1985 FORD GRANADA fuel pump

Chapter 11
Steering and suspension
Front anti-roll bar - removal and refitting . . . . . . . . . . . . . . . . . . . . .19
Front anti-roll bar bushes - renewal . . . . . . . . . . . . . . . . . . . . . . . . .20
Front stub axle carrier - removal and refitting . . . . . . . . . . . . . . . . .16
Front suspension crossmember - removal and refitting . . . . . . . . .15
Front suspension lower arm - removal, overhaul and refitting . . . . .18
Front suspension strut - dismantling and reassembly . . . . . . . . . . .22
Front suspension strut - removal and refitting . . . . . . . . . . . . . . . . .21
Front wheel alignment - checking and adjusting . . . . . . . . . . . . . . .14
Front wheel bearings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Power steering fluid - level check and bleeding . . . . . . . . . . . . . . . . .2
Power steering hoses - removal and refitting . . . . . . . . . . . . . . . . . .12
Power steering pump - removal and refitting . . . . . . . . . . . . . . . . . .11
Power steering pump drivebelt - removal, refitting and tensioning .10
Rear anti-roll bar - removal and refitting . . . . . . . . . . . . . . . . . . . . .30
Rear crossmember insulator - removal and refitting . . . . . . . . . . . .28
Rear hub - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Rear shock absorber - removal and refitting . . . . . . . . . . . . . . . . . .31Rear spring - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .27
Rear suspension and final drive assembly - removal and refitting . .23
Rear suspension lower arm - removal and refitting . . . . . . . . . . . . .29
Rear wheel bearings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Ride height control compressor - removal and refitting . . . . . . . . . .33
Ride height control sensor - removal and refitting . . . . . . . . . . . . . .34
Ride height control system - general information . . . . . . . . . . . . . .32
Steering column - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .7
Steering column lock - removal and refitting . . . . . . . . . . . . . . . . . . .8
Steering gear - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .3
Steering intermediate shaft and flexible coupling - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Steering rack bellows - renewal in vehicle . . . . . . . . . . . . . . . . . . . . .4
Steering wheel - centralising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Steering wheel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .5
Track rod end - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .13
Wheel stud - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
General
Suspension type:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent, MacPherson struts and anti-roll bar
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent, semi-trailing arms and anti-roll bar; ride height
control optionally available
Steering type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack and pinion, power-assisted on some models
Front wheel alignment
Toe:
Setting value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ± 1 mm (0.08 ± 0.04 in) toe-in
Tolerance in service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in) toe-out to 4.5 mm (0.18 in) toe-in
Castor :
SOHC and 2.8 litre models:
Standard, without ride height control . . . . . . . . . . . . . . . . . . . . . . . + 1°51’ ± 1°00’
Standard, with ride height control . . . . . . . . . . . . . . . . . . . . . . . . . . + 1°58’ ± 1°00’
Heavy duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + 1°46’ ± 1°00’
DOHC carburettor and low series fuel-injection models . . . . . . . . . . + 2°27’ ± 1°00’
DOHC high series models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + 2°26’± 1°00’
2.4 litre:
low series models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + 2°17’ ± 1°00’
high series models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + 2°50’ ± 1°00’
2.9 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + 2°22’ ± 1°00’
11•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty
Specifications Contents
11
procarmanuals.com

13•2Body electrical system
Fuses and circuit breakers- main fuse box (continued)
Fuse NoRating (A)Circuit(s) protected
715 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instrument illumination, number plate lights
810 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control circuits for air conditioning, heated windscreen and ride
height control
930 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlight washer pump, tailgate and fuel filler flap release
1020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Central locking system, interior lights, clock, mirror adjustment
1120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel pump (with air conditioning), taxi circuits
1210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hazard warning flasher
1330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated seats, cigarette lighters
1430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Horn
1530 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiper motors and screen washer pumps
1630 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated rear window, heated mirrors
1720 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front foglights
1830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heater blower
1910 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accessory circuits
2015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direction indicators, reversing lights
2115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stop-lights
2210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instrument and controls
23C20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power windows (front) and sliding roof
24C20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power windows (rear) and rear seat adjustment
C = Circuit breaker
Fuses and circuit breakers - auxiliary fuse box
Colour Rating (A)Circuit(s) protected
Black20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel-injection pump
Pink20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air conditioning cooling fan
Yellow20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Anti-lock braking system control circuitry
Green30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Anti-lock braking system pump
Brown30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated windscreen (left-hand side)
Brown30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated windscreen (right-hand side)
GreyC20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front seat adjustment
Orange20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ride height control
C = Circuit breaker
Relays in main fuse box
IdentificationFunction
I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ignition circuit
II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated rear window and mirrors
III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power windows and sliding roof
IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seat belt warning
V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intermittent wipe - front
VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intermittent wipe - rear
VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlight washer
VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interior light delay
IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear seat adjustment
X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlights (main beam)
XI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine auxiliary
XII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic transmission inhibitor
A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare
B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Radio
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Horn
D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tailgate release
E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare
F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlights (dipped beam)
G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seat heaters
H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front foglights
Other relays and modules
IdentificationFunction
Behind facia (centre):
L1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lights on buzzer
L2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear fog light control
L3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic transmission kickdown time
L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel pump (with air conditioning)
L5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic switch
L6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Anti-theft alarm
Behind facia (passenger side):
M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manifold heater (carburettor) or fuel pump (fuel-injection)
M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power hold (carburettor) or inspection valve (fuel-injection)
M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated windscreen (power)
procarmanuals.com

The electrical system is a 12 volt, negative
earth type. Electricity is generated by an
alternator, belt-driven from the crankshaft pulley.
A lead-acid battery provides a reserve of power
for starting and when the demands of the system
temporarily exceed the alternator output.
The battery negative terminal is connected
to “earth” - vehicle metal - and most electrical
system components are wired so that they
only receive a positive feed, the current
returning via vehicle metal. This means that
the component mounting forms part of the
circuit. Loose or corroded mountings can
therefore cause apparent electrical faults.
Many semiconductor devices are used in
the electrical system, both in the “black
boxes” which control vehicle functions and in
other components. Semiconductors are very
sensitive to excessive (or wrong polarity)
voltage, and to extremes of heat. Observe the
appropriate precautions to avoid damage.
Although some repair procedures are given
in this Chapter, sometimes renewal of a well-
used item will prove more satisfactory. The
reader whose interests extend beyond
component renewal should obtain a copy of
the “Automobile Electrical Manual”, available
from the publishers of this book.
Before starting work on the electrical
system, read the precautions listed in “Safety
first!” at the beginning of the manual.
Note:Refer to the precautions given in “Safety
first!” and in Section 1 of this Chapter before
starting work. The following tests relate to testing
of the main electrical circuits, and should not be
used to test delicate electronic circuits (such as
anti-lock braking systems), particularly where an
electronic control unit (ECU) is involved.
General
1A typical electrical circuit consists of an
electrical component, any switches, relays,
motors, fuses, fusible links or circuit breakers
related to that component, and the wiring and
connectors which link the component to both
the battery and the chassis. To help to
pinpoint a problem in an electrical circuit,
wiring diagrams are included at the end of this
Chapter.
2Before attempting to diagnose an electrical
fault, first study the appropriate wiring
diagram, to obtain a more complete
understanding of the components included in
the particular circuit concerned. The possible
sources of a fault can be narrowed down by
noting whether other components related to
the circuit are operating properly. If several
components or circuits fail at one time, the
problem is likely to be related to a shared fuse
or earth connection.
3Electrical problems usually stem from
simple causes, such as loose or corroded
connections, a faulty earth connection, a
blown fuse, a melted fusible link, or a faulty
relay. Visually inspect the condition of all
fuses, wires and connections in a problem
circuit before testing the components. Use the
wiring diagrams to determine which terminal
connections will need to be checked in order
to pinpoint the trouble-spot.
4The basic tools required for electrical fault-
finding include: a circuit tester or voltmeter (a
12-volt bulb with a set of test leads can also
be used for certain tests), a self-powered test
light (sometimes known as a continuity tester),
an ohmmeter (to measure resistance), a
battery and set of test leads, and a jumper
wire, preferably with a circuit breaker or fuse
incorporated, which can be used to bypass
suspect wires or electrical components.
Before attempting to locate a problem with
test instruments, use the wiring diagram to
determine where to make the connections.
5To find the source of an intermittent wiring
fault (usually due to a poor or dirty connection,
or damaged wiring insulation), an integrity testcan be performed on the wiring, which
involves moving the wiring by hand, to see if
the fault occurs as the wiring is moved. It
should be possible to narrow down the source
of the fault to a particular section of wiring.
This method of testing can be used in
conjunction with any of the tests described in
the following sub-Sections.
6Apart from problems due to poor
connections, two basic types of fault can
occur in an electrical circuit - open-circuit or
short-circuit.
7Open-circuit faults are caused by a break
somewhere in the circuit, which prevents
current from flowing. An open-circuit fault will
prevent a component from working, but will
not cause the relevant circuit fuse to blow.
8Short-circuit faults are caused by a “short”
somewhere in the circuit, which allows the
current flowing in the circuit to “escape” along
an alternative route, usually to earth. Short-
circuit faults are normally caused by a
breakdown in wiring insulation, which allows a
feed wire to touch either another wire, or an
earthed component such as the bodyshell. A
short-circuit fault will normally cause the
relevant circuit fuse to blow. Note: A short-
circuit that occurs in the wiring between a
circuit’s battery supply and its fuse will not
cause the fuse in that particular circuit to blow.
This part of the circuit is unprotected - bear
this in mind when fault-finding on the vehicle’s
electrical system.
Finding an open-circuit
9To check for an open-circuit, connect one
lead of a circuit tester or voltmeter to either the
negative battery terminal or a known good earth.
10Connect the other lead to a connector in
the circuit being tested, preferably nearest to
the battery or fuse.
11Switch on the circuit, bearing in mind that
some circuits are live only when the ignition
switch is moved to a particular position.
12If voltage is present (indicated either by
the tester bulb lighting or a voltmeter reading,
as applicable), this means that the section of
2Electrical fault-finding - general
information
1General information
Body electrical system 13•3
13
Other relays and modules (continued)
IdentificationFunction
Behind facia (passenger side) (continued):
M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated windscreen (timer)
M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air conditioning cooling fan
M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ABS pump relay
M7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ABS main relay
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ABS control unit
M9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ride height control
Below instrument panel (driver’s side):
N1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bulb failure warning unit
Below facia (passenger side):
P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ABS module
P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel-injection system module
Behind facia (passenger side):
R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Speed control system module
R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary warning system module
R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear audio console module
Torque wrench settingsNmlbf ft
Alternator adjusting strap:
To steering pump bracket (SOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2616 to 19
To front cover (V6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 to 5130 to 38
procarmanuals.com

13•14Body electrical system
16.9 Typical arrangement of relays, control units and module
LHD shown - RHD is mirror image
A Taxi equipment
B Bulb failure module
C EEC IV module
D ABS module
E Rear headphone relay
F Auxiliary warning system control unit
G Speed control system module
H Anti-theft alarm module
I Warning display lighting
K Relay bank
1 Inlet manifold heater relay (carburettor)
2 Fuel pump relay (fuel-injection)
3 Power hold relay (carburettor)
4 Injector relay (fuel-injection)
5 Heated windscreen relay
6 Heated windscreen timer
7 Cooling fan relay (air conditioning)
8 ABS pump relay
9 ABS relay
10 ABS diodes
12 Ride height control relay
12 Day running lights relay (not UK)
procarmanuals.com

Estate
7Note that when removing the rear window
wiper arm, it will be necessary to detach the
washer hose from the spindle prior to
removing the wiper arm retaining nut (see
illustration).
1Remove the windscreen wiper arms as
described in the previous Section.
2Undo the eight Torx screws which secure
the wiper motor and linkage to the bulkhead
(see illustrations).3Disconnect the multi-plug and remove the
motor and linkage (see illustration).
4The linkage arms can be removed by
levering them off the pivot pins.
5To remove the motor, undo the crank arm
nut and remove the three securing bolts (see
illustration). The motor cover can then be
removed. A defective motor must be renewed.
6Refit by reversing the removal operations.
Before refitting the wiper arms, switch the
wipers on and then off so that the motor takes
up the “parked” position.
1Remove the rear wiper arm from the spindle.
2Open the tailgate and remove the interior
trim panel, which is secured by eleven screws.
3Remove the three bolts which secure the
wiper motor bracket to the tailgate (see
illustration). Also remove the screw which
secures the earth tag. Disconnect the wiring
plug and remove the motor and bracket.
4The bracket can be unbolted from the motor
if wished. No spare parts for the motor are
available.
5Commence refitting by offering the motor
and bracket to the tailgate. Secure the
assembly with the three bolts, then reconnect
the wiring and secure the earth tag.
6Switch on the ignition and operate the rear
wiper control briefly so that the motor stops in
the “parked” position.7Refit the wiper arm and blade. Wet the
window and operate the rear wiper control
again to check the function of the motor.
8Switch off the ignition and refit the tailgate
interior trim panel.
Windscreen and rear washer jets are
removed simply by prising or pulling them
from their locations (see illustration).
Headlight washer jets can be unclipped from
their holders after disconnection of the high
pressure hose from the jet.
To remove a washer pump, first syphon out
the contents of the reservoir. Disconnect the
wiring and the hose from the pump, then pull
the pump out of its grommet in the reservoir.
Renew the grommet if necessary when
refitting the pump.
1The fuel tank sender unit, EEC IV module
and speedometer sender unit are not peculiar
to the fuel computer. Their removal and
refitting procedures are given in Chapter 4,
Chapter 5 and this Chapter respectively.
26Fuel computer components -
removal and refitting
25Windscreen, rear window and
headlight washer components
- removal and refitting
24Rear window wiper motor -
removal and refitting
23Windscreen wiper motor and
linkage - removal and refitting
Body electrical system 13•17
13
23.2a Two screws (arrowed) in the front of
the motor . . .23.2b . . . three screws around the right-
hand spindle . . .23.2c . . . and two screws on the left.
Eighth screw is midway between the spindles
23.5 Undo the crank arm nut and the three
bolts (arrowed)
23.3 Disconnecting the wiper motor multi-
plug
24.3 Three bolts secure the rear wiper
motor (two arrowed)25.1 A windscreen washer jet prised out of
its location in the bonnet
procarmanuals.com

REF•6
Engine fails to rotate when attempting to start
m mBattery terminal connections loose or corroded (Chapter 1).
m mBattery discharged or faulty (Chapter 5).
m mBroken, loose or disconnected wiring in the starting circuit
(Chapter 5).
m mDefective starter solenoid or switch (Chapter 5).
m mDefective starter motor (Chapter 5).
m mStarter pinion or flywheel/driveplate ring gear teeth loose or broken
(Chapters 2 or 5).
m mEngine earth strap broken or disconnected.
Starter motor turns engine slowly
m
mPartially-discharged battery (recharge, use jump leads, or push
start) (Chapter 5).
m mBattery terminals loose or corroded (Chapter 1).
m mBattery earth to body defective (Chapter 5).
m mEngine earth strap loose.
m mStarter motor (or solenoid) wiring loose (Chapter 5).
m mStarter motor internal fault (Chapter 5).
Engine rotates, but will not start
m
mFuel pump inertia switch tripped (electric pump) (Chapter 4).
m mFuel tank empty.
m mBattery discharged (engine rotates slowly) (Chapter 5).
m mBattery terminal connections loose or corroded (Chapter 1).
m mIgnition components damp or damaged (Chapters 1 and 5).
m mBroken, loose or disconnected wiring in the ignition circuit
(Chapters 1 and 5).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mFuel injection system fault (Chapter 4).
m mMajor mechanical failure (eg broken timing chain) (Chapter 2).
Engine difficult to start when cold
m
mBattery discharged (Chapter 5).
m mBattery terminal connections loose or corroded (Chapter 1).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mFuel injection system fault (Chapter 4).
m mOther ignition system fault (Chapters 1 and 5).
m mLow cylinder compressions (Chapter 2).
Engine difficult to start when hot
m
mAir filter element dirty or clogged (Chapter 1).
m mFuel injection system fault (Chapter 4).
m mLow cylinder compressions (Chapter 2).
Starter motor noisy or excessively-rough in
engagement
m mStarter pinion or flywheel/driveplate ring gear teeth loose or broken
(Chapters 2 or 5).
m mStarter motor mounting bolts loose or missing (Chapter 5).
m mStarter motor internal components worn or damaged (Chapter 5).
Engine starts, but stops immediately
m
mLoose or faulty electrical connections in the ignition circuit
(Chapters 1 and 5).
m mVacuum leak at the throttle body or inlet manifold (Chapter 4).
m mFuel injection system fault (Chapter 4).
Engine idles erratically
m
mCarburettor stepper motor plunger dirty (2.0 litre only) (Chapter 5)
m mIncorrectly-adjusted idle speed (Chapter 4).
m mAir filter element clogged (Chapter 1).
m mVacuum leak at the throttle body, inlet manifold or associated hoses
(Chapter 4).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mUneven or low cylinder compressions (Chapter 2).
m mCamshaft lobes worn (Chapter 2).
m mFuel injection system fault (Chapter 4).
Engine misfires at idle speed
m
mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mFaulty spark plug HT leads (Chapter 5).
m mVacuum leak at the throttle body, inlet manifold or associated hoses
(Chapter 4).
m mFuel injection system fault (Chapter 4).
m mDistributor cap cracked or tracking internally, where applicable
(Chapter 5).
m mUneven or low cylinder compressions (Chapter 2).
m mDisconnected, leaking, or perished crankcase ventilation hoses
(Chapter 4).
Fault Finding
spark plugs may only be pointers to some underlying fault.
The pages which follow provide an easy-reference guide to the more
common problems which may occur during the operation of the
vehicle. These problems and their possible causes are grouped under
headings denoting various components or systems, such as Engine,
Cooling system, etc. The Chapter and/or Section which deals with the
problem is also shown in brackets. Whatever the fault, certain basic
principles apply. These are as follows:
Verify the fault. This is simply a matter of being sure that you know
what the symptoms are before starting work. This is particularly
important if you are investigating a fault for someone else, who may
not have described it very accurately.
Don’t overlook the obvious. For example, if the vehicle won’t start, is
there fuel in the tank? (Don’t take anyone else’s word on this particular
point, and don’t trust the fuel gauge either!) If an electrical fault isindicated, look for loose or broken wires before digging out the test
gear.
Cure the disease, not the symptom. Substituting a flat battery with a
fully-charged one will get you off the hard shoulder, but if the
underlying cause is not attended to, the new battery will go the same
way. Similarly, changing oil-fouled spark plugs for a new set will get
you moving again, but remember that the reason for the fouling (if it
wasn’t simply an incorrect grade of plug) will have to be established
and corrected.
Don’t take anything for granted. Particularly, don’t forget that a
“new” component may itself be defective (especially if it’s been rattling
around in the boot for months), and don’t leave components out of a
fault diagnosis sequence just because they are new or recently-fitted.
When you do finally diagnose a difficult fault, you’ll probably realise
that all the evidence was there from the start.
1 Engine
procarmanuals.com

Engine misfires throughout the driving speed range
m mFuel filter choked (Chapter 1).
m mFuel pump faulty, or delivery pressure low (Chapter 4).
m mFuel tank vent blocked, or fuel pipes restricted (Chapter 4).
m mVacuum leak at the throttle body, inlet manifold or associated hoses
(Chapter 4).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mFaulty spark plug HT leads (Chapter 5).
m mDistributor cap cracked or tracking internally (Chapter 5).
m mFaulty ignition coil (Chapter 5).
m mUneven or low cylinder compressions (Chapter 2).
m mFuel injection system fault (Chapter 4).
Engine hesitates on acceleration
m
mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mVacuum leak at the throttle body, inlet manifold or associated hoses
(Chapter 4).
m mFuel injection system fault (Chapter 4).
Engine stalls
m
mVacuum leak at the throttle body, inlet manifold or associated hoses
(Chapter 4).
m mFuel filter choked (Chapter 1).
m mFuel pump faulty, or delivery pressure low (Chapter 4).
m mFuel tank vent blocked, or fuel pipes restricted (Chapter 4).
m mFuel injection system fault (Chapter 4).
Engine lacks power
m
mFuel filter choked (Chapter 1).
m mFuel pump faulty, or delivery pressure low (Chapter 4).
m mUneven or low cylinder compressions (Chapter 2).
m mWorn, faulty or incorrectly-gapped spark plugs (Chapter 1).
m mVacuum leak at the throttle body, inlet manifold or associated hoses
(Chapter 4).
m mFuel injection system fault (Chapter 4).
m mBrakes binding (Chapters 1 and 10).
m mClutch slipping (Chapter 6).
Engine backfires
m
mVacuum leak at the throttle body, inlet manifold or associated hoses
(Chapter 4).
m mFuel injection system fault (Chapter 4).
Oil pressure warning light illuminated with engine
running
m mLow oil level, or incorrect oil grade (Chapter 1).
m mFaulty oil pressure sensor (Chapter 2).
m mWorn engine bearings and/or oil pump (Chapter 2).
m mExcessively high engine operating temperature (Chapter 3).
m mOil pressure relief valve defective (Chapter 2).
m mOil pick-up strainer clogged (Chapter 2).
Note:Low oil pressure in a high-mileage engine at tickover is not
necessarily a cause for concern. Sudden pressure loss at speed is far
more significant. In any event, check the gauge or warning light sender
before condemning the engine.
Engine runs-on after switching off
m mExcessive carbon build-up in engine (Chapter 2).
m mExcessively high engine operating temperature (Chapter 3).
Engine noises
Pre-ignition (pinking) or knocking during acceleration or
under load
m mIgnition timing incorrect/ignition system fault (Chapters 1 and 5).
m mIncorrect grade of spark plug (Chapter 1).
m mIncorrect grade of fuel (Chapter 1).
m mVacuum leak at throttle body, inlet manifold or associated hoses
(Chapter 4).
m mExcessive carbon build-up in engine (Chapter 2).
m mFuel injection system fault (Chapter 4).
Whistling or wheezing noises
m
mLeaking inlet manifold or throttle body gasket (Chapter 4).
m mLeaking exhaust manifold gasket (Chapter 4).
m mLeaking vacuum hose (Chapters 4 and 10).
m mBlowing cylinder head gasket (Chapter 2).
Tapping or rattling noises
m
mWorn valve gear, timing chain, camshaft or hydraulic tappets
(Chapter 2).
m mAncillary component fault (water pump, alternator, etc) (Chapters 3,
5, etc).
Knocking or thumping noises
m mWorn big-end bearings (regular heavy knocking, perhaps less under
load) (Chapter 2).
m mWorn main bearings (rumbling and knocking, perhaps worsening
under load) (Chapter 2).
m mPiston slap (most noticeable when cold) (Chapter 2).
m mAncillary component fault (water pump, alternator, etc) (Chapters 3,
5, etc).
REF•7Fault Finding
2Cooling system
Overheating
m
mAuxiliary drivebelt broken or incorrectly adjusted (Chapter 1).
m mInsufficient coolant in system (Chapter 1).
m mThermostat faulty (Chapter 3).
m mRadiator core blocked, or grille restricted (Chapter 3).
m mElectric cooling fan or thermostatic switch faulty (Chapter 3).
m mViscous-coupled fan faulty (Chapter 3).
m mIgnition timing incorrect, or ignition system fault (Chapters 1 and 5).
m mInaccurate temperature gauge sender unit (Chapter 3).
m mAirlock in cooling system (Chapter 3).
Overcooling
m
mThermostat faulty (Chapter 3).
m mInaccurate temperature gauge sender unit (Chapter 3).
External coolant leakage
m
mDeteriorated or damaged hoses or hose clips (Chapter 1).
m mRadiator core or heater matrix leaking (Chapter 3).
m mPressure cap faulty (Chapter 3).
m mWater pump internal seal leaking (Chapter 3).
m mWater pump-to-block seal leaking (Chapter 3).
m mBoiling due to overheating (Chapter 3).
m mCore plug leaking (Chapter 2).
Internal coolant leakage
m
mLeaking cylinder head gasket (Chapter 2).
m mCracked cylinder head or cylinder block (Chapter 2).
Corrosion
m
mInfrequent draining and flushing (Chapter 1).
m mIncorrect coolant mixture or inappropriate coolant type (Chapter 1).
procarmanuals.com

Ignition/no-charge warning light remains illuminated
with engine running
m m
Auxiliary drivebelt broken, worn, or incorrectly adjusted (Chapter 1).m
mAlternator brushes worn, sticking, or dirty (Chapter 5).m
mAlternator brush springs weak or broken (Chapter 5).m
mInternal fault in alternator or voltage regulator (Chapter 5).m
mBroken, disconnected, or loose wiring in charging circuit (Chapter 5).
Ignition/no-charge warning light fails to come on
m m
Warning light bulb blown (Chapter 13).m
mBroken, disconnected, or loose wiring in warning light circuit
(Chapter 13).
m mAlternator faulty (Chapter 5).
Battery will not hold a charge for more than a few days
m m
Battery defective internally (Chapter 5).m
mBattery electrolyte level low - where applicable (Chapter 1).m
mBattery terminal connections loose or corroded (Chapter 1).m
mAuxiliary drivebelt worn - or incorrectly adjusted, where applicable
(Chapter 1).
m mAlternator not charging at correct output (Chapter 5).m
mAlternator or voltage regulator faulty (Chapter 5).m
mShort-circuit causing continual battery drain (Chapters 5 and 13).
Instrument readings inaccurate or erratic
Instrument readings increase with engine speed
m
mFaulty voltage regulator (Chapter 13).
Fuel or temperature gauges give no reading
m
mFaulty gauge sender unit (Chapters 4 and 5).m
mWiring open-circuit (Chapter 13).m
mFaulty gauge (Chapter 13).
Fuel or temperature gauges give continuous maximum
reading
m mFaulty gauge sender unit (Chapters 4 and 5).m
mWiring short-circuit (Chapter 13).m
mFaulty gauge (Chapter 13).
Horn inoperative, or unsatisfactory in operation
Horn operates all the time
m
mHorn contacts permanently bridged or horn push stuck down
(Chapter 13).
Horn fails to operate
m mBlown fuse (Chapter 13).m
mCable or cable connections loose, broken or disconnected
(Chapter 13).
m mFaulty horn (Chapter 13).
Horn emits intermittent or unsatisfactory sound
m
mCable connections loose (Chapter 13).m
mHorn mountings loose (Chapter 13).m
mFaulty horn (Chapter 13).
Windscreen/tailgate wipers inoperative, or
unsatisfactory in operation
Wipers fail to operate, or operate very slowly
m mWiper blades stuck to screen, or linkage seized or binding
(Chapters 1 and 13).
m mBlown fuse (Chapter 13).m
mCable or cable connections loose, broken or disconnected
(Chapter 13).
m mFaulty relay (Chapter 13).m
mFaulty wiper motor (Chapter 13).
Wiper blades sweep over too large or too small an area of
the glass
m mWiper arms incorrectly positioned on spindles (Chapter 1).m
mExcessive wear of wiper linkage (Chapter 13).m
mWiper motor or linkage mountings loose or insecure (Chapter 13).
Wiper blades fail to clean the glass effectively
m
mWiper blade rubbers worn or perished (Chapter 1).m
mWiper arm tension springs broken, or arm pivots seized (Chapter 13).m
mInsufficient windscreen washer additive to adequately remove road
film (Chapter 1).
Windscreen/tailgate washers inoperative, or
unsatisfactory in operation
One or more washer jets inoperative
m mBlocked washer jet (Chapter 1).m
mDisconnected, kinked or restricted fluid hose (Chapter 13).m
mInsufficient fluid in washer reservoir (Chapter 1).
Washer pump fails to operate
m
mBroken or disconnected wiring or connections (Chapter 13).m
mBlown fuse (Chapter 13).m
mFaulty washer switch (Chapter 13).m
mFaulty washer pump (Chapter 13).
Washer pump runs for some time before fluid is emitted
from jets
m mFaulty one-way valve in fluid supply hose (Chapter 13).
Electric windows inoperative, or unsatisfactory in
operation
Window glass will only move in one direction
m mFaulty switch (Chapter 13).
Window glass slow to move
m
mRegulator seized or damaged, or in need of lubrication (Chapter 12).m
mDoor internal components or trim fouling regulator (Chapter 12).m
mFaulty motor (Chapter 12).
Window glass fails to move
m
mBlown fuse (Chapter 13).m
mFaulty relay (Chapter 13).m
mBroken or disconnected wiring or connections (Chapter 13).m
mFaulty motor (Chapter 13).
Central locking system inoperative, or unsatisfactory
in operation
Complete system failure
m mBlown fuse (Chapter 13).m
mFaulty relay (Chapter 13).m
mBroken or disconnected wiring or connections (Chapter 13).
Latch locks but will not unlock, or unlocks but will not lock
m
mFaulty switch (Chapter 13).m
mBroken or disconnected latch operating rods or levers (Chapter 12).m
mFaulty relay (Chapter 13).
One solenoid/motor fails to operate
m
mBroken or disconnected wiring or connections (Chapter 13).m
mFaulty solenoid/motor (Chapter 12).m
mBroken, binding or disconnected latch operating rods or levers
(Chapter 12).
m mFault in door latch (Chapter 12).
REF•11Fault Finding
procarmanuals.com