1989-1994 Ford Crown Victoria & Mercury Grand Marquis Repair Manual – PDF DOWNLOAD

Description

1989-1994 Ford Crown Victoria & Mercury Grand Marquis Repair Manual – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

1989-1994 Ford Crown Victoria & Mercury Grand Marquis Repair Manual – PDF DOWNLOAD

How to Use this Manual:
Introduction:

Chilton’s Total Car Care manual for 1989-98 Ford Crown Victoria and Mercury Grand Marquis is intended to help you learn more about the inner workings of your vehicle while saving you money on its upkeep and operation. The beginning of the book will likely be referred to the most, since that is where you will find information for maintenance and tune-up.

• The other sections deal with the more complex systems of your vehicle. Operating systems from engine through brakes are covered to the extent that the average do-it-yourselfer becomes mechanically involved. This book will not explain such things as rebuilding a differential for the simple reason that the expertise required and the investment in special tools make this task uneconomical.
• It will, however, give you detailed instructions to help you change your own brake pads and shoes, replace spark plugs, and perform many more jobs that can save you money, give you personal satisfaction and help you avoid expensive problems. A secondary purpose of this book is a reference for owners who want to understand their vehicle and/or their mechanics better. In this case, no tools at all are required.

TABLE OF CONTENTS:

1989-1994 Ford Crown Victoria & Mercury Grand Marquis Repair Manual – PDF DOWNLOAD

FORD CROWN VICTORIA AND MERCURY GRAND MARQUIS 1989-94 2
How to Use this Manual 2
Introduction 2
Where to Begin 2
Avoiding Trouble 2
Maintenance or Repair? 2
Avoiding the Most Common Mistakes 2
Tools And Equipment 3
Introduction 3
Special Tools 10
Servicing Your Vehicle Safely 10
Introduction 10
Do’s 12
Don’ts 12
Fasteners, Measurements And Conversions 13
Bolts, Nuts and Other Threaded Retainers 13
Torque 14
TORQUE WRENCHES 15
Beam Type 15
Click (Breakaway) Type 15
Pivot Head Type 15
Rigid Case (Direct Reading) 16
TORQUE ANGLE METERS 16
Standard and Metric Measurements 17
Serial Number Identification 17
Vehicle 17
Engine 18
Transmission 19
Drive Axle 19
Routine Maintenance And Tune-up 20
Introduction 20
Air Cleaner Element 20
REMOVAL & INSTALLATION 20
Except 5 8L Engine 20
5 8L Engine 22
Fuel Filter 22
REMOVAL & INSTALLATION 22
In-Line Fuel Filter 22
Carburetor Fuel Inlet Filter 25
PCV Valve 27
REMOVAL & INSTALLATION 27
Evaporative Canister 29
SERVICING 29
Battery 30
PRECAUTIONS 30
GENERAL MAINTENANCE 30
BATTERY FLUID 31
Checking the Specific Gravity 31
CABLES 32
CHARGING 35
REPLACEMENT 35
Belts 35
INSPECTION 35
ADJUSTMENT 37
5 0L and 5 8L Engines 37
ALTERNATOR BELT 37
AIR CONDITIONER COMPRESSOR BELT 38
REMOVAL & INSTALLATION 38
4 6L Engine 38
5 0L and 5 8L Engines 40
ALTERNATOR BELT 40
AIR CONDITIONER COMPRESSOR BELT 40
Hoses 40
INSPECTION 40
REMOVAL & INSTALLATION 42
Spark Plugs 43
SPARK PLUG HEAT RANGE 43
REMOVAL & INSTALLATION 45
INSPECTION & GAPPING 48
Spark Plug Wires 50
TESTING 50
REMOVAL & INSTALLATION 51
Distributor Cap and Rotor 53
REMOVAL & INSTALLATION 54
INSPECTION 54
Ignition Timing 54
GENERAL INFORMATION 55
INSPECTION & ADJUSTMENT 55
5 0L Engine 55
5 8L Engine 56
Valve Lash 56
ADJUSTMENT 56
4 6L Engine 56
5 0L Engine 56
5 8L Engine 57
Idle Speed 58
ADJUSTMENT 58
4 6L and 5 0L Engines 58
5 8L Engine 58
Air Conditioning System 58
SYSTEM SERVICE & REPAIR 58
R-12 Refrigerant Conversion 59
PREVENTIVE MAINTENANCE 59
SYSTEM INSPECTION 60
Windshield Wipers 61
ELEMENT (REFILL) CARE & REPLACEMENT 61
Tires and Wheels 65
TIRE ROTATION 65
TIRE DESIGN 66
Snow Tires 67
TIRE STORAGE 67
INFLATION & INSPECTION 67
CARE OF SPECIAL WHEELS 70
Fluids And Lubricants 70
Fluid Disposal 70
Fuel and Engine Oil Recommendations 70
FUEL 70
OIL 71
Engine 72
OIL LEVEL CHECK 72
OIL & FILTER CHANGE 75
Automatic Transmission 79
FLUID RECOMMENDATIONS 80
LEVEL CHECK 80
PAN & FILTER SERVICE 82
Drive Axle 88
FLUID RECOMMENDATIONS 88
LEVEL CHECK 88
DRAIN AND REFILL 90
Cooling System 92
FLUID RECOMMENDATIONS 93
LEVEL CHECK 93
DRAIN & REFILL 96
FLUSHING & CLEANING THE SYSTEM 98
Brake Master Cylinder 99
FLUID RECOMMENDATIONS 99
LEVEL CHECK 100
Power Steering Pump 101
FLUID RECOMMENDATIONS 101
LEVEL CHECK 101
Chassis Greasing 103
Body Lubrication and Maintenance 104
CAR WASHING 104
WAXING 105
INTERIOR CLEANING 106
Upholstery 106
Floor Mats and Carpet 106
Dashboard, Console, Door Panels, Etc 106
Wheel Bearings 106
REPACKING 106
1989-91 Vehicles 106
1992-98 107
Towing The Vehicle 107
Jump Starting A Dead Battery 108
Introduction 108
Jump Starting Precautions 108
Jump Starting Procedure 109
Jacking 109
Introduction 109
Jacking Precautions 111
Specification Charts 112
Engine Electrical 114
Duraspark II Distributor Ignition System 114
Introduction 114
General Information 114
Primary Circuit 114
Secondary Circuit 114
Diagnosis and Testing 115
SECONDARY SPARK TEST 115
CYLINDER DROP TEST 117
Adjustments 118
Ignition Coil 119
TESTING 119
REMOVAL & INSTALLATION 119
Ignition Module 119
REMOVAL & INSTALLATION 119
Stator Assembly 119
REMOVAL & INSTALLATION 119
Distributor 120
REMOVAL & INSTALLATION 120
Removal 120
Installation 120
TIMING NOT DISTURBED 120
TIMING DISTURBED 121
Thick Film Integrated (TFI-IV) Distributor Ignition System 121
General Information 121
Diagnosis and Testing 123
Adjustments 123
Ignition Coil 123
TESTING 123
Primary Coil 123
Secondary Windings 123
REMOVAL & INSTALLATION 124
Ignition Module 126
REMOVAL & INSTALLATION 126
Stator Assembly 127
REMOVAL & INSTALLATION 127
Distributor 128
REMOVAL & INSTALLATION 128
Electronic Distributorless Ignition System (EDIS) 128
General Information 128
Diagnosis and Testing 129
Adjustments 129
Ignition Coil Pack 129
TESTING 129
Primary Winding Resistance 129
Secondary Winding Resistance 129
REMOVAL & INSTALLATION 130
Ignition Module 132
REMOVAL & INSTALLATION 132
Crankshaft and Camshaft Position Sensors 133
Firing Orders 133
Charging System 135
General Information 135
Alternator Precautions 135
Alternator 136
TESTING 136
Voltage Test 136
No-Load Test 136
Load Test 136
REMOVAL & INSTALLATION 136
5 0L and 5 8L Engines 136
4 6L Engine 137
Regulator 140
REMOVAL & INSTALLATION 140
Starting System 140
General Information 140
Starter 140
TESTING 140
Voltage Drop Test 141
REMOVAL & INSTALLATION 141
SOLENOID OR RELAY REPLACEMENT 142
Starter Mounted Solenoid 142
Relay 143
Sending Units And Sensors 143
Introduction 143
Coolant Temperature Sender 143
TESTING 143
REMOVAL & INSTALLATION 144
Oil Pressure Sender/Switch 145
TESTING 145
REMOVAL & INSTALLATION 146
Low Oil Level Sensor 148
TESTING 148
REMOVAL & INSTALLATION 148
Fuel Level Sending Unit 149
TESTING 149
REMOVAL & INSTALLATION 150
Troubleshooting Charts 150
Engine & Engine Overhaul 151
Engine Mechanical 151
Engine 151
REMOVAL & INSTALLATION 151
4 6L Engine 151
5 0L and 5 8L Engines 154
Rocker Arm (Valve) Cover 156
REMOVAL & INSTALLATION 156
4 6L Engine 156
PASSENGER SIDE 156
DRIVER’S SIDE 157
5 0L Engine 159
5 8L Engine 159
Rocker Arms/Roller Followers 159
REMOVAL & INSTALLATION 160
4 6L Engine 160
5 0L and 5 8L Engines 160
Thermostat 161
REMOVAL & INSTALLATION 161
4 6L Engine 161
5 0L and 5 8L Engines 163
Intake Manifold 165
REMOVAL & INSTALLATION 165
4 6L Engine 165
1992-95 MODELS 165
1996-98 MODELS 170
5 0L Engine 172
5 8L Engine 173
Exhaust Manifold 175
REMOVAL & INSTALLATION 175
4 6L Engine 175
5 0L and 5 8L Engines 179
Radiator 180
REMOVAL & INSTALLATION 180
Engine Fan 185
REMOVAL & INSTALLATION 185
1992-94 Models 185
1995-98 Models 188
BELT DRIVEN COOLING FAN 188
ELECTRIC COOLING FAN 188
1989-91 Models 189
Water Pump 189
REMOVAL & INSTALLATION 189
4 6L Engine 189
5 0L and 5 8L Engines 191
Cylinder Head 192
REMOVAL & INSTALLATION 192
4 6L Engine 192
1992-95 MODELS 192
1996-98 MODELS 197
5 0L and 5 8L Engines 200
CLEANING AND INSPECTION 202
Oil Pan 203
REMOVAL & INSTALLATION 203
4 6L Engine 203
5 0L and 5 8L Engines 205
Oil Pump 206
REMOVAL 206
4 6L Engine 206
5 0L and 5 8L Engines 206
INSPECTION AND OVERHAUL 206
4 6L Engine 206
5 0L and 5 8L Engines 206
INSTALLATION 207
4 6L Engine 207
5 0L and 5 8L Engines 208
Crankshaft Damper 208
REMOVAL & INSTALLATION 208
4 6L Engine 208
5 0L and 5 8L Engines 210
Timing Chain Cover Seal 211
REMOVAL & INSTALLATION 211
4 6L Engine 211
5 0 and 5 8L Engines 213
Timing Chain, Sprockets and Front Cover 213
REMOVAL & INSTALLATION 213
4 6L Engine 213
5 0L and 5 8L Engines 223
Camshaft 225
REMOVAL & INSTALLATION 225
4 6L Engine 225
5 0L and 5 8L Engines 228
INSPECTION 229
Camshaft Bearings 229
REMOVAL & INSTALLATION 230
4 6L Engine 230
5 0L and 5 8L Engines 230
Rear Main Seal 230
REMOVAL & INSTALLATION 230
4 6L Engine 231
5 0L and 5 8L Engines 231
Flexplate 232
REMOVAL & INSTALLATION 232
Exhaust System 232
REPLACEMENT 236
Flange Type 237
Slip Joint Type 237
Engine Reconditioning 238
Determining Engine Condition 238
COMPRESSION TEST 238
OIL PRESSURE TEST 239
Buy or Rebuild? 240
Engine Overhaul Tips 240
TOOLS 240
OVERHAUL TIPS 240
CLEANING 241
REPAIRING DAMAGED THREADS 243
Engine Preparation 245
Cylinder Head 245
DISASSEMBLY 246
5 0/5 8L Engines 246
4 6L Engine 249
INSPECTION 252
Valves 252
Springs, Retainers and Valve Locks 253
Cylinder Head 254
VALVE GUIDES 254
VALVE SEATS 255
CYLINDER HEAD SURFACE FLATNESS 255
CRACKS AND PHYSICAL DAMAGE 256
Camshaft and Followers 256
REFINISHING & REPAIRING 256
Valves 256
LAPPING THE VALVES 256
Springs, Retainers and Valve Locks 257
Cylinder Head 257
VALVE GUIDE 257
VALVE SEATS 257
CYLINDER HEAD SURFACE 257
CRACKS AND PHYSICAL DAMAGE 258
ASSEMBLY 258
5 0/5 8L Engines 258
4 6L Engine 258
Engine Block 259
GENERAL INFORMATION 259
Cylinder Ridge Removal 259
DISASSEMBLY 259
5 0/5 8L Engines 259
4 6L Engine 259
All Engines 260
INSPECTION 261
Engine Block 262
ENGINE BLOCK BEARING ALIGNMENT 262
DECK FLATNESS 262
CYLINDER BORES 262
Crankshaft 263
Pistons and Connecting Rods 263
PISTONS 263
CONNECTING ROD 263
Camshaft 264
Bearings 264
Oil Pump 264
REFINISHING 264
Pistons and Connecting Rods 264
C-CLIP TYPE PISTONS 265
ASSEMBLY 265
Crankshaft 265
Pistons and Connecting Rods 268
5 0/5 8L Engines 270
CAMSHAFT, LIFTERS AND TIMING ASSEMBLY 270
CYLINDER HEAD(S) 271
4 6L Engine 271
CYLINDER HEAD(S) 271
Engine Covers and Components 271
Engine Start-up and Break-in 271
STARTING THE ENGINE 271
BREAKING IT IN 271
KEEP IT MAINTAINED 271
Specification Charts 271
Driveability & Emission Controls 274
Air Pollution 274
Introduction 274
Natural Pollutants 274
Industrial Pollutants 274
Automotive Pollutants 274
TEMPERATURE INVERSION 274
HEAT TRANSFER 275
Automotive Emissions 275
Introduction 275
Exhaust Gases 275
HYDROCARBONS 275
CARBON MONOXIDE 276
NITROGEN 276
Ozone 276
OXIDES OF SULFUR 276
PARTICULATE MATTER 276
Crankcase Emissions 276
Evaporative Emissions 277
Emission Controls 277
Crankcase Ventilation System 277
OPERATION 277
COMPONENT TESTING 278
REMOVAL & INSTALLATION 279
Evaporative Emission Controls 279
OPERATION 279
OBD-II EVAP System Monitor 279
Carbon Canister 280
Fuel Tank Vapor Orifice and Roll over Valve Assembly 280
Purge Control Valve 280
Purge Solenoid Valve 281
Fuel Bowl Solenoid Vent Valve 281
Fuel Bowl Thermal Vent Valve 281
Auxiliary Fuel Bowl Vent Tube 281
Pressure/Vacuum Relief Fuel Cap 281
TESTING 282
Evaporative Emissions Canister 282
Evaporative Hoses and Tubes 282
Evaporative Emissions Valve 282
Canister Purge Valve/Vapor Management Valve 282
REMOVAL & INSTALLATION 283
Carbon Canister 283
Fuel Tank Vapor Orifice and Roll over Valve Assembly 285
Purge Control Valve 285
Purge Solenoid Valve 285
Fuel Bowl Solenoid Vent Valve 285
Fuel Bowl Thermal Vent Valve 285
Pressure/Vacuum Relief Fuel Cap 285
Exhaust Gas Recirculation System 285
OPERATION 285
COMPONENT TESTING 289
DPFE Sensor 289
EGR Valve Control Solenoid 289
EGR Valve 289
REMOVAL & INSTALLATION 290
DPFE Sensor 290
EGR Valve Control Solenoid 291
EGR Valve 293
4 6L ENGINE 293
5 0L ENGINE 296
Thermostatic Air Inlet System 297
OPERATION 297
Duct and Valve Assembly 297
Bimetal Sensor 297
Cold Weather Modulator 297
TESTING 297
Duct and Valve Assembly 297
Bimetal Sensor 298
Cold Weather Modulator 298
REMOVAL & INSTALLATION 298
Vacuum Motor 298
Bimetal Sensor 298
Cold Weather Modulator 299
Thermactor Air Injection System 299
OPERATION 299
Air Supply Pump 299
Air Bypass Valve 299
Air Check Valve 299
Air Supply Control Valve 300
Combination Air Bypass/Air Control Valve 300
Solenoid Vacuum Valve 300
Thermactor Idle Vacuum Valve 300
Vacuum Control Valve 300
Vacuum Check Valve 300
TESTING 300
Air Supply Pump 300
Air Bypass Valve 301
Air Check Valve 301
Air Supply Control Valve 301
Combination Air Bypass/Air Control Valve 302
Solenoid Vacuum Valve 302
TIV Valve 303
Vacuum Control Valve 303
Vacuum Check Valve 304
REMOVAL & INSTALLATION 304
Air Supply Pump 304
Air Bypass Valve 304
Air Check Valve 304
Air Supply Control Valve 304
Combination Air Bypass/Air Control Valve 304
Solenoid Vacuum Valve 304
TIV Valve 305
Vacuum Control Valve 305
Electronic Engine Controls 305
Powertrain Control Module (PCM) 305
OPERATION 305
REMOVAL & INSTALLATION 306
Oxygen Sensor 306
OPERATION 306
TESTING 306
REMOVAL & INSTALLATION 307
Idle Air Control Valve 310
OPERATION 310
TESTING 310
REMOVAL & INSTALLATION 311
Engine Coolant Temperature (ECT) Sensor 311
OPERATION 311
TESTING 311
REMOVAL & INSTALLATION 312
Intake Air Temperature Sensor 315
OPERATION 315
TESTING 316
REMOVAL & INSTALLATION 316
1992-95 Models 316
1996-98 Models 318
Mass Airflow Sensor 318
OPERATION 318
TESTING 319
REMOVAL & INSTALLATION 320
Manifold Air Pressure (MAP) Sensor 322
OPERATION 322
TESTING 322
REMOVAL & INSTALLATION 323
Throttle Position Sensor 323
OPERATION 323
TESTING 324
REMOVAL & INSTALLATION 325
4 6L Engine 325
5 0L Engine 327
Knock Sensor 327
OPERATION 327
TESTING 327
REMOVAL & INSTALLATION 327
4 6L Engine 327
Camshaft Position Sensor 328
TESTING 328
REMOVAL & INSTALLATION 328
4 6L Engine 328
Crankshaft Position Sensor 330
OPERATION 330
TESTING 330
REMOVAL & INSTALLATION 330
Vehicle Speed Sensor 331
OPERATION 331
TESTING 331
REMOVAL & INSTALLATION 331
Component Locations 333
Trouble Codes —EEC-IV System 334
General Information 334
FAILURE MODE EFFECTS MANAGEMENT (FMEM) 334
HARDWARE LIMITED OPERATION STRATEGY (HLOS) 334
Diagnostic Link Connector 334
HAND-HELD SCAN TOOLS 334
ELECTRICAL TOOLS 336
Reading Codes 336
VISUAL INSPECTION 336
ELECTRONIC TESTING 337
Key On Engine Off (KOEO) Test 337
Key On Engine Running (KOER) Test 339
Reading Codes With Analog Voltmeter 339
Malfunction Indicator Lamp Method 340
Other Test Modes 340
CONTINUOUS MONITOR OR WIGGLE TEST 340
OUTPUT STATE CHECK 340
Clearing Codes 341
CONTINUOUS MEMORY CODES 341
KEEP ALIVE MEMORY 341
EEC-IV Diagnostic Trouble Codes 341
Trouble Codes —EEC-V System (OBD-II) 342
General Information 342
Malfunction Indicator Lamp 342
Data Link Connector 342
ELECTRICAL TOOLS 342
Reading Codes 343
Clearing Codes 343
CONTINUOUS MEMORY CODES 343
KEEP ALIVE MEMORY 343
EEC-V Diagnostic Trouble Codes (DTC’s) 343
Vacuum Diagrams 354
Fuel System 358
Basic Fuel System Diagnosis 358
Fuel Lines And Fittings 358
Introduction 358
Hairpin Clip Fitting 358
REMOVAL & INSTALLATION 358
Duckbill Clip Fitting 359
REMOVAL & INSTALLATION 359
Spring Lock Coupling 360
REMOVAL & INSTALLATION 360
Carbureted Fuel System 364
Description 364
Mechanical Fuel Pump 364
REMOVAL & INSTALLATION 364
TESTING 365
Capacity Test 365
Pressure Test 366
Carburetor 366
ADJUSTMENTS 366
Choke 366
COLD ENRICHMENT ROD (CER) ADJUSTMENT 366
CONTROL VACUUM REGULATOR (CVR) SWIVEL ASSEMBLY REPLACEMENT 366
CER RUN POSITION ADJUSTMENT 367
CER START (CRANK) POSITION ADJUSTMENT 367
CHOKE DIAPHRAGM START (CRANK) POSITION FOR WARM ENGINE 367
CONTROL VACUUM ROD (CVR) POSITION 368
CHOKE DIAPHRAGM RUN POSITION FOR COLD ENGINE 368
FAST IDLE CAM SETTING 368
Venturi Valve Wide Open Throttle (WOT) Opening 369
Float Level 370
Float Drop 370
REMOVAL & INSTALLATION 371
Gasoline Fuel Injection System 371
General Information 371
FUEL SYSTEM SERVICE PRECAUTIONS 372
Relieving Fuel System Pressure 372
Fuel Pump 372
TESTING 372
REMOVAL & INSTALLATION 373
Inertia Switch 373
GENERAL INFORMATION 373
RESETTING THE SWITCH 374
REMOVAL & INSTALLATION 374
Throttle Body 375
REMOVAL & INSTALLATION 375
4 6L Engine 375
5 0L Engine 378
Fuel Rail And Fuel Injector(s) 378
REMOVAL & INSTALLATION 378
4 6L Engine 378
5 0L Engine 381
TESTING 382
All Injectors Clicking 382
One or More Injectors Are Not Clicking 382
Fuel Pressure Regulator 384
REMOVAL & INSTALLATION 384
Pressure Relief Valve 386
REMOVAL & INSTALLATION 386
Fuel Tank 386
Tank Assembly 387
REMOVAL & INSTALLATION 387
Electric Fuel Pump 387
REMOVAL & INSTALLATION 387
Chassis Electrical 390
Understanding And Troubleshooting Electrical Systems 390
Basic Electrical Theory 390
HOW DOES ELECTRICITY WORK: THE WATER ANALOGY 390
OHM’S LAW 391
Electrical Components 391
POWER SOURCE 391
The Battery 391
The Alternator 391
GROUND 391
PROTECTIVE DEVICES 391
SWITCHES & RELAYS 392
LOAD 393
WIRING & HARNESSES 393
CONNECTORS 394
Test Equipment 395
JUMPER WIRES 395
TEST LIGHTS 395
MULTIMETERS 396
Troubleshooting Electrical Systems 397
Testing 397
OPEN CIRCUITS 397
SHORT CIRCUITS 398
VOLTAGE 398
VOLTAGE DROP 398
RESISTANCE 399
Wire and Connector Repair 400
Battery Cables 401
Air Bag (Supplemental Restraint System) 401
SERVICE PRECAUTIONS 401
DISARMING THE SYSTEM 402
1990-91 Vehicles 402
1992-98 Vehicles 403
ARMING THE SYSTEM 403
1990-91 Vehicles 403
1992-98 Vehicles 403
Heating And Air Conditioning 404
Blower Motor 404
REMOVAL & INSTALLATION 404
Heater Core 406
REMOVAL & INSTALLATION 406
Air Conditioning Components 409
REMOVAL & INSTALLATION 409
Control Cables 409
REMOVAL & INSTALLATION 409
Vehicles with Manual Climate Control 409
1989 Vehicles with Automatic Temperature Control (ATC) 410
ADJUSTMENT 410
Vehicles with Manual Climate Control 410
1989 Vehicles with Automatic Temperature Control (ATC) 411
Control Panel 411
REMOVAL & INSTALLATION 411
1989 Vehicles 411
1990-98 Vehicles 411
Vacuum Motors 413
REMOVAL & INSTALLATION 413
Panel Door Vacuum Motor 413
Floor-Defrost Door Vacuum Motor 415
Outside-Recirculating Door Vacuum Motor 415
Thermal Blower Lock Out Switch 416
REMOVAL & INSTALLATION 416
Vehicles with Automatic Temperature Control 416
Servo Motor 416
REMOVAL & INSTALLATION 416
1989 Vehicles with Automatic Temperature Control 416
Variable Blower Speed Controller 417
REMOVAL & INSTALLATION 417
1990-98 Vehicles with Automatic Temperature Control 417
Temperature Blend Door Actuator 417
REMOVAL & INSTALLATION 417
1990-98 Vehicles with Automatic Temperature Control 417
In-Vehicle Temperature Sensor 418
REMOVAL & INSTALLATION 418
Vehicles with Automatic Temperature Control 418
1989 VEHICLES 418
1990-98 VEHICLES 419
Cruise Control 420
Entertainment Systems 421
Radio Receiver/Tape Player/CD Player (Except Changer) 421
REMOVAL & INSTALLATION 421
1989 Vehicles 421
1990-98 Models 421
Amplifier 423
REMOVAL & INSTALLATION 423
Sedan 424
Station Wagon 424
Compact Disc Changer 425
REMOVAL & INSTALLATION 425
Speakers 425
REMOVAL & INSTALLATION 425
Dash Mounted 425
1989 VEHICLES 425
Door Mounted 425
1989 AND 1992-98 VEHICLES 426
1990-91 VEHICLES 427
Rear 427
1989-91 SEDAN 427
1992-98 SEDAN 428
STATION WAGON 428
Subwoofer 428
Windshield Wipers And Washers 428
Windshield Wiper Blade and Arm 429
REMOVAL & INSTALLATION 429
1989-91 Vehicles 429
1992-98 Vehicles 429
Windshield Wiper Motor 430
REMOVAL & INSTALLATION 430
1989-91 Vehicles 430
1992-98 Vehicles 431
Windshield Washer Fluid Reservoir 436
REMOVAL & INSTALLATION 436
1989-91 Vehicles 436
1992-98 Vehicles 437
Windshield Washer Motor 437
REMOVAL & INSTALLATION 437
1989-91 Vehicles 437
1992-98 Vehicles 438
Instruments And Switches 438
Instrument Cluster 439
REMOVAL & INSTALLATION 439
Conventional Cluster 439
Electronic Cluster 442
Gauges 442
REMOVAL & INSTALLATION 442
Back-up Light Switch 445
REMOVAL & INSTALLATION 445
Headlight Switch 445
REMOVAL & INSTALLATION 445
1989 Vehicles 445
1990-95 Vehicles 446
1996-98 Models 446
Lighting 447
Headlights 447
REMOVAL & INSTALLATION 447
1989-91 Vehicles 447
1992-98 Vehicles 447
AIMING THE HEADLIGHTS 449
Signal and Marker Lights 450
REMOVAL & INSTALLATION 451
Front Turn Signal and Parking Lights 451
1989-91 VEHICLES 451
1992-98 CROWN VICTORIA 451
1992-98 GRAND MARQUIS 453
Side Marker/Cornering Lights 453
1989-91 VEHICLES—FRONT 453
1989-91 CROWN VICTORIA STATION WAGON/COUNTRY SQUIRE—REAR 454
1992-98 CROWN VICTORIA 454
1992-98 GRAND MARQUIS 454
Rear Turn Signal, Brake and Parking Lights 455
1989-91 SEDAN 455
1992-98 SEDAN 455
STATION WAGON 458
High-Mount Brake Light 459
1989-92 SEDAN 459
1993-98 VEHICLES 460
STATION WAGON 461
Dome Light 462
Cargo Light 464
STATION WAGON 465
License Plate Lights 465
Light Bulb Chart 467
Circuit Protection 468
Fuses 468
REPLACEMENT 468
Fusible Links 470
REPLACEMENT 471
Circuit Breakers 472
Flashers 472
REPLACEMENT 472
Wiring Diagrams 473
Drive Train 477
Automatic Transmission 477
Understanding the Automatic Transmission 477
TORQUE CONVERTER 477
PLANETARY GEARBOX 478
SERVOS AND ACCUMULATORS 479
HYDRAULIC CONTROL SYSTEM 480
Fluid Pan And Filter Service 480
REMOVAL & INSTALLATION 480
Neutral Safety Switch 480
REMOVAL & INSTALLATION 480
1989-91 Models Only 480
ADJUSTMENT 481
Manual Lever Position (MLP) Sensor/Transmission Range (TR) Sensor 481
REMOVAL & INSTALLATION 481
ADJUSTMENT 483
Extension Housing Seal 483
REMOVAL & INSTALLATION 483
Automatic Transmission Assembly 484
REMOVAL & INSTALLATION 484
ADJUSTMENTS 485
Shift Linkage 485
1989 VEHICLES 485
1990-92 VEHICLES 485
1993-98 VEHICLES 485
Shift Indicator Cable 486
Throttle Valve Linkage 486
4 6L AND 5 0L ENGINES 486
5 8L ENGINE 487
Driveline 487
REMOVAL & INSTALLATION 487
U-JOINT REPLACEMENT 489
DRIVESHAFT BALANCING 492
Rear Axle 494
Axle Shaft, Bearing and Seal 494
REMOVAL & INSTALLATION 494
Pinion Seal 498
REMOVAL & INSTALLATION 498
Axle Housing Assembly 500
REMOVAL & INSTALLATION 500
Specifications Chart 501
Suspension & Steering 503
Wheels 503
Introduction 503
REMOVAL & INSTALLATION 503
INSPECTION 505
Wheel Lug Studs 506
REMOVAL & INSTALLATION 506
With Disc Brakes 506
With Drum Brakes 507
Front Suspension 508
Introduction 508
Coil Springs 509
REMOVAL & INSTALLATION 509
Shock Absorbers 510
REMOVAL & INSTALLATION 510
TESTING 513
Upper Ball Joint 513
INSPECTION 513
REMOVAL & INSTALLATION 514
1989-91 Vehicles 514
1992-98 Vehicles 514
Lower Ball Joint 515
INSPECTION 515
REMOVAL & INSTALLATION 515
Stabilizer Bar 515
REMOVAL & INSTALLATION 515
Upper Control Arm 517
REMOVAL & INSTALLATION 517
1989-91 Vehicles 517
1992-98 Vehicles 517
CONTROL ARM BUSHING REPLACEMENT 518
Lower Control Arm 520
REMOVAL & INSTALLATION 520
CONTROL ARM BUSHING REPLACEMENT 521
Knuckle and Spindle 521
REMOVAL & INSTALLATION 521
Front Wheel Bearings 522
REMOVAL & INSTALLATION 522
1989-91 Vehicles 522
Front Hub and Bearing 523
REMOVAL & INSTALLATION 523
1992-98 Vehicles 523
Wheel Alignment 524
CASTER 524
CAMBER 524
TOE 524
Rear Suspension 525
Introduction 525
Coil Springs 525
REMOVAL & INSTALLATION 525
Air Springs 526
REMOVAL & INSTALLATION 526
Shock Absorbers 530
REMOVAL & INSTALLATION 530
Without Automatic Leveling 530
With Automatic Leveling 532
TESTING 533
Control Arms 533
REMOVAL & INSTALLATION 533
Upper Control Arm 533
Lower Control Arm 534
Stabilizer Bar 534
REMOVAL & INSTALLATION 534
Steering 536
Steering Wheel 536
REMOVAL & INSTALLATION 536
1989 Vehicles 536
1990-98 Vehicles 536
Multi-Function Switch 540
REMOVAL & INSTALLATION 540
1989 Vehicles 540
1990-98 Vehicles 541
Windshield Wiper Switch 541
REMOVAL & INSTALLATION 541
1989 Vehicles 541
Ignition Switch 541
REMOVAL & INSTALLATION 541
Ignition Lock Cylinder 541
REMOVAL & INSTALLATION 541
Functional Lock 541
Non-Functional Lock 543
Steering Linkage 543
REMOVAL & INSTALLATION 543
Pitman Arm 543
Idler Arm 546
Center Link 547
Tie Rod Ends 547
Power Steering Gear 550
ADJUSTMENTS 550
Meshload 550
REMOVAL & INSTALLATION 551
Power Steering Pump 552
REMOVAL & INSTALLATION 552
BLEEDING 553
Specifications Chart 553
Brakes 554
Brake Operating System 554
Basic Operating Principles 554
DISC BRAKES 554
DRUM BRAKES 555
POWER BOOSTERS 555
Vacuum Leak Test 555
System Operation Test 555
Brake Light Switch 556
REMOVAL & INSTALLATION 556
Master Cylinder 556
REMOVAL & INSTALLATION 556
1989-94 Vehicles 556
1995-98 Vehicles 560
BENCH BLEEDING 560
Power Brake Booster 561
REMOVAL & INSTALLATION 561
Vehicles Without ABS 561
Vehicles With ABS 561
Brake Pressure Control Valve 562
REMOVAL & INSTALLATION 562
Metering Valve 563
REMOVAL & INSTALLATION 563
Proportioning Valve 564
REMOVAL & INSTALLATION 564
Brake Hoses and Pipes 564
REMOVAL & INSTALLATION 564
Bleeding Brake System 567
Disc Brakes 569
Brake Pads 569
REMOVAL & INSTALLATION 569
Front 569
Rear 572
INSPECTION 577
Brake Caliper 578
REMOVAL & INSTALLATION 578
Front 578
Rear 579
OVERHAUL 580
Brake Disc (Rotor) 584
REMOVAL & INSTALLATION 584
Front 584
1989-91 VEHICLES 584
1992-98 VEHICLES 584
Rear 585
INSPECTION 586
Drum Brakes 587
Introduction 587
Brake Drums 587
REMOVAL & INSTALLATION 588
INSPECTION 588
Brake Shoes 589
INSPECTION 590
REMOVAL & INSTALLATION 590
ADJUSTMENTS 598
Drum Installed 598
Drum Removed 599
Wheel Cylinders 599
REMOVAL & INSTALLATION 600
OVERHAUL 602
Parking Brake 607
Cable(s) 607
REMOVAL AND INSTALLATION 607
Front Cable 607
1989-91 VEHICLES 607
1992-94 VEHICLES 608
1995-98 VEHICLES 609
Intermediate Cable 610
1989 VEHICLES 610
Rear Cables 610
1989-91 VEHICLES 610
1992-94 VEHICLES 611
1995-98 VEHICLES 611
ADJUSTMENT 612
1989 Vehicles 612
1990-94 Vehicles 612
1995-98 Vehicles 612
Brake Shoes 613
REMOVAL & INSTALLATION 613
1992-93 Vehicles 613
Anti-lock Brake System 614
General Information 614
Diagnosis 614
Control Module 615
REMOVAL & INSTALLATION 615
1992-94 Vehicles 615
1995-98 Vehicles 616
Hydraulic Control Unit (HCU) 616
REMOVAL & INSTALLATION 616
1992-94 Vehicles 616
1995-98 Vehicles 617
Pedal Travel Switch 617
REMOVAL & INSTALLATION 617
ADJUSTMENT 617
Speed Sensors 618
REMOVAL & INSTALLATION 618
Front 618
Rear 619
Tone (Exciter) Ring 621
REMOVAL & INSTALLATION 621
Front 622
Rear 622
Bleeding the ABS System 622
BLEEDING PROCEDURE 623
1992-1994 Vehicles 623
1995-98 Vehicles 623
Specifications Chart 623
Body 624
Exterior 624
Doors 624
REMOVAL & INSTALLATION 624
ADJUSTMENT 624
Door Hinges 624
Door Latch Striker 625
Hood 625
REMOVAL & INSTALLATION 625
ALIGNMENT 627
Hood Alignment 627
Hood Latch 628
Trunk Lid 628
REMOVAL & INSTALLATION 628
ALIGNMENT 629
Trunk Lid Alignment 629
Trunk Lid Latch/Striker 629
EXCEPT 1989-91 GRAND MARQUIS 629
1989-91 GRAND MARQUIS 629
Tailgate 629
REMOVAL & INSTALLATION 629
ALIGNMENT 630
Upper Latch-To-Lower Latch Link 630
Upper Hinge And Latch Release Link 630
Tailgate Striker 630
Upper Key Cylinder to Latch Link 630
Outside Handle to Latch Link 631
Tailgate 631
Grille 631
REMOVAL & INSTALLATION 631
Crown Victoria 631
1989-91 631
1993-98 MODELS 632
Grand Marquis 632
1989-91 632
1992-98 632
Outside Mirrors 633
REMOVAL & INSTALLATION 633
Manual Mirrors 633
LEFT SIDE 633
RIGHT SIDE 633
Power Mirrors 634
1989-91 VEHICLES 634
1992-98 VEHICLES 634
Antenna 636
REMOVAL & INSTALLATION 636
Fixed Antenna 636
1989 VEHICLES 636
1990-91 VEHICLES 637
1992-98 VEHICLES 637
Power Antenna 638
1989 VEHICLES 638
1990-98 VEHICLES 638
Fenders 638
REMOVAL & INSTALLATION 638
Interior 639
Instrument Panel 639
REMOVAL & INSTALLATION 639
1989 Vehicles 639
1990-91 Vehicles 641
1992-98 Vehicles 643
Door Panels 644
REMOVAL & INSTALLATION 644
1989-91 Vehicles 644
1992-98 Vehicles 645
Door Locks 650
REMOVAL & INSTALLATION 650
Front Door Latch 650
Rear Door Latch 651
Door Latch Remote Control 651
Door Lock Cylinder 652
Power Door Lock Actuator Motor 652
1989-91 VEHICLES 652
1992-98 VEHICLES 652
Power Door Lock Switch 653
1989-91 VEHICLES 653
1992-98 VEHICLES 653
Tailgate Lock 653
REMOVAL & INSTALLATION 653
Tailgate Upper Latch 653
Tailgate Lower Latch 653
Tailgate Lock Release Control 654
Tailgate Lock Cylinder 654
Tailgate Lock Actuator 654
Door Glass 654
REMOVAL & INSTALLATION 654
1989-91 Vehicles 654
FRONT DOOR 654
REAR DOOR 655
1992-98 Vehicles 656
Door Window Regulator 657
REMOVAL & INSTALLATION 657
1989-91 Vehicles 657
FRONT DOOR 657
REAR DOOR 658
1992-98 Vehicles 658
OPERATIONAL WINDOW 658
DOWN AND INOPERABLE WINDOW 658
Power Window Motor 659
REMOVAL & INSTALLATION 659
1989-91 Vehicles 659
1992-98 Vehicles 660
Tailgate Window Motor 660
REMOVAL & INSTALLATION 660
Windshield and Fixed Glass 661
REMOVAL & INSTALLATION 661
WINDSHIELD CHIP REPAIR 661
Inside Rear View Mirror 669
REMOVAL & INSTALLATION 669
Mirror 669
1989-91 VEHICLES 669
1992 VEHICLES 669
1992-98 VEHICLES 669
Mirror Mounting Bracket 670
Seats 670
REMOVAL & INSTALLATION 670
Front 670
MANUAL SEAT 670
POWER SEAT 671
Rear 671
SEDAN 671
STATION WAGON—SECOND SEAT 672
STATION WAGON—AUXILIARY SEAT 672
Power Seat Motor 672
REMOVAL & INSTALLATION 672
1989 Vehicles 672
RACK AND PINION DRIVE 672
SCREW DRIVE 673
1990-98 Vehicles 673
Specifications Chart 674

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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