3 Remove the oil filler cap from the rocker cover, 9 Use a clean rag to remove all oil, dirt and sludge from the filter sealing area on the. • Models with Weber 2V carburettor pipes. If any damage or deterioration is discovered, do not drive the vehicle until the 13 The procedure is the same as for the Ford necessary repair work has been carried out. VV carburettor as described previously in this Renew any damaged sections of hose or pipe. • 1•10 Every 6000 miles or 6 Months 10.13a Weber 2V carburettor idle speed adjustment screw (A) and 10.13b Weber 2V carburettor mixture adjustment screw (A) and mixture screw (B) - XR3 and 1.4 litre models idle speed adjustment screw (B) - 1.6 litre models Refer to the caution at the beginning of this Hook out the plug with a sharp pointed tool to 24 If the mixture adjustment cannot be.

• 32 Before proceeding ensure that the idle 3 Wipe clean the HT leads and the coil tower. Ford dealer for diagnostic checks and, if speed is correct.

4 Check the condition and security of all necessary, adjustment. • 1•12 Every 6000 miles or 6 Months 13.5a Contact breaker points gap (A) - Bosch distributor 13.5b Contact breaker points gap (A) - Lucas distributor 5 To adjust the points using feeler blades, 7 Refit the rotor arm and the distributor cap. Accordance with manufacturer’s.

• Every 6000 miles or 6 Months 1•13 14.5a Timing mark identification - 14.5b Crankshaft pulley notch (arrowed) 14.7 Distributor clamp pinch-bolt location OHV engines and timing scale - CVH engine (arrowed) - OHV engines A Notch on crankshaft pulley B Timing scale cast into timing cover scale is moulded into the timing belt cover 17 A secondary use of the timing light is to 14 Ignition timing check - models. • 1•14 Every 6000 miles or 6 Months 2 To remove the plugs, first mark the HT leads to ensure correct refitment, then pull them off the plugs. When removing the leads, pull the terminal insulator at the end of the lead - not the lead itself.

• Every 6000 miles or 6 Months 1•15 17.1a Brake shoe viewing hole location (arrowed) in backplate 17.1b Checking rear brake lining wear with a mirror specified intervals by prising out the small 5 Using a large screwdriver or flat bar, check Should any fluid be noticed, the suspension inspection plug from the brake backplate and for wear in the suspension mounting bushes. • 1•16 Every 6000 miles or 6 Months 20 Alternator drivebelt check 1 A conventional vee drivebelt is used to drive both the alternators and water pump pulleys on OHV and HCS engines, and the alternator pulley only on CVH engines, power being transmitted via a pulley on the engine crankshaft.

• Maintenance procedures 1•17 Every 12 000 miles or 12 months 5 The clearances for the inlet and exhaust 21 Valve clearance adjustment - 23 Turbocharger-to-manifold valves are different (see Specifications). Use a feeler blade of the appropriate thickness to OHV and HCS engines nut check - RS Turbo models check each clearance between the end of the valve stem and the rocker arm. • 1•18 Every 12 000 miles or 12 Months 26.1a Transmission oil filler plug (A) and selector shaft locking 26.1b Allen type transmission filler plug (arrowed) as fitted to mechanism cap (B) later models 6 Locate the new contact breaker points on from August 1985 have an E as the last letter 27 Automatic transmission fluid of the part number suffix. • Ford dealer check the transmission velocity joint.

If so, renewal of the driveshaft 1 Check the operation of all instruments and at the earliest opportunity. • 1•20 Every 12 000 miles or 12 Months 13 Check that there is no vibration through Carry out this check in both directions. If a should be a noticeable “give” in the brake clicking noise is heard, this indicates wear in a the steering when braking. • 1.3 litre CVH engine... Locations on 1.4 litre CVH engine clips, where fitted 16 It is recommended that Ford Super Plus Bosch K-Jetronic fuel injection antifreeze is used for filling and topping-up, as models. • 1•22 Every 24 000 miles or 2 Years 34.10a Lift the sensor plate clear...

Withdraw the shut-off valve... Lift out the cover... And withdraw the element - 34.12 Locating the sensor unit gasket K-Jetronic system sensor plate unit into position on the top.

• Every 24 000 miles or 2 Years 1•23 35.4 Crankcase ventilation filter location on KE-Jetronic fuel 36.3 Fuel filter inlet pipe (A), outlet pipe (B) and clamp screw (C) injection engines 3 Ensure that the sealing grommet is in Bosch K-Jetronic and KE-Jetronic 9 Refitting is a reversal of the removal position in the air cleaner before pushing a fuel injection models. • 1•24 Every 36 000 miles or 3 Years 3 Bend the hydraulic flexible hoses sharply 1 The procedure is similar to that for the 4 Work through all the remaining bleed bleeding of the hydraulic system as described screws in the sequence until new fluid can be with the fingers and examine the surface of seen at all of them. • 2A•1 Chapter 2 Part A: OHV and HCS engines Contents Crankcase emission control filter renewal.See Chapter 1 Engine/transmission - removal and separation.11 Crankshaft front oil seal - renewal. • 2A•2 OHV and HCS engines Cylinder bore diameter (continued): 1.1 litre HCS engine: Standard (1)... 68.680 to 68.690 mm Standard (2). • OHV and HCS engines 2A•3 Cylinder head Material.Cast iron Maximum permissible cylinder head distortion measured over entire length. • 2A•4 OHV and HCS engines Inlet valve (continued) Stem diameter: OHV engines: Standard.7.866 to 7.868 mm 0.076 mm oversize.

• 1989 and fitted to certain 1.1 different, being of “mirror” design, where the The crankshaft on 1.1 litre engines is Escort models and all 1.3 Escort models, inlet valves of the centre cylinders are next to supported in three shell type main bearings, including the Van and Combi, replacing the each other. • 2A•6 OHV and HCS engines electronic ignition system which has no moving parts, the result is an economical engine with cleaner exhaust emissions which can run on leaded or unleaded fuel without adjustment to the ignition system. Although most components of the HCS engine have been redesigned, for the most part the servicing and overhaul procedures remain unchanged, unless otherwise stated. • OHV and HCS engines 2A•7 on all except HCS engines with M11 necked- shank (a reduced diameter section between the bolt head and the threaded portion) cylinder head bolts there are four tightening stages. On HCS engines with M11 necked-shank cylinder head bolts there are three tightening stages.

• 2A•8 OHV and HCS engines starter ring gear on the flywheel after removing the clutch cover plate or starter motor (Chapter 5, Part A) for access. 4 Remove the crankshaft pulley.

This should come out using the hands but if it is tight, prise it carefully with two levers placed at opposite sides under the pulley flange. • OHV and HCS engines 2A•9 9.3a Transmission left-hand rear 9.3b Removing transmission left-hand rear 9.3c Right-hand rear engine mounting mounting-to-bracket attachment - mounting - pre-1986 models attachments - pre-1986 models pre-1986 models A Mounting to side member B Mounting to inner wheel arch crossmember at the front and rear and Refitting remove it from under the car. • 2A•10 OHV and HCS engines 11.22 Gearchange rod and stabiliser 11.24 Typical lifting gear connection to 11.26 Engine right-hand mounting disconnection points - washer fitted engine attachment at side member (A) and inner behind stabiliser arrowed wing panel (B) 9 Disconnect the choke cable (where fitted) 18 The vehicle should now be jacked up and 25 Just take. • OHV and HCS engines 2A•11 11.35 A locally made-up lifting eye - 11.41a Radiator lower mounting bolt... And upper locating peg - HCS engine HCS engine 32 Unscrew and remove the bolts from the mild steel bar, approximately 3”.

• 2A•12 OHV and HCS engines 11.57a Right-hand engine mounting 11.57b One bolt (arrowed) is accessible 11.58 Torx headed bolt (arrowed) securing nuts/bolts (arrowed) - HCS engine from within the wheelarch - HCS engine the mounting to the bracket - HCS engine 53 Remove the starter lead support bracket 58 Once removed, undo the Torx headed 64 Remove the nut from the left-hand front. • OHV and HCS engines 2A•13 12.13 Keep the pushrods in strict order 12.28 Removing the timing chain tensioner 12.31 Camshaft thrust plate removal after removal 10 Unbolt the thermostat housing cover and of the crankshaft sprocket. Remove it together with the thermostat (refer 27 Slide the chain tensioner arm from its 12 Engine - complete dismantling to Chapter 3). • 2A•14 OHV and HCS engines 38 Unbolt and remove the big-end bearing caps. If the bearing shell is to be used again, tape the shell to the cap.

39 Now check the top of the cylinder bore for a wear ring. If one can be felt, it should be removed with a scraper before the piston/rod is pushed out of the cylinder. • Ford dealer. 25 Use feeler blades to check the tolerances following way.

Drill the ring gear with two. • (tool No 21-242), leave this 1 With the cylinder head removed (Section 4), work to your Ford dealer.

The carbon deposits should be removed from Cam followers 43 Examine the valve seats. Normally, the. • OHV and HCS engines 2A•17 14.14a View of the swirl chamber in the 14.14b View of the cylinder head with 14.14c Tape the end of the valve stem cylinder head showing the valve seats valves fitted - HCS engine before fitting the valve stem seal - (arrowed) - HCS engine HCS engine A Inlet side. • Apply a suitable against the sprocket (see illustration).

The specified torque. Adhesive (available from Ford dealers) to the 16 Using a new gasket, fit the timing cover, which will already have been fitted with a new 9 Now check the crankshaft endfloat. • OHV and HCS engines 2A•19 15.16 Fitting the timing cover 15.17 Fitting the crankshaft rear oil seal 15.18a Locate the engine adapter plate retainer over the dowels (arrowed)... Bolts to the specified torque (see illustration). The oil hole in the connecting rod is on the left 18 Locate the engine adapter (back) plate on (see illustration 8.13a). • 2A•20 OHV and HCS engines HCS engines Reconnection linkage using the procedure described in Chapter 7, Part A. 2 Reconnection engine 43 The procedure is as described previously 10 Fit the starter motor leads to their transmission is a reversal of separation, but if in this Section for OHV engines, noting the terminals.

• 2B•1 Chapter 2 Part B: CVH engines Contents Camshaft - removal and refitting.6 Engine/transmission - removal and separation. • 2B•2 CVH engines Cylinder bore (diameter) (continued): 1.3 and 1.6 litre: Standard (1)...

79.94 to 79.95 mm Standard (2). • CVH engines 2B•3 Pistons and piston rings (continued) Diameter - 1.3 and 1.6 litre: Standard 1.79.910 to 79.920 mm Standard 2. • 2B•4 CVH engines Valve timing (1.1 litre and 1.3 litre) (continued): Exhaust valve opens.30°. • CVH engines 2B•5 Lubrication (continued) Relief valve opens..

4.0 bar (58 lbf/in Oil pump clearances (rotor type pump only): Outer rotor to body. • 2B•6 CVH engines 1.1a Cutaway view of the CVH engine 2 Major operations possible with the engine in the car The following work can be carried out without having to remove the engine: a) Timing belt - renewal. B) Camshaft oil seal - renewal. C) Camshaft - removal and refitting.

• Note: Accurate adjustment of the timing belt positions on all three sprockets. Through another complete turn and realign the entails the use of Ford special tools. An pulley notch with the TDC mark.

On EFI 9 Slip the timing belt off the camshaft, water. • On models with a two-piece approximate setting only and should be 8 Reconnect the battery. Timing belt cover, place the lower half in rechecked by a Ford dealer at the earliest position before refitting the pulley.

Crankshaft front oil seal. • CVH engines 2B•9 6.12 Removing the camshaft sprocket 6.13a Unscrew the camshaft thrust plate 6.13b... And withdraw the thrust plate bolts... Choke cable ends from the carburettor 13 Extract the two bolts and pull out the When in position tighten the cover retaining linkage, then undo the bolts and move the camshaft thrustplate (see illustrations). • 2B•10 CVH engines 7.5 Disconnect the choke cable from the 7.6 Disconnect the fuel feed pipe at the 7.7 Disconnect the brake servo vacuum linkage clamp (arrowed) - carburettor pump - carburettor engine hose (arrowed) - 1.4 litre carburettor engine engine 5 Disconnect the throttle and where fitted the 11 Unbolt the exhaust downpipe from the. • CVH engines 2B•11 7.22 The upper surface of the cylinder 7.23a Cylinder head bolt tightening 7.23b Tightening the cylinder head bolts head gasket is marked OBEN-TOP sequence (arrowed) (Stage 3) through 90° (quarter turn) followed 37 Disconnect the wiring multi plugs at the wiring to facilitate cylinder head removal, with by a further 90°.

• 2B•12 CVH engines 7.49 Wiring connections and hose attachments on the fuel- injection system - RS Turbo A Inlet air duct F Mounting bracket B Vacuum hose G Throttle position sensor multi- 7.46 Air inlet duct connecting hose clip (A) charge air temperature plug C Crankcase ventilation valve hose sensor multi-plug (B) and throttle position sensor multi-plug (C) on. • CVH engines 2B•13 8.9a Fitting the sump sealing strips... Followed by the side gaskets with 8.9c Apply sealer to the areas shown their ends overlapped when fitting a one piece sump gasket A Oil pump housing-to-block joint B Rear oil seal carrier-to-block joint side gaskets into position using thick grease. • 2B•14 CVH engines 9.11 Fitting the bearing shell in the 9.13a Arrow (A) or cast nipple (B) faces the 9.13b Installing a piston/connecting rod connecting rod timing belt end of the engine when installed assembly refitting. On models produced from February 1987 onwards, place the transmission in second gear on four-speed versions, or fourth gear on five-speed versions. • CVH engines 2B•15 11.12c... Temperature sender...

Oil pressure switch... Reversing lamp switch.. F) Electric choke (where applicable).

686 mm (27.0 in) is recommended between the cable and the downshift linkage. • 2B•16 CVH engines 11.25a Remove the right-hand splash 11.25b... And left-hand splash shield 11.26 Anti-lock Braking System (ABS) pipe shield... (arrowed) bracket retaining bolt location (arrowed) 26 On cars equipped with an Anti-lock their brackets and remove the front mounting bolts and remove the starter. • CVH engines 2B•17 11.66 Air cleaner retaining bolts (arrowed) 11.70 Vacuum and breather hose 11.74 Fuel pipe connections - RS Turbo on RS Turbo models connections - RS Turbo A Fuel injectors B Cold start valve A Crankcase ventilation hose at rocker cover unscrew and remove the four nuts securing B Vacuum hoses at inlet manifold 64 Drain the cooling system (Chapter 1). • 2B•18 CVH engines Move the fuel pipes clear of the engine.

76 Disconnect the wiring multi plugs at the 12 Engine - complete dismantling temperature gauge sender unit, ignition coil, throttle position sensor, solenoid control valve, coolant temperature sensor, thermo- 1 The need for dismantling will have been time switch, cold start valve, oil pressure dictated by wear or noise in most cases. • CVH engines 2B•19 top of the cylinder block, again retaining the bearing shell with the rod if the shell is to be used again. 31 Remove the remaining pistons/rods in a similar way. 32 Remove the main bearing caps, keeping the shells with their respective caps if the shells are to be used again. • Crankcase necessary reamer (Tool No 21-071 to 21-074), and their gaskets (Chapter 4, Part E) also the leave this work to your Ford dealer.

12 Refer to Section 13 in Part A of this Chapter. Thermostat housing (Chapter 3). 30 Examine the valve seats.

Normally the. • CVH engines 2B•21 13.37a Fit the valve spring... And spring retainer 13.38 Compress the spring and fit the collets 39 Repeat the operations on the remaining 2 Where a more thorough job is to be carried paste and examine the seat and bevelled edge valves, making sure that each valve is returned out, the cylinder head should be dismantled. • 2B•22 CVH engines 15.1 Crankcase ventilation baffle 15.2 Inserting a main bearing shell into the 15.3 Locating the crankshaft crankcase thrustwashers on the centre main bearing outwards (see illustration). (see illustration). Provided the thrustwashers 4 Oil the bearing shells and carefully lower at the centre bearing have been renewed, the 15 Engine - reassembly endfloat should be within specified tolerance.

• CVH engines 2B•23 15.12 Priming the oil pump prior to fitting 15.15 Fitting the oil pump pick-up tube 15.16 Fit the timing belt guide with its concave side towards the pump 14 Remove the adhesive tape and tap the spring (where fitted). Lever the tensioner fully pistons are not projecting from the block), fit Woodruff key into its groove. • 2B•24 CVH engines 15.24b... And manifold 15.27a Connecting the crankcase rear 15.27b... And the front hose ventilation hose...

7 On pre-1986 models refit the front mounting and anti-roll bar support plates, then refit the left-hand front and rear mountings loosely only. • Chapters 3, 4, 5 and 12 and to cylinder block. Any notes made during removal.

And refitting 7 Apply Omnifit Activator “Rapid” (to Ford 25 Fill up with engine oil, transmission oil or Specification SSM-998-9000-AA) to the fluid and coolant, then reconnect the battery. • 2B•26 Notes. • 3•1 Chapter 3 Cooling, heating and ventilation systems Contents Antifreeze mixture.See Chapter 1 Heater motor/fan - removal and refitting. • 3•2 Cooling, heating and ventilation systems General description The cooling system is of the pressurised pump-assisted thermo-syphon type. The system consists of the radiator, water pump, thermostat, electric cooling fan, expansion tank and associated hoses.

The system functions as follows. When the coolant is cold the thermostat is shut and coolant flow is restricted to the cylinder block, cylinder head, inlet manifold and the vehicle. • Cooling, heating and ventilation systems 3•3 2.14 Intercooler retaining bolt (A) and 2.20a Release the wiring harness clips... To gain access to the fan shroud upper air hose connection (B) - bolts on 1986 RS Turbo models 1985 RS Turbo that the base of the radiator is held in place by 21 Unhook the shroud from the top of the. • 3•4 Cooling, heating and ventilation systems 3.12 Radiator lower retaining bolts (A) and 3.23 Intercooler upper air hose 3.25 Radiator and intercooler retaining upper lugs (B) - 1986 models onwards attachment - RS Turbo from 1986 onwards bolts - RS Turbo from 1986 onwards (one (except RS Turbo) lower bolt not shown) insulators are in position. • Cooling, heating and ventilation systems 3•5 4.5 Testing the thermostat 4.10 Disconnect the expansion tank hose 4.13a Extract the retaining spring clip at the thermostat housing - CVH engine (arrowed)... 6 Remove the thermostat from the water and Testing and refitting pump and if the unit is leaking, noisy, or in any check that the valve closes as the unit cools.

• 3•6 Cooling, heating and ventilation systems 5.14 Crankshaft pulley notch aligned with 5.17 Timing belt tensioner retaining bolts - TDC (O) mark on timing belt cover scale - CVH engines CVH engines pulley is aligned with TDC (O) mark on the 5.15 Timing belt cover retaining bolts - Refitting timing belt cover scale (see illustration). • Base models and other versions in 5 Disconnect the wiring plug and unscrew the lever assembly in position.

The Escort range. On Base models, a two- switch from its location. 6 Carefully withdraw the control unit with the. • 3•8 Cooling, heating and ventilation systems 11 Heater - removal and refitting Removal 1 Disconnect the battery negative lead. 2 Refer to Chapter 11 and remove the centre console. 3 Working within the engine compartment, disconnect the coolant hoses from the heater pipe stubs at the rear bulkhead (see illustration).

• Weber 2V carburettor - adjustment.13 Ford VV carburettor - removal and refitting.12 Weber 2V carburettor - removal and refitting. • 4A•2 Carburettor fuel system Weber carburettor specification Weber 2V DFTM: Idle speed (cooling fan on).750 to 850 rpm Idle mixture CO content. • Removal dismantled.

2 This is accomplished by drawing in cold air The carburettor may be either a Ford variable 1 Disconnect the battery negative terminal. From an inlet at the front of the car, and hot air venturi (VV) type or one of four versions of the. • 4A•4 Carburettor fuel system 3.4 Thermostatically-controlled air cleaner 3.15 Waxstat type air cleaner components 4.3 CVH engine fuel pump filter operation under high vacuum conditions in air cleaner spout components A Vacuum hose to heat sensor A Wax capsule B Flap valve A Pump cover B Filter B Vacuum diaphragm. • Carburettor fuel system 4A•5 5.9 Removing the fuel pump push-rod 5.10 Fuel pump connections on 1.1 and 6.3 Fuel tank flexible hose connections at 1.3 litre HCS engines front of tank A Inlet from tank 7 To remove the pump, disconnect and plug 7 Lower the tank until the fuel hoses can be B Outlet to carburettor the fuel inlet and outlet hoses (and on HCS.

• 4A•6 Carburettor fuel system 7.11a Prise out the throttle cable retaining 7.11b... Then release the cable retainer clip... (arrowed) 7.8 Throttle cable attachment at pedal end 9 Working under the bonnet, release the 8 Accelerator pedal - removal 7 Throttle cable - adjustment, cable from the bulkhead. • Carburettor fuel system 4A•7 9.9 Choke cable adjustment spacer 9.10 Choke knob pulled out for adjustment 9.11 Choke cable adjustment at dimensions - pre-1986 models with spacer (B) in position - pre-1986 carburettor - pre-1986 models X = 37.0 to 37.5 mm models A Cable clamp bolt Y = 12.0 mm minimum. • (see illustration). 5 Carefully unscrew the three Torx screws which secure the main choke unit to the 10.8 Correct position of choke control spring leg - Ford VV carburettor carburettor and withdraw the choke unit A Correctly located B Incorrectly located.

• Carburettor fuel system 4A•9 10.9 Checking choke operation - Ford VV 10.12a Correct location of choke lever 10.12b Fitting lever housing to choke unit - carburettor housing gasket with tab (A) positioned as Ford VV carburettor shown - Ford VV carburettor. • 4A•10 Carburettor fuel system 12.4 Carburettor disconnection points for removal - Ford VV carburettor 13.4 Weber 2V carburettor choke linkage position for fast idle adjustment - XR3 models A Choke plates held closed B Throttle held partially open 5 Release the choke valve plates and without. • Carburettor fuel system 4A•11 13.11 Weber 2V carburettor fast idle 13.16 Weber 2V carburettor fast idle 13.23 Weber 2V carburettor fast idle adjustment - 1.4 litre models adjustment - 1.6 litre models adjustment screw (arrowed) - 1.1 and 1.3 A Choke plates held open A Fast idle cam litre HCS engine models B Fast idle adjustment screw. • 4A•12 Carburettor fuel system 14.4 Weber 2V carburettor vacuum pull- 14.5 Weber 2V carburettor vacuum pull- 14.7 Weber 2V carburettor choke phasing down check - XR3 models down adjustment - XR3 models check - XR3 models A Diaphragm connecting push-rod A Twist drill A Fast idle cam B Rubber band holding choke plates closed.

• Carburettor fuel system 4A•13 15.5 Weber 2V carburettor choke housing retaining screw locations - XR3 models 22 Place the bi-metal coil housing in position with the coil engaged with the slot in the choke lever which projects through the cut- out in the heat shield. • 4A•14 Carburettor fuel system 15.25 Exploded view of the Weber 2V carburettor automatic 16.3 Weber 2V carburettor disconnection points - XR3 models choke unit - 1.6 litre models A Upper choke operating link D Connecting rod and lever A Anti-run-on valve lead C Throttle cable B Fast idle cam return spring E Pull-down link.

• If crimped type clips are used, cut them off and use screw type clips 17.7a Exploded view of the Ford VV when refitting. Carburettor 17 Disconnect the distributor vacuum pipe and the throttle kicker vacuum pipe on automatic transmission models. • Carburettor overhaul kits are available from and possible overhaul. Chamber and blocking the jets, causing a a Ford dealer, but it is worth checking on the Complete overhaul of a carburettor is seldom weak mixture or power failure within a certain cost of a reconditioned or new unit before required.

• Carburettor fuel system 4A•17 17.7c Exploded view of Weber 2V DFTM carburettor - 1.4 litre models A Manual choke assembly F Mixture adjustment screw L Primary emulsion tube B Vacuum pull-down unit G Accelerator pump assembly M Primary idle jet C Secondary idle jet H Throttle kicker N Needle valve. • 4A•18 17.7d Exploded view of Weber 2V TLD carburettor - 1.6 litre models A Emulsion tubes F Secondary venturi vacuum unit K Throttle kicker (automatic transmission B Air correction jets G Power valve diaphragm models) C Automatic choke assembly H Accelerator pump diaphragm L Needle valve D Vacuum pull-down diaphragm J Mixture adjustment screw. • 4B•1 Chapter 4 Part B: Bosch K-Jetronic and KE-Jetronic mechanical fuel injection systems Contents Accelerator pedal - removal and refitting..5 Fuel pump - removal and refitting. • 4B•2 Bosch K and KE fuel injection systems Turbocharger Type... Garrett AiResearch T3 Maximum boost pressure. • Bosch K and KE fuel injection systems 4B•3 1.5 K-Jetronic system main component locations A Warm-up regulator B Speed sensing module C Fuel accumulator (early model location) D Fuel pump E Throttle housing F Cold start valve G Fuel distributor H Fuel filter The fuel accumulator has two functions, (i) the throttle butterfly. • Other adjustments and system checks are carried out on the car.

System is fitted to Escort RS Turbo models beyond the scope of most readers and should e) The ignition must be switched off when and is a further development of the K-Jetronic be left to a Ford dealer. • Bosch K and KE fuel injection systems 4B•5 2 Air cleaner - removal and refitting K-Jetronic system Removal 1 Remove the air cleaner element as described in Chapter 1. 2 Detach the fuel filter from the side of the cleaner casing (leave the fuel lines attached to the filter) and the air inlet hose from the front end of the case. • 4B•6 Bosch K and KE fuel injection systems 4 The injector fuel delivery pipes can be removed by unscrewing and removing the four banjo bolts at the distributor head. Note the respective pipe connections as they are detached and remove the pipes complete with the plastic hoses and the injector harness. • 6 The main system fuel pressure should be fracture (use a new one each side of the K-Jetronic system checked and if necessary adjusted by a Ford union).

Dealer to ensure satisfactory running of the 12 On completion restart the engine and system. • Refitting position for refitting and then have it pipe from the fuel distributor. Note the sealing accurately adjusted by a Ford dealer on washers on each side of the banjo unions 6 Refitting is a reversal of removal, but ensure completion. • Bosch K and KE fuel injection systems 4B•9 5 Remove the securing tie and withdraw the Refitting clean.

New O-rings must be used and care regulator from its bracket. Taken not to displace them when fitting.

On 7 Refitting is a reversal of removal, but use completion check for fuel leaks with the Refitting new sealing washers on each side of the banjo. • 4 Refitting is the reversal of removal. Escort RS Turbo models are equipped with from under the car (see illustration).

An exhaust driven turbocharger, which is a 5 Unscrew the unit and remove it from its device designed to increase the engine’s. • Bosch K and KE fuel injection systems 4B•11 20.4 Turbocharger and waste gate components 1 Turbocharger exhaust manifold and waste gate housing 2 Bypass duct 3 Waste gate 4 Waste gate actuator 5 Actuator rod 6 Waste gate lever The temperature of the inlet air is reduced, Lubrication oil for the turbocharger is taken expensive component and servicing or repairs thus increasing its density, by passing it. • 4B•12 Bosch K and KE fuel injection systems 22.3 Intercooler upper air hose attachment (arrowed) 22.7 Intercooler mountings and attachments - 1986 models onwards A Retaining bolts B Upper air hose 22 Intercooler - removal and refitting 23 Turbocharger- removal and refitting 1985 models Note: New gaskets and new tabwashers must. • 4C•1 Chapter 4 Part C: Central (single-point) Fuel Injection (CFI) system Contents Accelerator pedal - removal and refitting..5 Fuel system - depressurising. • 4C•2 Central (single-point) fuel injection system 1.2 Exploded view of the Central Fuel Injection (CFI) unit - 1.4 CFI engine 1 Fuel injector assembly 2 Fuel pressure regulator components 3 Fuel inlet connector 4 Air charge temperature (ACT) sensor 5 Throttle valve control motor 6 Throttle position sensor (TPS) 7 Fuel injector wiring The CFI unit, resembling a carburettor.

• Central (single-point) fuel injection system 4C•3 Precautions prevent it from turning while the inlet pipe union is loosened. Allow all pressure/fuel Note: Following disconnection of the battery, seepage to dissipate before fully unscrewing all Keep Alive Memory (KAM) values will be the union if it is to be disconnected, or erased from the EEC IV system module tightened if another part of the system is to be. • 1C171A or equivalent).

3 Examine all components and renew any 9 On completion, the fuel system pressure 10 Ensure that the locating peg on the defective items as necessary should be checked by a Ford dealer at the injector correctly positioned (see earliest opportunity. • 3 Unclip the wiring and disconnect the sensor 8 On completion, the idle speed should be illustration). Wiring plug (see illustration). Checked by a Ford dealer at the earliest 2 Disconnect the battery negative lead. 4 Remove the sensor heat shield, then opportunity.

• 4C•6 Central (single-point) fuel injection system Refitting 6 Refitting is a reversal of removal, but before refitting the spare wheel, ensure that the switch is reset by pushing down the button on the top of the switch, and on completion start the engine and check that the switch operates correctly. • 4D•1 Chapter 4 Part D: Electronic Fuel Injection (EFI) system Contents Accelerator pedal - removal and refitting..5 Fuel system - depressurising.6 Air Charge Temperature (ACT) sensor - removal and refitting. • 4D•2 Electronic fuel injection system The fuel pump is electric, and its electrical 1 General information and supply is provided via a relay controlled by the 3 Fuel tank - removal and refitting precautions EEC IV module.

When the ignition is switched on, the fuel pump is given a lead-in time of approximately one second in order to build up The procedure is as described in Part A of. • Electronic fuel injection system 4D•3 6 Disconnect the fuel supply hose from the fuel rail, and disconnect the fuel return hose and the vacuum hose from the pressure regulator. 7 Unscrew the two fuel rail securing bolts, and remove the fuel rail, complete with injectors. • 4D•4 Electronic fuel injection system 12.2 Idle speed control valve - 12.7 Using a screwdriver to move the idle 14.1 Air charge temperature sensor - 1.6 EFI engine speed control valve piston - 1.6 EFI engine 1.6 EFI engine A Wiring plug B Securing bolts Refitting A Wiring plug. • 4E•1 Chapter 4 Part E: Manifolds, exhaust and emission control systems Contents Crankcase emission control system components - removal and Exhaust system - renewal...4 refitting. • The components Crankcase emission control routing is still as just described, but in addition and system operation for Escort models the gases are drawn through a filter and pass operating in the United Kingdom are as follows.

• Manifolds, exhaust and emission control systems 4E•3 1.15d Emission control system layout for automatic transmission models with Ford VV carburettor 1.15c Emission control system layout for manual transmission A Fuel trap F Check valve models with Weber 2V carburettor G Restrictor. • 4E•4 Manifolds, exhaust and emission control systems 13 Make a note of the vacuum hose, 33 From beneath the manifold disconnect Refitting crankcase ventilation hose and wiring multi- the thermo-time switch and temperature 46 Commence refitting by cleaning all traces plug locations as applicable and disconnect sensor wiring multi-plugs after noting their of old gasket from the mating faces of the. • Manifolds, exhaust and emission control systems 4E•5 2 It is recommended when working on an exhaust system that the complete assembly be removed from under the vehicle by releasing the downpipe from the manifold and unhooking the flexible suspension hangers (see illustrations). • 4E•6 Manifolds, exhaust and emission control systems 6.10 Fuel shut-off valve hose (D) and 6.15a Unscrewing the plenum chamber 6.15b Correct setting of plenum chamber plenum chamber connector (C) on Mk 1 plug - fuel-injection models angled connector - fuel-injection models type crankcase ventilation system - Cars with earliest type (Mk 1) Cars with Mk 2 crankcase ventilation. • Manifolds, exhaust and emission control systems 4E•7 6 Reconnect water hoses 7 Exhaust emission control necessary top-up the cooling system. System components - removal Fuel trap and refitting Removal 7 Disconnect the vacuum lines and remove Carburettor engines the fuel trap from the engine.

Refitting Spark delay/sustain valve 8 When refitting, make sure that the fuel trap. • 4E•8 Notes. • 5A•1 Chapter 5 Part A: Starting and charging systems Contents Alternator - removal and refitting.5 Electrical fault finding - general information. • 3 If the specific gravity variation is 0.040 or and transistors), and to avoid the risk of 12.2 volts) have it recharged by your Ford more, the battery should be renewed. If the personal injury. In addition to the precautions dealer or local automotive electrician as the given in “Safety First!”. • Starting and charging systems 5A•3 5.4 Alternator mounting and adjuster link 5.6a Correct fitting of alternator mounting 5.6b Alternator mounting bolt bolts components - early models arrangement - later models A Adjuster link-to-alternator bolt A Large washer B Adjuster link-to-engine bolt B Small washer (pre-1985 CVH engines only) C and D Alternator mounting bolts C Mounting bracket.

• 5A•4 Starting and charging systems 6.6a Exploded view of the Lucas A115 and A133 alternator A Pulley B Fan C Drive end housing D Drive end bearing E Rotor F Slip ring G Slip ring end bearing H Rear cover J Anti-surge diode K Diode plate L Voltage regulator. • Starting and charging systems 5A•5 6.12 Exploded view of the Motorola alternator A Pulley B Fan C Drive end bearing D Drive end bearing retaining plate E Slip ring F Slip ring end bearing G Stator H Slip ring end housing J Rectifier assembly K End cover L Regulator.

• 7 Starter motor - testing in the sound, the fault must lie in the starter motor. The starter motor can be checked by a Ford dealer or an automotive electrical specialist. A specialist may be able to overhaul the unit at a. • 5B•1 Chapter 5 Part B: Ignition systems Contents Condenser (contact breaker ignition system) - testing, removal General description and precautions.1 and refitting. • 5B•2 Ignition systems Ignition coil - contact breaker ignition system Type... Low voltage for use with 1.5 ohm ballast resistance Output: OHV engines.

• Ford and the high tension voltage is created. At conventional systems, and dealer.

• For this reason any suspected tension circuit. For these tests it is sufficient to separate the faults in the system must be referred to a Ford 3 If the engine becomes very difficult to start, points with a piece of dry paper while testing dealer. • Ignition systems 5B•5 3.7 Distributor turned through 120° for 3.13 Bosch distributor condenser renewal 3.14 Lucas distributor condenser renewal condenser renewal - Bosch distributor, - CVH engines - CVH engines OHV engines A Condenser retaining screw A Condenser retaining screw A LT lead connector B LT lead connector B Contact breaker spring arm.

• Removal should be entrusted to a Ford dealer. 8 Withdraw the distributor from the cylinder 1 Disconnect the leads from the spark plugs, block.

As the distributor is removed, the rotor. • Ignition systems 5B•7 5.19 Align distributor shaft drive dog with 5.21 Distributor mounting flange and 5.25 Disconnecting the distributor LT slots in camshaft - CVH engines (contact cylinder head punch mark locations - CVH wiring multi-plug - CVH engines (electronic breaker system) engines (contact breaker system) breakerless system) • Ford applicable. 52 Disconnect the distributor wiring plug. Parts dealers and it will therefore also be. • 59 Reconnect the battery negative lead.

Electronic Spark Control (ESC II) taken to avoid personal injury. Refer to the 60 Take the vehicle to a Ford dealer at the module “Safety first!” Section at the beginning of earliest opportunity to have the ignition timing this manual before proceeding, and accurately adjusted. • 5B•10 Ignition systems 6.17 Disconnecting the vacuum hose from 6.18 Unscrewing the ESC module wiring 6.19 ESC module securing screws the ESC module plug securing screw (arrowed) 22 When refitting the fuel trap, the side 32 Remove the two securing screws and marked “DIST”. • 9•1 Chapter 9 Braking system Contents Anti-lock Braking System - description..19 Hydraulic system - bleeding (anti-lock braking system).23 Brake components check.

• (see illustration). In doubt about their condition, and use only 3 Using a screwdriver, prise free the retaining genuine Ford replacement parts, or at least clip from the caliper (see illustration). Download Epson L210 Scan Driver.

Those of known good quality. Note the 4 Using a 7 mm Allen key, unscrew the bolts warnings given in “Safety first”.

• Braking system 9•3 2.5 Withdraw the caliper piston housing 2.6 Removing the inboard pad from the 2.7... And the outboard pad from the piston housing... Anchor bracket with a length of wire to prevent strain on the Take care not to drip hydraulic fluid onto the from the surface of the new outboard pad and flexible hose (see illustration). • 9•4 Braking system 4 Apply air pressure to the fluid inlet hole and cracks are evident, it must either be refinished 3 Front brake caliper - removal, eject the piston (see illustration). Only low air or renewed. Any refinishing must not reduce overhaul and refitting pressure is needed for this, such as is the thickness of the disc to below a certain.

• Braking system 9•5 5.3a Remove the rear hub dust cap... Extract the split pin and nut 5.3c... Then unscrew the hub nut... And remove the thrustwasher 5.4 Remove the hub outer bearing. • 9•6 Braking system 5.8a Exploded view of the rear brake assembly as fitted to early models A Dust excluder B Piston C Seal D Spring E Cylinder body F Seal G Piston H Dust excluder I Gasket J Spring washer K Mounting bolt L Adjuster strut M Return spring.

• Braking system 9•7 5.10 Removing the handbrake cable from 5.11 Separating the trailing brake shoe 5.30 Removing the drum retaining screw the trailing brake shoe from the adjuster strut on models with a separate brake drum A Handbrake cable C Trailing shoe Fuel-injection engine models and to the warning at the beginning of Section 3 B Lever. • (arrowed) follows.

A Dust cap E Piston reconnect the fluid line and refit the shoes 7 Two cable types are used on Escort models B Bleed screw F Piston seal (Section 5). According to year of manufacture and it is.

• Braking system 9•9 locking pin is used to lock the adjusting nut in 9.3a Handbrake cable layout position (see illustration). If so remove the locking pin using pliers. Note that a new pin will be needed after adjustment. 15 Slacken the adjusting nut then apply the footbrake hard several times to ensure full self-adjustment of the brake shoes. • 9•10 Braking system and rear diagonally opposite).

If the master cylinder or the pressure regulating valve have been disconnected and reconnected, then the complete system must be bled. 2 When bleeding the brake hydraulic system on a Van, tie the light laden valve actuating lever to the right-hand rear roadspring so that it is in the fully open position (see illustration). • Braking system 9•11 12 Master cylinder - removal, overhaul and refitting Note: Before starting work, refer to the warning at the beginning of Section 3 concerning the dangers of hydraulic fluid. Removal 1 Disconnect the leads from the level warning switch in the reservoir cap. • 9•12 Braking system 23 Locate the two rubber seals and push the 12.14 Master cylinder primary piston components fluid reservoir into position. 24 It is recommended that a small quantity of fluid is now poured into the reservoir and the pushrod operated several times to prime the unit. • Braking system 9•13 14 Light laden valve (Van 14.1 Light laden valve components - Van models models) - adjustment, removal A Valve body G Control spring and refitting B Fluid outlet H Adjuster rod C Fluid inlet I Spacer tube 1 The light laden valve used on Van models is D Actuating lever J Link rod.

• 9•14 Braking system 15.8 Brake pipe flare 16.2 Heater plenum chamber removal 16.8a Vacuum servo unit connecting A Protective coating removed before flaring linkage A Grommet C Bush 6 If you are making up a brake pipe yourself, 7 Remove the servo from the vehicle. It must B Connecting link observe the following essential requirements.

• This causes the flywheel to 2 Some versions have front disc pad wear equipment on certain Escort models. Slide on the modulator shaft, move inward and sensors and a handbrake “ON” warning switch. • 9•16 Braking system 20.2 Removing the belt break switch from 20.3a Modulator and drivebelt details 20.3b Drivebelt cover retaining nuts the modulator drivebelt cover (arrowed) - models up to 1987 A Modulator E Driveshaft B Sprocket F Drivebelt cover angle of more than 45° from the outer C Drivebelt 20 Modulator drivebelt (anti- constant velocity joint. • Braking system 9•17 20.18 Using a ruler to check right-hand 20.26 Left-hand drivebelt cover retaining 21.3 Modulator fluid return pipes at master drivebelt adjustment bolt locations (arrowed) cylinder reservoir A To right-hand modulator 20 Refit the drivebelt cover and secure with right-hand modulator fluid return pipe at the B To left-hand modulator the two nuts and washers, and the bolt (where. • 9•18 Braking system 30 Undo the three bolts, two at the top and 43 Refit the belt break switch as described in paragraph 20.

One at the bottom securing the drivebelt cover 44 Refit the engine splash shield. To the modulator bracket. Remove the cover. 45 Refit the roadwheel and lower the car to 31 Disconnect the two hydraulic pipes and the ground. • Braking system 9•19 22.8 Separating apportioning valve 23.5 Modulator bypass valve (A) location 23.6 Modulator auto bleed plunger pushrod from adjusting bracket location (arrowed) 8 If required separate the valve pushrod from 19 It recommended that load Bleed procedure A the adjusting bracket by levering off the apportioning valve adjustment be checked by 4 Top-up the master cylinder reservoir to the.

• 9•20 Notes. • Hub bearing grease.To Ford specification SAM-1C-9111A Steering Type. • 10•2 Suspension and steering Front wheel alignment Toe setting: Pre-May 1983 models: Checking tolerance.1.5 mm toe-in to 5.5 mm toe-out Adjust to. • Suspension and steering 10•3 1.1 Exploded view of the front suspension components A Suspension strut B Top mounting (pre-May 1983 models) C Top mounting (post-May 1983 models) D Hub carrier E Front hub F Balljoint assembly G Pressed steel lower arm H Tie-bar J Anti-roll bar K Forged lower arm.

• 10•4 Suspension and steering bolted to the stub axle carriers at their lower ends which also carry the rear brake backplate as well as the rear hub/drum assemblies. Fore and aft location of the lower arms is by a tie-bar and an anti-roll bar is also fitted to models with fuel-injection (see illustration). • Ford special tool 14-022 or a suitable bolt. Note that the pinch-bolt is of the socket- 4 Front suspension lower arm alternative (see illustration). • Bushes of different 5.3a Anti-roll bar front mounting clamp 7 Refitting the tie-bar is a reversal of removal. Material have been introduced on Escort details - pre-1986 models Finally tighten all nuts and bolts to the models during the course of production and it. • Suspension and steering 10•7 6.12 Front tie-bar mountings - 1985 RS Turbo models A Retaining nut B Anti-roll bar clamp C Adjustment clamp D Front mounting bolt E Basic setting length = 565 ± 1.5 mm (22.24 ± 0.6 in) 7.3 Brake hose and grommet location in strut (A) and strut-to-hub carrier pinch-bolt (B) Overhaul.

• 10•8 Suspension and steering A fractional amount of wheel movement must be present. 10 Repeat the operations on the opposite hub, refit the roadwheels and lower the vehicle to the floor. 9 Rear hub bearings - renewal 1 Raise and support the rear of the vehicle on 7.9 Coil spring retained with spring stands (see “Jacking and Vehicle Support”). • Suspension and steering 10•9 10.3 Rear shock absorber top mounting 10.4 Removing the shock absorber top 10.6 Brake hydraulic hose-to-shock mounting nut - Saloon and Estate models absorber attachment (arrowed) - Saloon and Estate models 17 On fuel-injected models and Van versions 7 Undo the two bolts securing the shock 3 Unbolt the top mounting bracket from the refit the brake drum and secure with the. • 10•10 Suspension and steering 12.4 Tie-bar-to-stub axle carrier retaining 13.3 Anti-roll bar-to-lower arm shackle 13.4 Lower arm inboard pivot nuts and nut (arrowed) - Saloon and Estate models attachment (arrowed) bolts (arrowed) - Saloon and Estate models 4 Unscrew the nut from the rear end of the removal. • Suspension and steering 10•11 Refitting 16 Rear stub axle carrier 9 Refitting is the reverse sequence to removal (Saloon and Estate models) - bearing in mind the following: removal and refitting a) Adjust the hub bearings as described in Section 8. B) Tighten the U-bolt nuts to the specified Removal torque with the weight of the vehicle on.

• Ford dealer for accurate or calipers. This is important since if the 17 If applicable, add the correct quantity of checking on optical alignment equipment. • 1 According to model, either pull off the steering wheel trim, prise out the insert which carries the Ford motif at the centre, or carefully prise up and lift off the horn push followed by the contact plate (see illustrations). • 10•14 Suspension and steering 25.6a Removing the steering column 25.6b...

And lower shrouds on a pre-1986 25.6c... And on a post-1986 version upper... 4 Remove the steering wheel, as described in 3 Unscrew the bonnet release lever mounting 9 Refit the bonnet release lever and the screw and position the lever to one side. • 26 Reconnect the bonnet release lever.

That its chamfered edge will mate with the but this task should be entrusted to a Ford 27 Fit the column shrouds. Corresponding one in the column lower dealer. It is likely to be cheaper to obtain an 28 Check that the steering wheel is correctly bearing seat when the shaft is installed. • 10•16 Suspension and steering 9 Make sure that the steering gear is centred. Do this by turning the pinion shaft to full lock in one direction and then count the number of turns required to rotate it to the opposite lock. Now turn the splined pinion shaft through half the number of turns just counted. • 11•1 Chapter 11 Bodywork and fittings Contents Body exterior fittings - removal and refitting.25 Interior mirror - removal and refitting.28 Interior trim panels - removal and refitting.

• 11•2 Bodywork and fittings repairs and renovations are necessary. Steam mallet with a wooden or plastic head. Whilst doing this, hold a suitable block of wood cleaning is available at many garages and is 4 Minor body damage - repair firmly against the outside of the panel to necessary for removal of the accumulation of absorb the impact from the hammer blows. • Bodywork and fittings 11•3 used, it can be mixed with cellulose thinners filled, then position it in the hole so that its power drill. The damaged part is then welded edges are below the level of the surrounding to form a really thin paste which is ideal for back together by using a hot air gun to heat filling small holes. • 11•4 Bodywork and fittings 6.8 Front bumper attachments - pre-1986 6.13 Front bumper-to-arch screw (A) and 6.1 Bumper overrider details - pre-1986 models retaining nut (B) - 1986 models onwards models 1 Bumper bar 3 Retaining nut 13 From under the wheel arch, undo the A Without headlamp washer 2 Washer single bumper retaining nut on each side (see.

• Bodywork and fittings 11•5 6.22 Rear bumper attachments in luggage 7.2 Disconnecting the windscreen washer 7.8 Bonnet bump stop (arrowed) compartment - 1986 models onwards fluid pipe Models from 1986 onwards except bonnet lid, unbolt the hinges and lift the lid 2 Extract the single screw and remove the from the vehicle. • 11•6 Bodywork and fittings 11.2a Prise out the plastic insert... And unscrew the regulator 11.4 Unscrew the armrest handle remove the door pocket finisher. 1986 models onwards 11 Door trim panel - removal and 4 Remove the door pull/armrest. • Bodywork and fittings 11•7 11.10a Undo the remote control handle 11.10b... And remove the bezel 11.11a Release the trim cap and undo the bezel retaining screw...

Followed by the side screws 12.7a Front door lower hinge nuts 12.7b Door hinge assemblies - pre-1986 (arrowed) • 11•8 Bodywork and fittings 13.2 Peel back the waterproof sheet for 13.3 Door exterior handle retaining screws 13.7 Remote control handle retaining access to the door handle (arrowed) screw (arrowed) 14 Unbolt the hinges from the door and Refitting is to be renewed, the later type of lock must remove the door from the vehicle. • Bodywork and fittings 11•9 27 Where applicable, fit the central locking solenoid to the new lock, then fit the threaded plate in the door, and fit the lock. Tighten the securing screws finger-tight only at this stage. 28 Reconnect the control rods to the lock. 29 If a later type lock is being fitted to a model which was previously fitted with an early type lock, a revised lock striker plate. • 11•10 Bodywork and fittings 39 Lower the glass so that the channel and regulator attachments are accessible through the door aperture.

Detach the ball and socket joints (two for the front door, one for the rear door). 40 Lower the glass to the base of the door, then undo the seven screws, or drill out the seven rivets on later models, which secure the regulator in position. • Bodywork and fittings 11•11 14.48 Electric window regulator 14.51 Twist the motor clockwise to clear 14.53 Withdrawing the window motor and mechanism the door aperture regulator from the door A Regulator mounting screws whole assembly in a clockwise direction and Cabriolet models B Motor mounting screws guide it out of the cut-out (see illustration). • 11•12 Bodywork and fittings 14.80 Rear quarter window adjustments - Cabriolet models 15.2 Electrical connections at the tailgate (1986 model shown) A Wiper motor C Feed and relay connectors B Radio aerial connection D Earthing point 69 The remainder of the refitting procedure is 79 To remove the regulator, extract the six 6 From the top edge of the tailgate aperture, a reversal of removal. • Bodywork and fittings 11•13 5 The hinge assemblies can be removed from the lid by prising off the plastic covers and undoing the bolts securing the hinges to the lid.

One is accessible from outside and one from inside. Refitting 6 Refitting is a reversal of removal, but do not fully tighten the bolts until the lid has been lined up and closed properly.

• With remote control Removal 4 Two types of remote control mirror are used on Escort models. On the original version, a special wrench is needed to unscrew the mirror actuator bezel, although a C-spanner may serve as a substitute. Once the bezel is removed the mirror is removed as for the non- remote control type. • Bodywork and fittings 11•15 19.6a Extract the trim cover and undo the 19.6b... Then remove the trim panel 19.7 Removing the door mirror retaining screw... Screws 6 Extract the trim cover, undo the screw and and the screen is fully fitted. • 11•16 Bodywork and fittings 21 Sunroof components - removal, refitting and adjustment Sunroof panel Removal 1 To remove this type of glass panel, pull the sun blind into the open position and have the sliding roof closed.

2 Wind the sliding roof handle in an anti- clockwise direction for one complete turn. • Bodywork and fittings 11•17 23.6 Fluid level sight glass for power- 23.7 Filling the power-operated folding 23.9 Bypass valve (arrowed) on side of operated folding roof roof fluid pump reservoir power-operated folding roof fluid pump 6 Check that the fluid in the reservoir on the jerking, and the level of noise from the pump apply locking compound to them, then fit the end of the pump is between the “MIN”. • 11•18 Bodywork and fittings 24.22 Routing of power-operated folding 25.2a Front spoiler attachments - 25.2b Front wheel arch extension roof hydraulic hoses XR3 models attachments - RS Turbo models A Retaining screws B Retaining pegs A and B Rivets D Screw cap C Screws Refitting 20 Refitting is a reversal of removal. • Bodywork and fittings 11•19 Refitting Refitting 5 If a new windscreen is being installed, peel off the protective layer from the black patch, 8 Refitting is a reversal of removal, but ensure 26 Refitting is a reversal of removal, but which is pre-coated with adhesive. • 11•20 Bodywork and fittings 30.3b Centre console fixings 32.4 Rear quarter trim panel securing clip 32.7 Removing a sill scuff plate securing locations screw Cowl side trim panel 17 On three-door models, the rear quarter 31 Glove compartment - window will first have to be removed before Removal removal and refitting the pillar trim panel can be withdrawn. • Bodywork and fittings 11•21 32.25 Releasing a tailgate moulded cover fastener Rear wheelhouse covers 26 These are fitted to certain Base and L models and are of moulded type. On Ghia versions the covers are cloth covered while on 5-door versions, the covers have an upper finisher held by two screws.

• 11•22 Bodywork and fittings 19 Where applicable, refer to Chapter 12 and remove the warning indicator control unit of the auxiliary warning system and where fitted, the fuel computer. 20 Remove the choke cable, where fitted, as described in Chapter 4. 21 Remove the heater control knobs. • 12•1 Chapter 12 Electrical system Contents Aerial - removal and refitting.23 Heated rear window aerial amplifier - removal and refitting. • 12•2 Electrical system Torque wrench settings lbf ft Horn to body.25 to 35 18 to 26 Windscreen wiper arm to pivot mounting. • Electrical system 12•3 in operation), motors (eg wiper motors or the 3.2a Fuse and relay box showing plastic cover removal (2), fuse removal (3) and radiator cooling fan motor) may run slowly, relays (4).

Check if fuse has blown at point indicated in inset and the operation of one circuit may have an apparently-unrelated effect on another. • 12•4 Electrical system 4.9 Steering column multi-function switch 4.18 Courtesy lamp switch removal from 4.27 Removing the heater blower motor removal pre-1986 models door pillar switch - pre-1986 models A Switch retaining screws Reversing lamp switch Loudspeaker balance control joystick 9 Undo switch retaining. • Electrical system 12•5 4.41a Unscrewing the steering column 4.41b... And lower retaining screws 4.47 Heater control panel retaining screw shroud upper...

Locations - 1986 models onwards 42 Undo the retaining screws and remove 50 Disconnect the switch wiring multi-plug. Moistened with methylated spirit. • 12•6 Electrical system 5.16 Front auxiliary lamp lens retaining 5.17 Disconnecting auxiliary lamp earth 5.18 Removing the auxiliary lamp screw lead bulbholder Front auxiliary lamp and foglamp Rear lamps - Estate 6 Bulbs (interior lamps) - renewal 16 Undo the retaining screw at the bottom of 27 Open the tailgate and release the side trim the lens and withdraw the lens assembly (see panel by turning the four screws a quarter of a. • Electrical system 12•7 6.11 Removing the load space lamp 7.3a Releasing the headlamp side plastic 7.3b Headlamp upper plastic retaining clip retaining clip head head (arrowed) 12 Remove the bulb from its spring contact clip. 1986 models onwards 33 Refitting is a reversal of removal.

13 Fit the new bulb using a reversal of the Note: With the exception of the bulbs listed in removal procedure. • 13 Remove the lamp retaining screws or nuts 9 Undo the four screws securing the panel to work should be entrusted to a Ford dealer. As applicable, and remove the lamp.

The facia (see illustrations). • Electrical system 12•9 10.2 Instrument panel bulb renewal 10.11a Instrument panel assembly 10.11b Instrument panel assembly upper retaining screws-pre-1986 models retaining screws - 1986 models onwards instrument panel. It may be necessary to feed 6 Remove all illumination and warning lamp 11 Cigar lighter - removal and the speedometer cable slack through the bulbholders. • 12•10 Electrical system 3 Undo the nuts and remove the clock. 3 Withdraw the computer module from the 12 Undo the two retaining screws and facia to the right of the instrument panel. Remove the fuel flow sensor. Refitting 4 Disconnect the wiring multi-plug and Refitting 4 Refitting is a reversal of removal.

• Electrical system 12•11 Refitting 2 Depress the small clip on the blade and slide the blade out of the hooked part of the 3 Refit in reverse order of removal, checking arm (see illustration). That the grommet is correctly seated. On 3 Before removing the wiper arms it is completion, check that the switch is worthwhile marking their parked position on. • 12•12 Electrical system 4 Release the earth lead and unscrew the 10 The pump and fluid level sensor unit can 23 Adjustment of the jet spray pattern can be two, or on later models, three wiper motor done using a pin in the jet nozzle. Be eased away from their location apertures in mounting bolts (see illustration).

• (see Chapter 11). 38 Adjustment of the jets entails the use of special tool 32-004. If the tool is not available, have this work carried out by a Ford dealer.

21 Radio/cassette player and graphic equaliser - removal and refitting 21.11 Later type radio retaining tang. • 12•14 Electrical system 22.7 Cowl mounted loudspeaker retaining 22.10 Cowl mounted loudspeaker panel 22.11 Cowl mounted loudspeaker retaining screw locations - pre-1986 models retainer removal - 1986 models onwards screw locations - 1986 models onwards 10 Insert a screwdriver into the captive 20 On all models undo the four speaker Refitting plastic retainers and turn 90°. • Electrical system 12•15 23.9 Manually operated aerial location on 23.14 Power operated aerial attachments - 23.18 Power operated aerial location on Cabriolet models all models except Cabriolet Cabriolet models A Grommet 8 Release the tabs and remove the trim B Lower bracket screw 24 Heated rear window aerial panel. • WD•0 Internal connection details, all models. • WD•1 Internal connection details, all models continued. • Key to wiring diagrams. • Diagram 5: 1986-on in car entertainment.

• Diagram 1: 1980-86 Starting, charging, and ignition (except fuel injection models) • Diagram 1a: 1986-on Starting, charging, and ignition (except fuel injection) all models. • Diagram 2: 1980-86 Lighting all models. • Diagram 2a: 1986-on Lighting all models.

• Diagram 3: 1980-86 Ancilliary circuits all models. • Diagram 3a: 1986-on Ancilliary circuits all models. • Diagram 4: 1983-on K-Jetronic fuel injection For starting and charging circuits see Diagram 1.

• Diagram 4a: 1984-86 KE-Jetronic fuel injection For starting and charging circuits see Diagram 1. • Diagram 4b: 1986-on KE-Jetronic fuel injection For starting and charging circuits see Diagram 1a. • Reference REF•1 Dimensions and Weights.REF•1 Tools and Working Facilities.REF•6 Conversion factors. • Conversion factors REF•2 Length (distance) Inches (in) x 25.4 = Millimetres (mm) x 0.0394 = Inches (in) Feet (ft) x 0.305 = Metres (m) x 3.281 = Feet (ft) Miles x 1.609 = Kilometres (km) x 0.621 = Miles Volume (capacity) Cubic inches (cu in. • Buying Spare Parts REF•3 Spare parts are available from many sources, and greases, brake pads, touch-up paint, etc). Frequently offer competitive prices when including maker’s appointed garages, accessory Components of this nature sold by a compared with a main dealer or local garage, shops, and motor factors. • General Repair Procedures REF•4 Whenever servicing, repair or overhaul work unshouldered, the seal should be fitted with effectiveness after long periods of use, and is carried out on the car or its components, it its face flush with the housing top face (unless should be renewed as a matter of course.

• Jacking and Vehicle Support REF•5 may be jacked up under the rear spring seat, The jack supplied in the vehicle tool kit To raise the rear of a Van, place the jack should only be used for emergency roadside under the centre of the axle tube, taking care or the Van under the leaf spring-to-axle tube wheel changing unless it is supplemented not to contact the brake pressure regulating. • Tools and Working Facilities REF•6 Introduction Maintenance Repair and overhaul tool kit and minor repair tool kit A selection of good tools is a fundamental These tools are virtually essential for requirement for anyone contemplating the The tools given in this list should be anyone undertaking any major repairs to a maintenance and repair of a motor vehicle. • Tools and Working Facilities REF•7 Special tools Buying tools Working facilities Not to be forgotten when discussing tools The tools in this list are those which are not Reputable motor accessory shops and is the workshop itself. If anything more than used regularly, are expensive to buy, or which superstores often offer excellent quality tools routine maintenance is to be carried out, a. • MOT Test Checks REF•8 This is a guide to getting your vehicle through the MOT test. Obviously it will not be possible to examine the vehicle to the same standard as the professional MOT tester.

However, working through the following checks will enable you to identify any problem areas before submitting the vehicle for the test. • MOT Test Checks REF•9 Electrical equipment Inspect both front brake flexible hoses for cracks or deterioration of the rubber. Turn the Switch on the ignition and check the steering from lock to lock, and ensure that the operation of the horn. Hoses do not contact the wheel, tyre, or any Check the windscreen washers and wipers, part of the steering or suspension mechanism.

• MOT Test Checks REF•10 Exhaust system Front and rear suspension and The same general checks apply to vehicles wheel bearings fitted with other suspension types, such as Start the engine. With your assistant torsion bars, hydraulic displacer units, etc. Holding a rag over the tailpipe, check the Starting at the front right-hand side, grasp Ensure that all mountings and attachments are entire system for leaks. • MOT Test Checks REF•11 the engine speed to return to idle, and watch for smoke emissions from the exhaust tailpipe. If the idle speed is obviously much too high, or if dense blue or clearly-visible black smoke comes from the tailpipe for more than 5 seconds, the vehicle will fail. • Fault Finding REF•12 Engine Automatic transmission Fluid leakage Engine fails to rotate when attempting to start Transmission fluid brown or has burned smell Engine rotates but will not start General gear selection problems Engine difficult to start when cold Transmission will not downshift (kickdown) with accelerator fully Engine difficult to start when hot depressed Starter motor noisy or excessively rough in engagement.

• Fault Finding REF•13 Cure the disease, not the symptom. Substituting a flat battery with a The pages which follow provide an easy reference guide to the more common problems which may occur during the operation of the fully charged one will get you off the hard shoulder, but if the vehicle. • Fault Finding REF•14 1 Engine (continued) Engine hesitates on acceleration Oil pressure relief valve defective (Chapter 2). Oil pick-up strainer clogged (Chapter 2).

Worn, faulty or incorrectly gapped spark plugs (Chapter 1). Vacuum leak at the carburettor/fuel injection unit/throttle body, Engine runs-on after switching off inlet manifold or associated hoses (Chapter 4). • Fault Finding REF•15 3 Fuel and exhaust system Excessive fuel consumption Excessive noise or fumes from exhaust system Air filter element dirty or clogged (Chapter 1). Leaking exhaust system or manifold joints (Chapter 1 and Chapter 4, Carburettor or fuel injection system fault (Chapter 4). Carvin Amp Serial Number Search. • Air in hydraulic system (Chapters 1 and 9).

Hose connections, any faults occurring on the anti-lock braking system Faulty vacuum servo unit (Chapter 9). Should be referred to a Ford dealer for diagnosis. Brake pedal feels spongy when depressed Vehicle pulls to one side under braking Air in hydraulic system (Chapters 1 and 9).

• Fault Finding REF•17 Judder felt through brake pedal or steering wheel Brakes binding when braking Seized brake caliper or wheel cylinder piston(s) (Chapter 9). Excessive run-out or distortion of front discs or rear drums Incorrectly adjusted handbrake mechanism (Chapter 9). (Chapters 1 and 9). • Fault Finding REF•18 10 Electrical system (continued) Lights inoperative Windscreen/tailgate washers inoperative or unsatisfactory in operation Bulb blown (Chapter 12).

Corrosion of bulb or bulbholder contacts (Chapter 12). One or more washer jets inoperative Blown fuse (Chapter 12). Blocked washer jet (Chapter 12). Faulty relay (Chapter 12). • Glossary of Technical Terms REF•19 Asbestos is a health hazard and the dust Brake drum The component of a drum brake created by brake systems should never be that rotates with the wheels.

ABS (Anti-lock brake system) A system, inhaled or ingested. Brake linings The friction material which usually electronically controlled, that senses. • Glossary of Technical Terms REF•20 Catalytic converter A silencer-like device in Endfloat amount lengthwise the exhaust system which converts certain movement between two parts. As applied to a Diagnostic code Code numbers obtained by pollutants in the exhaust gases into less crankshaft, the distance that the crankshaft accessing the diagnostic mode of an engine harmful substances. • Earle on front-engined rear wheel drive vehicles. MacPherson at Ford of England. In its original Proportioning valve A hydraulic control form, a simple lateral link with the anti-roll bar valve which limits the amount of pressure to creates the lower control arm.

• Glossary of Technical Terms REF•22 Rotor In a distributor, the rotating device Sprocket A tooth or projection on the Turbocharger A centrifugal device, driven by inside the cap that connects the centre periphery of a wheel, shaped to engage with a exhaust gases, that pressurises the intake air. • Index REF•23 Note: References throughout this index are in the form - “Chapter number” • “page number” Accelerator pedal - 4A•6, 4B•5, 4C•3, 4D•2 Dents in bodywork - 11•2 Cables - 4A•6, 4B•5, 4C•3, 4D•2, 6•2, 7B•5, Acknowledgements - 0•4 Differential side gear oil seals - 7A•5 9•9, 11•5, 12•9 Aerial - 12•14, 12•15. • Fuel-injection control module - 4B•9 Intercooler - 4B•12 Fuel injectors - 4B•6, 4C•4, 4D•3 Introduction to the Ford Escort - 0•4 Fuel level sensor unit - 12•11 Oil and filter - 0•12, 1•8 Fuel pressure regulator - 4B•8, 4C•3, 4D•2 Oil cooler - 2B•25. • Index REF•25 Weights - REF•1 Wheel alignment - 10•16 Wheel arch deflectors - 11•18 Radiator - 3•3 Tachometer - 12•9 Wheel changing - 0•8 Radiator fan - 3•2, 3•6 Tailgate - 11•12, 11•14, 11•15, 11•20, Wheel cylinder - 9•7 Radiator grille - 11•5 12•11, 12•12 Wheelhouse covers - 11•21 Radio/cassette player - 12•13. • Leave blank for manual listing pages. • Leave blank for manual listing pages.

• Model J Duesenberg to curiosities like the bug-eyed BMW Isetta. There are also many old friends and flames. Perhaps you remember the 1959 Ford Popular that you did your courting in? The magnificent ‘Red Collection’ is a spectacle of classic sports cars including AC, Alfa Romeo, Austin Healey, Ferrari, Lamborghini, Maserati, MG, Riley, Porsche and Triumph.