1985 FORD GRANADA bonnet

1•3
1
Maintenance Schedule
Engine oil
SOHC:
With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.75 litres (6.6 pints)
DOHC:
With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 litres (7.9 pints)
Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.0 litres (7.0 pints)
V6:
With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.25 litres (7.5 pints)
Cooling system
OHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 litres (14.1 pints)
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5 litres (15.0 pints)
Fuel tank
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 litres (15.4 gallons)
Manual gearbox
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25 litres (2.2 pints)
Automatic transmission
All models (from dry) . . . . . . . . . . . . . . . . . . . . . . .8.5 litres (15.0 pints)
Final drive
7 inch crownwheel . . . . . . . . . . . . . . . . . . . . . . . . . .0.9 litres (1.6 pints)
7.5 inch crownwheel . . . . . . . . . . . . . . . . . . . . . . . . .1.3 litres (2.3 pints)
Power steering
OHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.65 litres (1.1 pints)
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.75 litres (1.3 pints)
Capacities
1 Battery
2 Engine oil dipstick
3 Inlet manifold
4 Throttle/kickdown cable
bracket
5 Suspension turrets
6 Ignition coil
7 Air cleaner cover
8 Fuel pressure regulator
9 Vane airflow meter
10 Headlight covers
11 Tune-up label
12 Idle speed control valve
13 Oil filler cap
14 Spark plug leads
15 VIN plate
16 Radiator hoses
17 Horn
18 Windscreen washer
pump19 Windscreen washer
reservoir
20 Alternator
21 Coolant expansion tank
cap
22 Engine mounting
23 Heater hose
24 Automatic transmission
fluid dipstick
25 Brake fluid reservoir
cap
26 Brake hydraulic unit
accumulator
27 Brake hydraulic unit
valve block
28 Main fuse/relay box
29 Wiper motor (behind
cover)
30 Heater blower cover
1 Windscreen wiper motor
2 Battery
3 Suspension strut top
mounting
4 Brake fluid reservoir
5 Ignition distributor
6 Coolant expansion tank
7 Washer fluid reservoir
8 Automatic transmission
fluid dipstick
9 Oil filler cap
10 Engine oil level dipstick
11 Air cleaner element
housing
12 Idle speed control valve
13 Ignition module
14 Manifold Absolute
Pressure (MAP) sensor15 Throttle position sensor
16 Power steering fluid
reservoir
17 Anti-theft alarm horn
18 Speed control system
diaphragm
19 Speed control system
vacuum pump
20 Vehicle identification
(VIN) plate
21 Fuel pressure regulator
22 Air charge temperature
sensor
23 Manifold absolute
pressure (MAP) sensor
vapour trap
24 Fuse/relay boxUnder-bonnet view of a 2.0 litre SOHC Granada with
fuel-injection
Under-bonnet view of a 2.0 litre DOHC Granada with
fuel-injection
procarmanuals.com

1•4Maintenance Schedule
1 Battery
2 Suspension turrets
3 Air cleaner cover
4 Vane airflow meters
5 Headlight covers
6 Tune-up label
7 Auxiliary driving light covers
8 Crankcase ventilation hoses
9 Throttle linkage cover
10 Throttle cable and kickdown switch
11 Plenum chamber
12 Idle speed control valve
13 Radiator top hose
14 Oil filler cap
15 Power steering fluid reservoir
16 Horn
17 Washer fluid level switch
18 Windscreen washer pump
19 Windscreen washer reservoir
20 Coolant level switch
21 Coolant expansion tank cap
22 Engine mounting
23 Heater hose
24 Brake hydraulic unit valve block
25 Brake fluid reservoir cap
26 Brake hydraulic unit accumulator
27 Main fuse/relay box
28 Wiper motor (behind cover)
29 Heater blower cover
30 Fuel pressure regulator
31 Distributor screening lid
32 Engine oil dipstick
33 Automatic transmission fluid dipstick Under-bonnet view of a 2.8 litre V6 Granada
1 Brake and fuel pipes
2 Transmission sump
3 Transmission crossmember
4 Speedometer sender unit
5 Propeller shaft coupling
6 Exhaust flanged joint
7 Exhaust mounting
8 Exhaust pipe
9 Jacking points
10 Anti-roll bar clamps
11 Anti-roll bar
12 Brake calipers
13 Brake flexible hoses
14 Suspension lower arms
15 Front crossmember
16 Track rods
17 Track rod ends
18 Steering rack bellows
19 Radiator bottom hose
20 Alternator
21 Transmission fluid cooler hoses
22 Crankshaft pulley
23 Fan
24 Oil filter
25 Sump drain plug
26 Starter motor
27 Starter motor solenoid Front underbody view of a 2.0 litre SOHC Granada with automatic transmission
procarmanuals.com

1•6Maintenance Procedures
This Chapter is designed to help the home
mechanic maintain his/her vehicle for safety,
economy, long life and peak performance.
The Chapter contains a master maintenance
schedule, followed by Sections dealing
specifically with each task in the schedule.
Visual checks, adjustments, component
renewal and other helpful items are included.
Refer to the accompanying illustrations of the
engine compartment and the underside of the
vehicle for the locations of the various
components.
Servicing your vehicle in accordance with
the mileage/time maintenance schedule and
the following Sections will provide a planned
maintenance programme, which should result
in a long and reliable service life. This is a
comprehensive plan, so maintaining some
items but not others at the specified service
intervals, will not produce the same results.
As you service your vehicle, you will
discover that many of the procedures can -
and should - be grouped together, because of
the particular procedure being performed, or
because of the close proximity of two
otherwise-unrelated components to one
another. For example, if the vehicle is raised
for any reason, the exhaust can be inspected
at the same time as the suspension and
steering components.
The first step in this maintenanceprogramme is to prepare yourself before the
actual work begins. Read through all the
Sections relevant to the work to be carried out,
then make a list and gather together all the
parts and tools required. If a problem is
encountered, seek advice from a parts
specialist, or a dealer service department.
If, from the time the vehicle is new, the
routine maintenance schedule is followed
closely, and frequent checks are made of fluid
levels and high-wear items, as suggested
throughout this manual, the engine will be kept
in relatively good running condition, and the
need for additional work will be minimised.
It is possible that there will be times when
the engine is running poorly due to the lack of
regular maintenance. This is even more likely if
a used vehicle, which has not received regular
and frequent maintenance checks, is
purchased. In such cases, additional work
may need to be carried out, outside of the
regular maintenance intervals.
If engine wear is suspected, a compression
test will provide valuable information regarding
the overall performance of the main internal
components. Such a test can be used as a
basis to decide on the extent of the work to be
carried out. If, for example, a compression test
indicates serious internal engine wear,
conventional maintenance as described in this
Chapter will not greatly improve theperformance of the engine, and may prove a
waste of time and money, unless extensive
overhaul work is carried out first.
The following series of operations are those
most often required to improve the
performance of a generally poor-running
engine:
Primary operations
a)Clean, inspect and test the battery
(Section 6)
b)Check all the engine-related fluids
(Section 3).
c)Check the condition and tension of the
auxiliary drivebelt (Section 21).
d)Renew the spark plugs (Section 20).
e)Inspect the distributor cap, rotor arm and
HT leads - as applicable (Chapter 5).
f)Check the condition of the air cleaner filter
element, and renew if necessary (Section 38).
g)Renew the fuel filter (Section 41).
h)Check the condition of all hoses, and
check for fluid leaks (Section 10).
i)Check the idle speed and mixture settings
- as applicable (Chapter 4).
If the above operations do not prove fully
effective, carry out the following secondary
operations:
Secondary operations
a)Check the charging system (Chapter 5).
b)Check the ignition system (Chapter 5).
c)Check the fuel system (Chapter 4).
d)Renew the distributor cap and rotor arm -
as applicable (Chapter 5).
f)Renew the ignition HT leads - as
applicable (Chapter 5).
2Intensive maintenance
1Introduction
Engine oil
1Check the oil level as follows.
2With the vehicle parked on level ground,
and with the engine having been stopped for a
few minutes, open and prop the bonnet.
Withdraw the dipstick, wipe it on a clean ragand re-insert it fully. Withdraw it again and
read the oil level relative to the marks on the
end of the stick (see illustration).
3The oil level should be in between the MAX
and MIN marks on the dipstick. If it is at or
below the MIN mark, top-up (via the oil filler
cap) without delay. The quantity of oil required
to raise the lever from MIN to MAX on the
dipstick is approximately 1 litre. Do not overfill
(see illustration).
4The rate of oil consumption depends onleaks and on the quantity of oil burnt. External
leakage should be obvious. Oil which is burnt
may enter the combustion chambers through
the valve guides or past the piston rings;
excessive blow-by past the rings can also
force oil out via the crankcase ventilation
system. Driving conditions also affect oil
consumption.
5Always use the correct grade and type of oil
as shown in “Lubricants and fluids”.
Coolant
6Check the coolant level as follows.
7Open and prop the bonnet. Observe the
level of coolant through the translucent walls
of the expansion tank (on the right-hand side
of the engine bay). The level should be up to
the MAX mark when the engine is cold, and
may be somewhat above the mark when hot.
8If topping-up is necessary, wait for the
system to cool down if it is hot. Place a thick
rag over the expansion tank cap and slacken it
3Fluid level checks
3.2 Dipstick markings3.3 Topping up the engine oil
Warning: DO NOT remove the
expansion tank pressure cap
when the engine is hot, as there
is a great risk of scalding.
Weekly checks
procarmanuals.com

to release any pressure. When pressure has
been released, carry on unscrewing the cap
and remove it.
9Top-up to the MAX mark with the specified
coolant (see illustration).In an emergency
plain water is better than nothing, but
remember that it is diluting the proper coolant.
Do not add cold water to an overheated
engine whilst it is still hot.
10Refit the expansion tank cap securely
when the level is correct. With a sealed type
cooling system like this, the addition of
coolant should only be necessary at very
infrequent intervals. If frequent topping-up is
required, it is likely there is a leak in the
system. Check the radiator, all hoses and joint
faces for any sign of staining or actual
wetness, and rectify as necessary. If no leaks
can be found, it is advisable to have the
pressure cap and the entire system pressure-
tested by a dealer or suitably-equipped
garage, as this will often show up a small leak
not previously apparent.
Brake fluid
Be sure to use only the specified brake
hydraulic fluid, since mixing different types of
fluid can cause damage to the system. See
“Lubricants, fluids and capacities”at the
beginning of this Chapter. When adding fluid,
it is a good idea to inspect the reservoir for
contamination. The system should be drained
and refilled if deposits, dirt particles or
contamination are seen in the fluid.
11Check the brake fluid level as follows.
12With the vehicle parked on level ground
and the ignition switched off, pump the brake
pedal at least 20 times or until the pedal feels
hard.
13Open the bonnet. Switch on the ignition:
the hydraulic unit pump will be heard running.
Wait until the pump stops, then switch off the
ignition.
14The fluid level in the reservoir should now
be between the MAX and MIN marks. If
topping-up is necessary, unplug the electrical
connectors from the cap, then unscrew and
remove it (see illustration).Catch the
hydraulic fluid which will drip off the level
sensor with a piece of rag.
15Top-up with fresh brake fluid of the
specified type (see illustration).Do not
overfill. Refit and reconnect the reservoir cap
immediately.16The fluid level in the reservoir will drop
slightly as the brake pads wear down during
normal operation. If the reservoir requires
repeated replenishment to maintain the proper
level, this is an indication of a hydraulic leak
somewhere in the system, which should be
investigated immediately.
Washer fluid
17When topping-up the windscreen or rear
screen washer fluid reservoir, a screenwash
additive should be added in the quantities
recommended on the bottle.
1On later models tyres may have tread wear
safety bands, which will appear when the
tread depth reaches approximately 1.6 mm.
Otherwise, tread wear can be monitored with a
simple, inexpensive device known as a tread
depth indicator gauge (see illustration).
2Wheels and tyres should give no real
problems in use, provided that a close eye is
kept on them with regard to excessive wear or
damage. To this end, the following points
should be noted.
3Ensure that the tyre pressures are checked
regularly and maintained correctly (see
illustration). Checking should be carried out
with the tyres cold, not immediately after the
vehicle has been in use. If the pressures are
checked with the tyres hot, an apparently-high
reading will be obtained, owing to heat
expansion. Under no circumstancesshould
an attempt be made to reduce the pressures
to the quoted cold reading in this instance, or
effective under-inflation will result.
4Note any abnormal tread wear (see
illustration). Tread pattern irregularities such
as feathering, flat spots, and more wear on
one side than the other, are indications of front
wheel alignment and/or balance problems. If
any of these conditions are noted, they should
be rectified as soon as possible.
5Under-inflation will cause overheating of the
tyre, owing to excessive flexing of the casing,
and the tread will not sit correctly on the road
surface. This will cause excessive wear, not to
mention the danger of sudden tyre failure due
to heat build-up.
4Tyre checks
1•7
1
Weekly checks
3.14 Removing the brake fluid reservoir cap3.15 Topping up the brake fluid reservoir
4.1 Checking the tyre tread depth4.3 Checking tyre pressure
3.9 Topping up the cooling system
Warning: Brake hydraulic fluid
can harm your eyes and damage
painted surfaces, so use extreme
caution when handling and
pouring it. Do not use fluid that has been
standing open for some time, as it absorbs
moisture from the air. Excess moisture can
cause a dangerous loss of braking
effectiveness.If any brake fluid gets onto
paintwork, wash it off
immediately with clean water.
procarmanuals.com

engine valve clearances must be correct. The
ignition system must also be in good
condition.
3Mixture adjustment is not usual on a routine
basis. If the CO level is incorrect, proceed as
follows.
4Connect the exhaust gas analyser as
instructed by the manufacturers.
5Raise the engine speed to 3000 rpm
approximately and hold it at this speed for
30 seconds, then allow it to idle. Repeat this
procedure every 60 seconds until adjustment
is complete.6Read the CO level when it has stabilised
after the 3000 rpm burst. The desired level is
given in the Specifications of Chapter 4
(Pierburg 2V carburettor).
7If the idle mixture needs adjustment, turn
the mixture adjusting screw. The screw may
be covered by a tamperproof plug.
8Recheck the idle speed after adjusting the
mixture.
9Stop the engine and disconnect the test
gear. 10Fit a new tamperproof plug to the mixture
adjusting screw if required.
2.0 litre SOHC engine
11If mixture adjustment is required, proceed
as described for the 1.8 litre engine above.
12See illustrationfor the location of the
mixture adjusting screw on the Weber 2V
carburettor fitted to this engine
DOHC engine
13Proceed as described for the 1.8 litre
engine, noting the following points (see
illustration).
14Refer to the Specification for the Weber 2V
(TLD) carburettor in Chapter 4.
15The air cleaner must be removed for
access to the mixture adjustment screw.
16Prise the tamperproof seal from the
mixture screw.
17Loosely refit the air cleaner, ensuring that
the vacuum pipe and the camshaft cover
breather hose are securely connected and free
from restrictions (there is no need to secure
the air cleaner in position).
18On completion, fit a new tamperproof seal
to the mixture screw (the service replacement
plug is coloured blue) and refit the air cleaner
assembly.
1Fluid level should be checked with the
transmission at operating temperature (after a
run) and with the vehicle parked on level
ground.
2Open and prop the bonnet. With the engine
idling and the handbrake and footbrake
applied, move the gear selector through all
positions three times, finishing up in position
P.
3Wait one minute. With the engine still idling,
withdraw the transmission dipstick (see
illustration).Wipe the dipstick with a clean
lint-free rag, re-insert it fully and withdraw itagain. Read the fluid level at the end of the
dipstick: it should be between the two
notches.
4If topping-up is necessary, do so via the
dipstick tube, using clean transmission fluid of
the specified type (see illustration).Do not
overfill.
5Stop the engine, refit the dipstick and close
the bonnet.
6Note that if the fluid level was below the
minimum mark when checked or is in constant
need oftopping-up, check around the
transmission for any signs of excessive fluid
leaks.If present, leaks must be rectified
without delay.
7If the colour of the fluid is dark brown or
black this denotes the sign of a worn brakeband or transmission clutches, in which case
have your Ford dealer check the transmission
at the earliest opportunity.
1Place the vehicle over a pit, or raise and
support it at front and rear. The vehicle must
be level for an accurate check.
2If the transmission is hot after a run, allow it
to cool for a few minutes. This is necessary
because the oil can foam when hot and give a
false level reading.
3Wipe clean around the filler/level plug,
which is located on the left-hand side of the
gearbox. Unscrew the plug with a square drive
key and remove it
4Using a piece of bent wire as a dipstick,
check that the oil level is up to the bottom of
the filler/level plug hole, or no more than 5 mm
(0.2 in) below it.
5Top-up if necessary using clean oil of the
specified type. Do not overfill; allow excess oil
to drip out of the plug hole if necessary. Refit
and tighten the filler/level plug.
6Frequent need for topping-up can only be
due to leaks, which should be rectified. The
rear extension oil seal can be renewedin situ
after removing the propeller shaft (N type
only).
7No periodic oil changing is specified, and no
drain plug is fitted.
18Manual gearbox oil level
check
17Automatic transmission fluid
level check
1•11
1
Every 12 000 miles or 12 months
16.13 Idle adjustment screws- Weber 2V
TLD carburettor
A Idle mixtureB Idle speed
16.12 Idle mixture adjustment screw
(arrowed) - Weber 2V carburettor
17.4 Topping up the transmission fluid17.3 The automatic transmission dipstick
Every 12 000 miles or 12 months
procarmanuals.com

1Work around the vehicle, and lubricate the
hinges and locks with a light machine oil.
2Lightly lubricate the bonnet release
mechanism and exposed sections of inner
cable with a smear of grease.
3Check the security and operation of all
hinges, latches and locks, adjusting them
where required. Where applicable, check the
operation of the central locking system.
4Check the condition and operation of the
tailgate struts, renewing them if either is
leaking or is no longer able to support the
tailgate securely when raised.
SOHC and V6 engines
1The correct functioning of the spark plugs is
vital for the correct running and efficiency of
the engine. It is essential that the plugs fitted
are appropriate for the engine.
2Make sure that the ignition is switched off
before inspecting the HT leads to see if they
carry their cylinder numbers - if not, number
each lead using sticky tape or paint.
3Pull the HT lead connectors off the plugs.
Pull on the connectors, not on the leads.
4Blow away any dirt from around the spark
plug recesses in the cylinder head(s).
5Unscrew and remove the plugs, using a
proprietary plug spanner or a spark plug
socket, extension and ratchet.
6The condition of the plugs will tell much
about the overall condition of the engine. If the
insulator nose of the spark plug is clean and
white, with no deposits, this is indicative of a
weak mixture or too hot a plug (a hot plug
transfers heat away from the electrode slowly,
a cold plug transfers heat away quickly).
7If the tip and insulator nose are covered with
hard black-looking deposits, then this is
indicative that the mixture is too rich. Should
the plug be black and oily, then it is likely that
the engine is fairly worn, as well as the mixture
being too rich.
8If the insulator nose is covered with light tan
to greyish-brown deposits, then the mixture is
correct, and it is likely that the engine is in
good condition.
9Apply a smear of anti-seize compound to
the threads of the new plugs. Make sure that
theinsulators are clean and that the screwed
HT lead adapters are tight. Pay particular
attention to the plug seating surfaces on OHC
engines, since these plugs have no sealing
washers (“taper seat” type) and any dirt will
cause a bad seal.
10Screw each plug into its hole by hand. If a
plug is reluctant to go in, do not force it with a
spanner, but unscrew it and try again. If the
plug is cross-threaded, it is the cylinder head
which will be damaged.11Final tightening of the spark plugs should
ideally be carried out using a torque wrench.
The tightening torques are given in the
Specifications. If a torque wrench is not
available, tighten the plugs beyond the point
where they contact the head as follows:
OHC (taper seat plugs) - One-sixteenth of a
turn maximum
V6 (plugs with washers) - One-quarter of a
turn maximum
12If the taper seat type of plug is
overtightened, the sealing faces will bite
together and removal will be very difficult.
13Refit the HT leads to the plugs, paying
attention to the cylinder numbers. Push each
connector firmly onto its plug.
14Run the engine to verify that the HT leads
have been refitted correctly.
DOHC engines
15Proceed as described above whilst noting
the following points.
a)Remove the air cleaner as described in
Chapter 4.
b)The minimal length of number 3 HT lead
makes removal from the spark plug
difficult. It is advisable to remove this lead
from the distributor prior to removing it
from the spark plug.
c)The spark plugs are deeply recessed in
the cylinder head and it will be necessary
to use a spark plug socket with a long
extension bar. If possible, use a spark plug
socket with a rubber grip inside as this will
hold onto the spark plug once loosened
and will enable the spark plugs to be
withdrawn and refitted more easily.
SOHC and all V6 engines
1All of these engines have one or two
drivebelts which drive the water pump and
alternator from the crankshaft pulley. When
power steering is fitted, the same belts drive
the steering pump. The air conditioning
compressor, when fitted, is driven
independently.
2Periodically inspect the drivebelt(s) for
fraying, cracks, glazing or other damage. Turn
the engine so that the full length of the belt(s)
can be viewed. Renew belts which are in poor
condition. When twin drivebelts are fitted, both
must be renewed together, even if only one is
damaged.
3Check the tension of the drivebelt(s) by
pressing firmly with the fingers in the middle of
the longest belt run (engine stopped). Tension
is correct when the belt can be deflected by
10 mm (0.4 in) under firm finger pressure (see
illustration).
4Renewal and adjustment procedures for
models with power steering are given in
Chapter 11. For other models proceed as
follows.
5Disconnect the battery negative lead.
6On models with air conditioning, remove the
compressor drivebelt.
7Slacken the alternator pivot and adjusting
bolts. Swing the alternator towards the engine
and slip the belt(s) off the pulleys.
8Fit the new belt(s) over the pulleys. Move
the alternator away from the engine until the
belt tension is correct, then tighten the
alternator adjusting strap and pivot bolts. If it
is necessary to lever against the alternator to
achieve the correct tension, only do so using a
wooden or plastic lever(seeillustration).
9Refit and tension the air conditioning
compressor drivebelt, when applicable.
10Reconnect the battery. If a new drivebelt
has been fitted, run the engine for a few
minutes, then stop it and recheck the tension.
11Check the tension of new belts again after
a few hundred miles.
21Auxiliary drivebelt check
20Spark plug renewal
19Hinge and lock check and
lubrication
1•12Every 12 000 miles or 12 months
21.3 Checking drivebelt tension
It is very often difficult to insert spark
plugs into their holes without cross-
threading them. To avoid this
possibility, fit a short length of 5/16-
inch internal diameter rubber hose over
the end of the spark plug. The flexible
hose acts as a universal joint to help
align the plug with the plug hole.
Should the plug begin to cross-thread,
the hose will slip on the spark plug,
preventing thread damage to the
aluminium cylinder head. Remove the
rubber hose, and tighten the plug to the
specified torque using the spark plug
socket and a torque wrench. Fit the
remaining spark plugs in the same
manner.
procarmanuals.com

The cylinder head is of crossflow design
with the inlet manifold mounted on the left-
hand side and the exhaust manifold mounted
on the right-hand side.
Lubrication is by means of a bi-rotor pump
which draws oil through a strainer located
inside the sump, and forces it through a full-
flow filter into the engine oil galleries where it
is distributed to the crankshaft, camshaft and
auxiliary shaft. The big-end bearings are
supplied with oil via internal drillings in the
crankshaft.The undersides of the pistons are
supplied with oil from drillings in the big-ends.
The distributor shaft is intermittently supplied
with oil from the drilled auxiliary shaft. The
camshaft and cam followers are supplied with
oil via a drilled spray tube from the centre
camshaft bearing.
A semi-closed crankcase ventilation system
is employed whereby piston blow-by gases
are drawn into the inlet manifold via an oil
separator and on carburettor models a control
valve.
The following operations can be carried out
without removing the engine, although the
work may be easier and quicker with the
engine removed:
a)Removal and refitting of the cylinder head
b)Removal and refitting of the camshaft
(after removing the cylinder head)
c)Removal and refitting of the timing belt
and sprockets
d)Removal and refitting of the sump and oil
pump
e)Removal and refitting of the pistons,
connecting rods and big-end bearings
f)Renewal of the engine mountings
g)Renewal of the crankshaft oil seals
h)Removal and refitting of the auxiliary shaft
j)Removal and refitting of the flywheel
The engine must be removed from the
vehicle for the following operations:
a)Renewal of the crankshaft main bearings
b)Removal and refitting of the crankshaft
The engine may be lifted out either on its
own or together with the gearbox. Unless work
is also necessary on the gearbox it is
recommended that the engine is removed on
its own. Where automatic transmission is
fitted, the engine should be removed on its
own owing to the additional weight. If the
engine and gearbox are removed together,
they will have to be tilted at a very steep angle;
make sure that the range of the lifting tackle is
adequate.1Disconnect the battery negative lead.
2Remove the bonnet.
3On carburettor models, remove the air
cleaner. On fuel-injection models, remove the
air cleaner cover, vane airflow meter and air
inlet trunking.
4If a splash guard is fitted, remove it.
5Release the securing clips and bolts and
remove the upper half of the fan shroud. On
carburettor models remove the lower half of
the shroud too.
6Drain the cooling system.
7Disconnect the radiator top and bottom
hoses from the thermostat housing and water
pump. Disconnect the top hose spur from the
expansion tank and unclip it.
8Disconnect the heater hoses from the water
pump and from the inlet manifold or automatic
choke housing. Unclip the hoses.
9On models with power steering, remove the
steering pump.
10Disconnect the vacuum pipe(s) from the
inlet manifold, labelling them if there is any
possibility of confusion.
11Disconnect the following wiring, as
applicable:
a)Alternator
b)Temperature gauge sender
c)Engine management temperature sensor
d)Distributor
e)Oil pressure switch
f)Automatic choke and thermo-switch
g)Carburettor stepper motor
h)Fuel-injection system sub-harness
j)Inlet manifold heater
12Disconnect the HT lead from the coil.
13If an oil level sensor is fitted, remove it
(see illustration).
14Unbolt the throttle cable bracket,
disconnect the inner cable and move the cable
and bracket aside. Also disconnect the
downshift cable on automatic transmission
models.
15On carburettor models, disconnect the
fuel lines from the fuel pump (mechanised
type) and from the carburettor. Be prepared
for fuel spillage.
16On fuel-injection models, disconnect the
fuel supply union from the injector rail, and the
fuel return pipe from the fuel pressureregulator. Be prepared for fuel spillage, and
for some spray if the supply side is still
under pressure.
17Unbolt the exhaust downpipe from the
manifold.
18On models with air conditioning, unbolt
the compressor and move it aside without
straining the flexible hoses.
19Remove the starter motor.
20Although not specified by the
manufacturers, the author advises that either
the radiator or the cooling fan be removed, to
reduce the risk of damage.
21Attach the lifting tackle to the two lifting
eyes on the engine, so that when suspended
the engine will be roughly horizontal. Take the
weight of the engine.
22Remove the single nut on each side which
secures each engine bearer to its mounting.
23Working under the vehicle, remove the
bracing strap which connects the engine and
transmission. Unbolt the adapter plate from
the bottom of the transmission bellhousing.
24On automatic transmission models, unbolt
the torque converter from the driveplate.
25Remove the engine-to-bellhousing bolts.
Note the location of the battery earth strap.
26Support the transmission, preferably with
a trolley jack.
27Check that nothing has been overlooked,
then raise the engine and draw it forwards
clear of the transmission input shaft. Do not
allow the weight of the engine to hang on the
shaft, and do not lift the transmission by it.
28On automatic transmission models, make
sure that the torque converter stays engaged
with the oil pump in the transmission as the
engine is withdrawn,
29Lift the engine out of the engine bay and
take it to the bench.
1Engine removal with automatic transmission
is not recommended.
2Proceed as in the previous Section,
paragraphs 1 to 18.
3Disconnect the wiring from the starter
motor, and release the battery earth cable
from its bellhousing bolt.
4Remove the radiator.
5Remove the propeller shaft.
6Disconnect and unclip the reversing light
switch and speedometer sender unit wiring.
7Disconnect the clutch cable.
8Unbolt the anti-roll bar mounting brackets
and lower the anti-roll bar as far as possible.
9From inside the vehicle remove the gear
lever.
10Drain the engine oil.
11Unhook the exhaust system from its
mounting on the gearbox crossmember. Either
support the system or remove it completely.
12Support the gearbox, preferably with a
trolley jack, then unbolt and remove the
gearbox crossmember. Note the earth strap (if
fitted) under one of the crossmember bolts.
13Attach lifting tackle to the two lifting eyes
on the engine so that when suspended it will
be at an angle of approximately 45°.
6Engine - removal with manual
gearbox
5Engine - removal leaving
gearbox/transmission in vehicle
4Methods of engine removal
3Major operations requiring
engine removal
2Major operations possible with
the engine in the vehicle
SOHCengines 2A•5
2A
5.13 Oil level sensor
procarmanuals.com

manifold. Piston blow-by gases are drawn
through the oil separator and the vent valve to
the inlet manifold. The blow-by gases are then
drawn into the engine together with the fuel/air
mixture. Refer to Chapter 1 for maintenance of
the system.
The following operations can be carried out
without removing the engine from the vehicle.
a)Removal of the camshafts.
b)Removal and servicing of the cylinder
head.
c)Removal of the timing chain and
sprockets.
d)Removal of the oil pump.
e)Removal of the sump.
f)Removal of the pistons and connecting
rods.
g)Removal of the big-end bearings.
h)Removal of the engine mountings.
i)Removal of the clutch and flywheel.
j)Removal of the crankshaft front and rear
oil seals.
The following operations can only be carried
out after removing the engine from the vehicle.
a)Removal of the crankshaft main bearings.
b)Removal of the crankshaft.
Note: A hoist and lifting tackle will be required
to lift the engine out of the vehicle.
1Disconnect the battery negative lead.
2Remove the bonnet.
3On carburettor models, remove the air cleaner.
4On fuel-injection models, remove the air
inlet hose, plenum chamber and air cleaner lid
as an assembly.
5Disconnect the breather hose from the
camshaft cover, and unscrew the bolt
securing the hose support bracket to the left-
hand side of the cylinder head (see
illustration).
6Drain the cooling system.
7To provide additional working space,
remove the radiator.8Disconnect the coolant hoses from the
water pump housing on the left-hand side of
the engine and the cylinder head (see
illustration).
9Disconnect the coolant hoses from the
thermostat housing.
10Disconnect the heater coolant hose from
the inlet manifold.
11Where applicable, release the coolant
hose from the bracket under the carburettor
automatic choke housing.
12Disconnect the throttle cable and (where
necessary) speed control cable from the
throttle linkage.
13On carburettor models, disconnect the
vacuum pipe from the engine management
module.
14Disconnect the brake servo vacuum hose
(where necessary) from the inlet manifold.
15On fuel-injection models, disconnect the
vacuum pipes from the MAP sensor (located
on the suspension turret on the right-hand
side of the engine compartment) and, where
applicable, the air conditioning system.
16On carburettor models, disconnect the
fuel supply and return hoses at the
carburettor, and plug the ends of the hoses to
minimise petrol spillage. Take adequate fire
precautions.
17On fuel-injection models, slowly loosen
the fuel feed union at the fuel rail to relieve the
pressure in the fuel system before
disconnecting the union. Be prepared for
petrol spillage and take adequate fire
precautions. Disconnect the fuel feed hose,and disconnect the fuel return hose from the
fuel pressure regulator. Plug the ends of the
hoses to minimise petrol spillage.
18Disconnect the HT lead from the ignition
coil, and unclip it from the timing chain cover.
19Disconnect the wiring from the following
components as applicable, depending on
model. Then free the wiring loom from any
necessary retaining clips or ties and position it
clear of the engine.
a)Alternator.
b)Starter motor.
c)Oil pressure warning lamp switch.
d)Temperature gauge sender.
e)Cooling fan switch.
f)Anti-dieselling valve (carburettor models).
g)Automatic choke heater (carburettor
models).
h)Engine coolant temperature sensor.
i)Crankshaft speed/position sensor.
j)Air charge temperature sensor.
k)Throttle position sensor.
l)Fuel temperature sensor.
m)Fuel injectors.
20Remove the water pump/alternator
drivebelt, then unbolt the power steering
pump from the mounting bracket and move it
clear of the engine. Note that there is no need
to disconnect the fluid hoses, but make sure
that the pump is adequately supported to
avoid straining them.
21On models fitted with air conditioning,
unbolt the air conditioning compressor from the
mounting bracket, and move it clear of the
engine (see illustration). Do notdisconnect the
hoses, but make sure that the compressor is
adequately supported to avoid straining them.
22Unscrew and remove the top engine-to-
gearbox bolts which are accessible from the
engine compartment. Note the location of the
bolts, and the positions of the earth strap and
any wiring clips attached to the bolts.
23Unscrew the securing bolt, and
disconnect the earth lead from the rear left-
hand side of the cylinder head.
24Unscrew the nuts securing the engine
mountings to the engine mounting brackets.
25Apply the handbrake, jack up the front of
the vehicle and support it securely on axle
stands (see “Jacking”).
26Drain the engine oil into a container.
5Engine - removal leaving manual
gearbox in vehicle
4Major operations requiring
engine removal
3Major operations possible with
the engine in the vehicle
2B•4DOHCengine
5.5 Removing the hose support bracket
bolt from the cylinder head5.8 Water pump coolant hoses (viewed
from above)
5.21 Air conditioning compressor mounting
bolts (arrowed) (viewed from underneath)
Warning: Vehicles equipped with
air conditioning: Components of
the air conditioning system may
obstruct work being undertaken
on the engine, and it is not always possible
to unbolt and move them aside sufficiently,
within the limits of their flexible pipes. In
such a case, the system should be
discharged by a Ford dealer or air
conditioning specialist. Refer also to the
precautions given in Chapter 3.
procarmanuals.com