Ford Courier (1982) Workshop Manual

Factory Workshop Manual

Ford

Courier

L4-2299cc (1982)

Anonymous

1st January 2018

Make

Model

Engine and year

This manual was submitted by

Date

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by System > A L L Diagnostic Trouble Codes Engine Controls > System Information > System Diagnosis > Transmisson Codes

A L L Diagnostic Trouble Codes - Engine Controls: Testing and Inspection Transmisson Codes For Transmission related codes, proceed to Computers and Control Systems.

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by System > A L L Diagnostic Trouble Codes Trans and Drivetrain > System Information > System Diagnosis

A L L Diagnostic Trouble Codes - Trans and Drivetrain: Testing and Inspection For Transmission related codes, proceed to Computers and Control Systems.

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Spark Control Relay > Component Information > Description and Operation

Spark Control Relay: Description and Operation Fig. 37 - Spark Timing Control System This system, Fig. 37, used on 1977-78 1.8 liter, 1979-82 2.0 liter and 1981-82 2.3 liter California

with manual transmission models reduces exhaust emissions by delaying vacuum to the distributor vacuum advance unit during vehicle acceleration.

The system consists of a vacuum delay valve installed in the vacuum line between the carburetor and distributor on 1.8 liter and 2.0 liter engines except California, or between the water thermo valve and distributor on 2.0 liter California engines. On 2.3 liter engines, the system consists of a spark delay valve (manual transmission equipped models) and a distributor solenoid valve installed in the vacuum line between the intake manifold and distributor. The distributor solenoid valve is controlled by a timer and water thermo switch (also a distributor water thermo switch on vehicles with automatic transmission).

The spark delay valve has an internal restrictor to slow air flow in one direction and a check valve which allows free air flow in the opposite direction.

On 1979-82 California models, distributor vacuum advance is restricted by the water thermo valve which detects engine coolant temperature. This helps to warm up the catalytic converter.

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve

Spark Control Relay: Testing and Inspection Spark Delay Valve Spark Delay Valve, 1977-80, 1980-82 exc. Calif.

1. Remove air cleaner and disconnect vacuum line from distributor. Fig. 38 - Spark Delay Valve Test

2. On 1977-78, disconnect vacuum control line at intake manifold fitting and install distributor vacuum line to intake manifold fitting, Fig. 38.

Fig. 39 - Spark Delay Valve Test Fig. 40 - Spark Delay Valve Test

3. On 1979-82, disconnect air bypass line on California models, Figs. 39 and 40, or air anti-afterburn valve on except California models and connect

distributor vacuum line disconnected previously to intake manifold fitting.

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 19

Fig. 41 - Spark Delay Valve Test

4. Remove vacuum line from carburetor side of vacuum delay valve, then plug in and connect a vacuum gauge to vacuum delay valve, Figs. 39, 40

and 41.

5. Start engine and allow to idle.

6. Disconnect vacuum line from intake manifold fitting. NOTE:The time required for vacuum reading to drop to 11.8 inches Hg. If amount of time is not

within 4-6 seconds, replace valve. Spark Delay Valve, 1981-82 2.3L Calif, 1982 2.OL Calif.

Fig. 42 - Spark Delay Valve Test

1. Disconnect vacuum sensing tube from spark delay valve at distributor solenoid and connect a vacuum gauge to tube.

NOTE: On 1982 vehicles, add a 30mm vacuum reservoir between spark delay valve and vacuum gauge.

2. Disconnect vacuum sensing tube from spark delay valve at distributor vacuum advance unit and connect tube to intake manifold.

3. Start engine and note vacuum reading at idle.

4. Disconnect tube from intake manifold and check time required for vacuum reading to drop decrease by 11.8 inches Hg. vacuum. Time required

should be 5 ± 1 seconds.

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 20

Spark Control Relay: Testing and Inspection Distributor Solenoid Valve

1. Start engine and allow to idle.

2. Separate connector at distributor solenoid valve and apply battery voltage to the two terminals to energize the solenoid.

3. Disconnect vacuum sensing tube from distributor solenoid valve at distributor vacuum advance.

4. Disconnect battery power from solenoid. Solenoid is functioning properly if vacuum is drawn into vacuum sensing tube when battery is

disconnected.

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 21

Spark Control Relay: Testing and Inspection Spark Control Timer Timer Test, 2.3L Calif. Fig. 43 - Timer Test

1. Remove timer.

2. Connect suitable test wires to timer terminals A, B and C respectively.

3. Connect a suitable test wire with a 30K ohm resistor to terminal D.

4. Connect a suitable test wire with a 3.4 watt lamp to terminal E.

5. Connect positive leads of a voltmeter to terminal D and negative test lead to battery negative terminal.

6. Connect test wires from timer terminals A, D and E to battery positive terminal. Do not connect test wire from terminal B at this time.

7. Connect wire from terminal C to battery negative terminal.

8. Voltmeter should not read 6 volts.

9. Connect test wire from timer terminal B with battery positive terminal. At the instant the connection is made, the volt. meter should read less than

1 volt and lamp should illuminate. Maintain this connection for 125 ± 15 seconds. Voltmeter should read 8 volts.

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 22

Spark Control Relay: Testing and Inspection Water Thermo Switch Water Thermo Switch, 2.3L Calif.

1. Remove thermo switch.

2. Connect an ohmmeter across the switch terminals and place sensor end of switch in a water filled container. Place a thermometer into water and

gradually heat water while observing thermometer.

3. Note temperature at which continuity exists between switch terminals. The specified temperature is 131 ±4°F. Replace switch if temperature is not

within specifications. Distributor Water Thermo Switch, 2.3L With Auto. Trans., Calif. The procedure to test this switch is the same as the one described previously for the Water Thermo

Switch, 2.3L Calif. However, the specified temperature is 50 ±4°F or above.

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications

Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical Service Bulletins > Customer Interest for Washer Fluid Level Switch: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On

Washer Fluid Level Switch: Customer Interest Wiper/Washer - Low Fluid Warning Light Stays On

Article No. 84-21-9 WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING

LIGHT LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT On some vehicles equipped with low fluid warning light, the light may stay on even when the

washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that has not been mixed with water according to the instructions. The undiluted washer solution is absorbed by the float resulting in the float sinking.

When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions on the can must be followed. Mixing the concentrated washer fluid with water will stop the float from sinking.

OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Washer Fluid Level Switch: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On

Washer Fluid Level Switch: All Technical Service Bulletins Wiper/Washer - Low Fluid Warning Light Stays On

Article No. 84-21-9 WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING

LIGHT LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT On some vehicles equipped with low fluid warning light, the light may stay on even when the

washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that has not been mixed with water according to the instructions. The undiluted washer solution is absorbed by the float resulting in the float sinking.

When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions on the can must be followed. Mixing the concentrated washer fluid with water will stop the float from sinking.

OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications

Alignment: Specifications Caster

Standard ..............................................................................................................................................

......................................................... +3/4° - 1 1/4°

Camber

Standard ..............................................................................................................................................

......................................................... +1/2° - 1 1/4°

Toe-inches

Standard ..............................................................................................................................................

.................................................................. 0" - 1/4"

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications

Fuel Pressure: Specifications FUEL PRESSURE

Pump Pressure ....................................................................................................................................

................................................................ 2.8 - 3.6 psi

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel Filter - Replacement Information

Fuel Filter: Technical Service Bulletins Fuel Filter - Replacement Information Article No. 85-6-10 FUEL FILTER REPLACEMENT INFORMATION - ALL WITH FUEL FILTERS ATTACHED TO THE

CARBURETOR AND/OR FUEL LINE WITH A RUBBER HOSE FORD ALL 1985 AND PRIOR LINCOLN-MERCURY ALL 1985 AND PRIOR LIGHT TRUCK ALL 1985 AND PRIOR New fuel connector hoses and clamps should be used whenever a fuel filter is replaced. Due to possible deterioration of hose materials which may result if a vehicle is fueled with gasoline

containing excessive levels of methanol or ethanol, a new fuel hose and clamps should be installed when the fuel filter is changed. DO NOT REUSE OLD HOSES OR CLAMPS.

OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY"

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel Filter - Replacement Information

Fuel Filter: Technical Service Bulletins Fuel Filter - Replacement Information Article No. 85-6-10 FUEL FILTER REPLACEMENT INFORMATION - ALL WITH FUEL FILTERS ATTACHED TO THE

CARBURETOR AND/OR FUEL LINE WITH A RUBBER HOSE FORD ALL 1985 AND PRIOR LINCOLN-MERCURY ALL 1985 AND PRIOR LIGHT TRUCK ALL 1985 AND PRIOR New fuel connector hoses and clamps should be used whenever a fuel filter is replaced. Due to possible deterioration of hose materials which may result if a vehicle is fueled with gasoline

containing excessive levels of methanol or ethanol, a new fuel hose and clamps should be installed when the fuel filter is changed. DO NOT REUSE OLD HOSES OR CLAMPS.

OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY"

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Hoses > System Information > Service Precautions

Hoses: Service Precautions SERVICE PRECAUTIONS To prevent vehicle damage, always observe the following precautions: After servicing a hose, check for leaks before and after test driving the vehicle.

- Always use the correct size hose. Do not use standard sized hose in place of metric hose or vice versa.

Always use the correct type of hose. Never use vacuum hose in place of fuel hose. Never use

heater hose in place of PCV hose.

- When replacing hoses which are attached to the engine on one end and the frame or body on the other end, always leave sufficient length to compensate for engine movement (from torque).

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips

Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips Article No. 95-18-2 09/11/95 ^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP ^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT

1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994 and after ASPIRE 1995 and after CONTOUR

LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and after MYSTIQUE

MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after

BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR

This TSB is being republished in its entirety to include warranty information when using recycled coolant

ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda Coolant Recycler (181-00003) process is the only approved coolant recycling method available through Ford that is capable of producing recycled engine coolant that meets Ford specification ESE-M97B44-A.

ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using Rotunda Coolant Recycler (181-00003).

NOTE: WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE

PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND LABELING CONCERNS

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 68

ASSOCIATED WITH THE RETAIL SALE OF CHEMICAL PRODUCTS. CAUTION: THE REINHIBITOR CHEMICALS PROVIDED WITH THIS EQUIPMENT ARE NOT

APPROPRIATE FOR USE ON MEDIUM/HEAVY TRUCK APPLICATIONS. WARNING: ROTUNDA PREMIUM COOLANT REINHIBITORS # 1 AND # 2 HAVE BEEN SPECIFICALLY

FORMULATED TO WORK WITH ROTUNDA COOLANT RECYCLER (181-00003). USE OF ANY OTHER CHEMICAL ADDITIVES WITH THIS SYSTEM WILL VOID ALL

WARRANTIES FOR THE EQUIPMENT AND FOR THE FINAL COOLANT PRODUCT. SERVICE PROCEDURE DIRECTIONS FOR PROCESSING USED ENGINE COOLANT WITH ROTUNDA COOLANT

RECYCLER

1. Close the drain valve on the unit.

2. Open the fill valve.

3. Pour used engine coolant into the funnel on the side of the unit. NOTE: MAXIMUM CAPACITY 15 25 GALLONS (95 L).

4. Insert the outlet hoses of the recycler into clean, properly labeled containers. One (1) container is for the outlet process water and the other container is for distilled ethylene glycol.

5. Push the "ON" switch on the front to start the operation. The unit will process 1 gallon (3.8 L) per hour of operation and will automatically shut off when cycle is complete.

6. Add reinhibitor following the directions in this article.

7. Open the drain valve to drain the residue from the distillation vessel. Dispose of residue in accordance with all local. state and federal regulations.

ADDING REINHIBITOR CHEMICALS

1. Process the coolant according to the directions listed in this article

2. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 1 to each gallon of distilled ethylene glycol.

3. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 2 to each gallon of distilled ethylene glycol.

4. Mix well.

5. Check the pH level of the coolant. The pH level must be between 9 and 11.

6. Add enough water to the concentrated coolant to produce a 50/50 mixture of coolant and water. NOTE: THE CONCENTRATED COOLANT MUST BE MIXED WITH WATER TO MEET THE

NECESSARY ENGINE FREEZE PROTECTION.

7. Check the coolant freeze point of the 50% coolant solution. Freeze point should be -34°F (-37°C).

Consult the Rotunda Coolant Recycler Manual for more detailed operating instructions. Call 1-800-ROTUNDA, 8 AM to 8 PM EST, for inquiries regarding the Rotunda Coolant Recycler and to order the Reinhibitor (187-R0001).

PART NUMBER PART NAME Rotunda # 187-R0001 Rotunda Premium Coolant Reinhibitor WARRANTY CLAIMS: Dealer can claim recycled engine coolant by Ford approved process via a

warranty repair on an 1863 claim as follows: Part Number: RECCOOL (not a valid part number, but it is recognized on an 1863 claim).

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 69

Quantity: Indicate the number of QUARTS of recycled coolant used. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-16-6 WARRANTY STATUS:

INFORMATION ONLY OASIS CODES: 402000

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications

Coolant: Capacity Specifications Coolant Capacity 8.8 qts

..............................................................................................................................................................

.........................................

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 72

Coolant: Fluid Type Specifications COOLING SYSTEM FLUID, PREMIUM Ford Part No. U.S.A (Except Oregon)

............................................................................................................................................................

E2FZ-19549-AA or -B Canada ............................................................................................................

.............................................................................................. CXC-8-B Oregon ..................................

.............................................................................................................................................................

F5FZ-19549-CC

Ford Specification ................................................................................................................................

................................................... ESE-M97B44-A

COOLING SYSTEM FLUSH

Ford Part No. .......................................................................................................................................

................................................... F1AZ-19A503-A Ford Specification .................................................

..................................................................................................................................... ESR-M14P7-A

Coolant Mixture with Water .................................................................................................................

...................................................................... 50%

Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type.

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - Oil Level Checking Procedure

Engine Oil: Technical Service Bulletins Engine - Oil Level Checking Procedure Article No. 85-25-20 OIL DIPSTICK - ENGINE OIL LEVEL CHECKING PROCEDURE - GASOLINE ENGINES LIGHT TRUCK 1986 AND PRIOR MEDIUM/HEAVY TRUCK 1986 AND PRIOR Figure 17 - Dipstick To correctly check the engine oil level, the vehicle must be parked on a level surface. Allow a few

minutes after shutting the engine off for oil to drain down before checking. For consistent oil level readings, insert the dipstick with the loop of the handle as shown in Figure 17.

Figure 18 - Dipstick - Calibration Figure 19 - Dipstick - Calibration Dipsticks in Ford vehicles do not incorporate a Full mark. Instead, the dipstick will have marks

indicating a Safe range and an Add range as shown in Figure 18 or 19. When the correct amount of oil is in the engine, the oil level indication will be in the Safe range or above the Minimum mark, but not necessarily at the top of the Safe range or at the Maximum mark.

When the indicated oil level is in the Add range put one quart of oil in the engine. Recheck the oil level to determine if the oil level is now in the Safe range or above the Minimum mark.

Add and recheck oil level one quart at a time until the oil level indicator moves into the Safe range or above the Minimum mark. Do not add additional oil to bring the level to the top of the Safe range or to the Maximum mark since this may result in overfill and increased oil consumption. If the accuracy of the engine oil dipstick is in doubt, it may be verified in the following manner:

^ Drain the oil and install a new filter. ^ Put in the specified amount of oil for an oil and filter change. (See owner guide) ^ Start the engine and operate a few minutes. ^ Shut off the engine and allow a few minutes for the oil to drain down. ^ Check the oil level with the dipstick. ^ If the oil level does not indicate in the Safe range or above the Minimum mark, rework or replace

the dipstick. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Air Conditioning - Use of Correct Fluorescent Tracer Dye

Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP

1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE

LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER

LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER

ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems.

ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company.

NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS

CODES: 208999

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Air Conditioning - Use of Correct Fluorescent Tracer Dye > Page 81

Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes Article No. 94-14-3 07/13/94 Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP

1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE

LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER

MERKUR: 1986-89 SCORPIO, XR4TI LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90

BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993 VILLAGER

MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000, CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES

This TSB is being republished in its entirety to include Heavy Truck models. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct

replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C system components.

ACTION: If service is required, use only NEW or RECYCLED refrigerant R-12. Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time.

R-134a is approved only for systems which specify R-134a,

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Air Conditioning - Use of Correct Fluorescent Tracer Dye > Page 82

and is not compatible with R-12 systems. R-22 likewise, is not compatible with R-12 systems. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN

SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: 91-9-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Page 83

Refrigerant: Specifications

Type .....................................................................................................................................................

............................................... Refrigerant 12 (R-12) Ford Part Number .............................................

........................................................................................................................................

D4AZ-19B519-A

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications

Refrigerant Oil: Specifications

Compressor ................................................................................................................... 500 viscosity

(C9AZ-19557-B or Motorcraft VN-2 or equivalent)

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > System Information > Service Precautions

Fuses and Circuit Breakers: Service Precautions FUSE AND CIRCUIT BREAKER PRECAUTIONS When replacing a blown fuse or defective circuit breaker, it is important to use only a fuse or circuit

breaker having the correct amperage rating. The use of a fuse or circuit breaker with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse or circuit breaker continues to blow or trip, it indicates a problem in the circuit that must be corrected.

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > EGR Maintenance Light > Component Information > Service and Repair

EGR Maintenance Light: Service and Repair EGR Warning Switch Reset NOTE: After performing the necessary EGR system maintenance, the EGR warning lamp switch can be

reset. The switch is installed behind the speedometer and is reset as follows: Procedure

1. Remove cover from switch.

2. Slide the switch knob to the opposite position and the warning lamp will go out.

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - Oil Level Checking Procedure

Engine Oil: Technical Service Bulletins Engine - Oil Level Checking Procedure Article No. 85-25-20 OIL DIPSTICK - ENGINE OIL LEVEL CHECKING PROCEDURE - GASOLINE ENGINES LIGHT TRUCK 1986 AND PRIOR MEDIUM/HEAVY TRUCK 1986 AND PRIOR Figure 17 - Dipstick To correctly check the engine oil level, the vehicle must be parked on a level surface. Allow a few

minutes after shutting the engine off for oil to drain down before checking. For consistent oil level readings, insert the dipstick with the loop of the handle as shown in Figure 17.

Figure 18 - Dipstick - Calibration Figure 19 - Dipstick - Calibration Dipsticks in Ford vehicles do not incorporate a Full mark. Instead, the dipstick will have marks

indicating a Safe range and an Add range as shown in Figure 18 or 19. When the correct amount of oil is in the engine, the oil level indication will be in the Safe range or above the Minimum mark, but not necessarily at the top of the Safe range or at the Maximum mark.

When the indicated oil level is in the Add range put one quart of oil in the engine. Recheck the oil level to determine if the oil level is now in the Safe range or above the Minimum mark.

Add and recheck oil level one quart at a time until the oil level indicator moves into the Safe range or above the Minimum mark. Do not add additional oil to bring the level to the top of the Safe range or to the Maximum mark since this may result in overfill and increased oil consumption. If the accuracy of the engine oil dipstick is in doubt, it may be verified in the following manner:

^ Drain the oil and install a new filter. ^ Put in the specified amount of oil for an oil and filter change. (See owner guide) ^ Start the engine and operate a few minutes. ^ Shut off the engine and allow a few minutes for the oil to drain down. ^ Check the oil level with the dipstick. ^ If the oil level does not indicate in the Safe range or above the Minimum mark, rework or replace

the dipstick. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Crankshaft Seal - Leaks, Air Pressure Test

Crankshaft Main Bearing Seal: Technical Service Bulletins Crankshaft Seal - Leaks, Air Pressure Test

Article No. 86-3-14 LEAK OIL - CRANKSHAFT SEAL - AIR PRESSURE TEST FORD 1986 and Prior FORD, THUNDERBIRD, LTD, ESCORT, FAIRMONT, MUSTANG, EXP,

TAURUS LINCOLN-MERCURY 1986 and Prior LINCOLN, MARK, CONTINENTAL, MERCURY, MARQUIS,

COUGAR, CAPRI, LYNX, LN7, SABLE LIGHT TRUCK 1986 and Prior RANGER, BRONCO II, AEROSTAR, E AND F SERIES To prevent repeat servicing on engines suspected of oil leakage at the crankshaft seal, determine if

the leak is actually from the seal or from another source such as the rear pan seal or galley plugs. The one-piece rear crankshaft seal is released for all passenger car and light truck engines and has proven to be more reliable than the rope or split lip design formerly used.

Performing the oil leak air pressure check outlined in all Car and Truck Powertrain Shop Manuals, Section 21- 01 will accurately identify the location of the leak and can verify correction after servicing before the transmission is reinstalled.

OTHER APPLICABLE ARTICLES: 80-15-5, 83-14-8 WARRANTY STATUS: "INFORMATION ONLY"

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications

Fuel Pressure: Specifications FUEL PRESSURE

Pump Pressure ....................................................................................................................................

................................................................ 2.8 - 3.6 psi

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel Filter - Replacement Information

Fuel Filter: Technical Service Bulletins Fuel Filter - Replacement Information Article No. 85-6-10 FUEL FILTER REPLACEMENT INFORMATION - ALL WITH FUEL FILTERS ATTACHED TO THE

CARBURETOR AND/OR FUEL LINE WITH A RUBBER HOSE FORD ALL 1985 AND PRIOR LINCOLN-MERCURY ALL 1985 AND PRIOR LIGHT TRUCK ALL 1985 AND PRIOR New fuel connector hoses and clamps should be used whenever a fuel filter is replaced. Due to possible deterioration of hose materials which may result if a vehicle is fueled with gasoline

containing excessive levels of methanol or ethanol, a new fuel hose and clamps should be installed when the fuel filter is changed. DO NOT REUSE OLD HOSES OR CLAMPS.

OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY"

Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips