Ford Escort Shop Manual 1981 – 1997 – PDF DOWNLOAD

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Ford Escort Shop Manual 1981 – 1997

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LANGUAGE:ENGLISH
PAGES:256
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FORD ESCORT SHOP MANUAL 1981 – 1997 – PDF DOWNLOAD:

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Ford Escort Shop Manual 1981 – 1997

Ford Escort maintenance schedule

• The maintenance intervals in this manual are provided with the assumption that you, not the dealer, will be carrying out the work. These are the minimum maintenance intervals recommended by the manufacturer for vehicles driven daily. If you wish to keep your vehicle in peak condition at all times, you may wish to perform some of these procedures more often.
• We encourage frequent maintenance, because it enhances the efficiency, performance and resale value of your vehicle. If the vehicle is driven in dusty areas, used to tow a trailer, or driven frequently at slow speeds (idling in traffic) or on short journeys, more frequent maintenance intervals are recommended.
• When the vehicle is new, it should be serviced by a factoryauthorised dealer service department, in order to preserve the factory warranty.

General information:

• This Chapter is designed to help the home mechanic maintain his/her vehicle for safety, economy, long life and peak performance. The Chapter contains a master maintenance schedule, followed by Sections dealing specifically with each task on the schedule. Visual checks, adjustments, component renewal and other helpful items are included. Refer to the accompanying illustrations of the engine compartment and the underside of the vehicle for the locations of the various components.
• Servicing of your vehicle in accordance with the mileage/time maintenance schedule and the following Sections will provide a planned maintenance program, which should result in a long and reliable service life. This is a comprehensive plan, so maintaining some items but not others at the specified service intervals will not produce the same results.
• As you service your vehicle, you will discover that many of the procedures can – and should – be grouped together because of the particular procedure being performed, or because of the close proximity of two otherwise unrelated components to one another. For example, if the vehicle is raised for any reason, the exhaust can be inspected at the same time as the suspension and steering components.

TABLE OF CONTENTS:

Ford Escort Shop Manual 1981 – 1997

Air cleaner element renewal 34
Alternator drivebelt check 20
Automatic transmission fluid level check27
Automatic transmission selector mechanism check28
Battery check 5
Brake components check 38
Brake fluid renewal 39
Contact breaker points adjustment – models with contact
breaker distributor13
Contact breaker points renewal 25
Coolant renewal 33
Crankcase emission control filter renewal 35
Distributor lubrication – models with contact breaker distributor 12
Driveshaft check 29
Engine oil and filter renewal 6
Exhaust manifold nut check – RS Turbo models 9
Exhaust system check 22
Fluid leak check 8
Fluid level checks 3
Front brake disc pad check 16
Fuel filter renewal – fuel injection engines 36
Hinge and lock check and lubrication 31
Idle speed and mixture adjustment 10
Ignition system components check 11
Ignition timing check – models with contact breaker distributor14
Intensive maintenance2
Introduction 1
Manual transmission oil level check 26
Oil filler cap cleaning – OHV and HCS engines 7
Rear brake shoe lining check17
Road test32
Roadwheel check30
Seat belt check 19
Spark plug renewal 24
Spark plug renewal – RS Turbo models 15
Suspension and steering check 18
Timing belt renewal 37
Turbocharger-to-manifold nut check – RS Turbo models 23
Tyre checks 4
Valve clearance adjustment – OHV and HCS engines 21
1•1
Easy, suitable for
novice with little
experience
Fairly easy, suitable
for beginner with
some experience
Fairly difficult, suitable
for competent DIY
mechanic
Difficult, suitable for
experienced DIY
mechanic
Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
Contents
1
Engine
Oil filter type Champion C104
Valve clearances (cold):
OHV engines:
Inlet 022 mm (0008 in)
Exhaust 059 mm (0023 in)
HCS engines:
Inlet 022 mm (0008 in)
Exhaust 032 mm (0012 in)
Cooling system
Recommended antifreeze concentration 45% by volume
Fuel system
Idle speed:
Carburettor models:
All except Weber 2V TLDM carburettor 750 to 850 rpm
Weber 2V TLDM carburettor 700 to 800 rpm
Bosch K-Jetronic fuel injection models750 to 850 rpm
Bosch KE-Jetronic fuel injection models:
1985 models 800 to 900 rpm
1986 models onwards920 to 960 rpm
Electronic Fuel Injection (EFI) models 900 ± 50 rpm
Idle mixture CO content:
Bosch K-Jetronic fuel injection models10 to 15 %
Bosch KE-Jetronic fuel injection models:
1985 models 025 to 075%
1986 models onwards05 to 11%
Electronic Fuel Injection (EFI) models 08 ± 025% (cooling fan running)
Air filter element type:
11 litre and 13 litre OHV engines Champion W153
11 litre and 13 litre HCS engines Champion W225
11 litre and 13 litre CVH engines Champion W127
14 litre CVH engine:
Carburettor engines Champion W179
Central Fuel Injection (CFI) engines Champion W201
16 litre CVH engine (except XR3 models):
Up to 1986 Champion W169
1986 to October 1988Champion W201
October 1988 on Champion W226
16 litre CVH engine (XR3 models) Champion W201
Ignition system
Contact breaker points gap:
Bosch distributor040 to 050 mm (0016 to 002 in)
Lucas distributor040 to 059 mm (0016 to 0023 in)
Dwell angle (contact breaker ignition system)48º to 52º
Ignition timing *:
OHV engines:
Up to 1984 (contact breaker) 12º BTDC at idle speed
1984-on (contact breaker) and all electronic ignition 6º BTDC at idle speed
CVH engines (all models) 12º BTDC at idle speed
* Note: Ignition timing on models with either a Distributorless Ignition Sytem (DIS) or a programmed ignition system (ESC) cannot be adjusted
Refer to Chapter 5, Part B for further information
Spark plugs:
Type:
OHV and HCS engines Champion RS9YCC or RS9YC
CVH engines:
Carburettor models Champion RC7YCC or RC7YC
Bosch K-Jetronic fuel injection and
Electronic Fuel Injection (EFI) modelsChampion C6YCC or RC6YC
Bosch KE-Jetronic fuel injection modelsChampion C61YC
Central Fuel Injection (CFI) models Champion RC7YCC or RC7YC4
Electrode gap:
All except HCS and CFI models:
RS9YCC, RC7YCC, C6YCC spark plugs08 mm (0032 in)
RS9YC, RC7YC, RC6YC,07 mm (0028 in)
HCS and CFI models 10 mm (0039 in)
1•2 Servicing Specifications
Servicing Specifications 1•3
1
Brakes
Minimum front brake disc pad thickness 15 mm (006 in)
Minimum rear brake shoe lining thickness10 mm (004 in)
Tyres
Tyre pressuresSee “Weekly checks” on page 0•16
Torque wrench settings Nm lbf ft
Exhaust manifold nuts – RS Turbo models14 to 17 10 to 13
Turbocharger-to-manifold nuts 21 to 26 15 to 19
Spark plugs:
OHV and HCS engines 13 to 20 10 to 15
CVH engines25 to 38 18 to 28
Seat belt anchor bolts 29 to 41 21 to 30
Roadwheel bolts 70 to 100 52 to 74
Capacities
Engine oil (drain and refill)
OHV engine:
With filter change 325 litres (57 pints)
Without filter change275 litres (48 pints)
CVH engine:
Carburettor engines with filter change:
Pre-July 1982375 litres (66 pints)
July 1982 onwards 350 litres (62 pints)
Carburettor engines without filter change:
Pre-July 1982350 litres (62 pints)
July 1982 onwards 325 litres (57 pints)
Fuel-injected engines with filter change385 litres (68 pints)
Fuel-injected engines without filter change360 litres (63 pints)
Fuel tank
All models (except XR3i and Van) pre-May 1983 40 litres (88 gallons)
All other models (except Van) 48 litres (106 gallons)
Van50 litres (110 gallons)
Cooling system
11 litre OHV engine 67 litres (118 pints)
11 litre CVH engine:
With small radiator 62 litres (110 pints)
With large radiator 72 litres (126 pints)
13 litre OHV engine 71 litres (125 pints)
13 litre CVH engine:
Pre-198671 litres (125 pints)
1986 onwards 76 litres (133 pints)
14 litre CVH engine 76 litres (133 pints)
16 litre CVH engine:
Pre-198669 litres (121 pints)
1986 onwards 78 litres (137 pints)
Transmission
4-speed manual 28 litres (49 pints)
5-speed manual 31 litres (55 pints)
Automatic transmission 79 litres (139 pints)

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