
7Unbolt the guide plate from the body on the
side concerned.
8Carefully lower the jack until the spring is no
longer under tension. Remove the spring and
the rubber buffer.
9Refit by reversing the removal operations,
tightening all fastenings to the specified torque
when known.
Note: Ford tool No 15-014, or locally made
equivalent, will be required for this job.
1Raise and support the rear of the vehicle.
2Flatten the lockwasher which secures the
guide plate centre bolt. Remove the centre
bolt and the two bolts which hold the guide
plate to the floor; remove the guide plate.
3Wedge a piece of wood between the
crossmember and the floor.
4Draw the insulator out with the special tool
(see illustration).
5Smear the new insulator with glycerine or
liquid soap, then press it in as follows.
6Use the special tool spindle or other long
M12 bolt. Screw a nut up to the bolt head,
then fit a plain washer and the insulator onto
the bolt. Pass the bolt through the hole in the
crossmember and screw it into the floor, then
press the insulator home by winding the nut
and washer up the bolt.
7Remove the installation tool and the wood.
8Refit the guide plate, tightening the bolts to
the specified torque. Secure the centre bolt
with the lockwasher.
9Lower the vehicle.
1Remove the rear hub.
2Disconnect both rear brake flexible hoses
from the brake pipes. Free the brake pipes
from the brackets on the lower arms.
3Unclip the handbrake cable from the lower
arm.
4Remove the rear spring.
5Remove the lower arm-to-crossmember
bolts. Withdraw the lower arm.6Renew the rubber bushes if wished, using
lengths of tube or sockets and a vice, or large
nuts and bolts. Lubricate the new bushes with
glycerine or liquid soap.
7Refit by reversing the removal operations,
tightening the lower arm-to-crossmember
bolts with the weight of the vehicle back on its
wheels. Bleed the brake hydraulic system on
completion.
1Raise and support the rear of the vehicle.
2Separate the anti-roll bar from the link rods
on each side by prising them free (see
illustration).
3Unbolt the two anti-roll bar brackets.
Remove the bar, brackets and bushes (see
illustration).
4Refit by reversing the removal operations.
Tighten the bracket bolts to the specified
torque.
1Working inside the vehicle, remove the
luggage area side trim to gain access to the
shock absorber top mounting.
2Raise and support the rear of the vehicle.
Raise a jack under the rear suspension lower
arm to take the load off the shock absorber.3On models with ride height control,
disconnect the air line from the shock
absorber.
4Unbolt the shock absorber top mounting
(see illustration).
5Unbolt the shock absorber lower mounting
(see illustration). Pull the shock absorber out
of the lower mounting bracket and remove it.
6Refit by reversing the removal operations.
Tighten the shock absorber mountings to the
specified torque. On models with ride height
control, use new O-rings on the air line union.
The ride height control system is an optional
extra, designed to keep the rear suspension
height constant regardless of vehicle load.
This is obviously useful if heavy loads are often
carried, or if the vehicle is used for towing.
The main components of the system are a
height sensor, a compressor and two special
rear shock absorbers. The compressor
supplies air to the shock absorbers, so
“pumping up” the rear suspension, when so
commanded by the height sensor. Other
components include the connecting pipes,
electrical wiring and a compressor relay. The
relay is mounted behind the glovebox.
Variations in vehicle height are not
recognised by the system for approximately
20 seconds, in order to prevent responses to
temporary changes such as those induced by
32Ride height control system -
general information
31Rear shock absorber -
removal and refitting
30Rear anti-roll bar - removal
and refitting
29Rear suspension lower arm -
removal and refitting
28Rear crossmember insulator
- removal and refitting
11•12Steering and suspension
28.4 Drawing out an insulator with the
special tool
31.4 Undoing a rear shock absorber top
mounting31.5 Undoing a rear shock absorber lower
mounting
30.2 Rear anti-roll bar link rod30.3 A rear anti-roll bar bracket - bolt
arrowed
procarmanuals.com

4Have an assistant support the tailgate.
Disconnect the struts from the tailgate.
5Jam the tailgate latch with a piece of wood
or cardboard so that the tailgate cannot shut.
Lower the tailgate.
6Working inside the vehicle, prise out the
hinge covers from the headlining. Remove the
hinge nuts and recover the washers (see
illustration).
7With the aid of an assistant, lift the tailgate
away from the vehicle.
8Commence refitting by offering the tailgate
to its aperture, aligning the hinges and
reconnecting the struts. Do not allow the
struts alone to support the tailgate until the
hinge nuts have been fitted.
9Fit the hinge nuts and washers. Do not fully
tighten the nuts yet.
10Secure any wiring looms and the washer
tube to the pieces of string used during
removal. (It is to be hoped that a new tailgate
will be supplied with wiring or string in place.)
Draw the wires and tube into position. Tape up
the connectors if necessary to prevent them
snagging.
11Reconnect the wires and the washer tube
and refit the grommets.
12Close and latch the tailgate and adjust its
position so that an even gap exists all round it,
then tighten the hinge nuts.
13Refit the hinge covers and the interior trim
panel.
Estate models
14On Estate models the tailgate can be
removed and refitted as described above,
noting the following points:
a)Prior to removing the interior trim panel. it
will be necessary to remove the upper rear
windscreen trim panel which is retained by
eight screws.
b)When removing the interior trim panel
note that it is retained by fourteen screws;
two are situated behind each of theaccess covers in the centre of the panel.
c)To gain access to the tailgate hinge
retaining nuts it will be necessary to
carefully peelthe headlining away from the
rear trim panel. Therefore if hinge removal
is not strictly necessary, it is
recommended that the hinges are left in
place on the vehicle and the tailgate is
unbolted from the hinges (see
illustration).
1On saloon models, open the boot lid and
using a suitable marker pen, mark the outline
of the hinges on the inside of the lid.
2Unclip the trim panel from the inside of the
lid to gain access to the boot lid lock and
warning switch wiring connectors (see
illustration). Release the wiring loom from the
retaining clips and tie a suitable length of
string to each of the wiring connectors.
Withdraw the wiring loom from the boot lid
until the connectors emerge then untie the
string and leave it in position in the lid; the
string can then be used to draw the wiring
loom back into position on refitting.
3Support the lid with the aid of an assistant
then slacken and remove the four hinge
retaining bolts (accessed from inside the lid)
and remove the boot lid from the car (see
illustration).
4Offer up the boot lid, aligning the hinges
with the marks made on removal, and tightenthe hinge bolts securely. Tie the piece of string
to the wiring loom and use the string to draw
the loom through the boot lid. If a new boot lid
is being installed it will be necessary to
centralise the boot lid on the hinges and feed
the wiring loom through the boot lid, ensuring
that it is correctly routed.
5Reconnect the wiring connectors to the lock
and warning switch.
6Refit the trim panel and check it is securely
held in position by the retaining clips.
7Close the boot lid and check that is
correctly aligned with all surrounding
bodywork with an equal clearance all around.
If necessary, adjustment can be made by
slackening the hinge bolts and repositioning
the boot lid. Once correctly positioned, tighten
the hinge bolts securely.
8Once the boot lid is correctly aligned ensure
that it closes without slamming and is securely
retained. If not, slacken the boot lid striker
retaining bolts and reposition the striker. Once
the boot lid operation is satisfactory tighten
the striker retaining bolts securely.
1This procedure applies to the manually-
operated roof. For removal of the electrically-
operated roof motor, see Chapter 13.
2Open the roof. Remove the four setscrews
and ten self-tapping screws which secure the
sliding roof frame.
10Sliding roof - removal and
refitting
9Boot lid - removal, refitting and
adjustment
Bodywork and fittings 12•5
12
8.6 Tailgate hinge nuts are accessible
through headlining8.14 Tailgate hinge retaining bolts
(arrowed) - Estate models9.2 On Saloon models remove the trim
panel to gain access to the lock and
warning switch wiring connectors
9.3 Boot lid retaining bolts (arrowed) -
Saloon models10.4 Removing the sliding roof operating
handle
Tie some string to each piece
of wiring, then free the
grommet and draw the wiring
out of the tailgate. Untie the
string and leave it in the tailgate for use
when refitting.
procarmanuals.com

REF•13Glossary of Technical Terms
Catalytic converterA silencer-like device in
the exhaust system which converts certain
pollutants in the exhaust gases into less
harmful substances.
CirclipA ring-shaped clip used to prevent
endwise movement of cylindrical parts and
shafts. An internal circlip is installed in a
groove in a housing; an external circlip fits into
a groove on the outside of a cylindrical piece
such as a shaft.
ClearanceThe amount of space between
two parts. For example, between a piston and
a cylinder, between a bearing and a journal,
etc.
Coil springA spiral of elastic steel found in
various sizes throughout a vehicle, for
example as a springing medium in the
suspension and in the valve train.
CompressionReduction in volume, and
increase in pressure and temperature, of a
gas, caused by squeezing it into a smaller
space.
Compression ratioThe relationship between
cylinder volume when the piston is at top
dead centre and cylinder volume when the
piston is at bottom dead centre.
Constant velocity (CV) jointA type of
universal joint that cancels out vibrations
caused by driving power being transmitted
through an angle.
Core plugA disc or cup-shaped metal device
inserted in a hole in a casting through which
core was removed when the casting was
formed. Also known as a freeze plug or
expansion plug.
CrankcaseThe lower part of the engine
block in which the crankshaft rotates.
CrankshaftThe main rotating member, or
shaft, running the length of the crankcase,
with offset “throws” to which the connecting
rods are attached.
Crocodile clipSee Alligator clipDDiagnostic codeCode numbers obtained by
accessing the diagnostic mode of an engine
management computer. This code can be
used to determine the area in the system
where a malfunction may be located.
Disc brakeA brake design incorporating a
rotating disc onto which brake pads are
squeezed. The resulting friction converts the
energy of a moving vehicle into heat.
Double-overhead cam (DOHC)An engine
that uses two overhead camshafts, usually
one for the intake valves and one for the
exhaust valves.
Drivebelt(s)The belt(s) used to drive
accessories such as the alternator, water
pump, power steering pump, air conditioning
compressor, etc. off the crankshaft pulley.
DriveshaftAny shaft used to transmit
motion. Commonly used when referring to the
axleshafts on a front wheel drive vehicle.
Drum brakeA type of brake using a drum-
shaped metal cylinder attached to the inner
surface of the wheel. When the brake pedal is
pressed, curved brake shoes with friction
linings press against the inside of the drum to
slow or stop the vehicle.
EEGR valveA valve used to introduce exhaust
gases into the intake air stream.
Electronic control unit (ECU)A computer
which controls (for instance) ignition and fuel
injection systems, or an anti-lock braking
system. For more information refer to the
Haynes Automotive Electrical and Electronic
Systems Manual.
Electronic Fuel Injection (EFI)A computer
controlled fuel system that distributes fuel
through an injector located in each intake port
of the engine.
Emergency brakeA braking system,
independent of the main hydraulic system,
that can be used to slow or stop the vehicle if
the primary brakes fail, or to hold the vehicle
stationary even though the brake pedal isn’t
depressed. It usually consists of a hand lever
that actuates either front or rear brakes
mechanically through a series of cables and
linkages. Also known as a handbrake or
parking brake.EndfloatThe amount of lengthwise
movement between two parts. As applied to a
crankshaft, the distance that the crankshaft
can move forward and back in the cylinder
block.
Engine management system (EMS)A
computer controlled system which manages
the fuel injection and the ignition systems in
an integrated fashion.
Exhaust manifoldA part with several
passages through which exhaust gases leave
the engine combustion chambers and enter
the exhaust pipe.
F
Fan clutchA viscous (fluid) drive coupling
device which permits variable engine fan
speeds in relation to engine speeds.
Feeler bladeA thin strip or blade of hardened
steel, ground to an exact thickness, used to
check or measure clearances between parts.
Firing orderThe order in which the engine
cylinders fire, or deliver their power strokes,
beginning with the number one cylinder.
Flywheel A heavy spinning wheel in which
energy is absorbed and stored by means of
momentum. On cars, the flywheel is attached
to the crankshaft to smooth out firing
impulses.
Free playThe amount of travel before any
action takes place. The “looseness” in a
linkage, or an assembly of parts, between the
initial application of force and actual
movement. For example, the distance the
brake pedal moves before the pistons in the
master cylinder are actuated.
FuseAn electrical device which protects a
circuit against accidental overload. The typical
fuse contains a soft piece of metal which is
calibrated to melt at a predetermined current
flow (expressed as amps) and break the
circuit.
Fusible linkA circuit protection device
consisting of a conductor surrounded by
heat-resistant insulation. The conductor is
smaller than the wire it protects, so it acts as
the weakest link in the circuit. Unlike a blown
fuse, a failed fusible link must frequently be
cut from the wire for replacement.Catalytic converter
Crankshaft assembly
Accessory drivebelts
Feeler blade
procarmanuals.com

REF•14Glossary of Technical Terms
GGapThe distance the spark must travel in
jumping from the centre electrode to the side
electrode in a spark plug. Also refers to the
spacing between the points in a contact
breaker assembly in a conventional points-
type ignition, or to the distance between the
reluctor or rotor and the pickup coil in an
electronic ignition.
GasketAny thin, soft material - usually cork,
cardboard, asbestos or soft metal - installed
between two metal surfaces to ensure a good
seal. For instance, the cylinder head gasket
seals the joint between the block and the
cylinder head.
GaugeAn instrument panel display used to
monitor engine conditions. A gauge with a
movable pointer on a dial or a fixed scale is an
analogue gauge. A gauge with a numerical
readout is called a digital gauge.
HHalfshaftA rotating shaft that transmits
power from the final drive unit to a drive
wheel, usually when referring to a live rear
axle.
Harmonic balancerA device designed to
reduce torsion or twisting vibration in the
crankshaft. May be incorporated in the
crankshaft pulley. Also known as a vibration
damper.
HoneAn abrasive tool for correcting small
irregularities or differences in diameter in an
engine cylinder, brake cylinder, etc.
Hydraulic tappetA tappet that utilises
hydraulic pressure from the engine’s
lubrication system to maintain zero clearance
(constant contact with both camshaft and
valve stem). Automatically adjusts to variation
in valve stem length. Hydraulic tappets also
reduce valve noise.
IIgnition timingThe moment at which the
spark plug fires, usually expressed in the
number of crankshaft degrees before the
piston reaches the top of its stroke.
Inlet manifoldA tube or housing with
passages through which flows the air-fuel
mixture (carburettor vehicles and vehicles with
throttle body injection) or air only (port fuel-
injected vehicles) to the port openings in the
cylinder head.
JJump startStarting the engine of a vehicle
with a discharged or weak battery by
attaching jump leads from the weak battery to
a charged or helper battery.
LLoad Sensing Proportioning Valve (LSPV)A
brake hydraulic system control valve that
works like a proportioning valve, but also
takes into consideration the amount of weight
carried by the rear axle.
LocknutA nut used to lock an adjustment
nut, or other threaded component, in place.
For example, a locknut is employed to keep
the adjusting nut on the rocker arm in
position.
LockwasherA form of washer designed to
prevent an attaching nut from working loose.
MMacPherson strutA type of front
suspension system devised by Earle
MacPherson at Ford of England. In its original
form, a simple lateral link with the anti-roll bar
creates the lower control arm. A long strut - an
integral coil spring and shock absorber - is
mounted between the body and the steering
knuckle. Many modern so-called MacPherson
strut systems use a conventional lower A-arm
and don’t rely on the anti-roll bar for location.
MultimeterAn electrical test instrument with
the capability to measure voltage, current and
resistance.
NNOxOxides of Nitrogen. A common toxic
pollutant emitted by petrol and diesel engines
at higher temperatures.
OOhmThe unit of electrical resistance. One
volt applied to a resistance of one ohm will
produce a current of one amp.
OhmmeterAn instrument for measuring
electrical resistance.
O-ringA type of sealing ring made of a
special rubber-like material; in use, the O-ring
is compressed into a groove to provide the
sealing action.
Overhead cam (ohc) engineAn engine with
the camshaft(s) located on top of the cylinder
head(s).Overhead valve (ohv) engineAn engine with
the valves located in the cylinder head, but
with the camshaft located in the engine block.
Oxygen sensorA device installed in the
engine exhaust manifold, which senses the
oxygen content in the exhaust and converts
this information into an electric current. Also
called a Lambda sensor.
PPhillips screwA type of screw head having a
cross instead of a slot for a corresponding
type of screwdriver.
PlastigageA thin strip of plastic thread,
available in different sizes, used for measuring
clearances. For example, a strip of Plastigage
is laid across a bearing journal. The parts are
assembled and dismantled; the width of the
crushed strip indicates the clearance between
journal and bearing.
Propeller shaftThe long hollow tube with
universal joints at both ends that carries
power from the transmission to the differential
on front-engined rear wheel drive vehicles.
Proportioning valveA hydraulic control
valve which limits the amount of pressure to
the rear brakes during panic stops to prevent
wheel lock-up.
RRack-and-pinion steeringA steering system
with a pinion gear on the end of the steering
shaft that mates with a rack (think of a geared
wheel opened up and laid flat). When the
steering wheel is turned, the pinion turns,
moving the rack to the left or right. This
movement is transmitted through the track
rods to the steering arms at the wheels.
RadiatorA liquid-to-air heat transfer device
designed to reduce the temperature of the
coolant in an internal combustion engine
cooling system.
RefrigerantAny substance used as a heat
transfer agent in an air-conditioning system.
R-12 has been the principle refrigerant for
many years; recently, however, manufacturers
have begun using R-134a, a non-CFC
substance that is considered less harmful to
the ozone in the upper atmosphere.
Rocker armA lever arm that rocks on a shaft
or pivots on a stud. In an overhead valve
engine, the rocker arm converts the upward
movement of the pushrod into a downward
movement to open a valve.
Adjusting spark plug gap
Plastigage
Gasket
procarmanuals.com

REF•16
Length (distance)Inches (in)X25.4=Millimetres (mm)X0.0394=Inches (in)
Feet (ft)X0.305=Metres (m)X3.281=Feet (ft)
MilesX1.609=Kilometres (km)X0.621=Miles
Volume (capacity)
Cubic inches (cu in; in3)X16.387=Cubic centimetres (cc; cm3)X0.061=Cubic inches (cu in; in3)
Imperial pints (Imp pt)X0.568=Litres (l)X1.76=Imperial pints (Imp pt)
Imperial quarts (Imp qt)X1.137=Litres (l)X0.88=Imperial quarts (Imp qt)
Imperial quarts (Imp qt)X1.201=US quarts (US qt)X0.833=Imperial quarts (Imp qt)
US quarts (US qt)X0.946=Litres (l)X1.057=US quarts (US qt)
Imperial gallons (Imp gal)X4.546=Litres (l)X0.22=Imperial gallons (Imp gal)
Imperial gallons (Imp gal)X1.201=US gallons (US gal)X0.833=Imperial gallons (Imp gal)
US gallons (US gal)X3.785=Litres (l)X0.264=US gallons (US gal)
Mass (weight)
Ounces (oz)X28.35=Grams (g)X0.035=Ounces (oz)
Pounds (lb)X0.454=Kilograms (kg)X2.205=Pounds (lb)
Force
Ounces-force (ozf; oz)X0.278=Newtons (N)X3.6=Ounces-force (ozf; oz)
Pounds-force (lbf; lb)X4.448=Newtons (N)X0.225=Pounds-force (lbf; lb)
Newtons (N)X0.1=Kilograms-force (kgf; kg)X9.81=Newtons (N)
Pressure
Pounds-force per square inchX0.070=Kilograms-force per squareX14.223=Pounds-force per square inch
(psi; lbf/in2; lb/in2)centimetre (kgf/cm2; kg/cm2)(psi; lbf/in2; lb/in2)
Pounds-force per square inchX0.068=Atmospheres (atm)X14.696=Pounds-force per square inch
(psi; lbf/in
2; lb/in2)(psi; lbf/in2; lb/in2)
Pounds-force per square inchX0.069=BarsX14.5=Pounds-force per square inch
(psi; lbf/in
2; lb/in2)(psi; lbf/in2; lb/in2)
Pounds-force per square inchX6.895=Kilopascals (kPa)X0.145=Pounds-force per square inch
(psi; lbf/in
2; lb/in2)(psi; lbf/in2; lb/in2)
Kilopascals (kPa)X0.01=Kilograms-force per squareX98.1=Kilopascals (kPa)
centimetre (kgf/cm
2; kg/cm2)
Millibar (mbar)X100=Pascals (Pa)X0.01=Millibar (mbar)
Millibar (mbar)X0.0145=Pounds-force per square inchX68.947=Millibar (mbar)
(psi; lbf/in
2; lb/in2)
Millibar (mbar)X0.75=Millimetres of mercury (mmHg)X1.333=Millibar (mbar)
Millibar (mbar)X0.401=Inches of water (inH
2O)X2.491=Millibar (mbar)
Millimetres of mercury (mmHg)X0.535=Inches of water (inH
2O)X1.868=Millimetres of mercury (mmHg)
Inches of water (inH
2O)X0.036=Pounds-force per square inchX27.68=Inches of water (inH2O)
(psi; lbf/in2; lb/in2)
Torque (moment of force)
Pounds-force inchesX1.152=Kilograms-force centimetreX0.868=Pounds-force inches
(lbf in; lb in)(kgf cm; kg cm)(lbf in; lb in)
Pounds-force inchesX0.113=Newton metres (Nm)X8.85=Pounds-force inches
(lbf in; lb in)(lbf in; lb in)
Pounds-force inchesX0.083=Pounds-force feet (lbf ft; lb ft)X12=Pounds-force inches
(lbf in; lb in)(lbf in; lb in)
Pounds-force feet (lbf ft; lb ft)X0.138=Kilograms-force metresX7.233=Pounds-force feet (lbf ft; lb ft)
(kgf m; kg m)
Pounds-force feet (lbf ft; lb ft)X1.356=Newton metres (Nm)X0.738=Pounds-force feet (lbf ft; lb ft)
Newton metres (Nm)X0.102=Kilograms-force metresX9.804=Newton metres (Nm)
(kgf m; kg m)
Power
Horsepower (hp)X745.7=Watts (W)X0.0013=Horsepower (hp)
Velocity (speed)
Miles per hour (miles/hr; mph)X1.609=Kilometres per hour (km/hr; kph)X0.621=Miles per hour (miles/hr; mph)
Fuel consumption*
Miles per gallon, Imperial (mpg)X0.354=Kilometres per litre (km/l)X2.825=Miles per gallon, Imperial (mpg)
Miles per gallon, US (mpg)X0.425=Kilometres per litre (km/l)X2.352=Miles per gallon, US (mpg)
Temperature
Degrees Fahrenheit = (°C x 1.8) + 32Degrees Celsius (Degrees Centigrade; °C) = (°F - 32) x 0.56
* It is common practice to convert from miles per gallon (mpg) to litres/100 kilometres (l/100km),
where mpg (Imperial) x l/100 km = 282 and mpg (US) x l/100 km = 235
Conversion Factors
procarmanuals.com