Page 1 Главы 01- GENERAL INFORMATION & MAINTENANCE 02-ENGINE PERFORMANCE & TUNE-UP 03-ENGINE & ENGINE OVERHAUL 04-EMISSION CONTROLS 05-FUEL SYSTEM 06-CHASSIS ELECTRICAL 07-DRIVE TRAIN 08-SUSPENSION & STEERING 09-BRAKES 10-BODY...
Page 2 ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ Часть Глава Подглава 01-HOW TO USE THIS MANUAL 02-TOOLS AND EQUIPMENT Introduction 03-SERVICING YOU VEHICLE SAFELY Do's Don'ts 04-MODEL IDENTIFICATION Vehicle Certification Label 05-SERIAL NUMBER IDENTIFICATION Engine Transaxle Air Cleaner Fuel Filter PCV Valve Evaporative Canister Battery Belts 06-ROUTINE MAINTENANCE...
Page 3 ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ Часть Глава Подглава Introduction 01-TUNE-UP PROCEDURES Spark Plugs Spark Plug Wires 02-FIRING ORDERS Introduction Discription & Operation 03-DISTRIBUTOR IGNITION SYSTEM Component Testing Component Replacement Description & Operation 02-ENGINE PERFORMANCE & TUNE-UP 04-ELECTRONIC IGNITION SYSTEMS Component Replacement Introduction 05-IGNITION TIMING Timing...
Page 4 ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ Часть Глава Подглава Introduction Battery And Starting System Charging System Ignition System Safety Precautions Alternator 01-ENGINE ELECTRICAL Voltage Regulator Battery Starter Sending Units And Sensors Relay, Sensor, Switch, Module And Computer Locations Engine Overhaul Tips Engine Engine Mounts Rocker Arm (Valve) Cover Rocker Arms...
Page 5 ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ Часть Глава Подглава Introduction Natural Pollutants Industrial Pollutants Automotive Pollutants 01-AIR POLLUTION Temperature lnversion Internal Combustion Engine Pollutants Heat Transfer Composition Of The Exhaust Gases 02-EXHAUST EMISSIONS Other Automobile Emission Sources Introduction Positive Crankcase Ventilation (PCV) System Evaporative Emission Control (EEC) System Exhaust Gas Recirculation...
Page 6 ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ Часть Глава Подглава Introduction 01-BASIC FUEL SYSTEM DIAGNOSIS Precautions General Description Relieving Fuel System Pressure Electric Fuel Pump 02-CENTRAL FUEL INJECTION (CFI) Thrattle Body/Fuel Charging Assembly Fuel Pressure Regulator Pressure Relief Valve Tnrottle Position (TP) Sensor General Description Relieving Fuel System Pressure Electric Fuel Pump...
Page 7 ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ Часть Глава Подглава Introduction 01-UNDERSTANDING AND TROUBLESHOOTING Safety Precautions ELECTRICAL SYSTEMS Wring Harnesses Mechanical Test Equipment 02-SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) Blower Motor Blower Motor Resistor HeaterCore 03-HEATER Control Cables Control Panel Blower Switch Vacuum Selector Switch Compressor Condenser Evaporator Core...
Page 8 ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ Часть Глава Подглава Identification Adjustments Shift Linkage 01-MANUAL TRANSAXLE Shift Handle Back-Up Light Switch Transaxle Halfshafts Introduction Adjustments Clutch Pedal 02-CLUTCH Driven Disc And Pressure Plate Cutch Cable 07-DRIVE TRAIN Cutch Interlock/Pedal Position Switch Identification Fluid Pan Adjustments Neutral Safety Switch/Back-Up 03-AUTOMATIC TRANSAXLE...
Page 9 ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ Часть Глава Подглава lntroduction 01-WHEELS Wheel Lug Studs/Hub Bolts MacPherson Struts Lower Ball Joint Stabilizer Bar Lower Control Arm 02-FRONT SUSPENSION Knuckle And Spindle Front Hub And Bearing Upper Mount And Bearing Assembly Front End Alignment Coil Springs Shock Absorbers 08-SUSPENSION &...
Page 10 ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ Часть Глава Подглава Adjustments Brake Light Switch Brake Pedal Master Cylinder 01-BRAKE OPERATING SYSTEM Power Brake Booster Proportioning Valve Brake Hoses And Pipes Bleeding Brake Pads 02-FRONT DISC BRAKES Brake Caliper Brake Rotor Brake Drums Brake Shoes 03-REAR DRUM BRAKES Wheel Cylinders Brake Backing Plate...
Page 11 ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ Часть Глава Подглава Doors Hood Hood Latch Control Cable Hood Latch Litigate Liftgate Support Cylinder/Gas Lift Trunk Lid 01-EXTERIOR Trunk Lid Latch And Lock Front Bumper Rear Bumper Grille Outside Mirrors Antenna Fenders Power Sunroof lnstrument Panel And Pad Console Door Trim Panels lnterior Trim Panels...
Page 12 Стр. 1 из 2 HOW TO USE THIS MANUAL Chilton's Total Car Care manual for Ford Taurus and Mercury Sable is intended to help you learn more about the inner workings of your car and save you money on its upkeep and operation. The first two sections will be used the most, since they contain maintenance and tune-up information and procedures.
Page 13 Стр. 2 из 2 extra time; however it CAN break something. Read the entire procedure before beginning disassembly. Do everything in the order in which the instructions say you should do it, even if you can't immediately see a reason for it. When you're taking apart something that is very intricate, you might want to draw a picture of how it looks when assembled at one point in order to make sure you get everything back in its proper position.
Page 14 TOOLS AND EQUIPMENT Стр. 1 из 8 TOOLS AND EQUIPMENT Naturally, without the proper tools and equipment it is impossible to properly service your vehicle. It would be impossible to catalog each tool that you would need to perform each or every operation in this book. It would also be unwise for the amateur to rush out and buy an expensive set of tools on the theory that he may need one or more of them at sometime.
Page 15 TOOLS AND EQUIPMENT Стр. 2 из 8 All but the most basic procedure will require an assortment of ratchets and sockets In addition to ratchets, a good set of wrenches and hex keys will be necessary Jackstands for support. http://www.chiltondiy.com/content/8687/8687_1_2.html 18.11.2005...
Page 16 TOOLS AND EQUIPMENT Стр. 3 из 8 A hydraulic floor jack and a set of jackstands are essential for lifting and supporting the vehicle An assortment of pliers will be handy, especially for old rusted parts and stripped bolt heads http://www.chiltondiy.com/content/8687/8687_1_2.html 18.11.2005...
Page 17 TOOLS AND EQUIPMENT Стр. 4 из 8 You should have various screwdrivers, a hammer, chisels and prybars in your toolbox Many repairs will require the use of torque wrench to assure the components are properly fastened http://www.chiltondiy.com/content/8687/8687_1_2.html 18.11.2005...
Page 18 TOOLS AND EQUIPMENT Стр. 5 из 8 Although not always necessary, using specialized brake tools will save time Oil filter wrench. Oil filter spout for pouring oil. Grease gun for chassis lubrication. A few inexpensive lubrication tools will make regular service easier Hydrometer for checking the battery.
Page 19 TOOLS AND EQUIPMENT Стр. 6 из 8 Various pullers, clamps and separator tools are needed for the repair of many components In addition to the above items, there are several others that are not absolutely necessary, but handy to have around. These include oil-dry (cat box litter works just as well and may be cheaper), a transmission funnel and the usual supply of lubricants, antifreeze and fluids, although these can be purchased as needed.
Page 20 TOOLS AND EQUIPMENT Стр. 7 из 8 Dwell/tachometer unit (typical) Inductive type timing light Compression gauge and a combination vacuum/fuel pressure gauge Normally, the use of special factory tools is avoided for repair procedures, since these are not readily available for the do-it-yourself mechanic. When it is possible to perform the job with more commonly available tools, it will be pointed out, but occasionally, a special tool was designed to perform a specific function and should be used.
Page 21 When a special tool is indicated, it will be referred to by the manufacturer's part number. Some special tools are available commercially from major tool manufacturers. Others for your car can be purchased from your Ford/Mercury dealer or from the Owatonna Tool Co., Owatonna, Minnesota 55060.
Page 22 SERVICING YOUR VEHICLE SAFELY Стр. 1 из 2 SERVICING YOUR VEHICLE SAFELY Introduction It is virtually impossible to anticipate all of the hazards involved with automotive maintenance and service but care and common sense will prevent most accidents. The rules of safety for mechanics range from "don't smoke around gasoline,'' to "use the proper tool for the job.'' The trick to avoiding injuries is to develop safe work habits and take every possible precaution.
Page 23 SERVICING YOUR VEHICLE SAFELY Стр. 2 из 2 Don'ts Don't run an engine in a garage or anywhere else without proper ventilation-EVER! Carbon monoxide is poisonous. It is absorbed by the body 400 times faster than oxygen. It takes a long time to leave the human body and you can build up a deadly supply of it in your system by simply breathing in a little every day.
Page 24 Стр. 1 из 1 MODEL IDENTIFICATION Two models of the Ford Taurus/Mercury Sable are offered-the 4-door sedan and the 4-door station wagon. The body style of the vehicle can be confirmed by locating the 6th and 7th positions of the VIN code. Vehicle model year identification can be verified by locating the 10th position of the VIN code and using the Vehicle Identification Chart.
Page 25 SERIAL NUMBER IDENTIFICATION Стр. 1 из 2 SERIAL NUMBER IDENTIFICATION Vehicle The official vehicle identification (serial) number (used for title and registration purposes) is stamped on a metal tab fastened to the instrument panel and visible through the driver's side of the windshield from the outside. The vehicle identification (serial) number contains a 17-digit number.
Page 26 SERIAL NUMBER IDENTIFICATION Стр. 2 из 2 Location of the Vehicle Certification Label Engine The vehicle's engine identification is located in the 8th position of the VIN code. Transaxle The transaxle code is located on the bottom edge of the Vehicle Certification Label for vehicles equipped with the manual transaxle.
Page 27 ROUTINE MAINTENANCE Стр. 1 из 52 ROUTINE MAINTENANCE Air Cleaner The air cleaner element should be replaced every 30 months or 30,000 miles (48,000 km). More frequent changes are necessary if the car is operated in dusty conditions. REMOVAL & INSTALLATION Except 1994-95 Vehicles Loosen the air cleaner outlet tube clamps at both ends, then remove the tube.
Page 28 ROUTINE MAINTENANCE Стр. 2 из 52 Removing the air cleaner element-early model 2.5L engine shown To install: Clean the inside surfaces of the air cleaner body, then install the new filter element. Install the air cleaner upper cover, then install the bolts or fasten the retaining clips.
Page 29 ROUTINE MAINTENANCE Стр. 3 из 52 Exploded view of the air cleaner assembly and components-3.0L engine shown Click to enlarge Air cleaner assembly components-3.0L & 3.2L SHO engines shown Click to enlarge http://www.chiltondiy.com/content/8687/8687_1_6.html 18.11.2005...
Page 30 ROUTINE MAINTENANCE Стр. 4 из 52 Air cleaner assembly components-3.8L engine shown Click to enlarge 1994-95 Vehicles Loosen the clamp securing the air cleaner outlet tube to the mass air flow sensor, then disconnect the air cleaner outlet tube. If equipped, disconnect the engine control sensor wiring from the mass air flow sensor and the intake air temperature sensor.
Page 31 ROUTINE MAINTENANCE Стр. 5 из 52 Except 2.5L CFI Engine The pressure in the fuel system must be relieved before attempting to disconnect any fuel lines. A special valve is incorporated on the fuel rail assembly for the purpose of relieving the pressure in the fuel system. Remove the fuel tank cap.
Page 32 ROUTINE MAINTENANCE Стр. 6 из 52 Removing the push connect fitting from the bottom of the fuel filter-Early model 2.5L shown Removing the fuel line from the filter http://www.chiltondiy.com/content/8687/8687_1_6.html 18.11.2005...
Page 33 ROUTINE MAINTENANCE Стр. 7 из 52 Loosen the mounting clamp enough to allow the filter to pass through Slide the fuel filter out of the mounting clamp To install: Install the filter in the mounting bracket, ensuring that the flow direction arrow is pointing forward.
Page 34 ROUTINE MAINTENANCE Стр. 8 из 52 Start the engine and check for leaks. PCV Valve The Positive Crankcase Ventilation (PCV) system cycles crankcase gases back through the engine, where they are burned. The PCV valve regulates the amount of ventilating air and blow-by gas to the intake manifold and prevents backfire from traveling into the crankcase.
Page 35 ROUTINE MAINTENANCE Стр. 9 из 52 To install: PCV system-early model 2.5L engine shown Inspect the valve and grommet for deterioration, and replace if necessary. http://www.chiltondiy.com/content/8687/8687_1_6.html 18.11.2005...
Page 36 ROUTINE MAINTENANCE Стр. 10 из 52 PCV system-late model 3.0L shown Click to enlarge Install the PCV valve into the valve grommet, then connect the fuel vapor and crankcase ventilation hoses. http://www.chiltondiy.com/content/8687/8687_1_6.html 18.11.2005...
Page 37 ROUTINE MAINTENANCE Стр. 11 из 52 3.0L and 3.2L SHO Engines Loosen the crankcase ventilation tube clamps. Carefully disconnect the tube from the left-hand side valve cover fitting and the throttle body. To install: PCV system-3.0L/3.2L SHO shown Click to enlarge Inspect the crankcase ventilation tube for deterioration and replace if necessary.
Page 38 ROUTINE MAINTENANCE Стр. 12 из 52 PCV system-late model 3.8L shown Click to enlarge Inspect the PCV valve and grommet for deterioration, and replace if necessary. Install the PCV valve into the valve grommet, then connect the crankcase ventilation tube. Evaporative Canister To prevent gasoline vapors from being vented into the atmosphere, an evaporative emission system captures the vapors and stores them in a carbon-...
Page 39 ROUTINE MAINTENANCE Стр. 13 из 52 Evaporative emission control system and related components-2.5L engine Click to enlarge Evaporative emission control system and related components-3.0L engine (Except Flexible Fuel) Click to enlarge http://www.chiltondiy.com/content/8687/8687_1_6.html 18.11.2005...
Page 40 ROUTINE MAINTENANCE Стр. 14 из 52 Evaporative emission control system and related components-3.0L Flexible Fuel (FF) engine Click to enlarge Location of system components-3.0L Flexible Fuel (FF) engine Click to enlarge http://www.chiltondiy.com/content/8687/8687_1_6.html 18.11.2005...
Page 41 ROUTINE MAINTENANCE Стр. 15 из 52 Evaporative emission control system and related components-3.0L SHO shown; 3.2L SHO similar Click to enlarge Evaporative emission control system and related components-3.8L engine Click to enlarge SERVICING Since the canister is purged of fumes when the engine is operating, no real maintenance is required.
Page 42 ROUTINE MAINTENANCE Стр. 16 из 52 Removing the carbon canister-Early model 2.5L shown Battery GENERAL MAINTENANCE Loose, dirty, or corroded battery terminals are a major cause of "no-start.'' Every 3 months or so, remove the battery terminals and clean them. This will help to retard corrosion.
Page 43 ROUTINE MAINTENANCE Стр. 17 из 52 Battery maintenance may be accomplished with household items (such as baking soda to neutralize spilled acid) or with special tools such as this post and terminal cleaner The underside of this special battery tool has a wire brush to clean post terminals http://www.chiltondiy.com/content/8687/8687_1_6.html 18.11.2005...
Page 44 ROUTINE MAINTENANCE Стр. 18 из 52 Place the tool over the terminals and twist to clean the post FLUID LEVEL (EXCEPT MAINTENANCE-FREE BATTERIES) Check the battery electrolyte level at least once a month, or more often in hot weather or during periods of extended car operation. The level can be checked through the case on translucent polypropylene batteries;...
Page 45 ROUTINE MAINTENANCE Стр. 19 из 52 If water is added in freezing weather, the car should be driven several miles to allow the water to mix with the electrolyte. Otherwise, the battery could freeze. SPECIFIC GRAVITY (EXCEPT MAINTENANCE-FREE BATTERIES) At least once a year, check the specific gravity of the battery using a hydrometer. A hydrometer, is an inexpensive instrument available from many sources, including auto parts stores.
Page 46 ROUTINE MAINTENANCE Стр. 20 из 52 plenty of clear water; if it lands in your eyes, get medical help immediately. CHARGING Before recharging a battery, see if any of the following problems exist: Loose alternator belt Pinched or grounded alternator/voltage regulator wiring harness Loose wiring connection at the alternator and/or voltage regulator Loose or corroded connections at the battery and/or the engine ground Excessive battery drain due to any accessories or lighting left on.
Page 47 ROUTINE MAINTENANCE Стр. 21 из 52 excessive gassing will result in non-replaceable loss of electrolyte, shortening the battery life. The total charge necessary will vary with battery size and its initial state of charge. In general, to bring a discharged battery to a serviceable state of charge, the amount of charging current multiplied by the charging time should equal the battery amp-hour capacity.
Page 48 ROUTINE MAINTENANCE Стр. 22 из 52 Common battery hold-down assembly Click to enlarge To install: Clean the battery tray and hold-down clamp(s) with a wire brush and scraper. Replace any components that are worn. Place the battery in the battery tray making sure that the positive and negative terminals are in the same position as they were previous to removal.
Page 49 ROUTINE MAINTENANCE Стр. 23 из 52 All vehicles are equipped with V-ribbed drive belts. Replacement belts should be of the same type as originally installed. Loose belts will result in slippage and cause improper operation of the driven accessory, power steering, air conditioning, etc.
Page 50 ROUTINE MAINTENANCE Стр. 24 из 52 Loosen the idler/tensioner pulley nut. Turn the adjusting bolt until the belt is adjusted properly. Turning the wrench to the right tightens the belt adjustment; turning the wrench to the left loosens the belt tension. Tighten the idler/tensioner pulley nut to 25-37 ft.
Page 51 ROUTINE MAINTENANCE Стр. 25 из 52 Turn the alternator belt adjusting screw counterclockwise until the old belt can be removed. Remove the belt. To install: Install the new belt over the pulleys. Check that all the V-grooves make proper contact with the pulleys. Adjust the belt tension, then tighten the adjusting arm and pivot bolts.
Page 52 ROUTINE MAINTENANCE Стр. 26 из 52 3.0L SHO accessory drive belts schematic Click to enlarge POWER STEERING AND AIR CONDITIONING BELT Remove the alternator belt. Loosen the nut on the tensioner pulley. Turn the belt adjusting screw on the tensioner counterclockwise until the belt can be removed, then remove the belt.
Page 53 ROUTINE MAINTENANCE Стр. 27 из 52 3.2L SHO Engine WITH AUTOMATIC TENSIONER Place a 14mm socket over the bolt on the drive belt tensioner and rotate it clockwise (downward) to release belt tension. Remove the drive belt from the pulleys. 3.2L SHO belt schematic Click to enlarge To install:...
Page 54 ROUTINE MAINTENANCE Стр. 28 из 52 3.0L belt schematic-1993 shown 3.8L belt schematic-1993 shown Click to enlarge To install: Install the drive belt over all the pulleys, except for the alternator pulley on the 3.0L engine for vehicles through 1992, or the idler pulley for 1993 3.0L vehicles. Rotate tensioner counterclockwise and install the belt over the alternator pulley.
Page 55 ROUTINE MAINTENANCE Стр. 29 из 52 Using a 15mm socket or wrench on the attaching bolt, rotate the drive belt tensioner pulley clockwise to relieve the tension. Remove the drive belt. 3.0L accessory drive belt schematic-1995 shown Click to enlarge http://www.chiltondiy.com/content/8687/8687_1_6.html 18.11.2005...
Page 56 ROUTINE MAINTENANCE Стр. 30 из 52 3.8L accessory drive belt schematic-1995 shown Click to enlarge To install: Install the drive belt over all the pulleys, other than the drive belt tensioner. Rotate the drive belt tensioner clockwise, using a 15mm socket or wrench, then install the belt over the drive belt tensioner pulley.
Page 57 ROUTINE MAINTENANCE Стр. 31 из 52 Upper and lower radiator hoses, along with the heater hoses, should be inspected for deterioration, leaks and loose hose clamps at least every 15,000 miles (24,000 km). It is also wise to check the hoses periodically in early spring and at the beginning of the fall or winter when you are performing other maintenance.
Page 58 ROUTINE MAINTENANCE Стр. 32 из 52 Attaching a small hose to the draincock will help direct the flow of coolant into the drainpan, thereby reducing the mess CAUTION The engine should be cool before any hoses are replaced. If engine is hot, let it cool down for at least an hour.
Page 59 ROUTINE MAINTENANCE Стр. 33 из 52 Click to enlarge To remove the upper hose, loosen the retaining clamps, then disconnect and remove the hose. Engine cooling system schematic-3.0L engine Click to enlarge Exploded view of the engine cooling system-3.8L engine Click to enlarge To remove the heater hose(s), loosen the clamps, then remove the hose(s).
Page 60 Tighten the hose clamps to 20-30 inch lbs. (2.2-3.4 Nm). Cooling system components-3.0L and 3.2L SHO engines Click to enlarge Close the radiator draincock. Fill the cooling system with a 50/50 mixture of Ford Premium Cooling System Fluid E2FZ-19549-AA or B (CXC-8-B in Canada) or equivalent and water.
Page 61 ROUTINE MAINTENANCE Стр. 35 из 52 Click to enlarge Heater hose assembly-3.8L engine Click to enlarge Connect the negative battery cable, then start the engine and check for coolant leaks. Heater hose components-3.0L SHO engine Click to enlarge When the engine cools, recheck the coolant level in the radiator, or reservoir container, then remove the fender covers.
Page 62 ROUTINE MAINTENANCE Стр. 36 из 52 manual. View of a torn CV boot View of a CV boot in good condition Air Conditioning Some 1992-93 and all 1994-95 vehicles are equipped with a refrigerant (R-134a) that is incompatible with the older R-12 or Freon®. This newerrefrigerant is NOT available commercially in most areas, and it may be illegalto service a vehicle with this refrigerant.
Page 63 ROUTINE MAINTENANCE Стр. 37 из 52 has many of the same properties as the old type of refrigerant and is similar in both form and function. These two refrigerants are not interchangeable with one another. Therefore, do not mix the two types of refrigerant, the tools used in servicing the air conditioning system, or component replacement parts from these two types of air conditioning systems.
Page 64 ROUTINE MAINTENANCE Стр. 38 из 52 be spent detecting leaks, repairing them, and then restoring the purity and quantity of the refrigerant charge. A list of general rules should be followed in addition to all safety precautions: Keep all tools as clean and dry as possible. Thoroughly purge the service gauges and hoses of air and moisture before connecting them to the system.
Page 65 ROUTINE MAINTENANCE Стр. 39 из 52 when tightening these flare nut fittings. R-12 refrigerant is a chlorofluorocarbon which, when released into theatmosphere, can contribute to the depletion of the ozone layer in the upperatmosphere. Ozone filters out harmful radiation from the sun. Do NOT attempt to discharge the system by merely loosening a fitting, or removing the service valve caps and cracking these valves.
Page 66 ROUTINE MAINTENANCE Стр. 40 из 52 the compressor clutch indicates that the air conditioning system is low on refrigerant. The normal refrigerant capacity is 39-41 oz. (1106-1162 grams). GAUGE SETS The following procedure is for the attachment of a manifold gauge set to the service gauge port valves.
Page 67 ROUTINE MAINTENANCE Стр. 41 из 52 removed. If a recovery system or recycling station is used, the following general procedures should be followed, in addition to the operating instructions provided by the equipment manufacturer. Connect the refrigerant recycling station hose(s) to the vehicle air conditioning service ports and the recovery station inlet fitting.
Page 68 ROUTINE MAINTENANCE Стр. 42 из 52 gauge port valve. Leak test all connections and components with flame-type leak detector 023-00006 or equivalent, or electronic leak detector 055-00014, 055-00015 or equivalent. CAUTION Fumes from flame-type leak detectors are noxious; avoid inhaling fumes orpersonal injury may result.
Page 69 ROUTINE MAINTENANCE Стр. 43 из 52 connection at the manifold gauge set. Detach the wire harness snap lock connector from the clutch cycling or low pressure switch and install a jumper wire across the 2 terminals of the connector. Open the manifold gauge set low side valve to allow refrigerant to enter the system.
Page 70 ROUTINE MAINTENANCE Стр. 44 из 52 Normally, if the wipers are not cleaning the windshield properly, only the refill has to be replaced. The blade and arm usually require replacement only in the event of damage. It is not necessary (except on new Tridon® refills) to remove the arm or the blade to replace the refill (rubber part), though you may have to position the arm higher on the glass.
Page 71 ROUTINE MAINTENANCE Стр. 45 из 52 Wiper blade replacement-Trico® Click to enlarge Another type of refill is made from polycarbonate. The refill has a simple locking device at one end which flexes downward out of the groove into which the jaws of the holder fit, allowing easy release.
Page 72 ROUTINE MAINTENANCE Стр. 46 из 52 Wiper blade replacement-Tridon® Click to enlarge Regardless of the type of refill used, make sure that all of the frame jaws are engaged as the refill is pushed into place and locked. If the metal blade holder and frame are allowed to touch the glass during wiper operation, the glass will be scratched.
Page 73 ROUTINE MAINTENANCE Стр. 47 из 52 Tire rotation patterns-NEVER use the temporary spare for tire rotation or as a regular tire Click to enlarge TIRE DESIGN All tires made since 1968 have 8 built-in tread wear indicator bars that show up in.
Page 74 ROUTINE MAINTENANCE Стр. 48 из 52 Tread depth can be checked using an inexpensive gauge If a gauge is not available, a penny may be used to check for tire tread depth; when the top of Lincoln's head is visible, it is probably time for a new tire You can check your own tread depth with an inexpensive gauge or by using a Lincoln head penny.
Page 75 ROUTINE MAINTENANCE Стр. 49 из 52 If tires are used beyond the point of tread life, built-in wear indicators will begin to appear as lines perpendicular to the tread Click to enlarge Wear that occurs only on certain portions of the tire may indicate a particular problem which, when corrected or avoided, may significantly extend tire life.
Page 76 ROUTINE MAINTENANCE Стр. 50 из 52 Store the tires at their recommended inflation pressures if they are mounted on wheels. All tires should be kept in a cool, dry place. If they are stored in the garage or basement, do not let them stand on a concrete floor; set them on strips of wood.
Page 77 ROUTINE MAINTENANCE Стр. 51 из 52 Spare tire assembly and related components-station wagon Click to enlarge TIRE INFLATION Tire inflation is the most ignored item of auto maintenance. Gasoline mileage can drop as much as 0.8% for every 1 pound per square inch (psi) of underinflation. Two items should be a permanent fixture in every glove compartment: a tire pressure gauge and a tread depth gauge.
Page 78 ROUTINE MAINTENANCE Стр. 52 из 52 CARE OF WHEEL COVERS AND ALUMINUM WHEELS To clean the wheels, wheel covers and wheel ornamentation, use a mild soap solution and thoroughly rinse with clean water. Do not use steel wool, abrasive type cleaner or strong detergents containing high alkaline or caustic agents, as damage to the protective coating and discoloration may result.
Page 79 FLUIDS AND LUBRICANTS Стр. 1 из 34 FLUIDS AND LUBRICANTS Introduction Used fluids such as engine oil, transmission fluid, antifreeze and brake fluid are hazardous wastes and must be disposed of properly. Before draining any fluid, consult your local authorities; in many areas, waste oil, etc. is being accepted as a part of recycling programs.
Page 80 SAE grade number and the API designation can be found of the side of the oil bottle. Oil meeting API classification SG, SG/CC or SG/CD is recommended for use in your vehicle. Ford has filled your crankcase with SAE 5W-30 and recommends that you continue to use this as long as the outside temperatures don't exceed 100°F (38°C).
Page 81 FLUIDS AND LUBRICANTS Стр. 3 из 34 Synthetic Oil There are excellent synthetic and fuel-efficient oils available that, under the right circumstances, can help provide better fuel mileage and better engine protection. However, these advantages come at a price, which can be three or four times the price per quart of conventional motor oils.
Page 82 FLUIDS AND LUBRICANTS Стр. 4 из 34 Remove the dipstick from the engine Wipe the dipstick with a clean, lint-free rag Pull the dipstick out again and, holding it horizontally, read the oil level. The oil should be between the MAX and ADD marks on the dipstick. If the oil is below the ADD mark, add oil of the proper viscosity through the capped opening in the top of the cylinder head cover or filler tube, as applicable.
Page 83 FLUIDS AND LUBRICANTS Стр. 5 из 34 intervals will help keep you car engine in good condition. Dirty oil loses its lubricating qualities and can cause premature wear in your engine. Make sure the engine is at normal operating temperature (this promotes complete draining of the old oil).
Page 84 FLUIDS AND LUBRICANTS Стр. 6 из 34 Having the engine at normal operating temperature will promote complete draining of the engine oil Move the drain pan under the engine oil filter. Use a strap-type or cap-type filter wrench to loosen the oil filter. Cover your hand with a rag and spin the filter off by hand;...
Page 85 FLUIDS AND LUBRICANTS Стр. 7 из 34 then check the oil level with the dipstick. The oil level will drop as the filter fills up with oil. Add oil to the proper dipstick level. Remove the oil filler cap located on the valve cover Refill the crankcase with the proper grade and capacity of engine oil When you have finished this job, you will notice that you now possess four or five quarts of dirty oil.
Page 86 FLUIDS AND LUBRICANTS Стр. 8 из 34 Manual Transaxle FLUID RECOMMENDATIONS AND LEVEL CHECK Each time the engine oil is changed, the fluid level of the transaxle should be checked. The car must be resting on level ground or supported on jackstands (front and back) evenly.
Page 87 FLUIDS AND LUBRICANTS Стр. 9 из 34 and check the fluid level. The fluid level should be between the FULL and ADD marks. If necessary, add enough fluid through the dipstick tube/filler to bring the level to the FULL mark on the dipstick. Use Dexron®II or Mercon® fluid in the ATX 3-speed transaxle, AXOD and AXOD-E overdrive transaxles.
Page 88 If the coolant level is found to be low, add a 50/50 mixture of coolant that meets Ford specifications, such as Ford Cooling System Fluid, Prestone® II or other approved coolant and clean water. Coolant may be added either through the filler neck on the radiator or directly into the recovery reservoir.
Page 89 FLUIDS AND LUBRICANTS Стр. 11 из 34 marks on the recovery reservoir. If, for some reason, the vehicle does not have a coolant recovery tank,maintain the coolant level 1-2 in. (25-51mm) below the bottom of the radiatorfiller neck when the engine is cold and 1 in. (25mm) below the bottom of thefiller neck when the engine is hot.
Page 90 FLUIDS AND LUBRICANTS Стр. 12 из 34 bottom of the radiator. With the engine cool, set the heater control to the maximum heat position. Remove the radiator cap and open the drain valve or loosen the Allen® head plug in. (5mm), allowing the coolant to drain into a suitable container.
Page 91 FLUIDS AND LUBRICANTS Стр. 13 из 34 Reinstall the radiator cap to the fully installed position, then back it off to the first stop. Start and idle the engine until the upper radiator hose is warm. Immediately shut off the engine. Cautiously remove the radiator cap and add water until the radiator is full.
Page 92 FLUIDS AND LUBRICANTS Стр. 14 из 34 Check the coolant level to make sure it is sufficient Check the system for leaks and return the heater temperature control to its normal position. RADIATOR CAP INSPECTION Allow the engine to cool sufficiently before attempting to remove the radiator cap. Use a rag to cover the cap, then remove by pressing down and turning counterclockwise to the first stop.
Page 93 FLUIDS AND LUBRICANTS Стр. 15 из 34 DO NOT attempt to remove the radiator cap while the engine is hot. Severepersonal injury from steam burns can result. Check the condition of the radiator cap gasket and seal inside the cap. The radiator cap is designed to seal the cooling system under normal operating conditions which allow the buildup of a certain amount of pressure (this pressure rating is stamped or printed on the cap).
Page 94 FLUIDS AND LUBRICANTS Стр. 16 из 34 brake fluid that meets or exceeds Ford Motor Company specification ESA-M6C25- A, such as Motorcraft C6AZ-19542-AA or BA or equivalent. CAUTION Brake fluid damages paint. It also absorbs moisture from the air; never leave a container or the master cylinder uncovered any longer than necessary.
Page 95 FLUIDS AND LUBRICANTS Стр. 17 из 34 proper operation of your vehicle. A low fluid level indicates a need for service (there may be a leak in the system or the brake pads may just be worn and in need of replacement). In any case, the brake fluid level should be inspected at least during every oil change, but more often is desirable.
Page 96 Power Steering Pump FLUID RECOMMENDATIONS Use Ford Motor Company's premium power steering fluid E6AZ-19582-AA (ESW- M2C33-F) or equivalent. LEVEL CHECK You should check the level of the power steering fluid at least twice a year. You may check the fluid when the engine is either hot or cold.
Page 97 FLUIDS AND LUBRICANTS Стр. 19 из 34 Make sure the cap is clean before removing it; this will prevent dirt from contaminating the system If checking the fluid when the engine is hot, it should be within the proper marks of the FULL HOT side of the dipstick http://www.chiltondiy.com/content/8687/8687_1_7.html 18.11.2005...
Page 98 FULL COLD range on the dipstick. However, the reading will only be accurate if the fluid temperature is approximately 50-85°F (10-30°C). Steering Rack FLUID RECOMMENDATIONS Use Ford Motor Company's premium power steering fluid E6AZ-19582-AA (ESW- M2C33-F) or equivalent. Windshield Washer Pump http://www.chiltondiy.com/content/8687/8687_1_7.html 18.11.2005...
Page 99 FLUIDS AND LUBRICANTS Стр. 21 из 34 FLUID RECOMMENDATIONS AND LEVEL CHECK The windshield washer pump fluid reservoir is a plastic container usually found on the right (passenger) side of the engine compartment. If equipped, the rear window washer pump fluid reservoir is located under the rear right-hand quarter panel and the fill cap is found outside, near the liftgate opening.
Page 100 FLUIDS AND LUBRICANTS Стр. 22 из 34 products that meet or exceed Ford Motor Company's specifications. Replace all damaged weatherstrips as needed. Replace all chipped or cracked glass as needed. Drain holes are located under each rocker panel, quarter panel and door;...
Page 101 FLUIDS AND LUBRICANTS Стр. 23 из 34 Protect disassembled bearings from rust and dirt by covering them up. Use clean rags to wipe bearings. Keep the bearings in oil-proof paper when they are to be stored or are not in use. Clean the inside of the housing before replacing the bearing.
Page 102 FLUIDS AND LUBRICANTS Стр. 24 из 34 Wheel bearing adjustment-1986-89 vehicles ONLY Click to enlarge Tighten the adjusting nut to 17-25 ft. lbs. (23-24 Nm) while rotating the hub and drum assembly to seat the bearings. Back off the adjusting nut turn, then retighten it to 24-28 inch lbs.
Page 103 FLUIDS AND LUBRICANTS Стр. 25 из 34 hub and drum. Remove the grease cap from the hub. Remove the cotter pin, nut retainer, adjusting nut and keyed flat washer from the spindle. Discard the cotter pin. Pry the grease cap from the hub. Be careful not to distort or damage the flange After removing the grease cap, unbend the cotter pin http://www.chiltondiy.com/content/8687/8687_1_7.html 18.11.2005...
Page 104 FLUIDS AND LUBRICANTS Стр. 26 из 34 Grasp the cotter pin with needle-nose pliers and pull or pry it free of the spindle. Discard the cotter pin and replace it with a new one during installation Remove the adjusting nut from the spindle http://www.chiltondiy.com/content/8687/8687_1_7.html 18.11.2005...
Page 105 FLUIDS AND LUBRICANTS Стр. 27 из 34 Remove the keyed washer from the spindle Pull the hub and drum assembly off the spindle, being careful not to drop the outer bearing assembly. Remove the outer bearing assembly. Remove the outer bearing assembly. Note that this can be done with the hub and drum on or off the vehicle http://www.chiltondiy.com/content/8687/8687_1_7.html 18.11.2005...
Page 106 FLUIDS AND LUBRICANTS Стр. 28 из 34 Remove the hub and drum assembly from the spindle Using seal remover tool 1175-AC or equivalent, remove and discard the grease seal. Remove the inner bearing assembly from the hub. Removing the grease seal; discard the seal after removing. Note that the preferred method for removing the seal is with a proper seal remover tool http://www.chiltondiy.com/content/8687/8687_1_7.html 18.11.2005...
Page 107 FLUIDS AND LUBRICANTS Стр. 29 из 34 With the seal removed, the inner bearing may be removed from the hub Wipe all the lubricant from the spindle and inside of the hub. Cover the spindle with a clean cloth, then vacuum all loose dust and dirt from the brake assembly. Carefully remove the cloth to prevent dirt from falling on the spindle.
Page 108 FLUIDS AND LUBRICANTS Стр. 30 из 34 This is NOT the proper method for installing the grease seal, refer to the procedure for the proper tool to use when installing the seal Apply a light film of grease on the spindle shaft bearing surfaces. Install the hub and drum assembly on the spindle.
Page 109 FLUIDS AND LUBRICANTS Стр. 31 из 34 Exploded view of the rear wheel assembly-1990-95 vehicles with drum brakes Click to enlarge To install: Position the bearing and hub assembly onto the spindle. Install a new rear axle wheel hub retaining nut, then tighten the nut to 188-254 ft. lbs.
Page 110 FLUIDS AND LUBRICANTS Стр. 32 из 34 Clean both bearing assemblies and cups using a suitable solvent. Inspect the bearing assemblies and cups for excessive wear, scratches, pits or other damage and replace as necessary. If the cups are being replaced, remove them with impact slide hammer tool T50T- 100-A and bearing cup puller tool T77F-1102-A, or equivalent.
Page 111 FLUIDS AND LUBRICANTS Стр. 33 из 34 Install the outer bearing assembly and keyed flat washer on the spindle. Install the adjusting nut and adjust the wheel bearings as previously described. Install a new cotter pin and the grease cap. Install the disc brake rotor to the hub assembly.
Page 112 FLUIDS AND LUBRICANTS Стр. 34 из 34 Exploded view of the rear wheel assembly-station wagon shown Click to enlarge Position the rear hub on the rear wheel spindle. Install a new rear axle wheel hub retainer. Tighten the retainer to 188-254 ft. lbs. (255-345 Nm).
Page 113 TRAILER TOWING Стр. 1 из 3 TRAILER TOWING General Recommendations Do NOT tow a trailer unless your vehicle has been driven at least 500 miles! Towing a trailer puts additional load on your vehicle's engine, drivetrain, brakes, tires and suspension. For your safety, as well as your car's well being, make sure the trailer towing equipment is properly matched to the trailer.
Page 114 TRAILER TOWING Стр. 2 из 3 again. To assist in obtaining good handling with the car/trailer combination, it is important that the trailer tongue load be maintained at approximately 10-15% of the loaded trailer weight. Check everything before starting out on the road, then stop after you've traveled about 50 miles (80 km).
Page 115 TRAILER TOWING Стр. 3 из 3 braking power and your chances of an accident greatly increase. Electric brakes and manual, automatic, or surge-type brakes are safe if you install them properly and adjust them according to the manufacturer's instructions. Always follow the manufacturer's instructions and make sure that the brakes you are using meet local and federal regulations.
Page 116 TOWING THE VEHICLE Стр. 1 из 2 TOWING THE VEHICLE WARNING Do NOT allow the vehicle to be towed using J-hooks under any circumstances. J-hooks will damage the vehicle's halfshafts and control arms. If the car is being towed with the front (drive) wheels on the ground, never depend on the steering lock to keep the wheels straight, as damage to the steering could occur.
Page 117 TOWING THE VEHICLE Стр. 2 из 2 Schematic of front towing connections Click to enlarge Schematic of rear towing connections Click to enlarge Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_1_9.html 18.11.2005...
Page 118 JACKING Стр. 1 из 1 JACKING The service jack that is provided with your vehicle is designed for changing tires. It should NOT, under any circumstances be used to support the car while you crawl under it and work. To do so is to recklessly jeopardize your life. Whenever it is necessary to get under a car to perform service operations, always be sure that it is adequately supported using jackstands at the proper points.
Page 119 MAINTENANCE COMPONENT LOCATIONS Стр. 1 из 5 MAINTENANCE COMPONENT LOCATIONS Engine component service points-2.5L engine Click to enlarge http://www.chiltondiy.com/content/8687/8687_1_11.html 18.11.2005...
Page 120 MAINTENANCE COMPONENT LOCATIONS Стр. 2 из 5 Engine component service points-3.0L engine Click to enlarge http://www.chiltondiy.com/content/8687/8687_1_11.html 18.11.2005...
Page 121 MAINTENANCE COMPONENT LOCATIONS Стр. 3 из 5 Engine component service points-3.0L Flexible Fuel (FF) engine Click to enlarge http://www.chiltondiy.com/content/8687/8687_1_11.html 18.11.2005...
Page 122 MAINTENANCE COMPONENT LOCATIONS Стр. 4 из 5 Engine component service points-3.0L/3.2L SHO engines Click to enlarge Engine component service points-3.8L engine http://www.chiltondiy.com/content/8687/8687_1_11.html 18.11.2005...
Page 123 MAINTENANCE COMPONENT LOCATIONS Стр. 5 из 5 Click to enlarge Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_1_11.html 18.11.2005...
Page 124 SPECIFICATION CHARTS Стр. 1 из 4 SPECIFICATION CHARTS Vehicle Identification Chart Click to enlarge Engine Identification Click to enlarge http://www.chiltondiy.com/content/8687/8687_1_12.html 18.11.2005...
Page 125 SPECIFICATION CHARTS Стр. 2 из 4 Engine Identification Click to enlarge Capacities Click to enlarge Capacities http://www.chiltondiy.com/content/8687/8687_1_12.html 18.11.2005...
Page 126 SPECIFICATION CHARTS Стр. 3 из 4 Click to enlarge Maintenance Inverval Schedule A Click to enlarge 1986-93 Maintenance Interval Schedule B Click to enlarge 1994-95 Maintenance Interval Schedule B Click to enlarge http://www.chiltondiy.com/content/8687/8687_1_12.html 18.11.2005...
Page 127 SPECIFICATION CHARTS Стр. 4 из 4 Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_1_12.html 18.11.2005...
Page 139 Стр. 1 из 1 Your Current Chilton Manual Year: 1986 - 1995 Ford Mfg: Make: Ford Taurus Model: Print Content >>> http://www.chiltondiy.com/display/minor_frame.aspx?CID=281 18.11.2005...
Page 188 TUNE-UP PROCEDURES Стр. 1 из 9 TUNE-UP PROCEDURES Introduction In order to extract the full measure of performance and economy from your engine, it is essential that it be properly tuned at regular intervals. A regular tune-up will keep your car's engine running smoothly and will prevent the annoying breakdowns and poor performance associated with an untuned engine.
Page 189 The average life of a spark plug is dependent on a number of factors; the mechanical condition of the engine, the type of fuel, driving conditions and driving style. Ford recommends that spark plugs be changed every 30,000 miles (48,000 km). Under severe driving conditions, those intervals should be halved. Severe driving conditions are: Extended periods of idling or low speed operation, such as off-road or door-to- door delivery.
Page 190 TUNE-UP PROCEDURES Стр. 3 из 9 Used spark plugs which show damage may indicate engine problems Click to enlarge A small deposit of light tan or gray material on a spark plug that has been used for any period of time is considered normal. Any other color, or abnormal amounts of deposit, indicate that there is something amiss in the engine.
Page 191 TUNE-UP PROCEDURES Стр. 4 из 9 Inspect the spark plug to determine engine running conditions Click to enlarge SPARK PLUG HEAT RANGE Spark plug heat range is the ability of the plug to dissipate heat. The longer the insulator (or the farther it extends into the engine), the hotter the plug will operate;...
Page 192 TUNE-UP PROCEDURES Стр. 5 из 9 A set of spark plugs usually requires replacement every 30,000 miles (48,000 km), depending on your style of driving. In normal operation, plug gap increases about 0.001 in. (0.025mm) for every 1,000-2,500 miles (1,600-4,000 km). As the gap increases, the plug's voltage requirement also increases.
Page 193 TUNE-UP PROCEDURES Стр. 6 из 9 When possible, use a special grasping tool for removing the spark plug wires WARNING NEVER pull on the wire itself, as damage to the inside conductor couldoccur! If available, use Spark Plug Remover Tool Y74P-6666-A or equivalent toprevent the wire separating from its connector inside the boot.
Page 194 TUNE-UP PROCEDURES Стр. 7 из 9 Inspect the plug for signs of fouling or deposits To install: If the old plugs are to be reused, clean and regap them. If new spark plugs are to be installed, always check the gap. Use a round wire feeler gauge to check plug gap.
Page 195 TUNE-UP PROCEDURES Стр. 8 из 9 Adjust the gap by bending the side electrode very slightly towards or away from the center electrode Squirt a drop of penetrating oil on the threads of the spark plug and install it. Don't oil the threads heavily.
Page 196 TUNE-UP PROCEDURES Стр. 9 из 9 available. For 3.0L and 3.2L SHO vehicles, in order to remove the wires from the ignition coil, squeeze the locking tabs of the ignition wire retainer and use a gentle twisting/pulling motion. When possible, use a special grasping tool for removing the spark plug wires For SHO vehicles, squeeze the locking tabs together to remove the wires from the ignition coil Always coat the terminals of any wire that is removed or replaced with a...
Page 197 FIRING ORDERS Стр. 1 из 2 FIRING ORDERS To aid in installation and avoid confusion, remove and tag the spark plug wires one at a time. 2.5L Engine Firing Order: 1-3-4-2 Distributor Rotation: Clockwise 3.0L Engine-Except SHO and Flexible Fuel Firing Order: 1-4-2-5-3-6 Distributor Rotation: Clockwise http://www.chiltondiy.com/content/8687/8687_2_2.html 18.11.2005...
Page 198 FIRING ORDERS Стр. 2 из 2 3.8L Engine Firing Order: 1-4-2-5-3-6 Distributor Rotation: Counterclockwise 3.0L and 3.2L SHO Engines; 3.0L Flexible Fuel Engine Firing Order: 1-4-2-5-3-6 Distributorless Ignition System Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_2_2.html 18.11.2005...
Page 199 Discription & Operation Taurus and Sable models equipped with the 2.5L, 3.0L, and 3.8L engines incorporate an ignition system using a Universal Distributor. The ignition system includes: A universal distributor that has a diecast housing with a Hall effect distributor stator.
Page 200 DISTRIBUTOR IGNITION SYSTEM Стр. 2 из 18 View of the Hall effect vane switch assembly View of the rotary vane cup which is made of ferrous material The vane switch is an encapsulated package consisting of a Hall sensor on one side and a permanent magnet on the other side.
Page 201 DISTRIBUTOR IGNITION SYSTEM Стр. 3 из 18 Push the connector tabs together to separate. Attach a 12 volt DC test light between the coil Tach terminal and an engine ground, then crank the engine. If the light flashes or is continuous: Turn the ignition switch OFF.
Page 202 DISTRIBUTOR IGNITION SYSTEM Стр. 4 из 18 Testing ignition coil secondary resistance Component Replacement REMOVAL & INSTALLATION Distributor Cap and Rotor Disconnect the negative battery cable. If equipped, remove the distributor cap cover, then disengage the electrical connector, if applicable. If equipped, remove the distributor cap cover http://www.chiltondiy.com/content/8687/8687_2_3.html 18.11.2005...
Page 203 DISTRIBUTOR IGNITION SYSTEM Стр. 5 из 18 Disengage the electrical connector If necessary, tag and remove the spark plug wires from the cap. Loosen the distributor hold-down screws. Remove the distributor cap by lifting it straight off the distributor to prevent damage to the rotor blade and spring.
Page 204 DISTRIBUTOR IGNITION SYSTEM Стр. 6 из 18 Matchmark the position of the rotor for installation purposes Pull the rotor upward to remove it from the distributor shaft and armature To install: Install the rotor according to the marks made during removal, making sure to align the locating boss on the rotor with the hole on the armature, then fully seat the rotor on the distributor shaft.
Page 205 DISTRIBUTOR IGNITION SYSTEM Стр. 7 из 18 View of the spring, blade and the locating boss on the rotor Click to enlarge Position the distributor cap on the housing, noting the square alignment locator, if equipped. Tighten the hold-down screws to 18-23 inch lbs. (2.0-2.6 Nm). Location of the square alignment indicator on the distributor cap Click to enlarge If removed, connect the spark plug wires to their correct location on the distributor...
Page 206 DISTRIBUTOR IGNITION SYSTEM Стр. 8 из 18 Disconnect the distributor-to-ignition coil wire-early model 2.5L shown Disengage the TFI-IV harness or the engine control sensor wiring connector from the ignition coil, as applicable. Disengage the engine wiring connector from the coil-early model 2.5L shown On the 3.8L engine, disengage the engine control wiring connector from the radio ignition interference capacitor.
Page 207 DISTRIBUTOR IGNITION SYSTEM Стр. 9 из 18 Remove the ignition coil retaining screws Remove the ignition coil cover from the ignition coil by releasing the locking tabs on both sides of the cover, then remove the ignition coil. Ignition coil and related components-late model 3.0L shown Click to enlarge http://www.chiltondiy.com/content/8687/8687_2_3.html 18.11.2005...
Page 208 DISTRIBUTOR IGNITION SYSTEM Стр. 10 из 18 Ignition coil and related components-late model 3.8L shown Click to enlarge To install: http://www.chiltondiy.com/content/8687/8687_2_3.html 18.11.2005...
Page 209 DISTRIBUTOR IGNITION SYSTEM Стр. 11 из 18 Install the ignition coil, then attach ignition coil cover, making sure the cover is firmly in place. If removed, connect the ignition coil and radio interference capacitor, then install the ignition coil retaining screws. Tighten the retaining screws to 25-35 inch lbs. (2.8-4.0 Nm).
Page 210 Стр. 12 из 18 To install: Coat the metal base of the module with Silicone Dielectric Compound D7AZ- 19A331-A, or equivalent meeting Ford specifications, approximately (0.79mm) thick. Place the module on the distributor housing mounting flange. Carefully position the module toward the distributor housing, then align the three distributor connecting pins.
Page 211 DISTRIBUTOR IGNITION SYSTEM Стр. 13 из 18 Location of the ignition control module-3.8L engines only Click to enlarge To install: Coat the metal base of the ICM or TFI module uniformly with Silicone Dielectric Compound D7AZ-19A331-A or equivalent, about in. (0.79mm) thick. Place the module onto the heatsink.
Page 212 DISTRIBUTOR IGNITION SYSTEM Стр. 14 из 18 Position the cap with the wires intact out of the way for ease of removal Matchmark the position of the rotor, then remove it by pulling it upward from the distributor shaft and armature. Disconnect the hold-down clamp and distributor retaining bolt, then remove the distributor from the engine by pulling it upward.
Page 213 DISTRIBUTOR IGNITION SYSTEM Стр. 15 из 18 Lift the distributor from the engine; once the distributor is lifted partly out it, may be tilted slightly and removed Cover the distributor opening in the cylinder block or engine front cover, as applicable, with a clean rag to prevent any foreign material or debris from entering the engine.
Page 214 DISTRIBUTOR IGNITION SYSTEM Стр. 16 из 18 If the O-ring is cracked or nicked, it must be replaced TIMING NOT DISTURBED This condition exists if the engine has not been rotated while the distributor was removed. Install the distributor and the rotor, aligning the distributor housing and the rotor with the marks made during removal.
Page 215 DISTRIBUTOR IGNITION SYSTEM Стр. 17 из 18 After the distributor is installed, check the timing with a timing light TIMING DISTURBED This condition exists if the engine has been rotated with the distributor removed. To correctly install the distributor, the No. 1 piston must be at TDC of the compression stroke.
Page 216 DISTRIBUTOR IGNITION SYSTEM Стр. 18 из 18 connect the negative battery cable. Start the engine, then check and adjust the timing, as necessary. Turn the engine OFF, then tighten the distributor hold-down bolt. Tighten the bolt to 17-25 ft. lbs. (23-34 Nm) on the 2.5L engine, 14-21 ft. lbs. (19-28 Nm) on the 3.0L engine, or 20-29 ft.
Page 217 ELECTRONIC IGNITION SYSTEMS Стр. 1 из 15 ELECTRONIC IGNITION SYSTEMS Description & Operation 3.0L/3.2L SHO Tauruses with 3.0L and 3.2L SHO engines are equipped with an Electronic Ignition (EI) system previously known as the Distributorless Ignition System (DIS). As the name implies, there is no conventional distributor assembly in the engine.
Page 218 ELECTRONIC IGNITION SYSTEMS Стр. 2 из 15 Camshaft position sensor mounting-SHO vehicles Click to enlarge An ignition coil that houses the spark plug wires like the convention distributor cap. The ignition "coil'' actually contains three separate ignition coils. Each coil is controlled by the Ignition Control Module (ICM) through three coil leads.
Page 219 The ignition control module is mounted to the engine air inlet connector 3.0L FLEXIBLE FUEL (FF) VEHICLES The 3.0L Flexible Fuel Taurus is equipped with an ignition system that is very similar to that of the 3.0/3.2L SHO vehicles. The main difference is the crankshaft position sensor.
Page 220 ELECTRONIC IGNITION SYSTEMS Стр. 4 из 15 Location of the crankshaft position sensor-3.0L FF engine Click to enlarge An ignition "coil'' which is mounted to the rear of the left-hand cylinder head. It actually contains three separate ignition coils. Each ignition coil is controlled by the ignition control module through three coil leads.
Page 221 ELECTRONIC IGNITION SYSTEMS Стр. 5 из 15 The spark plug wire numbers are marked on the ignition coil towers Click to enlarge An Ignition Coil Module (ICM) which is located on the dash panel in the engine compartment. It receives engine position and speed information from the CKP sensor, and desired spark advance information from the PCM.
Page 222 ELECTRONIC IGNITION SYSTEMS Стр. 6 из 15 Disconnect the negative battery cable. Loosen the drive belt tensioner for the A/C compressor and power steering drive belts. Remove the drive belts from the crankshaft vibration damper and pulley. Disconnect the ignition control module, then remove the engine air inlet connector.
Page 223 ELECTRONIC IGNITION SYSTEMS Стр. 7 из 15 Setting the clearance using a feeler gauge Click to enlarge Do NOT overtighten the CKP retaining screws! Damage to the crankshaftposition sensor will result. Install the lower outer timing belt cover. Make sure you don't damage the CKP sensor wiring harness.
Page 224 ELECTRONIC IGNITION SYSTEMS Стр. 8 из 15 Camshaft Position (CMP) sensor-3.0L/3.2L SHO Click to enlarge To install: Install the camshaft position sensor and secure using the retaining bolts. Tighten the bolts to 22-31 inch lbs. (2.5-3.5 Nm). Engage the camshaft position sensor wiring connector. Install the power steering pump pulley, then install the power steering belt.
Page 225 ELECTRONIC IGNITION SYSTEMS Стр. 9 из 15 Ignition coil and related system components-3.0L/3.2L SHO Click to enlarge To install: Install the ignition coil, radio ignition interference capacitor (if equipped) and the retaining screws. Tighten the screws to 40-62 inch lbs. (4.5-7.0 Nm). Connect the ignition wires to the proper ignition coil terminals.
Page 226 ELECTRONIC IGNITION SYSTEMS Стр. 10 из 15 Ignition control module mounting-3.0L/3.2L SHO Click to enlarge To install: Apply an even coat of about in. (0.8mm) of Silicone Dielectric Compound D7AZ-19A331-A, or equivalent, to the mounting surface of the ignition control module.
Page 227 ELECTRONIC IGNITION SYSTEMS Стр. 11 из 15 Crankshaft position sensor-3.0L Flexible Fuel (FF) Click to enlarge To install: Position the crankshaft position sensor and secure using the retaining bolts. Tighten the retaining bolts to 44-61 inch lbs. (5-7 Nm). Do NOT overtighten the retaining bolts or damage to thecrankshaft position sensor may result! Properly route the fuel charging wiring, then connect it to the crankshaft position sensor.
Page 228 ELECTRONIC IGNITION SYSTEMS Стр. 12 из 15 Disconnect the negative battery cable. Disengage the fuel charging wiring connectors from the ignition coil and the radio ignition interference capacitor. Disconnect the ignition wires by squeezing the locking tabs together and twisting while pulling upward.
Page 229 ELECTRONIC IGNITION SYSTEMS Стр. 13 из 15 Ignition coil-3.0L FF vehicles Click to enlarge To install: Position the ignition coil and radio ignition interference capacitor to the ignition coil bracket and secure with the retaining screws. Tighten the retaining screws to 44-61 inch lbs.
Page 230 ELECTRONIC IGNITION SYSTEMS Стр. 14 из 15 Apply Silicone Dielectric Compound D7AZ-19A331-A, or equivalent, to all ignition wire boots. Install each ignition wire connector to the proper terminal on the ignition coil, making sure all of the boots are fully seated. Connect the fuel charging wiring to the ignition coil and radio ignition interference capacitor, then connect the negative battery cable.
Page 231 ELECTRONIC IGNITION SYSTEMS Стр. 15 из 15 Connect the negative battery cable. Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_2_4.html 18.11.2005...
Page 232 IGNITION TIMING Стр. 1 из 7 IGNITION TIMING Introduction Ignition timing is the measurement, in degrees of crankshaft rotation, of the point at which the spark plugs fire in each of the cylinders. It is measured in degrees before or after Top Dead Center (TDC) of the compression stroke. Because it takes a fraction of a second for the spark plug to ignite the mixture in the cylinder, the spark plug must fire a little before the piston reaches TDC.
Page 233 IGNITION TIMING Стр. 2 из 7 Timing mark on flywheel-2.5L engine with manual transaxle Timing pointer location-2.5L engine with manual transaxle Click to enlarge Timing mark on flywheel-2.5L engine with automatic transaxle http://www.chiltondiy.com/content/8687/8687_2_5.html 18.11.2005...
Page 234 IGNITION TIMING Стр. 3 из 7 Timing pointer location-2.5L engine with automatic transaxle Timing mark location-3.0L expcept Flexible Fuel and SHO engines http://www.chiltondiy.com/content/8687/8687_2_5.html 18.11.2005...
Page 235 IGNITION TIMING Стр. 4 из 7 Timing mark location-3.0L SHO engine Click to enlarge There are three basic types of timing lights available. The first is a simple neon bulb with two wire connections (one for the spark plug and one for the plug wire, to connect the light in series).
Page 236 IGNITION TIMING Стр. 5 из 7 in the transaxle case. The 3.0L and 3.8L engines have the timing marks on the crankshaft pulley and a timing pointer near the pulley. To check and adjust the ignition timing: Timing mark location-3.0L except Flexible Fuel and SHO engines Place the transaxle in the P (AT) or N (MT) position.
Page 237 IGNITION TIMING Стр. 6 из 7 this procedure. Connect a suitable tachometer, Rotunda tool No. 099-00003 or equivalent, to the engine. The ignition coil connector allows a test lead with an alligator clip to be connected to the Distributor Electronic Control (DEC) terminal without removing the connector.
Page 238 IGNITION TIMING Стр. 7 из 7 Click to enlarge TACHOMETER HOOKUP On distributor-equipped models with an "E'' type ignition coil, the tachometer connection is made at the back of the wire harness connector. A cut-out is provided and the tachometer lead wire alligator clip can be connected to the dark green/yellow dotted wire of the electrical harness plug.
Page 239 VALVE LASH Стр. 1 из 6 VALVE LASH Introduction Valve lash adjustment determines how far the valves enter the cylinder and how long they stay open and/or closed. While all valve adjustments must be made as accurately as possible, it is better to have the valve adjustment slightly loose than slightly tight, as a burned valve may result from overly tight adjustments.
Page 240 VALVE LASH Стр. 2 из 6 No. 1 intake and No. 1 exhaust valves No. 3 intake and No. 2 exhaust valves No. 6 intake and No. 4 exhaust valves Checking the valve clearance-3.0L engine, except SHO Click to enlarge http://www.chiltondiy.com/content/8687/8687_2_6.html 18.11.2005...
Page 241 VALVE LASH Стр. 3 из 6 Checking the valve clearance-3.8L engine Click to enlarge Rotate the crankshaft 360° and check the clearance between the rocker arm and the following valves: No. 2 intake and No. 3 exhaust valves No. 4 intake and No. 5 exhaust valves No.
Page 242 VALVE LASH Стр. 4 из 6 Checking the valve clearance-3.0L and 3.2L SHO engines Insert a feeler gauge under the cam lob at a 90° angle to the camshaft. Clearance for the intake valves should be 0.006-0.010 in. (0.15-0.25mm). Clearance for the exhaust valves should be 0.010-0.014 in.
Page 243 VALVE LASH Стр. 5 из 6 Install the compressor tool under the cam, next to the lobe, and rotate it down to depress the valve lifter/tappet Click to enlarge Install the valve lifter/tappet holding tool T89P-6500-B or equivalent, and remove the compressor tool.
Page 244 VALVE LASH Стр. 6 из 6 Using the O-ring tool to lift the spacer Click to enlarge Determine the size of the spacer by the numbers on the bottom face of the spacer, or by measuring it with a micrometer. Install the replacement valve adjusting spacer that will permit the specified clearance.
Page 245 IDLE SPEED AND MIXTURE ADJUSTMENTS Стр. 1 из 6 IDLE SPEED AND MIXTURE ADJUSTMENTS Idle Speed Adjustment The idle speed on 1991-95 vehicles is preset at the factory, and is not adjustable. 2.5L ENGINE 1986-90 Vehicles The curb idle and fast idle speeds are controlled by the EEC-IV computer and the Idle Speed Control (ISC) device.
Page 246 IDLE SPEED AND MIXTURE ADJUSTMENTS Стр. 2 из 6 Place the ignition key in the RUN position, but do not start the engine. The Idle Speed Control (ISC) plunger will retract, so wait approximately 10-15 seconds until the plunger is fully retracted. Turn the ignition key to the OFF position.
Page 247 IDLE SPEED AND MIXTURE ADJUSTMENTS Стр. 3 из 6 Adjustment of this setting should be performed only as part of a full EEC- IV diagnosis of irregular idle conditions or idle speeds. Failure to accurately set the throttle plate stop position as described in the following procedure could result in false idle speed control.
Page 248 IDLE SPEED AND MIXTURE ADJUSTMENTS Стр. 4 из 6 the SPOUT line and the idle speed control/air bypass solenoid. Make sure the throttle plate is not stuck in the bore and that the linkage is not preventing the throttle from closing. 3.0L SHO ENGINE 1989-90 Vehicles Apply the parking brake, turn the A/C control selector OFF, then block the wheels.
Page 249 IDLE SPEED AND MIXTURE ADJUSTMENTS Стр. 5 из 6 Apply the parking brake, block the drive wheels and place the vehicle in P (AT) or N (MT). Start the engine and let it run until it reaches normal operating temperature, then turn the engine OFF.
Page 250 IDLE SPEED AND MIXTURE ADJUSTMENTS Стр. 6 из 6 Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_2_7.html 18.11.2005...
Page 251 SPECIFICATION CHARTS Стр. 1 из 1 SPECIFICATION CHARTS Gasoline Engine Tune-Up Specifications Click to enlarge Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_2_8.html 18.11.2005...
Page 285 ENGINE ELECTRICAL Стр. 1 из 46 ENGINE ELECTRICAL Introduction The engine electrical can be broken down into three distinct subsystems: The starting system The charging system The ignition system Battery and Starting System The battery is the first link in the chain of mechanisms which work together to provide cranking of the engine.
Page 286 ENGINE ELECTRICAL Стр. 2 из 46 supplied by the starting switch circuit of the ignition switch. This magnetic action moves a plunger which mechanically engages the starter and electrically closes the heavy switch which connects it to the battery. The starting switch circuit commonly consists of the starting switch contained within the ignition switch, a transmission neutral or clutch safety switch and the wiring necessary to connect these with the starter solenoid or relay.
Page 287 ENGINE ELECTRICAL Стр. 3 из 46 All vehicles covered in this manual are equipped with an alternating current generator or alternator. Such units are more efficient than the generators used in older vehicles, can be rotated at higher speeds, and have fewer brush problems. In an alternator, the field rotates while all the current produced passes only through the stator windings.
Page 288 Disconnect the battery if arc welding is to be done on the vehicle. REMOVAL & INSTALLATION The different engine applications that the Ford Taurus and Mercury Sable are equipped with utilize different types of alternators. The following is a list of vehicle applications.
Page 289 ENGINE ELECTRICAL Стр. 5 из 46 Side Terminal Alternator Disconnect the negative battery cable. Loosen the alternator pivot bolt, then remove the adjusting bolt. Remove the alternator drive belt from the drive pulley. Tag and disengage the wiring terminals from the back of the alternator. The stator and the field wiring are the push-on type of retainer.
Page 290 ENGINE ELECTRICAL Стр. 6 из 46 Disconnect the negative battery cable. Disengage the wiring harness electrical connectors from the alternator and the regulator. Disengage the wiring harness from the alternator-early model 2.5L shown Disengage the wiring harness from the voltage regulator-early model 2.5L shown Loosen the pivot bolt, then remove the mounting brace bolt from the alternator.
Page 291 ENGINE ELECTRICAL Стр. 7 из 46 Loosen the mounting/pivot bolts-early model 2.5L shown Remove the mounting/pivot bolts from the alternator-early model 2.5L shown Remove the accessory drive belt from the alternator pulley. If equipped, remove the alternator brace, then remove the alternator/voltage regulator assembly from the engine.
Page 292 ENGINE ELECTRICAL Стр. 8 из 46 Remove the alternator/regulator assembly from the vehicle-early model 2.5L shown Alternator/regulator assemblies-late model 3.0L and 3.8L engines shown Click to enlarge To install: http://www.chiltondiy.com/content/8687/8687_3_1.html 18.11.2005...
Page 293 ENGINE ELECTRICAL Стр. 9 из 46 Position the alternator/regulator assembly on the engine, then install the pivot and mounting brace bolts, but do NOT tighten the bolts until the drive belt is tensioned. If equipped, install the alternator brace. Tighten the retaining nut to 15-22 ft. lbs. (20-30 Nm).
Page 294 ENGINE ELECTRICAL Стр. 10 из 46 Alternator assembly-3.0L SHO engine equipped with the rear mount regulator and internal fan Click to enlarge To install: Position the alternator on the engine and install the mounting bolts. Tighten the rear mounting bolts to 15-22 ft. lbs. (20-30 Nm) and the front bolt to 30-41 ft. lbs. (40-55 Nm).
Page 295 ENGINE ELECTRICAL Стр. 11 из 46 For this procedure, you will need Belt Tension Gauge T63L-8620-A, Alternator Pulley Remover T65P-10300-B, and Rotunda Belt Tension Gauge 021-00019. Disconnect the battery cables (negative, then positive), then remove the battery and battery tray. For details regarding this procedure, please refer to the procedure later in this section.
Page 296 ENGINE ELECTRICAL Стр. 12 из 46 Alternator assembly-3.0L and 3.2L SHO vehicles through 1993 Click to enlarge To install: Position the alternator in the vehicle, then install the three mounting bolts. Tighten the front bolt to 36-53 ft. lbs. (48-72 Nm) and the rear bolts to 26-36 ft. lbs. (34-50 Nm).
Page 297 ENGINE ELECTRICAL Стр. 13 из 46 used belt, or to 220-264 lbs. (978-1178 N) for a new belt, using the earlier specified tension gauge. Engage the output terminal wire and the electrical harness connector to the alternator. Install the battery tray and the battery, then connect the battery cables. For details regarding battery and tray installation, please refer to the procedure later in this section.
Page 298 ENGINE ELECTRICAL Стр. 14 из 46 ADJUSTMENT The electronic voltage regulator is calibrated and preset by the manufacturer. No adjustment is required or possible. REMOVAL & INSTALLATION Side Terminal Alternator This voltage regulator is mounted on the right-hand fender apron of the vehicle. Disconnect the negative battery cable.
Page 299 ENGINE ELECTRICAL Стр. 15 из 46 Voltage regulator mounting-vehicles equipped with the rear mount regulator alternator Click to enlarge To install: Install the regulator to the rear of the alternator assembly and fasten using the four retaining screws. Tighten the screws to 20-30 inch lbs. (2.3-3.4 Nm). Connect the negative battery cable.
Page 300 ENGINE ELECTRICAL Стр. 16 из 46 Battery and related components-3.0L (except SHO) and 3.8L shown, 2.5L similar Click to enlarge Battery and related components-3.0L and 3.2L SHO http://www.chiltondiy.com/content/8687/8687_3_1.html 18.11.2005...
Page 301 ENGINE ELECTRICAL Стр. 17 из 46 Click to enlarge View of the battery hold-down clamp assembly Click to enlarge To install: Clean the cable terminals and the hold-down clamp with a wire brush. Replace all cables or parts that are worn or frayed. Clean the battery tray with a wire brush and a suitable scraping tool.
Page 302 ENGINE ELECTRICAL Стр. 18 из 46 Battery Tray Remove the battery from the vehicle, as explained previously in this section. Remove the retaining bolts, screws and washers from the battery tray, then remove the tray from the vehicle. Battery tray assembly Click to enlarge To install: Position the battery tray to the front fender apron in the engine compartment.
Page 303 ENGINE ELECTRICAL Стр. 19 из 46 all connections as required. REMOVAL & INSTALLATION 1986-91 Vehicles ALL 2.5L AND 3.0L MODELS; 3.8L SEDAN Disconnect the negative battery cable and the cable connection at the starter. Raise and safely support the vehicle. Remove the cable support and ground cable connection from the upper starter stud bolt.
Page 304 ENGINE ELECTRICAL Стр. 20 из 46 Remove the starter retaining bolts-early model 2.5L shown On vehicles equipped with an automatic transaxle, remove the starter between the subframe and the radiator. For vehicles equipped with a manual transaxle, remove the starter between the subframe and the engine. Remove the starter motor from the vehicle-early model 2.5L shown http://www.chiltondiy.com/content/8687/8687_3_1.html 18.11.2005...
Page 305 ENGINE ELECTRICAL Стр. 21 из 46 Exploded view of starter motor Click to enlarge Location of the starter motor and relay-1989 3.0L SHO shown Click to enlarge To install: Position the starter, then secure using the retaining bolts. Tighten the bolts to 15- 20 ft.
Page 306 ENGINE ELECTRICAL Стр. 22 из 46 3.8L STATION WAGON Disconnect the negative battery cable, then raise and safely support the vehicle. Disengage the the starter cable and the relay connector from the starter solenoid. When disengaging the hardshell connector at the S-terminal, be sure to grasp the connector to pull it off.
Page 307 ENGINE ELECTRICAL Стр. 23 из 46 adaptive strategy. The vehicle may have to be driven 10 or more miles to relearn its strategy. Raise and safely support the vehicle. Disengage the starter cable and the push-on connector from the starter solenoid. Remove the upper and lower retaining bolts, then remove the starter motor from the vehicle.
Page 308 ENGINE ELECTRICAL Стр. 24 из 46 Disconnect the negative battery cable. Disengage the relay-to-ignition switch electrical connector. Disengage the relay-to-ignition switch electrical connector-early model 2.5L shown Disconnect the nut retaining the relay-to-starter and relay-to-battery electrical connectors. Unfasten the nut retaining the starter and battery connections-early model 2.5L shown Disconnect the retaining screws, then remove the relay from the vehicle.
Page 309 ENGINE ELECTRICAL Стр. 25 из 46 After disconnecting the retaining screws, remove the relay from the vehicle To install: Position the relay in the vehicle, then install the retaining screws. Fasten the nuts retaining the relay-to-starter and relay-to-battery electrical connectors. Tighten the nuts to 45-89 inch lbs. (5-10 Nm). Engage the relay-to-ignition switch electrical connector.
Page 310 ENGINE ELECTRICAL Стр. 26 из 46 Location of the engine coolant temperature sensor-3.0L engine shown, except SHO Click to enlarge http://www.chiltondiy.com/content/8687/8687_3_1.html 18.11.2005...
Page 311 ENGINE ELECTRICAL Стр. 27 из 46 Engine coolant temperature sensor mounting-3.0L/3.2L SHO engines Click to enlarge Location of the engine coolant temperature sensor-3.8L engine shown Click to enlarge To install: Before installing, apply Pipe Sealant with Teflon®, D8AZ-19554-A or equivalent, on the sensor threads.
Page 312 Стр. 28 из 46 Engage the electrical connector, then refill the cooling system to the correct level with a 50/50 mixture of Ford approved coolant and water. Connect the negative battery cable, then start the engine and check the coolant level.
Page 313 ENGINE ELECTRICAL Стр. 29 из 46 Intake air temperature sensor location-3.0L, except Flexible Fuel (FF) and SHO vehicles Click to enlarge http://www.chiltondiy.com/content/8687/8687_3_1.html 18.11.2005...
Page 314 ENGINE ELECTRICAL Стр. 30 из 46 IAT sensor mounting-3.0L Flexible Fuel (FF) shown Click to enlarge Intake air temperature sensor-late model SHO shown Click to enlarge http://www.chiltondiy.com/content/8687/8687_3_1.html 18.11.2005...
Page 315 ENGINE ELECTRICAL Стр. 31 из 46 Intake air temperature sensor location-late model 3.8 shown Click to enlarge To install: If applicable, install the sensor into the throttle body or intake manifold, then tighten it to 12-17 ft. lbs. (16-23 Nm). If applicable, install the sensor into the air cleaner cover or body, being careful not to damage the plastic threads.
Page 316 ENGINE ELECTRICAL Стр. 32 из 46 tube with the tube stop on the throttle body, then tighten the retaining clamps to 24-48 inch lbs. (2.7-5.4 Nm). Engage the engine control sensor wiring connector to the mass air flow sensor. Connect the negative battery cable, then start the engine and check for vacuum leaks.
Page 317 ENGINE ELECTRICAL Стр. 33 из 46 Loosen the sensor-to-air cleaner cover seal clamp. Remove the sensor retaining screws from the air cleaner cover, then remove the mass air flow sensor. To install: Install the mass air flow sensor and fasten using the retaining screws. Tighten the screws to 71-102 inch lbs.
Page 318 ENGINE ELECTRICAL Стр. 34 из 46 to 12-22 inch lbs. (1.4-2.5 Nm). Engage the engine control sensor wiring connector to the mass air flow sensor. Connect the negative battery cable. Heated Oxygen Sensor (HO The oxygen sensor supplies the PCM with a signal which indicates a rich or lean condition during engine operation.
Page 319 ENGINE ELECTRICAL Стр. 35 из 46 Remove the heated oxygen sensor from the vehicle-2.5L engine shown If the heated oxygen sensor is difficult to take off, put a few drops of penetrating oil around the sensor to aid in removal. Using Oxygen Sensor Wrench T94P-9472-A, or equivalent, remove the heated oxygen sensor(s) from the left-hand exhaust manifold and/or Y-pipe, as applicable.
Page 320 ENGINE ELECTRICAL Стр. 36 из 46 View of heated oxygen sensor locations-3.0L, 3.0L/3.2L SHO and 3.8L engines Click to enlarge To install: Install the sensor(s) to the exhaust manifold and/or Y-pipe, as applicable. Engage the engine control sensor wiring connector(s) to the heated oxygen sensor(s).
Page 321 ENGINE ELECTRICAL Стр. 37 из 46 The knock sensor detects spark knock or detonation, and if found, sends a signal to the PCM. After the PCM receives this signal, it will retard ignition timing as necessary to eliminate the knock/detonation. The knock sensor is located under the intake manifold and fuel injection rails.
Page 322 ENGINE ELECTRICAL Стр. 38 из 46 Manifold Absolute Pressure (MAP) sensor Click to enlarge To install: Install the MAP sensor using the retaining bolts. Engage the vacuum line and the electrical connector to the sensor. Connect the negative battery cable. Throttle Position (TP) Sensor The TP sensor is mounted to the throttle shaft and is used to supply a voltage output change proportional to the change in the throttle position.
Page 323 ENGINE ELECTRICAL Стр. 39 из 46 Throttle position sensor-3.0L engine (except SHO) Click to enlarge Disconnect the negative battery cable. Make scribe marks on the throttle body and the throttle position sensor to indicated proper alignment during installation. Disengage the electrical connector from the throttle position sensor. Unfasten the mounting screws, then remove the sensor.
Page 324 ENGINE ELECTRICAL Стр. 40 из 46 Throttle position sensor-SHO engines Click to enlarge To install: Install the throttle position sensor. Make sure that the rotary tangs on the sensor are in proper alignment and that the wires are pointing down. Slide the rotary tangs into position over the throttle shaft blade, then rotate the TP sensor clockwise ONLY to the installed position.
Page 325 ENGINE ELECTRICAL Стр. 41 из 46 Throttle position sensor-3.8L engine Click to enlarge Engage the throttle position sensor electrical connector. Connect the negative battery cable. Relay, Sensor, Switch, Module and Computer Locations A/C Clutch Cycling Pressure Switch (except SHO engine) is at the right rear of the engine compartment, mounted on A/C accumulator.
Page 326 ENGINE ELECTRICAL Стр. 42 из 46 Anti-Lock Power Relay is at the left rear corner of the engine compartment. Anti-Lock Test Connector is at the left rear corner of the engine compartment. Autolamp Dual Coil Relay is behind the center of the instrument panel, mounted on a brace.
Page 327 ENGINE ELECTRICAL Стр. 43 из 46 Fan Dropping Resistor (2.5L and 3.0L engine) is at the left front of the engine. Fan Dropping Resistor (SHO engine) is at the center of the firewall. Fog Light Relay is behind the center of the instrument panel, mounted on a brace. Fog Light Fuse is behind the left side of the instrument panel, near the fuse panel.
Page 328 ENGINE ELECTRICAL Стр. 44 из 46 package tray. Keyless Entry Module (Wagon) is inside the center of the left rear quarter panel. Knock Sensor (except SHO engine) is at the center rear of the engine. Knock Sensor (SHO engine) is at the lower left front of the engine on the air cleaner assembly.
Page 329 ENGINE ELECTRICAL Стр. 45 из 46 Radiator Coolant Sensor is at the right front of the engine compartment. Radio Noise Capacitor (2.5L and 3.0L engine) is at the left front of the engine, near the ignition coil. Radio Noise Capacitor (3.8L engine) is at the left rear of the engine, near the ignition coil.
Page 330 ENGINE ELECTRICAL Стр. 46 из 46 Vehicle Speed Sensor (SHO engine) is at the lower left rear of the engine or mounted on the transaxle. VIP Self-Test Output Connector is at the right rear of the engine compartment, near the EEC module. Voltage Regulator is on the left front fender apron.
Page 331 Стр. 1 из 211 ENGINE MECHANICAL Engine Overhaul Tips Most engine overhaul procedures are fairly standard. In addition to specific parts replacement procedures and specifications for your individual engine, this section is also a guide to acceptable rebuilding procedures. Examples of standard rebuilding practice are shown and should be used along with specific details concerning your particular engine.
Page 332 Стр. 2 из 211 Occasionally, the use of special tools is called for. See the information on Special Tools and the Safety Notice in the front of this book before substituting another tool. INSPECTION TECHNIQUES Procedures and specifications are given in this section for inspecting, cleaning and assessing the wear limits of most major components.
Page 333 Стр. 3 из 211 Before effecting a repair to a threaded hole, remove any snapped, broken or damaged bolts or studs. Penetrating oil can be used to free frozen threads. The offending item can be removed with locking pliers or with a screw or stud extractor.
Page 334 Стр. 4 из 211 Drill out the damaged threads with the specified drill. Be sure to drill completely through the hole or to the bottom of a blind hole Using the kit, tap the hole in order to receive the thread insert. Keep the tap well oiled and back it out frequently to avoid clogging the threads file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 335 Стр. 5 из 211 Screw the threaded insert onto the installer tool until the tang engages the slot. Thread the insert into the hole until it is turn below the top surface, then remove the tool and break off the tang using a punch Engine REMOVAL &...
Page 336 Стр. 6 из 211 the air conditioning system may utilize R-12 or R-134a refrigerant. These two refrigerants should NOT be mixed, and depending on your local laws, attempting to service your A/C system could be illegal! 2.5L Engine Properly relieve the fuel system pressure. For fuel system relief procedures, please refer to Section 1 or Section 5 of this manual.
Page 337 Стр. 7 из 211 Disconnect the canister and halfshaft brackets from the engine. Remove the lower engine-to-transaxle retaining bolts. Disconnect the lower radiator hose. Carefully lower the vehicle, then position a floor jack under the transaxle. Disconnect the power steering lines from the power steering pump. Install engine lifting eyes tool D81L-6001-D or equivalent and engine support tool T79P-6000-A or equivalent.
Page 338 Стр. 8 из 211 Connect the fuel lines to the fuel rail. Connect the crankcase ventilation hose at the valve cover and the intake manifold. Connect the engine control sensor wiring assembly and vacuum lines. Connect the upper radiator hose at the engine, then install the air cleaner assembly.
Page 339 Стр. 9 из 211 Raise the vehicle and support it safely. Remove the engine mount bolts and engine mounts. Remove the transaxle to engine mounting bolts and transaxle brace assembly. Lower the vehicle. Install a suitable engine lifting plate onto the engine and use a suitable engine hoist to remove the engine from the vehicle.
Page 340 Стр. 10 из 211 Engine removal/component disconnect points (continued)-3.0L Flexible Fuel (FF) engine Click to enlarge To install: Install the main wiring harness on the engine. Position the engine in the vehicle and remove the engine lifting plate. Raise the vehicle and support it safely. Install the engine mounts and bolts, and tighten to 40-55 ft.
Page 341 Стр. 11 из 211 mark the position of the hood hinges and remove the hood. Remove the oil level dipstick. Disengage the alternator and voltage regulator wiring assembly. Remove the radiator upper sight shield. Properly discharge the air conditioning system, using suitable equipment. Remove the radiator coolant recovery reservoir assembly.
Page 342 Стр. 12 из 211 Disconnect the 4 dual converter/Y pipe-to-exhaust manifold retaining bolts. Remove the starter motor assembly. For details, please refer to the procedure located earlier in this section. Remove the lower transaxle-to-engine retaining bolts. Remove the front engine mount-to-front subframe retaining nuts. Remove the crankshaft vibration damper and pulley assembly.
Page 343 Стр. 13 из 211 then connect the cycling switch to the top of the accumulator. For the 3.2L SHO, install the accessory drive belt tensioner pulley. For the 3.0L SHO, install the lower belt tensioner. For the 3.0L SHO, install the power steering accessory belt (4-rib belt), then tighten the accessory drive belt tensioner pulley.
Page 344 Стр. 14 из 211 Remove the air cleaner assembly. Disconnect the cooling fan motor and the front center radiator primary crash sensor wire connectors. Remove the cooling fan motor/fan blade and fan shroud assembly. Remove the upper radiator hose. Disconnect and plug the transaxle oil cooler inlet and outlet tubes to prevent dirt and grease from entering the tubes.
Page 345 Стр. 15 из 211 Remove the distributor cap and position aside, then pull out the distributor rotor. Remove the radiator. Unfasten the exhaust manifold bolt lock retaining bolts. Remove the thermactor air pump retaining bolts and the thermactor air pump. Disconnect the engine control sensor wiring from the oil pressure sensor.
Page 346 Стр. 16 из 211 Connect the vacuum pump and install the exhaust air supply pump pulley assembly. Install the wiring shield. Install the distributor cap and rotor. Install the radiator coolant recovery reservoir assembly, upper radiator hose and water pump pulley. Connect the alternator-to-voltage regulator wiring assembly, then fasten the fuel charging wiring to the engine control sensor wiring.
Page 347 Стр. 17 из 211 support bracket. Installation is the reverse of the removal procedure. Tighten the insulator-to- engine support bracket to 40-55 ft. lbs. (54-75 Nm). Tighten the nut attaching the right, front and rear insulators to the frame to 55-75 ft. lbs. (75-102 Nm). LEFT ENGINE INSULATOR AND SUPPORT ASSEMBLY-AUTOMATIC TRANSAXLE Disconnect the negative battery cable.
Page 348 Стр. 18 из 211 Remove the lower damper bolt from the right side of the engine. Raise the vehicle and support it safely. Place a jack and a wood block in a suitable place under the engine. Remove the roll damper-to-engine retaining nuts and remove the roll damper. Raise the engine enough to unload the insulator.
Page 349 Стр. 19 из 211 Installation is the reverse of the removal procedure. Tighten the upper insulator stud retaining nut to 40-55 ft. lbs. (54-75 Nm) and the lower retaining nut to 50-70 ft. lbs. (68-95 Nm). RIGHT REAR ENGINE INSULATOR (NO. 3) Disconnect the negative battery cable and raise, then support the vehicle safely.
Page 350 Стр. 20 из 211 Disconnect the PCV hose, then set it aside-early model 2.5L shown Disconnect the throttle linkage cable from the top of the rocker arm cover. If equipped, disconnect the speed control cable from the top of the rocker arm cover.
Page 351 Стр. 21 из 211 Remove the rocker arm cover from the engine-early model 2.5L shown Inspect the rocker arm cover gasket for damage-early model 2.5L shown file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 352 Стр. 22 из 211 Rocker arm cover assembly-2.5L engine shown Click to enlarge To install: Clean the cylinder head and rocker arm cover mating surfaces. When using RTV sealant, install the rocker arm cover within five minutes to prevent the sealant from "skinning'' over. If the gasket is damaged by a cut and/or nick of about in.
Page 353 Стр. 23 из 211 and the oil fill cap, if removed. RTV must be cured completely before coming in contact with engine oil. Wait about one hour before starting the engine to allow the RTV to cure. Connect the negative battery cable, then start the engine and run it at a fast idle. Check for any oil leaks.
Page 354 Стр. 24 из 211 If the left rocker arm cover is being installed: install the oil fill cap, connect the air cleaner closure system hose to the nipple, and install the fuel injector harness stand-offs to the appropriate inboard rocker arm cover studs. If the right rocker arm cover is being installed: install the throttle body (refer to Section 5 for details), then install the PCV valve and connect the hoses.
Page 355 Стр. 25 из 211 Rocker arm/valve cover assembly-1991-95 3.0L engines (except SHO) Click to enlarge To install: Lightly oil all bolt and stud bolt threads before installation. Clean the gasket with a soft, clean cloth to remove any dirt, then using a suitable solvent, clean off any remaining silicone sealant.
Page 356 Стр. 26 из 211 Rocker arm/valve cover tightening sequence-1991-95 3.0L vehicles (except SHO) If the left cover is being installed: install the oil filler cap, fasten the crankcase ventilation tube to the connector, and install the fuel charging wiring stand-offs to the appropriate inboard valve cover stud bolts.
Page 357 Стр. 27 из 211 If the right valve cover is being installed, connect the fuel lines. Connect the spark plug wires as tagged during removal. Install the upper intake manifold. For details, please refer to the procedure located later in this section. Engage all vacuum lines and electrical connectors, as tagged during removal, to the intake manifold.
Page 358 Стр. 28 из 211 Rocker arm/valve cover-3.8L engine shown Click to enlarge To install: Lightly oil all bolt and stud bolt threads, then, using solvent, clean the cylinder head and valve cover sealing surface to remove all gasket material and dirt. Position a new rocker arm/valve cover gasket on the cylinder head, then install the retaining bolts.
Page 359 Стр. 29 из 211 REMOVAL & INSTALLATION 2.5L Engine Disconnect the negative battery cable. Remove the rocker arm cover. For details, please refer to the procedure located earlier in this section. Remove the rocker arm bolts, fulcrums, rocker arms and fulcrum washers. Keep all parts in order so they can be reinstalled to their original position.
Page 360 Стр. 30 из 211 When removing the rocker arm and fulcrum, make sure to keep all parts in order so they can be installed in their original position To install: Clean the cylinder head and rocker arm cover mating surfaces. Coat the valve tips, rocker arm and fulcrum contact areas with Lubricate®...
Page 361 Стр. 31 из 211 19579-D, or equivalent. Rocker arm seats must be fully seated in the cylinder head, and the pushrod(s) must be fully seated in the rocker arm valve lifter sockets before final tightening. Install the rocker arms into position with the pushrods, then snug the retaining bolt.
Page 362 Стр. 32 из 211 CAUTION When draining the coolant, keep in mind that cats and dogs are attracted byethylene glycol antifreeze, and are quite likely to drink any that is left inan uncovered container or in puddles on the ground. This will prove fatal insufficient quantity.
Page 363 Стр. 33 из 211 Remove the vent plug from the water outlet connection. Loosen the top hose clamp at the radiator, then remove the water outlet connection retaining bolts and lift the outlet clear of the engine. Remove the thermostat by pulling it out of the water outlet connection. Do NOT pry the housing off.
Page 364 Стр. 34 из 211 connection to the cylinder head using a new gasket. Tighten the bolts to 12-18 ft. lbs. (16-24 Nm). Position the top hose to the radiator and tighten the clamps. Use a new gasket when installing the water outlet connection Refill the cooling system.
Page 365 Стр. 35 из 211 Thermostat and related components-3.0L engine (except SHO) Click to enlarge To install: Make sure all sealing surfaces are free of old gasket material. Insert the thermostat into the water outlet connection/housing and rotate clockwise to lock it in. Note the location of the jiggle valve in relation to the water outlet connection.
Page 366 Стр. 36 из 211 the draincock. Partially drain the cooling system, then close the draincock. Remove the air cleaner outlet tube. Disconnect the upper radiator hose from the water outlet connection. Remove the two retaining nuts, then remove the water outlet connection. Remove the thermostat and the water hose connection gasket from the water outlet connection.
Page 367 Стр. 37 из 211 Loosen the upper radiator hose clamp at the radiator, then remove the water outlet connection retaining bolts and lift the water outlet clear of the engine. Remove the thermostat by rotating it counterclockwise in the water outlet connection until the thermostat becomes free to remove.
Page 368 Стр. 38 из 211 Fully insert the thermostat and rotate it clockwise in the water outlet connection to secure. Position the water outlet connection to the intake manifold with a new gasket and secure the retaining bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm). Make sure the hose clamps are beyond the bead and placedin the center of the clamping surface of the connection.
Page 369 Стр. 39 из 211 Intake Manifold REMOVAL & INSTALLATION 2.5L Engine Open and secure the hood. Common intake manifold assembly-late model 2.5L engine shown Click to enlarge Properly relieve the fuel system pressure, then disconnect the negative battery cable. Drain the cooling system. Remove accelerator cable and, if equipped, the cruise control cable.
Page 370 Стр. 40 из 211 Tag and disengage any required vacuum lines and electrical connections. As required on vehicles before 1990, disconnect the thermactor check valve hose at the tube assembly and remove the bracket-to-EGR valve attaching nuts. Disconnect the fuel supply and return lines. As required on vehicles before 1990, disconnect the water inlet tube at the intake manifold.
Page 371 Стр. 41 из 211 Install the intake manifold using a new gasket, then secure using the retaining bolts. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm) in the proper sequence. As required on vehicles before 1990, connect the water inlet tube at the intake manifold, connect the thermactor check valve hose at the tube assembly and install the bracket-to-EGR valve attaching nuts.
Page 372 Стр. 42 из 211 Tag and disconnect the spark plug wires, then remove the rocker arm covers. For details regarding rocker arm cover removal, please refer to the procedure located earlier in this section. Disconnect the upper radiator hose and heater hoses. If equipped, remove the distributor cap rubber boot, then mark the position of the distributor housing to the engine block and remove the cap and note the rotor position.
Page 373 Стр. 43 из 211 Lower intake manifold assembly-3.0L engine (except SHO) Click to enlarge To install: Lightly oil all the attaching bolts and stud threads before installation. When using a silicone rubber sealer, assembly must occur within 15 minutes after the sealer has been applied. After this time, the sealer may start to set-up and its sealing quality may be reduced.
Page 374 Стр. 44 из 211 Intake manifold gasket and front and rear seal location-3.0L engine (except SHO) Click to enlarge Carefully lower the intake manifold into position on the cylinder block and cylinder heads to prevent smearing the silicone sealer and causing gasket voids. Using a Torx®...
Page 375 Стр. 45 из 211 Connect the fuel lines, then install the fuel line safety clips. Install the distributor assembly, aligning the marks that were made during the removal procedure, then engage the electrical connector. Install the distributor cap rubber boot, if equipped. Install the spark plug wire harness to the plugs, using the retaining features attaching onto the rocker cover stud bolts.
Page 376 Стр. 46 из 211 throttle body removal, please refer to the procedure in Section 5 of this manual. Throttle body (upper intake manifold) removal-1994 3.0L unleaded gasoline engine shown Click to enlarge file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 377 Стр. 47 из 211 Throttle body (upper intake manifold removal-1994 3.0L flexible fuel (FF) engine shown Click to enlarge Loosen the EGR retaining nut, them remove it from the EGR valve-to-exhaust manifold tube from the exhaust manifold. Disconnect the fuel injector harness retaining stand-offs from the inboard rocker arm cover studs.
Page 378 Стр. 48 из 211 Disconnect the heater hoses. Tag and remove the spark plug wires using a twisting motion on the plug rubber boot. Do NOT pull on the wire itself. Remove the harness retaining stand-offs from the rocker arm cover studs. Do NOT remove or disturb the camshaft position sensor during the disassembly process.
Page 379 Стр. 49 из 211 Intake manifold gasket and seal location-3.0L engine Click to enlarge Position the intake gaskets onto the cylinder heads. Align the intake gasket locking tabs to the provisions on the cylinder head gaskets. Install the front and rear intake manifold seals and secure with the retainers. Carefully lower the intake manifold into position, aligning the manifold bolts holes to those in the cylinder head.
Page 380 Стр. 50 из 211 Connect the fuel lines, then install the fuel lines safety clips. Install the upper radiator hose and heater hoses. Make sure to tighten the retaining clamps securely. Connect the vacuum lines as tagged during removal. For unleaded fuel engines only, engage the electrical connectors to the intake air temperature, and the distributor.
Page 381 Стр. 51 из 211 Intake manifold and bracket assembly-3.0L and 3.2L SHO engines Click to enlarge To install: Lightly oil all of the retaining bolts and stud threads before installation. If not damaged, the intake manifold upper gasket is reusable. Position the intake manifold upper gasket on the cylinder head, then position the intake manifold on the cylinder heads.
Page 382 Стр. 52 из 211 Install the intake manifold supports, then tighten the retaining bolts to 11-17 ft. lbs. (15-23 Nm). Connect the coolant hoses, throttle position sensor wiring and cables to the throttle body. Engage all electrical connectors and vacuum lines to the intake manifold. Install the air cleaner outlet tube.
Page 383 Стр. 53 из 211 Upper intake manifold assembly-3.8L engine Click to enlarge Remove the injectors and fuel injection supply manifold assembly. Remove the heater water outlet hose. When removing the intake manifold retainers keep them in order so they can be installed in their original positions. Remove the lower intake manifold attaching bolts/studs, then remove the lower intake manifold.
Page 384 Стр. 54 из 211 Lower intake manifold assembly-3.8L engine Click to enlarge Lower intake manifold gasket and seal locations-3.8L engine Click to enlarge The manifold is sealed at each end with RTV-type sealer. To break the seal, it may be necessary to pry on the front of the manifold with a small or medium pry bar.
Page 385 Стр. 55 из 211 Apply a dab of Gasket and Trim Adhesive D7AZ-19B508-B, or equivalent adhesive, to each cylinder head mating surface. Press the new intake manifold gaskets into place, using locating pins as necessary to aid in assembly alignment. Apply a in.
Page 386 Стр. 56 из 211 upper intake manifold. Fill the cooling system to the proper level with the specified coolant. Connect the negative battery cable, then start the engine and check for coolant or fuel leaks. Check and, if necessary, adjust engine idle speed, transaxle throttle linkage and speed control.
Page 387 Стр. 57 из 211 Upper intake manifold assembly-1995 3.8L engine shown Click to enlarge Disconnect the upper radiator hose from the water hose connection. file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 388 Стр. 58 из 211 Disconnect the heater water hose from the lower intake manifold, then disconnect the heater water outlet tube from the lower intake manifold. Remove the fuel injectors and the fuel injection supply manifold. The lower intake manifold is secured at each corner with sealer. To break the seal you may have to carefully pry the front of the manifold with a suitable prybar.
Page 389 Стр. 59 из 211 cylinder head mating surface. Press the new gaskets into place, using locating pins as necessary to aid in alignment. Apply a in. (3-4mm) bead of Silicone Rubber D6AZ-19562-BA or equivalent, at each corner where the cylinder head joins the cylinder block. Install the front and rear intake manifold end seals.
Page 390 Стр. 60 из 211 REMOVAL & INSTALLATION 2.5L Engine Disconnect the negative battery cable. Drain the cooling system. Remove the accelerator cable and, if equipped, the cruise control cable. Remove air cleaner assembly and heat stove tube at the heat shield. Identify, tag and disengage all necessary vacuum lines and electrical connections.
Page 391 Стр. 61 из 211 attaching bolts in holes 2 and 3. Tighten all of the exhaust manifold retaining bolts, in sequence, to 5-7 ft. lbs. (7-10 Nm), then retorque, in sequence, to 20-30 ft. lbs. (27-41 Nm). Install the intake manifold gasket and bolts. Tighten the intake manifold retaining bolts to 15-23 ft.
Page 392 Стр. 62 из 211 Left side exhaust manifold mounting-3.0L engine (except SHO) Click to enlarge To install: Clean all exhaust manifold, cylinder head and Y-pipe mating surfaces, then lightly oil all bolt and stud threads. Position the exhaust manifold on the cylinder head, then install the retaining bolts. Tighten the retaining bolts to 15-22 ft.
Page 393 Стр. 63 из 211 If equipped, remove the water bypass tube. Raise and safely support the vehicle. Remove the exhaust manifold-to-dual converter Y-pipe retaining nuts, then remove the pipe from the manifold. Lower the vehicle. Remove the exhaust manifold retaining bolts, then remove the exhaust manifold from the vehicle.
Page 394 Стр. 64 из 211 and install it on the new manifold. Position the exhaust manifold on the cylinder head, then install the retaining bolts. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm). Raise and safely support the vehicle. Connect the dual converter Y-pipe to the exhaust manifold.
Page 395 Стр. 65 из 211 Remove the exhaust manifold retaining nuts, then remove the exhaust manifold. To install: Clean all of the cylinder head, exhaust manifold and Y-pipe mating surfaces, then lightly oil all bolt and stud threads. Position the exhaust manifold on the cylinder head, a new gasket, then install the retaining nuts.
Page 396 Стр. 66 из 211 A slight warpage in the exhaust manifold may cause a misalignment betweenthe bolt holes in the head and the manifold. Elongate the holes in the exhaustmanifold as necessary to correct the misalignment, if apparent. Do NOT elongatethe pilot hole, the lower front bolt on No. 5 cylinder.
Page 397 Стр. 67 из 211 Right side exhaust manifold mounting-3.8L engine Click to enlarge To install: Lightly oil all bolt and stud threads before installation. Clean the exhaust manifold, cylinder head and Y-pipe mating surfaces. Position the inner half of the heat shroud, if equipped, and exhaust manifold on cylinder head.
Page 398 Remove the rubber overflow tube from the coolant recovery bottle and detach it from the radiator. On the Taurus SHO, disconnect the tube from the radiator and remove the recovery bottle.
Page 399 Стр. 69 из 211 radiator upper retaining screws. For vehicles through 1992, if equipped with the 3.8L engine, remove 2 hex nuts from the right radiator support bracket and 2 screws from the left radiator support bracket and remove the brackets. For 1993-94 3.0L engines, remove the two radiator upper retaining screws.
Page 400 Стр. 70 из 211 If the lower or upper radiator hose it to be replaced, loosen the clamp at the engine end and, using a twisting motion, slip the hose off the connections. Remove the radiator lower support rubber pads, if pad replacement is necessary. Radiator and related components-2.5L engine Click to enlarge file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm...
Page 401 Стр. 71 из 211 Radiator and related components-3.0L engine (except SHO) Click to enlarge Radiator and fan retainer locations-3.0L engine (except SHO) file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 402 Стр. 72 из 211 Click to enlarge Radiator and related components-3.0L and 3.2L SHO Click to enlarge Radiator and fan retainer locations-3.0L SHO engine Click to enlarge file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 403 Стр. 73 из 211 Radiator and fan retainer locations-3.2L SHO engine Click to enlarge Radiator and related components-3.8L engine Click to enlarge file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 404 Стр. 74 из 211 Radiator and fan retainer locations-3.8L engine Click to enlarge To install: Position the radiator lower support rubber pads to the lower support, if removed. Make sure the hose clamps are beyond the bead and placed in the center of the clamping surface of the connection.
Page 405 Стр. 75 из 211 On the 3.8L engine through 1992, position the left hand support bracket over the radiator and the radiator support. Align the holes in the bracket with the corresponding holes in the radiator support and secure with the two retaining screws.
Page 406 Стр. 76 из 211 Using a prybar to gently bend the tabs away from the radiator tank Remove the retaining nuts and washers from the oil cooler inlet and outlet connections, then lift the oil cooler from the radiator outlet tank. Remove the radiator tank gasket from the oil cooler inlet and outlet connections, if the cooler is to be reused.
Page 407 Стр. 77 из 211 Tighten the oil cooler retaining nuts to 12-14 ft. lbs. (15-19 Nm). Tighten the intermediate fitting to 18-23 ft. lbs. (24-31 Nm). Install the radiator outlet tank on the radiator core header. To install the outlet tank: Inspect the seal surface of the radiator core header to ensure it is clean and undamaged.
Page 408 Стр. 78 из 211 Adjusting the height of the crimp. NOTE: It is important that the height of the crimp be in. (10.9mm) (maximum) when measured from the bottom of the header to the top of the tab Click to enlarge Crimping the tabs using locking-type pliers file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 409 Стр. 79 из 211 Crimping the tabs using a special crimping tool Connect the negative battery cable, then start the engine and check for leaks. Engine Fan REMOVAL & INSTALLATION Disconnect the negative battery cable. Remove the radiator upper sight shield. Disconnect the radiator upper sight shield retaining bolts Remove the radiator upper sight shield Disengage the electrical connector, then remove the integrated relay...
Page 410 Стр. 80 из 211 Location of the relay module-Early model 2.5L engine Disconnect the relay retaining bolts file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 411 Стр. 81 из 211 Remove the relay from the radiator support Constant control relay module location-3.0L engine (except SHO) Click to enlarge file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 412 Стр. 82 из 211 Disengage the relay module electrical connector Disconnect the fan electrical connector. Disengage the fan electrical connector If necessary, remove the air bag crash sensor. Unbolt the fan/shroud assembly from the radiator and remove. file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 413 Стр. 83 из 211 Unbolt the fan assembly from the radiator Remove the fan from the engine Remove the retainer and the fan from the motor shaft and unbolt the fan motor from the shroud. Installation is the reverse of the removal procedures. Tighten the fan shroud retaining bolt to 23-33 inch lbs.
Page 414 Стр. 84 из 211 Constant control relay module location-3.0L SHO, 3.2L SHO and 3.8L engines Click to enlarge Water Pump REMOVAL & INSTALLATION 2.5L Engine Disconnect the negative battery cable. Carefully remove the radiator cap, then position a drain pan under the bottom radiator hose.
Page 415 Стр. 85 из 211 Remove the water pump inlet tube Loosen the belt tensioner by inserting a in. flex handle in the square hole of the tensioner, then rotate the tensioner counterclockwise and remove the belt from the pulleys. Disconnect the heater hose from the water pump. Remove the water pump retaining bolts, then remove the water pump assembly from the engine.
Page 416 Стр. 86 из 211 If necessary, removing the water pump-to-pulley retaining bolts, then remove the pulley To install: Using a gasket scraper, clean the water pump and cylinder block so that they are free of old gasket material. Apply Perfect Seal Sealing Compound B5A-19554-A or equivalent to the new water pump gasket, then place the water pump assembly and new gasket to the cylinder block.
Page 417 Стр. 87 из 211 please refer to Section 1 of this manual. Use a new O-ring for the water pump inlet, then install the water pump inlet. Tighten the retaining bolts to 7 ft. lbs. (10 Nm). Close the radiator draincock. Install the drive belt on the water pump pulley, then adjust the tension.
Page 418 Стр. 88 из 211 Location of the water pump-to-engine retaining bolts Click to enlarge To install: Lightly oil all bolt and stud threads before installation except thosespecifying special sealant. Clean the water pump and engine front cover gasket mating surfaces. Position a new gasket on the water pump sealing surface using Gasket and Trim Adhesive D7AZ-19B508-AA or equivalent.
Page 419 Стр. 89 из 211 Location and size of the water pump mounting bolts and torque specifications-1986-89 3.0L engine (except SHO) Click to enlarge Two different lengths of retaining bolts are used. Refer to theaccompanying figure for specifications. Install the pulley-to-pump hob bolts. Tighten the bolts to 16 ft. lbs. (22 Nm). Connect the coolant bypass/heater hose to the water pump.
Page 420 Стр. 90 из 211 Remove the two nuts and bolt retaining the drive belt automatic tensioner to the engine, then remove the tensioner. Disconnect and remove the lower radiator and heater hose from the water pump. Remove the eleven water pump-to-engine retaining bolts, then lift the water pump and pulley up and out of the vehicle.
Page 421 Стр. 91 из 211 Water pump retaining fastener locations, size and torque specification Click to enlarge Hand-tighten the water pump pulley retaining bolts. Install the automatic belt tensioner assembly. Tighten the two retaining nuts and bolt to 35 ft. lbs. (47 Nm). Install the alternator and power steering belts.
Page 422 Стр. 92 из 211 refer to Section 1 of this manual. For the 3.0L SHO, remove the left-hand side drive belt tensioner pulley and bracket. For the 3.2L SHO remove the left-hand side drive belt pulleys. Disengage the electrical connector from the ignition control module and the ground strap.
Page 423 Стр. 93 из 211 in position. Install the water pump and retaining bolts to the cylinder block, then tighten the bolts to 12-17 ft. lbs. (16-23 Nm). On the 3.0L SHO, install the right-hand drive belt tensioner idler pulley and bracket.
Page 424 Стр. 94 из 211 Water pump and gasket mounting-3.8L engine Click to enlarge To install: Lightly oil all bolt and stud threads before installation except those that require sealant. Thoroughly clean the water pump and front cover gasket contact surfaces. Position the new water pump gasket on the pump sealing surface using Gasket and Trim Adhesive D7AZ-19B508-B or equivalent.
Page 425 Стр. 95 из 211 3.8L engine water pump retaining bolt locations. Since two bolt lengths are used, install the bolts as shown to prevent possible damage to the engine Click to enlarge Install the water pump pulley bolts, then tighten the bolts to 16 ft. lbs. (21 Nm). Connect the heater water hose to the water pump.
Page 426 Стр. 96 из 211 normal operating temperatures, then check for leaks and check the coolant level. Cylinder Head REMOVAL & INSTALLATION 2.5L Engine Disconnect the negative battery cable. Drain the cooling system. Cylinder head assembly and head bolt tightening sequence-2.5L engine Click to enlarge Remove the air cleaner assembly.
Page 427 Стр. 97 из 211 Remove the cylinder head bolts. Remove the cylinder head and gasket with the exhaust and intake manifolds attached. Removing the cylinder head bolts-2.5L engine An assistant is handy when removing the cylinder head from the engine file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 428 Стр. 98 из 211 Remove the cylinder head gasket and replace with a new one when installing the head To install: Clean all gasket material from the mating surface of the cylinder head and block. Position the cylinder head gasket on the cylinder block, using a suitable sealer to retain the gasket.
Page 429 Стр. 99 из 211 Torque the head bolts in sequence and to the correct specification Raise and safely support the vehicle. Connect the exhaust system at the exhaust pipe and hose to metal tube. Lower the vehicle. Install the thermactor pump drive belt, if equipped. Connect the accelerator cable and speed control cable, if equipped.
Page 430 Стр. 100 из 211 Remove the automatic belt tensioner assembly. Remove the alternator. Remove the power steering mounting bracket retaining bolts. Leave the hoses connected and place the pump aside in a position to prevent fluid from leaking out. Remove the engine oil dipstick tube from the exhaust manifold.
Page 431 Стр. 101 из 211 Installing a new cylinder head gasket, using the dowels in the block for alignment. If the dowels are damaged, they must be replaced Click to enlarge Position the cylinder head on the cylinder block. Tighten the cylinder head attaching bolts in 2 steps following the proper torque sequence.
Page 432 Стр. 102 из 211 Cylinder head bolt torque sequence-3.0L engine (except SHO) Click to enlarge When cylinder head attaching bolts have been tightened using the aboveprocedure, it is not necessary to retighten the bolts after extended engineoperation. The bolts can be rechecked for tightness if desired. Install the intake manifold.
Page 433 Стр. 103 из 211 Disconnect the negative battery cable. Drain the cooling system, then properly relieve the fuel system pressure. Remove the air cleaner outlet tube. Remove the intake manifold. For detail, please refer to the procedure located earlier in this section. Loosen the accessory drive belt tensioners, then remove the drive belts.
Page 434 Стр. 104 из 211 Timing alignment marks-3.0L and 3.2L SHO engines Click to enlarge Release the tension on the belt by loosening the tensioner nut and rotating the tensioner with a hex head wrench. When tension is released, tighten the nut. This will hold the tensioner in place.
Page 435 Стр. 105 из 211 Use a hex head wrench to loosen the tensioner nut Click to enlarge Disconnect the crankshaft position (CKP) sensor wiring assembly. Remove the center cover assembly. Remove the timing belt, noting the location of the letters KOA on the belt. The belt must be installed in the same direction.
Page 436 Стр. 106 из 211 MUST be installed in the same direction Remove the rocker arm/valve covers covers. For details, please refer to the procedure located earlier in this section. Remove the camshaft sprockets. Remove the upper and the center inner timing belt covers. If the left-hand cylinder head is being removed, remove the ignition control module, ignition coil bracket and the oil level dipstick tube.
Page 437 Стр. 107 из 211 hose and connect the dual converter Y-pipe. Install the upper and center inner timing belt covers. Install the camshaft pulleys in the timed position. Install the rocker arm/valve covers head covers. For details, please refer to the procedure located earlier in this section.
Page 438 Стр. 108 из 211 If equipped, disconnect the thermactor tube support bracket from the rear of cylinder head. Remove accessory drive idler. Remove the thermactor pump pulley and thermactor pump. Remove the PCV valve. Remove the upper intake manifold. For details, please refer to the procedure located earlier in this section.
Page 439 Стр. 109 из 211 Always use new cylinder head bolts to ensure a leak-tightassembly. Torque retention with used bolts can vary, which may result incoolant or compression leakage at the cylinder head mating surface area. For vehicles through 1994, tighten the cylinder head attaching bolts, in sequence, to the following specifications: Step 1: 37 ft.
Page 440 Стр. 110 из 211 Cylinder head bolt tightening sequence-3.8L engine Click to enlarge Dip each pushrod end in oil conditioner or heavy engine oil, then install the pushrods in their original position. For each valve, rotate crankshaft until the tappet rests on the heel (base circle) of the camshaft lobe.
Page 441 Стр. 111 из 211 serviceability, consult a reputable automotive machine shop. Remove the valves, springs and retainers, then clean the valve guide bores with a valve guide cleaning tool. Remove all dirt, oil and old gasket material from the cylinder head with solvent. Clean the bolt holes and the oil passage. Remove all deposits from the valves with a wire brush or buffing wheel.
Page 442 Стр. 112 из 211 Checking the cylinder head for flatness diagonally across the head surface Checking the cylinder head for flatness straight across the head surface Place a straightedge straight across and diagonally across the gasket surface of the cylinder head (in the positions shown in the figures). Using feeler gauges, determine the clearance at the center of the straightedge.
Page 443 The valve guide, if worn, must be repaired before the valve seats can be resurfaced. Ford supplies valves with oversize stems to fit valve guides that are reamed to oversize for repair. The machine shop will be able to handle the guide file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm...
Page 444 Стр. 114 из 211 reaming for you. In some cases, if the guide is not too badly worn, knurling may be all that is required. Reface, or have the valves and valve seats refaced. The valve seats should be a true 45°...
Page 445 Стр. 115 из 211 Position the engine so that both the intake and exhaust valves are closed. Screw the proper tool into the spark plug hole. Attach an air line to the tool and pressurize the cylinder with low pressure compressed air, just enough to hold the valves in the closed position.
Page 446 Стр. 116 из 211 Drain the cooling system and relieve the fuel system pressure. Disconnect the fuel lines from the fuel supply manifold and remove the throttle body. Disconnect the spark plug wires from the spark plugs. Remove the ignition wire/separator assembly from the rocker cover retaining studs.
Page 447 Стр. 117 из 211 3.8L Engine Disconnect the negative battery cable. Disconnect the secondary ignition wires at the spark plugs. Remove the plug wire routing clips from mounting studs on the rocker arm cover attaching bolts. Lay plug wires with routing clips toward the front of engine. Remove the upper intake manifold, rocker arm covers and lower intake manifold.
Page 448 Стр. 118 из 211 Start the engine and check for oil or coolant leaks. Oil Pan REMOVAL & INSTALLATION CAUTION The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil.
Page 449 Стр. 119 из 211 Remove the coolant tube-to-oil pan retainers, then..remove the coolant tube from the pan Disconnect the retaining bolts, then remove the oil pan. file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 450 Стр. 120 из 211 Remove the oil pan retaining bolts Carefully lower the oil pan from the engine To install: Clean both mating surfaces of oil pan and cylinder block, making certain all traces of RTV sealant are removed. file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 451 Стр. 121 из 211 Clean all traces of gasket/sealer from the oil pan Remove and clean oil pump pick-up tube and screen assembly. After cleaning, install tube and screen assembly. Fill the oil pan groove with RTV sealer; the bead should be approximately (3mm) above the surface of the pan rail.
Page 452 Стр. 122 из 211 Remove the oil pan attaching bolts, then slowly remove the oil pan, making sure the internal pan baffle does not snag the oil pump screen cover and tube. Remove the oil pan gasket. Exploded view of the oil pan-3.0L engine (except SHO) Click to enlarge To install: Clean the gasket surfaces on the cylinder block and oil pan.
Page 453 Стр. 123 из 211 and amount of engine oil, then start the engine and check for oil and exhaust leaks. 3.0L and 3.2L SHO Engines Disconnect the negative battery cable. Remove the oil level dipstick. Raise and safely support the vehicle. If equipped with a low oil level sensor, remove the retainer clip, then disengage the electrical connector from the sensor.
Page 454 Стр. 124 из 211 file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 455 Стр. 125 из 211 Exploded view of the oil pan assembly-3.0L and 3.2L engine Click to enlarge To install: Clean the gasket surfaces of the cylinder block and the oil pan. When using silicone sealer, assembly should occur within 15 minutes of application or the sealer may start to seal up losing its effectiveness.
Page 456 Стр. 126 из 211 Exploded view of the oil pan assembly-3.8L engine Click to enlarge To install: Clean the gasket surfaces on cylinder block and the oil pan. Trial fit oil pan to cylinder block. Ensure that enough clearance has been provided to allow the oil pan to be installed without sealant being scraped off when pan is positioned under the engine.
Page 457 Стр. 127 из 211 2.5L Engine Disconnect the negative battery cable, then remove the oil pan. Disconnect the oil pump attaching bolts, then remove the oil pump and intermediate driveshaft. To install: Prime the oil pump by filling the inlet port with engine oil. Rotate the pump shaft until oil flows from the outlet port.
Page 458 Стр. 128 из 211 Exploded view of the oil pump and related components-3.0L engine (except SHO) Click to enlarge To install: file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 459 Стр. 129 из 211 Prime the oil pump by filling either the inlet or the outlet port with engine oil. Rotate the pump shaft to distribute the oil within the oil pump body cavity. Insert the oil pump intermediate shaft assembly into the hex drive hole in the oil pump assembly until the retainer "clicks'' into place.
Page 460 Стр. 130 из 211 INSPECTION AND OVERHAUL 2.5L and 3.0L Engines Remove the oil pump from the vehicle. Inspect the inside of the pump housing for damage or excessive wear. Check the mating surface for wear. Minor scuff marks are normal but if the cover, gears or housing are excessively worn, scored or grooved, replace the pump.
Page 461 Стр. 131 из 211 If the depth is more than 1.202 in. (30.53mm), replace the oil pump body. PUMP GEAR SIDE CLEARANCE Measure the side clearance by inserting a feeler gauge between the gear tooth and the side wall of the gear pocket. The clearance should be a maximum of 0.005 in.
Page 462 Стр. 132 из 211 Click to enlarge Exploded view of the timing chain/engine front cover-late model 2.5L engine shown Click to enlarge To install: Clean and inspect all parts before installation. Make sure that the cylinder block and front cover are free of old gasket material and/or dirt. Apply oil resistant sealer to a new front cover gasket, then position the gasket into front cover.
Page 463 Стр. 133 из 211 the left or right (depending upon application) to remove the water pump drive belt. Remove the lower radiator hose and the heater hose from the water pump. Remove the crankshaft pulley and damper: If necessary, raise and safely support the vehicle, then remove the right-hand front wheel and tire assembly.
Page 464 Стр. 134 из 211 After removing the retaining bolts, remove the front cover from the engine Click to enlarge To install: Lightly oil all bolt and stud threads except those specifying special sealant. Be careful when scraping the old gasket material from the timing/front cover because aluminum gouges easily, and if scratched, leakage may occur.
Page 465 Стр. 135 из 211 Cover mounting bolt location and torque specifications Click to enlarge Install the oil pan and tighten the retaining bolts to 9 ft. lbs. (12 Nm). Hand tighten the water pump pulley retaining bolts. Install the crankshaft damper and pulley: Lubricate the oil seal with clean oil, then install the seal suing Vibration Damper and Seal Replacer T82L-6316-A and Front Cover Replacer T70P.
Page 466 Стр. 136 из 211 Location of the crankshaft vibration damper-3.0L engine (except SHO) Click to enlarge Location of the crankshaft pulley-3.0L engine (except SHO) Click to enlarge Install the automatic belt tensioner. Tighten the two retaining nuts and bolt to 35 ft. lbs.
Page 467 Стр. 137 из 211 Fill the crankcase with the correct amount and type of engine oil. Connect the negative battery cable. Fill and bleed the cooling system. Start the engine and check for coolant and oil leaks. 3.8L Engine Disconnect the negative battery cable. Properly drain the cooling system and the engine oil.
Page 468 Стр. 138 из 211 installed, remove the water pump and oil pump from the old front cover. Timing/engine front cover mounting-3.8L engine Click to enlarge To install: Lightly oil all bolt and stud threads before installation. Clean all gasket surfaces on the front cover, cylinder block and fuel pump.
Page 469: Remove The Water Pump/Power Steering Belt Tensioner Pulley Only
Стр. 139 из 211 Raise the vehicle and support safely. Install the oil pan. Connect the radiator lower hose. Install a new oil filter. Coat the crankshaft damper sealing surface with clean engine oil. Position the crankshaft pulley key in the crankshaft keyway. Install the damper with damper washer and attaching bolt.
Page 470: Remove The Upper Timing Belt Cover
Стр. 140 из 211 Remove the upper timing belt cover. Disconnect the crankshaft sensor connectors. Raise and safely support the vehicle. Remove the right front wheel and tire assembly. Loosen the fender splash shield and move aside. Remove the crankshaft vibration damper and pulley using Steering Wheel Puller T67L-3600-A, Step Plate Adapter D80L-630-3 or equivalent and Screw and Washer Set T89P-6701-A.
Page 471: Raise And Safely Support The Vehicle
Стр. 141 из 211 Using strap wrench D85L-6000-A, or equivalent, to hold the power steering pump pulley, remove the nut, washer, then remove the power steering pulley. Remove the retaining bolt from the belt tensioner, then remove the tensioner. Remove the upper and center timing belt covers. Disengage the crankshaft position (CKP) sensor electrical connectors.
Page 472 Стр. 142 из 211 To install: Before installation, inspect the front cover and shaft seal surface of the crankshaft damper for damage, nicks, burrs or other roughness which may cause the new seal to fail. Service or replace components as necessary.
Page 473: Remove The Right Front Wheel And Tire Assembly
Стр. 143 из 211 Check accessory drive belt for proper routing and engagement in the pulleys. Adjust the drive belt tension. Connect the negative battery cable. Start the engine and check for leaks. Timing Belt Cover Oil Seal REMOVAL & INSTALLATION 3.0L and 3.2L SHO Engines Loosen the accessory drive belts.
Page 474: Click To Enlarge
Стр. 144 из 211 Using a suitable steering wheel puller to remove the crankshaft sprocket Click to enlarge Remove the crankshaft front oil seal using Locknut Pin Remover T87P-3504-N, or equivalent. To remove the front oil seal, use a suitable locknut pin remover Click to enlarge To install: Inspect the front cover and shaft seal surface of the crankshaft damper for...
Page 475 Стр. 145 из 211 Repair or replace as necessary. Using Vibration Damper Remover Adapter T82L-6316-A, Crankshaft Seal Replacer/Cover Aligner Plate T88T-6701-A2 and Front Crank Replacer T89P-6701- B, install a new crankshaft front oil seal. Install Crankshaft Seal Replacer/Cover Aligner T88T-6701-A with forcing screw from Vibration Damper Remover Adapter T82L-6316-A to press the crankshaft front seal the rest of the way into the oil.
Page 476 Стр. 146 из 211 Remove the engine and transaxle from the vehicle as an assembly and position in a suitable holding fixture. Remove the dipstick. Remove accessory drive pulley, if equipped, Remove the crankshaft pulley attaching bolt and washer and remove pulley. Remove front cover attaching bolts from front cover.
Page 477 Стр. 147 из 211 Timing chain-1991 2.5L engine shown Click to enlarge To install: Clean and inspect all parts before installation. Clean the oil pan, cylinder block and front cover of gasket material and dirt. Slide both sprockets and timing chain onto the camshaft and crankshaft with timing marks aligned.
Page 478 Стр. 148 из 211 Click to enlarge Remove the camshaft sprocket attaching bolt and washer. Slide both sprockets and timing chain forward and remove as an assembly. Check the timing chain and sprockets for excessive wear. Replace if necessary. Exploded view of the timing chain and related components Click to enlarge To install: Before installation, clean and inspect all parts.
Page 479 Стр. 149 из 211 crankshaft damper bolt to 93-121 ft. lbs. (126-164 Nm) and the pulley bolts to 30-44 ft. lbs. (41-60 Nm). Fill the crankcase with the proper type and quantity of oil. Fill and bleed the engine cooling system. Connect the negative battery cable, then start the engine and check for coolant, oil and exhaust leaks.
Page 480 Стр. 150 из 211 installed, remove the water pump and oil pump from the old frontcover. Timing chain and related components-3.8L engine Click to enlarge To install: Lightly oil all bolt and stud threads before installation. Clean all gasket surfaces on the front cover, cylinder block and fuel pump.
Page 481 Стр. 151 из 211 Position of the timing marks when the No. 1 piston is at TDC Click to enlarge Install the distributor drive gear. Install the camshaft sprocket washer and bolt at the end of the camshaft, then tighten to 30-37 ft. lbs. (41-50 Nm). Install the timing chain/engine front cover, using a new gasket.
Page 482 Стр. 152 из 211 Location of the front engine support damper-3.0L SHO engine Click to enlarge Disconnect the wiring to the ignition control module. Remove the engine air inlet/intake manifold crossover tube bolts. Loosen the intake manifold tube hose clamps. Remove the engine air inlet/intake manifold crossover tube.
Page 483: Table Of Contents
Стр. 153 из 211 tension on the belt by backing out the adjustment screw. Remove the water pump/power steering belt. Remove the alternator/air conditioning belt tensioner pulley and bracket assembly. Remove the water pump/power steering belt tensioner pulley only. Remove the upper timing belt cover. Disengage the crankshaft position (CKP) sensor connectors.
Page 484: The Belt Koa Should Be Readable From The Rear Of The Engine; Top Of The Lettering To
Стр. 154 из 211 Loosening the timing belt tensioner-3.0L SHO engine Click to enlarge Carefully lower the vehicle, then remove the timing belt. To install: Before installing the timing belt, inspect it for cracks, wear or otherdamage and replace, if necessary. Do NOT allow the timing belt to come intocontact with gasoline, oil, water, coolant or steam.
Page 485 Стр. 155 из 211 Rotate the crankshaft 2 revolutions in the clockwise direction until the yellow mark on the damper aligns with the 0° mark on the lower timing belt cover. Rotate the crankshaft 2 revolutions (clockwise) until the yellow mark on the vibration damper aligns with the 0°...
Page 486 Стр. 156 из 211 the tension. Tighten the idler pulley nut to 25-36 ft. lbs. (34-49 Nm). Install the engine air inlet connector/intake manifold crossover tube. Tighten the bolts to 11-17 ft. lbs. (15-23 Nm). Install the engine roll damper/engine front support damper. Install the battery, then connect the battery cables.
Page 487 Стр. 157 из 211 Rotate the drive belt tensioner clockwise to relieve tension, then remove the belt Click to enlarge Disconnect the surge tank fitting. Remove the bolts retaining the upper and lower idler pulleys to the engine, then remove the pulleys. file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 488 Стр. 158 из 211 Location of the upper and lower idler pulleys Click to enlarge Using Strap Wrench D85L-6000-A or equivalent, to hold the power steering pump pulley, remove the nut and the washer, then remove the power steering pulley. Remove the retaining bolt from the belt tensioner, then remove the tensioner.
Page 489: Loosen The Fender Splash Shield And Place It Aside
Стр. 159 из 211 Remove the retaining bolt from the belt tensioner, then remove the tensioner Click to enlarge Remove the upper and center timing belt covers. Disengage the crankshaft position (CKP) sensor electrical connectors. Place the transaxle selector in N (neutral). Rotate the crankshaft until the No.
Page 490: Remove The Lower Timing Belt Cover
Стр. 160 из 211 Using a suitable puller, remove the crankshaft vibration damper. Remove the lower timing belt cover and belt guide. Remove the upper timing belt tensioner bolt. Slowly loosen the lower timing belt tension bolt, then remove the tensioner. Carefully lower the vehicle, then remove the timing belt.
Page 491 Стр. 161 из 211 Index marks on the camshaft sprockets and oil pump Click to enlarge Install the timing belt over the crankshaft and camshaft sprockets. The lettering on the belt KOB should be readable from the rear of the engine; top of the lettering to the front of the engine.
Page 492 Стр. 162 из 211 Location of the rubber grommets Click to enlarge Remove the in. (1.27mm) hex wrench from the timing belt tensioner. If a new belt is being installed, perform the following steps: Position the timing belt tensioner tool T93P-6254-A or equivalent, using the power steering pump bracket holes.
Page 493 Стр. 163 из 211 Position the timing belt tensioner tool, using the power steering pump bracket holes Click to enlarge Using an inch lbs. torque wrench with a belt tensioner attachment, rotate clockwise to 4.3 inch lbs. (0.5 Nm) Click to enlarge Raise and safely support the vehicle.
Page 494 Стр. 164 из 211 Rotate the crankshaft 2 revolutions (clockwise) until the white mark on the vibration damper aligns with the 0° mark on the lower timing belt cover Carefully lower the vehicle. Make sure the index marks on the camshaft sprockets align with the marks on the rear metal timing belt cover.
Page 495 Стр. 165 из 211 Raise and safely support the vehicle. Install the fender splash shield, then install the right front wheel and tire assembly. Carefully lower the vehicle, then tighten the lug nuts to 85-105 ft. lbs. (115-142 Nm). Timing Sprockets REMOVAL &...
Page 496 Стр. 166 из 211 Disconnect the negative battery cable. Remove the timing belt. For details, please refer to the procedure located earlier in this section. Be careful not to damage the crankshaft position (CKP) sensor or the pulse wheel. Remove the crankshaft sprocket using Steering Wheel Puller T67L-3600-A or equivalent.
Page 497 Стр. 167 из 211 located earlier in this section. Using a magnet, remove the hydraulic lifters and label them so they can be installed in their original positions. If the tappets are stuck in the bores by excessive varnish, etc., use a suitable claw-type puller to remove the tappets. Loosen and remove the drive belt, fan and pulley.
Page 498 Стр. 168 из 211 Connect engine temperature sending unit wire. Connect coil primary wire. Install distributor cap. Connect spark plug wires and the coil high tension lead. Fill the cooling system and crankcase to the proper levels. Connect the negative battery cable.
Page 499 Стр. 169 из 211 Remove the camshaft thrust plate. Carefully remove the camshaft by pulling it toward the front of the engine. Remove it slowly to avoid damaging the bearings, journals and lobes. Be careful when removing the camshaft to avoid damaging the bearings, journals and lobes Click to enlarge To install:...
Page 500 Стр. 170 из 211 Lubricate the pushrods and rocker arms with heavy engine oil. Install the pushrods and rocker arms into their original positions. Rotate the crankshaft to set each lifter on its base circle, then tighten the rocker arm bolt. Tighten the rocker arm bolts to 19-28 ft.
Page 501 Стр. 171 из 211 Camshaft sprocket mounting bolt locations-SHO engines Install the chain over the camshaft sprockets. Align the white painted link with the timing mark on the sprocket. Align the white painted links with the timing mark on the camshaft sprockets Rotate the camshafts 60°...
Page 502 Стр. 172 из 211 Timing chain tensioner mounting-SHO engines Click to enlarge Apply a thin coat of engine oil to the camshaft journals and install bearing caps No. 2 through No. 5 and loosely install the bolts. The arrows on the bearing caps point to the front of the engine when installed.
Page 503 Стр. 173 из 211 Installing the camshaft seal using the specified tools Click to enlarge Apply silicone sealer to the No. 1 bearing cap, then install the bearing cap while holding the camshaft front seal in place with the Cam Seal Replacer. Loosely install the bolts.
Page 504 Стр. 174 из 211 Apply sealer to the No. 1 cylinder head camshaft journal cap Tighten the bearing caps in sequence using a 2 step method. Tighten to 6-9 ft. lbs. (8-12 Nm), then tighten to 12-16 ft. lbs. (16-22 Nm). For left camshaft installation, apply pressure to the chain tensioner to avoid damage to the bearing caps.
Page 505 Стр. 175 из 211 Click to enlarge Install the chain tensioner and tighten the bolts to 11-14 ft. lbs. (15-19 Nm). Rotate the camshafts 60° ( turn) clockwise and check for proper alignment of the timing marks. Marks on the camshaft sprockets should align with the cylinder head cover mating surface.
Page 506 Стр. 176 из 211 3.8L Engine Disconnect the negative battery cable. Properly relieve the fuel system pressure. Drain the cooling system and crankcase. Remove the engine from the vehicle and position in a suitable holding fixture. Remove the intake manifold. Remove the rocker arm covers, rocker arms, pushrods and lifters.
Page 507 Стр. 177 из 211 INSPECTION Remove the camshaft from the engine. Check each lobe for excessive wear, flatness, pitting or other physical damage. Replace the camshaft as required. Using a micrometer measure the lobes, if not within specification, replace the camshaft.
Page 508 Стр. 178 из 211 Install the timing chain and camshaft sprocket. Install the oil pan. Install the timing cover. Install the intake manifolds. Install the engine in the vehicle. Pistons and Connecting Rods REMOVAL Although in some cases the pistons and connecting rods may be removed with the engine still in the vehicle, it is rarely worth the aggravation, especially when you are not working with a lift.
Page 509 Стр. 179 из 211 Removing the ridge from the cylinder bore using a ridge cutter A ridge reamer is necessary for this operation. Place the piston at the bottom of its stroke, and cover it with a rag. Cut the ridge away with the ridge reamer, using extreme care to avoid cutting too deeply.
Page 510 Стр. 180 из 211 Match the connecting rods to their cylinders using a number stamp Matchmark the connecting rod cap to the connecting rod with a scribe; each cap must be reinstalled on its proper rod in the proper direction. Remove the connecting rod bearing cap and the rod bearing.
Page 511 Стр. 181 из 211 assembly on the proper cylinder. Cut lengths of rubber hose for connecting rod bolt guides Click to enlarge Carefully tap the piston and rod assembly out using a wooden hammer handle Remove remaining pistons in similar manner. Clean and inspect the engine block, the crankshaft, the pistons and the connecting rods.
Page 512 Стр. 182 из 211 CLEANING AND INSPECTION Pistons A piston ring expander is necessary for removing piston rings without damaging them; any other method (screwdriver blades, pliers, etc.) usually results in the ring being bent, scratched or distorted, or the piston itself being damaged. When the rings are removed, clean the piston grooves using an appropriate ring groove cleaning tool, using care not to cut too deeply.
Page 513 Стр. 183 из 211 Clean the piston grooves using a ring groove cleaner Clean the varnish from the piston skirts and pins with a cleaning solvent. DO NOT WIRE BRUSH ANY PART OF THE PISTON. Clean the ring grooves with a groove cleaner and make sure that the oil ring holes and slots are clean.
Page 514 Стр. 184 из 211 Measure the piston's outer diameter using a micrometer The cylinder bore may also be measured using a dial gauge file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 515 Стр. 185 из 211 Cylinder bore measuring points Connecting Rods Wash the connecting rods in cleaning solvent and dry with compressed air. Check for twisted or bent rods and inspect for nicks or cracks. Replace connecting rods that are damaged. Cylinder Bores The piston should also be checked in relation to the cylinder diameter.
Page 516 Стр. 186 из 211 Before the piston is removed from the cylinder, check for a ridge at the top of the cylinder bore. This ridge occurs because the piston ring does not travel all the way to the top of the bore, thereby leaving an unworn portion of the bore surface. Clean away any carbon buildup at the top of the cylinder with sand paper, in order to see the extent of the ridge more clearly.
Page 517 Стр. 187 из 211 Removing cylinder glazing using a flexible hone Cylinder bore cross-hatch pattern Honing can be done either with a flexible glaze breaker type hone or with a rigid hone that has honing stones and guide shoes. The flexible hone removes the least amount of metal, and is especially recommended if your piston-to-cylinder bore clearance is on the loose side.
Page 518 Стр. 188 из 211 uniform finish. A rigid hone will provide a definite cross-hatch finish; operate the rigid hone at a speed to obtain a 45-65 degree included angle in the cross-hatch. The finish marks should be clean but not sharp, free from embedded particles and torn or folded metal.
Page 519 Стр. 189 из 211 called measuring the ring end gap. Compare the reading to the one called for in the specifications table. If the measurement is too small, when the engine heats up the ring ends will butt together and cause damage. File the ends of the ring with a fine file to obtain necessary clearance.
Page 520 Стр. 190 из 211 necessary to push the piston down in the cylinder bore to to this. Installation is the reverse of the removal procedure. Freeze Plugs For the vehicles covered by this manual, one of two types of freeze plugs may be used: a cup-type plug or an expansion-type plug.
Page 521 Стр. 191 из 211 Use the proper tool when installing a cup-type plug For the expansion-type plug, it is important to pull the plug into the machined bore by using a properly designed tool. Never drive the plug into the bore using a tool that contacts the flange.
Page 522 Стр. 192 из 211 Rear Main Seal REMOVAL & INSTALLATION Disconnect the negative battery cable. Raise and safely support the vehicle. Remove the transaxle. For details, please refer to the procedure located in Section 7 of this manual. Remove the flywheel and the rear cover plate, if necessary. Using a sharp awl, punch one hole into the crankshaft rear oil seal metal surface between the seal lip and the cylinder block.
Page 523 Стр. 193 из 211 Rear main bearing installation-3.0L engine (except SHO) Click to enlarge Removing the rear main oil seal using the specified tool-3.0L and 3.2L SHO engines file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 524 Стр. 194 из 211 Crankshaft rear main oil seal cover-3.0L and 3.2L SHO engines file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 525 Стр. 195 из 211 Installing the rear main oil seal on the SHO engines using the required tools Click to enlarge file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 526 Стр. 196 из 211 For the 3.8L engine, you have to remove the flywheel to access the rear main oil seal Click to enlarge Exploded view of installing the rear main oil seal-3.8L engine Click to enlarge To install: Inspect the crankshaft seal area for any damage which may cause the seal to leak. If damage is evident, service or replace the crankshaft as necessary.
Page 527 Стр. 197 из 211 Coat the crankshaft seal area and the lip with engine oil. Using a Rear Crankshaft Seal Replacer T81P-6701-A seal installer tool, install the seal. Tighten the bolts of the seal installer tool evenly so the seal is straight and seats without misalignment.
Page 528 Стр. 198 из 211 Remove the main bearing caps by removing the retaining bolts Carefully lift crankshaft out of the block so the upper thrust bearing surfaces are not damaged. Reinstall the main bearing caps on the block. Handle the crankshaft with care to avoid possible fracture or damage to the finished surfaces.
Page 529 Remove the connecting rod bearing inserts from the connecting rods and caps. Install a new rear oil seal in the rear seal cover. Apply a thin coat of Ford Polyethylene Grease D0AZ-19584-A (ESR-M1C159-A or ESB-M1C93-A) or equivalent, to the rear crankshaft surface. Do not apply sealer to the area forward of oil sealer groove.
Page 530 Стр. 200 из 211 If the end play exceeds specification, replace the upper thrust bearing. If the end play is less than the specification, inspect the thrust bearing faces for damage, dirt or improper alignment. Install the thrust bearing and align the faces. Check the end play.
Page 531 Стр. 201 из 211 Handle the crankshaft with care to avoid possible damage to the finished surfaces or the engine. Carefully lift the crankshaft out of the block so that the upper thrust bearing surfaces are not damaged. Exploded view of the crankshaft, main bearing caps, and bearings-3.0L engine (except SHO) Click to enlarge To install:...
Page 532 Стр. 202 из 211 in the slot provided. Install the lower main bearing inserts in the bearing caps. Carefully lower the crankshaft into place. Check the clearance of each main bearing. Select fit the bearings for proper clearance. After the bearings have been fitted, apply a light coat of Oil Conditioner part No. D9AZ-19578-CO or heavy engine oil, SAE 50 weight, to the journals bearings and rear seal surface.
Page 533 Tag and disconnect the ignition wires from the spark plugs, then remove the distributor cap and ignition wires as an assembly. Remove the spark plugs. On Taurus Police vehicles, remove the oil pan baffle. Remove the oil pan and oil pickup tube.
Page 534 Стр. 204 из 211 Exploded view of the crankshaft, main bearing caps and bearings-3.8L engine Click to enlarge To install: Make sure all crankshaft bearing journals and bearing caps are clean. Contaminants under a bearing will cause distortion. Contaminants on the bearing surface will cause damage to the bearing journals.
Page 535 Стр. 205 из 211 the thrust bearing faces for damage, dirt or improper alignment. Install the thrust bearing and align the faces. Recheck the end play. Install a new crankshaft rear oil seal. Install the used connecting rod bearings to their original positions. If using new ones, install the tabs on the bearings into the slots in the cap and the rod.
Page 536 Стр. 206 из 211 run-out as shown. Compare to specifications. Measure the main and connecting rod journals for wear, out-of-roundness or taper, using a micrometer. Measure in at least 4 places around each journal and compare your findings with the journal diameter specifications. If the crankshaft fails any inspection for wear or damage, it must be reground or replaced.
Page 537 Стр. 207 из 211 Inspect the crankshaft journals as detailed in the Cleaning and Inspection procedure. If the crankshaft journals appear usable, clean them and the bearing shells until they are completely free of oil. Blow any oil from the oil hole in the crankshaft. To check the crankshaft/rod bearing clearances using a micrometer, perform the following procedures: Set the crankshaft on V-blocks.
Page 538 Стр. 208 из 211 Apply a strip of gauging material to the bearing, then install and tighten the cap As with the connecting rod bearings, remove the cap and compare the gauging material to the provided scale file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsHIPBC.htm 18.11.2005...
Page 539 Стр. 209 из 211 Place a strip of Plastigage® or equivalent gauging material, lengthwise along the bottom center of the lower bearing shell, then install the cap with the shell and torque the connecting rod nuts or main cap bolts to specification. When the Plastigage®...
Page 540 Стр. 210 из 211 Flywheel mounting-3.0L engine (except SHO) Flywheel mounting-3.8L engine To install: All major rotating components including the flexplate/flywheel are individually balance to zero. Engine assembly balancing is not required. Balance weights should not be installed on new flywheels. Install the rear cover plate, if removed.
Page 541 Стр. 211 из 211 Position the flywheel on the crankshaft and install the attaching bolts. For all engines except the SHO, tighten the attaching bolts to 54-64 ft. lbs. (73-87 Nm), using the standard cross-tightening sequence. For the SHO engines, tighten the bolts in two steps: Step 1: 29-39 ft.
Page 542 Стр. 1 из 9 EXHAUST SYSTEM Introduction Location of the muffler--Early model 2.5L shown Location of the catalytic converter-- early model 2.5L shown file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsIHDLA.htm 18.11.2005...
Page 543 Стр. 2 из 9 Exploded view of the exhaust system -- 2.5L engine Click to enlarge Exploded view of the exhaust system -- 3.0L engine(expect SHO) equipped with the AX4S transaxle Click to enlarge file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsIHDLA.htm 18.11.2005...
Page 544 Стр. 3 из 9 Exploded view of the exhaust system -- 3.0L engine(expect SHO) equipped with the AX4N transaxle Click to enlarge Exploded view of the exhaust system -- 3.8L engine Police sedan file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsIHDLA.htm 18.11.2005...
Page 545 Стр. 4 из 9 Click to enlarge Exploded view of the exhaust system -- 3.0L SHO engine Click to enlarge file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsIHDLA.htm 18.11.2005...
Page 546 Стр. 5 из 9 Exploded view of the exhaust system -- 3.2L SHO engine Click to enlarge General Information Two types of pipe connections are used on most exhaust systems; they are: the ball joint (to allow angular movement for alignment purposes) and the slip joint. Gaskets are used only with the ball joint type connections.
Page 547 Стр. 6 из 9 dangers. Always follow safety precautions carefully during exhaust system service. Safety Precautions Safety glasses should be worn at all times when working on or near the exhaust system. Older exhaust systems will almost always be covered with loose rust particles which will shower you when disturbed.
Page 548 Стр. 7 из 9 Before removing any component of the exhaust system, ALWAYS squirt a liquid rust dissolving agent onto the fasteners for ease of removal. A lot of knuckle skin will be saved by following this rule. Coat all of the exhaust connections and bolt threads with anti-seize compound to prevent corrosion from making the next disassembly difficult.
Page 549 Стр. 8 из 9 of freeing rusted parts considerably. Remember that these solvents are often flammable. Apply only to parts that have been allowed to cool! Resonator Assembly REMOVAL & INSTALLATION Raise and safely support the vehicle. Remove the front resonator flange fasteners at the flex joint, then discard the flex joint gasket.
Page 550 Стр. 9 из 9 Separate the catalytic converter inlet and outlet connections. Remove the converter. Installation is the reverse of the removal procedure. Be sure to use new retaining clamps. Lower the vehicle. Start the engine and check for leaks. Tailpipe REMOVAL &...
Page 551 BASIC MECHANICAL TROUBLESHOOTING Стр. 1 из 6 BASIC MECHANICAL TROUBLESHOOTING Engine Speed Oscillates at Idle When the engine idle speed will not remain constant, check for the following, as necessary: A faulty fuel pump A leaky Exhaust Gas Recirculation (EGR) valve A blown head gasket A worn camshaft Worn timing gears, chain or sprockets...
Page 552 BASIC MECHANICAL TROUBLESHOOTING Стр. 2 из 6 When the engine cannot maintain high speed operations, check for the following, as necessary: A faulty fuel pump producing low fuel volume A restriction in the intake manifold A worn distributor shaft Unadjusted valve timing Leaking valves or worn valve springs Fault with the computerized engine control system Poor Acceleration...
Page 553 BASIC MECHANICAL TROUBLESHOOTING Стр. 3 из 6 Inoperative Positive Crankcase Ventilation (PCV) valve Faulty or loose spark plugs Clogged fuel delivery system Sticking, leaking or broken valves Excessive deposits in the combustion chambers Leaks in the vacuum system Fault with the computerized engine control system Excessive Oil Leakage When large amounts of oil are noticed under the engine after each operation, check for the following, as necessary:...
Page 554 BASIC MECHANICAL TROUBLESHOOTING Стр. 4 из 6 Damaged valve stem oil deflectors Too long intake gasket dowels Mismatched rail and expander of the oil ring Excessive clearance of the main and connecting rods Scored or worn cylinder walls Negative Oil Pressure When the engine presents no oil pressure, check for the following, as necessary: Low oil level in the crankcase Broken oil pressure gauge or sender...
Page 555 BASIC MECHANICAL TROUBLESHOOTING Стр. 5 из 6 Loose torque converter or flywheel mounting bolts Loose damper pulley hub Excessive clearance of the main bearings Excessive belt tension Low oil supply to the main bearings Extreme crankshaft end play Knocking Connecting Rods When the connecting rod bearings are constantly making noise, check for the following, as necessary: Misaligned connecting rod or cap...
Page 556 BASIC MECHANICAL TROUBLESHOOTING Стр. 6 из 6 Excessively worn camshaft lobes Bent or worn pushrods Excessively worn bridged pivots or rocker arms Cocked or broken valve springs Bent valve(s) Worn valve lifter face(s) Damaged lifter plunger or pushrod seat Knocking Valves When the valves are constantly noisy, check for the following, as necessary: Unadjusted valve lash Broken valve springs...
Page 557 SPECIFICATION CHARTS Стр. 1 из 7 SPECIFICATION CHARTS Valve Specifications Click to enlarge Camshaft Specifications Click to enlarge http://www.chiltondiy.com/content/8687/8687_3_5.html 18.11.2005...
Page 558 SPECIFICATION CHARTS Стр. 2 из 7 Crankshaft and Connecting Rod Specifications Click to enlarge Piston and Ring Specifications Click to enlarge Torque Specifications Click to enlarge http://www.chiltondiy.com/content/8687/8687_3_5.html 18.11.2005...
Page 559 SPECIFICATION CHARTS Стр. 3 из 7 Torque Specifications Click to enlarge Torque Specifications Click to enlarge http://www.chiltondiy.com/content/8687/8687_3_5.html 18.11.2005...
Page 560 SPECIFICATION CHARTS Стр. 4 из 7 Engine Rebuilding Specifications Click to enlarge http://www.chiltondiy.com/content/8687/8687_3_5.html 18.11.2005...
Page 561 SPECIFICATION CHARTS Стр. 5 из 7 Engine Rebuilding Specifications Click to enlarge http://www.chiltondiy.com/content/8687/8687_3_5.html 18.11.2005...
Page 562 SPECIFICATION CHARTS Стр. 6 из 7 Engine Rebuilding Specifications Click to enlarge http://www.chiltondiy.com/content/8687/8687_3_5.html 18.11.2005...
Page 563 SPECIFICATION CHARTS Стр. 7 из 7 Engine Rebuilding Specifications Click to enlarge Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_3_5.html 18.11.2005...
Page 729 AIR POLLUTION Стр. 1 из 4 AIR POLLUTION Introduction The earth's atmosphere, at or near sea level, consists approximately of 78% nitrogen, 21% oxygen and 1% other gases. If it were possible to remain in this state, 100% clean air would result. However, many varied causes allow other gases and particulates to mix with the clean air, causing the air to become unclean or polluted.
Page 730 AIR POLLUTION Стр. 2 из 4 leaving in its path a barren and unhealthy environment for all living things. Working with Federal, State and Local mandated rules, regulations and by carefully monitoring the emissions, industries have greatly reduced the amount of pollutant emitted from their industrial sources, striving to obtain an acceptable level.
Page 731 AIR POLLUTION Стр. 3 из 4 trapped, so are the pollutants, causing a severe smog condition. Should this stagnant air mass extend to a few thousand feet high, enough air movement with the inversion takes place to allow the smog layer to rise above ground level but the pollutants still cannot dissipate.
Page 732 AIR POLLUTION Стр. 4 из 4 Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_4_1.html 18.11.2005...
Page 733 EXHAUST EMISSIONS Стр. 1 из 5 EXHAUST EMISSIONS Composition Of The Exhaust Gases The exhaust gases emitted into the atmosphere are a combination of burned and unburned fuel. To understand the exhaust emission and its composition review some basic chemistry. When the air/fuel mixture is introduced into the engine, we are mixing air, composed of nitrogen (78%), oxygen (21%) and other gases (1%) with the fuel, which is 100% hydrocarbons (HC), in a semi-controlled ratio.
Page 734 EXHAUST EMISSIONS Стр. 2 из 5 Carbon monoxide is formed when not enough oxygen is present during the combustion process to convert carbon (C) to carbon dioxide (CO ). An increase in the carbon monoxide (CO) emission is normally accompanied by an increase in the hydrocarbon (HC) emission because of the lack of oxygen to completely burn all of the fuel mixture.
Page 735 EXHAUST EMISSIONS Стр. 3 из 5 between 10 and 20 miles (16-32km) up in the atmosphere, much of the ultra violet radiation from the sun's rays are absorbed and screened. If this ozone layer were not present, much of the earth's surface would be burned, dried and unfit for human life.
Page 736 EXHAUST EMISSIONS Стр. 4 из 5 Good grades of engine lubricating oils should be used, meeting the manufacturers specification. "Cut-rate'' oils can contribute to the particulate emission problem because of their low "flash'' or ignition temperature point. Such oils burn prematurely during the combustion process causing emissions of particulate matter.
Page 737 EXHAUST EMISSIONS Стр. 5 из 5 FUEL EVAPORATIVE EMISSIONS Gasoline fuel is a major source of pollution, before and after it is burned in the automobile engine. From the time the fuel is refined, stored, pumped and transported, again stored until it is pumped into the fuel tank of the vehicle, the gasoline gives off unburned hydrocarbons (HC) into the atmosphere.
Page 738 EMISSION CONTROLS Стр. 1 из 51 EMISSION CONTROLS Introduction There are three sources of automotive pollutants: crankcase fumes, exhaust gases and gasoline evaporation. The pollutants formed from these substances can be grouped into three categories: unburned hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NO ).
Page 739 EMISSION CONTROLS Стр. 2 из 51 Positive Crankcase Ventilation (PCV) system schematic-except SHO vehicles Click to enlarge The PCV system on the SHO vehicles is unique because is does not use a PCV valve. Instead, the crankcase gases flow through an oil separator to three ports in the throttle body.
Page 740 EMISSION CONTROLS Стр. 3 из 51 Click to enlarge On some engine applications, the PCV system is connected with the evaporative emission system. Do not remove the PCV system from the engine, as doing so will adversely affect fuel economy and engine ventilation, with resultant shortening of engine life.
Page 741 EMISSION CONTROLS Стр. 4 из 51 PCV system components-3.0L shown, 2.5L similar Click to enlarge SYSTEM INSPECTION Visually inspect the components of the PCV system. Check for rough idle, slow http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 742 EMISSION CONTROLS Стр. 5 из 51 starting, high oil consumption and loose, leaking, clogged or damaged hoses. Check the fresh air supply hose and the PCV hose for air leakage or flow restriction caused by loose engagement, hose splitting, cracking, kinking, nipple damage, poor rubber grommet fit or any other damage.
Page 743 EMISSION CONTROLS Стр. 6 из 51 Place a stiff piece of paper over the hose/nipple, as in Step 4 and wait 1 minute. If vacuum holds the paper in place, proceed to evaporative emission system testing. If the paper is not held in place, check for vacuum leaks/obstruction in the system: oil cap, PCV valve, hoses, cut grommets, the oil separator on the 2.5L engine and valve cover for bolt torque/gasket leak.
Page 744 EMISSION CONTROLS Стр. 7 из 51 Evaporative emission control components consist of the carbon canister, purge valve(s), vapor valve, rollover vent valve, check valve and the necessary lines. All vehicles may not share all components. The carbon canister contains vapor absorbent material to facilitate the storage of fuel vapors.
Page 745 EMISSION CONTROLS Стр. 8 из 51 Fuel odor or leakage Damaged vacuum or fuel vapor lines Loose or poor line connections Poor driveability during engine warm-up Check the wiring and connectors for the solenoids, vane air flow meter, speed sensor and ECU, as applicable, for looseness, corrosion, damage or other problems.
Page 746 EMISSION CONTROLS Стр. 9 из 51 EEC system for the 3.0L Flexible Fuel (FF) engine Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 747 EMISSION CONTROLS Стр. 10 из 51 The 3.0L Flexible Fuel vehicles utilize four canisters mounted under the rear floor pan Click to enlarge REMOVAL & INSTALLATION Carbon Canister Disconnect the negative battery cable. Detach the vapor hoses from the carbon canister. http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 748 EMISSION CONTROLS Стр. 11 из 51 Remove the canister mounting bolts and/or retaining straps, then remove the canister. The 3.0L Flexible Fuel engine uses four canisters mounted under the rear floor pan. Installation is the reverse of the removal procedure. http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 749 EMISSION CONTROLS Стр. 12 из 51 http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 750 EMISSION CONTROLS Стр. 13 из 51 EEC system for the 3.0L SHO engine Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 751 EMISSION CONTROLS Стр. 14 из 51 http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 752 EMISSION CONTROLS Стр. 15 из 51 EEC system for the 3.2L SHO engine Click to enlarge EEC system for the 3.8L engine Click to enlarge Purge Valves http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 753 EMISSION CONTROLS Стр. 16 из 51 Disconnect the negative battery cable. Disconnect the vacuum hose or the electrical connector from the purge valve. Disconnect the vapor hoses and remove the purge valve from the vehicle. Installation is the reverse of the removal procedure. Vapor Valve Disconnect the negative battery cable.
Page 754 EMISSION CONTROLS Стр. 17 из 51 Pressure Feedback Electronic (PFE) EGR system schematic Click to enlarge Differential Pressure Feedback Electronic (DPFE) EGR system schematic Click to enlarge The Electronic EGR (EEGR) valve system is used on some vehicles equipped with the 2.5L engine.
Page 755 EMISSION CONTROLS Стр. 18 из 51 Electronic EGR (EEGR) system schematic Click to enlarge The ported EGR valve is the most common form of EGR valve. It is operated by a vacuum signal which actuates the valve diaphragm. As the vacuum increases sufficiently to overcome the power spring, the valve is opened allowing EGR flow.
Page 756 EMISSION CONTROLS Стр. 19 из 51 Back pressure Variable Transduced (BVT) EGR system schematic Click to enlarge The EGR Vacuum Regulator (EVR) is an electromagnetic device which controls vacuum output to the EGR valve. The EVR replaces the EGR solenoid vacuum vent valve assembly.
Page 757 EMISSION CONTROLS Стр. 20 из 51 EGR system and related components for the 3.0L engine (except SHO) Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 758 EMISSION CONTROLS Стр. 21 из 51 Exploded view of the EGR valve and related components-3.0L and 3.2L SHO engines Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 759 EMISSION CONTROLS Стр. 22 из 51 View of the EGR system components-late model 3.8L engine shown Click to enlarge TESTING Back pressure Variable Transducer (BVT) Make sure all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. Make sure there is no vacuum to the EGR valve at idle with the engine at normal operating temperature.
Page 760 EMISSION CONTROLS Стр. 23 из 51 Slowly apply 5-10 in. Hg (17-34 kPa) of vacuum to the EGR valve vacuum nipple using a suitable hand vacuum pump. When vacuum is fully applied to the EGR valve, check for the following: If idle speed drops more than 100 rpm or if the engine stalls, perform the next step.
Page 761 EMISSION CONTROLS Стр. 24 из 51 Cross-sectional view of a ported EGR valve assembly To install: Using a new gasket, install the EGR valve, then secure using the retaining bolts. Attach any vacuum lines or electrical connectors disengaged during removal. Connect the negative battery cable.
Page 762 EMISSION CONTROLS Стр. 25 из 51 Cross-sectional view of a base entry-type electronic EGR valve Click to enlarge Cross-sectional view of a side (external) entry-type electronic EGR valve Click to enlarge Disconnect the negative battery cable. Disengage the the electrical connector from the EVP sensor. Disengage the electrical connector from the EVP sensor-early model 2.5L engine Disconnect the vacuum line from the EGR valve.
Page 763 EMISSION CONTROLS Стр. 26 из 51 Disconnect the vacuum line from the EGR valve Remove the mounting bolts and remove the EGR valve. Disconnect the mounting bolts from the EGR valve Remove the mounting bolts from the EGR valve http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 764 EMISSION CONTROLS Стр. 27 из 51 Remove the EGR valve from the vehicle-early model engine shown When installing the EGR valve, be sure to remove the old gasket and install a new one Remove the EVP sensor from the EGR valve. Remove all old gasket material from the mating surfaces.
Page 765 EMISSION CONTROLS Стр. 28 из 51 To install: Install the transducer, then engage the electrical connector and connect the exhaust pressure line to the transducer. Connect the negative battery cable. EGR Valve Position (EVP) Sensor EGR sensor-late model 3.0L (except SHO and Flexible Fuel) shown Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 766 EMISSION CONTROLS Стр. 29 из 51 EGR sensor location-3.0L Flexible Fuel engines Click to enlarge Disconnect the negative battery cable. Disengage the electrical connector from the sensor. EGR sensor-late model 3.8L shown Click to enlarge Disconnect the sensor mounting nuts, then remove the sensor from the EGR valve.
Page 767 EMISSION CONTROLS Стр. 30 из 51 Cross-sectional view of a Back Pressure Variable Transducer (BVT) Click to enlarge Remove the BVT from its mounting position, then remove it from the vehicle. To install: Install the BVT in its mounting position. Connect the vacuum lines to the BVT, then connect the negative battery cable.
Page 768 EMISSION CONTROLS Стр. 31 из 51 Install the regulator in the vehicle, then secure using the retaining bolts. Connect the vacuum lines, then engage the electrical connector to the regulator. Connect the negative battery cable. Exhaust Emission Control System The exhaust emission control system begins at the air intake and ends at the tailpipe.
Page 769 EMISSION CONTROLS Стр. 32 из 51 Duct assembly-3.0L engine (except SHO) Click to enlarge Duct assembly-3.0L/3.2L SHO engines Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 770 EMISSION CONTROLS Стр. 33 из 51 Duct assembly-3.8L engine Click to enlarge Bimetal Sensor The core of the bimetal sensor is made of two different types of metals bonded together, each having different temperature expansion rates. At a given increase in temperature, the shape of the sensor core changes, bleeding off vacuum available at the vacuum motor.
Page 771 EMISSION CONTROLS Стр. 34 из 51 Bimetal Sensor Bring the temperature of the bimetal sensor below 75°F (24°C) and apply 16 in. Hg (54 kPa) of vacuum with a vacuum pump at the vacuum source port of the sensor. The duct door should stay closed. If not, replace the bimetal sensor. The sensor will bleed off vacuum to allow the duct door to open and let in fresh air at or above the following temperatures: Brown: 75°F (24°C)
Page 772 EMISSION CONTROLS Стр. 35 из 51 Disconnect the negative battery cable. Remove the air cleaner housing lid to gain access to the sensor. Disconnect the vacuum hoses from the sensor. It may be necessary to move the air cleaner housing to accomplish this. Remove the sensor from the air cleaner housing.
Page 773 EMISSION CONTROLS Стр. 36 из 51 concentration, and converting some of them into harmless carbon dioxide and water. During highway cruising and WOT operation, the thermactor air is dumped to atmosphere to prevent overheating in the exhaust system. A typical air injection system consists of an air supply pump and filter, air bypass valve, check valves, air manifold, air hoses and air control valve.
Page 774 EMISSION CONTROLS Стр. 37 из 51 Air supply pump assembly Air Bypass Valve The air bypass valve supplies air to the exhaust system with medium and high applied vacuum signals when the engine is at normal operating temperature. With low or no vacuum applied, the pumped air is dumped through the silencer ports of the valve or through the dump port.
Page 775 EMISSION CONTROLS Стр. 38 из 51 Air check valve Click to enlarge Air Supply Control Valve The air supply control valve directs air pump output to the exhaust manifold or downstream to the catalyst system, depending upon the engine control strategy. It may also be used to dump air to the air cleaner or dump silencer.
Page 776 EMISSION CONTROLS Стр. 39 из 51 The air bypass portion controls the flow of thermactor air to the exhaust system or allows thermactor air to be bypassed to atmosphere. When air is not being bypassed, the air control portion of the valve switches the air injection point to either an upstream or downstream location.
Page 777 EMISSION CONTROLS Стр. 40 из 51 The TIV valve vents the vacuum signal to the atmosphere when the preset manifold vacuum or pressure is exceeded. It is used to divert thermactor airflow during cold starts to control exhaust backfire. Thermactor idle vacuum valve assembly TESTING Air Supply Pump Check belt tension and adjust if needed.
Page 778 EMISSION CONTROLS Стр. 41 из 51 Visually inspect the thermactor system hoses, tubes, control valve(s) and check valve(s) for leaks that may be due to the backflow of exhaust gas. If holes are found and/or traces of exhaust gas products are evident, the check valve may be suspect.
Page 779 EMISSION CONTROLS Стр. 42 из 51 Thermactor Idle Vacuum Valve The following applies to TIV valves with the code words ASH or RED on the decal. Apply the parking brake and block the drive wheels. With the engine at idle, and the transaxle selector lever in N on automatic transaxle equipped vehicles or Neutral on manual transaxle equipped vehicles, apply vacuum to the small nipple and place fingers over the TIV valve atmospheric vent holes.
Page 780 EMISSION CONTROLS Стр. 43 из 51 Disconnect the negative battery cable. Disconnect the input hose from the check valve. Remove the check valve from the connecting tube. To install: Fasten the check valve to the connecting tube. Connect the input hose to the check valve. Connect the negative battery cable.
Page 781 EMISSION CONTROLS Стр. 44 из 51 Thermactor Idle Vacuum Valve Disconnect the negative battery cable. Disconnect the vacuum lines from the TIV valve, then remove the valve from the vehicle. To install: Install the TIV valve in the vehicle, then connect the vacuum lines to the valve. Connect the negative battery cable.
Page 782 EMISSION CONTROLS Стр. 45 из 51 Pulse air valve flow schematic Air Silencer/Filter The air silencer is a combustion silencer and filter for the pulse air system. The air silencer is mounted in a convenient position in the engine compartment and is connected to the pulse air valve inlet by means of a flexible hose.
Page 783 EMISSION CONTROLS Стр. 46 из 51 should be drawn into the valve. Remove the vacuum line; the air flow should stop. If these conditions are met, the valve is operating properly. If these conditions are not met, verify that vacuum is present at the valve. Check the solenoid valve if vacuum is not present.
Page 784 EMISSION CONTROLS Стр. 47 из 51 Install the pulse air valve, then, if removed, connect the vacuum line. Connect the air hose(s) from the pulse air valve. Connect the negative battery cable. Air Silencer/Filter Disconnect the negative battery cable. Disconnect the hose from the silencer. Remove the silencer from the vehicle.
Page 785 EMISSION CONTROLS Стр. 48 из 51 The catalytic converter, mounted in the engine exhaust stream, plays a major role in the emission control system. The converter works as a gas reactor whose catalytic function is to speed up the heat producing chemical reaction between the exhaust gas components in order to reduce the air pollutants in the engine exhaust.
Page 786 EMISSION CONTROLS Стр. 49 из 51 Catalyst and exhaust system diagnostic data Click to enlarge Service Interval Reminder Lights RESETTING http://www.chiltondiy.com/content/8687/8687_4_3.html 18.11.2005...
Page 787 EMISSION CONTROLS Стр. 50 из 51 Approximately every 5,000 or 7,500 miles (8,000 or 12,000 km), depending on engine application, the word SERVICE will appear on the electronic display for the first 1.5 miles (2.4 km) to remind the driver that is is time for the regular vehicle service interval maintenance (for example, an oil change).
Page 788 EMISSION CONTROLS Стр. 51 из 51 Oxygen sensor (HEGO) assembly electrical connector Disconnect and plug the vacuum line at the MAP sensor and set the voltmeter on the 20 volt scale. Apply 10-14 in. Hg (34-47 kPa) of vacuum to the MAP sensor. Start the engine and run it at approximately 2000 rpm for 2 minutes.
Page 789 As the Taurus and Sable changed through the years, so did the name of the computer control module. Depending on the year of the vehicle it was called the EEC-IV Processor, Electronic Control Assembly (ECA), Electronic Control Unit (ECU) or Powertrain Control Module (PCM).
Page 790 ELECTRONIC ENGINE CONTROLS Стр. 2 из 10 View of the computer control module-Powertrain Control Module (PCM) shown (other modules are basically identical) Click to enlarge Regardless of the name, all computer control modules are serviced in a similar manner. Care must be taken when handling these expensive components in order to protect them from damage.
Page 791 ELECTRONIC ENGINE CONTROLS Стр. 3 из 10 Computer control module mounting Click to enlarge Installation is the reverse of the removal procedure. Tighten the module retaining screw to 24-32 inch lbs. (2.7-3.7 Nm). Tighten the engine control sensor wiring connector retaining bolt to 32 inch lbs. (3.7 Nm). Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor directly measures the mass of the air flowing into the engine.
Page 792 ELECTRONIC ENGINE CONTROLS Стр. 4 из 10 module harness, then connect the control module. Start the engine and let it idle. Use a voltmeter to measure the voltage between test pin 50 of the breakout box and the battery negative post. Replace the MAF sensor if the voltage is not 0.36-1.50 volts.
Page 793 ELECTRONIC ENGINE CONTROLS Стр. 5 из 10 Disconnect the air bypass valve. Use an ohmmeter to measure the resistance between the terminals of the valve solenoid. Due to the diode in the solenoid, place the ohmmeter positive lead on the VPWR pin and the negative lead on the ISC pin.
Page 794 ELECTRONIC ENGINE CONTROLS Стр. 6 из 10 negative circuit of the motor, test pin 41, to battery ground for 4 seconds. Reverse the jumper wires, connecting the positive circuit of the ISC motor to battery ground and the negative circuit to battery positive for 4 seconds. The ISC motor shaft should extend to greater than 2 in.
Page 795 ELECTRONIC ENGINE CONTROLS Стр. 7 из 10 used to measure the temperature of the incoming air and send the information to the computer control module. In all other systems, the sensor provides the computer control module with mixture, fuel and air temperature information. The air temperature sensor is located in the meter in vane air flow meter systems.
Page 796 ELECTRONIC ENGINE CONTROLS Стр. 8 из 10 ACT and ECT temperature sensor value chart Click to enlarge With Vane Air Flow Meter Unfasten the vane air flow meter connector. Access the sensor in the meter. Monitor the temperature near the sensor. If using a hot air gun to heat the sensor, be careful not to melt any plastic or rubber components.
Page 797 ELECTRONIC ENGINE CONTROLS Стр. 9 из 10 Engine Coolant Temperature (ECT) Sensor ACT and ECT temperature sensor value chart Click to enlarge The Engine Coolant Temperature (ECT) sensor detects the temperature of engine coolant and supplies that information to the computer control module. The ECT sensor is located on the cylinder head or on the intake manifold.
Page 798 ELECTRONIC ENGINE CONTROLS Стр. 10 из 10 The MAP sensor measures manifold vacuum using a frequency. This gives the computer control module information on engine load. It is used as a barometric sensor for altitude compensation, updating the control module during key ON, engine OFF and every wide-open throttle.
Page 799 SELF-DIAGNOSTIC SYSTEMS Стр. 1 из 5 SELF-DIAGNOSTIC SYSTEMS General Information All vehicles covered by this manual have self-diagnostic capabilities. Malfunctions in the engine control system are found through the Self-Test procedure. The vehicles covered by this manual use the Electronic Engine Control-IV (EEC-IV) system, which utilizes a Self-Test divided into 3 specialized tests: Key On Engine Off Self-Test, Engine Running Self-Test and Continuous Self-Test.
Page 800 SELF-DIAGNOSTIC SYSTEMS Стр. 2 из 5 STAR tester hook-up Click to enlarge STAR tester output code format Click to enlarge If it is desired to clear the display window during the Self-Test, turn OFF the vehicle's engine, press the tester's button once to unlatch it, then press the button again to latch down the button.
Page 801 SELF-DIAGNOSTIC SYSTEMS Стр. 3 из 5 USING THE ANALOG VOLTMETER Service codes will be represented by pulsing or sweeping movements of the voltmeter's needle across the dial face of the voltmeter. Therefore, a single digit number of 3 will be reported by 3 needle sweeps. However, a service code is represented by a 2-digit or 3-digit number, such as 23.
Page 802 SELF-DIAGNOSTIC SYSTEMS Стр. 4 из 5 Click to enlarge Set the voltmeter on a DC voltage range to read from 0-20 volts. On all EEC-IV vehicles, connect the voltmeter from the battery positive post to the Self-Test Output (STO) pin of the large Self-Test connector. On all other vehicles, connect the positive voltmeter lead to the EEC STO line and the negative lead to engine ground, then jumper the EEC Self-Test Input (STI) to ground.
Page 803 SELF-DIAGNOSTIC SYSTEMS Стр. 5 из 5 Start the engine. Record all service codes displayed. Engine identification codes are issued at the beginning of the Engine Running Self-Test and are 1-digit numbers represented by the number of pulses sent out. The engine identification code is equal to the number of engine cylinders.
Page 804 DIAGNOSTIC TROUBLE CODES Стр. 1 из 8 DIAGNOSTIC TROUBLE CODES Listings of the Diagnostic Trouble Codes (DTCs) for the various engine control systems covered in this manual are located in this section. When using these codes, remember that a code only points to the faulty circuit, NOT necessarily to a faulty component.
Page 805 DIAGNOSTIC TROUBLE CODES Стр. 2 из 8 Diagnostic Trouble Codes Click to enlarge Diagnostic Trouble Codes Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_6.html 18.11.2005...
Page 806 DIAGNOSTIC TROUBLE CODES Стр. 3 из 8 Diagnostic Trouble Codes Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_6.html 18.11.2005...
Page 807 DIAGNOSTIC TROUBLE CODES Стр. 4 из 8 Diagnostic Trouble Codes Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_6.html 18.11.2005...
Page 808 DIAGNOSTIC TROUBLE CODES Стр. 5 из 8 Diagnostic Trouble Codes Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_6.html 18.11.2005...
Page 809 DIAGNOSTIC TROUBLE CODES Стр. 6 из 8 Diagnostic Trouble Codes Click to enlarge Diagnostic Trouble Codes Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_6.html 18.11.2005...
Page 810 DIAGNOSTIC TROUBLE CODES Стр. 7 из 8 Diagnostic Trouble Codes Click to enlarge http://www.chiltondiy.com/content/8687/8687_4_6.html 18.11.2005...
Page 811 DIAGNOSTIC TROUBLE CODES Стр. 8 из 8 Diagnostic Trouble Codes Click to enlarge Diagnostic Trouble Codes Click to enlarge Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_4_6.html 18.11.2005...
Page 871 BASIC FUEL SYSTEM DIAGNOSIS Стр. 1 из 1 BASIC FUEL SYSTEM DIAGNOSIS Introduction When there is a problem starting or driving a vehicle, two of the most important checks involve the ignition and the fuel systems. The two questions that mechanics attempt to answer first, "is there spark?'' and "is there fuel?'' will often lead to solving most basic problems.
Page 872 CENTRAL FUEL INJECTION (CFI) Стр. 1 из 9 CENTRAL FUEL INJECTION (CFI) General Description The Central Fuel Injection (CFI) system is a single point, pulse time modulated injection system which was used on 1986-90 2.5L engines. Fuel is metered into the air intake stream according to engine demands by one or two solenoid injection valves, mounted in a throttle body on the intake manifold.
Page 873 CENTRAL FUEL INJECTION (CFI) Стр. 2 из 9 Click to enlarge The fuel manifold (or fuel rail) evenly distributes fuel to each injector. Its main purpose is to equalize the fuel flow. One end of the fuel rail contains a relief valve for testing fuel pressure during engine operation.
Page 874 CENTRAL FUEL INJECTION (CFI) Стр. 3 из 9 Inertia switch location Click to enlarge Crank the engine for 15 seconds. Engage the electrical connector to the inertia switch located on the left side of the storage compartment. Electric Fuel Pump REMOVAL &...
Page 875 CENTRAL FUEL INJECTION (CFI) Стр. 4 из 9 Raise and safely support the vehicle, then disconnect and remove the fuel filler tube. Support the fuel tank, then remove the fuel tank support straps. Partially lower the fuel tank, then remove the fuel lines, electrical connectors and vent lines from the tank.
Page 876 CENTRAL FUEL INJECTION (CFI) Стр. 5 из 9 To install: Clean the fuel pump mounting flange, along with the fuel tank mounting surface and seal ring groove. Put a light coating of grease on the new seal gasket to hold it in place during assembly, then install the gasket in the fuel ring groove.
Page 877 CENTRAL FUEL INJECTION (CFI) Стр. 6 из 9 Remove the fuel cap and release the fuel tank pressure. Release the fuel system pressure by disengaging the inertia switch electrical connector, then cranking the engine for 15 seconds. Disconnect the negative battery cable. Disconnect the throttle cable and transmission throttle valve lever.
Page 878 CENTRAL FUEL INJECTION (CFI) Стр. 7 из 9 Adjust the engine idle speed if necessary. Refer to the Engine/Emission Control Decal for idle speed specifications. INJECTOR REPLACEMENT Remove the fuel injector retaining screw and retainer. Remove the injector and the lower O-ring. Discard the O-ring. Cross-sectional view of a CFI fuel injector Click to enlarge To install:...
Page 879 CENTRAL FUEL INJECTION (CFI) Стр. 8 из 9 Disengage the electrical connector from inertia switch on the left-hand side of the luggage compartment. Crank the engine for 15 seconds to reduce fuel system pressure. Disconnect the fuel supply line at the throttle body using Spring Lock Coupling Adapter D85L-9974-C or equivalent.
Page 880 CENTRAL FUEL INJECTION (CFI) Стр. 9 из 9 REMOVAL & INSTALLATION Disconnect the negative battery cable. Disconnect the Throttle Position (TP) sensor from the wiring harness. Scribe a reference mark across the edge of the sensor where it meets the throttle body to ensure correct position during installation.
Page 881 ELECTRONIC FUEL INJECTION (EFI) Стр. 1 из 31 ELECTRONIC FUEL INJECTION (EFI) General Description The Electronic Fuel Injection (EFI) system was used on 1991 2.5L, 1986-92 3.0L (except SHO) and 1988-92 3.8L engines. The EFI fuel system includes a high pressure (30-45 psi/209-310 kPa) tank-mounted electric fuel pump, throttle body, fuel charging manifold, pressure regulator, fuel filter, and both solid and flexible fuel lines.
Page 882 ELECTRONIC FUEL INJECTION (EFI) Стр. 2 из 31 diaphragm. Control of the fuel system is maintained through the Electronic Engine Control (EEC) power relay and the EEC-IV control unit, although electrical power is routed through the fuel pump relay and an inertia switch. The fuel pump relay is normally located on a bracket somewhere above the Electronic Control Assembly (ECA) and the inertia switch is located in the storage compartment.
Page 883 ELECTRONIC FUEL INJECTION (EFI) Стр. 3 из 31 http://www.chiltondiy.com/content/8687/8687_5_3.html 18.11.2005...
Page 884 ELECTRONIC FUEL INJECTION (EFI) Стр. 4 из 31 Cross-sectional view of an EFI fuel injector Click to enlarge Fuel supply manifold assembly Click to enlarge The fuel manifold is normally removed with fuel injectors and pressure regulator attached. Fuel injector electrical connectors are plastic and have locking tabs that must be released when disconnecting the wiring harness.
Page 885 ELECTRONIC FUEL INJECTION (EFI) Стр. 5 из 31 Throttle position sensor and idle air bypass valve location on the throttle body Click to enlarge The throttle air bypass valve is an electro-mechanical (solenoid) device whose operation is controlled by the EEC-IV control unit. A variable air metering valve controls both cold and warm idle air flow in response to commands from the control unit.
Page 886 ELECTRONIC FUEL INJECTION (EFI) Стр. 6 из 31 Using Fuel Tank Sender Wrench D84P-9275-A or equivalent, turn the fuel pump lock ring counterclockwise, then remove the lock ring. Remove the fuel pump and bracket assembly from the fuel tank, then remove and discard the flange gasket.
Page 887 ELECTRONIC FUEL INJECTION (EFI) Стр. 7 из 31 not damaged. Make sure that the locating keys are in the keyways and that the seal ring stays in place. Hold the assembly in place, then install the lock ring finger-tight, making sure all locking tabs are under the tank lock ring tabs.
Page 888 ELECTRONIC FUEL INJECTION (EFI) Стр. 8 из 31 rod. Disconnect and remove the throttle bracket. Carefully separate the throttle body from the upper intake manifold. Remove and discard the gasket between the throttle body and upper intake manifold. If scraping is necessary to clean the surfaces, be careful not to damage the air bypass valve or throttle body gasket surfaces.
Page 889 ELECTRONIC FUEL INJECTION (EFI) Стр. 9 из 31 Loosen the air cleaner duct hose retaining clamps, then remove the hose. Remove the idle speed control solenoid shield. Disconnect the throttle/accelerator and TV cable from the throttle body linkage. Accelerator and TV cable locations Click to enlarge Matchmark and disconnect the vacuum hoses at the vacuum tree.
Page 890 ELECTRONIC FUEL INJECTION (EFI) Стр. 10 из 31 Tag and remove the six throttle body retaining bolts, then lift the throttle body from the intake manifold Click to enlarge Lift and remove the throttle body assembly from the intake manifold, then discard the old gasket.
Page 891 ELECTRONIC FUEL INJECTION (EFI) Стр. 11 из 31 Lightly oil all bolt and stud threads. Clean and inspect the intake manifold and throttle body mating surfaces. Be careful when cleaning the gasket mating surfaces because aluminum gouges easily and may form leak paths. If available, position guide pins to aid in the alignment during installation.
Page 892 ELECTRONIC FUEL INJECTION (EFI) Стр. 12 из 31 body primary lever (the lever to which the TV- driving nail is attached) by hand to the wide-open- throttle position. The white adjuster shank must be seen to advance. If not, look for the cable sheath/foam hang-up on engine/body components.
Page 893 ELECTRONIC FUEL INJECTION (EFI) Стр. 13 из 31 Upper intake manifold mounting-3.8L engine Click to enlarge To install: Clean and inspect the mating surfaces of the lower and upper intake manifold. Position a new gasket on the lower intake manifold mounting surface. Using alignment studs will make the job easier.
Page 894 ELECTRONIC FUEL INJECTION (EFI) Стр. 14 из 31 Connect the PCV hose to the rear of the upper manifold. Connect the vacuum lines to the vacuum tree, EGR valve, and fuel pressure regulator. Position the throttle linkage bracket with cables to the upper intake manifold. Install the two retaining bolts, then tighten them to 13 ft.
Page 895 ELECTRONIC FUEL INJECTION (EFI) Стр. 15 из 31 Throttle body and related components-3.8L engine Click to enlarge To install: Install the throttle body using a new gasket on the four studs of the upper intake manifold. Tighten the retaining nuts to 19 ft. lbs. (26 Nm). Engage the throttle position sensor and the idle air bypass valve.
Page 896 ELECTRONIC FUEL INJECTION (EFI) Стр. 16 из 31 spring lock coupling. Remove the engine air cleaner outlet tube. Disconnect and remove the accelerator and speed control cables from the accelerator mounting bracket and the throttle lever. Detach the top manifold vacuum fitting by disconnecting the rear vacuum line to the dash panel vacuum tee, the vacuum line at the intake manifold, the MAP sensor vacuum line and the fuel pressure regulator vacuum line.
Page 897 ELECTRONIC FUEL INJECTION (EFI) Стр. 17 из 31 Detach the wiring connectors from the fuel injectors. Remove the snow/ice shield to expose the throttle linkage. Disconnect the throttle cable from the ball stud. Remove the engine air cleaner outlet tube (between the air cleaner and air throttle body) by loosening the two clamps.
Page 898 ELECTRONIC FUEL INJECTION (EFI) Стр. 18 из 31 If the lower intake manifold was removed, fill and bleed the cooling system. 3.8L Engine Disconnect the negative battery cable. Drain the cooling system. Remove the fuel cap at the tank. Release the fuel pressure by attaching a Fuel Pressure Gauge part No. T80L-9974- B or equivalent to the pressure relief valve on the fuel rail assembly.
Page 899 ELECTRONIC FUEL INJECTION (EFI) Стр. 19 из 31 Disconnect the negative battery cable. Remove the throttle body and/or upper intake manifold. For details, please refer to the procedure earlier in this section. Disengage the electrical connectors from the fuel injectors. Disengage the electrical connectors from the main wiring harness and throttle position sensor, ACT sensor and the air bypass valve.
Page 900 ELECTRONIC FUEL INJECTION (EFI) Стр. 20 из 31 Position the wiring harness alongside the fuel injectors. Snap the electrical connectors into position on the injectors. Install the throttle body. For details, please refer to the procedure earlier in this section. Make sure that all of the electrical connectors are firmly in place.
Page 901 ELECTRONIC FUEL INJECTION (EFI) Стр. 21 из 31 Push the fuel rail down to be sure that all of the injector O-rings are fully seated in the fuel rail cups and intake manifold. While holding the fuel rail down, install and tighten the retaining bolts to 15-22 ft. lbs.
Page 902 ELECTRONIC FUEL INJECTION (EFI) Стр. 22 из 31 View of the 3.0L EFI injector wiring harness Click to enlarge http://www.chiltondiy.com/content/8687/8687_5_3.html 18.11.2005...
Page 903 ELECTRONIC FUEL INJECTION (EFI) Стр. 23 из 31 Fuel injector manifold mounting-3.0L engine Click to enlarge Carefully disengage the fuel rail assembly from the fuel injectors by lifting and gently rocking the rail. Remove the injectors by lifting while gently rocking from side to side. Place removed components in a clean container to keep clean and free of contamination.
Page 904 ELECTRONIC FUEL INJECTION (EFI) Стр. 24 из 31 prevent damage to the sealing areas and sensitive fuel metering openings. To install: Lubricate new O-rings with engine oil and install 2 on each injector. Make sure the injector cups are clean and undamaged. Install the injectors in the fuel rail using a light twisting-pushing motion.
Page 905 ELECTRONIC FUEL INJECTION (EFI) Стр. 25 из 31 Fuel rail assembly-3.8L EFI engine Click to enlarge To install: When you are installing the fuel rail assemblies, make sure that the O- rings are properly seated so that no fuel leaks occur. Push the fuel rail down to be sure that all of the injector O-rings are fully seated in the fuel rail clips and intake manifold.
Page 906 ELECTRONIC FUEL INJECTION (EFI) Стр. 26 из 31 REMOVAL & INSTALLATION Disconnect the negative battery cable. Remove the fuel tank cap and release the pressure from the fuel system at the Schrader (pressure relief) valve of the fuel rail assembly, using Fuel Pressure Gauge T80L-9974-B or equivalent.
Page 907 ELECTRONIC FUEL INJECTION (EFI) Стр. 27 из 31 Cross-sectional view of the fuel pressure regulator-2.5L and 3.8L EFI engine Click to enlarge To install: Lubricate the new fuel pressure regulator O-ring with clean engine oil. Ensure that the gasket surfaces of the fuel pressure regulator and fuel rail assembly are clean.
Page 908 ELECTRONIC FUEL INJECTION (EFI) Стр. 28 из 31 Using an open-end wrench or suitable deep well socket, remove the pressure relief valve from the fuel injection manifold. Fuel pressure valve and related components Click to enlarge Fuel pressure relief valve location-2.5L EFI engine Click to enlarge To install: Install the pressure relief valve and the cap.
Page 909 ELECTRONIC FUEL INJECTION (EFI) Стр. 29 из 31 Location of the throttle position sensor-3.0L EFI engine Click to enlarge To install: Install the throttle position sensor. Make sure that the rotary tangs on the sensor are properly aligned and that the red seal is inside the connector housing. Slide the rotary tangs into position over the throttle shaft blade, then rotate the TP sensor clockwise to its installed position.
Page 910 ELECTRONIC FUEL INJECTION (EFI) Стр. 30 из 31 Click to enlarge Idle Air Bypass Valve REMOVAL & INSTALLATION Disconnect the negative battery cable. Disengage the idle air bypass valve electrical connector from the wiring harness. Remove the two idle air bypass retaining screws, then remove the idle air bypass valve and gasket.
Page 911 ELECTRONIC FUEL INJECTION (EFI) Стр. 31 из 31 To install: Make sure that the throttle body and air bypass valve mating surfaces are clean. Install the gasket on the throttle body surface, then mount the idle air bypass valve assembly, using the two retaining screws to secure it. Tighten the screws to 84 inch lbs.
Page 912 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 1 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) General Information The Sequential Electronic Fuel Injection (SEFI) system is used on all Super High Output (SHO) vehicles, as well as on 1993 and later 3.0L and 3.8L engines. It is classified as a multi-point, pulse time, speed density control fuel injection system.
Page 913 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 2 из 44 The injectors receive high pressure fuel from the fuel manifold (fuel rail) assembly. The complete assembly includes a single, preformed tube with six injector connectors, mounting flange for the pressure regulator, mounting attachments which locate the fuel manifold assembly and provide fuel injector retention, and a Schrader®...
Page 914 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 3 из 44 Remove the push connect fittings at both ends of the fuel filter. This is accomplished by removing the hairpin clips from the fittings. Remove the hairpin clips by first bending and then breaking the shipping tabs on the clips. Then spread the 2 clip legs approximately in.
Page 915 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 4 из 44 Turn the fuel pump locking ring counterclockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent, then remove the lock ring. Remove the fuel pump from the fuel tank and discard the flange gasket. View of the SEFI system fuel pump-except 3.0L FF vehicles Click to enlarge http://www.chiltondiy.com/content/8687/8687_5_4.html...
Page 916 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 5 из 44 To install: Clean the fuel pump mounting flange and fuel tank mating surfaces and seal ring groove. Put a light coating of grease on the new seal gasket to hold it in place during assembly and install it in the fuel ring groove.
Page 917 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 6 из 44 Exploded view of the fuel pump and related components-3.0L Flexible Fuel (FF) engine http://www.chiltondiy.com/content/8687/8687_5_4.html 18.11.2005...
Page 918 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 7 из 44 Click to enlarge The FF fuel tank cannot be drained through the fuel tank filler pipe because a special screen is installed in the fuel tank filler pipe to prevent siphoning of fuel through the pipe. The fuel tank on this vehicle is equipped with a drain tube connected to the fuel pump module on the right-hand side of the vehicle, which had a quick disconnect for this purpose.
Page 919 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 8 из 44 Fuel pump locking retainer ring Lift the fuel pump locating tabs from the fuel tank location slots. Lift the fuel pump upward rotating left, while aligning the float wiper arm retainer and return line into the fuel tank location slots.
Page 920 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 9 из 44 Apply slight pressure to remove the fuel pump Lift the float wiper arm through the left-hand fuel tank slot, then pass the pump motor retaining bracket through the right-hand fuel tank slot. Lift the float wiper arm through the left-hand fuel tank slot and pass the pump motor retaining bracket through the right-hand fuel tank slot Remove the fuel pump keeping return line in the fuel tank slot.
Page 921 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 10 из 44 Remove the fuel pump while keeping the return line in the fuel tank slot. Lift the fuel pump inlet filter and then the sender arm float through the fuel tank opening Remove and discard the fuel pump mounting gasket.
Page 922 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 11 из 44 then install the three retaining screws. Insert Rotunda Fuel Tanker Adapter Hose 034-00020 or equivalent into the fuel tank through the fuel tank filler pipe. Transfer the fuel from the Rotunda Fuel Storage Tanker 034-00002 or equivalent to the fuel tank.
Page 923 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 12 из 44 Lift and remove the throttle body assembly from the manifold. Discard the intake manifold upper gasket. Throttle body assembly-3.0L SEFI engine (except SHO and FF) Click to enlarge To install: Clean and inspect all gasket surfaces. When cleaning aluminum parts be careful http://www.chiltondiy.com/content/8687/8687_5_4.html 18.11.2005...
Page 924 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 13 из 44 not to gouge the surfaces. Lightly coat all bolts with clean engine oil prior to installation. If available, install guide pins to guide the assembly onto its mounting. Place a new gasket on the manifold surface. Aligning the bolt holes, install the throttle body on the intake manifold.
Page 925 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 14 из 44 TV-driving nail is attached, to the wide-open-throttle position. The white adjuster shank must be seen to advance. If not, look for the cable sheath/foam hang-up on engine/body components. Attach the TV cable into the top position of the right intake manifold clip.
Page 926 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 15 из 44 Throttle body assembly-3.0L Flexible Fuel (FF) engine Click to enlarge To install: For the FF vehicle, the throttle body is to be replaced as an assembly. If replacing the throttle body with a new one, reuse the original intake manifold vacuum outlet fitting and cap, EGR valve and EGR pressure sensor with the new throttle body.
Page 927 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 16 из 44 Carefully clean the intake manifold and throttle body gasket mating surfaces, being careful not the gouge the aluminum which will cause leaks, then inspect the mating surfaces for damage. Lightly coat all bolt and stud threads with oil. If available, install guide pins in the front and rear bolt holes to aid in alignment.
Page 928 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 17 из 44 or disconnected components, then repeat the procedure. Install the snowshield onto the idle air control valve, then tighten the retaining screw to 13 inch lbs. (1.4 Nm). 3.0L and 3.2L SHO Engines Disconnect the negative battery cable.
Page 929 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 18 из 44 surfaces or allow and gasket and/or foreign material to enter the intake manifold. Install a new throttle body gasket, then position the throttle body and secure using the retaining bolts. Tighten the bolts to 12-17 ft. lbs. (16-23 Nm). Connect the crankcase ventilation tubes.
Page 930 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 19 из 44 Exploded view of the throttle body and related fuel system components-3.8L SEFI engine Click to enlarge To install: Clean and inspect the gasket mating surfaces. If scraping is required to clean the surface, be careful not the damage the gasket surfaces or allow any gasket material or foreign material to drop into the intake manifold.
Page 931 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 20 из 44 Open the hood and install protective fender covers. Disconnect the negative battery cable. Remove the fuel cap at the tank. Release the fuel pressure from the fuel system. Depressurize the fuel system by connecting a Fuel Pressure Gauge part No.
Page 932 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 21 из 44 CAUTION The fuel system is under high pressure. Use care when servicing the fuel system or personal injury may occur. Remove the fuel tank filler cap to release the fuel tank pressure, then properly release the fuel system pressure.
Page 933 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 22 из 44 Inspect the injector O-rings, end cap, body and washer for signs of damage and/or deterioration, and replace worn components as necessary To install: Lubricate new O-rings with clean engine oil. Install the fuel injectors using a light, twisting-pushing motion. Install the fuel injection supply manifold.
Page 934 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 23 из 44 then disconnect the PCV hoses. Remove the 12 manifold retaining bolts, then remove the intake manifold and throttle body assembly. Disengage the electrical connectors at the fuel injectors. Remove the fuel injection supply manifold/rail retaining bolts. Raise and slightly rotate the fuel injection supply manifold/rail assembly, then remove the injectors.
Page 935 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 24 из 44 3.8L Engine Disconnect the negative battery cable. Remove the fuel cap at the tank to release the fuel tank pressure. Properly relieve the pressure from the fuel system. For details, please refer to the procedure located earlier in this section.
Page 936 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 25 из 44 To install: Lubricate new engine O-rings with engine oil and install 2 on each injector. Install the injectors, using a light, twisting, pushing motion to install them. Reconnect the injector retaining clips. Install the fuel rail assembly.
Page 937 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 26 из 44 Fuel injection supply manifold-3.0L SEFI engine (except SHO) Click to enlarge To install: When installing the manifold, make sure that the O-rings are properly seated to avoid leakage. Examine the fuel injector O-rings for deterioration, and install new ones if necessary.
Page 938 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 27 из 44 On unleaded gasoline engines only: Lift the distributor enough to allow the fuel injection supply manifold to clear the distributor and intake manifold, then position the fuel injection manifold. Lower the distributor into position, then install the hold-down clamp and align the scribe marks made during removal.
Page 939 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 28 из 44 Fuel injection supply manifold-3.0/3.2L SHO engines Click to enlarge To install: WARNING ALWAYS use new gaskets when assembling the fuel injection supply manifold to avoid possible fire from fuel leakage! Using a new gasket, install the fuel injection supply manifolds, making sure that all of the injectors are properly seated.
Page 940 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 29 из 44 Connect the negative battery cable, then turn the ignition ON and OFF several times, without starting the engine, to pressurize the fuel system. Start and run the engine, then check for leaks. 3.8L Engine Disconnect the negative battery cable.
Page 941 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 30 из 44 Fuel injection supply manifold and related components-3.8L SEFI engine Click to enlarge To install: When installing the fuel injection supply manifold, make sure that the O- rings are properly seated so that there is no fuel leakage. Push the fuel injector supply manifold down to be sure that all of the fuel injector O-rings are fully seated in the cylinder head pockets.
Page 942 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 31 из 44 Install the fuel tank cap, then connect the negative battery cable. With the fuel charging wiring still disconnected, turn the ignition switch ON and OFF several times. This allows the fuel pump to pressurize the system. Using a clean towel, check for fuel leaks.
Page 943 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 32 из 44 Cross-sectional view of a fuel pressure regulator-3.0L SEFI engine (except SHO) Click to enlarge To install: Lubricate new regulator O-rings with clean engine oil, then make sure the mating surfaces of the regulator and fuel injection supply manifold are clean. If scraping is necessary, be careful not to damage the fuel pressure regulator or fuel injection supply manifold sealing surfaces.
Page 944 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 33 из 44 Using new Allen® head retaining screws, install the fuel pressure regulator on the fuel injection supply manifold. Tighten the screws to 34 inch lbs. (4 Nm). Carefully install the fuel injection supply manifold to the fuel injectors. If the fuel injectors were completely disengaged from the fuel injection supply manifold, lubricate the fuel injector O-rings with clean engine oil before inserting them in the fuel supply manifold cups.
Page 945 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 34 из 44 Remove the fuel pressure regulator, return seal and the O-rings. Discard the return seal and the O-rings. Cross-sectional view of a fuel pressure regulator-3.8L SEFI engine Click to enlarge To install: Make sure the mating surfaces of the fuel pressure regulator and the fuel injection supply manifold are clean.
Page 946 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 35 из 44 Lubricate new O-rings with clean engine oil, then install a new return seal and O- rings on the fuel pressure regulator. Install the fuel pressure regulator on the fuel injection supply manifold. Tighten the retaining screws to 34 inch lbs.
Page 947 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 36 из 44 Idle Air Control (IAC) valve-3.0L engine (except SHO) To install: Clean the gasket mating surfaces. If scraping is necessary, be careful not to damage the idle air control valve or throttle body gasket surfaces. Also, do not allow gasket material to drop into the throttle body.
Page 948 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 37 из 44 Disengage the idle air control bypass valve assembly electrical connector from the wiring harness. Remove the IAC valve retaining bolts. Remove the top retaining bolt first and swing the valve upward to provide working clearance in order to remove the lower retaining bolt.
Page 949 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 38 из 44 Fuel Pressure Relief Valve REMOVAL & INSTALLATION Be sure to remove the cap from the fuel pressure relief valve! Disconnect the negative battery cable. If the fuel injection supply manifold is mounted to the engine, remove the fuel tank filler cap.
Page 950 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 39 из 44 Location of the fuel pressure relief valve-3.0L and 3.2L SHO engines Click to enlarge http://www.chiltondiy.com/content/8687/8687_5_4.html 18.11.2005...
Page 951 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 40 из 44 Fuel pressure relief valve location-3.8L SEFI engine Click to enlarge To install: Install the fuel pressure relief valve and fuel pressure relief valve cap. Tighten the valve to 69 inch lbs. (7.75 Nm) and the cap to 5.3 inch lbs. (0.6 Nm). Connect the negative battery cable.
Page 952 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 41 из 44 Throttle position sensor-3.0L SEFI engine (except SHO) Click to enlarge Throttle position sensor-3.0L and 3.2L SHO SEFI engines Click to enlarge To install: Slide the rotary tangs into position over the throttle shaft blade, then rotate the throttle position sensor clockwise to the installed position only.
Page 953 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 42 из 44 Install the TP sensor, make sure that the rotary tangs on the sensor are in proper alignment and that the red seal is inside the connector. Secure the TP sensor to the throttle body assembly with the two retaining screws, then tighten the screws as follows: For the 3.0L unleaded and flexible fuel vehicles, tighten the screws to 25-34 inch lbs.
Page 954 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 43 из 44 Disconnect the negative battery cable. Remove the fuel filler tank cap to relieve the fuel tank pressure. Properly relieve the fuel system pressure. There is a pressure relief valve located on the fuel injection supply manifold for this purpose. For more details regarding this procedure, please refer to the fuel pressure relief procedure located earlier in this section.
Page 955 SEQUENTIAL ELECTRONIC FUEL INJECTION (SEFI) Стр. 44 из 44 Carefully lower the vehicle. Engage the flexible fuel sensor electrical connector. Install the fuel tank filler cap at the fuel tank. Connect the negative battery cable, then check all of the connections at the fuel injection supply manifold, fuel injectors, push connect fittings, etc.
Page 956 FUEL LINE FITTINGS Стр. 1 из 6 FUEL LINE FITTINGS Spring Lock Coupling The spring lock coupling is a fuel line coupling held together by a garter spring inside a circular cage. When the coupling is connected, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting.
Page 957 FUEL LINE FITTINGS Стр. 2 из 6 Disconnecting and connecting the spring lock coupling Click to enlarge Make sure that the garter spring is in the cage of the male fitting. If the garter spring is missing, install a new spring by pushing it into the cage opening. If the garter spring is damaged, remove it from the cage with a small wire hook (do NOT use a screwdriver) and install a new spring.
Page 958 FUEL LINE FITTINGS Стр. 3 из 6 and visually checking to make sure the garter spring is over the flared end of the female fitting. All vehicles require the large black clip to be installed on the supply-side fuel line and the small grey clip to be installed on the return-side fuel line.
Page 959 FUEL LINE FITTINGS Стр. 4 из 6 Grasp the fitting and hose assembly and pull in an axial direction to remove the fitting from the steel tube. Adhesion between sealing surfaces may occur. A slight twist of the fitting may be required to break this adhesion and permit effortless removal.
Page 960 FUEL LINE FITTINGS Стр. 5 из 6 Removing the push connect fitting using the proper tool Removing the push connect fitting IN. FITTING (AND ALTERNATE METHOD FOR IN. FITTING) This method of disassembly disengages the retaining clip from the fitting body. Use a pair of narrow pliers (6 in.
Page 961 FUEL LINE FITTINGS Стр. 6 из 6 cracks and the ring will pinch back to its circular configuration, it is not damaged. If there is any doubt, replace the clip. Install the clip into the body by inserting one of the retaining clip serrated edges on the duck bill portion into one of the window openings.
Page 962 FUEL TANK Стр. 1 из 11 FUEL TANK REMOVAL & INSTALLATION Disconnect the negative battery cable. Relieve the fuel system pressure. Siphon or pump the fuel from the fuel tank, through the filler neck, into a suitable container. There are reservoirs inside the fuel tank to maintain fuel near the fuel pickup during cornering and under low fuel operating conditions.
Page 963 FUEL TANK Стр. 2 из 11 Common fuel tank location and related components Click to enlarge To install: If the fuel pump has been removed, the O-ring seal on unleaded gasoline vehicles, or gasket on flexible fuel vehicles must be replaced. Before installing the fuel tank, check the following: Check the fuel pump for leaks.
Page 964 FUEL TANK Стр. 3 из 11 tank as far forward in the vehicle as possible while securing the retaining bolts. If equipped with a heat shield, make sure it is installed with the straps and positioned correctly on the tank. Check the hoses and wiring mounted on the tank top, to make sure they are correctly routed and will not be pinched between the tank and the body.
Page 965 FUEL TANK Стр. 4 из 11 View of the fuel tank sending unit and pump assembly-except 3.0L FF vehicles Click to enlarge To install: Clean the sending unit/pump mounting flange and fuel tank mating surfaces and seal ring groove. http://www.chiltondiy.com/content/8687/8687_5_6.html 18.11.2005...
Page 966 FUEL TANK Стр. 5 из 11 Put a light coating of grease on the new seal gasket to hold it in place during assembly and install it in the fuel ring groove. Install the fuel pump and sender assembly carefully to be sure that the filter is not damaged.
Page 967 FUEL TANK Стр. 6 из 11 Exploded view of the fuel tank sending unit/pump and related components-3.0L Flexible http://www.chiltondiy.com/content/8687/8687_5_6.html 18.11.2005...
Page 968 FUEL TANK Стр. 7 из 11 Fuel (FF) engine Click to enlarge The FF fuel tank cannot be drained through the fuel tank filler pipe because a special screen is installed in the fuel tank filler pipe to prevent siphoning of fuel through the pipe. The fuel tank on this vehicle is equipped with a drain tube connected to the fuel pump module on the right-hand side of the vehicle, which had a quick disconnect for this purpose.
Page 969 FUEL TANK Стр. 8 из 11 Fuel pump locking retainer ring Lift the fuel pump locating tabs from the fuel tank location slots. Lift the fuel pump upward rotating left, while aligning the float wiper arm retainer and return line into the fuel tank location slots. Lift the fuel pump upward and rotate to the left, while aligning the float wiper arm retainer and return line with the fuel tank location slots Apply light pressure to remove the fuel pump.
Page 970 FUEL TANK Стр. 9 из 11 Apply slight pressure to remove the fuel pump Lift the float wiper arm through the left-hand fuel tank slot, then pass the pump motor retaining bracket through the right-hand fuel tank slot. Lift the float wiper arm through the left-hand fuel tank slot and pass the pump motor retaining bracket through the right-hand fuel tank slot Remove the fuel pump keeping return line in the fuel tank slot.
Page 971 FUEL TANK Стр. 10 из 11 Remove the fuel pump while keeping the return line in the fuel tank slot. Lift the fuel pump inlet filter and then the sender arm float through the fuel tank opening Remove and discard the fuel pump mounting gasket. To install: Position a new methanol compatible pump gasket on the fuel pump.
Page 972 FUEL TANK Стр. 11 из 11 Install the fuel tank filler cap to the tether location, then install the three retaining screws. Insert Rotunda Fuel Tanker Adapter Hose 034-00020 or equivalent into the fuel tank through the fuel tank filler pipe. Transfer the fuel from the Rotunda Fuel Storage Tanker 034-00002 or equivalent to the fuel tank.
Page 973 SPECIFICATION CHARTS Стр. 1 из 2 SPECIFICATION CHARTS Torque Specifications Click to enlarge Torque Specifications Click to enlarge http://www.chiltondiy.com/content/8687/8687_5_7.html 18.11.2005...
Page 974 SPECIFICATION CHARTS Стр. 2 из 2 Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_5_7.html 18.11.2005...
Page 1033 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 1 из 16 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Introduction Most new vehicles are equipped with one or more on-board computers, like the unit(s) installed on vehicles covered by this manual. These electronic components (with no moving parts) should theoretically last the life of the vehicle, provided nothing external happens to damage the circuits or memory chips.
Page 1034 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 2 из 16 running. Jumper cables should be connected with the key OFF to avoid power surges that can damage electronic control units. Engines equipped with computer controlled systems should avoid both giving and getting jump starts due to the possibility of serious damage to components from arcing in the engine compartment when connections are made with the ignition ON.
Page 1035 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 3 из 16 system; a careful inspection of components during testing is essential for quick and accurate troubleshooting. Special, hand held computerized testers designed specifically for diagnosing the system are available from a variety of aftermarket sources, as well as from the vehicle manufacturer, but care should be taken to assure that any test equipment being used is designed to diagnose that particular computer controlled system accurately without damaging the computer control...
Page 1036 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 4 из 16 may overheatand possibly melt. Never use jumpers to bypass high resistance loads (such asmotors) in a circuit. Bypassing resistances, in effect, creates a short circuitwhich may, in turn, cause damage and fire.
Page 1037 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 5 из 16 Open Circuit Testing To use the self-powered test light to check for open circuits, first isolate the circuit from the vehicle's 12 volt power source by disconnecting the battery or wiring harness connector. Connect the test light ground clip to a good ground and probe sections of the circuit sequentially with the test light.
Page 1038 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 6 из 16 WARNING Do NOT use a multimeter to probe electronic ignition spark plug or coilwires. Small pin holes in secondary ignition wires will allow high voltage toarc from the wire to a metal part, external to the secondary ignition circuit.This arcing may cause misfiring, leading to a driveability complaint.
Page 1039 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 7 из 16 Connect the voltmeter negative lead to the ground side of the resistance load to be measured. Connect the positive lead to the positive side of the resistance or load to be measured.
Page 1040 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 8 из 16 the circuit. Current flow from an outside voltage source (such as the vehicle battery) can damage the ohmmeter, so the circuit or component should be isolated from the vehicle electrical system before any testing is done. Since the ohmmeter uses its own voltage source, either lead can be connected to any test point.
Page 1041 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 9 из 16 theself-powered test light, the ohmmeter is designed to operate on its own powersupply. The normal 12 volt automotive electrical system current could damagethe meter. Ammeters An ammeter measures the amount of current flowing through a circuit in units called amperes or amps.
Page 1042 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 10 из 16 some electronic engine control systems. Some tach/dwell meters are powered by an internal battery, while others take their power from the vehicle battery in use. The internal battery powered testers usually require calibration much like an ohmmeter before testing.
Page 1043 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 11 из 16 harnesses serve different parts of the vehicle. Individual wires are color coded to help trace them through a harness where sections are hidden from view. A loose or corroded connection or a replacement wire that is too small for the circuit will add extra resistance and an additional voltage drop to the circuit.
Page 1044 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 12 из 16 wire. Main power distribution circuits and larger accessories usually use 10 and 12 gauge wire. Battery cables are usually 4 or 6 gauge, although 1 and 2 gauge wires are occasionally used. Wire length must also be considered when making repairs to a circuit.
Page 1045 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 13 из 16 but to heat the parts being soldered to a temperature high enough to melt the solder when it is touched to the work. Melting flux-cored solder on the soldering iron will usually destroy the effectiveness of the flux. Soldering tips are made of copper for good heat conductivity, but must be "tinned'' regularly for quick transference of heat to the project and to prevent the solder from sticking to the iron.
Page 1046 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 14 из 16 means splicing a new connector assembly into the harness. All splices in on-board computer systems should be soldered to insure proper contact. Use care when probing the connections or replacing terminals in them as it is possible to short between opposite terminals.
Page 1047 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 15 из 16 looseness before performing any power feed checks to eliminate the chance of a bad ground affecting the circuit. Repairing Hard Shell Connectors Unlike molded connectors, the terminal contacts in hard shell connectors can be replaced.
Page 1048 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS Стр. 16 из 16 Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_6_1.html 18.11.2005...
Page 1049 Стр. 1 из 7 SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) Introduced in 1990, a driver's side air bag became standard on Taurus and Sables. In 1992 an optional passenger side air bag was first offered on these vehicles, then in 1994, driver and passenger side air bags became standard equipment on the Taurus and Sable.
Page 1050 SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) Стр. 2 из 7 Air bag module mounting-1990-91 vehicles Click to enlarge Disengage the driver air bag module and attach a jumper wire to the air bag terminals on the clockspring. Connecting a jumper wire to the air bag terminals on the clockspring-1990-91 vehicles Click to enlarge Connect the backup power supply and the negative battery cable.
Page 1051 SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) Стр. 3 из 7 Rotunda Air Bag Simulator-105-00010 shown, 105-00008 similar Disconnect the negative, then the positive battery cables. Wait one minute for the backup power supply in the diagnostic monitor to deplete its stored energy. Remove the fasteners attaching the air bag module to the steering wheel.
Page 1052 SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) Стр. 4 из 7 Connecting the air bag simulator tool Click to enlarge If your vehicle is equipped with an optional passenger side air bag, both the driver and the passenger air bag modules must be disconnected. If equipped with a passenger air bag, proceed as follows: Remove the right-hand and left-hand finish panels.
Page 1053 SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) Стр. 5 из 7 Passenger air bag mounting-1995 vehicle shown http://www.chiltondiy.com/content/8687/8687_6_2.html 18.11.2005...
Page 1054 SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) Стр. 6 из 7 Click to enlarge Connect the positive battery cable, then the negative battery cable. ENABLING THE SYSTEM 1990-91 Vehicles Disconnect the negative battery cable. Open the glove compartment, then lower the door past its stops. Disconnect the backup power supply located to the right of the glove compartment opening.
Page 1055 SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) Стр. 7 из 7 Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_6_2.html 18.11.2005...
Page 1056 HEATER Стр. 1 из 19 HEATER Blower Motor REMOVAL & INSTALLATION Disconnect the negative battery cable. Open the glove compartment door, release the door retainers and lower the door. Release the glove compartment door retainers, then lower the door Remove the screw attaching the recirculation duct support bracket to the instrument panel cowl.
Page 1057 HEATER Стр. 2 из 19 Remove the screws attaching the recirculation duct to the heater assembly, then remove the duct Remove the recirculation duct from the heater assembly, lowering the duct from between the instrument panel and the heater case. Disconnect the blower motor electrical lead.
Page 1058 HEATER Стр. 3 из 19 Remove the blower motor wheel Disengage the electrical connector Remove the blower motor mounting plate screws and remove the blower motor from the evaporator case. http://www.chiltondiy.com/content/8687/8687_6_3.html 18.11.2005...
Page 1059 HEATER Стр. 4 из 19 Remove the blower motor retaining screws Remove the blower motor assembly from the vehicle http://www.chiltondiy.com/content/8687/8687_6_3.html 18.11.2005...
Page 1060 HEATER Стр. 5 из 19 Exploded view of a blower motor and wheel assembly-1995 vehicle shown Click to enlarge To install: Feed the blower motor electrical connector through the evaporator housing. Position the blower motor into the evaporator housing. Install the retaining screws, making sure the mounting seal is in place.
Page 1061 HEATER Стр. 6 из 19 Blower motor resistor assembly-1995 vehicle shown Click to enlarge To install: Position the resistor assembly in the evaporator case opening and install the two attaching screws. Do not apply sealer to the resistor assembly mounting surface. Engage the wire harness connector to the resistor.
Page 1062 Remove the cluster opening finish panel retaining screws. On Taurus remove the jam nut behind the headlight switch and the screw behind the clock or clock cover. Remove the finish panel by rocking the upper edge toward the driver.
Page 1063 HEATER Стр. 8 из 19 Remove the instrument panel on 1990-95 vehicles as follows: Position the front wheels in the straight-ahead position. Disconnect the positive battery cable. Remove the ignition lock cylinder and, if equipped, remove the tilt lever. Remove the steering column trim shrouds. Tag and disengage all electrical connections from the steering column switches.
Page 1064 HEATER Стр. 9 из 19 panel and remove the three screws attaching the top of the instrument panel to the cowl top and disconnect any remaining wires. Remove the panel from the vehicle. Drain the coolant from the radiator. Disconnect and plug the heater hoses at the heater core. Plug the heater core tubes.
Page 1065 HEATER Стр. 10 из 19 Location of the vacuum source line Click to enlarge http://www.chiltondiy.com/content/8687/8687_6_3.html 18.11.2005...
Page 1066 (R-134a). This new refrigerant is not available commercially in most areas, as it is usually illegal for do-it-yourselfers to service a vehicle with this refrigerant. If you have a Taurus or Sable that uses the new refrigerant, R-134a, the vehicle should be taken to a qualified technician for any repair requiring A/C system service.
Page 1067 Remove the cluster opening finish panel retaining screws. On Taurus remove jam nut behind the headlight switch and screw behind the clock or clock cover. Remove the finish panel by rocking the upper edge toward the driver.
Page 1068 HEATER Стр. 13 из 19 Remove the ignition lock cylinder and, if equipped, remove the tilt lever. Remove the steering column trim shrouds. Disconnect all electrical connections from the steering column switches. Remove the four bolts and opening cover and the two bolts and reinforcement from under the steering column.
Page 1069 HEATER Стр. 14 из 19 system. Be sure to consult the laws in your area before beginning any procedure which requires servicing the air conditioning system. In some states, it is illegal to perform repairs involving refrigerant unless the work is done by a certified technician.
Page 1070 HEATER Стр. 15 из 19 Fill and bleed the cooling system. Connect the negative battery cable. Leak test, evacuate and charge the air conditioning system. Observe all safety precautions. Some 1992-93 and all 1994-95 vehicles covered by this manual are equipped with R-134a NOT R-12 refrigerant.
Page 1071 HEATER Стр. 16 из 19 Removing the cable using the specified tool Click to enlarge Disconnect the cable wire from the temperature door crank arm, using the proper tool. Remove the retaining screws that secure the control assembly to the instrument panel.
Page 1072 HEATER Стр. 17 из 19 Temperature control cable and related components Click to enlarge To install: Position the self-adjusting clip on the control cable. Insert the cable through the control assembly opening of the instrument panel and over the left-hand duct to the left-hand side of the evaporator case. Rotate the temperature control knob to the "COOL'' position.
Page 1073 HEATER Стр. 18 из 19 Disconnect the negative battery cable. Remove the instrument panel finish applique. Depending on vehicle application, the control assembly may be retained to the instrument panel by Torx® screws, in which case a Torx® head screwdriver must be used to remove them. Remove the four screws attaching the control assembly to the instrument panel.
Page 1074 HEATER Стр. 19 из 19 Install the instrument panel finish applique. Connect the negative battery cable, then check the system for proper operation. Blower Switch REMOVAL & INSTALLATION Disconnect the negative battery cable. Remove the climate control assembly from the instrument panel. For details, please refer to the procedure located earlier in this section.
Page 1075 AIR CONDITIONER Стр. 1 из 35 AIR CONDITIONER Refer to Section 1 for air conditioning system discharging information. Compressor CAUTION Please refer to Section 1 of this manual before discharging/recovering the A/C system or disconnecting the air conditioning lines. Damage to the air conditioning system or personal injury could result.
Page 1076 AIR CONDITIONER Стр. 2 из 35 compressor was between 3-5 oz. (90-148 ml), pour the same amount of clean refrigerant oil into the new compressor. If the amount of oil that was removed from the old compressor is greater than 5 oz. (148 ml), pour 5 oz.
Page 1077 AIR CONDITIONER Стр. 3 из 35 A/C compressor and related component locations-3.2L SHO shown Click to enlarge 1988-95 Vehicles With 3.8L Engine; All 1995 Vehicles Whenever a compressor is replaced, it will be necessary to replace the suction accumulator/drier. Disconnect the negative battery cable and properly discharge the air conditioning system.
Page 1078 AIR CONDITIONER Стр. 4 из 35 The assembly can be removed from the bottom using care not to scrape against the condenser. Remove the manifold and tube assemblies from the compressor. If the compressor is to be replaced, remove the clutch and field coil assembly. To install: A new service replacement 10P15F compressor contains 8 oz.
Page 1079 AIR CONDITIONER Стр. 5 из 35 A/C condenser core assembly-1995 vehicle shown Click to enlarge To install: Add 1 oz. (30 ml) of clean refrigerant oil to a new replacement condenser. Position the condenser assembly to the radiator support brackets, then install the attaching bolts or screws and washers.
Page 1080 AIR CONDITIONER Стр. 6 из 35 Evaporator Core Refer to Section 1 for air conditioning system discharging information. REMOVAL & INSTALLATION Whenever an evaporator is removed, it will be necessary to replace the accumulator/drier. Disconnect the negative battery cable. Drain the coolant from the radiator into a clean container. Exploded view of the evaporator case and related components Click to enlarge Properly discharge the refrigerant from the air conditioning system.
Page 1081 AIR CONDITIONER Стр. 7 из 35 dirt and moisture. Remove the instrument panel and place it on the front seat. For details, please refer to the procedure located in Section 10 of this manual. Remove the screw holding the instrument panel shake brace to the evaporator case, then remove the instrument panel shake brace.
Page 1082 AIR CONDITIONER Стр. 8 из 35 After unfastening the six retaining screws, remove the recirculation duct from the evaporator case Click to enlarge Remove the two screws from the air inlet duct, then remove the duct from the evaporator case. Unfasten the two screws securing the air inlet duct, then remove the duct from the case Click to enlarge Remove the support bracket from the evaporator case.
Page 1083 AIR CONDITIONER Стр. 9 из 35 screw holding the electronic connector bracket to the A/C recirculating air duct. Disconnect the engine harness from the blower speed control connector. Release the three connectors from the bracket, then remove the bracket, then disconnect the aspirator duct.
Page 1084 AIR CONDITIONER Стр. 10 из 35 Removing the A/C door actuator assembly-vehicles equipped with automatic temperature control Click to enlarge Remove the moulded seals from the evaporator core tubes. Drill a in. (4.75mm) hole in both upright tabs on top of the evaporator case. Drill a in.
Page 1085 AIR CONDITIONER Стр. 11 из 35 Click to enlarge Using a suitable tool, cut the top of the evaporator case between the raised outline. Fold the cutout cover back from the opening and lift the evaporator core from the case. Using a hot knife, small saw blade, or other suitable tool, carefully cut the top of the evaporator case between the raised outline Click to enlarge...
Page 1086 AIR CONDITIONER Стр. 12 из 35 After cutting the evaporator case, fold the cutout cover back from the opening, then lift out the core Click to enlarge To install: Add 3 oz. (90 ml) of clean refrigerant oil to a new replacement evaporator core to maintain total system refrigerant oil requirements.
Page 1087 AIR CONDITIONER Стр. 13 из 35 After installing and aligning a spring nut on each of the two tabs with the holes drilled into them, tighten the screw in each spring nut to secure the cutout cover closed Click to enlarge Install Caulking Cord D6AZ-19560-A or equivalent, to seal the evaporator case against leakage along the cut line.
Page 1088 AIR CONDITIONER Стр. 14 из 35 Locations to install caulking cord sealer to seal the evaporator case against leakage along the cut line Click to enlarge Install the air inlet duct to the evaporator case and tighten the two screws. Install the recirculation duct to the evaporator case, then tighten the six screws.
Page 1089 AIR CONDITIONER Стр. 15 из 35 Connect the liquid line and accumulator/drier to the evaporator core and connect the heater hoses to the heater core. Connect the black vacuum supply hose to the vacuum check valve in the engine compartment. Fill the radiator to the correct level with the previously removed coolant.
Page 1090 AIR CONDITIONER Стр. 16 из 35 To install: Connect the temperature cable to the control assembly. Engage the harness connectors and vacuum harness to the control assembly using new pushnuts. Push on the vacuum harness retaining nuts. Do not attempt to screw them onto the post.
Page 1091 AIR CONDITIONER Стр. 17 из 35 Engage the two electrical harness connectors to the control assembly. Push the keyed connectors in until a click is heard. Attach the vacuum harness to the vacuum port assembly. Secure the harness by tightening the two nuts. Position the control assembly into the instrument panel opening and install the four attaching Torx®...
Page 1092 Accumulator/drier and related components Click to enlarge To install: On Taurus SHO, Taurus and Sable equipped with the 3.8L engine, drill a in. hole in the removed accumulator/drier body and drain the refrigerant oil through the hole. Add the same amount of oil removed, plus 2 oz. (60 ml) of clean refrigerant oil to the new accumulator/drier.
Page 1093 AIR CONDITIONER Стр. 19 из 35 REMOVAL & INSTALLATION Whenever a refrigerant line is replaced, it will be necessary to replace the suction accumulator/drier. Disconnect the negative battery cable. Properly discharge the air conditioning system using the correct equipment. Observe all safety precautions. Disconnect the condenser-to-evaporator tube at the A/C condenser core inlet connections using the spring lock coupling procedure located later in this section.
Page 1094 AIR CONDITIONER Стр. 20 из 35 Spring Lock Coupling REMOVAL & INSTALLATION Disconnect the negative battery cable, then discharge the A/C system properly. Fit a in., in., in., or in. Spring Lock Coupling Tool to the coupling. The garter spring may not release if the tool is cocked while pushing it into the cage opening.
Page 1095 AIR CONDITIONER Стр. 21 из 35 use a screwdriver), then install a new spring. Clean all dirt or foreign material from both pieces of the coupling. On the female spring lock design, check the inside of each fitting for scratches, corrosion, or debris from deteriorated O-rings.
Page 1096 AIR CONDITIONER Стр. 22 из 35 Remove the control assembly from the instrument panel. Disconnect the cable retainer and wire from the control assembly. Disconnect the temperature cable from the plenum temperature blend door crank arm and cable mounting bracket. Removing and installing the control cable end attachment Click to enlarge To install:...
Page 1097 AIR CONDITIONER Стр. 23 из 35 Check to make sure the self-adjusting clip is at least 1 in. (25.4mm) from the end loop of the control cable. Route the cable behind the instrument panel and connect the control cable to the mounting bracket on the plenum.
Page 1098 AIR CONDITIONER Стр. 24 из 35 Cycling Clutch Switch Refer to Section 1 for air conditioning system discharging information. REMOVAL & INSTALLATION Disconnect the negative battery cable. Disconnect the wire harness connector from the pressure switch. Unscrew the A/C cycling switch from the top of the suction accumulator/drier. A/C cycling clutch switch http://www.chiltondiy.com/content/8687/8687_6_4.html 18.11.2005...
Page 1099 AIR CONDITIONER Стр. 25 из 35 Click to enlarge To install: Install a new O-ring seal, lubricated with clean refrigerant oil, on the A/C cycling switch. Lubricate the O-ring seal on the suction accumulator/drier nipple with clean refrigerant oil. Screw the A/C cycling switch on the suction accumulator/drier nipple, then tighten the switch hand-tight.
Page 1100 AIR CONDITIONER Стр. 26 из 35 Locating the orifice tube Cut a 2 in. (63.5mm) section from the tube at the orifice tube location. Do not cut closer than 1 in. (25.4mm) from the start of the bend in the tube. Cut a 2 in.
Page 1101 AIR CONDITIONER Стр. 27 из 35 Exploded view of the A/C evaporator orifice tube kit Click to enlarge While holding the hex of the tube in a vise, tighten each compression nut to 65-70 ft. lbs. (88-94 Nm) with a crow foot wrench. With the nut in a vise, tighten each compression nut to the specified torque Click to enlarge Assemble the liquid line to the vehicle using new O-rings lubricated with clean...
Page 1102 AIR CONDITIONER Стр. 28 из 35 Leak test, evacuate and charge the system according to the proper procedure. Observe all safety precautions. Check the system for proper operation. Cold Engine Lockout Switch OPERATION The cold engine lockout switch is used in the automatic temperature control systems.
Page 1103 AIR CONDITIONER Стр. 29 из 35 air. The sensor is located in front of the condenser on the left side of the vehicle. REMOVAL & INSTALLATION Disconnect the negative battery cable. Remove the ambient sensor and bracket mounting nut, then remove the sensor. Disengage the electrical connector from the ambient sensor and bracket.
Page 1104 AIR CONDITIONER Стр. 30 из 35 retainer by squeezing the side tabs. Pull the sensor down into the glove compartment, then disengage the electrical connector and aspirator flex hose from the sensor. Removing the in-vehicle sensor-vehicles with automatic temperature control only Click to enlarge To install: Engage the electrical connector and aspirator flex hose to the sensor.
Page 1105 AIR CONDITIONER Стр. 31 из 35 Install the negative battery cable. Blower Motor Speed Controller OPERATION The blower speed controller is used with automatic temperature control. It converts the base current received from the electronic control assembly into high current, variable ground feed to the blower motor. The blower fan speed is therefore infinitely variable.
Page 1106 AIR CONDITIONER Стр. 32 из 35 attaching screws. Engage the wire connector and aspirator hose to the blower controller. Install the connector on the mounting bracket. Close the glove compartment door, connect the negative battery cable and check the system for proper operation. Temperature Blend Door Actuator OPERATION The temperature blend door actuator is used on vehicles equipped with automatic...
Page 1107 AIR CONDITIONER Стр. 33 из 35 into the vehicle. The motor is mounted on the recirculate/fresh air duct. REMOVAL & INSTALLATION Disconnect the negative battery cable. Lower the glove compartment door to provide access to the recirculation duct assembly. Disconnect the vacuum hose from the end of the vacuum motor and the motor arm retainer from the door crank arm.
Page 1108 AIR CONDITIONER Стр. 34 из 35 Panel/Defrost Door Vacuum Motor Disconnect the negative battery cable. Remove the instrument panel. Remove the panel-defrost door vacuum motor arm to door shaft. Remove the two nuts retaining the vacuum motor to the mounting bracket. Remove the vacuum motor from the mounting bracket and disconnect the vacuum hose.
Page 1109 AIR CONDITIONER Стр. 35 из 35 Follow the instructions in each step of the Functional Test. VACUUM SYSTEM DIAGNOSIS To test the automatic temperature control vacuum system, start the engine and depress the function buttons slowly from one position to another. A momentary hiss should be heard as each button is depressed from one position to another, indicating that vacuum is available at the control assembly.
Page 1110 CRUISE CONTROL Стр. 1 из 33 CRUISE CONTROL General Description and Operation The Integrated Vehicle Speed Control (IVSC) system consists of operator controls, servo (throttle actuator), brake light switch, speed sensor (not required for vehicles equipped with an electronic cluster), horn relay, vacuum dump valve, vacuum reservoir (called an aspirator on some models), check valve(s), wiring and hoses for vacuum.
Page 1111 CRUISE CONTROL Стр. 2 из 33 depending upon vehicle application. In addition, when the ignition switch is turned OFF, the speed control memory is erased and the resume feature will not function. Actuator Cable REMOVAL & INSTALLATION Except .2L SHO Disconnect the negative battery cable.
Page 1112 CRUISE CONTROL Стр. 3 из 33 Cruise control actuator cable assembly-3.0L engine except SHO Click to enlarge http://www.chiltondiy.com/content/8687/8687_6_5.html 18.11.2005...
Page 1113 CRUISE CONTROL Стр. 4 из 33 Cruise control actuator cable assembly-3.8L engine Click to enlarge http://www.chiltondiy.com/content/8687/8687_6_5.html 18.11.2005...
Page 1114 CRUISE CONTROL Стр. 5 из 33 Cruise control actuator cable assembly-3.0L SHO engine Click to enlarge To install: Install the complete actuator cable/servo assembly. For details, please refer to the servo procedure located later in this section. Connect the negative battery cable. http://www.chiltondiy.com/content/8687/8687_6_5.html 18.11.2005...
Page 1115 CRUISE CONTROL Стр. 6 из 33 3.2L SHO Vehicles Disconnect the negative battery cable. Actuator assembly and related components-3.2L SHO Click to enlarge Remove the screw attaching the actuator assembly cable to the accelerator shaft bracket. Remove the actuator assembly cable from the throttle control. Remove the actuator cable cap from the speed control servo by depressing the cap locking arm and rotating the cap counterclockwise.
Page 1116 CRUISE CONTROL Стр. 7 из 33 When removing the slug from the servo pulley, gently pry the arm up SLIGHTLY using a suitable tool, while pushing the cable slug out of the pulley slot-3.2L SHO Click to enlarge To install: Make sure that the rubber seal is fully seated on the actuator cap.
Page 1117 CRUISE CONTROL Стр. 8 из 33 Align the cable cap tabs with the slots in the servo housing, then insert the cap into the speed control servo and rotate it until the locking arm engages-3.2L SHO Click to enlarge Snap the actuator assembly cable onto the throttle control, then install the screw at the accelerator shaft.
Page 1118 CRUISE CONTROL Стр. 9 из 33 Remove the retaining clip from the actuator cable adjuster at the throttle. Make sure the throttle is in a fully closed position. Pull on the actuator cable to take up the slack. Loosen at least one notch so there is about 0.118 in.
Page 1119 CRUISE CONTROL Стр. 10 из 33 wiring. Failure to follow safety and disabling procedures could result in possible air bag deployment, personal injury or unnecessary air bag system repairs. Disconnect the negative battery cable and air bag back up power supply. Remove the four nut and washer assemblies retaining the air bag module to the steering wheel.
Page 1120 CRUISE CONTROL Стр. 11 из 33 Remove the screws from the speed control switch assemblies; there are usually two on each side-1990-93 vehicles Click to enlarge Disconnect the speed control switches from the wiring harness, then remove the switches. Disconnect the speed control switches from the wiring harness, then remove the switches-1990-93 vehicles Click to enlarge To install:...
Page 1121 CRUISE CONTROL Стр. 12 из 33 Position the switches onto the steering wheel, then install the retaining screws. Connect the wiring harness to the horn buttons, then install the horn buttons. Connect the speed control switches. Make sure the wires are positioned so that no interference is encountered when installing the air bag module.
Page 1122 CRUISE CONTROL Стр. 13 из 33 Disengage the air bag module electrical connector-1994-95 vehicles Click to enlarge Remove the driver side air bag module from the steering wheel, then place it on a bench with the trim cover facing up. Remove the air bag module from the steering wheel, then place it on a work bench with the trim cover facing UPWARD-1994-95 vehicles Click to enlarge...
Page 1123 CRUISE CONTROL Стр. 14 из 33 Carefully pry the right side of the steering wheel back cover for clearance to remove the right hand speed control switch wiring, then ..repeat on the left hand side and remove the speed control actuator switch To install: Carefully pry away the right-hand side of the steering wheel back cover to allow enough clearance to insert the right-hand aide of the speed control switch wiring...
Page 1124 CRUISE CONTROL Стр. 15 из 33 bag sliding contact. Install the driver side air bag module on the steering wheel, then install the two screw and washer assemblies. Tighten to 8-10 ft. lbs. (10.2-13.8 Nm). Install the two back cover plugs. Because battery voltage to the PCM was interrupted, performance may be affected until the PCM re-learns its driving strategy.
Page 1125 CRUISE CONTROL Стр. 16 из 33 Remove the tilt lever, if so equipped. Remove the ignition lock cylinder and steering column lower trim shroud. Separate the speed control brush wire harness at the connector and remove the wire harness retainers from the steering column. Remove the screw securing the brush assembly to the upper steering column.
Page 1126 CRUISE CONTROL Стр. 17 из 33 Place the air bag module on the bench with the trim cover facing upward to prevent personal injury in the event of accidental deployment of the air bag. Disconnect the speed control switches and horn switches from the contact assembly.
Page 1127 CRUISE CONTROL Стр. 18 из 33 Apply two pieces of tape across the contact assembly stator and rotor to prevent accidental rotation, then remove the three contact assembly retaining screws Click to enlarge Disengage the speed control brush wiring harness at the connector, then remove the wiring harness retainers from the steering column.
Page 1128 CRUISE CONTROL Стр. 19 из 33 Align the contact assembly to the column shaft and mounting bosses and slide the contact assembly onto the shaft. Install the three screws that retain the contact assembly, then tighten to 18-26 inch lbs. (2-3 Nm). Remove the tape from the contact assembly. Route the contact assembly harness down the column and connect to the main wiring harness.
Page 1129 CRUISE CONTROL Стр. 20 из 33 Vehicle speed sensor assembly-vehicles equipped with automatic transaxles Click to enlarge Vehicle speed sensor assembly-vehicles equipped with manual transaxles Click to enlarge To install: Position the driven gear to the speed sensor. Install the gear retainer. Engage the electrical connector.
Page 1130 CRUISE CONTROL Стр. 21 из 33 speedometer cable into the sensor housing. Insert the sensor assembly into the transaxle housing. Tighten the retaining nut/bolt to 30-40 inch lbs. (3.4-4.5 Nm). Install the retaining clip. On 1992-95 vehicles equipped with an automatic transaxle, install the Y-pipe and HEGO sensors to the exhaust system.
Page 1131 CRUISE CONTROL Стр. 22 из 33 Disconnect the negative battery cable. Disengage the two electrical connectors at the amplifier. Remove the two screws retaining the amplifier and bracket assembly. Remove the amplifier and bracket assembly from the instrument panel. Remove the two bolts and nuts retaining the amplifier assembly to the mounting bracket.
Page 1132 CRUISE CONTROL Стр. 23 из 33 ON switch in steering wheel is depressed and held. If voltage is not present, perform control switch test. Release ON button, voltmeter should read about 7.8 volts, this indicates that ON circuit is engaged. If voltmeter reads 0.0, check for a bad ground at amplifier. If there is no ground at amplifier, check system ground connections and wiring.
Page 1133 CRUISE CONTROL Стр. 24 из 33 REMOVAL & INSTALLATION Except 3.2L SHO Disconnect the negative battery cable. Remove the screw, then disconnect the speed control actuator cable from the accelerator cable bracket. Disconnect the speed control actuator cable with the adjuster from the accelerator cable.
Page 1134 CRUISE CONTROL Стр. 25 из 33 Click to enlarge Servo assembly and related components-3.8L engine Click to enlarge Servo assembly and related components-3.0L SHO engine Click to enlarge To install: Attach the cable to the servo. Attach the cable cover to the servo with the two retaining nuts. For vehicles through 1993, tighten the nuts to 45-61 inch lbs.
Page 1135 CRUISE CONTROL Стр. 26 из 33 Snap the actuator cable with the adjuster onto the accelerator cable bracket and install the screw. Connect the actuator cable to the accelerator cable bracket and install the fastener. Install the two vacuum hoses and electrical connector at the servo. Connect negative battery cable.
Page 1136 CRUISE CONTROL Стр. 27 из 33 Push the actuator tube out of the adjuster fitting attached to the throttle cable. Disengage the harness connector at the speed control servo. Remove the three nuts attaching the assembly to the vehicle. Remove the actuator cable cap from the speed control servo by depressing the cap locking arm and rotating the cap counterclockwise.
Page 1137 CRUISE CONTROL Стр. 28 из 33 locking tab on the speed control servo. Align the cable cap tabs with the slots in the servo housing, then insert the cap into the speed control servo and rotate it clockwise until the locking arm engages the locking tab on the servo Click to enlarge Position the actuator cable and servo assembly in the vehicle.
Page 1138 CRUISE CONTROL Стр. 29 из 33 Connect an ohmmeter between yellow/red wire and brown/light green wire. Resistance should be 20,000-30,000 ohms. If proper reading is not obtained, check wiring and servo assembly separately for damage. Repair and/or replace as required. Start engine and, with servo disconnected from amplifier, connect orange/yellow wire of servo to battery positive terminal.
Page 1139 CRUISE CONTROL Стр. 30 из 33 Vacuum dump valve location Click to enlarge To install: Install the valve to the bracket. Connect the vacuum hose. Adjust vacuum dump valve. For details, please refer to the adjustment procedure located later in this section. Connect the negative battery cable.
Page 1140 CRUISE CONTROL Стр. 31 из 33 The dump valve black housing must clear white plastic pad on brake pedal by 0.05-0.10 in. (1.3-2.5mm) with the brake pedal pulled to rearmost position. Clutch Switch REMOVAL & INSTALLATION Except 1995 3.0L SHO Disconnect the negative battery cable.
Page 1141 CRUISE CONTROL Стр. 32 из 33 Adjusting the clutch switch-except 1995 3.0L SHO vehicles Click to enlarge Slide the switch forward toward the clutch pedal until the switch plunger cap is 0.030 in. (0.76mm) from contacting the switch housing. Tighten the retaining screw.
Page 1142 CRUISE CONTROL Стр. 33 из 33 The speed control system is designed to disengage when the clutch pedal is depressed. This is accomplished with a clutch switch. The speed control system disengage function is operated by opening the circuit between the speed control module and the brake lamps.
Page 1143 ENTERTAINMENT SYSTEMS Стр. 1 из 10 ENTERTAINMENT SYSTEMS Radio Receiver/Tape Player REMOVAL & INSTALLATION 1986-89 Vehicles Disconnect the negative battery cable. Remove the trim panel-to-center instrument panel. Remove the center instrument panel Remove the radio/bracket-to-instrument panel retaining screws. http://www.chiltondiy.com/content/8687/8687_6_6.html 18.11.2005...
Page 1144 ENTERTAINMENT SYSTEMS Стр. 2 из 10 Remove the four screws retaining the radio and mounting bracket to the instrument panel Push the radio toward the front, then raise the rear of the radio slightly so that the rear support bracket clears the clip in the instrument panel. Slowly, pull the radio from the instrument panel.
Page 1145 ENTERTAINMENT SYSTEMS Стр. 3 из 10 Disengage the electrical connector from the radio To install: Engage the wiring connectors and antenna cable to the radio. Slide the radio into the instrument panel, keeping the rear of the radio slightly raised to engage the rear mounting bracket to clip in the instrument panel. Install the four retaining screws, then torque the radio/bracket-to-instrument panel screws to 14-16 inch lbs.
Page 1146 ENTERTAINMENT SYSTEMS Стр. 4 из 10 Common radio assembly and mounting Click to enlarge http://www.chiltondiy.com/content/8687/8687_6_6.html 18.11.2005...
Page 1147 ENTERTAINMENT SYSTEMS Стр. 5 из 10 Compact disc player mounting Click to enlarge To install: Engage the electrical wiring connectors, then connect the antennal cable to the radio or CD player assembly. Slide the assembly into the instrument panel, making sure that the rear radio or CD player assembly support is engaged on the upper support rail.
Page 1148 ENTERTAINMENT SYSTEMS Стр. 6 из 10 Speakers REMOVAL & INSTALLATION Door Mounted Disconnect the negative battery cable. Remove the front door trim panel. Remove the screws retaining the speaker to its mounting bracket. Pull the speaker away from the mounting bracket far enough to disconnect the speaker electrical wires.
Page 1149 ENTERTAINMENT SYSTEMS Стр. 7 из 10 Standard rear speaker mounting-Sedan Click to enlarge To install: Position the speaker and strap assembly in place with one end of the strap over the tab on the package tray. Pull the opposite end of the strap to index over the other tab, securing the assembly.
Page 1150 ENTERTAINMENT SYSTEMS Стр. 8 из 10 Earlier model optional rear speaker mounting-Taurus only Click to enlarge Earlier model optional rear speaker mounting-Sable only Click to enlarge http://www.chiltondiy.com/content/8687/8687_6_6.html 18.11.2005...
Page 1151 ENTERTAINMENT SYSTEMS Стр. 9 из 10 Late model speaker mounting-Taurus and Sable shown Click to enlarge To install: Connect the speaker electrical wiring, then install the speaker in the vehicle. Secure using the retaining screws. Install the speaker grille to the package tray panel.
Page 1152 ENTERTAINMENT SYSTEMS Стр. 10 из 10 Station Wagon Disconnect the negative battery cable. Remove the inner rear corner of the upper finish panel. Remove the screws retaining the speaker mounting bracket and speaker assembly. Disconnect the speaker electrical wiring, then slide the speaker mounting bracket edge out from under the headlining.
Page 1153 WINDSHIELD WIPERS AND WASHERS Стр. 1 из 16 WINDSHIELD WIPERS AND WASHERS Windshield Wiper Blade and Arm REMOVAL & INSTALLATION Turn the ignition switch to the ACC position. Turn the wiper switch ON. Allow the motor to move the pivot shafts 3 or 4 cycles, then turn off the switch. This operation will place the pivot shafts in the PARK position.
Page 1154 WINDSHIELD WIPERS AND WASHERS Стр. 2 из 16 Windshield wiper blade and arm assembly-1995 vehicles Click to enlarge Remove the wiper arm and blade assembly by first applying downward pressure on the wiper arm head while holding the wiper arm. Then, lift the arm to the highest position and, using finger pressure only, grasp the slide latch tab and slide the latch out from under the arm head.
Page 1155 WINDSHIELD WIPERS AND WASHERS Стр. 3 из 16 ... remove the arm and blade assembly To remove the blade assembly for vehicles through 1994, insert a screwdriver into the slot provided at the top of the blade frame, push down on the spring lock and pull the blade assembly from the wiper arm pin.
Page 1156 WINDSHIELD WIPERS AND WASHERS Стр. 4 из 16 Removing the windshield wiper blade assembly-1995 vehicles Click to enlarge Install the blade onto the new replacement wiper arm assembly. To install: Position the bottom surface of the wiper arm parallel with the top surface of the cowl screen louvers, making sure that arm rests against the top surface of the cowl screen.
Page 1157 WINDSHIELD WIPERS AND WASHERS Стр. 5 из 16 Specifications for installing the windshield wiper arm and blade assembly Click to enlarge Make sure the blade is fully seated on the arm and the arm is against (rearward of) the the wiper stop, before operating the wipers to verify the correction. If the blade does not touch the windshield, the slide latch is not completely in place.
Page 1158 WINDSHIELD WIPERS AND WASHERS Стр. 6 из 16 Rear wiper blade and arm assembly Click to enlarge To remove the rear wiper blade, press down on the arm to unlatch the top stud, then pull the blade from the rear wiper pivot arm. Removing the rear wiper arm blade from the pivot arm Click to enlarge To install:...
Page 1159 WINDSHIELD WIPERS AND WASHERS Стр. 7 из 16 Windshield Wiper Motor REMOVAL & INSTALLATION Disconnect the negative, then the positive battery cables. Disconnect the power lead from the windshield wiper motor. Disconnect the power lead from the windshield wiper motor Remove the left windshield wiper pivot arm.
Page 1160 WINDSHIELD WIPERS AND WASHERS Стр. 8 из 16 Remove the attaching screws/bolts from the windshield motor and bracket assembly, then remove the assembly. Remove the retaining bolts from the motor, then ..remove the windshield wiper motor assembly from the vehicle To install: Position the windshield wiper motor, then install the retaining bolts/screws.
Page 1161 WINDSHIELD WIPERS AND WASHERS Стр. 9 из 16 Install the left-hand watershield or cowl screen, as applicable. Connect the positive, then the negative battery cables, then check the wiper operation through all of the modes. Install the left-hand windshield wiper blade. Rear Window Wiper Motor REMOVAL &...
Page 1162 WINDSHIELD WIPERS AND WASHERS Стр. 10 из 16 The internal governor is mounted on a bracket near the steering column support bracket. Disconnect the negative battery cable. Disengage the electrical connector. Remove the two retaining screws, then remove the component from the vehicle. View of the internal governor/windshield wiper control module Click to enlarge To install:...
Page 1163 Connect the negative battery cable. Windshield Washer Fluid Reservoir REMOVAL & INSTALLATION Except Taurus SHO Disconnect the negative battery cable. Remove the assembly retaining screw. Disengage the electrical connectors. The reservoir will drain with the washer hose(s) disconnected.
Page 1164 Engage the electrical connectors. Install the reservoir assembly retaining screw. Connect the negative battery cable, then fill the windshield washer reservoir with fluid. Taurus SHO Disconnect the negative battery cable. Remove the two assembly retaining screws. Remove the right side inner splash shield.
Page 1165 WINDSHIELD WIPERS AND WASHERS Стр. 13 из 16 Windshield washer reservoir location-SHO vehicles Click to enlarge To install: Install the reservoir assembly in the vehicle, then connect the hoses. Engage the electrical connectors. Install the right side inner splash shield. Install the two windshield washer reservoir retaining screws.
Page 1166 WINDSHIELD WIPERS AND WASHERS Стр. 14 из 16 Location of the windshield washer pump Click to enlarge To install: Insert the seal. Lubricate the inside of the seal with soapy solution, then insert the pump into the reservoir cavity until it is firmly seated in the seal. Engage the electrical connector, connect the hose, then install the reservoir in the vehicle.
Page 1167 WINDSHIELD WIPERS AND WASHERS Стр. 15 из 16 Rear window washer pump and fluid reservoir Click to enlarge Rear window washer pump mounting in the fluid reservoir http://www.chiltondiy.com/content/8687/8687_6_7.html 18.11.2005...
Page 1168 WINDSHIELD WIPERS AND WASHERS Стр. 16 из 16 Click to enlarge To install: Insert the seal. Lubricate the inside of the seal with soapy solution, then insert the pump into the reservoir cavity until it is firmly seated in the seal. Engage the electrical connector, connect the supply window washer hose, then install the reservoir in the vehicle and secure using the retaining screws.
Page 1169 Early model instrument cluster-Sable and optional Taurus models Click to enlarge On the Taurus only, remove the clock assembly (or clock cover) to gain access to the finish panel screw behind the clock. Remove the seven cluster opening finish panel retaining screws, and the jam nut behind the headlight switch.
Page 1170 On column shift vehicles, disconnect the transaxle selector indicator from the column by removing the retaining screw and cable loop. Disconnect the upper speedometer cable from the lower speedometer cable in the engine compartment. Late model instrument cluster-Taurus SHO and Sable Click to enlarge http://www.chiltondiy.com/content/8687/8687_6_8.html 18.11.2005...
Page 1171 Remove the instrument cluster. To install: Position the cluster in front of the cluster opening. Exploded view of the instrument cluster mounting-late model Taurus shown Click to enlarge Connect the speedometer cable, then engage the electrical connectors.
Page 1172 Exploded view of the instrument cluster mounting-late model Sable shown Click to enlarge Install the cluster opening finish panel. On Taurus vehicles, install the clock assembly or clock cover. Install the lower left and radio finish panels. Install the steering column trim shrouds.
Page 1173 INSTRUMENTS AND SWITCHES Стр. 5 из 17 Early model electronic instrument cluster Click to enlarge Swing the bottom of the cluster out to clear the top of the cluster from the crash pad, then remove the instrument cluster. To install: Insert the top of the cluster under the crash pad, leaving the bottom out.
Page 1174 On column shift vehicles, remove the screws attaching the transaxle selector indicator to the main dial. Remove the transaxle selector indicator from the main dial/instrument cluster. On Sable and optional Taurus, remove the odometer drive jack shaft and remove the attachment clip at the odometer, slip the jack shaft out of the odometer bracket and speedometer bridge.
Page 1175 INSTRUMENTS AND SWITCHES Стр. 7 из 17 Remove the instrument cluster. For details, please refer to the procedure located earlier in this section. Remove the screws retaining the mask and warning lamp, then remove the mask and lens. For vehicles through 1992, remove the two screws attaching the transaxle selector indicator or the filler bezel to the speedometer and remove the indicator or filler bezel from the cluster.
Page 1176 INSTRUMENTS AND SWITCHES Стр. 8 из 17 the gauge side of the cluster. Install the four speedometer retaining screws. Push the switch connector through the hole in the mask. Make sure that the wires are routed to the top of the mask, out of the way of the gauges.
Page 1177 INSTRUMENTS AND SWITCHES Стр. 9 из 17 The tachometer is part of a single electronic instrument cluster module and cannot be removed separately. Speedometer Core REMOVAL & INSTALLATION Disconnect the negative battery cable. Disconnect the speedometer cable from the speedometer head. Pull the speedometer core out of the upper end of the casing.
Page 1178 INSTRUMENTS AND SWITCHES Стр. 10 из 17 socket assemblies. Position the mask and lens assembly, then install the cluster mask and warning lamp lenses retaining screws. Install the instrument finish panel. Connect the negative battery cable. Engine Coolant Temperature Gauge REMOVAL &...
Page 1179 INSTRUMENTS AND SWITCHES Стр. 11 из 17 Windshield Wiper Switch REMOVAL & INSTALLATION The front windshield wiper switch is located deep inside the steering column assembly and is actuated by the multi-function lever on the left of the steering column. For details concerning removal and installation, please refer to the steering column procedures located in Section 8 of this manual.
Page 1180 Disengage the electrical wiring connector from the rear wiper/washer switch. Remove the washer switch from the cluster finish panel. Location of the rear wiper/washer switch-Taurus shown, Sable similar To install: Push the rear washer switch into the cluster finish panel until it snaps into place.
Page 1181 Remove the instrument cluster finish panel. Remove the two screws retaining the headlight switch, then pull the switch out of the instrument panel, disengage the electrical connector, then remove the switch. Taurus headlight switch location-1986-89 vehicles Click to enlarge To install: Position the switch, engage the electrical connector, then install the switch securing with the two retaining screws.
Page 1182 INSTRUMENTS AND SWITCHES Стр. 14 из 17 Remove the lower left-hand finish panel. Remove the two screws retaining the headlight switch to the finish panel, then disengage the electrical connector and remove the switch. Sable headlight switch location-1986-89 vehicles Click to enlarge To install: Position the switch, engage the electrical connector, then install the switch using the two retaining screws.
Page 1183 INSTRUMENTS AND SWITCHES Стр. 15 из 17 Remove the two screws retaining the headlight switch to the instrument panel, pull the switch out of the instrument panel, disengage the electrical connector, then remove the switch. To install: Position the headlight switch, then engage the electrical connector. Install the switch in the instrument panel, then secure using the two retaining screws.
Page 1184 INSTRUMENTS AND SWITCHES Стр. 16 из 17 Using a scriber to remove the clock-vehicles through 1992 Click to enlarge Gently pull the scriber tool outward until the bottom clock retaining spring releases. Grasp the clock and pull it outward to remove. Disengage the clock electrical connector.
Page 1185 INSTRUMENTS AND SWITCHES Стр. 17 из 17 Electric clock location-1993-95 vehicles Click to enlarge To install: Install the clock to the instrument panel upper finish panel and secure using the two retaining screws (one on each side). Engage the clock electrical connector. Install the instrument panel upper finish panel.
Page 1186 LIGHTING Стр. 1 из 29 LIGHTING Headlights REMOVAL & INSTALLATION Bulb Replacement CAUTION The replaceable Halogen headlamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or the bulb is dropped. Handle the bulb carefully. Grasp the bulb ONLY by its plastic base.
Page 1187 LIGHTING Стр. 2 из 29 On some vehicles, such as this early model Taurus, it it possible to remove the headlight bulb and electrical connector as an assembly After removing the bulb/connector assembly, gently pull the light bulb from the socket...
Page 1188 Disconnect the negative battery cable. Make sure the headlight switch is in the OFF position. Exploded view of the headlight assembly-1986-88 Taurus shown Click to enlarge Exploded view of the headlight assembly-1986-88 Sable shown http://www.chiltondiy.com/content/8687/8687_6_9.html...
Page 1189 Remove the electrical connector from the headlight bulb by grasping the wires firmly, then snapping the connector rearward. On Taurus, remove the grille. On Sable, remove the lighted grille. On Taurus, detach the grille retainers, then remove the grille Once the grille is removed, you can access the headlight assembly retaining bolts and screws Remove the lamp just outboard of the headlight;...
Page 1190 On the Taurus only, remove the park/turn lamp bulb and connector. Remove the two bolts attaching the headlight housing to the fender. Remove the two bolts attaching the headlight housing to the fender Remove the three bolts (Taurus) or four bolts (Sable) attaching the headlight housing to the brackets. http://www.chiltondiy.com/content/8687/8687_6_9.html...
Page 1191 LIGHTING Стр. 6 из 29 When removing the retaining bolts, be careful not to drop any into the engine compartment Remove the headlight assembly retaining bolts, then ... http://www.chiltondiy.com/content/8687/8687_6_9.html 18.11.2005...
Page 1192 Install the two bolts attaching the headlight housing to the fender. On Taurus only, install the park/turn lamp bulb and connector. Install the grille or lighted grille, as applicable. Engage the headlight bulb electrical connector.
Page 1193 Стр. 8 из 29 Exploded view of the headlight assembly-1989-95 Taurus, except SHO Click to enlarge Exploded view of the headlight assembly-1989-95 Sable and Taurus SHO Click to enlarge To install: Install the headlight and secure using the three retainers.
Page 1194 LIGHTING Стр. 9 из 29 The headlights must be properly aimed to provide the best, safest road illumination. The lights should be checked for proper aim and adjusted as necessary. Certain state and local authorities have requirements for headlight aiming; these should be checked before adjustment is made. Headlight adjustment may be temporarily made using a wall, or on the rear of another vehicle.
Page 1195 Install the bulb in the socket, then install the socket in the lamp assembly by twisting. Position the parking lamp in place, then install the retaining screws. Connect the negative battery cable. Side Marker Lights TAURUS Disconnect the negative battery cable. http://www.chiltondiy.com/content/8687/8687_6_9.html 18.11.2005...
Page 1196 LIGHTING Стр. 11 из 29 Exploded view of the side marker light and related components-1989 Taurus shown Click to enlarge Remove the nut(s) and washer(s) from the attaching stud at the top of the lamp assembly. Remove the nut and washer from the attaching stud at the top of the lamp assembly Rotate the top outboard until the stud tip has cleared the slot in the housing.
Page 1197 LIGHTING Стр. 12 из 29 Remove the lamp to clear the tab(s) on the headlamp housing Remove the socket by twisting it counterclockwise, then pull the bulb from the socket. Remove the socket by twisting it counterclockwise http://www.chiltondiy.com/content/8687/8687_6_9.html 18.11.2005...
Page 1198 If necessary, install a new bulb in the socket. Install the bulb and socket assembly into the cornering lamp by twisting clockwise. Position the cornering lamp, then secure by installing the retaining screws/nuts. Connect the negative battery cable. SABLE AND TAURUS SHO http://www.chiltondiy.com/content/8687/8687_6_9.html 18.11.2005...
Page 1199 Position the cornering light back in place, and install the two screws. Connect the negative battery cable. Auxiliary Headlight Assembly TAURUS SHO Disconnect the negative battery cable. Remove the headlight assembly. Remove the two screws attaching the auxiliary headlight to the headlight assembly.
Page 1200 LIGHTING Стр. 15 из 29 Headlight assembly-Taurus SHO Click to enlarge To install: Connect the auxiliary headlight assembly using the two attaching screws. Install the headlight assembly. Connect the battery cable. Rear Turn Signal/Brake Lights SEDAN Bulbs can be serviced from the inside of the luggage compartment by removing the luggage compartment rear trim panel, if so equipped.
Page 1201 LIGHTING Стр. 16 из 29 Brake light mounting-1995 Taurus shown Click to enlarge http://www.chiltondiy.com/content/8687/8687_6_9.html 18.11.2005...
Page 1202 LIGHTING Стр. 17 из 29 Brake light mounting-1995 Sable shown Click to enlarge From inside the trunk, remove the lower back panel trim cover. http://www.chiltondiy.com/content/8687/8687_6_9.html 18.11.2005...
Page 1203 LIGHTING Стр. 18 из 29 To access the rear lights, the lower back panel trim cover must be removed Remove the nuts securing the rear lamp to the lower back panel, then pull the rear lamp away from the vehicle. Remove the socket(s) from the lamp body and replace the bulb(s), if necessary.
Page 1204 LIGHTING Стр. 19 из 29 Disconnect the negative battery cable. Remove the two screws securing the rear lamp to the quarter panel. Remove the lamp socket and wiring from the lamp, then remove the lamp from the vehicle. Station wagon brake light/turn signal mounting Click to enlarge If necessary, replace the bulb.
Page 1205 On the sedan, remove the two covers and screws that retain the lamp assembly to the retainer, then disengage the electrical connector. Sedan high mount brake light-Taurus shown, Sable similar Click to enlarge On the wagon, remove the lamp assembly trim cover at the top of the liftgate frame.
Page 1206 Remove the lamp assembly from its mounting. Installation is the reverse of the removal procedure. SHO VEHICLES The Taurus SHO is equipped with a high-mount brake light which is part of the spoiler. Disconnect the negative battery cable. From inside the luggage compartment, disengage the wiring connector, then remove the five nuts retaining the spoiler to the trunk lid.
Page 1207 LIGHTING Стр. 22 из 29 Remove the three nuts retaining the rear high-mount brake light to the spoiler, then remove the light from the spoiler. Taurus SHO high mount brake light Click to enlarge To install: http://www.chiltondiy.com/content/8687/8687_6_9.html 18.11.2005...
Page 1208 LIGHTING Стр. 23 из 29 Position the rear-high mount lamp to the spoiler, then install the three retaining nuts and tighten the lamp securely to the spoiler. Make sure the sealer washers are on the five studs before setting it on the trunk lid.
Page 1209 LIGHTING Стр. 24 из 29 Dome lamp assembly-vehicle with moonroof Click to enlarge Installation is the reverse of the removal procedure. License Plate Lights Disconnect the negative battery cable. Remove the two lamp body plastic retaining rivets. Remove the lamp assembly. http://www.chiltondiy.com/content/8687/8687_6_9.html 18.11.2005...
Page 1210 LIGHTING Стр. 25 из 29 License plate lamp-sedan Click to enlarge Remove the socket and bulb assembly from the rear of the lamp assembly. If necessary, replace the defective bulb. http://www.chiltondiy.com/content/8687/8687_6_9.html 18.11.2005...
Page 1211 Install the lamp assembly, then secure using the plastic rivets. Connect the negative battery cable. Fog/Driving Lights The Taurus SHO is the only vehicle covered by this manual which is equipped with fog lamps. REMOVAL & INSTALLATION Fog Lamp Bulb If you are only replacing the bulb, you don't have to remove the fog lamp http://www.chiltondiy.com/content/8687/8687_6_9.html...
Page 1212 LIGHTING Стр. 27 из 29 mounting bracket or fog lamp assembly. Disconnect the negative battery cable. Disengage the electrical wiring connector from the fog lamp miniature bulb. Do NOT touch the glass part of the fog lamp bulb. Grasp the bulb by its plastic base only.
Page 1213 LIGHTING Стр. 28 из 29 Cross-sectional view of the fog lamp assembly-Taurus SHO only Click to enlarge Disengage the fog lamp electrical wiring connector. Disengage the electrical wiring connector from the rear of the fog lamp assembly Click to enlarge From under the front bumper cover, remove nut(s) retaining the fog lamp to the mounting bracket.
Page 1214 LIGHTING Стр. 29 из 29 To install: If removed, position the fog lamp mounting bracket, then secure to the front bumper using the retaining screw. Slide the fog lamp assembly into the mounting bracket assembly, then install the nut(s) retaining the fog lamp to the mounting bracket. Engage the fog lamp electrical wiring connector.
Page 1215 TRAILER WIRING Стр. 1 из 1 TRAILER WIRING Wiring the car for towing is fairly easy. There are a number of good wiring kits available and these should be used, rather than trying to design your own. All trailers will need brake lights and turn signals as well as tail lights and side marker lights.
Page 1216 CIRCUIT PROTECTION Стр. 1 из 7 CIRCUIT PROTECTION Fuse Panel and Fuses The fuse panel or block on most vehicles covered by this manual is located to the left of the steering column tube, and is hung from the instrument panel. To gain access the fuses, pull the release bar up with the right hand, pull the fuse panel down with the left hand, then remove the cover.
Page 1217 CIRCUIT PROTECTION Стр. 2 из 7 Fuse panel/block location-Early model Taurus shown Each fuse block uses miniature fuses (normally cartridge-type for these vehicles) which are designed for increased circuit protection and greater reliability. The cartridge-type design allows for fingertip removal and replacement.
Page 1218 CIRCUIT PROTECTION Стр. 3 из 7 Location of fuses and the circuits they protect-1995 vehicle shown Click to enlarge Fusible Links REPLACEMENT Fusible links are used to prevent major wire harness damage in the event of a short circuit or an overload condition in the wiring circuits that are normally not fused, due to carrying high amperage loads or because of their locations within the wiring harness.
Page 1219 Стр. 4 из 7 General fusible link repair procedures Click to enlarge Taurus and Sable Gray 12 Gauge Wire -located in left side of engine compartment at starter relay; used to protect battery to alternator circuit on all except 3.0L SHO engine.
Page 1220 Station Wagon Rear Window Wiper/Washer -One 4.5 amp circuit breaker located on the instrument panel brace, on the left side of the steering column on Taurus or on the left instrument panel end panel on Sable.
Page 1221 Electronic Engine Control Module -located on the passenger side of the firewall. Anti-lock Brake Control Module -located at the front of the engine compartment next to the passenger side fender, except on Taurus SHO, where it is located at the front of the engine compartment on the driver's side.
Page 1222 CIRCUIT PROTECTION Стр. 7 из 7 Location of the indicator flasher assembly Click to enlarge The turn signal unit is located on the LH side of the instrument panel. The combination turn signal and hazard flasher can be removed by pressing the plastic retaining clip and pulling straight rearward.
Page 1223 WIRING DIAGRAMS Стр. 1 из 2 WIRING DIAGRAMS 4-cylinder engine control wiring diagram-1986 vehicles 6-cylinder engine control wiring diagram-1986 vehicles Body wiring diagram-1986 vehicles Body wiring diagram (continued)-1986 vehicles Instrument cluster wiring diagram-1986 vehicles 4-cylinder engine control wiring diagram-1987 vehicles 6-cylinder engine control wiring diagram-1987 vehicles Body wiring diagram-1987 vehicles Body wiring diagram (continued)-1987 vehicles...
Page 1224 WIRING DIAGRAMS Стр. 2 из 2 3.0L engine control wiring diagram-1991 vehicles 3.8L engine control wiring diagram-1991 vehicles 3.0L SHO engine control wiring diagram-1991 vehicles Body wiring diagram-1991 vehicles Starting and charging system wiring diagram-1991 vehicles 3.0L engine control wiring diagram-1992 vehicles 3.8L engine control wiring diagram-1992 vehicles 3.0L SHO engine control wiring diagram-1992 vehicles Body wiring diagram-1992 vehicles...
Page 1398 MANUAL TRANSAXLE Identification Your Taurus or Sable uses a front wheel drive transmission called a transaxle. A 5-speed fully synchronized manual transaxle is available on the 2.5L and 3.0L SHO Taurus/Sable models. An internally-gated shift mechanism and a single rail shift linkage eliminate the need for periodic shift linkage adjustments.
Page 1399 MANUAL TRANSAXLE Стр. 2 из 39 Install the rear seat heat duct. Fold back the carpet over the cables. Install the shifter, shift knob, boot and console. Raise and support the vehicle safely. Install the clamp assembly onto the transaxle input shift shaft.
Page 1400 MANUAL TRANSAXLE Стр. 3 из 39 Using a 22mm box-end wrench, remove the switch. Common back-up light switch-manual transaxle Click to enlarge To install: Apply Pipe Sealant with Teflon® part No. D8AZ-19554-A or equivalent to the threads of the switch. Turn the switch into the transaxle case clockwise and tighten to 12-15 ft.
Page 1401 MANUAL TRANSAXLE Стр. 4 из 39 Wedge a wood block about 7 in. (178mm) long under the clutch pedal to hold the pedal up slightly beyond its normal position Click to enlarge Grasp the clutch cable and pull it forward, disconnecting it from the clutch release shaft assembly.
Page 1402 MANUAL TRANSAXLE Стр. 5 из 39 procedure on the opposite side. Remove the nut and bolt that retain the lower control arm ball joint to the steering knuckle assembly Click to enlarge Using Tool D83P-4026-A, or equivalent, carefully pry the lower control arm away from the knuckle.
Page 1403 MANUAL TRANSAXLE Стр. 6 из 39 Plug the seal opening to prevent lubricant leakage. Using a large prybar, carefully pry the left inboard CV-joint assembly from the transaxle Click to enlarge Remove the inboard CV-joint from the transaxle by grasping the left-hand steering knuckle and swinging the knuckle and halfshaft outward from the transaxle.If the CV-joint assembly cannot be pried from the transaxle, insert differential rotator tool T81P-4026-A or equivalent, through the left side and tap the joint out.
Page 1404 MANUAL TRANSAXLE Стр. 7 из 39 Wire the halfshaft assembly in a near level position to prevent damage to the assembly during the remaining operations. Repeat this procedure on the opposite side. Wire the halfshaft assembly in a near level position to prevent damage to the assembly during the remainder of the procedure Click to enlarge Disengage the locking tabs using a small screwdriver, then remove the backup...
Page 1405 MANUAL TRANSAXLE Стр. 8 из 39 Remove the starter stud bolts; there are usually three Click to enlarge Remove the shift mechanism to shift shaft attaching nut and bolt and control selector indicator switch arm. Remove from the shift shaft. Remove the bolts attaching the shift cable and bracket assembly to the transaxle.
Page 1406 MANUAL TRANSAXLE Стр. 9 из 39 Remove the subframe. Position a suitable jack under the transaxle. Position a suitable jack, such as Rotunda Hi-Lift Jack 014-00210, under the transaxle Click to enlarge Lower the transaxle support jack. Remove the lower engine to transaxle attaching bolts. Remove the transaxle from the rear face of the engine and lower it from the vehicle.
Page 1407 MANUAL TRANSAXLE Стр. 10 из 39 When threading the speedometer cable nut onto the retainer, be careful to avoid crossthreading Click to enlarge Install the 10M and 12M bolts attaching the the shift cable and bracket to the transaxle. Tighten the 10M bolt to 16-22 ft. lbs. (22-30 Nm) and the 12M bolt to 22- 35 ft.
Page 1408 MANUAL TRANSAXLE Стр. 11 из 39 Using a deep well socket, install the starter stud bolt, then tighten to specification Click to enlarge Install the backup light switch connector to the transaxle switch. Attach the back-up lamp switch connector to the transaxle switch Click to enlarge Remove the seal plugs, then install the inner CV-joints into the transaxle.
Page 1409 MANUAL TRANSAXLE Стр. 12 из 39 After removing the plugs, install the inner CV-joints into the transaxle Click to enlarge Install the center bearing to the bracket on the right-side halfshaft. New circlips are required on both inner CV-joints prior to installation. Make sure both CV-joints are seated in the transaxle.
Page 1410 MANUAL TRANSAXLE Стр. 13 из 39 service pinch bolt and a new nut. Tighten the nut to 37-44 ft. lbs. (50-60 Nm) but do not tighten the bolt. Attach the subframe and the lower ball joint to the steering knuckle, then insert a new service pinch bolt and a new nut Click to enlarge Fill the transaxle with the proper type and quantity of transmission fluid.
Page 1411 MANUAL TRANSAXLE Стр. 14 из 39 Attach the clutch cable to the clutch release lever Click to enlarge Remove the wood block from under the clutch pedal. Before starting the engine, set the hand brake, then pump the clutch pedal at least 2 times to ensure proper clutch adjustment.
Page 1412 MANUAL TRANSAXLE Стр. 15 из 39 its normal position Click to enlarge Remove the air cleaner hose. Grasp the clutch cable and pull it forward, disconnecting it from the clutch release shaft assembly. Grasp the clutch cable and pull it forward, disconnecting it from the clutch release shaft Click to enlarge Disconnect the clutch cable casing from the rib on top of the transaxle case.
Page 1413 MANUAL TRANSAXLE Стр. 16 из 39 Remove the nut and bolt retaining the lower control arm ball joint to the steering knuckle assembly. Be sure to discard the nut and bolt, since new ones must be used for installation Click to enlarge Using a suitable halfshaft remover, pry the lower control arm away from the knuckle.
Page 1414 MANUAL TRANSAXLE Стр. 17 из 39 Remove the upper nut from the stabilizer bar and separate the stabilizer bar from the knuckle. Remove the tie rod nut and separate the tie rod end from the knuckle. Disconnect the heated oxygen sensor. Remove the catalytic converter assembly.
Page 1415 MANUAL TRANSAXLE Стр. 18 из 39 If the CV-joint assembly cannot be pried from the transaxle, insert Differential Rotator T81P-4026-A or equivalent through the left side and tap the joint out Click to enlarge Support the halfshaft assembly with wire in a near level position to prevent damage to the assembly during the remaining operations.
Page 1416 MANUAL TRANSAXLE Стр. 19 из 39 the shift rod-to-shift shaft retaining nut and bolt, then remove the rods from the transaxle. Unfasten the shift mechanism stabilizer bar-to-transaxle retaining bolt. Remove the shift rod-to-shift shaft retaining nut and bolt, then remove the rods from the transaxle Click to enlarge Remove the engine mount bolts.
Page 1417 MANUAL TRANSAXLE Стр. 20 из 39 Unfasten the starter mounting bolts, then remove the starter motor assembly from the vehicle Click to enlarge Remove the left engine vibration dampener lower bracket. Using a small screwdriver, remove the backup light switch connector from the transaxle backup light switch, located on top of the transaxle.
Page 1418 MANUAL TRANSAXLE Стр. 21 из 39 Click to enlarge Position a suitable support jack and adapter under the transaxle. Position a suitable jack, such as Rotunda Hi-Lift Jack 014-00210 and Rotunda Transmission Adapter 014-00225, or equivalent under the transaxle Click to enlarge Lower the transaxle, remove it from the engine and lower it from the vehicle.
Page 1419 MANUAL TRANSAXLE Стр. 22 из 39 Engage the back-up light switch electrical connector, making sure that the locking tabs are secured Click to enlarge Install the starter motor. Tighten the retaining bolts to 30-40 ft. lbs. (41-54 Nm). Install the starter motor using the mounting bolts Click to enlarge http://www.chiltondiy.com/content/8687/8687_7_1.html 18.11.2005...
Page 1420 MANUAL TRANSAXLE Стр. 23 из 39 Using jacks, position the subframe and raise it into position. Install the 4 bolts and tighten to 65-85 ft. lbs. (88-115 Nm). Install the left vibration dampener lower bracket. Install the engine mount bolts and tighten to 40-55 ft. lbs. (54-75 Nm). Connect the shift cables to the transaxle.
Page 1421 MANUAL TRANSAXLE Стр. 24 из 39 Install the lower control arm ball joint to the steering knuckle assembly, using a new retaining nut and bolt Click to enlarge Install the wheel and tire assemblies. Apply Pipe Sealant with Teflon® D8AZ-19554-A or equivalent, to the transaxle fill plug threads, in a clockwise direction, then check the transaxle fluid level.
Page 1422 MANUAL TRANSAXLE Стр. 25 из 39 Fill the transaxle with the correct type of fluid to the bottom of the fill plug hole Click to enlarge Carefully lower the vehicle. Remove the engine support tool. Using a crows foot wrench, install the speedometer cable. Connect the speedometer cable and speed sensor wire.
Page 1423 MANUAL TRANSAXLE Стр. 26 из 39 Using a crow's foot wrench to install the speedometer cable Click to enlarge Remove the engine lifting eyes. Connect the clutch cable to the clutch release lever. http://www.chiltondiy.com/content/8687/8687_7_1.html 18.11.2005...
Page 1424 MANUAL TRANSAXLE Стр. 27 из 39 Connecting the clutch cable to the clutch release lever Click to enlarge Install the air cleaner hose, then remove the wood block from the clutch pedal. Connect the negative battery cable, then check the transaxle for fluid leaks. Halfshafts When removing both the left and right halfshafts, install suitable shipping plugs to prevent dislocation of the differential side gears.
Page 1425 MANUAL TRANSAXLE Стр. 28 из 39 With the vehicle still on the ground, remove the wheel cover from the wheel and tire assembly, then loosen the lug nuts Raise and safely support the vehicle. Remove the wheel and tire assembly, then remove the axle wheel hub nut and washer.
Page 1426 MANUAL TRANSAXLE Стр. 29 из 39 After removing the front axle wheel hub retainer, discard and replace it with a new one during installation Click to enlarge Remove the nut from the ball joint-to-steering knuckle attaching bolt(s). Drive the bolt out of the steering knuckle using a punch and hammer. Discard this bolt and nut after removal.
Page 1427 MANUAL TRANSAXLE Стр. 30 из 39 If your vehicle is equipped with anti-lock brakes, remove the anti-lock brake sensor, then position it aside Click to enlarge Separate the ball joint from the steering knuckle using a suitable prybar. Position the end of the prybar outside of the bushing pocket to avoid damage to the bushing.
Page 1428 MANUAL TRANSAXLE Стр. 31 из 39 These tools are required to remove the front wheel driveshaft and joints Click to enlarge To remove the right halfshaft perform the following: Remove the bolts attaching the bearing support to the bracket. Slide the halfshaft out of the transaxle. Support the end of the shaft by suspending it from a convenient underbody component with a piece of wire.
Page 1429 MANUAL TRANSAXLE Стр. 32 из 39 convenient underbody component with a piece of wire. Do NOT allow it to hang unsupported, as damage to the joint may occur Click to enlarge Separating the right-side driveshaft joint from the wheel hub using the required tools Click to enlarge To remove the left halfshaft perform the following: Install the CV-joint puller tool T86P-3514-A1 or...
Page 1430 MANUAL TRANSAXLE Стр. 33 из 39 Remove the halfshaft assembly from the vehicle. Removing the left-side front wheel driveshaft and joint from the transaxle using the specified tools Click to enlarge Support the end of the left-side shaft by suspending it from a convenient underbody component with wire Click to enlarge http://www.chiltondiy.com/content/8687/8687_7_1.html...
Page 1431 MANUAL TRANSAXLE Стр. 34 из 39 Separating the outboard CV-joint from the hub using the specified tools Click to enlarge Exploded view of the halfshaft assemblies Click to enlarge To install: Install a new circlip on the inboard CV-joint stub shaft and/or link shaft. The outboard CV-joint does not have a circlip.
Page 1432 MANUAL TRANSAXLE Стр. 35 из 39 in the groove and work the circlip over the stub shaft end into the groove. This will avoid overexpanding the circlip. The circlip must not be re-used. A new circlip must beinstalled each time the inboard CV-joint is installed into the transaxledifferential.
Page 1433 MANUAL TRANSAXLE Стр. 36 из 39 Carefully align the splines of the inboard CV-joint stub shaft with the splines in the differential Click to enlarge Carefully align the splines of the outboard CV-joint stub shaft with the splines in the hub and push the shaft into the hub as far as possible. Temporarily fasten the rotor to the hub with washers and 2 wheel lug nuts.
Page 1434 MANUAL TRANSAXLE Стр. 37 из 39 Connect the lower control arm to the steering wheel knuckle using a new nut and bolt Click to enlarge Install the anti-lock brake sensor and/or the ride height sensor bracket, if equipped. If your vehicle is so equipped, install the anti-lock brake sensor Click to enlarge Connect the stabilizer link to the stabilizer bar.
Page 1435 MANUAL TRANSAXLE Стр. 38 из 39 Connect the stabilizer link to the stabilizer bar Click to enlarge Tighten the hub retainer nut to 180-200 ft. lbs. (245-270 Nm). Remove the steel rod. Do NOT use power tools or an impact gun to tighten the hub nut, and make sure to tighten it to specification Click to enlarge Install the wheel and tire assembly, then lower the vehicle.
Page 1436 MANUAL TRANSAXLE Стр. 39 из 39 Make sure to tighten the lug nuts to the proper torque Click to enlarge Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_7_1.html 18.11.2005...
Page 1437 Стр. 1 из 20 CLUTCH Introduction CAUTION The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid Adjustments PEDAL HEIGHT/FREE-PLAY...
Page 1438 Стр. 2 из 20 View of the clutch pedal and related components-1986 2.5L Taurus shown Prop the clutch pedal up to disengage the automatic clutch adjuster using tape or a piece of wire. Remove the air cleaner assembly to gain access to the clutch cable.
Page 1439 Стр. 3 из 20 Position the clutch shield away from the mounting plate bracket by removing the rear retaining screw. Loosen the front retaining screw located near the toe board, then rotate the shield out of the way. Secure by snugging up the front screw (the rear retaining screw is closest to the instrument panel).
Page 1440 Стр. 4 из 20 clip Click to enlarge Note the proper position of the pawl spring and pawl Click to enlarge Assemble the gear quadrant spring to the gear quadrant noting the direction of the hook on the free end of the spring. file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsPDIPH.htm 18.11.2005...
Page 1441 Стр. 5 из 20 Assemble the gear quadrant spring to the gear quadrant, making sure to note the direction of the hook on the free end of the spring Click to enlarge Feed the gear quadrant tension spring into the pedal. Rotate the gear quadrant, then place the pawl on the gear quadrant face.
Page 1442 Стр. 6 из 20 Install the two bushings and pivot sleeve into the clutch pedal Click to enlarge Hook the tension spring to the hole in the clutch pedal. Place the bolt through the pivot sleeve. Position the spring washer, stop mounting bracket and install the switch plate and pivot bolt nut.
Page 1443 Стр. 7 из 20 to be sure the pawl is disengaged from the quadrant. Hook the clutch cable into the release lever in the engine compartment. Remove the equipment used to secure the clutch pedal up against the stop in step Adjust the clutch by depressing the clutch pedal up against its stop several times.
Page 1444 Стр. 8 из 20 Grasp the extended tip of the clutch cable with a pair of pliers and unlock the cable from the release lever. Do not grasp the wire strand portion of the inner cable because the strands may be damaged, causing cable failure. Do NOT grasp the wire strand portion of the inner cable because this may cut the wires, causing cable failure.
Page 1445 Стр. 9 из 20 Lubricate the quadrant pivot bore, pawl pivot bore, quadrant pivot pin, and quadrant pivot sleeve with Premium Long Life Grease XG-1-C, or equivalent. Insert the pawl, spring, and the pivot pin into the clutch pedal, then secure the retaining clip.
Page 1446 Стр. 10 из 20 Connect the clutch pedal lever assist spring to the quadrant, noting the direction of the hook on the free end of the spring Click to enlarge Feed the clutch pedal lever assist spring into the clutch pedal. Rotate the clutch pedal adjuster quadrant, then place the pawl on the quadrant face.
Page 1447 Стр. 11 из 20 Install the two clutch release idler level rod bushings and pivot sleeve into the clutch pedal. Click to enlarge Hook the clutch pedal lever assist spring to the hole in the clutch pedal. Make sure the spring washer is functional and is not trapped under the pivot sleeve.
Page 1448 Стр. 12 из 20 Place the bolt through the pivot sleeve. Position the clutch and brake pedal shaft spring washer, clutch and brake pedal shaft spring washer, clutch pedal bumper bracket, then install the clutch pedal position switch mounting bracket and pivot bolt nut.
Page 1449 Стр. 13 из 20 Installing the clutch arbor/alignment tool-this can be done before removal, or during installation Once the transaxle is removed, the clutch pressure plate cover is visible file://C:\DOCUME~1\SILENT~1\LOCALS~1\Temp\trsPDIPH.htm 18.11.2005...
Page 1450 Стр. 14 из 20 If the pressure plate cover is dirty or dusty, clean it with a commercially available spray cleaner Loosen the six clutch pressure plate cover retaining bolts evenly to release the spring tension gradually, and to avoid distorting the cover. If the same clutch pressure plate and cover are to be installed, mark the cover and the flywheel so the pressure plate can be installed in its original position.
Page 1451 Стр. 15 из 20 After all of the retaining bolts are removed, you can remove the pressure plate and clutch disc from the flywheel View of a common clutch disc and pressure plate mounting Click to enlarge Inspect the flywheel, clutch disc, pressure plate, throwout bearing and the clutch fork for wear.
Page 1452 Стр. 16 из 20 Exploded view of the location of the clutch disc, pressure plate and related components Click to enlarge To install: Avoid touching the clutch disc face, dropping parts or contaminating parts with oil or grease. The clutch disc must be assembled so that the stamped notation is facing toward the engine.
Page 1453 Стр. 17 из 20 Alternately tighten the bolts, in a crisscross pattern, until the cover is fully seated to avoid cover distortion, then tighten the bolts to specification Install the transaxle. For details, please refer to the procedure earlier in this section.
Page 1454 Стр. 18 из 20 Grasp the end of the clutch cable (not the wire strand part of the inner cable) with pliers, then unhook the clutch cable from the clutch lever Disconnect the cable from the insulator that is located on the rib of the transaxle. Pull the cable out through the recess between the pedal and the quadrant, and from the insulator on the pedal assembly.
Page 1455 Стр. 19 из 20 With the quadrant at the window stop position, push the cable through the insulator on the bumper bracket and through the recess between the pedal and quadrant With the clutch pedal lifted up to release the pawl, rotate the gear quadrant forward.
Page 1456 Стр. 20 из 20 Common clutch interlock/pedal position switch location To install: Always install the switch with the self adjusting clip about 1 in. (25mm) from the end of the rod. Be sure that the clutch pedal is in the full up position or the switch will be improperly adjusted.
Page 1457 AUTOMATIC TRANSAXLE Стр. 1 из 70 AUTOMATIC TRANSAXLE Identification Four automatic transaxle units are available. The ATX (automatic transaxle) model which is used with the 2.5L engine, and the AXOD (automatic transaxle overdrive) which is used with the 3.0L and 3.8L engine. Beginning in 1991 some vehicles were equipped with the AXOD-E transaxle which is basically the same as the AXOD with the addition of electronic transaxle controls.
Page 1458 AUTOMATIC TRANSAXLE Стр. 2 из 70 automatic transaxle. However, under severe operation or dusty conditions the fluid should be changed every 20 months or 20,000 miles (32,206 km). Raise and safely support the vehicle on jack stands. If the pan is equipped with a drain plug, drain the fluid into a suitable container. If the pan does not have a drain plug, place a suitable drain pan underneath the transaxle oil pan.
Page 1459 AUTOMATIC TRANSAXLE Стр. 3 из 70 Transaxle downshift control is controlled through the throttle position switch on 1991-95 vehicles equipped with the electronic automatic overdrive transaxle. 1986-90 3.0L and 3.8L Engines The Throttle Valve (TV) cable normally does not need adjustment. The cable should be adjusted only if one of the following components is removed for service or replacement: Main control assembly...
Page 1460 AUTOMATIC TRANSAXLE Стр. 4 из 70 While the spring is compressed, push the threaded shank toward the spring with the index and middle fingers of the left hand. Do not pull on the cable sheath Click to enlarge Attach the end of the TV cable to the throttle body. If equipped with the 3.8L engine, rotate the throttle body primary lever by hand, the lever to which the TV-driving nailhead is attached, to the wide-open-throttle position.
Page 1461 AUTOMATIC TRANSAXLE Стр. 5 из 70 THROTTLE VALVE CONTROL LINKAGE ATX Transaxle The Throttle Valve (TV) Control Linkage System consists of a lever on the throttle body of the injection unit, linkage shaft assembly, mounting bracket assembly, control rod assembly, a control lever on the transaxle and a lever return spring. The coupling lever follows the movement of throttle lever and has an adjustment screw that is used for setting TV linkage adjustment when a line pressure gauge is used.
Page 1462 AUTOMATIC TRANSAXLE Стр. 6 из 70 Set the coupling lever adjustment screw at its approximate midrange. Make sure the TV linkage shaft assembly is fully seated upward into the coupling lever. CAUTION If adjustment of the linkage is necessary, allow the EGR valve to cool so you won't get burned.
Page 1463 AUTOMATIC TRANSAXLE Стр. 7 из 70 Disconnect the negative battery cable. Disengage the neutral start switch electrical connector, then remove the shift control lever on top of the switch. Remove the two neutral switch attaching bolts, then remove the switch. Neutral safety switch location-vehicles equipped with automatic transaxle Click to enlarge Adjusting the neutral safety switch...
Page 1464 AUTOMATIC TRANSAXLE Стр. 8 из 70 Click to enlarge To install: Install the switch on the manual shaft. Loosely install the two attaching bolts and washers. Insert a No. 43 drill (0.089 in.) through the hole. Tighten the attaching bolts to 7-9 ft. lbs. (9-12 Nm), then remove the drill. Engage the switch electrical connector, then connect the negative battery cable.
Page 1465 AUTOMATIC TRANSAXLE Стр. 9 из 70 EXCEPT TAURUS WITH 2.5L ENGINE Disconnect the negative battery cable. Remove the air cleaner assembly. Remove the bolt retaining the shift cable and bracket assembly to the transaxle. Hold the bracket with a prybar in the slot to prevent the bracket from moving.
Page 1466 AUTOMATIC TRANSAXLE Стр. 10 из 70 Location of the throttle valve cable cover-3.8L engines only Click to enlarge Carefully pull up on the throttle valve cable and disconnect the throttle valve cable from the TV link. Pulling too hard on the throttle valve may bend the internal TV bracket. Removing the accelerator cable Click to enlarge Install engine lifting brackets.
Page 1467 AUTOMATIC TRANSAXLE Стр. 11 из 70 Installing engine lifting brackets Click to enlarge Disconnect the power steering pump pressure and return line bracket. Remove the converter housing bolts from the top of the transaxle. Remove the four torque converter housing bolts from the top of the transaxle Click to enlarge Install a suitable engine support fixture.
Page 1468 AUTOMATIC TRANSAXLE Стр. 12 из 70 Remove the lower ball joint attaching nuts and bolts. Remove the lower ball joints and remove the lower control arms from each spindle. Remove stabilizer bar bolts. Remove the nuts securing the steering rack to the subframe. Remove the nut securing the steering rack to the subframe Click to enlarge For 3.8L engines, disengage the oxygen sensor electrical connection, then remove...
Page 1469 AUTOMATIC TRANSAXLE Стр. 13 из 70 Remove the bolts from the left engine support, then remove the support Click to enlarge Position a suitable subframe removal tool. Remove the steering gear from the subframe and secure to the rear of the engine compartment.
Page 1470 AUTOMATIC TRANSAXLE Стр. 14 из 70 Transaxle cooler line locations Click to enlarge Remove the engine-to-transaxle retaining bolts. Remove the speedometer sensor heat shield. Remove the vehicle speed sensor from the transaxle. Vehicles with electronic instrument clusters do not use a speedometer cable.
Page 1471 AUTOMATIC TRANSAXLE Стр. 15 из 70 Tools necessary to remove the halfshafts Click to enlarge Position the puller behind the CV-joint, then remove the joint Click to enlarge Remove the two remaining torque converter housing bolts. Separate the transaxle from the engine, then carefully lower the transaxle from the vehicle.
Page 1472 23-39 ft. lbs. (31-53 Nm) Insulator-to-bracket bolts: 55-70 ft. lbs. (75-95 Nm) TAURUS WITH 2.5L ENGINE Disconnect the negative battery cable. Remove the air cleaner assembly. Position the engine control wiring harness away from the transaxle converter housing area.
Page 1473 AUTOMATIC TRANSAXLE Стр. 17 из 70 shock tower. Place another support bar across the vehicle approximately between the alternator and valve cover. Attach chains to the lifting brackets. Raise and safely support the vehicle. Remove the wheel and tire assemblies. Remove the catalytic converter inlet pipe and disconnect the exhaust air hose assembly.
Page 1474 AUTOMATIC TRANSAXLE Стр. 18 из 70 Clean the transaxle oil cooler lines using Rotunda Torque Converter Cleaner 014-00028 or equivalent. Install new circlips on the CV-joint seals. Carefully install the halfshafts in the transaxle by aligning the splines of the CV-joint with the splines of the differential.
Page 1475 AUTOMATIC TRANSAXLE Стр. 19 из 70 On the 3.0L engine, install engine lifting eyes D81L-6001-D to the left rear cylinder with a bolt. The engine plant lifting eye should still be on the right front cylinder. If not, install second lifting eye. On the 3.2L SHO, remove the bracket on the back of the engine that retains the wiring harness and coolant line and attach Engine Lifting Eyes to the alternator bracket.
Page 1476 AUTOMATIC TRANSAXLE Стр. 20 из 70 Installing lifting equipment on the 3.2L SHO engine Click to enlarge Secure the wiring harness aside and remove the radiator sight shield. Position a suitable engine support fixture. Position Three Bar Engine Support D88L-6000-A or equivalent. If equipped with air suspension, turn the air suspension switch located in the luggage compartment to the OFF position.
Page 1477 AUTOMATIC TRANSAXLE Стр. 21 из 70 Remove the four torque converter housing bolts from the top of the transaxle Click to enlarge Raise and safely support the vehicle. Remove the front wheel and tire assemblies. Disconnect the left outer tie rod end. Remove the suspension height sensor, if equipped.
Page 1478 AUTOMATIC TRANSAXLE Стр. 22 из 70 Remove the steering gear-to-subframe retaining nuts Click to enlarge Remove the two bolts from the engine mount and the four bolts from the left engine support, then remove the support. http://www.chiltondiy.com/content/8687/8687_7_3.html 18.11.2005...
Page 1479 AUTOMATIC TRANSAXLE Стр. 23 из 70 Remove the two retaining bolts from the engine mount, then remove the mount Click to enlarge http://www.chiltondiy.com/content/8687/8687_7_3.html 18.11.2005...
Page 1480 AUTOMATIC TRANSAXLE Стр. 24 из 70 Remove the four bolts from the left engine support, then remove the support Click to enlarge Position Rotunda Subframe Removal Kit 014-00751, or equivalent. Remove the steering gear from the subframe and secure it to the rear of the engine compartment.
Page 1481 AUTOMATIC TRANSAXLE Стр. 25 из 70 Remove the vehicle speed sensor from the transaxle Click to enlarge Position a suitable transaxle jack. WARNING Make sure the puller does not contact the speed sensor or damage will occur. Do NOT pry against the case. Remove the halfshafts as follows: Screw Extension T86P-35140A2 into the CV-Joint Puller and install Impact Slide Hammer D79P-100-A...
Page 1482 AUTOMATIC TRANSAXLE Стр. 26 из 70 Tools required to remove the halfshafts Click to enlarge Position the puller behind the CV-joint, then remove the joint Click to enlarge Remove the last two torque converter housing bolts, carefully separate the transaxle from the engine and lower out of the vehicle. To install: Place the transaxle assembly on the jack, and raise to the engine.
Page 1483 AUTOMATIC TRANSAXLE Стр. 27 из 70 Install the transaxle housing bolts, then tighten to 41-50 ft. lbs. (55-68 Nm). Install the four torque converter bolts through the starter drive hole by rotating the engine at the crankshaft pulley bolt with a in.
Page 1484 AUTOMATIC TRANSAXLE Стр. 28 из 70 Install the engine mount, then tighten to specification Click to enlarge Install the front exhaust pipe, converter assembly and mounting bracket. Connect the heated oxygen sensor. Install the power steering gear assembly and retaining nuts, then tighten the nuts to 85-100 ft.
Page 1485 AUTOMATIC TRANSAXLE Стр. 29 из 70 Install the power steering gear to the subframe Click to enlarge Install the left and right lower arm assembly, Insert a new pinch bolt and nut, then tighten to 40-53 ft. lbs. (53-72 Nm). Install the stabilizer retaining bolts, then tighten to 23-29 ft.
Page 1486 AUTOMATIC TRANSAXLE Стр. 30 из 70 Halfshafts When removing both the left and right halfshafts, install suitable shipping plugs to prevent dislocation of the differential side gears. Should the gears become misaligned, the differential will have to be removed from the transaxle to re-align the side gears.
Page 1487 AUTOMATIC TRANSAXLE Стр. 31 из 70 Before removing the hub nut and washer, insert a steel rod in the rotor to prevent it from turning Remove the hub nut and washer, then discard the nut and replace with a new one during installation Remove the nut from the ball joint to steering knuckle attaching bolts.
Page 1488 AUTOMATIC TRANSAXLE Стр. 32 из 70 Drive the bolt out of the front wheel knuckle using a punch and hammer, then discard the nut and bolt and replace with new ones during installation Click to enlarge If equipped with anti-lock brakes, remove the anti-lock brake sensor and position it aside.
Page 1489 Click to enlarge The following removal procedure applies to the right-side halfshaft/link shaft for the 1986-90 2.5L engine Taurus. (For all other automatic transaxles, proceed to Step 9): Remove the bolts attaching the bearing support to the bracket. Slide the link shaft out of the transaxle.
Page 1490 AUTOMATIC TRANSAXLE Стр. 34 из 70 Support the end of the shaft by suspending it from a convenient underbody component with a piece of wire. Do not allow the shaft to hang unsupported, damage to the outboard CV-joint may occur. Separate the outboard CV-joint from the hub using front hub remover tool T81P-1104-C or equivalent and metric adapter tools T83P-1104-BH, T86P-1104-...
Page 1491 T83P-1104-BH, T86P-1104-Al and T81P-1104-A or equivalent, then remove the halfshaft assembly from the vehicle Click to enlarge The following removal procedure applies to the left-side halfshaft for the 1986-90 Taurus with 2.5L engine automatic transaxle: http://www.chiltondiy.com/content/8687/8687_7_3.html 18.11.2005...
Page 1492 AUTOMATIC TRANSAXLE Стр. 36 из 70 Due to the automatic transaxle case configuration, theright halfshaft assembly must be removed first. Differential rotator toolT81P-4026-A or equivalent, is then inserted into the transaxle to drive theleft inboard CV- joint assembly from the transaxle. If only the left halfshaftassembly is to be removed for service, remove the right halfshaft assembly fromthe transaxle first.
Page 1493 AUTOMATIC TRANSAXLE Стр. 37 из 70 Always use a new circlip on the inboard CV-joint stub shaft and/or link shaft. When installing the new circlip, start one end in the groove and work the circlip over the stub shaft end into the groove. This will avoid overexpanding the circlip Carefully align the splines of the inboard CV-joint stub shaft with the splines in the differential.
Page 1494 AUTOMATIC TRANSAXLE Стр. 38 из 70 differential Click to enlarge Temporarily fasten the rotor to the hub with washers and two wheel lug nuts. Insert a steel rod into the rotor and rotate clockwise to contact the knuckle to prevent the rotor from turning during the CV-joint installation. Install the hub nut washer and a new hub nut.
Page 1495 AUTOMATIC TRANSAXLE Стр. 39 из 70 Connect the control arm to the steering knuckle and install a new nut and bolt. Tighten to 40-55 ft. lbs. (54-74 Nm) Click to enlarge If equipped, install the anti-lock brake sensor and/or the ride height sensor bracket.
Page 1496 AUTOMATIC TRANSAXLE Стр. 40 из 70 Connect the stabilizer link to the stabilizer bar. Tighten to 35-48 ft. lbs. (47-65 Nm) Click to enlarge Install a new hub retainer nut, then tighten the nut to 180-200 ft. lbs. (245-270 Nm). Remove the steel rod.
Page 1497 AUTOMATIC TRANSAXLE Стр. 41 из 70 After the vehicle is lowered, tighten the lug nuts to 80-105 ft. lbs. (108-142 Nm) CV-Joint REMOVAL & INSTALLATION Outboard CV-Joint Disconnect the negative battery cable. Raise and safely support the vehicle. Exploded view of the outboard CV-joint assembly http://www.chiltondiy.com/content/8687/8687_7_3.html 18.11.2005...
Page 1498 AUTOMATIC TRANSAXLE Стр. 42 из 70 Before removal, check the CV-boot for wear or damage Clean the CV-joint prior to removing the boot, but be careful not to damage anything Remove the halfshaft assembly from the vehicle. For details, please refer to the procedure located earlier in this section.
Page 1499 AUTOMATIC TRANSAXLE Стр. 43 из 70 Clamp the halfshaft in a vise with soft jaw covers, but do not allow the vise jaws to contact the boot or boot clamp Cut the boot clamp with a pair of side cutters, then pull the clamp away from the boot.
Page 1500 AUTOMATIC TRANSAXLE Стр. 44 из 70 Slide the boot back over the shaft once the clamp has been removed Support the interconnecting shaft in a soft jawed vise and angle the CV-joint pointing downward so the inner bearing race is exposed. Use a brass drift and hammer, give a sharp tap to the inner bearing race to dislodge the internal driveshaft bearing retainer circlip and separate the CV-joint from the interconnecting shaft.
Page 1501 AUTOMATIC TRANSAXLE Стр. 45 из 70 Using a brass drift and hammer, give a sharp tap to the inner bearing race to dislodge the internal driveshaft bearing retainer circlip and separate the CV-joint from the interconnecting shaft. Make sure to secure the CV-joint so it does not drop after separation.
Page 1502 AUTOMATIC TRANSAXLE Стр. 46 из 70 Remove the boot from the shaft. Inspect the CV-joint grease for contamination. If the CV-joints are working correctly, and the grease doesn't seem to be contaminated, add grease, then replace the CV-joint boot. Check the CV-joint grease for contamination or foreign debris by visually inspecting it and rubbing it with fingers.
Page 1503 AUTOMATIC TRANSAXLE Стр. 47 из 70 The stop ring, located just below the circlip, should be removed and replaced only if damaged or worn The vise must be equipped with soft jaw covers to avoid damaging the shaft splines. Clamp the CV-joint in a vise with soft jaw covers, with the outer face pointing upward.
Page 1504 AUTOMATIC TRANSAXLE Стр. 48 из 70 Click to enlarge Press down on the inner race until it tilts enough to permit removal of the ball. A tight assembly can be tilted by tapping the inner race with a wooden dowel and hammer, but do not hit the cage.
Page 1505 AUTOMATIC TRANSAXLE Стр. 49 из 70 With the cage sufficiently tilted, remove a ball from the cage. Repeat this until all of the balls are removed. If the balls are tight in the cage, use a blunt edged prytool to pry the balls from the cage Click to enlarge Pivot the cage and inner race assembly until it is straight up and down in the outer...
Page 1506 Click to enlarge To install: Apply a light coating of Ford High Temperature Constant Velocity Joint Grease E43Z-19590-A or equivalent, on the inner and outer ball races. Install the inner race in the bearing cage.
Page 1507 AUTOMATIC TRANSAXLE Стр. 51 из 70 Install the inner race in the bearing cage Click to enlarge Install the inner race and cage assembly in the outer race. Install the assembly vertically, then pivot 90° into position. Install the inner race and cage assembly in the outer race. Install the assembly vertically, then pivot 90°...
Page 1508 AUTOMATIC TRANSAXLE Стр. 52 из 70 Align the bearing cage and inner race with the outer race. Tilt the inner race and cage, then install a ball. Repeat until all balls are installed Click to enlarge On some vehicles, the left and right interconnecting shafts are different, depending on year and vehicle application.
Page 1509 AUTOMATIC TRANSAXLE Стр. 53 из 70 Make sure the CV boot is seated in its groove and the clamp is in position using Boot http://www.chiltondiy.com/content/8687/8687_7_3.html 18.11.2005...
Page 1510 AUTOMATIC TRANSAXLE Стр. 54 из 70 Clamp Installer T95P-3514-A or equivalent. Tighten the tool through the bolt until it's in a closed position, then remove the tool Click to enlarge If removed, install the stop ring. If not removed, make sure the ring is properly seated in its groove.
Page 1511 This will avoid overexpanding the circlip Click to enlarge Before positioning the boot over the CV-joint, pack the joint and boot with Ford High Temperature Constant Velocity Joint Grease E43Z-19590-A or equivalent. Pack the joint with grease. Any remaining grease in the tube is to be spread evenly inside of the boot.
Page 1512 AUTOMATIC TRANSAXLE Стр. 56 из 70 With the front wheel driveshaft joint boot held back, position the CV-joint on the shaft and tap into position using a plastic tipped hammer Click to enlarge The CV-joint is fully seated when the circlip locks in the groove cut into the CV- joint inner race.
Page 1513 AUTOMATIC TRANSAXLE Стр. 57 из 70 Position the tool on the clamp ear and tighten the tool through the bolt, until it is in the closed position, then remove the tool Click to enlarge Install the halfshaft assembly and lower the vehicle. Connect the negative battery cable.
Page 1514 AUTOMATIC TRANSAXLE Стр. 58 из 70 Slide the outer race off of the tripod Click to enlarge Move the stop ring back on the shaft using snapring pliers. Move the tripod assembly back on the shaft to allow access to the circlip. Move the stop ring back on the shaft using snapring pliers, then ...
Page 1515 AUTOMATIC TRANSAXLE Стр. 59 из 70 as necessary. To install: Install the CV-joint boot. Make sure the boot is seated in the boot groove on the shaft. Tighten the clamp using crimping pliers, but do not tighten to the point where the clamp bridge is cut or the boot is damaged.
Page 1516 Move the CV-joint in and out, as necessary, to adjust the length to the following specifications: Automatic transaxle left halfshaft, except 1986-90 Taurus with 2.5L engine-18.27 in. (464mm) Automatic transaxle right halfshaft, except 1986-90 Taurus with 2.5L engine-23.58 in. (599mm) Automatic transaxle left halfshaft, 1986-90 Taurus with 2.5L engine-22.80 in.
Page 1517 AUTOMATIC TRANSAXLE Стр. 61 из 70 Engage hook C in the window. Place the pincer jaws of the crimping pliers in closing hooks A and B. Secure the clamp by drawing the closing hooks together. When windows 1 and 2 are above locking hooks D and E, the spring tab will press the windows over the locking hooks and engage the clamp.
Page 1518 AUTOMATIC TRANSAXLE Стр. 62 из 70 Removing the clamp using Boot Clamp Pliers D87P-1090-A Click to enlarge Slide the inboard CV-joint housing off of the tripod. Slide the inboard CV-joint housing off of the tripod When replacing damaged boots, the grease should be checked for contamination. If the CV-joints are operating satisfactorily, and the grease does not seem to be contaminated, add grease, then replace the boot.
Page 1519 Install the trilobe insert on the CV-joint housing positioning in the groove on the outer race. Fill the CV-joint housing with Ford High Temperature Constant Velocity Grease E43Z-19590-A or equivalent, and spread remaining grease evenly inside of the joint boot. The total fill amount is 9 oz. (250 grams).
Page 1520 AUTOMATIC TRANSAXLE Стр. 64 из 70 Click to enlarge Install the CV-joint on the tripod assembly. Before installing the boot clamp, make sure any air pressure that may have built up in the boot is relieved. Insert a small prybar between the boot and outer race to allow the trapped air to escape.
Page 1521 AUTOMATIC TRANSAXLE Стр. 65 из 70 Secure the clamp by drawing the closing hooks together. When windows 1 and 2 are above locking hooks D and E, the spring tab will press the windows over the locking hooks and engage the clamp.
Page 1522 AUTOMATIC TRANSAXLE Стр. 66 из 70 Removing the boot clamps using pliers Slide the boot back on the shaft, then wipe the grease away from the CV-joint. After sliding the boot back on the shaft, wipe away the grease from the CV-joint Click to enlarge When replacing damaged boots, the grease should be checked for contamination.
Page 1523 Using the boot clamp installer to fasten the small boot clamp Using Ford High Temperature Constant Velocity Grease E43Z-19590-A or equivalent, fill the inboard CV-joint with grease, then spread the remaining grease evenly inside of the boot.
Page 1524 AUTOMATIC TRANSAXLE Стр. 68 из 70 Filling the CV-joint and boot with grease Click to enlarge Before installing the boot clamp, make sure any air pressure that may have built up in the boot is relieved. Insert a small prybar between the boot and outer race to allow the trapped air to escape.
Page 1525 AUTOMATIC TRANSAXLE Стр. 69 из 70 Make sure the boot is seated in its groove and the clamp is in position. Position the Boot Clamp Replacer T95T-3514-A or equivalent on the clamp ear, then tighten the tool through the bolt until the tool is in a closed position. Position the Boot Clamp Replacer T95T-3514-A or equivalent, on the clamp ear, then tighten the tool through the bolt until the tool is in a closed position Click to enlarge...
Page 1526 AUTOMATIC TRANSAXLE Стр. 70 из 70 Do not overexpand or twist the circlip during installation. ALWAYS replace the circlip with a new one during installation Click to enlarge Install the halfshaft assembly, then carefully lower the vehicle. Connect the negative battery cable. Chilton®...
Page 1670 WHEELS Стр. 1 из 3 WHEELS Introduction REMOVAL & INSTALLATION All vehicles use Metric (M-12) lug nuts. Replacement lug nuts must be of the same type and thread size. Metric lug nuts are identified by the word "Metric'' stamped in the top surface of the nut. Position the vehicle on a level surface.
Page 1671 WHEELS Стр. 2 из 3 To install: Install the tire and wheel assembly to the brake rotor or drum. Install the lug nuts, then finger-tighten then is a crisscross pattern. Lower the vehicle to the ground. Cross-tighten the lug nuts to 85-105 ft. lbs. (115-142 Nm). Align the hub cap/wheel cover with the tire valve and cap extension, matching the hole in the cover (also identified on the backside of the wheel cover with the valve stem logo).
Page 1672 WHEELS Стр. 3 из 3 Install the bolt/stud into the wheel hub. Using a lug nut, seat the bolt/stud into the wheel hub. Install the caliper and rotor. Install the wheel and tire assembly, then carefully lower the vehicle. Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. http://www.chiltondiy.com/content/8687/8687_8_1.html 18.11.2005...
Page 1673 FRONT SUSPENSION Стр. 1 из 31 FRONT SUSPENSION MacPherson Struts REMOVAL & INSTALLATION Place the ignition switch in the OFF position and the steering column in the UNLOCKED position. View of the front suspension components Click to enlarge http://www.chiltondiy.com/content/8687/8687_8_2.html 18.11.2005...
Page 1674 FRONT SUSPENSION Стр. 2 из 31 http://www.chiltondiy.com/content/8687/8687_8_2.html 18.11.2005...
Page 1675 FRONT SUSPENSION Стр. 3 из 31 Exploded view of a MacPherson strut assembly Click to enlarge Remove the hub nut. Loosen the 3 top mount-to-shock tower nuts; but do not remove the nuts at this time. Loosen, but do not remove, the 3 top mount-to-shock tower nuts Raise and safely support the vehicle.
Page 1676 FRONT SUSPENSION Стр. 4 из 31 Remove the stabilizer bar link nut, then ..remove the stabilizer bar link from the strut Remove the lower arm-to-steering knuckle pinch bolt and nut; it may be necessary to use a drift punch to remove the bolt. Using a suitable tool, spread the knuckle- to-lower arm pinch joint, then remove the lower arm from the steering knuckle.
Page 1677 FRONT SUSPENSION Стр. 5 из 31 Remove the halfshaft from the hub and support it on a wire to maintain a level position Remove the strut-to-steering knuckle pinch bolt. Using a small prybar, spread the pinch bolt joint and separate the strut from the steering knuckle. Remove the steering knuckle/hub assembly from the strut.
Page 1678 FRONT SUSPENSION Стр. 6 из 31 Install a new strut-to-steering knuckle pinch bolt. Tighten the bolt to 73-97 ft. lbs. (98-132 Nm). Install the halfshaft into the hub. Install the lower arm to the steering knuckle, making sure the ball stud groove is properly positioned.
Page 1679 FRONT SUSPENSION Стр. 7 из 31 Tighten the 3 top mount-to-shock tower nuts to 23-29 ft. lbs. (31-40 Nm) Click to enlarge Lower the vehicle, then tighten the hub nut to 170-203 ft. lbs. (230-275 Nm). Depress the brake pedal a few times before moving the vehicle. OVERHAUL CAUTION NEVER attempt to disassemble the spring or top mount without...
Page 1680 FRONT SUSPENSION Стр. 8 из 31 Carefully compress the spring using a suitable spring compressor tool Place a 10mm box wrench on top of the shock strut shaft and hold while removing the top shaft mounting nut with a 21mm 6-point crow's foot wrench and ratchet. It is important that the mounting nut be turned and the rod held still toprevent fracture of the rod at the base of the hex.
Page 1681 FRONT SUSPENSION Стр. 9 из 31 ... remove the mounting nut Loosen the spring compressor tool, then remove the top mounting bracket assembly, bearing plate assembly and spring. After loosening the spring compressor tool, remove the washer, then ... http://www.chiltondiy.com/content/8687/8687_8_2.html 18.11.2005...
Page 1682 FRONT SUSPENSION Стр. 10 из 31 ... remove the mounting bracket and bearing plate assembly To assemble: Ensure that the correct assembly sequence and proper positioning of thebearing and seat assembly are followed. The bearing and seat assembly ispress-fit onto the upper mount. The mount washers must be installed with thecorrect orientation.
Page 1683 FRONT SUSPENSION Стр. 11 из 31 Compress the coil spring using the proper tool Click to enlarge Install the upper washer and nut on the shock strut shaft. Place a 10mm box end wrench on the top of the shock strut shaft and hold while tightening the top shaft mounting nut with a 21mm 6-point crow's foot wrench and a ratchet.
Page 1684 FRONT SUSPENSION Стр. 12 из 31 Place a 10mm box end wrench on top of the shock strut shaft, and hold while tightening the top shaft mounting nut with a 21mm 6-point crow's foot wrench and ratchet. Tighten to 40-53 ft. lbs. (53-72 Nm) Click to enlarge The strut assembly may now be installed in the vehicle.
Page 1685 FRONT SUSPENSION Стр. 13 из 31 Remove the stabilizer bar link-to-stabilizer bar nut, the stabilizer bar link-to-strut nut and the link from the vehicle with an 8mm closed-end wrench and an 18mm open-end wrench. Discard the nuts, and replace with new ones during installation. Be very careful not to damage the line ball joint boot seal.
Page 1686 FRONT SUSPENSION Стр. 14 из 31 Position another set of jackstands under the front subframe, then remove the rear subframe-to-frame bolts. Lower the rear or the subframe to access the stabilizer bar brackets Click to enlarge Remove the stabilizer bar U-bracket bolts and the stabilizer bar from the vehicle. When removing the stabilizer bar, replace the insulators and the U- bracket bolts with new ones.
Page 1687 FRONT SUSPENSION Стр. 15 из 31 Remove the wheel and tire assembly. Remove and discard the tension strut-to-control arm nut, then pull off the dished washer. When separating the control arm from the steering knuckle, do not use a hammer. Be careful not to damage the ball joint boot seal. Remove and discard the control arm-to-steering knuckle pinch bolt.
Page 1688 FRONT SUSPENSION Стр. 16 из 31 attachment. Insert the strut into the inner bushing. Position the lower control arm into the subframe bracket, using a new nut and bolt. Tighten to 73-97 ft. lbs. (98-132 Nm). Assemble the lower control arm ball joint stud to the steering knuckle, making sure the ball stud groove is positioned properly.
Page 1689 FRONT SUSPENSION Стр. 17 из 31 Control arm bushing assembly Click to enlarge To install: Before installing the new bushing, saturate it in vegetable oil, as this will aid in the installation process. Use only vegetable oil; do NOT use mineral or petroleum based oil, as these will deteriorate the rubber.
Page 1690 FRONT SUSPENSION Стр. 18 из 31 REMOVAL & INSTALLATION Turn the ignition switch to the OFF position. Position the steering wheel in the unlocked position. Remove the hub nut. Raise and safely support the vehicle, then remove the tire and wheel assembly. Remove the cotter pin from the tie rod end stud, then remove the slotted nut.

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