Ford - Courier - Workshop Manual - 1982 - 1982

Factory Workshop Manual Make Ford Model Courier Engine and year L4-2299cc (1982) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 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 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 > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 119 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 > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 120 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 > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 8.8 qts .............................................................................................................................................................. ......................................... Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 123 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 > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > 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 > Engine, Cooling and Exhaust > 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 > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips Heater Core: Technical Service Bulletins Heater Core - Leakage Diagnostic Tips Article No. 85-8-2 HEATER CORE - LEAK - DIAGNOSTIC TIPS FORD ALL LINCOLN-MERCURY ALL LIGHT TRUCK ALL Good heater cores are being returned through the parts return system coded as leaking. Complaints of leaking may be caused by an inadequate seal between the heater hose and the heater core tubes allowing coolant to follow the tube to the heater core, leak into the passenger compartment and appear as a leaking heater core. When diagnosing a suspect heater core leak, inspect the hose to heater core tube attachment to assure the connection is not leaking. If a leaking connection is found, correct the leak. If the connection appears not to be leaking, leak test the heater core before removing it from the vehicle using the following procedure: HEATER CORE LEAK TEST Pressure Test 1. Drain the coolant from the cooling system. 2. Disconnect the heater hoses from the heater core tubes. 3. Install a short piece of heater hose (approximately 4 inches long) on each heater core tube. Figure 1 4. Fill the heater core and hoses with water and install plug BT-7422-B and adapter BT-7422-A from Rotunda model 021-00012 or equivalent in the hose ends (Figure 1). Secure the hoses, plug and adapter with hose clamps. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 136 Figure 2 Figure 3 - TOOL 021-00012 WITH HEATER HOSE AND CLAMPS 5. Attach the pump and gauge assembly Rotunda model 021-00012 or equivalent to the adapter (Figure 2). Close the bleed valve at the base of the gauge and pump 30 psi of air pressure into the heater core (Figure 3). 6. Observe the pressure gauge for a minimum of three minutes. The pressure should not drop. 7. If the pressure does not drop, no leaks are indicated. 8. If the pressure drops, check the hose connections to the core tubes for leaks. If the hoses do not leak, remove the heater core from the vehicle and perform the bench test. Bench Test 1. Drain all coolant from the heater core. Figure 4 - HEATER CORE BENCH TEST 2. Connect the 4-inch test hoses with plug and adapter to the core tubes. Then connect the air pump and gauge assembly to the adapter (Figure 4). 3. Apply 30 psi of air pressure to the heater core with Rotunda model 021-00012 or equivalent, and submerge the core in water. 4. If a leak is observed, service or replace the heater core as necessary. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 137 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > 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 > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation Some 1976-82 vehicles use a catalytic converter to reduce hydrocarbon and carbon monoxide exhaust emission levels. These vehicles are also equipped with a catalyst warning system. This system is comprised of a thermo sensor on the catalytic converter, monitoring converter temperature, and a warning lamp on the instrument panel which illuminates when the thermo sensor detects converter temperatures over 1742°F. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 147 Catalytic Converter: Testing and Inspection Warning System Test 1. Turn ignition switch to "On" position. The warning lamp should illuminate, indicating that the bulb and electrical wiring are satisfactory. If lamp does not light, check bulb. 2. Start engine and if the system is satisfactory, the warning lamp should go out. If not, stop engine and tilt the seatback forward. Fig. 31 - Catalyst Warning System Test 3. Disconnect the catalytic converter thermo sensor electrical connectors, Fig. 31. 4. With an ohmmeter, check the circuit on the thermo sensor side of the wiring for continuity, Fig. 31. Replace the thermo sensor if the reading indicates no continuity. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Muffler - Unnecessary Replacement Muffler: Technical Service Bulletins Muffler - Unnecessary Replacement Article No. 83-11-11 EXHAUST - MUFFLER - POWER LOW - UNNECESSARY MUFFLER REPLACEMENT LIGHT TRUCKS 1982 AND LATER LIGHT TRUCKS Mufflers are being replaced on leaded fuel vehicles in an effort to resolve concerns of "lack of power" or poor performance", apparently in the belief that a plugged muffler is the cause. Although plugging with lead deposits was possible on certain models prior to the 1982 Model Year, muffler modifications incorporated on 1982 and later models make this an unlikely cause of the concern. Thus, replacing mufflers on the newer model vehicles normally will not satisfy the customer. Prior to replacing any muffler believed to be restricted, a vacuum check as described in Section 26-01 of the Light Truck Shop Manual should be performed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > 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 > Powertrain Management > 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 > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 160 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 > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 161 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 > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 162 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 > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 163 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 > Powertrain Management > 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 > Powertrain Management > 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 > Powertrain Management > Computers and Control Systems > 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 > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications Idle Speed/Throttle Actuator - Electronic: Technical Service Bulletins High Altitude Driveability Modifications Article No. 82-11A-1O June 4, 1982 Subject: Modification Of Sea Level Calibrations For Altitude Applications Light Trucks 1982 Courier - All Except 2.0L High Altitude Calibration Applicable Model: WARNING: This Modification Is Authorized Only For The Listed Engines. Performing This Modification On Other Engines Is Unauthorized And Could Create Liability Under Applicable Federal Or Local Laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitudes (above 4,000 ft. altitude) may have the following procedures performed to improve performance: 1. Remove the air cleaner and duct assembly. 2. Remove the bolts attaching the accelerator shaft to the throttle lever. 3. Disconnect the fuel line and fuel return line at the carburetor. 4. Disconnect the leads for the slow fuel cut valve (throttle solenoid) and coasting richer (deceleration valve) (2.3 litre only) at the quick disconnects. Also, disconnect the carburetor-to-distributor vacuum line at the carburetor. Disconnect the hose connecting the carburetor to the vacuum amplifier. Disconnect the vacuum hose for the purge control valve. 5. Disconnect the throttle return spring (2.3 litre only). Then, disconnect the lead wire for the automatic choke. Remove the servo diaphragm link for the throttle opener (2.0 litre only). 6. Using Tool T72J-9510, remove the carburetor attaching nuts from the intake manifold studs and remove the carburetor. 7. Remove the locking plate (only for Courier 2.3 litre and Courier chassis cab). 8. Remove the plugs and main jets from the carburetor. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications > Page 181 Figure 7 9. Install the high altitude jets indicated in the table (Figure 7.) 10. Install the plugs. 11. Install the locking plate (only for Courier 2.3 litre and Courier chassis cab). 12. Position the carburetor and a new gasket on the intake manifold and install the attaching nuts. 13. Connect the throttle return spring (2.3 litre only). 14. Connect the accelerator shaft to the throttle lever and install the attaching bolts. 15. Connect the slow fuel cut valve, automatic choke, and coasting richer (2.3 litre only) leads at the quick disconnect. 16. Connect the carburetor-to-distributor vacuum line. Connect the vacuum hose for the purge control valve. 17. Connect the fuel line and fuel return line to the carburetor. Install the air cleaner and duct assembly. 18. Start the engine and check for fuel leaks. 19. For 2.3 litre California Courier with manual transmission, adjust the dash pot as per "1981 Ford Courier Truck Shop Manual", Deceleration Control System, Section 29-03-05. 20. For 2.0 litre Courier, adjust the throttle positioner system as per "1981 Ford Courier Truck Shop Manual", Deceleration Control System, Section 29-03-06. Install a Courier Vehicle Emission Control Information Update Label (available at all Ford or Lincoln-Mercury dealers) in a prominent place adjacent to the Vehicle Emission Control Information Label. Do not install the label on any component that can be easily detached from the vehicle. Clean the area before installing the label. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications > Page 182 Vehicle Emission Control Information Update Label for Low Altitude Adjustment: This label is attached firmly to a readily visible position and beside to the existing vehicle emission control information label, Do not Install the label on any equipment that can be easily detached from the vehicle. NOTE: The Vehicle Emission Control Information Update Label is a new label to be used for altitude modifications. Do not Use the Authorized Modifications label which is used to indicate other types of modifications. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the Vehicle Emission Control Information Update Label should be removed. Install the low altitude jets and make the required adjustments. WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. Coding: Basic Part No. Code: L05 53 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Testing and Inspection Air Injection Bypass Valve: Testing and Inspection 1. Disconnect air hose at the check valve. 2. Open the choke and start and run engine at 1500 RPM. Air should flow from the hose. 3. Close choke. No air should flow from the hose at full choke. Replace bypass valve if air flow is noted. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Testing and Inspection Air Injection Check Valve: Testing and Inspection Fig. 7 - Air Manifold Check Valve Test 1. Remove check valve from air injection manifold. 2. Blow through the intake side of the valve, then the outlet side, Fig. 7. 3. Air should pass through the valve from the intake side only. If air passes from the outlet side, replace the check valve. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection Air Injection Control Valve: Testing and Inspection AUTOMATIC TRANSMISSION Fig. 8b - Air Control Valve Test Fig. 8c - Air Control Valve Test 1. Disconnect air hose at bottom of air control valve, Figs. 8B and 8C. 2. Start and run engine at idle speed. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Page 194 3. Air should not be discharged from air control valve outlet port. 4. Disconnect intake manifold vacuum line from top of air control valve. Air should now be discharged from the outlet port. 5. If valve does not operate properly, replace air control valve, if necessary. 1977-79 MANUAL TRANSMISSION Fig. 8D - Air Control Valve Test 1. Disconnect air hose from bottom of air control valve, Fig. 8D. 2. Start and run engine at idle speed. 3. Disconnect vacuum line from air bypass valve. Air should be discharged from air control valve outlet port. 4. Plug the disconnected air bypass valve vacuum line. No air should be discharged from the outlet port. Fig. 9 - Air Control Valve Test 5. Disconnect intake manifold vacuum line from the No. 2 relief valve. Remove plug from disconnect air bypass valve vacuum line and connect line Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Page 195 to the No. 2 relief valve, Fig. 9. Air should be discharged from the air control valve outlet port. 6. If valve does not operate properly, check vacuum lines and replace air control valve, if necessary. 1980-82 MANUAL TRANSMISSION Fig. 9A - Air Control Valve Test Fig. 9B - Air Control Valve Test 1. Start engine and bring to normal operating temperature. 2. Shut engine off, and disconnect air hose from bottom of air control valve, Figs. 9A and 9B. 3. Start engine and run at idle speed. 4. Disconnect vacuum control line from No. 1 relief valve of air control valve. Observe outlet port of air control valve. Air should be discharged. 5. Reconnect vacuum control line to No. 1 relief valve of air control valve. Observe outlet port of air control valve. Air should not be discharged. 6. Disconnect vacuum control line from No. 2 relief valve of air control valve. 7. Disconnect vacuum line from air bypass valve on 2.3 Liter engines, or from the EVAP shutter valve on 2.0 Liter engines. Reconnect this line to the Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Page 196 No. 2 relief valve of the air control valve. Observe outlet port of air control valve. Air should be discharged. 8. Disconnect vacuum control line from No. 2 relief valve of air control valve. Connect this line to the air bypass valve on 2.3 Liter engines, or to the EVAP shutter valve on 2.0 Liter engines. Observe outlet port of air control valve. Air should not be discharged. 9. If valve does not operate properly, check vacuum lines, and replace air control valve if required. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Testing and Inspection Air Injection Pump: Testing and Inspection 1. Disconnect air pump outlet hose from bypass valve or air control valve. Fig. 5 - Air Pump Test 2. Connect a tee fitting in the outlet hose and connect a pressure gauge to the tee fitting. Also, insert a plug with a 11/32 inch hole in the remaining port of the tee fitting, Fig. 5. 3. Start and run engine at 1250-1500 RPM. Ensure the choke is fully open. 4. Check pressure reading. If below 1 psi, replace the air pump. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Relief Valve > Component Information > Testing and Inspection Air Injection Relief Valve: Testing and Inspection Fig. 6 - Air Pump Relief Valve Test 1. With engine operating at idle speed, check relief valve for air flow, Fig. 6. If air flow is noted, replace the relief valve and air pump assembly. 2. Increase engine speed to 3000 RPM on 1972-77 and 4500 on 1978-82. If air flows from the valve, the valve is satisfactory. If air does not flow from the valve or if the valve is excessively noisy, replace the relief valve and air pump assembly. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation Some 1976-82 vehicles use a catalytic converter to reduce hydrocarbon and carbon monoxide exhaust emission levels. These vehicles are also equipped with a catalyst warning system. This system is comprised of a thermo sensor on the catalytic converter, monitoring converter temperature, and a warning lamp on the instrument panel which illuminates when the thermo sensor detects converter temperatures over 1742°F. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 206 Catalytic Converter: Testing and Inspection Warning System Test 1. Turn ignition switch to "On" position. The warning lamp should illuminate, indicating that the bulb and electrical wiring are satisfactory. If lamp does not light, check bulb. 2. Start engine and if the system is satisfactory, the warning lamp should go out. If not, stop engine and tilt the seatback forward. Fig. 31 - Catalyst Warning System Test 3. Disconnect the catalytic converter thermo sensor electrical connectors, Fig. 31. 4. With an ohmmeter, check the circuit on the thermo sensor side of the wiring for continuity, Fig. 31. Replace the thermo sensor if the reading indicates no continuity. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Description and Operation > Air Bypass Valve, Turbocharger Deceleration Valve: Description and Operation Air Bypass Valve, Turbocharger This valve prevents afterburning in the exhaust system during deceleration. At the start of sudden deceleration, a rich air-fuel mixture is present in the intake manifold and is supplied to each cylinder. This rich fuel mixture does not burn completely during normal combustion and is discharged into the exhaust system. The air supplied from the air pump to the exhaust port dilutes the unburned rich mixture to a combustible mixture, causing abnormal burning or afterburning in the exhaust system. To prevent this, the air bypass valve senses the high intake manifold vacuum and diverts the air. On 1977-78 models, this air is diverted into the air pump inlet. On 1979-82 models, most of the air is diverted to the air pump inlet while some of it is diverted to the intake manifold. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Description and Operation > Air Bypass Valve, Turbocharger > Page 211 Deceleration Valve: Description and Operation Anti-Afterburn Valve Fig. 14 - Anti-Afterburn Valve The anti-afterburn valve, Fig. 14, is controlled and operated by intake manifold vacuum. The valve is activated when intake manifold vacuum suddenly increases and is kept open in proportion to the amount of pressure change sensed by the diaphragm of the valve system. The diaphragm is installed with the check valve and the metering orifice. The check valve permits air flow only from the vacuum sensing chamber to the air chamber. Therefore, if the air in the vacuum sensing tube decreases, the check valve opens and allows air flow into the air chamber to equalize the vacuum of both chambers. If the vacuum increases, the check valve closes and the diaphragm moves downward until the air flow through the metering orifice equalizes the vacuum. When the diaphragm is pushed downward, the air valve opens to allow air flow to the intake manifold. However, as the pressure is equalized, the spring returns the diaphragm and air valve to the closed position. The time required to equalize the vacuum is in proportion to the amount of vacuum change applied to the diaphragm. As the anti-afterburn valve completes its operation, the deceleration valve adds additional fuel to enrichen the lean mixture created in the intake manifold by the deceleration action. This additional fuel permits more complete combustion and reduced emission contaminants. The deceleration valve operates when all its controlling switches are closed. The accelerator switch closes the circuit when the accelerator pedal is released. The speedometer switch closes the circuit at speeds above 17-23 mph. On 1972-74 models, the clutch switch closes the circuit when the clutch pedal is released. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Description and Operation > Air Bypass Valve, Turbocharger > Page 212 Deceleration Valve: Description and Operation Coasting Valve This valve adds additional fuel to the lean air fuel mixture caused by deceleration. This additional fuel insures more complete combustion and reduces exhaust emissions. This valve is controlled by two switches; the speedometer switch and accelerator switch. Both of these switches must be closed in order for the coasting richer valve to function. The accelerator switch closed the coasting richer circuit whenever the accelerator pedal is in the released position. Depressing the accelerator pedal opens the circuit. The speedometer switch completes the circuit at speeds above 17 to 23 mph. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Description and Operation > Air Bypass Valve, Turbocharger > Page 213 Deceleration Valve: Description and Operation Dashpot The dashpot prevents instant throttle closure when the accelerator pedal is released for slowing down or shifting the transmission. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Description and Operation > Air Bypass Valve, Turbocharger > Page 214 Deceleration Valve: Description and Operation Air Bypass Valve, Turbocharger This valve prevents afterburning in the exhaust system during deceleration. At the start of sudden deceleration, a rich air-fuel mixture is present in the intake manifold and is supplied to each cylinder. This rich fuel mixture does not burn completely during normal combustion and is discharged into the exhaust system. The air supplied from the air pump to the exhaust port dilutes the unburned rich mixture to a combustible mixture, causing abnormal burning or afterburning in the exhaust system. To prevent this, the air bypass valve senses the high intake manifold vacuum and diverts the air. On 1977-78 models, this air is diverted into the air pump inlet. On 1979-82 models, most of the air is diverted to the air pump inlet while some of it is diverted to the intake manifold. Anti-Afterburn Valve Fig. 14 - Anti-Afterburn Valve The anti-afterburn valve, Fig. 14, is controlled and operated by intake manifold vacuum. The valve is activated when intake manifold vacuum suddenly increases and is kept open in proportion to the amount of pressure change sensed by the diaphragm of the valve system. The diaphragm is installed with the check valve and the metering orifice. The check valve permits air flow only from the vacuum sensing chamber to the air chamber. Therefore, if the air in the vacuum sensing tube decreases, the check valve opens and allows air flow into the air chamber to equalize the vacuum of both chambers. If the vacuum increases, the check valve closes and the diaphragm moves downward until the air flow through the metering orifice equalizes the vacuum. When the diaphragm is pushed downward, the air valve opens to allow air flow to the intake manifold. However, as the pressure is equalized, the spring returns the diaphragm and air valve to the closed position. The time required to equalize the vacuum is in proportion to the amount of vacuum change applied to the diaphragm. As the anti-afterburn valve completes its operation, the deceleration valve adds additional fuel to enrichen the lean mixture created in the intake manifold by the deceleration action. This additional fuel permits more complete combustion and reduced emission contaminants. The deceleration valve operates when all its controlling switches are closed. The accelerator switch closes the circuit when the accelerator pedal is released. The speedometer switch closes the circuit at speeds above 17-23 mph. On 1972-74 models, the clutch switch closes the circuit when the clutch pedal is released. Coasting Valve This valve adds additional fuel to the lean air fuel mixture caused by deceleration. This additional fuel insures more complete combustion and reduces exhaust emissions. This valve is controlled by two switches; the speedometer switch and accelerator switch. Both of these switches must be closed in order for the coasting richer valve to function. The accelerator switch closed the coasting richer circuit whenever the accelerator pedal is in the released position. Depressing the accelerator pedal opens the circuit. The speedometer switch completes the circuit at speeds above 17 to 23 mph. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Description and Operation > Air Bypass Valve, Turbocharger > Page 215 Dashpot The dashpot prevents instant throttle closure when the accelerator pedal is released for slowing down or shifting the transmission. System Description 1972 Exc. California The deceleration control system on these models is a three part system. One part controls throttle opening during deceleration, another part acts to retard spark during deceleration and a third part retards the spark during engine idle. A vacuum control valve is the component which controls both the spark retard and the throttle opening during deceleration. The vacuum control valve senses the higher Intake manifold vacuum and activates both systems. The throttle opening system uses a servo diaphragm assembly connected to the primary throttle shaft. During deceleration, the vacuum control valve opens to allow vacuum to be applied to the servo diaphragm. The diaphragm then moves to open the primary throttle plate slightly and feeds additional fuel to richen the mixture. The spark retard system uses a dual point distributor and a vacuum switch. During deceleration, the vacuum control valve opens to allow vacuum to be applied to the vacuum switch. The vacuum switch then closes and activates the retard breaker points in the distributor to retard the spark. During acceleration and normal operation, the spark is controlled by the standard breaker point set. During deceleration, the standard breaker points are by-passed and the spark is controlled by the retard set. This retard circuit retards spark advance 7-10 degrees, decreasing engine speed. During engine idle, the accelerator switch controls the retard points in the distributor. When the engine is running above idle, the accelerator switch is open and the distributor operates on the standard breaker point set. When the accelerator pedal is released, the switch is closed and the retard breaker point set is activated, retarding spark advance. 1972 California & 1973-82 This system maintains a balanced air fuel mixture during deceleration. Fig. 13 - Deceleration Control System This system on 1972 California and 1973-76 engines consists of an air control valve, anti-afterburn valve and a coasting richer valve, Fig. 13. This system on 1977-78 1.8 liter engines except California, consists of an anti-afterburn valve, dashpot and a throttle opener system that is composed of a servo diaphragm connected to the throttle lever and a vacuum control valve. This system on 1977-78 1.8 liter California engines consist of an anti-afterburn valve and a throttle position system composed of a servo Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Description and Operation > Air Bypass Valve, Turbocharger > Page 216 diaphragm connected to the throttle lever and a vacuum control valve. This system on 1977-78 2.3 liter engines except California, consist of an air bypass valve, a dashpot on manual transmission equipped models, and a coasting richer valve which is actuated by vehicle speed and the accelerator switch. This system on 1977 2.3 liter California engines consists of an air bypass valve and a dashpot on manual transmission equipped vehicles. This system on 1977-82 2.3 liter California engines consists of an air bypass valve, a dashpot on manual transmission equipped vehicles and a coasting richer solenoid valve which is actuated by vehicle speed and an accelerator switch. This system on 1979-82 2.0 liter engines except California consist of an anti-afterburn valve and a throttle positioner. This system on 1979-81 2.0 liter California engines, consist of an air bypass valve and throttle positioner. Throttle Opener Throttle Opener System, 1976 California vehicles equipped with manual transmission are equipped with this system to protect the catalytic converter from abnormally high temperatures by maintaining an optimum air-fuel mixture to the engine during deceleration. This system incorporated a servo diaphragm and throttle lever which opens the primary throttle valve in the carburetor. A vacuum control valve issued to detect intake manifold vacuum and actuates the servo diaphragm during deceleration. Throttle Opener System, 1977-82 This system opens the primary throttle valve slightly so that an optimum amount of air-fuel mixture is fed to the engine to reduce emissions during deceleration, since during deceleration, the air-fuel mixture entering the engine is not sufficient for complete combustion. This system consists of a servo diaphragm connected to a throttle lever, a three way solenoid valve which controls intake manifold vacuum to the servo diaphragm and an engine speed switch which grounds the throttle positioner circuit. When engine speed is above 1700 RPM, the engine speed switch opens the throttle positioner circuit and the three way solenoid valve allows intake manifold vacuum to actuate the servo diaphragm and increase engine speed. When engine speed is less than 1700 RPM, the engine speed switch grounds the throttle positioner circuit. The three way solenoid valve prevents vacuum from applying the servo diaphragm. On 1979-82 models with air conditioning, when the air conditioning is turned on, the air conditioning relay opens the throttle positioner circuit regardless of the position of the engine speed switch. With the three way solenoid valve energized, vacuum is applied to the servo diaphragm to increase engine speed. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Testing and Inspection > Anti-Afterburn Valve Deceleration Valve: Testing and Inspection Anti-Afterburn Valve 1. Disconnect inlet hose from anti-afterburn valve. Fig. 23 - Anti-afterburn Valve Test 2. With engine idling, lightly hold finger over inlet hose opening, Fig. 23. This should not cause the engine speed to vary. 3. With finger lightly placed over inlet hose opening, increase engine speed and quickly release accelerator. Air should flow inward for 3 seconds. If air flows inward longer than 3 seconds, or if air does not flow inward at all, replace valve. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Testing and Inspection > Anti-Afterburn Valve > Page 219 Deceleration Valve: Testing and Inspection Servo Diaphragm 1. Disconnect the vacuum control valve intake manifold vacuum sensing hose from tee fitting near the air control valve. 2. Disconnect vacuum line from vacuum control valve and connect line to tee fitting so intake manifold vacuum can be applied directly to the servo diaphragm. 3. Disconnect vacuum hose from distributor vacuum advance unit. Fig. 28 - Deceleration Valve Test 4. Start engine. The engine speed should rise to 1300-1500 RPM. If engine speed is not within specifications, adjust by turning adjusting screw on servo diaphragm throttle lever, Fig. 28. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Testing and Inspection > Anti-Afterburn Valve > Page 220 Deceleration Valve: Testing and Inspection Three-Way Solenoid Valve 1. Start engine and allow to idle. 2. Disconnect wire at three way solenoid valve. 3. The engine speed should increase to 1000 RPM on except California models, and 1100 RPM for California models. If speed does not increase, the three way solenoid valve or the servo diaphragm is not operating properly. 4. To adjust servo diaphragm: a. Inspect throttle positioner vacuum hoses for cracks or hardening. Replace as required. b. Start engine and set idle speed to specifications. c. Turn engine off and disconnect vacuum hose from distributor and plug hose. d. Disconnect vacuum line at vacuum amplifier and vacuum hose at three way solenoid valve. Connect vacuum hose from servo diaphragm to vacuum amplifier so intake manifold vacuum is applied directly to servo diaphragm. e. Connect a tachometer to engine and start engine. Engine speed should increase to 1000 ±100 RPM on all except California, and 1100 ±100 on California models. If not, adjust engine speed by turning adjusting screw on servo diaphragm throttle lever until proper engine speed is obtained. f. Reconnect all vacuum hoses to their original positions. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Testing and Inspection > Anti-Afterburn Valve > Page 221 Deceleration Valve: Testing and Inspection Vacuum Control Valve Fig. 29 - Vacuum Control Valve Test 1. Disconnect and plug intake manifold vacuum hose from anti-afterburn valve at the tee fitting. Connect a vacuum gauge to the tee fitting, Fig. 29. 2. Start engine and raise speed to 3000 RPM, then release accelerator and observe vacuum gauge. The vacuum reading should drop to 22.4 inch Hg. momentarily before dropping to the normal idle vacuum reading. 3. If the vacuum reading is not within specifications, loosen locking screw and rotate adjusting screw on vacuum control valve until the proper reading is obtained. NOTE: The vacuum level at which the vacuum control valve operates was set at an atmospheric pressure of 22.9 inch Hg. If the atmospheric pressure at time of testing is different than 22.9 inch Hg., change the desired reading by adding or subtracting the amount equivalent to the difference between 22.9 inch Hg. and the actual atmospheric reading. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Deceleration Valve > Component Information > Testing and Inspection > Anti-Afterburn Valve > Page 222 Deceleration Valve: Testing and Inspection Water Thermo Valve 1. Remove thermo valve. 2. Place thermo valve in a container of water with a thermometer. 3. Gradually heat water while observing temperature. 4. Apply air pressure to thermo valve. Air should flow when valve opens at 115°F. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > EFE Valve > Component Information > Testing and Inspection EFE Valve: Testing and Inspection Fig. 36 - Evaporation Shutter Valve Test 1. Start engine and allow to idle. 2. Remove air cleaner element. 3. Check to make sure that shutter valve is completely open. 4. Check to make sure that shutter valve closes completely when disconnecting vacuum sensing tube from vacuum diaphragm. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Testing and Inspection Canister Purge Control Valve: Testing and Inspection Fig. 35 - Testing Purge Control Valve 1. Disconnect vacuum sensing tubes from water thermo valve and from intake manifold at purge control valve. 2. Plug vacuum sensing tube to intake manifold. 3. Start engine and operate at idle. 4. Connect a hose to inlet port "b" of valve and lightly apply air pressure to valve. No air should flow through valve. 5. Disconnect vacuum sensing tube from intake manifold and connect tube to water thermo port "a" of purge control valve. Again, lightly apply air pressure to port "b." Air should pass through valve. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Thermal Vacuum Valve - EVAP > Component Information > Testing and Inspection Thermal Vacuum Valve - EVAP: Testing and Inspection Water Thermo Valve, Exc. Calif. 2.3L 1. Remove valve. 2. Connect hoses to inlet and outlet ports of valve and submerge valve in a water filled container. 3. Place a thermometer in water and gradually heat water while applying air pressure to valve. 4. Air should flow through valve when water temperature reaches 131°F, or above on all except California with 2.3L engine, or 110°F, or above on California models with 2.3L engine. Water Thermo Valve, Calif. 2.3L 1. Remove switch. 2. Place sensor portion of switch in water, and slowly heat water. 3. Attach ohmmeter to switch terminals, and observe temperature at which continuity exists. Specification requires continuity to occur at 131 ±4°F. If not within this range, switch is defective. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > EGR Solenoids - Contamination EGR Control Solenoid: Technical Service Bulletins EGR Solenoids - Contamination Article No. 85-13-5 EGR SOLENOIDS - CONTAMINATION FORD 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT SOLENOIDS LINCOLN-MERCURY 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT SOLENOIDS The use of starter fluids (ether and xylene), choke and/or fuel injector cleaners, can contaminate the EGR control and vent solenoids EGRC/EGRY. These solvents may affect the upper elastomer tip of the solenoid armature, causing an inoperative condition. Care must also be used to avoid getting these starter fluids into the vacuum harness, and contaminating these emission components in this way. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Page 242 EGR Control Solenoid: Testing and Inspection Three-way Solenoid Valve Test 1. Disconnect electrical connecters from water thermo switch and connect a jumper wire between the connectors. 2. Turn ignition switch to "On" position. 3. Disconnect vacuum hose from EGR valve and blow into the hose, Fig. 12. Check for air discharge at the three-way solenoid valve relief port. If air does not discharge, replace the three-way solenoid valve. 4. Turn ignition switch to "Off" position. Fig. 12 - EGR Three-Way Solenoid Valve Test 5. Remove jumper wire from the water thermo switch connectors and disconnect vacuum amplifier vacuum line from the three-way solenoid valve, Fig. 12. 6. Turn ignition switch to "On" position. 7. Blow into EGR valve hose. Check for air discharge at the vacuum amplifier port of the three-way control valve. If air does not discharge, replace the three-way solenoid valve. 8. If valve tests satisfactory, reconnect all vacuum hoses and electrical connections in original positions. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Technical Service Bulletins > EGR Solenoids Contamination EGR Electronic Vacuum Regulator Solenoid: Technical Service Bulletins EGR Solenoids Contamination Article No. 85-13-5 EGR SOLENOIDS - CONTAMINATION FORD 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT SOLENOIDS LINCOLN-MERCURY 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT SOLENOIDS The use of starter fluids (ether and xylene), choke and/or fuel injector cleaners, can contaminate the EGR control and vent solenoids EGRC/EGRY. These solvents may affect the upper elastomer tip of the solenoid armature, causing an inoperative condition. Care must also be used to avoid getting these starter fluids into the vacuum harness, and contaminating these emission components in this way. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > 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 > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection EGR Valve: Testing and Inspection 1. Run engine at idle speed and disconnect vacuum hose from EGR valve. 2. Disconnect intake manifold vacuum line from vacuum amplifier and connect to EGR valve. The engine should then stall or idle roughly. If not, stop engine and remove the EGR valve. 3. Clean passages of EGR valve and pipe with a brush and a wire. 4. Install EGR valve and repeat test. If engine still does not stall or run roughly, replace the EGR valve and repeat test. 5. If test is satisfactory, reconnect vacuum lines to original positions. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Testing and Inspection Thermal Vacuum Valve: Testing and Inspection 81-82 2.3L California 1. Remove thermo switch. 2. Connect an ohmmeter across 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 122 ±4° F or above. If temperature is not within specifications, replace switch. 79-82 Exc. 81-82 2.3L California 1. Remove thermo valve. 2. Place valve in a water filled container. Place a thermometer into water and gradually heat water while observing thermometer. 3. Apply air pressure to valve. Air should flow indicating that valve is open when water temperature reaches 115°F on 1979-80, 122°F for 1981-82 2.0L engines, and 131°F for 1981-82 2.3L engines. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Vacuum Amplifier, EGR > Component Information > Testing and Inspection Vacuum Amplifier: Testing and Inspection 1. Start engine and allow to reach normal operating temperature. 2. On 1976-78, disconnect vacuum amplifier vacuum hose from three-way solenoid valve and connect a vacuum gauge to hose. 3. On 1979-80 and 1981 except California, disconnect vacuum amplifier vacuum hose from water thermo valve and connect a vacuum gauge to hose. 4. On 1981 California, disconnect vacuum amplifier hose from EGR control valve and connect a vacuum gauge to hose. 5. Disconnect vacuum amplifier hose from carburetor. 6. Depress accelerator several times and allow engine to return to idle. The vacuum gauge should indicate 2 ± .04 inches Hg vacuum. 7. Reconnect vacuum amplifier hose to carburetor and increase engine speed to 3500 RPM. The vacuum gauge should now indicate 3.54 inches Hg vacuum. If not, replace vacuum amplifier. 8. Reconnect all vacuum hoses to original positions. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: Description and Operation Description This system diverts blow-by gases into the intake manifold to be burned by the engine. The system consists of a positive crankcase ventilation (PCV) valve, an oil separator and the hoses needed to connect these components. Operation Fig. 1 - PCV Valve Operation Ventilating air is routed into the rocker cover from the air cleaner, then through the oil separator and to the PCV valve. The PCV valve is operated by the difference in pressure between the intake manifold and the rocker cover. When there is no difference in pressure or the pressure of the intake manifold is greater than the rocker cover, the PCV valve is pulled toward the rocker cover by the tension of the valve spring, Fig. 1. If there is a large difference in pressure, the high vacuum of the intake manifold overcomes the tension of the valve spring and the valve is pulled toward the intake manifold side by the manifold vacuum, Fig. 1. The air then passes through the restricted passage in the valve. If the difference in pressure is small, the valve is balanced by the tension of the valve spring and intake manifold vacuum, Fig. 1. This valve position increases the flow of ventilating air. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 262 Positive Crankcase Ventilation: Testing and Inspection 1. Remove hose from PCV valve. 2. Start and run engine at 700-1000 RPM. 3. Hold a finger over end of PCV valve. A distinct vacuum should be felt. If not, replace PCV valve. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > 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 > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications Carburetor Jet: Technical Service Bulletins High Altitude Driveability Modifications Article No. 82-11A-1O June 4, 1982 Subject: Modification Of Sea Level Calibrations For Altitude Applications Light Trucks 1982 Courier - All Except 2.0L High Altitude Calibration Applicable Model: WARNING: This Modification Is Authorized Only For The Listed Engines. Performing This Modification On Other Engines Is Unauthorized And Could Create Liability Under Applicable Federal Or Local Laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitudes (above 4,000 ft. altitude) may have the following procedures performed to improve performance: 1. Remove the air cleaner and duct assembly. 2. Remove the bolts attaching the accelerator shaft to the throttle lever. 3. Disconnect the fuel line and fuel return line at the carburetor. 4. Disconnect the leads for the slow fuel cut valve (throttle solenoid) and coasting richer (deceleration valve) (2.3 litre only) at the quick disconnects. Also, disconnect the carburetor-to-distributor vacuum line at the carburetor. Disconnect the hose connecting the carburetor to the vacuum amplifier. Disconnect the vacuum hose for the purge control valve. 5. Disconnect the throttle return spring (2.3 litre only). Then, disconnect the lead wire for the automatic choke. Remove the servo diaphragm link for the throttle opener (2.0 litre only). 6. Using Tool T72J-9510, remove the carburetor attaching nuts from the intake manifold studs and remove the carburetor. 7. Remove the locking plate (only for Courier 2.3 litre and Courier chassis cab). 8. Remove the plugs and main jets from the carburetor. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications > Page 272 Figure 7 9. Install the high altitude jets indicated in the table (Figure 7.) 10. Install the plugs. 11. Install the locking plate (only for Courier 2.3 litre and Courier chassis cab). 12. Position the carburetor and a new gasket on the intake manifold and install the attaching nuts. 13. Connect the throttle return spring (2.3 litre only). 14. Connect the accelerator shaft to the throttle lever and install the attaching bolts. 15. Connect the slow fuel cut valve, automatic choke, and coasting richer (2.3 litre only) leads at the quick disconnect. 16. Connect the carburetor-to-distributor vacuum line. Connect the vacuum hose for the purge control valve. 17. Connect the fuel line and fuel return line to the carburetor. Install the air cleaner and duct assembly. 18. Start the engine and check for fuel leaks. 19. For 2.3 litre California Courier with manual transmission, adjust the dash pot as per "1981 Ford Courier Truck Shop Manual", Deceleration Control System, Section 29-03-05. 20. For 2.0 litre Courier, adjust the throttle positioner system as per "1981 Ford Courier Truck Shop Manual", Deceleration Control System, Section 29-03-06. Install a Courier Vehicle Emission Control Information Update Label (available at all Ford or Lincoln-Mercury dealers) in a prominent place adjacent to the Vehicle Emission Control Information Label. Do not install the label on any component that can be easily detached from the vehicle. Clean the area before installing the label. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications > Page 273 Vehicle Emission Control Information Update Label for Low Altitude Adjustment: This label is attached firmly to a readily visible position and beside to the existing vehicle emission control information label, Do not Install the label on any equipment that can be easily detached from the vehicle. NOTE: The Vehicle Emission Control Information Update Label is a new label to be used for altitude modifications. Do not Use the Authorized Modifications label which is used to indicate other types of modifications. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the Vehicle Emission Control Information Update Label should be removed. Install the low altitude jets and make the required adjustments. WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. Coding: Basic Part No. Code: L05 53 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Housing > Component Information > Technical Service Bulletins > Electric Choke System - Testing Tool Choke Housing: Technical Service Bulletins Electric Choke System - Testing Tool Article No: 82-10-13 May 24, 1982 Subject: Rotunda Choke Cap Tester No. 90-0001 FORD All Vehicles With Single - And Two-stage Electric Chokes LINCOLN-MERCURY All Vehicles With Single - And Two-stage Electric Chokes The tool was recently released to improve performance and reduce diagnosis time when servicing choke systems. Testing time has been reduced to a few minutes with the all electric two-stage choke system. The temperature range of the tester is from -1 °F to 165 °F. For optimum tool performance, shop air with a line pressure of 90 PSI with 6-8 C.F.M. volume is required. An adaptor is provided to service older model single-stage and hot-air-only systems. The unit is also recommended for testing other heat sensitive/actuated components and auto/temp control systems. Refer to the Engine/Emission/Diagnosis Manual and the Manufacturers Instruction Manual (provided) for procedures and instructions. Warranty Status: Information Only Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Thermostat/Heater > Component Information > Technical Service Bulletins > Alternator - Replacement Precautions Choke Thermostat/Heater: Technical Service Bulletins Alternator - Replacement Precautions Article No. 85-12-24 RICH MIXTURE - CHOKE DOES NOT OPEN - ELECTRIC CHOKE CONNECTION TO NON-OEM ALTERNATOR LIGHT TRUCK ALL SERIES Replacement of the OEM alternator to accomodate higher current requirements of vehicle-mounted electrical equipment may adversely affect the operation of the electric choke on those vehicles so equipped. For this reason, it is important to examine the electrical system on a subject vehicle to determine if an electric choke is connected to the OEM alternator stator terminal. If there is such a connection, a similar connection must be provided on the replacement alternator. Contact the manufacturer of the replacement alternator to determine the correct method of connecting to the alternator stator. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Dashpot > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications Dashpot: Technical Service Bulletins High Altitude Driveability Modifications Article No. 82-11A-1O June 4, 1982 Subject: Modification Of Sea Level Calibrations For Altitude Applications Light Trucks 1982 Courier - All Except 2.0L High Altitude Calibration Applicable Model: WARNING: This Modification Is Authorized Only For The Listed Engines. Performing This Modification On Other Engines Is Unauthorized And Could Create Liability Under Applicable Federal Or Local Laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitudes (above 4,000 ft. altitude) may have the following procedures performed to improve performance: 1. Remove the air cleaner and duct assembly. 2. Remove the bolts attaching the accelerator shaft to the throttle lever. 3. Disconnect the fuel line and fuel return line at the carburetor. 4. Disconnect the leads for the slow fuel cut valve (throttle solenoid) and coasting richer (deceleration valve) (2.3 litre only) at the quick disconnects. Also, disconnect the carburetor-to-distributor vacuum line at the carburetor. Disconnect the hose connecting the carburetor to the vacuum amplifier. Disconnect the vacuum hose for the purge control valve. 5. Disconnect the throttle return spring (2.3 litre only). Then, disconnect the lead wire for the automatic choke. Remove the servo diaphragm link for the throttle opener (2.0 litre only). 6. Using Tool T72J-9510, remove the carburetor attaching nuts from the intake manifold studs and remove the carburetor. 7. Remove the locking plate (only for Courier 2.3 litre and Courier chassis cab). 8. Remove the plugs and main jets from the carburetor. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Dashpot > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications > Page 286 Figure 7 9. Install the high altitude jets indicated in the table (Figure 7.) 10. Install the plugs. 11. Install the locking plate (only for Courier 2.3 litre and Courier chassis cab). 12. Position the carburetor and a new gasket on the intake manifold and install the attaching nuts. 13. Connect the throttle return spring (2.3 litre only). 14. Connect the accelerator shaft to the throttle lever and install the attaching bolts. 15. Connect the slow fuel cut valve, automatic choke, and coasting richer (2.3 litre only) leads at the quick disconnect. 16. Connect the carburetor-to-distributor vacuum line. Connect the vacuum hose for the purge control valve. 17. Connect the fuel line and fuel return line to the carburetor. Install the air cleaner and duct assembly. 18. Start the engine and check for fuel leaks. 19. For 2.3 litre California Courier with manual transmission, adjust the dash pot as per "1981 Ford Courier Truck Shop Manual", Deceleration Control System, Section 29-03-05. 20. For 2.0 litre Courier, adjust the throttle positioner system as per "1981 Ford Courier Truck Shop Manual", Deceleration Control System, Section 29-03-06. Install a Courier Vehicle Emission Control Information Update Label (available at all Ford or Lincoln-Mercury dealers) in a prominent place adjacent to the Vehicle Emission Control Information Label. Do not install the label on any component that can be easily detached from the vehicle. Clean the area before installing the label. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Dashpot > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications > Page 287 Vehicle Emission Control Information Update Label for Low Altitude Adjustment: This label is attached firmly to a readily visible position and beside to the existing vehicle emission control information label, Do not Install the label on any equipment that can be easily detached from the vehicle. NOTE: The Vehicle Emission Control Information Update Label is a new label to be used for altitude modifications. Do not Use the Authorized Modifications label which is used to indicate other types of modifications. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the Vehicle Emission Control Information Update Label should be removed. Install the low altitude jets and make the required adjustments. WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. Coding: Basic Part No. Code: L05 53 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Rotunda Gas Chek Kit - Requires Modification Fuel: Technical Service Bulletins Rotunda Gas Chek Kit - Requires Modification Article No. FUEL SYSTEM - ROTUNDA "GAS-CHEK" KIT 87-23-9 TOOL MODIFICATION FORD: 1988 And Prior ALL CAR LINES LINCOLN-MERCURY: 1988 And Prior ALL CAR LINES LIGHT TRUCK: 1988 And Prior ALL LIGHT TRUCK LINES ISSUE: The Rotunda "Gas-Chek Kit" (Tool Number 113-00002) that you may have purchased prior to October, 1987 requires modification. The necessary components and new operating instructions will be shipped to you at no charge. This tool modification will provide greater accuracy when performing high fuel vapor pressure testing of gasoline. ACTION: To modify the Rotunda "Gas-Chek Kit", use the following service instructions. NOTE: This modification MUST be done because it will seriously affect the volatility tests. Figure 11 1. Remove adapter fitting attached to the 0-30 PSI gauge. CARE SHOULD BE TAKEN TO PREVENT DAMAGE TO GAUGE ASSEMBLY WHEN REMOVING FITTING. Throw away the adapter fitting, Figure 11. 2. Remove and throw away the aluminum vial, Figure 11. 3. Remove plastic thermos cup cap and throw away, Figure 11. 4. Remove the set of instructions from the lid of the Gas-Chek plastic storage box and throw them away. NOTE: USE ONLY THE NEW instruction booklet that is furnished in the modification kit. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Rotunda Gas Chek Kit - Requires Modification > Page 292 Figure 12 5. Using thread sealer or teflon tape on the threads of the PSI gauge, install gauge and tighten into new cover and air chamber, Figure 12. After installation is made, this assembly should not be disassembled. 6. Position small, plastic gasoline sample container and gas cup holder into gauge and vial cavity of die-cut, foam material for storage, Figure 12. 7. Care should be taken when storing unit to prevent damage which could then cause bad readings when checking gasoline vapor pressure. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > 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 > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Technical Service Bulletins > Fuel Filter - Replacement Information Fuel Hose Clamp: 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 > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > 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 > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Service Precautions Fuel Tank: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537° C (1000° F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications Idle Speed/Throttle Actuator - Electronic: Technical Service Bulletins High Altitude Driveability Modifications Article No. 82-11A-1O June 4, 1982 Subject: Modification Of Sea Level Calibrations For Altitude Applications Light Trucks 1982 Courier - All Except 2.0L High Altitude Calibration Applicable Model: WARNING: This Modification Is Authorized Only For The Listed Engines. Performing This Modification On Other Engines Is Unauthorized And Could Create Liability Under Applicable Federal Or Local Laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitudes (above 4,000 ft. altitude) may have the following procedures performed to improve performance: 1. Remove the air cleaner and duct assembly. 2. Remove the bolts attaching the accelerator shaft to the throttle lever. 3. Disconnect the fuel line and fuel return line at the carburetor. 4. Disconnect the leads for the slow fuel cut valve (throttle solenoid) and coasting richer (deceleration valve) (2.3 litre only) at the quick disconnects. Also, disconnect the carburetor-to-distributor vacuum line at the carburetor. Disconnect the hose connecting the carburetor to the vacuum amplifier. Disconnect the vacuum hose for the purge control valve. 5. Disconnect the throttle return spring (2.3 litre only). Then, disconnect the lead wire for the automatic choke. Remove the servo diaphragm link for the throttle opener (2.0 litre only). 6. Using Tool T72J-9510, remove the carburetor attaching nuts from the intake manifold studs and remove the carburetor. 7. Remove the locking plate (only for Courier 2.3 litre and Courier chassis cab). 8. Remove the plugs and main jets from the carburetor. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications > Page 312 Figure 7 9. Install the high altitude jets indicated in the table (Figure 7.) 10. Install the plugs. 11. Install the locking plate (only for Courier 2.3 litre and Courier chassis cab). 12. Position the carburetor and a new gasket on the intake manifold and install the attaching nuts. 13. Connect the throttle return spring (2.3 litre only). 14. Connect the accelerator shaft to the throttle lever and install the attaching bolts. 15. Connect the slow fuel cut valve, automatic choke, and coasting richer (2.3 litre only) leads at the quick disconnect. 16. Connect the carburetor-to-distributor vacuum line. Connect the vacuum hose for the purge control valve. 17. Connect the fuel line and fuel return line to the carburetor. Install the air cleaner and duct assembly. 18. Start the engine and check for fuel leaks. 19. For 2.3 litre California Courier with manual transmission, adjust the dash pot as per "1981 Ford Courier Truck Shop Manual", Deceleration Control System, Section 29-03-05. 20. For 2.0 litre Courier, adjust the throttle positioner system as per "1981 Ford Courier Truck Shop Manual", Deceleration Control System, Section 29-03-06. Install a Courier Vehicle Emission Control Information Update Label (available at all Ford or Lincoln-Mercury dealers) in a prominent place adjacent to the Vehicle Emission Control Information Label. Do not install the label on any component that can be easily detached from the vehicle. Clean the area before installing the label. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > High Altitude Driveability Modifications > Page 313 Vehicle Emission Control Information Update Label for Low Altitude Adjustment: This label is attached firmly to a readily visible position and beside to the existing vehicle emission control information label, Do not Install the label on any equipment that can be easily detached from the vehicle. NOTE: The Vehicle Emission Control Information Update Label is a new label to be used for altitude modifications. Do not Use the Authorized Modifications label which is used to indicate other types of modifications. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the Vehicle Emission Control Information Update Label should be removed. Install the low altitude jets and make the required adjustments. WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. Coding: Basic Part No. Code: L05 53 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Customer Interest for Throttle Cable/Linkage: > 83720 > Apr > 83 > Accelerator Linkage - Raspy/Sticky Throttle Cable/Linkage: Customer Interest Accelerator Linkage - Raspy/Sticky Article No. 83-7-20 ACCELERATOR LINKAGE - DIAGNOSTIC PROCEDURE LIGHT TRUCKS 1980-83 LIGHT TRUCKS Servicing of Cable-Type Acceleration Linkage The following procedure will assist in diagnosing accelerator linkage concerns on 1980-83 light trucks. If the accelerator pedal, when operated, is hard to push down or feels "raspy" or "sticky", perform the following: 1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball stud. Also disconnect the cruise control from the accelerator cable if so equipped. 2. Then check the following items: ^ Be sure that the disconnected end of the cable or its spring does not come into contact with any of the surrounding parts. ^ Operate the pedal by foot. ^ If accelerator operation is smooth, the pedal assembly and cable are not the cause of the concern. Refer to the carburetor/injector pump diagnosis procedures in the appropriate shop manual for additional checks. ^ E, F, Bronco and Ranger with gas engine - See General Fuel System Service Section 24-01. ^ Ranger with Diesel Engine - See Ranger Shop Manual - 2.2L Diesel Engine Section 22-09 of the Engine Performance Diagnostic Guide. ^ F Series with the 6.9L Diesel Engine - See the 1983 Car/Truck Shop Manual - Engine Electronics Section 25-64. ^ If the concern persists (being sure disconnected end of cable has not come into contact with anything), check foot pedal assembly for free operation. If pedal operation is free, replace the cable. If you have a high engine idle speed concern, check the following linkage systems: 1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball stud. Also disconnect the cruise control from the accelerator cable if so equipped. ^ If the cable ball socket extends beyond the throttle lever ball stud, refer to the carburetor diagnosis procedures in the appropriate shop manual for the correct adjustment procedure. ^ If the socket does not extend beyond the stud, check the foot pedal assembly for free operation. If the pedal operation is free, replace the cable. NOTE: The accelerator cable should not be lubricated and it is not serviceable. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: M TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9A758 Code: 41 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 83720 > Apr > 83 > Accelerator Linkage - Raspy/Sticky Throttle Cable/Linkage: All Technical Service Bulletins Accelerator Linkage - Raspy/Sticky Article No. 83-7-20 ACCELERATOR LINKAGE - DIAGNOSTIC PROCEDURE LIGHT TRUCKS 1980-83 LIGHT TRUCKS Servicing of Cable-Type Acceleration Linkage The following procedure will assist in diagnosing accelerator linkage concerns on 1980-83 light trucks. If the accelerator pedal, when operated, is hard to push down or feels "raspy" or "sticky", perform the following: 1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball stud. Also disconnect the cruise control from the accelerator cable if so equipped. 2. Then check the following items: ^ Be sure that the disconnected end of the cable or its spring does not come into contact with any of the surrounding parts. ^ Operate the pedal by foot. ^ If accelerator operation is smooth, the pedal assembly and cable are not the cause of the concern. Refer to the carburetor/injector pump diagnosis procedures in the appropriate shop manual for additional checks. ^ E, F, Bronco and Ranger with gas engine - See General Fuel System Service Section 24-01. ^ Ranger with Diesel Engine - See Ranger Shop Manual - 2.2L Diesel Engine Section 22-09 of the Engine Performance Diagnostic Guide. ^ F Series with the 6.9L Diesel Engine - See the 1983 Car/Truck Shop Manual - Engine Electronics Section 25-64. ^ If the concern persists (being sure disconnected end of cable has not come into contact with anything), check foot pedal assembly for free operation. If pedal operation is free, replace the cable. If you have a high engine idle speed concern, check the following linkage systems: 1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball stud. Also disconnect the cruise control from the accelerator cable if so equipped. ^ If the cable ball socket extends beyond the throttle lever ball stud, refer to the carburetor diagnosis procedures in the appropriate shop manual for the correct adjustment procedure. ^ If the socket does not extend beyond the stud, check the foot pedal assembly for free operation. If the pedal operation is free, replace the cable. NOTE: The accelerator cable should not be lubricated and it is not serviceable. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: M TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9A758 Code: 41 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition - Coil Durability/Radio Frequency Interference Ignition Coil: Technical Service Bulletins Ignition - Coil Durability/Radio Frequency Interference Article No. 84-22-8 IGNITION - COIL DURABILITY AND RADIO FREQUENCY INTERFERENCE LIGHT TRUCKS 1985 AND PRIOR YEARS - ALL SERIES MEDIUM/HEAVY TRUCKS 1985 AND PRIOR YEARS - ALL SERIES Relocation of the ignition coil to accomodate the installation of non-Ford engine-mounted equipment may effect the durability of the coil and/or cause a radio frequency interference condition. For these reasons movement of the ignition coil from its original location is not recommended. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > 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 > Powertrain Management > Ignition System > 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 > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 338 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 > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 339 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 > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 340 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 > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 341 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 > Powertrain Management > 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 > Powertrain Management > 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 > Powertrain Management > Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 347 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 > Powertrain Management > Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 348 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 > Powertrain Management > Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 349 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 > Powertrain Management > Ignition System > Spark Control Relay > Component Information > Testing and Inspection > Spark Delay Valve > Page 350 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 > Powertrain Management > Transmission Control Systems > System Information > System Diagnosis Transmission Control Systems: Testing and Inspection For Transmission Control Systems Diagnosis, go to Powertrain Management/Computers and Control Systems/Testing and Inspection. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > 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 > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > A/T - Choosing the Right ATF Automatic Transmission/Transaxle: Technical Service Bulletins A/T - Choosing the Right ATF TRANSMISSION: ALL BULLETIN: # 9002006 SUBJECT: Automatic Transmission Fluid DATE: Feb 1990 AUTOMATIC TRANSMISSION FLUID CHOOSING YOUR ATF Different ATF's (Automatic Transmission Fluid) can have different frictional properties which can produce different shift characteristics. You may have already experienced problems like lock-up shudder, or squawks on shifts and have corrected them by changing the fluid. This alone tells, you that friction material and fluids are critical in today's cars. MEETING THE O.E.M. SPECIFICATIONS The first thing to consider when choosing an ATF is "Does it meet the O.E.M. specification?" ATF's wishing to be labeled as DEXRON II and/or MERCON must first meet the respective minimum requirements. It's important to note that even though the specification for DEXRON II and MERCON are currently very similar, THEY ARE NOT IDENTICAL. Also note, even fluids which meet the same specification may not be identical. One fluid may just meet a specification and, another may far surpass it. You should know what your fluids properties are! You can get that information from your fluid supplier. EVALUATING YOUR FLUID Ask your supplier to prove (certify) that the fluid meets O.E.M. specifications (MERCON OR DEXRON II). He will do that by supplying you with the license (certification) number issued to him by the O.E.M. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > A/T - Choosing the Right ATF > Page 362 A DEXRON-II license number (sometimes referred to as a "D" number) will always start D-2. A typical DEXRON license number can be seen in Figure 2. MERCON license numbers will be six digits starting with M as shown in Figure 3.. TRY TO MEET SEVERAL SPECIFICATIONS! DEXRON II and MERCON have different minimum specifications, so a product that meets BOTH specifications may be better then those meeting only one spec. Meeting other specs, in addition to the first two can be an added benefit. If a fluid is licensed as DEXRON II AND MERCON as well as others like Allison C-4, or Caterpillar TO-2/TO-4, it means the fluid had to pass more tests and may be a better fluid. Lastly, demand that the license numbers be placed on all your invoices especially if you buy in bulk. If your supplier is unwilling, it is very likely that they are supplying you an unlicensed fluid. Licensed suppliers are required to supply the license numbers to their customers as part of their agreement with the O.E.M. OTHER THINGS TO CHECK So now you've narrowed your choices down to a few suppliers that have O.E.M. license numbers. How do you compare two fluids that meet the same O.E.M. Spec.? Ask your supplier to give you the viscometrics on the fluid you buy. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > A/T - Choosing the Right ATF > Page 363 An excellent "bench mark of the overall quality of a fluid is its viscosity at -40 degrees. This is measured in "centipoise" or "cPs". DEXRON II specification says viscosity will be no more then 50,000 cPs @ - 40 degrees. (Some poor fluids have tested at over 1,000,000 cPs) In general, the lower the number, the better the fluid. Keep in mind that as the number goes down the price of the fluid usually goes up. (You get what you pay for) Most good fluids will average around 35,000 cPs. Hydrotreated (or Hydrocracked) fluids average around 20,000 cPs or less. (Hydrotreating is a refining process done to the base oil to clean out contaminants or impurities) Synthetic ATF's average 10,000 cPs or less, and some are as low as 5000 cPs. Viscosity at -40 degrees is a function of the base stock from which the ATF is made. A low number indicates a premium base oil OR an expensive refining process. (Hydrotreating) FOR ADDITIONAL INFORMATION: Transmission Digest August '89 Page 91 December '89 Page 51 BULLETIN RECAP ^ Only use fluids with O.E.M. approvals. ^ Try to get a fluid that meets more than one spec (e.g DEXRON II AND MERCON) ^ Check the viscosity at -40 degrees. The lower the number the better. ^ Avoid bargain basement fluids with no license numbers. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > 951610 > Aug > 95 > A/T - New Rotunda Fluid Changer Service Tip Automatic Transmission/Transaxle: Technical Service Bulletins A/T - New Rotunda Fluid Changer Service Tip Article No. 95-16-10 08/14/95 FLUID - NEW ROTUNDA FLUID CHANGER - SERVICE TIP FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 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 1981-87 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 ISSUE: Rotunda Equipment has available a new piece of equipment for automatic transmission fluid changes. Using the Rotunda ATF 2000 (199-00001) is an efficient way to change automatic transmission fluid. ACTION: When changing automatic transmission fluid using the Rotunda ATF 2000 (199-00001) it is not necessary to remove the transmission pan and/or torque converter drainplug. Contact Rotunda Equipment at 1-800-ROTUNDA for more information regarding the Rotunda ATF 2000. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 510000 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB078 > Nov > 91 > A/T - How To Use A Pressure Gauge Automatic Transmission/Transaxle: Technical Service Bulletins A/T - How To Use A Pressure Gauge BULLETIN : # 078 SUBJECT: Pressure Gauge APPLICATION: Misc. DATE: November 1991 HOW TO USE A PRESSURE GAUGE A significant number of calls we receive involve improper pressures, so we need to use a pressure gauge when diagnosing problems. Using a pressure gauge can seem like a formidable task. The reason most people do not use a pressure gauge is because they do not see the value in using one. Technicians do not see the value because the gauge readings do not tell them how to fix the problem. This article will attempt to show the technician how to interpret pressure gauge readings so the technician can find the fix to the problem. It is best to start pressure tests with mainline pressure. Mainline pressure should be checked in each range: P, R, N, D, 3, 2, 1. Each range, except Park and Neutral, should be checked under three conditions: Slow idle, fast idle, and wide open throttle. A form, as in figure 1 should be made to record the readings. If all pressures are within specification at slow idle then the pump and pressure regulator are functioning properly. If all pressures are low at slow idle, it indicates a potential problem in the pump, pressure regulator, filter, low fluid, or internal leakage. To help verify where the problem is, check pressures at fast idle. If all the pressures now read normally, it usually indicates a worn pump but the problem could still be internal leaks. Internal leaks will usually show up in a particular range. For example a forward clutch leak would have normal pressure in Park, Reverse and Neutral but have low pressure in all forward ranges. A direct clutch leak will show a pressure drop when the transmission shifts to third and low pressure in reverse because in most cases, the direct clutch is on in third and reverse. A restricted filter will usually show up as a gradual pressure drop at higher engine RPM because the filter cannot pass as much fluid as the pump is trying to draw. A stuck pressure regulator valve will show up as fixed line pressure which means the same pressure all the time. The pressure may vary with engine RPM which means low pressure at slow RPM and higher pressure at higher RPM. There will be no boost in pressure from the TV or modulator system and no reverse boost. If pressures are high at slow idle it indicates a pressure regulator or throttle pressure problem. On most cars, the modulator controls throttle pressure. If the transmission has a throttle pressure tap, it will tell you if the throttle pressure circuit is the problem. On GM units without a throttle pressure tap, remove the TV plunger. If line pressure is now normal then it's a TV problem, if not it's a pressure regulator problem. Pressures also need to be checked at stall or wide open throttle (WOT). When doing a stall test, always observe safety precautions such as checking for broken mounts or bad brakes. Testing should always be done under operating conditions. To do a stall test, put the selector in the range to be tested and with one foot firmly on the brake, press the accelerator to the floor then note your pressure reading. Some technicians will pull the vacuum line off or pull the TV cable with the engine at fast idle. That is not operating conditions and will not detect a problem of trapped vacuum or a cable problem. If all pressure at stall are low, then you should pull the TV cable to maximum or disconnect the vacuum line. If the pressures are now OK, the problem is in the cable or vacuum system. If the pressures are still low, then the problem is in the pump or control system. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB078 > Nov > 91 > A/T - How To Use A Pressure Gauge > Page 373 If all pressures at stall are high, then look at the idle pressures. If the idle pressures are also high then this could be a pressure regulator or throttle system problem. If idle pressures are normal then the problem is in just the throttle system. The reverse stall test is also a maximum pump output test. If you suspect a weak pump then this test will help find it. Often this will show up as low pressure at reverse stall but all other pressures including idle will be normal. If a person wanted to become really proficient with a pressure gauge they should first put a pressure gauge on their own vehicle and leave it there for exactly one week. Every time they drive the car they should watch the gauge. After one week, they should then put the pressure gauge on every single car in the shop that DOES NOT have a problem. Don't use the gauge on cars WITH problems yet. After 30 days of using a gauge on units that work properly, they can then start using the gauge on units with problems. The technician is accustomed to normal readings, abnormal readings will stand out like a sore thumb. To fix today's transmissions, every professional technician must be proficient in the use of a pressure gauge. The only way to gain this proficiency is to use the pressure gauge daily. Practice makes perfect. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB028 > Oct > 90 > A/T - Engine Vacuum Testing Automatic Transmission/Transaxle: Technical Service Bulletins A/T - Engine Vacuum Testing BULLETIN: # 028 DATE: October 1990 SUBJECT: Engine Testing With A Vacuum Gauge TRANSMISSION: All Engine Testing With A Vacuum Gauge ENGINE/TRANSMISSION RELATIONS An important part of transmission diagnosis is to make certain the engine operates properly. If the engine performance is incorrect, the transmission will receive the wrong information. The engine sends signals to the transmission through a vacuum line, throttle cable or both. These signals basically synchronize torque with transmission line pressure, shift feel and shift timing. Malfunctions in items like the air filter, spark plugs, EGR valves and other parts of the fuel, electrical and emission systems could result in improper transmission performance. VACUUM GAUGE ENGINE PERFORMANCE TESTING A vacuum gauge shows the difference between outside atmospheric pressure and the amount of vacuum present in the intake manifold. The pistons in the engine serve as suction pumps and the amount of vacuum they create is affected by the related actions of: ^ Piston rings ^ Valves ^ Ignition system ^ Fuel control system ^ Other parts affecting the combustion process (emission devices, etc.). Each has a characteristic effect on vacuum and you judge their performance by watching variations from normal. It is important to judge engine performance by the general location and action of the needle on a vacuum gauge, rather than just by a vacuum reading. Gauge readings which may be found are as follows: NORMAL ENGINE OPERATION At idling speed, an engine at sea level should show a steady vacuum reading between 14" and 22" HG. A quick opening and closing of the throttle should cause vacuum to drop below 5" then rebound to 23" or more. See figure 1. GENERAL IGNITION TROUBLES OR STICKING VALVES Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB028 > Oct > 90 > A/T - Engine Vacuum Testing > Page 378 With the engine idling, continued fluctuation of 1 to 2 inches may indicate an ignition problem. Check the spark plugs, spark plug gap, primary ignition circuit, high tension cables, distributor cap or ignition coil. Fluctuations of 3 to 4 inches may be sticking valves. See figure 2. INTAKE SYSTEM LEAKAGE, VALVE TIMING, OR LOW COMPRESSION A vacuum reading at idle much lower than normal can indicate leakage through intake manifold gaskets, manifold-to-carburetor gaskets, vacuum brakes or the vacuum modulator. Low readings could also be very late valve timing or worn piston rings. See figure 3. EXHAUST BACK PRESSURE Starting with the engine at idle, slowly increase engine speed to 3000 RPM, engine vacuum should be equal to or higher than idle vacuum at 3000 RPM. If vacuum decreases at higher engine RPM's, an excessive exhaust back pressure is probably present. CYLINDER HEAD GASKET LEAKAGE With the engine Idling, the vacuum gauge pointer will drop sharply, every time the leak occurs. The drop will be from the steady reading shown by the pointer to a reading of 10" to 12" Hg or less. If the leak Is between two cylinders, the drop will be much greater. You can determine the location of the leak by compression tests. See figure 4. FUEL CONTROL SYSTEM TROUBLES All other systems in an engine must be functioning properly before you check the fuel control system as a cause for poor engine performance. If the pointer has a slow floating motion of 4 to 5 inches - you should check the fuel control. BULLETIN RECAP ^ Engine problems can affect transmission performance. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB028 > Oct > 90 > A/T - Engine Vacuum Testing > Page 379 ^ If you suspect an engine problem, connect a vacuum gauge to the intake manifold. ^ Note the location and action of the vacuum gauge needle. ^ Use the information in the bulletin to determine the engine problem. ^ Correct the engine problem before doing extensive calibration work on the transmission. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB9002006 > Feb > 90 > A/T - Choosing the Right ATF Automatic Transmission/Transaxle: Technical Service Bulletins A/T - Choosing the Right ATF TRANSMISSION: ALL BULLETIN: # 9002006 SUBJECT: Automatic Transmission Fluid DATE: Feb 1990 AUTOMATIC TRANSMISSION FLUID CHOOSING YOUR ATF Different ATF's (Automatic Transmission Fluid) can have different frictional properties which can produce different shift characteristics. You may have already experienced problems like lock-up shudder, or squawks on shifts and have corrected them by changing the fluid. This alone tells, you that friction material and fluids are critical in today's cars. MEETING THE O.E.M. SPECIFICATIONS The first thing to consider when choosing an ATF is "Does it meet the O.E.M. specification?" ATF's wishing to be labeled as DEXRON II and/or MERCON must first meet the respective minimum requirements. It's important to note that even though the specification for DEXRON II and MERCON are currently very similar, THEY ARE NOT IDENTICAL. Also note, even fluids which meet the same specification may not be identical. One fluid may just meet a specification and, another may far surpass it. You should know what your fluids properties are! You can get that information from your fluid supplier. EVALUATING YOUR FLUID Ask your supplier to prove (certify) that the fluid meets O.E.M. specifications (MERCON OR DEXRON II). He will do that by supplying you with the license (certification) number issued to him by the O.E.M. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB9002006 > Feb > 90 > A/T - Choosing the Right ATF > Page 384 A DEXRON-II license number (sometimes referred to as a "D" number) will always start D-2. A typical DEXRON license number can be seen in Figure 2. MERCON license numbers will be six digits starting with M as shown in Figure 3.. TRY TO MEET SEVERAL SPECIFICATIONS! DEXRON II and MERCON have different minimum specifications, so a product that meets BOTH specifications may be better then those meeting only one spec. Meeting other specs, in addition to the first two can be an added benefit. If a fluid is licensed as DEXRON II AND MERCON as well as others like Allison C-4, or Caterpillar TO-2/TO-4, it means the fluid had to pass more tests and may be a better fluid. Lastly, demand that the license numbers be placed on all your invoices especially if you buy in bulk. If your supplier is unwilling, it is very likely that they are supplying you an unlicensed fluid. Licensed suppliers are required to supply the license numbers to their customers as part of their agreement with the O.E.M. OTHER THINGS TO CHECK So now you've narrowed your choices down to a few suppliers that have O.E.M. license numbers. How do you compare two fluids that meet the same O.E.M. Spec.? Ask your supplier to give you the viscometrics on the fluid you buy. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB9002006 > Feb > 90 > A/T - Choosing the Right ATF > Page 385 An excellent "bench mark of the overall quality of a fluid is its viscosity at -40 degrees. This is measured in "centipoise" or "cPs". DEXRON II specification says viscosity will be no more then 50,000 cPs @ - 40 degrees. (Some poor fluids have tested at over 1,000,000 cPs) In general, the lower the number, the better the fluid. Keep in mind that as the number goes down the price of the fluid usually goes up. (You get what you pay for) Most good fluids will average around 35,000 cPs. Hydrotreated (or Hydrocracked) fluids average around 20,000 cPs or less. (Hydrotreating is a refining process done to the base oil to clean out contaminants or impurities) Synthetic ATF's average 10,000 cPs or less, and some are as low as 5000 cPs. Viscosity at -40 degrees is a function of the base stock from which the ATF is made. A low number indicates a premium base oil OR an expensive refining process. (Hydrotreating) FOR ADDITIONAL INFORMATION: Transmission Digest August '89 Page 91 December '89 Page 51 BULLETIN RECAP ^ Only use fluids with O.E.M. approvals. ^ Try to get a fluid that meets more than one spec (e.g DEXRON II AND MERCON) ^ Check the viscosity at -40 degrees. The lower the number the better. ^ Avoid bargain basement fluids with no license numbers. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8930 > Oct > 89 > A/T - Math Part II Automatic Transmission/Transaxle: Technical Service Bulletins A/T - Math Part II TSB: 89-30 (Oct) SUBJECT: TRANSMISSION MATH - Part II Planetary Gear Sets: Knowing the gear ratios of an automatic transmission can come in handy at times -- especially when you're swapping transmission types or differentials. The problem is in trying to find a manual with the ratios listed. What do you do? BREAK OUT THE CALCULATOR, AND FIGURE IT OUT. When you figure the gear ratios for planetary gear sets, it is just like any other gear set. You divide the output gear by the input. Also, don't count the idler gear; planetaries are considered idler gears. Set them aside, their tooth count doesn't matter. Now for the tricky part -- which gear do you consider the input, and which one the output? Figure 1 shows a planetary gear set with 34 teeth on the ring gear and 20 teeth on the Sun gear. FOR GEAR REDUCTION, one of the gears is held stationary, and the other is used for the INPUT. THE TOOTH COUNT FOR THE OUTPUT GEAR IS THE SUM OF THE SUN GEAR AND THE RING GEAR, so if you are using the Sun gear for the input, then the ring gear + the Sun gear divided by the Sun gear = Ratio. EXAMPLE: 34 + 20 divided by 20 = 2.7:1 This is how 1st gear on a THM 700 R4 is calculated. (See figure) When the ring gear is used as the input, then the ring gear + the Sun gear divided by the ring gear = Ratio. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8930 > Oct > 89 > A/T - Math Part II > Page 390 EXAMPLE: 34 + 20 divided by 34 = 1.58 This is now 2nd gear on a THM 350 is calculated. (See figure) FOR OVERDRIVE, the sum of the ring gear + Sun gear is used for the input tooth count. So, IF THE SUN GEAR IS HELD, then the ring gear divided by (ring gear + Sun gear) = Ratio EXAMPLE: 34 divided by (34 + 20) = .63:1 Look familiar? The A4LD, the THM 200-4R, the A-140E, the A-40D, the THM 325-4L are some of the units that use this method of getting overdrive. (See figure) If the ring gear is held, then the Sun gear divided by (ring gear = Sun gear) = Ratio EXAMPLE: 20 divided by (34 + 20) = .37:1 (See figure) REVERSE IS THE EASIEST - THE PLANET IS HELD. The Sun gear is the input, and the ring gear is the output. The formula for this is: The ring gear divided by the Sun gear = Ratio. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8930 > Oct > 89 > A/T - Math Part II > Page 391 EXAMPLE: 34 divided by 20 = 1.7 (See figure) Occasionally, the ring gear is used as the input, and the Sun gear as the output. The formula for this is: The Sun gear divided by the ring gear = Ratio. EXAMPLE: 20 divided by 34 = .59 (See figure) Notice that the output is overdriven. A transmission using this method must use another planetary gear set to reduce the output. The Mercedes W3A-040 is a good example of this To get more than one gear forward and a reverse, requires multiple, or compound planetary gear sets. Two of the most common of these are the SIMPSON GEAR SET, used in transmissions like the THM 350, the Ford C-4, and the TF 6 & 8, and the RAVIGNEAUX GEAR SET, found in transmissions such as the FMX, the AOD, and the T-35. Figuring out all the ratios for these transmissions is a little tricky, so I'll give you the formulas, and let you figure out how these formulas were derived. THE SIMPSON GEAR SET: For this example I'll use a THM 200, which has 74 TEETH ON THE FRONT RING GEAR, 42 TEETH ON THE FRONT SUN GEAR, 30 TEETH ON THE REAR SUN GEAR, AND 62 TEETH ON THE REAR RING GEAR. The formula for 1ST GEAR is: rear ring divided by rear Sun x front Sun plus front Sun + front ring divided by front ring. EXAMPLE: On the THM 200, it would be: 62 divided by 30 x 42 + 42 + 74 divided by 74 = 2.74:1 SECOND GEAR is easy: Front Sun + front ring divided by front ring. EXAMPLE: 42 + 74 divided by 74 = 1.57:1 THIRD GEAR is Direct Drive, or 1:1 REVERSE is rear ring divided by rear Sun EXAMPLE: 62 divided by 30 = 2.06 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8930 > Oct > 89 > A/T - Math Part II > Page 392 THM 440-T4 (BACKWARDS SIMPSON): The THM 440 T4 is sort of a backwards version of a Simpson gear set, and although it looks complicated, it really is very simple. The front Sun gear has 26 teeth, while the rear Sun gear has 42. The front ring gear has 62 teeth, but keep in mind that it is part of the rear carrier, just as the rear ring gear is part of the front carrier, with a tooth count of 74. As I said earlier, the THM 440 T4 is sort of a backwards version of a Simpson gear set, so in figuring the ratio for 1ST GEAR -- it is identical, except you substitute the words "front" and "rear" in the appropriate places. Front ring divided by front sun x rear Sun + rear Sun + rear ring divided by rear ring = Ratio EXAMPLE: 62 divided by 26 x 42 + 42 + 74 divided by 74 = 2.92:1 2ND GEAR: Rear Sun + rear ring divided by rear ring Example: 42 + 74 divided by 74 = 1.57:1 3RD GEAR: Direct Drive, or 1:1 4TH GEAR: Front ring divided by (front Sun + front ring = Ratio EXAMPLE: 62 divided by (26 + 62) = .74:1 RAVIGNEAUX GEAR SET: This is considered a compound gear set, and for this example I'll use an AOD, which has: 36 teeth on the front Sun gear 30 teeth on the rear Sun gear, and 72 teeth on the ring gear The formula for first gear is: Ring gear divided by rear Sun gear = Ratio EXAMPLE: 72 divided by 30 = 2.4:1 SECOND GEAR formula is: Rear Sun + front Sun divided by rear Sun x Ring divided by (Ring + front Sun) EXAMPLE: (30 + 36) divided by 30 x 72 divided by (72 + 36) = Ratio 66 divided by 30 x 72 divided by 108 = 1.47 THIRD GEAR is Direct, or 1:1 FOURTH GEAR is: Ring gear divided by (ring gear + front Sun gear) = Ratio EXAMPLE: 72 divided by (72 + 36) = .67:1 REVERSE on a Ford AOD is: Ring gear divided by front Sun gear. EXAMPLE: 72 divided by 36 = 2:1 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8927 > Sep > 89 > A/T - Twenty Steps To Successful Repairs Automatic Transmission/Transaxle: Technical Service Bulletins A/T - Twenty Steps To Successful Repairs TSB 89-27 (Sept) SUBJECT: TWENTY STEPS TO SUCCESSFUL TRANSMISSION REPAIR 1. As you start work on a transmission, read your ATRA bulletins pertaining to that transmission. (If you do this every time, before you know it you'll have the bulletins memorized.) 2. Clean the entire transmission, including the valve body. 3. Check pumps, valve bodies, and cases for warpage. 4. Flat file pumps, valve bodies, and cases. (Just a few strokes with the file to knock off high spots and handle burrs.) 5. Check all pump gear clearances. 6. Check planet pinion endplay and side to side motion. 7. Soak all planet assemblies. 8. Soak all friction material for 15-30 minutes. 9. Sand, tumble, or replace all steel plates. 10. Re-surface all drums on which a band rides. 11. Replace all rotating oi1 control rings. 12. Check all oil control rings, and rubber products in their bores for proper fit. 13. Replace all major support bushings and bushings that control lube oil. 14. Pre-lubricate all bushings and thrust washers. 15. Pre-lube pumps. 16. Pre-fill torque converters. 17. Use available manuals to find specifications. 18. Set correct clutch and band clearances 19. Take the time to set total unit endplay 20. Use a torque wrench on all pumps and valve bodies. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8923 > Aug > 89 > A/T - Math Formulas Part I Technical Service Bulletin # ATRATB8923 Date: 890801 A/T - Math Formulas Part I TSB: 89-23 (Aug) SUBJECT: TRANSMISSION MATH FORMULAS (Your most valuable tool) Transmission math formulas are not reserved exclusively for engineers. Understanding some basic mathematical formulas can be one of your most valuable tools. The following information contained in this bulletin will discuss various basic formulas dealing with: 1. Shift Speed 2. Pressure 3. Speedometer ratios Take the time, now, to understand these relatively simple concepts. You will be saving yourself many problems, and considerable frustration, and also dollars, in the future. Shift Speed and Pressure SHIFT SPEED AND PRESSURE To figure the area of a circle (valve or servo): Radius (which is 1/2 the diameter) x Radius x 3.14159 = Area EXAMPLE: A 1" diameter circle has a radius of 0.5" 0.5 x 0.5 x 3.14159 = 0.785 Therefore a 1" diameter circle has an Area of 0.785 sq. inches Pressure x Area = Force EXAMPLE: 100 psi line pressure, on a servo with an area of 2 square inches = force So, 100 psi line pressure x 2 sq in = 200 pounds of force. Force divided by Area = Pressure EXAMPLE: 200 lbs divided by 2" = 100 psi Force divided by Pressure = Area EXAMPLE: 200 lbs divided by 100 psi = 2 inches THINGS WE CAN DO WITH THESE FORMULAS: EXAMPLE: A 700 R4 has 62 psi of line pressure at Idle. The PR spring weighs 6.5 lbs The tip (reaction end) of the PR valve has a diameter of 0.365" (0.365 divided by 2 = 0.1825 radius) 0.1825 x 0.1825 x 3.14159 = 0.1046" area We want 75 psi of line pressure at Idle First, let's see if those numbers add up, using: Pressure x Area = Force 62 psi x 0.1046 = 6.48, or 6 1/2 lb PR Spring We want 75 psi: Pressure x Area = Force (Spring) 75 psi x 0.1046 = 7.85 lb spring What if we put in an 8 lb Spring? Force divided by Area = Pressure Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8923 > Aug > 89 > A/T - Math Formulas Part I > Page 401 8 lbs divided by 0.1046 = 76.48 or 76 1/2 line pressure Now, let's look at RATIO. Ratio is the relationship in quantity, amount or size, between two or more things. In our example ratio is: How many psi each pound of spring will add. Pressure divided by Force = Ratio EXAMPLE: 62 psi divided by 6.5 lbs = 9.5 ratio Each pound of spring will increase pressure 9.5 psi Force x Ratio = Pressure EXAMPLE: 6.5 lbs x 9.5 = 61.75 or 62 psi (Let's add 1 lb of spring, and see if we get 9.5 more psi.) Force x Ratio = Pressure EXAMPLE: 7.5 lbs x 9.5 = 71.25 New pressure Old pressure = Pressure difference 71.25 minus 61.75 = 9.5 psi change (by adding 1 lb of spring) Once you know the ratio, a lot can be determined. Pressure divided by Ratio = Force 62 psi (actually 61.75) divided by 9.5 = 6.5 lb spring The ratio never changes. This means that if I know that line pressure is 55 psi at idle, in a 700 R4, the the PR spring must be 5.78 lbs. Pressure divided by Ratio = Force So, 55 psi divided by 9.5 = 5.78 lbs. Now, let's look at a math formula for shift speeds. Suppose we had shift speeds of 15 mph and 20 mph, for the 1-2 & 2-3 shifts on a transmission. 20 mph may be too early for the 2-3 shift. If we adjust TV modulator, we will move both shifts. We don't want to do that because the 1-2 shift is fine, so let's work with just the 2-3 shift spring. EXAMPLE: Original spring divided by Original MPH = Ratio As, 4 lbs divided by 25mph = 0.2 Ratio x Desired MPH = New Spring 0.2 x 25 mph = 5 lb spring A 5 lb spring will raise the shift on this transmission to 25 mph. All you need to know is -- Where is it shifting now (at MINIMUM throttle) and what does the spring weigh. This formula will get you very close, but may be a "tad" off, because we are not accounting for TV pressure helping the spring. This is why you want to check it at minimum throttle, so TV has the least effect. Speedometer Ratios Finally, let's look at speedometer ratios. Suppose we put an exchange transmission in a car, and now the speedometer is off, because the speedometer drive gear has a different tooth count. What do we have to do to the driven gear to correct it? Let's say the old drive gear had 7 teeth and the old driven gear had 21 teeth. The exchange unit had 8 teeth on the drive gear. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8923 > Aug > 89 > A/T - Math Formulas Part I > Page 402 Old Drive Gear divided by the New Drive Gear = Ratio 7 teeth divided by 8 teeth = 0.875 Old Driven Gear divided by Ratio = New Driven Gear 21 teeth divided by 0.875 = 24 teeth A 24 tooth driven gear will correct the speedometer error. Let's do one more speedometer change. This time the old drive is 9, and the new drive is 10. The old driven gear is still 21. Old Drive Gear divided by New Drive Gear = Ratio 9 tooth divided by 10 tooth = 0.9 Old Driven Gear divided by Ratio = New Driven Gear 21 tooth divided by 0.9 = 23.33 teeth We can't get a 23.3 tooth count so we round it off to 23 teeth. Now the speedometer will be close, but not exact, because we had to round off the number. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > 8912289614 > Jun > 89 > Adhesives & Sealants - Availability and Usage Automatic Transmission/Transaxle: Technical Service Bulletins Adhesives & Sealants - Availability and Usage ^ ADHESIVES AND SEALANTS-AVAILABILITY AND USAGE ^ ENGINE-ADHESIVES AND SEALANTS-AVILABILITY AND USAGE ^ STEERING-ADHESIVES AND SEALANTSAVAILABILITY AND USAGE ^ TRANSMISSION-ADHESIVES AND SEALANTSAVAILABILITY AND USAGE Article No. 89-12-2 FORD: 1989 and prior ALL FORD LINES LINCOLN-MERCURY: 1989 and prior ALL LINCOLN-MERCURY LINES MERKUR: 1989 and prior ALL MERKUR LINES LIGHT TRUCK: 1989 and prior ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1989 and prior ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Various adhesives and sealants are used to perform many service repairs. A partial list of these Ford products that are available through the Ford Parts System along with their proper use and application is shown below. ACTION: If adhesives and sealants are required to perform a service repair, refer to the following product information and the appropriate Shop Manual. Ford Stud And Bearing Mount (EOAZ-19554-BA)/ Ford Threadlocker 262 (E2FZ-19554-B) These adhesives are high strength threadlockers. They are used for locking all fasteners that must withstand: ^ Heavy shock and vibration. ^ Extreme chemical and environmental conditions, such as solvents, oils, and water immersion. They prevent fluid/vacuum leaks and seal out rust or corrosion. Their typical applications include securing the following items. ^ Intake manifold bolts ^ Power steering pump adjusting bolts ^ Engine studs ^ Ring gear bolts ^ Seat bolts ^ Cup plugs To use these adhesives, clean the fastener threads with a wire brush and a non-petroleum based solvent. Apply one or two drops to the threads and torque to the required specifications. NOTE: THESE ARE HIGH STRENGTH THREADLOCKERS AND THEY REQUIRE SPECIAL EFFORT FOR REMOVAL. Ford Threadlock And Sealer (EOAZ-19554-AA) This product is a medium strength threadlocker and sealer which stops air, oil, and fuel leakage. It is a hand tool removable adhesive and is used on aluminum threads. It prevents fluid/vacuum leaks and seals out rust or corrosion. Its typical applications include sealing and securing the following items. ^ Oil pan bolts ^ Valve cover bolts ^ Flywheel attaching bolts Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > 8912289614 > Jun > 89 > Adhesives & Sealants - Availability and Usage > Page 407 ^ Door latch attaching bolts To use this adhesive, clean the fastener threads with a wire brush and a non-petroleum based solvent. Apply one or two drops to the threads and torque to the required specifications. Ford Pipe Sealant With Teflon (D8AZ-19554-A) This product seals and locks air, oil, fuel and hydraulic threaded fasteners. This light paste sealant instantly seals without fouling. It is non-shredding and operates in temperatures up to 400~F. It prevents corrosion of fitting /fastener threads and locks against vibrational loosening. Its typical applications include sealing the following items. ^ Transmission oil coolant lines ^ Fuel inlet fittings ^ Intake manifold vacuum switches ^ Engine oil galley plugs To use this sealer, clean off residual oil, coolant and other contaminants from the threads. Apply sealer completely around the second and third threads. Install the part and torque to the required specifications. Ford Gasket Maker (E2AZ-19562-B) And Ford Gasket Eliminator (E1FZ-19562-A) These products cure in the absence of air. They are used to gasket two machined surfaced flanges. Each product will fill a gap up to .010". The sealants will not cure until the parts are assembled. Once cured, they will remain pliable and flex with movement of the parts. Their typical applications include sealing the following items. ^ Oil dip stick tubes ^ MTX case halves (Gasket Eliminator) ^ Water Pumps ^ Input bearing retainers ^ Rear main bearing parting lines To use these sealants, make sure all the old gasket material has been removed. CAUTION: AVOID USING METAL SCRAPERS BECAUSE THEY CAN ETCH THE SURFACES AND PREVENT A GOOD SEAL. Clean both surfaces with a non-petroleum based solvent to remove all oil, grease and other contaminants. Apply a small bead of sealant continuously around one surface only and then put the pieces together. NOTE: REMEMBER, THESE PRODUCTS CURE IN THE ABSENCE OF AIR, SO PLENTY OF TIME IS AVAILABLE TO DO A THOROUGH JOB. PART NUMBER PART NAME CLASS E0AZ-19554-BA Stud and Bearings Mount BM E2FZ-19554-B Ford Threadlocker 262 R E0AZ-19554-AA Threadlock and Sealer B D8AZ-19554-A Pipe Sealant with Teflon B E2AZ-19562-B Gasket Maker AM E1FZ-19562-A Gasket Eliminator AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8754 > Sep > 87 > A/T - Front Bushing Wear Automatic Transmission/Transaxle: Technical Service Bulletins A/T - Front Bushing Wear TSB 87-54 (Sept) SUBJECT: ALL AUTOMATICS PROBLEM: Front Bushing Wear CAUSE: When diagnosing front pump bushing wear, the cause may be: 1. Excessive CONVERTER HUB RUN-OUT. This may, or may not be due to a faulty torque converter. The torque converter can be checked visually, and with a dial indicator. (See Figure 1) Hub run-out should not exceed .010". 2. BROKEN, BENT OR CRACKED FLYWHEELS can also cause run-out. If the torque-converter-to-flywheel bolts have been loose, the flywheel holes can become egg-shaped, or the torque converter pads may wear into the flywheel, causing run-out. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8754 > Sep > 87 > A/T - Front Bushing Wear > Page 412 3. Another possibility is WEAR IN THE CRANKSHAFT, where it supports the torque converter pilot.(See Figure 2) Often the crankshaft is only worn in a small area where the torque converter pilot has been against it. If only a portion of the crankshaft is worn, rotate the crankshaft until the worn area is at 12:00 o'clock. When the torque converter is pushed forward into the crankshaft, the torque converter pilot will bottom on a good portion, and should center properly. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8748 > Aug > 87 > A/T - Slipping or No-Shift/Metal Sealing Rings Automatic Transmission/Transaxle: Technical Service Bulletins A/T - Slipping or No-Shift/Metal Sealing Rings TSB 87-48 (Aug) SUBJECT: Metal sealing rings Various Units PROBLEM: Slipping, or sometimes no-shift POSSIBLE SOLUTION: Sealing rings could be under-size. 1. Always inspect rings as outlined in SIL 84-29 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > ATRATB8748 > Aug > 87 > A/T - Slipping or No-Shift/Metal Sealing Rings > Page 417 2. Place ring in bore of drum where they will be running. (See Figures 1 & 2) 3. Sealing rings should be snug in bore; rings should fit all around the drum. (drum could be out-of-round) 4. Air check all drums. (Use 30 PSI air pressure only.) If air escapes you have leaks -- better find now, than later. This represents lost clutch pressure, and could result in soft application and burned friction material. 5. Following these steps will help you save money, plus help you build better units. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > Page 418 Automatic Transmission/Transaxle: Technical Service Bulletins A/T - Math Part II TSB: 89-30 (Oct) SUBJECT: TRANSMISSION MATH - Part II Planetary Gear Sets: Knowing the gear ratios of an automatic transmission can come in handy at times -- especially when you're swapping transmission types or differentials. The problem is in trying to find a manual with the ratios listed. What do you do? BREAK OUT THE CALCULATOR, AND FIGURE IT OUT. When you figure the gear ratios for planetary gear sets, it is just like any other gear set. You divide the output gear by the input. Also, don't count the idler gear; planetaries are considered idler gears. Set them aside, their tooth count doesn't matter. Now for the tricky part -- which gear do you consider the input, and which one the output? Figure 1 shows a planetary gear set with 34 teeth on the ring gear and 20 teeth on the Sun gear. FOR GEAR REDUCTION, one of the gears is held stationary, and the other is used for the INPUT. THE TOOTH COUNT FOR THE OUTPUT GEAR IS THE SUM OF THE SUN GEAR AND THE RING GEAR, so if you are using the Sun gear for the input, then the ring gear + the Sun gear divided by the Sun gear = Ratio. EXAMPLE: 34 + 20 divided by 20 = 2.7:1 This is how 1st gear on a THM 700 R4 is calculated. (See figure) When the ring gear is used as the input, then the ring gear + the Sun gear divided by the ring gear = Ratio. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > Page 419 EXAMPLE: 34 + 20 divided by 34 = 1.58 This is now 2nd gear on a THM 350 is calculated. (See figure) FOR OVERDRIVE, the sum of the ring gear + Sun gear is used for the input tooth count. So, IF THE SUN GEAR IS HELD, then the ring gear divided by (ring gear + Sun gear) = Ratio EXAMPLE: 34 divided by (34 + 20) = .63:1 Look familiar? The A4LD, the THM 200-4R, the A-140E, the A-40D, the THM 325-4L are some of the units that use this method of getting overdrive. (See figure) If the ring gear is held, then the Sun gear divided by (ring gear = Sun gear) = Ratio EXAMPLE: 20 divided by (34 + 20) = .37:1 (See figure) REVERSE IS THE EASIEST - THE PLANET IS HELD. The Sun gear is the input, and the ring gear is the output. The formula for this is: The ring gear divided by the Sun gear = Ratio. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > Page 420 EXAMPLE: 34 divided by 20 = 1.7 (See figure) Occasionally, the ring gear is used as the input, and the Sun gear as the output. The formula for this is: The Sun gear divided by the ring gear = Ratio. EXAMPLE: 20 divided by 34 = .59 (See figure) Notice that the output is overdriven. A transmission using this method must use another planetary gear set to reduce the output. The Mercedes W3A-040 is a good example of this To get more than one gear forward and a reverse, requires multiple, or compound planetary gear sets. Two of the most common of these are the SIMPSON GEAR SET, used in transmissions like the THM 350, the Ford C-4, and the TF 6 & 8, and the RAVIGNEAUX GEAR SET, found in transmissions such as the FMX, the AOD, and the T-35. Figuring out all the ratios for these transmissions is a little tricky, so I'll give you the formulas, and let you figure out how these formulas were derived. THE SIMPSON GEAR SET: For this example I'll use a THM 200, which has 74 TEETH ON THE FRONT RING GEAR, 42 TEETH ON THE FRONT SUN GEAR, 30 TEETH ON THE REAR SUN GEAR, AND 62 TEETH ON THE REAR RING GEAR. The formula for 1ST GEAR is: rear ring divided by rear Sun x front Sun plus front Sun + front ring divided by front ring. EXAMPLE: On the THM 200, it would be: 62 divided by 30 x 42 + 42 + 74 divided by 74 = 2.74:1 SECOND GEAR is easy: Front Sun + front ring divided by front ring. EXAMPLE: 42 + 74 divided by 74 = 1.57:1 THIRD GEAR is Direct Drive, or 1:1 REVERSE is rear ring divided by rear Sun EXAMPLE: 62 divided by 30 = 2.06 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > Page 421 THM 440-T4 (BACKWARDS SIMPSON): The THM 440 T4 is sort of a backwards version of a Simpson gear set, and although it looks complicated, it really is very simple. The front Sun gear has 26 teeth, while the rear Sun gear has 42. The front ring gear has 62 teeth, but keep in mind that it is part of the rear carrier, just as the rear ring gear is part of the front carrier, with a tooth count of 74. As I said earlier, the THM 440 T4 is sort of a backwards version of a Simpson gear set, so in figuring the ratio for 1ST GEAR -- it is identical, except you substitute the words "front" and "rear" in the appropriate places. Front ring divided by front sun x rear Sun + rear Sun + rear ring divided by rear ring = Ratio EXAMPLE: 62 divided by 26 x 42 + 42 + 74 divided by 74 = 2.92:1 2ND GEAR: Rear Sun + rear ring divided by rear ring Example: 42 + 74 divided by 74 = 1.57:1 3RD GEAR: Direct Drive, or 1:1 4TH GEAR: Front ring divided by (front Sun + front ring = Ratio EXAMPLE: 62 divided by (26 + 62) = .74:1 RAVIGNEAUX GEAR SET: This is considered a compound gear set, and for this example I'll use an AOD, which has: 36 teeth on the front Sun gear 30 teeth on the rear Sun gear, and 72 teeth on the ring gear The formula for first gear is: Ring gear divided by rear Sun gear = Ratio EXAMPLE: 72 divided by 30 = 2.4:1 SECOND GEAR formula is: Rear Sun + front Sun divided by rear Sun x Ring divided by (Ring + front Sun) EXAMPLE: (30 + 36) divided by 30 x 72 divided by (72 + 36) = Ratio 66 divided by 30 x 72 divided by 108 = 1.47 THIRD GEAR is Direct, or 1:1 FOURTH GEAR is: Ring gear divided by (ring gear + front Sun gear) = Ratio EXAMPLE: 72 divided by (72 + 36) = .67:1 REVERSE on a Ford AOD is: Ring gear divided by front Sun gear. EXAMPLE: 72 divided by 36 = 2:1 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > Page 422 Automatic Transmission/Transaxle: Technical Service Bulletins A/T - Twenty Steps To Successful Repairs TSB 89-27 (Sept) SUBJECT: TWENTY STEPS TO SUCCESSFUL TRANSMISSION REPAIR 1. As you start work on a transmission, read your ATRA bulletins pertaining to that transmission. (If you do this every time, before you know it you'll have the bulletins memorized.) 2. Clean the entire transmission, including the valve body. 3. Check pumps, valve bodies, and cases for warpage. 4. Flat file pumps, valve bodies, and cases. (Just a few strokes with the file to knock off high spots and handle burrs.) 5. Check all pump gear clearances. 6. Check planet pinion endplay and side to side motion. 7. Soak all planet assemblies. 8. Soak all friction material for 15-30 minutes. 9. Sand, tumble, or replace all steel plates. 10. Re-surface all drums on which a band rides. 11. Replace all rotating oi1 control rings. 12. Check all oil control rings, and rubber products in their bores for proper fit. 13. Replace all major support bushings and bushings that control lube oil. 14. Pre-lubricate all bushings and thrust washers. 15. Pre-lube pumps. 16. Pre-fill torque converters. 17. Use available manuals to find specifications. 18. Set correct clutch and band clearances 19. Take the time to set total unit endplay 20. Use a torque wrench on all pumps and valve bodies. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > Page 423 Technical Service Bulletin # ATRATB8923 Date: 890801 A/T - Math Formulas Part I TSB: 89-23 (Aug) SUBJECT: TRANSMISSION MATH FORMULAS (Your most valuable tool) Transmission math formulas are not reserved exclusively for engineers. Understanding some basic mathematical formulas can be one of your most valuable tools. The following information contained in this bulletin will discuss various basic formulas dealing with: 1. Shift Speed 2. Pressure 3. Speedometer ratios Take the time, now, to understand these relatively simple concepts. You will be saving yourself many problems, and considerable frustration, and also dollars, in the future. Shift Speed and Pressure SHIFT SPEED AND PRESSURE To figure the area of a circle (valve or servo): Radius (which is 1/2 the diameter) x Radius x 3.14159 = Area EXAMPLE: A 1" diameter circle has a radius of 0.5" 0.5 x 0.5 x 3.14159 = 0.785 Therefore a 1" diameter circle has an Area of 0.785 sq. inches Pressure x Area = Force EXAMPLE: 100 psi line pressure, on a servo with an area of 2 square inches = force So, 100 psi line pressure x 2 sq in = 200 pounds of force. Force divided by Area = Pressure EXAMPLE: 200 lbs divided by 2" = 100 psi Force divided by Pressure = Area EXAMPLE: 200 lbs divided by 100 psi = 2 inches THINGS WE CAN DO WITH THESE FORMULAS: EXAMPLE: A 700 R4 has 62 psi of line pressure at Idle. The PR spring weighs 6.5 lbs The tip (reaction end) of the PR valve has a diameter of 0.365" (0.365 divided by 2 = 0.1825 radius) 0.1825 x 0.1825 x 3.14159 = 0.1046" area We want 75 psi of line pressure at Idle First, let's see if those numbers add up, using: Pressure x Area = Force 62 psi x 0.1046 = 6.48, or 6 1/2 lb PR Spring We want 75 psi: Pressure x Area = Force (Spring) 75 psi x 0.1046 = 7.85 lb spring What if we put in an 8 lb Spring? Force divided by Area = Pressure Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > Page 424 8 lbs divided by 0.1046 = 76.48 or 76 1/2 line pressure Now, let's look at RATIO. Ratio is the relationship in quantity, amount or size, between two or more things. In our example ratio is: How many psi each pound of spring will add. Pressure divided by Force = Ratio EXAMPLE: 62 psi divided by 6.5 lbs = 9.5 ratio Each pound of spring will increase pressure 9.5 psi Force x Ratio = Pressure EXAMPLE: 6.5 lbs x 9.5 = 61.75 or 62 psi (Let's add 1 lb of spring, and see if we get 9.5 more psi.) Force x Ratio = Pressure EXAMPLE: 7.5 lbs x 9.5 = 71.25 New pressure Old pressure = Pressure difference 71.25 minus 61.75 = 9.5 psi change (by adding 1 lb of spring) Once you know the ratio, a lot can be determined. Pressure divided by Ratio = Force 62 psi (actually 61.75) divided by 9.5 = 6.5 lb spring The ratio never changes. This means that if I know that line pressure is 55 psi at idle, in a 700 R4, the the PR spring must be 5.78 lbs. Pressure divided by Ratio = Force So, 55 psi divided by 9.5 = 5.78 lbs. Now, let's look at a math formula for shift speeds. Suppose we had shift speeds of 15 mph and 20 mph, for the 1-2 & 2-3 shifts on a transmission. 20 mph may be too early for the 2-3 shift. If we adjust TV modulator, we will move both shifts. We don't want to do that because the 1-2 shift is fine, so let's work with just the 2-3 shift spring. EXAMPLE: Original spring divided by Original MPH = Ratio As, 4 lbs divided by 25mph = 0.2 Ratio x Desired MPH = New Spring 0.2 x 25 mph = 5 lb spring A 5 lb spring will raise the shift on this transmission to 25 mph. All you need to know is -- Where is it shifting now (at MINIMUM throttle) and what does the spring weigh. This formula will get you very close, but may be a "tad" off, because we are not accounting for TV pressure helping the spring. This is why you want to check it at minimum throttle, so TV has the least effect. Speedometer Ratios Finally, let's look at speedometer ratios. Suppose we put an exchange transmission in a car, and now the speedometer is off, because the speedometer drive gear has a different tooth count. What do we have to do to the driven gear to correct it? Let's say the old drive gear had 7 teeth and the old driven gear had 21 teeth. The exchange unit had 8 teeth on the drive gear. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Component Information > Technical Service Bulletins > Technical Service Bulletins for Automatic Transmission/Transaxle: > Page 425 Old Drive Gear divided by the New Drive Gear = Ratio 7 teeth divided by 8 teeth = 0.875 Old Driven Gear divided by Ratio = New Driven Gear 21 teeth divided by 0.875 = 24 teeth A 24 tooth driven gear will correct the speedometer error. Let's do one more speedometer change. This time the old drive is 9, and the new drive is 10. The old driven gear is still 21. Old Drive Gear divided by New Drive Gear = Ratio 9 tooth divided by 10 tooth = 0.9 Old Driven Gear divided by Ratio = New Driven Gear 21 tooth divided by 0.9 = 23.33 teeth We can't get a 23.3 tooth count so we round it off to 23 teeth. Now the speedometer will be close, but not exact, because we had to round off the number. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Differential Pinion Bolt - Removal Aid Pinion Gear: Technical Service Bulletins Differential Pinion Bolt - Removal Aid Article No. 84-6-15 AXLE - FORD-BUILT CAST CENTER AXLES - AID TO BOLT REMOVAL PROCEDURE FOR DIFFERENTIAL PINION SHAFT LOCK BOLT FORD 1977-84 FORD CARLINES WITH 7.5", 8.5", 8.7", 8.8" REAR AXLES LINCOLN-MERCURY 1977-84 LINCOLN-MERCURY CARLINES WITH 7.5", 8.5", 8.7", 8.8" REAR AXLES LIGHT TRUCKS 1977-84 LIGHT TRUCKS WITH 7.5", 8.8" REAR AXLES The subject bolt head may round off during removal with a conventional wrench or socket. To eliminate this condition, a socket type wrench may be made from a 3/8-inch Allen head bolt and a steel rod. FIGURE 12 Cut the Allen head from the bolt and weld the head to the 6" rod. The rod will serve as a handle (Figure 12). In addition, the recess in the Allen head fits the 5/16-inch head in the differential pinion shaft lock bolt precisely. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter M/T: > 831917 > Sep > 83 > Shift Lever Knob Pulls Off Shifter M/T: Customer Interest Shift Lever Knob - Pulls Off Article No. 83-19-17 TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS Figure 17 Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is out of specification. The following procedure is to identify the cause and to service the condition (See Figure 17). Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter M/T: > 831917 > Sep > 83 > Shift Lever Knob Pulls Off > Page 440 1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert from the shift ball. Knock the ball off the lever with a block of wood and a hammer. 2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken or missing pieces are noted. (Retain the plastic shift pattern insert). 3. On T-19 transmission inspect the knurled end of the shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter should be between 37/64" and 19/32" in diameter. 4. If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever should be replaced with a new one with good knurls. Also install a new shift ball with the new lever. Figure 17 5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using the original shift lever and shift ball insert. NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or suitable hand grinder, file or grind a radius Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter M/T: > 831917 > Sep > 83 > Shift Lever Knob Pulls Off > Page 441 or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the lever and (Figure 17, View A) to aid installation. 6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern insert. NOTE: Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View A) below the knurled section of the shift lever assembly. PART NUMBER PART NAME CLASS E2TZ-7213-B Shift Ball B E2TZ-7210-D Shift Lever T-18 R E3TZ-7210-N Shift Lever T-19 C E2TZ-7210-C Shift Lever NPG435 B E2TZ-7210-L Shift Lever SROD R E2TZ-7210-E Shift Lever M4OD R E3TZ-7210-A Shift Lever TK 4 spd. C E4TZ-7210-C Shift Lever TK 5 spd.* C E2TZ-7210-B Shift Lever NP208/W1345 C E3TZ-7210-K Shift Lever W-1350 C * - Shift lever assembly includes shift tower. OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210 Code: 01 or 16 as applicable. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter M/T: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off Shifter M/T: All Technical Service Bulletins Shift Lever Knob - Pulls Off Article No. 83-19-17 TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS Figure 17 Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is out of specification. The following procedure is to identify the cause and to service the condition (See Figure 17). Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter M/T: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 447 1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert from the shift ball. Knock the ball off the lever with a block of wood and a hammer. 2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken or missing pieces are noted. (Retain the plastic shift pattern insert). 3. On T-19 transmission inspect the knurled end of the shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter should be between 37/64" and 19/32" in diameter. 4. If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever should be replaced with a new one with good knurls. Also install a new shift ball with the new lever. Figure 17 5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using the original shift lever and shift ball insert. NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or suitable hand grinder, file or grind a radius Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter M/T: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 448 or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the lever and (Figure 17, View A) to aid installation. 6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern insert. NOTE: Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View A) below the knurled section of the shift lever assembly. PART NUMBER PART NAME CLASS E2TZ-7213-B Shift Ball B E2TZ-7210-D Shift Lever T-18 R E3TZ-7210-N Shift Lever T-19 C E2TZ-7210-C Shift Lever NPG435 B E2TZ-7210-L Shift Lever SROD R E2TZ-7210-E Shift Lever M4OD R E3TZ-7210-A Shift Lever TK 4 spd. C E4TZ-7210-C Shift Lever TK 5 spd.* C E2TZ-7210-B Shift Lever NP208/W1345 C E3TZ-7210-K Shift Lever W-1350 C * - Shift lever assembly includes shift tower. OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210 Code: 01 or 16 as applicable. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off Shifter Transfer Case: Customer Interest Shift Lever Knob - Pulls Off Article No. 83-19-17 TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS Figure 17 Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is out of specification. The following procedure is to identify the cause and to service the condition (See Figure 17). Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 458 1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert from the shift ball. Knock the ball off the lever with a block of wood and a hammer. 2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken or missing pieces are noted. (Retain the plastic shift pattern insert). 3. On T-19 transmission inspect the knurled end of the shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter should be between 37/64" and 19/32" in diameter. 4. If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever should be replaced with a new one with good knurls. Also install a new shift ball with the new lever. Figure 17 5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using the original shift lever and shift ball insert. NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or suitable hand grinder, file or grind a radius Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 459 or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the lever and (Figure 17, View A) to aid installation. 6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern insert. NOTE: Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View A) below the knurled section of the shift lever assembly. PART NUMBER PART NAME CLASS E2TZ-7213-B Shift Ball B E2TZ-7210-D Shift Lever T-18 R E3TZ-7210-N Shift Lever T-19 C E2TZ-7210-C Shift Lever NPG435 B E2TZ-7210-L Shift Lever SROD R E2TZ-7210-E Shift Lever M4OD R E3TZ-7210-A Shift Lever TK 4 spd. C E4TZ-7210-C Shift Lever TK 5 spd.* C E2TZ-7210-B Shift Lever NP208/W1345 C E3TZ-7210-K Shift Lever W-1350 C * - Shift lever assembly includes shift tower. OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210 Code: 01 or 16 as applicable. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off Shifter Transfer Case: All Technical Service Bulletins Shift Lever Knob - Pulls Off Article No. 83-19-17 TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS Figure 17 Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is out of specification. The following procedure is to identify the cause and to service the condition (See Figure 17). Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 465 1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert from the shift ball. Knock the ball off the lever with a block of wood and a hammer. 2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken or missing pieces are noted. (Retain the plastic shift pattern insert). 3. On T-19 transmission inspect the knurled end of the shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter should be between 37/64" and 19/32" in diameter. 4. If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever should be replaced with a new one with good knurls. Also install a new shift ball with the new lever. Figure 17 5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using the original shift lever and shift ball insert. NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or suitable hand grinder, file or grind a radius Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 466 or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the lever and (Figure 17, View A) to aid installation. 6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern insert. NOTE: Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View A) below the knurled section of the shift lever assembly. PART NUMBER PART NAME CLASS E2TZ-7213-B Shift Ball B E2TZ-7210-D Shift Lever T-18 R E3TZ-7210-N Shift Lever T-19 C E2TZ-7210-C Shift Lever NPG435 B E2TZ-7210-L Shift Lever SROD R E2TZ-7210-E Shift Lever M4OD R E3TZ-7210-A Shift Lever TK 4 spd. C E4TZ-7210-C Shift Lever TK 5 spd.* C E2TZ-7210-B Shift Lever NP208/W1345 C E3TZ-7210-K Shift Lever W-1350 C * - Shift lever assembly includes shift tower. OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210 Code: 01 or 16 as applicable. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > System Information > System Diagnosis Transmission Control Systems: Testing and Inspection For Transmission Control Systems Diagnosis, go to Powertrain Management/Computers and Control Systems/Testing and Inspection. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Brake Master Cylinder - Rebuilding Procedure Brake Master Cylinder: Technical Service Bulletins Brake Master Cylinder - Rebuilding Procedure Article No. 83-19-14 BRAKE MASTER CYLINDERS - REBUILDING PROCEDURE LIGHT TRUCKS 1981-84 ALL LIGHT TRUCKS Rebuilding of brake master cylinders during the vehicle warranty period for the subject vehicles has been authorized. Service kits (Base Part Number 2004) are now available for all light truck series vehicles. The following procedure is recommended for rebuilding: DISASSEMBLY 1. Clean the outside of the master cylinder and remove the filler cover and diaphragm. Drain and discard any brake fluid that remains in the cylinder. 2. Depress the primary piston and remove snap ring from retaining groove at the rear of the master cylinder bore. 3. Remove primary piston assembly from the master cylinder bore and inspect for seal damage or twisting. Record condition of piston assembly on service order and discard assembly. 4. Remove the secondary piston assembly by directing compressed air into the outlet port at the blind end of the bore while plugging the other outlet port. Inspect for seal damage or twisting. Record condition of piston assembly on service order and discard assembly. 5. Inspect the master cylinder bore for signs of etching, pitting, scoring or other damage. a. If bore is damaged, discard and replace with new master cylinder assembly. Do not attempt to hone bore. b. If bore is not damaged, rebuild master cylinder assembly using the proper service kit and the procedure outlined below. ASSEMBLY 1. Clean the master cylinder body with clean isopropyl alcohol to remove any contamination. 2. Dip the service kit piston assemblies in clean brake fluid (ESA-M6C25-A) to lubricate seals. 3. Carefully insert the complete secondary piston assembly in the master cylinder bore. 4. Carefully insert the primary piston assembly in the master cylinder bore. 5. Depress the primary piston and install the snap ring in the cylinder bore groove. 6. On manual brake vehicles, install the push rod retainer onto the push rod and install into the primary piston. Make sure the retainer is properly seated and holding the push rod securely. 7. Install the cover and gasket on the master cylinder assembly and secure into position with the retainer. OTHER APPLICABLE ARTICLES: 80-21-14 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 2004 Code: 53 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Technical Service Bulletins > Alternator - Rectifier Bench Test Procedure Rectifier Diode / Bridge: Technical Service Bulletins Alternator - Rectifier Bench Test Procedure Article No. 84-3-5 ALTERNATOR - RECTIFIER BENCH TEST PROCEDURE FORD ALL LINCOLN-MERCURY ALL LIGHT TRUCKS ALL MEDIUM/HEAVY TRUCKS ALL During a recent dealer survey, it was discovered that some technicians are using digital meters for alternator testing, despite specific instructions in the Shop Manual to the contrary. The digital meters cannot be used for checking rectifier assemblies or diodes in the alternator. This may explain a portion of non-defective rectifiers returned under warranty. Alternator Rectifier Testing Information The use of digital meters when bench testing an alternator rectifier assembly can cause misdiagnosis. It is recommended in the Shop Manual (Section 31) that a Rotunda Meter Model #059-00003, or equivalent, be used. Equivalent test meters must be of the "analog" type, not digital. A digital meter could only be used if it has a diode checking function. However, the readings should be compared with those of a new part to confirm the results. If the rectifier is found to be okay, check for possible pinched or grounded wires to the inside of the housing. Then reassemble the alternator with the tested rectifier. The Shop Manual Charging System Diagnostic Procedure should be reviewed to confirm proper procedures were used. Remember to first check for proper drive belt tension and proper wire connections at the alternator and voltage regulator. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Connector Views Ignition Lock: Connector Views For Connector Views, please refer to: Ignition Switch/Diagrams, Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Connector Views > Page 488 Ignition Lock: Electrical Diagrams For Wiring Diagrams, please refer to: Starting System/Diagrams, Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Starter - Motor Current Draw Revision Starter Motor: Technical Service Bulletins Starter - Motor Current Draw Revision Article No. 85-9-39 START - MOTOR CURRENT DRAW LIGHT TRUCK ALL The 1985 Light Truck Specification Book incorrectly states the starter motor current draw under normal conditions as 50-180 Amps (page 334). The Specification Book should state that the starter motor current draw under normal conditions should be 125 to 200 Amps. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary Technical Service Bulletin # TECGLOS Date: 890503 Electrical/Electronic/Fuel Induction - Glossary TECGLOS890503 DATE 05/03/89 TYPICAL ELECTRICAL COMPONENT SYMBOLS TECHNICIAN'S GLOSSARY This package contains a listing and explanation of Electrical/Electronic and Fuel Induction terms and components found in Ford Service and Training Publications. It is intended to be used as a quick reference and aid by technicians who service Ford built vehicles. (ELECTRICAL/ELECTRONIC AND FUEL INDUCTION) A AC - Abbreviation for alternating current. ACTIVE CIRCUIT - A circuit consisting of some active (semiconductor) elements. ACTIVE SENSOR - A sensor in which the output is taken directly from the sensor. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 497 ACTUATOR - A device which delivers motion in response to an electric signal. ACTUATOR CABLE - In a speed control system, the cable responsible for transferring movement of the vacuum diaphragm in the servo to the throttle plates. ADDRESS - A specific memory location. A microprocessor (or CPU) sends information to a specific address, or reads information from an address. AC/DC WAVEFORMS ALTERNATING CURRENT (AC) - Electrical flow that periodically reverses direction; two flows of current, from positive to negative, one in each direction, are called a "cycle." Abbreviation is AC. ALTERNATOR - Belt-driven electrical generator on the engine that produces a flow of alternating current and converts it to direct current. The current produced by the alternator is stored in the battery and used to supply all electrical needs of the vehicle. AMMETER - A device that measures the flow of electrical current in a circuit; readings are given in "amperes" AMPERAGE - The amount of electrical current flowing in a circuit as read in amperes. AMPERE - A unit measurement for the flow of electric current; 1 ampere flowing at 1 volt equals 1 watt of power. AMPERE HOUR CAPACITY - A figure indicating the capacity of a storage battery in that it will provide a certain amount of amperes over a certain number of hours. AMPLIFIER - (1) A circuit or device used to increase the voltage or current of a signal. (2) In a speed control system the solid state device that controls the operation of the system. Not used in IVSC system. AMPLIFY - To build up the strength of a signal. ANALOG - A continuously variable voltage signal. ANALOG - DIGITAL CONVERTER (A/D CONVERTER) - A circuit within the signal processing section of the ECA that takes an analog and converts it to a digital signal to be used in the microprocessor. ANALOG METER - A meter that uses a needle to point to a number on a scale of numbers, usually of the low impedance type. AND GATE - A type of logic circuit that requires all inputs to be YES in order for the output to be YES. ANTENNA ISOLATOR/AMPLIFIER - Device used on vehicles that utilize a combination antenna/rear window defroster. It amplifies radio signals from the rear defroster/antenna grid. It also provides power to the defroster grid. ARCING - (1) Electrical spark jumping from one electrode to another, as in a spark plug. (2) The occurrence of undesired sparking between electrical conductors or between a conductor and ground when insulation is damaged or inadequate. AUXILIARY WARNING MODULE - Module used on the Merkur Scorpio which controls the operation of the auxiliary warning system. B Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 498 B + - Abbreviation for the positive side of the power source. BASE - One of three elements or terminals of a transistor, usually where an input signal is applied. BATTERY - A device which converts chemical energy into electrical energy. A group of complete electrical cells assembled in one housing or case. BATTERY ACID - A solution of sulfuric acid used as the electrolyte in automotive storage batteries. BENDIX DRIVE - A starter drive system design used to engage the starter motor shaft with the gear teeth on the flywheel. Disengages automatically when the engine starts. BIAS - Term used to indicate a certain voltage operating position or range. BINARY - A number system using two digits - 0 and 1. BLOCK DIAGRAM - A simplified schematic diagram made up of boxes labeled with the circuit functions. BRUSH - A pad of electrically conductive material that bears on the commutator to provide an electrical circuit between rotating and stationary components. See also "commutator" BULB OUTAGE MODULE - Module used on the Merkur Scorpio which controls the lamp out warning system. C CAPACITIVE DISCHARGE - Ignition system in which primary power is stored in a capacitor; ignition spark is created by discharge of the capacitor. Also called "capacitor discharge." CAPACITOR - Electrical storage component also known as a "condensor" which acts as an electrical sponge. Wired across the distributor's breaker points, a capacitor absorbs electricity when points open, discharges it when they close. Capacitors are also used to suppress radio interference. CATHODE - Negative pole of an electric current. CHARGE (or Recharge) - Passing an electrical current through a battery to restore it to its proper energy level. CHIP - A miniaturized electronic circuit etched into a base of silicon. CIRCUIT - A system through which electricity flows before it returns to its source (thus having completed a circuit). CIRCUIT BREAKER CIRCUIT BREAKER - A mechanical device that opens contacts when an electric flow is excessive; used in place of a fuse. When current flow returns to normal, the circuit breaker in a car closes. CLOCK SIGNAL - Continuous series of pulses at a constant frequency. CLOSED CIRCUIT - A circuit which is uninterrupted from the current source and back to the current source. CLOSED LOOP - A system that feeds back its output to the input side of electronic control assembly which monitors the output and makes corrections as necessary. COAST - A speed control operating mode where the system is deactivated to reduce speed by pressing the COAST button. Once the COAST button is released, speed control is set at the speed that the vehicle is currently travelling. If the vehicle speed is reduced below approximately 30 mph (48 km/h), the operator must manually increase the speed and reset the system. COIL - An assembly of two wire coils in a transformer that steps up low-voltage current to the high levels needed to produce an ignition spark. COIL SECONDARY - Refer to "Secondary Circuit". Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 499 COLD CRANKING RATE - A rating for automotive batteries in a 30-sec discharge test; measured in amperes at either 0~F or -20~F. COLLECTOR - One of three elements or terminals of a transistor, usually where the output signal is taken from. COMMUTATOR - A slotted metal ring on the end of the rotor of a generator or electric motor. When in contact with stationary brushes, segments of the commutator conduct electricity to or from the turning rotor. COMPUTER - A device that takes information, processes it, makes decisions and outputs those decisions. CONDENSER - See "Capacitor." CONDUCTOR - A material, normally metallic, that permits easy passage of heat or electricity. CURRENT - A flow of electricity. Under the Electron Theory, flow is from negative to positive poles. Under the Conventional Theory, flow is from positive to negative. CURRENT LIMITING - A function usually done in the electronic control unit that allows B + to be connected to the sensor without short circuiting. D DARLINGTON - A two-transistor switch with transistors connected so that their collectors are common and their gains multiplied. DATA OUTPUT LINK (DOL) - Fuel calculation data from the EEC-IV processor to the electronic trip minder. DC - Abbreviation for direct current. DE-ENERGIZED - Having the electric current or energy source turned off. DIGITAL - A signal that has two states: ON or OFF. DIGITAL AUDIO DISC SYSTEM - Sound system that incorporates a compact audio disc player. The player picks up audio signals digitally encoded on the disc through a laser beam. DIGITAL METER - A meter that uses a numerical display in place of a needle and is usually of the high impedance type. DIMMER SWITCH - Handor foot-operated switch that turns the high-beam filaments of headlights on or off. DIODE - Electrical device that permits current to flow in only one direction. Most often used as a component in electronic controls and accessories. Also converts the output of an alternator from AC to DC. DIRECT CURRENT (DC) - Electric current flowing in one direction. DISABLE - A type of microcomputer decision which results in an automotive system being deactivated and not permitted to operate. DISCHARGE - Term describing the flow of electric current from a battery. Opposite of charge. DISPLAY - An output device used to display information. DISTRIBUTOR CAM - A shaft which is geared to the camshaft on the bottom, and has lobes on the top which open and close the breaker points. The rotor is also mounted on the top of this shaft just past the lobes. DRIVER - A transistor in the output control area of the ECA that is used to turn on and off various actuators. DUTY CYCLE SIGNAL - A type of square-wave signal that does not have a constant on and off time. DURASPARK II - A breakerless, solid state ignition system introduced in 1978. DURASPARK II used a module and coil similar to the earlier Solid State Ignition (SSI) system except for calibration. This system incorporated an adapter on the distributor to accommodate the large distributor terminal housing and larger rotor required for use with the higher voltage breakerless system. In addition, spark plug wire diameter was increased to 8 mm and improved silicone jacketing was incorporated. E EARTH - Term referring to a ground. ECA - Electronic Control Assembly E-CELL - A cell which deplates material from the anode to the cathode as a current in the microampere range is passed through it. When the anode is completely deplated, the E-cell becomes open which turns on a three stage transistor to switch a signal output. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 500 ELECTRODE - Posts or plates which have an electrical potential with respect to each other, such as in a spark plug or battery. Electrodes are either positive or negative. ELECTROLYTE - Active chemical filler in a battery. ELECTROMAGNETIC - Refers to a device which incorporates both electronic and magnetic principles together in its operation. ELECTROMECHANICAL - Refers to a device which incorporates both electronic and mechanical principles together in its operation. ELECTROMECHANICAL INSTRUMENT CLUSTER Instrument cluster, first introduced on Taurus/Sable models, that utilizes magnetic gauges and an "overlapping subassemblies" design. Use of the "overlapping sub-assemblies" design eases service because individual gauge sub-assemblies can be removed as individual pieces. ELECTRON - Negatively charged portion of an atom that orbits around the nucleus of the atom. ELECTRONIC - An operation, produced or caused by the action of electrons or by devices which function as a result of electron action. Electronic is often used to describe the control of systems or devices by the use of small electrical signals and various semiconductor devices and circuits. EMF - Electromotive force or voltage. EMITTER - One of three elements or terminals of a transistor that emits the electrons that the collector collects. ENABLE - A type of microcomputer decision which results in an automotive system being activated and permitted to operate. ENERGIZED - Having the electrical current or electrical source turned on. F FAILURE MODE EFFECTS MANAGEMENT (FMEM) STRATEGY - EEC IV strategy designed to reduce the adverse effects that may be caused by an EEC system sensor failure. Should a sensor fail, the ECA substitutes a good sensor signal in its place. This allows the engine to keep running so that the vehicle can be driven to the dealer for service. FIELD (A/C) - A coil with many turns of wire located behind the clutch rotor. Current passing through this coil sets up a magnetic field and causes the clutch to engage. FIELD - Magnetic lines of force orientated from north to south as in a magnetic field. A magnetic field may be natural as with a permanent magnet or created when electricity flows in a wire. FIELD COIL - A coil of insulated wire usually wound around an iron core. Current flowing in the coil produces a magnetic field. Also called "field winding." FILAMENT - A resistance in a light bulb which glows and produces light when a current is forced through it. FIRING LINE FIRING LINE - The total amount of voltage being expended through the secondary circuit. FLUX Electric or magnetic lines of force passing or flowing in a magnetic field. Also, material used to cause joining metal to adhere to both parts to be joined. FOUR-WAY FLASHERS - See "hazard warning system." FREE ELECTRON - Electrons that are not bound to a certain atom but are free to move around from atom to atom. FREQUENCY - Refers to the number of times something repeats itself (such as a signal from a sensor) in one second. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 501 FUEL PUMP MONITOR (FPM) - Input used to monitor the fuel pump secondary circuit. FUEL PUMP RELAY (FP) - Relay or its control line. Relay is controlled by ECA processor. Supplies power to electric fuel pump of EFI/CFI system. FUSE - A metal link in a circuit that melts when the current flow is excessive, thereby breaking the circuit. FUSE BLOCK - An assembly concentrating most or all of a car's fuses at one point. FUSIBLE LINK - A wire or bar designed to melt if more than a certain amount of electrical current is transmitted through it. Often used as a main fuse or backup fuse for large sectional portions of a car's electrical system. G GAIN - A comparison of an input signal level to an output signal level. GASSING - The venting of hydrogen bubbles from battery acid as the battery is recharged. GENERATOR - An electromechanical device that converts mechanical power into direct current electricity. GLOW PLUG IN CYLINDER HEAD GLOW PLUG - An assembly that resembles spark plug but with a heating element instead of electrodes. Used at the beginning of the starting cycle in a diesel engine to aid compression ignition. Sometimes spelled "glo plug" GND (or Ground) - Common line for all vehicle power, vehicle chassis ground and engine block ground, connected to vehicle battery negative terminal. GROUND - The negatively charged side of a circuit. A ground can be a wire, the negative side of the battery or even the vehicle chassis. The ground circuit must be at least the same size or bigger than the positive (hot) wire. GROUND CIRCUIT - The return side of an electric circuit. Usually the frame, body or engine of a single-wire automotive system. GROUNDING - Connecting one side of a car's electric circuit to the chassis, body, or engine. These parts then provide a metal path that conducts electrical current back to the car's battery to complete a circuit. Grounding may be done with a jumper wire. GROUP - A set of battery plates, either positive or negative, joined together but not assembled with separators. GROWLER - An electrical device for testing electric motor or generator armatures for shorts. H HALF-WAVE - A pulsating DC produced by rectifying AC. HALL-EFFECT - The "Hall Effect" is a process where current is passed through a small slice of semi-conductor material at the same time as a magnetic field to produce a small voltage in the semi-conductor. HARD SOLDER - Uniting two pieces of metal with material having a melting point higher than "soft" solder. Example: silver soldering. HAZARD WARNING SYSTEM - Electrical switching device and associated lights (usually the front and rear turn-signal lights) producing flashes of light to indicate that a car is in a distress situation. Also called "emergency flashers" or "fourway flashers". HEAT RANGE - A classification for spark plugs. The higher the number, the "hotter" the plug runs, which means that the plug does not dissipate heat as quickly as a "cooler" plug does. HEAT SINK - Metal bracket in end frame of alternator that contains and absorbs heat from diodes. HIGH TENSION - Secondary or induced high voltage electrical current. Circuit includes wiring fron. ignition distributor cap to coil and to each spark Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 502 plug. HIGH TENSION SECONDARY VOLTAGE - Voltage which enables current to jump the spark plug gap. This voltage is caused by the collapse of the magnetic field around the coil secondary windings. HOLE - A moveable vacancy which acts as a positive charge in a semi-conductor. HORN RELAY - Electromagnetic circuit-closing device that switches electricity to the horn when the horn button is depressed. HOT LEAD - A wire, or conductor, in the hot or power circuit. HYDROMETER - An instrument used to measure the specific gravity of liquids. Hydrometers can be calibrated to indicate the charge level of a battery or the percentage of antifreeze in a coolant mixture. I IDENTIFICATION CODE - A single digit, selftest service code, output at the beginning of the "engine running" test which is equal to one-half of the number of engine cylinders. IGNITION RESERVE - The differential between available voltage and the required voltage. IGNITION SWITCH - Key-operated main power switch in a car. Its chief function is to close the primary ignition circuit, but modern designs include several other circuits and even a steering column lock. IGNITION SYSTEM IGNITION SYSTEM - All the components that together produce the ignition spark: battery, distributor, ignition coil, spark plugs and associated switches and wiring. IMAGE LINE - The electronic picture tracing as seen on the screen of an oscilloscope. IMPEDANCE - A form of opposition to AC current flow (resistance) measured in OHMS. INDUCTION - The spontaneous creation of an electric current in a coil as it passes through a magnetic field. INERTIA SWITCH - A switch in the fuel pump circuit which shuts off power to the fuel pump in the event the vehicle is involved in a collision. This switch must be manually reset. INPUT - Information provided to a microcomputer to allow accurate control of a system. INPUT CONDITIONER - A device or circuit that conditions or prepares an input signal for use by a microcomputer. INSULATION - Materials which do not readily conduct electricity. INSULATOR - A nonconducting substance or body, such as porcelain, glass, or bakelite used for insulating wires in electrical circuits to prevent the leakage of electricity. INTEGRAL RELAY CONTROL MODULE (IRCM) - A module which interfaces with the EEC-IV processor to provide control of the cooling fan, A/C clutch and fuel pump. The module also incorporates the EEC power relay to provide power to the EEC-IV system. INTEGRATED CIRCUIT (IC) - A small semiconductor device that contains thousands of component parts and is capable of doing many circuit functions. Also called "chips" INTEGRATED VEHICLE SPEED CONTROL (IVSC) - A Ford speed control system which is integrated with the on-board EEC TV engine control system. This system does not require an amplifier because all computer control is through the EEC IV processor. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 503 INVERTERA - A circuit that takes an input and converts it to the opposite state in the output. J JUICE - A slang term for electricity. K KILOWATT - A measurement of power equal to 1,000 watts. 100 volts flowing at the rate of 10 amperes equals 1 kilowatt. Abbreviation is kw or KW. KILOWATT HOUR - The work accomplished by an agent operating at a power level of a kilowatt for one hour. 1kw. hr. = 1,000 watts x 3,600 seconds or 3,600,000 watt seconds. kw or KW Abbreviation for kilowatt. L LEAD - (1) An elemental metal that is heavy, pliable and easily melted. (2) Abbreviated term for tetraethyl lead. (3) A wire conductor. LEAD SULFATE - A product of the electrochemical action in a lead-acid battery. The sulfate deposit forms on the plates and slowly fouls the battery. LIGHT-EMITTING DIODE (LED) - A positivenegative junction of crystal material, housed in a dome-shaped housing, which produces light when forward bias current is applied. LINEAR POTENTIOMETER - A variable resistance whose resistance changes in direct proportion to the travel of the moveable terminal. LOAD - An electrical device connected into a circuit to provide a resistance and control the rate of current rate. LOAD TEST - (1) A test for starter motors in which the current draw is measured while the engine is cranking. (2) A battery test. LOGIC GATE - A circuit that will give an output when certain inputs are present. LOW FREQUENCY OSCILLATIONS - The long-tracing vertical image lines which are seen in the coil section. M MAGNET - Any body with the property of attracting iron or steel. MAGNETIC FIELD - The area surrounding the poles of a magnet which is affected by its attraction or repulsion forces. MAGNETIC GAUGE - Special type of instrument gauge, used in the electro-mechanical instrument cluster, that accurately show values even when the ignition is off. MAGNETIC PICKUP COIL - Coil used in the distributor of the breakerless solid state ignition systems to determine exactly when to switch off the coil secondary. MAGNETIC RELUCTANCE The resistance of a magnetic path to the flow of magnetic flux lines through it. MAGNETIC SWITCH - A switch operated by a small electromagnet. Solenoids and relays are magnetic switches. MAGNETO - A type of generator used in early vehicles which produced an extremely high voltage spark. MICROCOMPUTER - A device that takes information, processes it, makes decisions and outputs those decisions. Microcomputers are generally small and portable, and are located inside a processor. MICROPROCESSOR - A small processor contained within the on-board computer (processor). MINIMUM SPEED LOCKOUT (MSLO) - An additional safety feature added to Ford speed control systems that prevents speed control operation at very low speeds. MODULE - A control assembly. A module could be any package that is intended to perform a specific task (such as ignition). Usually modules can be disconnected and replaced easily. MOTOR - Electromechanical device that converts electricity into mechanical energy. MULTIPLE FUNCTION WARNING INDICATOR - A warning indicator assembly, first introduced on the 1987 Mustang GT that indicates low oil, low coolant, low fuel, and low washer conditions. N Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 504 N-TYPE - A semi-conductor material that has an excess of free electrons. NAND GATE - A type of logic device that requires all inputs to be YES in order for the output to be NO. NEGATIVE POLE - Point from which an electrical current flows as it passes through a circuit. NO-LOAD TEST - A test for starter motors in which current draw is measured when the starter's pinion gear is not engaged. NOR GATE - A type of logic circuit that if either input is YES, the output is NO. NORMALLY CLOSED - Refers to a switch or a solenoid that is closed when no control or force is acting on it. NORMALLY OPEN - Refers to a switch or solenoid that is open when no control or force is acting on it. NOT GATE - A type of logic circuit that has an inverted output; if the input is YES, the output is NO, and vice versa. NPN - A transistor with a P type base sandwiched between an N type emitter and collector. O OHM - A unit of electrical resistance opposing current flow. Resistance varies in different materials and varies with temperature. OHMMETER OHMMETER - An instrument that measures electrical resistance of a conductor in units called ohms. OHM'S LAW - A law of electricity which states the relationship between voltage, current and resistance. It takes an electromotive force of one volt to force one ampere of current through one ohm of resistance. Equation - volts = amperes x ohms (E = I x R) ON DEMAND TEST - In Self-Test, the Key On/Engine Off and Engine Running positions, which are technician initiated, are run from a program within the processor. OPEN CIRCUIT - An electrical circuit that because of break or because a switch has failed to close is not complete. See also "short circuit." OPEN LOOP - A system that does not feed back its output to its input. OPERATIONAL AMPLIFIER - A device with two inputs and one output having a very high voltage gain. OPTIC SENSOR - A device that produces a voltage signal by using a light source, a light sensitive material and a slotted wheel between the two. OR GATE - A type of logic circuit that if either input is YES, the output is YES. OSCILLATION - A rapid back-and-forth movement. OSCILLOSCOPE - Instrument that converts voltage and frequency readings into traces on a cathrode ray tube. OUTPUT - Decisions or commands issued by a microcomputer to output devices to allow displays and actuators to function. OUTPUT CONTROL - Circuits inside of the ECA that are used to turn external devices on and off. OUTPUT CYCLING CHECK (OCC) - A position of the end of the Key On/Engine Off test that enables energizing and de-energizing the auxiliary output on demand. OUTPUT DRIVER - A transistor in the output control area of the processor that is used to turn various actuators on and off. OUTPUT STATE CHECK - A test performed in the Key On/Engine Off mode after the continuous codes have been sent which forces the processor to Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 505 activate some actuators for additional diagnostics. OVERCHARGING - Continuing to charge a battery after it has a full charge; can damage the battery. P P TYPE - A semi-conductor material that has holes or a lack of electrons. PARALLEL CIRCUIT PARALLEL - Electrical design in which two or more circuits, batteries or components share common negative and positive connections. PASSIVE CIRCUIT - A circuit consisting of all passive elements, resistors, capacitors or inductors. PASSIVE SENSOR - A sensor which modifies the output of a voltage-divider network that the sensor is part of. PERMEABLE - A characteristic of how good a material is as a magnetic path. PHOTOELECTRIC CELL (PE) - A light sensitive material that changes variations of light into varying voltage signals. PHOTOTRANSISTOR - A light sensitive transistor that generates an output signal in proportion to the light picked up. PICKUP COIL PICKUP COIL - An electromagnetic device in the distributor of the electronic ignition system. It creates an electromagnetic field due to the permanent magnet that is part of the pickup assembly. Then the magnetic field produces an a.c. signal to the control module, informing the module of the turning position of the distributor shaft. PIEZOELECTRIC - Refers to an electronic device which is capable of generating a voltage when subjected to mechanical pressure. PLATE - (1) Component of a storage battery, one of a series of flat lead sheets with which acid reacts to produce electricity. (2) A pivoting flap in the choke or throttle valve of a carburetor. (3) To apply a coating or layer of one material over another. PNP - A transistor with an N type base sandwiched between a P type emitter and collector. POINT GAP - The space between the point contacts which is adjusted to provide the correct dwell. POLARITY - The difference in properties or powers between two bodies or the ends of one body, as in a magnet. According to the Current Theory, polarities in an electric circuit are established by an excess of electrons on one side (negative) and a deficiency on the other (positive). POSITIVE TEMPERATURE COEFFICIENT (PTC) HEATER - A heater system used on chokes and on diesel fuel heaters. PTC heaters are self regulating because as their temperature rises so too does the resistance limiting the amount of electrical flow and overall heating. POSITIVE TERMINAL - That terminal in a circuit to which current flows. POTENTIAL - Electrical force measured in volts. Sometimes used interchangeably with voltage. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 506 POTENTIAL DIFFERENCE - A difference of electrical pressure that sets up a flow of electric current. POTENTIAL DROP - A loss of electrical pressure due to resistance. POTENTIOMETER POTENTIOMETER (POT) - A variable resistor with three connections. The third connection (wiper) moves physically up and down the resistive element which has each end attached to one of the other two connections. PRIMARY - (1) A low-voltage circuit or part of a circuit. (2) The input coil of a transformer. PRIMARY WINDING - Low voltage winding of the coil which is electronically connected to its secondary only by the magnetic field they share. When the primary winding is connected across, a potential current flows through it, building a magnetic field around itself and inducing a voltage in the secondary. When disconnected, the cease in current through the primary again induces a voltage in the secondary which is used to ignite the air/fuel mixture. PRINTED CIRCUIT - Electrically conductive metal paths that are produced by printing a pattern on a board, then etching away all areas that are not printed. PROCESSOR - A metal housing which contains a microcomputer and other components used in providing electronic system control. The Electronic Control Assembly (ECA) is often referred to as the processor. PROGRAM - A set of detailed instructions which a microcomputer follows when controlling a system. PULSE - An abrupt change in voltage whether positive or negative. PULSE WIDTH - The length of time an actuator, such as a fuel injector, remains energized. Q QUARTZ-HALOGEN HEADLIGHT - A modern headlight design that produces a much brighter, whiter light than the conventional tungsten-filament light. The bulb is made of, quartz, rather than glass, and is filled with a halogen gas. Also called "halogen headlight." R RANDOM ACCESS MEMORY (RAM) - A type of memory which is used to store information temporarily. Information can be written to and read from RAM. READ - A microcomputer operation where information is retrieved from memory. READ ONLY MEMORY (ROM) - A type of memory which is used to store information permanently. Information can not be written to ROM; as the name implies, information can only be read from ROM. READOUT CONTROL - Circuits inside of the ECA that are used for operating digital instrument displays. RECHARGE - (1) To restore energy to a battery by means of an electric current. (2) To restore the level of a substance in a system, as recharging an air conditioner with refrigerant. RECTIFIER (diode) - Electrical device that permits alternating current to flow in only one direction thereby transforming it into direct current. REDUNDANT BRAKE SHUTOFF - A safety feature of Ford speed control systems that shuts the speed control system off if there is a 10-15 mph drop in speed. REFERENCE VOLTAGE (VREF) - Power supplied by the ECA to some sensors that are regulated at a specific voltage. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 507 STARTER RELAY RELAY - An electromagnetic switching device using low current to open or close a high-current circuit. RELUCTANCE - The resistance of a material to the flow of magnetic lines of force. REQUIRED VOLTAGE - Voltage necessary to overcome the resistance of the secondary circuit and establish a spark to the ground electrode of the spark plug. RESERVE CAPACITY - The length of time that a fully charged battery at 80~F will remain functional when it is discharging at a rate of 25 amps. This rating is intended to tell the driver how long the car can be operated with headlights and certain other accessories on after an alternator failure. RESIDUAL MAGNETISM - Slight magnetic properties retained by metal, such as a wiring coil in a generator, after it has passed through a magnetic field. RESISTANCE - The opposition offered by a conductor to a flow of electricity; measured in ohms. RESISTOR - A device installed in an electrical circuit which tends to prevent or reduce the flow of current. RESUME - An operating mode of the speed control system which reactivates the system after it has been disabled (such as by stepping on the brake or clutch pedal) and returns it to the speed at which it was previously set. Shutting the vehicle off erases the resume memory. RHEOSTAT - A device for regulating a current by means of a variable resistance. ROTOR ROTOR - The rotating part of a distributor that transfers current from the coil cable to the spark plug cables. S SAMPLING - The act of periodically collecting or sending information. A microcomputer samples input from various sensors in the process of controlling a system. SCHEMATIC DIAGRAM Symbolic representation of an electric circuit or vacuumhose circuit. SEALED-BEAM - Headlight design incorporating filaments, reflector, and a lens in a unit with no separate bulb. SECONDARY - (1) A high-voltage circuit or part of a circuit. (2) The output coil of a transformer. SECONDARY CIRCUIT - The high voltage part of the ignition system which extends from the center tower of the coil all the way down to and across the spark plug gap. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 508 SECONDARY INSULATION (SPARK PLUG WIRE) SECONDARY INSULATION - The material that contains the spark from the time it leaves the center tower of the coil to the time it reaches the insulated electrode of the spark plug. SECONDARY RESISTANCE - The resistance encountered by electricity as it travels on its route from the center tower of the coil to the ground electrode of the spark plug. SECONDARY WINDING - See "Secondary Circuit." SEMICONDUCTOR - General term for transistors, integrated circuits, and other electronic devices made of materials, such as silicone, that conduct electricity poorly. SENSOR - Used as inputs to the ECA, a device that measures a condition and converts it into some kind of electrical signal. SERIES - An electrical connection in which two or more circuits, batteries or components are connected negative to positive. The opposite of "parallel." SERVO - In a speed control system, a vacuum operated device controlled by the amplifier responsible for changing the throttle plate settings in relationship to engine speed. The servo contains solenoid valves for controlling vacuum to the diaphragm and a throttle position sensor (servo in IVSC system does not contain throttle position sensor). SET/ACCEL - In a speed control system, a driver control button that is responsible for setting a speed. It can also be used to raise the speed by holding it down until the desired speed is reached. SHIFT INDICATOR LIGHT (SIL) - A system primarily controlled by engine speed and manifold vacuum which provides a visual indication to the driver of when to shift to the next higher gear to obtain fuel economy. SHORT CIRCUIT - Defect in an electric circuit in which electricity flows directly from one conductor to another rather than through the intended circuit. SHUNT - A conductor joining two points in a circuit so as to form a parallel circuit through which a portion of the current may pass in order to regulate the amount of current flowing in the main circuit. SHUNT CIRCUIT - A minor side circuit that parallels and feeds off a main circuit. SIGNAL - A voltage condition that transmits specific information in an electronic system. SIGNAL PROCESSING - A general term used for conditioning input signals. It covers many functions such as A/D converting, amplifying, counting, etc. It describes what happens to input signals from the sensor on their way to the microprocessor. SINE-WAVE - A voltage signal generated by a coil of wire, a magnetic field and movement between them. SLIP RING - A circular conductor on a rotor or armature that contacts brushes. Electricity flows from the brushes to the slip ring, thus allowing current to pass from a stationary part to a rotating part. SLOW CHARGE - The preferred method of administering a charge to a battery where current is applied over a long period of time and at a low rate. SOLENOID - A wire coil with a moveable core which changes position by means of electromagnetism when current flows through the coil. Sometimes synonymous with "relay." SOLENOID RELAY - A switching component in the starter motor circuit. Light current operates the solenoid, which closes the contacts carrying the heavy current to the starter motor. SOLENOID SWITCH - A switch operated by a solenoid. SOLENOID VACUUM SWITCH - Any one of a variety of engine control devices that combine a solenoid switch and a vacuum valve. The solenoid opens or closes a valve in a vacuum line, usually as part of a pollution-control system. SOLID STATE - General term for transistors and related electronic components that are replacing vacuum tubes. SOLID STATE IGNITION (SSI) - The ignition systems that used a transistor to switch the coil. One used breaker points to switch on the transistor, the Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 509 other used the magnetic pickup coil. Both of these systems precede the Duraspark systems, but the one that used the pickup coil is the same. SPARK ADVANCE - Causing the ignition spark to occur earlier. SPARK GAP - The space between the spark plugs center electrode and ground electrode. SPARK LINE - The pattern that represents the time during which the air/fuel mixture is being burned within the combustion chamber. SPARK PLUG - Electrical component that produces a spark to ignite the air/fuel mixture in the cylinders. SPARK RETARD - Causing less spark advance to be added, resulting in an ignition spark introduced later. SPLICE - The joining of two or more conductors at a single point by crimping, soldering or brazing. SQUARE-WAVE - A digital on-off type of signal that has a very fast rise and fall. STARTER - The electric motor and drive mechanism used to start an engine. STOPLAMP SWITCH - Switch responsible for disabling the speed control system when the brakes are applied. Also responsible for operating the stoplamps when the brake pedal is depressed. STORAGE CELLS - A cell which stores potential for electricity in the form of chemicals. Once discharged it can be recharged by forcing current through it in the opposite direction. These cells, when placed in series, form a storage battery. STRATEGY - The programming of the ECA determining how it reacts under certain conditions. Some currently used strategies are Failure Mode Effects Management (FMEM), Idle, Lean Cruise, etc. SWITCH - A device used to open, close or redirect the current in an electrical circuit. T TERMINAL - A device attached to the end of a wire or cable to make an electrical connection. THERMISTOR - A resistor that changes its resistance with temperature. THERMOCOUPLE - A thermoelectric device used to measure temperature accurately, especially one consisting of two dissimilar metals joined together so that a potential difference is generated between the points of contact. The amount of potential difference is a measure of the heat at the point of contact of the two dissimilar metals. THICK FILM IGNITION (TFI) -IV - Electronic ignition system utilizing a Hall-Effect sensor to switch the ignition coil on and off through the ECA. The term "thick film" is Lised to describe the process used to build the TFI circuit on the module. The basic circuit is placed on a layer of alumina. Several layers of film are required to print the circuit - hence the name "thick film." The resistors and connecting paths are part of the film. Other components such as capacitors, diodes, darlington transistors and integrated circuits are added on top of the thick film or are attached to it. There are two TFI systems, TFI-I used on 1982 1.6L engines, and TFI-II used on engines after 1983 with EEC-IV. The TFI-IV ignition system uses no vacuum or centrifugal advance, all advance is controlled by the ECA. TFII utilizes vacuum and centrifugal advance. Both TFI-I and IV use an E-core coil instead of an oil filled coil. THICK FILM IGNITION (TFI) MODULE - Smaller module which is mounted on the distributor and fires the ignition coil. THROUGHPUT - The flow of a voltage signal from input to output. TIMER - A feature of microcomputers which allows the microcomputer to measure time intervals, such as "time since engine start" or "time in neutral idle." TRANSDUCER - A device that changes energy from one form to another. For example, a transducer is used to change the pulse of fuel injection in a diesel to electricity so that timing can be checked. In automotive air-conditioning controls used in automatic temperature systems, a transducer changes an electrical signal to a vacuum signal, which operates mechanical doors. TRANSFER HOSE - Hose on the speed control servo that connects either manifold vacuum or atmospheric pressure to the sealed side of the diaphragm, depending on servo solenoid positions. TRANSISTOR - A small solid-state electronic switching device which uses semiconductors. Widely used to replace vacuum tubes and switches. TRUTH TABLE - A chart that lists all of the possible combinations of inputs and the corresponding outputs for a logic gate. U UNIVERSAL DISTRIBUTOR - Distributor which uses a PIP sensor instead of a CP sensor, and TFI module instead of the Dura-Spark ignition module. This distributor can be used with EEC only. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 510 V VACUUM DUMP VALVE - A valve that mechanically releases the vacuum from the servo when the brake pedal is depressed. VACUUM SOLENOID VALVE - An electrically operated vacuum on and off valve similar in operation to a relay. VEHICLE SPEED SENSOR - Device mounted on the transmission or speedometer cable that is responsible for monitoring vehicle speed and passing the information on to the speed control amplifier or EEC IV module. VOLT - The unit of measurement for the force or pressure of a flow of electricity. VOLTAGE - The electrical pressure which causes current to flow in a circuit. VOLTAGE APPLIED The actual voltage read at a given point in a circuit. It equals the available voltage of the power supply minus the losses in the circuit up to that point. VOLTAGE AVAILABLE - The voltage delivered by the power supply (battery, alternator, generator, etc.). VOLTAGE DIVIDER - Two or more resistances connected in series form a voltage divider network. When current flows the voltage divides itself across the resistances. VOLTAGE DROP - A lowering of the voltage in a circuit when resistance, or electrical load, is added. VOLTAGE REGULATOR - An electrical device that prevents excessive voltage on, or overcharge of, the battery by the generator or alternator. VOLTMETER - An instrument used to measure the voltage in an electrical circuit. VOLT-OHM-METER (VOM) - Combination meter used to measure voltage and resistance (ohms). They are available in both analog (measures by needle movement) or digital (measures by a numeric display). May be referred to as an AVOM (analog) or DVOM (digital). VREF - Abbreviation for reference voltage. W WATT - A measurement of power. One volt multiplied by 1 amp equals 1 watt, and 746 watts equal 1 horsepower. One "kilowatt" equals 1,000 watts. WIGGLE TEST - Performed with either a voltmeter or star tester while wiggling or tapping the system harness connectors. WIPER - Refer to "potentiometer." WIRING HARNESS - A bundle of insulated electrical wires covered by an additional insulating jacket. The individual wires emerge from the harness at different points to go to various components. WRITE - A microcomputer operation where information is sent to and stored in memory. X X-NOR GATE - A logic circuit that requires both inputs to be the same for a YES output. X-OR GATE - A logic circuit that requires both inputs to be the same for a NO output. Z ZENER DIODE - A two terminal device with 1 PN junction that can conduct in the reverse direction when a certain voltage is reached. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 511 Power and Ground Distribution: Technical Service Bulletins Wire Harness Terminal and Connector - Service Kit WIRING-WIRE HARNESS TERMINAL AND CONNECTOR SERVICE KIT Article No. 89-19-5 FORD: 1990 and prior ALL FORD LINES LINCOLN-MERCURY: 1990 and prior ALL LINCOLN-MERCURY LINES MERKUR: 1990 and prior ALL MERKUR LINES LIGHT TRUCK: 1990 and prior ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1990 and prior ALL MEDIUM/HEAVY TRUCK LINES This TSB article is being republished in its entirety to make dealers aware of availability of the wiring harness terminal and connector repair kit. ISSUE: A wire harness terminal and connector repair kit is available for repairing electrical wire harnesses. This kit allows dealers to repair broken or corroded terminals and connectors instead of replacing an entire wire harness. The kit is easy to use and allows the technician to perform a professional looking repair in a short period of time. ACTION: To purchase a wire harness terminal and connector repair kit, contact Altair International Incorporated. Refer to the following information for ordering details. ALTAIR INTERNATIONAL INC. ATTN: SALES DEPARTMENT 22800 HALL ROAD MT. CLEMENS, MI 48043 TELEPHONE: (313) 466-1200 An order form is included in the back of this TSB issue. To order: ^ Fill out the order form. ^ Enclose a check for the total amount. (This kit cannot be charged to your dealership parts code.) ^ Send the completed form and check to the ALTAIR INTERNATIONAL INC. The kit consists of: ^ Two 50 drawer metal cabinets that contain 6 each of the 96 different terminals, machined crimped with a four inch "pigtail" of 12 or 16 gauge wire. ^ A unique, high compression crimping tool that will make sure of a solid connection preventing moisture or contaminants from affecting the wire splice. OTHER APPLICABLE ARTICLES: none SUPERSEDES: 88-17-5, Date 8/17/88 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2770, 2700 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 512 Technical Service Bulletin # 87153 Date: 870729 Wiring - Circuit Number/Color Code Charts WIRING - CORPORATE STANDARD CIRCUIT Article No. NUMBER CHARTS FOR WIRE CIRCUIT NUMBER, 87-15-3 AND COLOR CODES FORD: 1980-88 ALL CAR LINES LINCOLN-MERCURY: 1980-88 ALL CAR LINES MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1980-88 F SERIES, BRONCO 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR ISSUE: The Standard Circuit Number Charts on pages 11 through 20 of this TSB are being printed for your information. The electrical circuits are listed by number code with the description/name and the matching color code as specified by Ford Corporate Standards. These charts are also printed in the reference section of the Vacuum and Wiring Manual. ACTION: When tracing circuits or trying to pinpoint individual circuits, use these charts with the appropriate Shop Manual, EVTM (Electrical and Vacuum Troubleshooting Manual), or the Vacuum and Wiring Manual. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Color Codes The wire color code indicates the circuit number, color of the wire and the wire gauge size. Where two colors are shown for a wire, the first color is the basic color of the wire. The second color is the dot, hash, or stripe marking. If D or H is given, the second color is dots or hash marks. If there is no letter after the second color, the wire has a stripe. For example: BR/O is a brown wire with an orange stripe. R/Y D is a red wire with yellow dots. BK/W H is a black wire with white hash marks. Color Abbreviations BL Blue N Natural BK Black O Orange BR Brown PK Pink DB Dark Blue P Purple DG Dark Green R Red GR Green T Tan GY Gray W White LB Light Blue Y Yellow LG Light Green If a vehicle specific wire color in a connector does not match the diagram shown, it can usually be identified by comparing the other colors shown at the wire connectors. Specific wire color deviations in the manufacturing of a wire harness are usually for a short duration. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 513 WIRE TYPES Standard Circuit Number Chart Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 514 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 515 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 516 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 517 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 518 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 519 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 520 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 521 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 522 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 523 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary Technical Service Bulletin # TECGLOS Date: 890503 Electrical/Electronic/Fuel Induction - Glossary TECGLOS890503 DATE 05/03/89 TYPICAL ELECTRICAL COMPONENT SYMBOLS TECHNICIAN'S GLOSSARY This package contains a listing and explanation of Electrical/Electronic and Fuel Induction terms and components found in Ford Service and Training Publications. It is intended to be used as a quick reference and aid by technicians who service Ford built vehicles. (ELECTRICAL/ELECTRONIC AND FUEL INDUCTION) A AC - Abbreviation for alternating current. ACTIVE CIRCUIT - A circuit consisting of some active (semiconductor) elements. ACTIVE SENSOR - A sensor in which the output is taken directly from the sensor. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 528 ACTUATOR - A device which delivers motion in response to an electric signal. ACTUATOR CABLE - In a speed control system, the cable responsible for transferring movement of the vacuum diaphragm in the servo to the throttle plates. ADDRESS - A specific memory location. A microprocessor (or CPU) sends information to a specific address, or reads information from an address. AC/DC WAVEFORMS ALTERNATING CURRENT (AC) - Electrical flow that periodically reverses direction; two flows of current, from positive to negative, one in each direction, are called a "cycle." Abbreviation is AC. ALTERNATOR - Belt-driven electrical generator on the engine that produces a flow of alternating current and converts it to direct current. The current produced by the alternator is stored in the battery and used to supply all electrical needs of the vehicle. AMMETER - A device that measures the flow of electrical current in a circuit; readings are given in "amperes" AMPERAGE - The amount of electrical current flowing in a circuit as read in amperes. AMPERE - A unit measurement for the flow of electric current; 1 ampere flowing at 1 volt equals 1 watt of power. AMPERE HOUR CAPACITY - A figure indicating the capacity of a storage battery in that it will provide a certain amount of amperes over a certain number of hours. AMPLIFIER - (1) A circuit or device used to increase the voltage or current of a signal. (2) In a speed control system the solid state device that controls the operation of the system. Not used in IVSC system. AMPLIFY - To build up the strength of a signal. ANALOG - A continuously variable voltage signal. ANALOG - DIGITAL CONVERTER (A/D CONVERTER) - A circuit within the signal processing section of the ECA that takes an analog and converts it to a digital signal to be used in the microprocessor. ANALOG METER - A meter that uses a needle to point to a number on a scale of numbers, usually of the low impedance type. AND GATE - A type of logic circuit that requires all inputs to be YES in order for the output to be YES. ANTENNA ISOLATOR/AMPLIFIER - Device used on vehicles that utilize a combination antenna/rear window defroster. It amplifies radio signals from the rear defroster/antenna grid. It also provides power to the defroster grid. ARCING - (1) Electrical spark jumping from one electrode to another, as in a spark plug. (2) The occurrence of undesired sparking between electrical conductors or between a conductor and ground when insulation is damaged or inadequate. AUXILIARY WARNING MODULE - Module used on the Merkur Scorpio which controls the operation of the auxiliary warning system. B Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 529 B + - Abbreviation for the positive side of the power source. BASE - One of three elements or terminals of a transistor, usually where an input signal is applied. BATTERY - A device which converts chemical energy into electrical energy. A group of complete electrical cells assembled in one housing or case. BATTERY ACID - A solution of sulfuric acid used as the electrolyte in automotive storage batteries. BENDIX DRIVE - A starter drive system design used to engage the starter motor shaft with the gear teeth on the flywheel. Disengages automatically when the engine starts. BIAS - Term used to indicate a certain voltage operating position or range. BINARY - A number system using two digits - 0 and 1. BLOCK DIAGRAM - A simplified schematic diagram made up of boxes labeled with the circuit functions. BRUSH - A pad of electrically conductive material that bears on the commutator to provide an electrical circuit between rotating and stationary components. See also "commutator" BULB OUTAGE MODULE - Module used on the Merkur Scorpio which controls the lamp out warning system. C CAPACITIVE DISCHARGE - Ignition system in which primary power is stored in a capacitor; ignition spark is created by discharge of the capacitor. Also called "capacitor discharge." CAPACITOR - Electrical storage component also known as a "condensor" which acts as an electrical sponge. Wired across the distributor's breaker points, a capacitor absorbs electricity when points open, discharges it when they close. Capacitors are also used to suppress radio interference. CATHODE - Negative pole of an electric current. CHARGE (or Recharge) - Passing an electrical current through a battery to restore it to its proper energy level. CHIP - A miniaturized electronic circuit etched into a base of silicon. CIRCUIT - A system through which electricity flows before it returns to its source (thus having completed a circuit). CIRCUIT BREAKER CIRCUIT BREAKER - A mechanical device that opens contacts when an electric flow is excessive; used in place of a fuse. When current flow returns to normal, the circuit breaker in a car closes. CLOCK SIGNAL - Continuous series of pulses at a constant frequency. CLOSED CIRCUIT - A circuit which is uninterrupted from the current source and back to the current source. CLOSED LOOP - A system that feeds back its output to the input side of electronic control assembly which monitors the output and makes corrections as necessary. COAST - A speed control operating mode where the system is deactivated to reduce speed by pressing the COAST button. Once the COAST button is released, speed control is set at the speed that the vehicle is currently travelling. If the vehicle speed is reduced below approximately 30 mph (48 km/h), the operator must manually increase the speed and reset the system. COIL - An assembly of two wire coils in a transformer that steps up low-voltage current to the high levels needed to produce an ignition spark. COIL SECONDARY - Refer to "Secondary Circuit". Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 530 COLD CRANKING RATE - A rating for automotive batteries in a 30-sec discharge test; measured in amperes at either 0~F or -20~F. COLLECTOR - One of three elements or terminals of a transistor, usually where the output signal is taken from. COMMUTATOR - A slotted metal ring on the end of the rotor of a generator or electric motor. When in contact with stationary brushes, segments of the commutator conduct electricity to or from the turning rotor. COMPUTER - A device that takes information, processes it, makes decisions and outputs those decisions. CONDENSER - See "Capacitor." CONDUCTOR - A material, normally metallic, that permits easy passage of heat or electricity. CURRENT - A flow of electricity. Under the Electron Theory, flow is from negative to positive poles. Under the Conventional Theory, flow is from positive to negative. CURRENT LIMITING - A function usually done in the electronic control unit that allows B + to be connected to the sensor without short circuiting. D DARLINGTON - A two-transistor switch with transistors connected so that their collectors are common and their gains multiplied. DATA OUTPUT LINK (DOL) - Fuel calculation data from the EEC-IV processor to the electronic trip minder. DC - Abbreviation for direct current. DE-ENERGIZED - Having the electric current or energy source turned off. DIGITAL - A signal that has two states: ON or OFF. DIGITAL AUDIO DISC SYSTEM - Sound system that incorporates a compact audio disc player. The player picks up audio signals digitally encoded on the disc through a laser beam. DIGITAL METER - A meter that uses a numerical display in place of a needle and is usually of the high impedance type. DIMMER SWITCH - Handor foot-operated switch that turns the high-beam filaments of headlights on or off. DIODE - Electrical device that permits current to flow in only one direction. Most often used as a component in electronic controls and accessories. Also converts the output of an alternator from AC to DC. DIRECT CURRENT (DC) - Electric current flowing in one direction. DISABLE - A type of microcomputer decision which results in an automotive system being deactivated and not permitted to operate. DISCHARGE - Term describing the flow of electric current from a battery. Opposite of charge. DISPLAY - An output device used to display information. DISTRIBUTOR CAM - A shaft which is geared to the camshaft on the bottom, and has lobes on the top which open and close the breaker points. The rotor is also mounted on the top of this shaft just past the lobes. DRIVER - A transistor in the output control area of the ECA that is used to turn on and off various actuators. DUTY CYCLE SIGNAL - A type of square-wave signal that does not have a constant on and off time. DURASPARK II - A breakerless, solid state ignition system introduced in 1978. DURASPARK II used a module and coil similar to the earlier Solid State Ignition (SSI) system except for calibration. This system incorporated an adapter on the distributor to accommodate the large distributor terminal housing and larger rotor required for use with the higher voltage breakerless system. In addition, spark plug wire diameter was increased to 8 mm and improved silicone jacketing was incorporated. E EARTH - Term referring to a ground. ECA - Electronic Control Assembly E-CELL - A cell which deplates material from the anode to the cathode as a current in the microampere range is passed through it. When the anode is completely deplated, the E-cell becomes open which turns on a three stage transistor to switch a signal output. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 531 ELECTRODE - Posts or plates which have an electrical potential with respect to each other, such as in a spark plug or battery. Electrodes are either positive or negative. ELECTROLYTE - Active chemical filler in a battery. ELECTROMAGNETIC - Refers to a device which incorporates both electronic and magnetic principles together in its operation. ELECTROMECHANICAL - Refers to a device which incorporates both electronic and mechanical principles together in its operation. ELECTROMECHANICAL INSTRUMENT CLUSTER Instrument cluster, first introduced on Taurus/Sable models, that utilizes magnetic gauges and an "overlapping subassemblies" design. Use of the "overlapping sub-assemblies" design eases service because individual gauge sub-assemblies can be removed as individual pieces. ELECTRON - Negatively charged portion of an atom that orbits around the nucleus of the atom. ELECTRONIC - An operation, produced or caused by the action of electrons or by devices which function as a result of electron action. Electronic is often used to describe the control of systems or devices by the use of small electrical signals and various semiconductor devices and circuits. EMF - Electromotive force or voltage. EMITTER - One of three elements or terminals of a transistor that emits the electrons that the collector collects. ENABLE - A type of microcomputer decision which results in an automotive system being activated and permitted to operate. ENERGIZED - Having the electrical current or electrical source turned on. F FAILURE MODE EFFECTS MANAGEMENT (FMEM) STRATEGY - EEC IV strategy designed to reduce the adverse effects that may be caused by an EEC system sensor failure. Should a sensor fail, the ECA substitutes a good sensor signal in its place. This allows the engine to keep running so that the vehicle can be driven to the dealer for service. FIELD (A/C) - A coil with many turns of wire located behind the clutch rotor. Current passing through this coil sets up a magnetic field and causes the clutch to engage. FIELD - Magnetic lines of force orientated from north to south as in a magnetic field. A magnetic field may be natural as with a permanent magnet or created when electricity flows in a wire. FIELD COIL - A coil of insulated wire usually wound around an iron core. Current flowing in the coil produces a magnetic field. Also called "field winding." FILAMENT - A resistance in a light bulb which glows and produces light when a current is forced through it. FIRING LINE FIRING LINE - The total amount of voltage being expended through the secondary circuit. FLUX Electric or magnetic lines of force passing or flowing in a magnetic field. Also, material used to cause joining metal to adhere to both parts to be joined. FOUR-WAY FLASHERS - See "hazard warning system." FREE ELECTRON - Electrons that are not bound to a certain atom but are free to move around from atom to atom. FREQUENCY - Refers to the number of times something repeats itself (such as a signal from a sensor) in one second. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 532 FUEL PUMP MONITOR (FPM) - Input used to monitor the fuel pump secondary circuit. FUEL PUMP RELAY (FP) - Relay or its control line. Relay is controlled by ECA processor. Supplies power to electric fuel pump of EFI/CFI system. FUSE - A metal link in a circuit that melts when the current flow is excessive, thereby breaking the circuit. FUSE BLOCK - An assembly concentrating most or all of a car's fuses at one point. FUSIBLE LINK - A wire or bar designed to melt if more than a certain amount of electrical current is transmitted through it. Often used as a main fuse or backup fuse for large sectional portions of a car's electrical system. G GAIN - A comparison of an input signal level to an output signal level. GASSING - The venting of hydrogen bubbles from battery acid as the battery is recharged. GENERATOR - An electromechanical device that converts mechanical power into direct current electricity. GLOW PLUG IN CYLINDER HEAD GLOW PLUG - An assembly that resembles spark plug but with a heating element instead of electrodes. Used at the beginning of the starting cycle in a diesel engine to aid compression ignition. Sometimes spelled "glo plug" GND (or Ground) - Common line for all vehicle power, vehicle chassis ground and engine block ground, connected to vehicle battery negative terminal. GROUND - The negatively charged side of a circuit. A ground can be a wire, the negative side of the battery or even the vehicle chassis. The ground circuit must be at least the same size or bigger than the positive (hot) wire. GROUND CIRCUIT - The return side of an electric circuit. Usually the frame, body or engine of a single-wire automotive system. GROUNDING - Connecting one side of a car's electric circuit to the chassis, body, or engine. These parts then provide a metal path that conducts electrical current back to the car's battery to complete a circuit. Grounding may be done with a jumper wire. GROUP - A set of battery plates, either positive or negative, joined together but not assembled with separators. GROWLER - An electrical device for testing electric motor or generator armatures for shorts. H HALF-WAVE - A pulsating DC produced by rectifying AC. HALL-EFFECT - The "Hall Effect" is a process where current is passed through a small slice of semi-conductor material at the same time as a magnetic field to produce a small voltage in the semi-conductor. HARD SOLDER - Uniting two pieces of metal with material having a melting point higher than "soft" solder. Example: silver soldering. HAZARD WARNING SYSTEM - Electrical switching device and associated lights (usually the front and rear turn-signal lights) producing flashes of light to indicate that a car is in a distress situation. Also called "emergency flashers" or "fourway flashers". HEAT RANGE - A classification for spark plugs. The higher the number, the "hotter" the plug runs, which means that the plug does not dissipate heat as quickly as a "cooler" plug does. HEAT SINK - Metal bracket in end frame of alternator that contains and absorbs heat from diodes. HIGH TENSION - Secondary or induced high voltage electrical current. Circuit includes wiring fron. ignition distributor cap to coil and to each spark Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 533 plug. HIGH TENSION SECONDARY VOLTAGE - Voltage which enables current to jump the spark plug gap. This voltage is caused by the collapse of the magnetic field around the coil secondary windings. HOLE - A moveable vacancy which acts as a positive charge in a semi-conductor. HORN RELAY - Electromagnetic circuit-closing device that switches electricity to the horn when the horn button is depressed. HOT LEAD - A wire, or conductor, in the hot or power circuit. HYDROMETER - An instrument used to measure the specific gravity of liquids. Hydrometers can be calibrated to indicate the charge level of a battery or the percentage of antifreeze in a coolant mixture. I IDENTIFICATION CODE - A single digit, selftest service code, output at the beginning of the "engine running" test which is equal to one-half of the number of engine cylinders. IGNITION RESERVE - The differential between available voltage and the required voltage. IGNITION SWITCH - Key-operated main power switch in a car. Its chief function is to close the primary ignition circuit, but modern designs include several other circuits and even a steering column lock. IGNITION SYSTEM IGNITION SYSTEM - All the components that together produce the ignition spark: battery, distributor, ignition coil, spark plugs and associated switches and wiring. IMAGE LINE - The electronic picture tracing as seen on the screen of an oscilloscope. IMPEDANCE - A form of opposition to AC current flow (resistance) measured in OHMS. INDUCTION - The spontaneous creation of an electric current in a coil as it passes through a magnetic field. INERTIA SWITCH - A switch in the fuel pump circuit which shuts off power to the fuel pump in the event the vehicle is involved in a collision. This switch must be manually reset. INPUT - Information provided to a microcomputer to allow accurate control of a system. INPUT CONDITIONER - A device or circuit that conditions or prepares an input signal for use by a microcomputer. INSULATION - Materials which do not readily conduct electricity. INSULATOR - A nonconducting substance or body, such as porcelain, glass, or bakelite used for insulating wires in electrical circuits to prevent the leakage of electricity. INTEGRAL RELAY CONTROL MODULE (IRCM) - A module which interfaces with the EEC-IV processor to provide control of the cooling fan, A/C clutch and fuel pump. The module also incorporates the EEC power relay to provide power to the EEC-IV system. INTEGRATED CIRCUIT (IC) - A small semiconductor device that contains thousands of component parts and is capable of doing many circuit functions. Also called "chips" INTEGRATED VEHICLE SPEED CONTROL (IVSC) - A Ford speed control system which is integrated with the on-board EEC TV engine control system. This system does not require an amplifier because all computer control is through the EEC IV processor. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 534 INVERTERA - A circuit that takes an input and converts it to the opposite state in the output. J JUICE - A slang term for electricity. K KILOWATT - A measurement of power equal to 1,000 watts. 100 volts flowing at the rate of 10 amperes equals 1 kilowatt. Abbreviation is kw or KW. KILOWATT HOUR - The work accomplished by an agent operating at a power level of a kilowatt for one hour. 1kw. hr. = 1,000 watts x 3,600 seconds or 3,600,000 watt seconds. kw or KW Abbreviation for kilowatt. L LEAD - (1) An elemental metal that is heavy, pliable and easily melted. (2) Abbreviated term for tetraethyl lead. (3) A wire conductor. LEAD SULFATE - A product of the electrochemical action in a lead-acid battery. The sulfate deposit forms on the plates and slowly fouls the battery. LIGHT-EMITTING DIODE (LED) - A positivenegative junction of crystal material, housed in a dome-shaped housing, which produces light when forward bias current is applied. LINEAR POTENTIOMETER - A variable resistance whose resistance changes in direct proportion to the travel of the moveable terminal. LOAD - An electrical device connected into a circuit to provide a resistance and control the rate of current rate. LOAD TEST - (1) A test for starter motors in which the current draw is measured while the engine is cranking. (2) A battery test. LOGIC GATE - A circuit that will give an output when certain inputs are present. LOW FREQUENCY OSCILLATIONS - The long-tracing vertical image lines which are seen in the coil section. M MAGNET - Any body with the property of attracting iron or steel. MAGNETIC FIELD - The area surrounding the poles of a magnet which is affected by its attraction or repulsion forces. MAGNETIC GAUGE - Special type of instrument gauge, used in the electro-mechanical instrument cluster, that accurately show values even when the ignition is off. MAGNETIC PICKUP COIL - Coil used in the distributor of the breakerless solid state ignition systems to determine exactly when to switch off the coil secondary. MAGNETIC RELUCTANCE The resistance of a magnetic path to the flow of magnetic flux lines through it. MAGNETIC SWITCH - A switch operated by a small electromagnet. Solenoids and relays are magnetic switches. MAGNETO - A type of generator used in early vehicles which produced an extremely high voltage spark. MICROCOMPUTER - A device that takes information, processes it, makes decisions and outputs those decisions. Microcomputers are generally small and portable, and are located inside a processor. MICROPROCESSOR - A small processor contained within the on-board computer (processor). MINIMUM SPEED LOCKOUT (MSLO) - An additional safety feature added to Ford speed control systems that prevents speed control operation at very low speeds. MODULE - A control assembly. A module could be any package that is intended to perform a specific task (such as ignition). Usually modules can be disconnected and replaced easily. MOTOR - Electromechanical device that converts electricity into mechanical energy. MULTIPLE FUNCTION WARNING INDICATOR - A warning indicator assembly, first introduced on the 1987 Mustang GT that indicates low oil, low coolant, low fuel, and low washer conditions. N Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 535 N-TYPE - A semi-conductor material that has an excess of free electrons. NAND GATE - A type of logic device that requires all inputs to be YES in order for the output to be NO. NEGATIVE POLE - Point from which an electrical current flows as it passes through a circuit. NO-LOAD TEST - A test for starter motors in which current draw is measured when the starter's pinion gear is not engaged. NOR GATE - A type of logic circuit that if either input is YES, the output is NO. NORMALLY CLOSED - Refers to a switch or a solenoid that is closed when no control or force is acting on it. NORMALLY OPEN - Refers to a switch or solenoid that is open when no control or force is acting on it. NOT GATE - A type of logic circuit that has an inverted output; if the input is YES, the output is NO, and vice versa. NPN - A transistor with a P type base sandwiched between an N type emitter and collector. O OHM - A unit of electrical resistance opposing current flow. Resistance varies in different materials and varies with temperature. OHMMETER OHMMETER - An instrument that measures electrical resistance of a conductor in units called ohms. OHM'S LAW - A law of electricity which states the relationship between voltage, current and resistance. It takes an electromotive force of one volt to force one ampere of current through one ohm of resistance. Equation - volts = amperes x ohms (E = I x R) ON DEMAND TEST - In Self-Test, the Key On/Engine Off and Engine Running positions, which are technician initiated, are run from a program within the processor. OPEN CIRCUIT - An electrical circuit that because of break or because a switch has failed to close is not complete. See also "short circuit." OPEN LOOP - A system that does not feed back its output to its input. OPERATIONAL AMPLIFIER - A device with two inputs and one output having a very high voltage gain. OPTIC SENSOR - A device that produces a voltage signal by using a light source, a light sensitive material and a slotted wheel between the two. OR GATE - A type of logic circuit that if either input is YES, the output is YES. OSCILLATION - A rapid back-and-forth movement. OSCILLOSCOPE - Instrument that converts voltage and frequency readings into traces on a cathrode ray tube. OUTPUT - Decisions or commands issued by a microcomputer to output devices to allow displays and actuators to function. OUTPUT CONTROL - Circuits inside of the ECA that are used to turn external devices on and off. OUTPUT CYCLING CHECK (OCC) - A position of the end of the Key On/Engine Off test that enables energizing and de-energizing the auxiliary output on demand. OUTPUT DRIVER - A transistor in the output control area of the processor that is used to turn various actuators on and off. OUTPUT STATE CHECK - A test performed in the Key On/Engine Off mode after the continuous codes have been sent which forces the processor to Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 536 activate some actuators for additional diagnostics. OVERCHARGING - Continuing to charge a battery after it has a full charge; can damage the battery. P P TYPE - A semi-conductor material that has holes or a lack of electrons. PARALLEL CIRCUIT PARALLEL - Electrical design in which two or more circuits, batteries or components share common negative and positive connections. PASSIVE CIRCUIT - A circuit consisting of all passive elements, resistors, capacitors or inductors. PASSIVE SENSOR - A sensor which modifies the output of a voltage-divider network that the sensor is part of. PERMEABLE - A characteristic of how good a material is as a magnetic path. PHOTOELECTRIC CELL (PE) - A light sensitive material that changes variations of light into varying voltage signals. PHOTOTRANSISTOR - A light sensitive transistor that generates an output signal in proportion to the light picked up. PICKUP COIL PICKUP COIL - An electromagnetic device in the distributor of the electronic ignition system. It creates an electromagnetic field due to the permanent magnet that is part of the pickup assembly. Then the magnetic field produces an a.c. signal to the control module, informing the module of the turning position of the distributor shaft. PIEZOELECTRIC - Refers to an electronic device which is capable of generating a voltage when subjected to mechanical pressure. PLATE - (1) Component of a storage battery, one of a series of flat lead sheets with which acid reacts to produce electricity. (2) A pivoting flap in the choke or throttle valve of a carburetor. (3) To apply a coating or layer of one material over another. PNP - A transistor with an N type base sandwiched between a P type emitter and collector. POINT GAP - The space between the point contacts which is adjusted to provide the correct dwell. POLARITY - The difference in properties or powers between two bodies or the ends of one body, as in a magnet. According to the Current Theory, polarities in an electric circuit are established by an excess of electrons on one side (negative) and a deficiency on the other (positive). POSITIVE TEMPERATURE COEFFICIENT (PTC) HEATER - A heater system used on chokes and on diesel fuel heaters. PTC heaters are self regulating because as their temperature rises so too does the resistance limiting the amount of electrical flow and overall heating. POSITIVE TERMINAL - That terminal in a circuit to which current flows. POTENTIAL - Electrical force measured in volts. Sometimes used interchangeably with voltage. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 537 POTENTIAL DIFFERENCE - A difference of electrical pressure that sets up a flow of electric current. POTENTIAL DROP - A loss of electrical pressure due to resistance. POTENTIOMETER POTENTIOMETER (POT) - A variable resistor with three connections. The third connection (wiper) moves physically up and down the resistive element which has each end attached to one of the other two connections. PRIMARY - (1) A low-voltage circuit or part of a circuit. (2) The input coil of a transformer. PRIMARY WINDING - Low voltage winding of the coil which is electronically connected to its secondary only by the magnetic field they share. When the primary winding is connected across, a potential current flows through it, building a magnetic field around itself and inducing a voltage in the secondary. When disconnected, the cease in current through the primary again induces a voltage in the secondary which is used to ignite the air/fuel mixture. PRINTED CIRCUIT - Electrically conductive metal paths that are produced by printing a pattern on a board, then etching away all areas that are not printed. PROCESSOR - A metal housing which contains a microcomputer and other components used in providing electronic system control. The Electronic Control Assembly (ECA) is often referred to as the processor. PROGRAM - A set of detailed instructions which a microcomputer follows when controlling a system. PULSE - An abrupt change in voltage whether positive or negative. PULSE WIDTH - The length of time an actuator, such as a fuel injector, remains energized. Q QUARTZ-HALOGEN HEADLIGHT - A modern headlight design that produces a much brighter, whiter light than the conventional tungsten-filament light. The bulb is made of, quartz, rather than glass, and is filled with a halogen gas. Also called "halogen headlight." R RANDOM ACCESS MEMORY (RAM) - A type of memory which is used to store information temporarily. Information can be written to and read from RAM. READ - A microcomputer operation where information is retrieved from memory. READ ONLY MEMORY (ROM) - A type of memory which is used to store information permanently. Information can not be written to ROM; as the name implies, information can only be read from ROM. READOUT CONTROL - Circuits inside of the ECA that are used for operating digital instrument displays. RECHARGE - (1) To restore energy to a battery by means of an electric current. (2) To restore the level of a substance in a system, as recharging an air conditioner with refrigerant. RECTIFIER (diode) - Electrical device that permits alternating current to flow in only one direction thereby transforming it into direct current. REDUNDANT BRAKE SHUTOFF - A safety feature of Ford speed control systems that shuts the speed control system off if there is a 10-15 mph drop in speed. REFERENCE VOLTAGE (VREF) - Power supplied by the ECA to some sensors that are regulated at a specific voltage. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 538 STARTER RELAY RELAY - An electromagnetic switching device using low current to open or close a high-current circuit. RELUCTANCE - The resistance of a material to the flow of magnetic lines of force. REQUIRED VOLTAGE - Voltage necessary to overcome the resistance of the secondary circuit and establish a spark to the ground electrode of the spark plug. RESERVE CAPACITY - The length of time that a fully charged battery at 80~F will remain functional when it is discharging at a rate of 25 amps. This rating is intended to tell the driver how long the car can be operated with headlights and certain other accessories on after an alternator failure. RESIDUAL MAGNETISM - Slight magnetic properties retained by metal, such as a wiring coil in a generator, after it has passed through a magnetic field. RESISTANCE - The opposition offered by a conductor to a flow of electricity; measured in ohms. RESISTOR - A device installed in an electrical circuit which tends to prevent or reduce the flow of current. RESUME - An operating mode of the speed control system which reactivates the system after it has been disabled (such as by stepping on the brake or clutch pedal) and returns it to the speed at which it was previously set. Shutting the vehicle off erases the resume memory. RHEOSTAT - A device for regulating a current by means of a variable resistance. ROTOR ROTOR - The rotating part of a distributor that transfers current from the coil cable to the spark plug cables. S SAMPLING - The act of periodically collecting or sending information. A microcomputer samples input from various sensors in the process of controlling a system. SCHEMATIC DIAGRAM Symbolic representation of an electric circuit or vacuumhose circuit. SEALED-BEAM - Headlight design incorporating filaments, reflector, and a lens in a unit with no separate bulb. SECONDARY - (1) A high-voltage circuit or part of a circuit. (2) The output coil of a transformer. SECONDARY CIRCUIT - The high voltage part of the ignition system which extends from the center tower of the coil all the way down to and across the spark plug gap. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 539 SECONDARY INSULATION (SPARK PLUG WIRE) SECONDARY INSULATION - The material that contains the spark from the time it leaves the center tower of the coil to the time it reaches the insulated electrode of the spark plug. SECONDARY RESISTANCE - The resistance encountered by electricity as it travels on its route from the center tower of the coil to the ground electrode of the spark plug. SECONDARY WINDING - See "Secondary Circuit." SEMICONDUCTOR - General term for transistors, integrated circuits, and other electronic devices made of materials, such as silicone, that conduct electricity poorly. SENSOR - Used as inputs to the ECA, a device that measures a condition and converts it into some kind of electrical signal. SERIES - An electrical connection in which two or more circuits, batteries or components are connected negative to positive. The opposite of "parallel." SERVO - In a speed control system, a vacuum operated device controlled by the amplifier responsible for changing the throttle plate settings in relationship to engine speed. The servo contains solenoid valves for controlling vacuum to the diaphragm and a throttle position sensor (servo in IVSC system does not contain throttle position sensor). SET/ACCEL - In a speed control system, a driver control button that is responsible for setting a speed. It can also be used to raise the speed by holding it down until the desired speed is reached. SHIFT INDICATOR LIGHT (SIL) - A system primarily controlled by engine speed and manifold vacuum which provides a visual indication to the driver of when to shift to the next higher gear to obtain fuel economy. SHORT CIRCUIT - Defect in an electric circuit in which electricity flows directly from one conductor to another rather than through the intended circuit. SHUNT - A conductor joining two points in a circuit so as to form a parallel circuit through which a portion of the current may pass in order to regulate the amount of current flowing in the main circuit. SHUNT CIRCUIT - A minor side circuit that parallels and feeds off a main circuit. SIGNAL - A voltage condition that transmits specific information in an electronic system. SIGNAL PROCESSING - A general term used for conditioning input signals. It covers many functions such as A/D converting, amplifying, counting, etc. It describes what happens to input signals from the sensor on their way to the microprocessor. SINE-WAVE - A voltage signal generated by a coil of wire, a magnetic field and movement between them. SLIP RING - A circular conductor on a rotor or armature that contacts brushes. Electricity flows from the brushes to the slip ring, thus allowing current to pass from a stationary part to a rotating part. SLOW CHARGE - The preferred method of administering a charge to a battery where current is applied over a long period of time and at a low rate. SOLENOID - A wire coil with a moveable core which changes position by means of electromagnetism when current flows through the coil. Sometimes synonymous with "relay." SOLENOID RELAY - A switching component in the starter motor circuit. Light current operates the solenoid, which closes the contacts carrying the heavy current to the starter motor. SOLENOID SWITCH - A switch operated by a solenoid. SOLENOID VACUUM SWITCH - Any one of a variety of engine control devices that combine a solenoid switch and a vacuum valve. The solenoid opens or closes a valve in a vacuum line, usually as part of a pollution-control system. SOLID STATE - General term for transistors and related electronic components that are replacing vacuum tubes. SOLID STATE IGNITION (SSI) - The ignition systems that used a transistor to switch the coil. One used breaker points to switch on the transistor, the Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 540 other used the magnetic pickup coil. Both of these systems precede the Duraspark systems, but the one that used the pickup coil is the same. SPARK ADVANCE - Causing the ignition spark to occur earlier. SPARK GAP - The space between the spark plugs center electrode and ground electrode. SPARK LINE - The pattern that represents the time during which the air/fuel mixture is being burned within the combustion chamber. SPARK PLUG - Electrical component that produces a spark to ignite the air/fuel mixture in the cylinders. SPARK RETARD - Causing less spark advance to be added, resulting in an ignition spark introduced later. SPLICE - The joining of two or more conductors at a single point by crimping, soldering or brazing. SQUARE-WAVE - A digital on-off type of signal that has a very fast rise and fall. STARTER - The electric motor and drive mechanism used to start an engine. STOPLAMP SWITCH - Switch responsible for disabling the speed control system when the brakes are applied. Also responsible for operating the stoplamps when the brake pedal is depressed. STORAGE CELLS - A cell which stores potential for electricity in the form of chemicals. Once discharged it can be recharged by forcing current through it in the opposite direction. These cells, when placed in series, form a storage battery. STRATEGY - The programming of the ECA determining how it reacts under certain conditions. Some currently used strategies are Failure Mode Effects Management (FMEM), Idle, Lean Cruise, etc. SWITCH - A device used to open, close or redirect the current in an electrical circuit. T TERMINAL - A device attached to the end of a wire or cable to make an electrical connection. THERMISTOR - A resistor that changes its resistance with temperature. THERMOCOUPLE - A thermoelectric device used to measure temperature accurately, especially one consisting of two dissimilar metals joined together so that a potential difference is generated between the points of contact. The amount of potential difference is a measure of the heat at the point of contact of the two dissimilar metals. THICK FILM IGNITION (TFI) -IV - Electronic ignition system utilizing a Hall-Effect sensor to switch the ignition coil on and off through the ECA. The term "thick film" is Lised to describe the process used to build the TFI circuit on the module. The basic circuit is placed on a layer of alumina. Several layers of film are required to print the circuit - hence the name "thick film." The resistors and connecting paths are part of the film. Other components such as capacitors, diodes, darlington transistors and integrated circuits are added on top of the thick film or are attached to it. There are two TFI systems, TFI-I used on 1982 1.6L engines, and TFI-II used on engines after 1983 with EEC-IV. The TFI-IV ignition system uses no vacuum or centrifugal advance, all advance is controlled by the ECA. TFII utilizes vacuum and centrifugal advance. Both TFI-I and IV use an E-core coil instead of an oil filled coil. THICK FILM IGNITION (TFI) MODULE - Smaller module which is mounted on the distributor and fires the ignition coil. THROUGHPUT - The flow of a voltage signal from input to output. TIMER - A feature of microcomputers which allows the microcomputer to measure time intervals, such as "time since engine start" or "time in neutral idle." TRANSDUCER - A device that changes energy from one form to another. For example, a transducer is used to change the pulse of fuel injection in a diesel to electricity so that timing can be checked. In automotive air-conditioning controls used in automatic temperature systems, a transducer changes an electrical signal to a vacuum signal, which operates mechanical doors. TRANSFER HOSE - Hose on the speed control servo that connects either manifold vacuum or atmospheric pressure to the sealed side of the diaphragm, depending on servo solenoid positions. TRANSISTOR - A small solid-state electronic switching device which uses semiconductors. Widely used to replace vacuum tubes and switches. TRUTH TABLE - A chart that lists all of the possible combinations of inputs and the corresponding outputs for a logic gate. U UNIVERSAL DISTRIBUTOR - Distributor which uses a PIP sensor instead of a CP sensor, and TFI module instead of the Dura-Spark ignition module. This distributor can be used with EEC only. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 541 V VACUUM DUMP VALVE - A valve that mechanically releases the vacuum from the servo when the brake pedal is depressed. VACUUM SOLENOID VALVE - An electrically operated vacuum on and off valve similar in operation to a relay. VEHICLE SPEED SENSOR - Device mounted on the transmission or speedometer cable that is responsible for monitoring vehicle speed and passing the information on to the speed control amplifier or EEC IV module. VOLT - The unit of measurement for the force or pressure of a flow of electricity. VOLTAGE - The electrical pressure which causes current to flow in a circuit. VOLTAGE APPLIED The actual voltage read at a given point in a circuit. It equals the available voltage of the power supply minus the losses in the circuit up to that point. VOLTAGE AVAILABLE - The voltage delivered by the power supply (battery, alternator, generator, etc.). VOLTAGE DIVIDER - Two or more resistances connected in series form a voltage divider network. When current flows the voltage divides itself across the resistances. VOLTAGE DROP - A lowering of the voltage in a circuit when resistance, or electrical load, is added. VOLTAGE REGULATOR - An electrical device that prevents excessive voltage on, or overcharge of, the battery by the generator or alternator. VOLTMETER - An instrument used to measure the voltage in an electrical circuit. VOLT-OHM-METER (VOM) - Combination meter used to measure voltage and resistance (ohms). They are available in both analog (measures by needle movement) or digital (measures by a numeric display). May be referred to as an AVOM (analog) or DVOM (digital). VREF - Abbreviation for reference voltage. W WATT - A measurement of power. One volt multiplied by 1 amp equals 1 watt, and 746 watts equal 1 horsepower. One "kilowatt" equals 1,000 watts. WIGGLE TEST - Performed with either a voltmeter or star tester while wiggling or tapping the system harness connectors. WIPER - Refer to "potentiometer." WIRING HARNESS - A bundle of insulated electrical wires covered by an additional insulating jacket. The individual wires emerge from the harness at different points to go to various components. WRITE - A microcomputer operation where information is sent to and stored in memory. X X-NOR GATE - A logic circuit that requires both inputs to be the same for a YES output. X-OR GATE - A logic circuit that requires both inputs to be the same for a NO output. Z ZENER DIODE - A two terminal device with 1 PN junction that can conduct in the reverse direction when a certain voltage is reached. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 542 Power and Ground Distribution: Technical Service Bulletins Wire Harness Terminal and Connector - Service Kit WIRING-WIRE HARNESS TERMINAL AND CONNECTOR SERVICE KIT Article No. 89-19-5 FORD: 1990 and prior ALL FORD LINES LINCOLN-MERCURY: 1990 and prior ALL LINCOLN-MERCURY LINES MERKUR: 1990 and prior ALL MERKUR LINES LIGHT TRUCK: 1990 and prior ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1990 and prior ALL MEDIUM/HEAVY TRUCK LINES This TSB article is being republished in its entirety to make dealers aware of availability of the wiring harness terminal and connector repair kit. ISSUE: A wire harness terminal and connector repair kit is available for repairing electrical wire harnesses. This kit allows dealers to repair broken or corroded terminals and connectors instead of replacing an entire wire harness. The kit is easy to use and allows the technician to perform a professional looking repair in a short period of time. ACTION: To purchase a wire harness terminal and connector repair kit, contact Altair International Incorporated. Refer to the following information for ordering details. ALTAIR INTERNATIONAL INC. ATTN: SALES DEPARTMENT 22800 HALL ROAD MT. CLEMENS, MI 48043 TELEPHONE: (313) 466-1200 An order form is included in the back of this TSB issue. To order: ^ Fill out the order form. ^ Enclose a check for the total amount. (This kit cannot be charged to your dealership parts code.) ^ Send the completed form and check to the ALTAIR INTERNATIONAL INC. The kit consists of: ^ Two 50 drawer metal cabinets that contain 6 each of the 96 different terminals, machined crimped with a four inch "pigtail" of 12 or 16 gauge wire. ^ A unique, high compression crimping tool that will make sure of a solid connection preventing moisture or contaminants from affecting the wire splice. OTHER APPLICABLE ARTICLES: none SUPERSEDES: 88-17-5, Date 8/17/88 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2770, 2700 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 543 Technical Service Bulletin # 87153 Date: 870729 Wiring - Circuit Number/Color Code Charts WIRING - CORPORATE STANDARD CIRCUIT Article No. NUMBER CHARTS FOR WIRE CIRCUIT NUMBER, 87-15-3 AND COLOR CODES FORD: 1980-88 ALL CAR LINES LINCOLN-MERCURY: 1980-88 ALL CAR LINES MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1980-88 F SERIES, BRONCO 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR ISSUE: The Standard Circuit Number Charts on pages 11 through 20 of this TSB are being printed for your information. The electrical circuits are listed by number code with the description/name and the matching color code as specified by Ford Corporate Standards. These charts are also printed in the reference section of the Vacuum and Wiring Manual. ACTION: When tracing circuits or trying to pinpoint individual circuits, use these charts with the appropriate Shop Manual, EVTM (Electrical and Vacuum Troubleshooting Manual), or the Vacuum and Wiring Manual. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Color Codes The wire color code indicates the circuit number, color of the wire and the wire gauge size. Where two colors are shown for a wire, the first color is the basic color of the wire. The second color is the dot, hash, or stripe marking. If D or H is given, the second color is dots or hash marks. If there is no letter after the second color, the wire has a stripe. For example: BR/O is a brown wire with an orange stripe. R/Y D is a red wire with yellow dots. BK/W H is a black wire with white hash marks. Color Abbreviations BL Blue N Natural BK Black O Orange BR Brown PK Pink DB Dark Blue P Purple DG Dark Green R Red GR Green T Tan GY Gray W White LB Light Blue Y Yellow LG Light Green If a vehicle specific wire color in a connector does not match the diagram shown, it can usually be identified by comparing the other colors shown at the wire connectors. Specific wire color deviations in the manufacturing of a wire harness are usually for a short duration. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 544 WIRE TYPES Standard Circuit Number Chart Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 545 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 546 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 547 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 548 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 549 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 550 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 551 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 552 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 553 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Power and Ground Distribution > System Information > Technical Service Bulletins > Electrical/Electronic/Fuel Induction - Glossary > Page 554 STANDARD CIRCUIT NUMBER CHART Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Steering and Suspension > 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 > Steering and Suspension > Steering > System Information > Technical Service Bulletins > Adhesives & Sealants - Availability and Usage Steering: Technical Service Bulletins Adhesives & Sealants - Availability and Usage ^ ADHESIVES AND SEALANTS-AVAILABILITY AND USAGE ^ ENGINE-ADHESIVES AND SEALANTS-AVILABILITY AND USAGE ^ STEERING-ADHESIVES AND SEALANTSAVAILABILITY AND USAGE ^ TRANSMISSION-ADHESIVES AND SEALANTSAVAILABILITY AND USAGE Article No. 89-12-2 FORD: 1989 and prior ALL FORD LINES LINCOLN-MERCURY: 1989 and prior ALL LINCOLN-MERCURY LINES MERKUR: 1989 and prior ALL MERKUR LINES LIGHT TRUCK: 1989 and prior ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1989 and prior ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Various adhesives and sealants are used to perform many service repairs. A partial list of these Ford products that are available through the Ford Parts System along with their proper use and application is shown below. ACTION: If adhesives and sealants are required to perform a service repair, refer to the following product information and the appropriate Shop Manual. Ford Stud And Bearing Mount (EOAZ-19554-BA)/ Ford Threadlocker 262 (E2FZ-19554-B) These adhesives are high strength threadlockers. They are used for locking all fasteners that must withstand: ^ Heavy shock and vibration. ^ Extreme chemical and environmental conditions, such as solvents, oils, and water immersion. They prevent fluid/vacuum leaks and seal out rust or corrosion. Their typical applications include securing the following items. ^ Intake manifold bolts ^ Power steering pump adjusting bolts ^ Engine studs ^ Ring gear bolts ^ Seat bolts ^ Cup plugs To use these adhesives, clean the fastener threads with a wire brush and a non-petroleum based solvent. Apply one or two drops to the threads and torque to the required specifications. NOTE: THESE ARE HIGH STRENGTH THREADLOCKERS AND THEY REQUIRE SPECIAL EFFORT FOR REMOVAL. Ford Threadlock And Sealer (EOAZ-19554-AA) This product is a medium strength threadlocker and sealer which stops air, oil, and fuel leakage. It is a hand tool removable adhesive and is used on aluminum threads. It prevents fluid/vacuum leaks and seals out rust or corrosion. Its typical applications include sealing and securing the following items. ^ Oil pan bolts ^ Valve cover bolts ^ Flywheel attaching bolts Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > System Information > Technical Service Bulletins > Adhesives & Sealants - Availability and Usage > Page 563 ^ Door latch attaching bolts To use this adhesive, clean the fastener threads with a wire brush and a non-petroleum based solvent. Apply one or two drops to the threads and torque to the required specifications. Ford Pipe Sealant With Teflon (D8AZ-19554-A) This product seals and locks air, oil, fuel and hydraulic threaded fasteners. This light paste sealant instantly seals without fouling. It is non-shredding and operates in temperatures up to 400~F. It prevents corrosion of fitting /fastener threads and locks against vibrational loosening. Its typical applications include sealing the following items. ^ Transmission oil coolant lines ^ Fuel inlet fittings ^ Intake manifold vacuum switches ^ Engine oil galley plugs To use this sealer, clean off residual oil, coolant and other contaminants from the threads. Apply sealer completely around the second and third threads. Install the part and torque to the required specifications. Ford Gasket Maker (E2AZ-19562-B) And Ford Gasket Eliminator (E1FZ-19562-A) These products cure in the absence of air. They are used to gasket two machined surfaced flanges. Each product will fill a gap up to .010". The sealants will not cure until the parts are assembled. Once cured, they will remain pliable and flex with movement of the parts. Their typical applications include sealing the following items. ^ Oil dip stick tubes ^ MTX case halves (Gasket Eliminator) ^ Water Pumps ^ Input bearing retainers ^ Rear main bearing parting lines To use these sealants, make sure all the old gasket material has been removed. CAUTION: AVOID USING METAL SCRAPERS BECAUSE THEY CAN ETCH THE SURFACES AND PREVENT A GOOD SEAL. Clean both surfaces with a non-petroleum based solvent to remove all oil, grease and other contaminants. Apply a small bead of sealant continuously around one surface only and then put the pieces together. NOTE: REMEMBER, THESE PRODUCTS CURE IN THE ABSENCE OF AIR, SO PLENTY OF TIME IS AVAILABLE TO DO A THOROUGH JOB. PART NUMBER PART NAME CLASS E0AZ-19554-BA Stud and Bearings Mount BM E2FZ-19554-B Ford Threadlocker 262 R E0AZ-19554-AA Threadlock and Sealer B D8AZ-19554-A Pipe Sealant with Teflon B E2AZ-19562-B Gasket Maker AM E1FZ-19562-A Gasket Eliminator AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > System Information > Technical Service Bulletins > Suspension - Vehicle Lean or Spring Sag Suspension: Technical Service Bulletins Suspension - Vehicle Lean or Spring Sag Article No. ^ SPRINGS - RATE AND CAPACITY 87-19-10 INFORMATION ^ SUSPENSION - VEHICLE LEAN OR SPRING SAG LIGHT TRUCK: 1980-88 ALL LIGHT TRUCK LINES ISSUE: Vehicle lean, or spring sag conditions, are more often related to payload/body weights (especially on recreational vehicles) than to weakened or sagged springs. Sometimes, springs may be replaced unnecessarily because the available spring information in the Light Truck Sales Data Book is not used. ACTION: If service is required, make sure of proper spring usage. The vehicle should first be weighed (front, rear, and total) so that the values can be compared to the ratings on the vehicle's certification label. Vehicle design heights for curb (empty) and loaded vehicles are included in the Body Builder's Layout Book. Spring rates, capacities, and codes are listed in the Light Truck Sales Data Book. The spring charts will provide full information for the spring's characteristics. (Both books should be available in the dealership sales department.) Comparing vehicle weights, rated capacities, and design height should determine the cause of most sag/lean concerns. If more help is necessary, contact the Technical Service Hotline. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > A/C - Warner Compressor Clutch Replacement Compressor Clutch: Technical Service Bulletins A/C - Warner Compressor Clutch Replacement Article No. 85-4-3 AIR CONDITIONING - REPLACEMENT OF WARNER A/C COMPRESSOR CLUTCH ASSEMBLY FORD 1980-84 ALL LINCOLN-MERCURY 1980-84 ALL LIGHT TRUCK 1980-84 ALL LIGHT TRUCKS When existing stock of 1980-84 Warner Electric A/C compressor clutch hub and pulley parts is exhausted, it will be necessary to replace the entire clutch assembly, including the field coil, with current Ford manufactured clutch parts. Replacement of the Warner field coil is necessary because it is not compatible with the Ford clutch parts. The Warner field coil will continue to be available for replacement on Warner clutch assemblies. NOTE: Never intermix clutch parts from different manufacturers. Refer to the Master Parts Catalog for part numbers and vehicle application. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips Heater Core: Technical Service Bulletins Heater Core - Leakage Diagnostic Tips Article No. 85-8-2 HEATER CORE - LEAK - DIAGNOSTIC TIPS FORD ALL LINCOLN-MERCURY ALL LIGHT TRUCK ALL Good heater cores are being returned through the parts return system coded as leaking. Complaints of leaking may be caused by an inadequate seal between the heater hose and the heater core tubes allowing coolant to follow the tube to the heater core, leak into the passenger compartment and appear as a leaking heater core. When diagnosing a suspect heater core leak, inspect the hose to heater core tube attachment to assure the connection is not leaking. If a leaking connection is found, correct the leak. If the connection appears not to be leaking, leak test the heater core before removing it from the vehicle using the following procedure: HEATER CORE LEAK TEST Pressure Test 1. Drain the coolant from the cooling system. 2. Disconnect the heater hoses from the heater core tubes. 3. Install a short piece of heater hose (approximately 4 inches long) on each heater core tube. Figure 1 4. Fill the heater core and hoses with water and install plug BT-7422-B and adapter BT-7422-A from Rotunda model 021-00012 or equivalent in the hose ends (Figure 1). Secure the hoses, plug and adapter with hose clamps. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 578 Figure 2 Figure 3 - TOOL 021-00012 WITH HEATER HOSE AND CLAMPS 5. Attach the pump and gauge assembly Rotunda model 021-00012 or equivalent to the adapter (Figure 2). Close the bleed valve at the base of the gauge and pump 30 psi of air pressure into the heater core (Figure 3). 6. Observe the pressure gauge for a minimum of three minutes. The pressure should not drop. 7. If the pressure does not drop, no leaks are indicated. 8. If the pressure drops, check the hose connections to the core tubes for leaks. If the hoses do not leak, remove the heater core from the vehicle and perform the bench test. Bench Test 1. Drain all coolant from the heater core. Figure 4 - HEATER CORE BENCH TEST 2. Connect the 4-inch test hoses with plug and adapter to the core tubes. Then connect the air pump and gauge assembly to the adapter (Figure 4). 3. Apply 30 psi of air pressure to the heater core with Rotunda model 021-00012 or equivalent, and submerge the core in water. 4. If a leak is observed, service or replace the heater core as necessary. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 579 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Heating and Air Conditioning > 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 > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Air Conditioning - Use of Correct Fluorescent Tracer Dye > Page 584 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 > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Air Conditioning - Use of Correct Fluorescent Tracer Dye > Page 585 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 > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Page 586 Refrigerant: Specifications Type ..................................................................................................................................................... ............................................... Refrigerant 12 (R-12) Ford Part Number ............................................. ........................................................................................................................................ D4AZ-19B519-A Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Heating and Air Conditioning > 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 > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information Technical Service Bulletin # 8524 Date: 850124 Seat/Shoulder Belts - General Service Information Article No. 85-2-4 SEAT/SHOULDER BELTS - GENERAL SERVICE INFORMATION FORD ALL - 1974-85 LINCOLN-MERCURY ALL - 1974-85 LIGHT TRUCKS ALL - 1974-85 MEDIUM/HEAVY TRUCKS ALL - 1974-85 The States of New York, New Jersey and Illinois recently enacted a mandatory seat belt usage law. With these laws and impending similar belt usage legislation in other states, dealers can expect customer inquiries regarding seat belts. The following information is being published in an effort to refamiliarize dealership service personnel with seat and shoulder belt systems utilized over the past several model years. Previous Service Recall and TSB articles pertaining to seat belt usage and servicing are also included. Section 1 -Identification of Seat Belt System Types For Model Years 1974-1985 There are three distinct types of seat belt systems. Two of the systems are three-point anchoring systems. One three-point system has dual retractors; one retractor for the lap and one for the shoulder belt. The other three-point system is the continuous loop single retractor system for the lap and shoulder belts. The third system is a two-point system that contains a lap belt only which is used for rear seat and front center passenger restraint. Continuous Loop Three-Point System The continuous loop system has a moveable tongue on the front outboard lap/shoulder belt and only one retractor. Dual Retractor Three-Point System The dual retractor system has a fixed tongue on the front outboard lap/shoulder belt. (Note that on the Econoline for 1982-85 model years, the two retractors are on one frame attached to the seat pedestal.) Front Center/Rear Seat Two-Point System A 2-point system provides a lap belt only and applies to the front seat center position and all rear seat positions. Rear outboard belts are equipped with retractors, while front and rear center belts are not. A.Continuous Loop Three-Point Shoulder/Lap Belt - System With Moveable Tongue and One Retractor - 1976 to Present Cars and Ligh Figure 5 The continuous loop three-point system (Figure 5) is used for front outboard passengers. The outboard lap/shoulder belt uses a common moveable tongue. To fasten the seat belt, the tongue is inserted into the inboard buckle. The webbing of the lap belt is anchored to the side of the body without a Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 596 retractor. The shoulder harness webbing has the other end fixed in a retractor, which is located on the "B" pillar post or in the quarter panel. The shoulder harness retractor is designed to let the webbing freely move in or out, except during sufficient vehicle deceleration, when it is automatically locked by a mechanically actuated inertia sensor. The inboard (buckle) portion of the seat belt assembly passes between the seat cushion and seat back on bench seat installations, and directly to a fixed anchorage on the floor. On bucket seat installations, it is routed along the side of the seat and is fastened to a slide bar. The slide bar is connected to the seat track, the seat, and the floor pan. On LTD/Marquis and Thunderbird/Cougar, the buckle end passes between the seat and the consolette and is connected to the seat track. Attaching the tongue to the buckle secures the occupant with both lower and upper restraints. This attachment of the tongue and buckle can be accomplished by a single continuous movement. This system may also include a tension eliminator that is designed to release automatically when the respective front door is opened. As the seatbelt is unbuckled, the tongue end of the belt should be hand-guided back to the retractor to prevent the belt tongue from striking occupants or objects nearby during retraction. B.Dual Retractor Three-Point Shoulder/Lap System - 1974 to 1983 Cars and Light Trucks and 1974 to 1985 Econolines and Club Wago Figure 4 The dual retractor three-point system is used for front outboard occupants (Figure 4). The lap belt portion and shoulder harness are joined at the tongue. To secure the belt, the tongue is inserted into the buckle of the inboard belt portion. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 597 Figure 4 Figure 6 Except for the 1983-85 Econoline and Club Wagon, the webbing for the outboard lap belt extends from the belt retractor located on the rocker panel that automatically locks when the belt is being worn. This locking feature prevents the belt from being pulled out further, but allows the belt to retract, thus maintaining a snug fit around the user for increased safety. This lap belt retractor is located on or in the rocker panel (depending on car line and model - Figure 4) or on the seat pedestal for 1983-85 Econoline and Club Wagon (Figure 6). Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 598 Figure 4 The shoulder harness webbing has one end fixed in a retractor (Figure 4) which is located in or on the rocker panel, or in the "B" pillar post (depending on car/truck line and model). The Mustang/Capri shoulder harness retractor is located in the quarter panel. From the retractor, the webbing then passes through a guide above and behind the occupant's shoulder which directs the webbing at the proper downward angle over the occupant's shoulder and chest, and attaches the tongue to the inboard belt buckle. The shoulder harness retractor is designed to let the webbing move freely in or out at all times, except during vehicle deceleration, when the retractor is automatically locked by a mechanically actuated retractor inertia sensor. The inboard belt buckle passes through the seat cushion on a bench seat or around the side of the cushion on a bucket seat to a fixed anchorage on the floor or seat pedestal for Econolines. Attaching (locking together) the tongue and buckle secures the occupant with both lower and upper restraints. This attachment of the tongue and buckle can be accomplished by a single continuous movement. C.Two-Point System - Center Front/Rear and Rear Seat Lap Belts Those vehicles designed to accommodate a center rear seat occupant have a center lap belt without a retractor. The belt should be adjusted by the tongue to fit snugly and as low as possible around the hips. Figure 6 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 599 Figure 7 In passenger cars and light trucks, the rear seat two-point lap belt system for outboard passengers has the retractor located in the quarter panel or attached to the floor under the seat (Figure 7). On Econoline, Club Wagon, Bronco and Bronco II vehicles, the rear seat retractors are attached to the seat frame or the floor. The buckle portions of the seat belt are all attached to the floor on passenger cars, and either to the floor or seat frame on Broncos and Econolines. Most rear seat lap belt retractor assemblies are equipped with a sleeve to prevent the tongue from being lost between the seat cushion and seat back. The buckle ends pass between the seat cushion and seat back. On passenger cars, the locking together of the tongue and buckle can be made by a single continuous movement. On Bronco and Econoline vehicles, the outboard buckle ends pass around the outside of the rear seat (Figure 6, View B). Section 3-Functional Test Procedure For Shoulder Harness Shoulder Harness Functional Test Procedure for Three-Point Systems (Both Dual Retractor and Continuous Loop Systems) Driver should buckle up and proceed to a test area appropriate for making sudden stops. If the RH passenger seat belt must be tested, a passenger should be buckled into the RH seat. The passenger belt may be tested utilizing a driver only, providing the driver has the ability to grasp the RH shoulder belt and extend it approximately (660 mm) 26 inches with no compromise to safe driving. This method applies to the (8 km/h) 5 mph test only. NOTE: The RH shoulder belt should not be extended during testing. This avoids the possibility of a false lock-up that is caused by a fully extended belt. After reaching an area to safely perform sudden stops, the driver should attain a speed of approximately (8 km/h) 5 mph. The driver should inform the passenger (if any), that he is preparing to make a brake application. At this time, both driver and passenger should prepare to lean slightly forward at the moment the brake application is made. The driver should make a moderately hard brake application (approximately l6 ft./sec.) without tire skid. The brake application should be on dry concrete or equivalent hard road surface (never on a wet or gravel road). The driver and passenger should lean forward slightly into the shoulder harness; at this instant, the belt retractor should lock-up without webbing payout. If there is a retractor lock-up on both driver and passenger shoulder straps, the seat belt assemblies are functioning properly. Should either or both retractors fail to lock-up at the (8 km/h) 5 mph speed, the test should be repeated at a constant (24 km/h) 15 mph. (This test must be performed with a RH passenger if the RH belt is to be tested.) If either or both shoulder belt assemblies do not lock-up at the (24 km/h) 15 mph test, the vehicle is to be returned for removal and replacement of the seat belt assembly, then retest. WARNING: WHEN REPLACING A SEAT BELT ASSEMBLY, BE SURE TO INSTALL A COMPLETE NEW ASSEMBLY (BUCKLE PORTION AND TONGUE PORTION TOGETHER) AS RECEIVED FROM FORD MOTOR COMPANY. DO NOT REPLACE ONE PART OF A SEAT BELT ASSEMBLY WITHOUT INSTALLING THE ENTIRE SEAT BELT ASSEMBLY. THIS WILL ASSURE THAT THE BUCKLE PORTION IS MANUFACTURED BY THE SAME MANUFACTURER AS THE TONGUE PORTION AND IS COMPATIBLE WITH IT. ALSO BE SURE THAT THE BELTS INSTALLED ARE INTENDED SPECIFICALLY FOR THE VEHICLE IN WHICH THEY ARE BEING INSTALLED. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 600 Section 4-Functional Test Procedure For Lap Belts and Retractor Webbing Cannot Be Fully Extracted From Lap Belt Retractor - 2-Door and 4-Door (Front Outboard - Except Versailles) 1. Pull webbing from the shoulder harness retractor, allowing the lap belt to retract fully into the retractor. Pull webbing from the lap belt retractor, allow it to retract fully. 2. If OK, buckle up while sitting in seat. Repeat five times to ensure proper operation. If not OK, inspect for webbing twists in the seat belt assembly and remove the twists, if possible, without dismantling the retractor assembly. Otherwise, replace the seat belt assembly and repeat the buckle-up procedure five times. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Lap Belt Retractor Does Not Lock - Dual Retractor 2-Door and 4-Door Models - Front Outboard Seat (Except Versailles) 1. Withdraw a minimum of 18 inches (460mm) of webbing from the lap belt retractor and check for lock-up. Retractor must lock-up after 18 inches (460mm) of webbing withdrawal and return of 2 inches (50mm) into retractor and pull out. 2. If the retractor does not lock, replace the entire seat belt assembly and retest. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Lap Belt Retractor Does Not Lock - Dual Retractor 2-Door and 4-Door Models - Front Outboard Seat (Versailles Only) 1. Fasten the seat belt. Pull on the lap belt webbing - the retractor should be locked if OK. Unbuckle, allow the lap belt retractor to fully retract. 2. Repeat Step 1 five (5) times to ensure proper operation. 3. If not OK, replace the seat belt assembly for that seating position and retest. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! NOTE: There are two ways to stop the retractor from "free wheeling". One way is to "buckle up" and the retractor will lock immediately. The second way is to pull approximately 12" of webbing from the lap belt retractor, wait approximately 15 seconds, and a thermal timer will deactivate the "free wheeling" feature. Webbing Cannot Be Fully Extracted From Lap Belt Retractor 1. If the webbing cannot be pulled from the lap belt retractor, it may be twisted and jammed in a partially extended position. If the twist can be removed without retractor disassembly, allow the webbing to fully retract and then withdraw a minimum of 18 inches (460mm) of webbing from the retractor, return 2 inches (50mm) and check for lock-up. If OK, allow to retract fully and buckle up while sitting in the seat. Repeat five times to ensure proper operation. Verify that belt webbing can be extended far enough to expose the manufacturer's certification label. 2. If not OK, replace the seat belt assembly and repeat appropriate portions of Step 1, above. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Figure 7 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 601 Seats - Rear - Lap Belt Retractor Does Not Lock - 2-Point System (Figure 7) 1. Withdraw a minimum of 18 inches (460mm) of webbing from lap belt retractor and check for lock-up. Retractor must lock-up after 18 inches (460mm) of webbing withdrawn and return of 2 inches (50mm) into retractor and pull out. If OK, allow it to retract fully and buckle up while sitting in the seat. Repeat five times to ensure proper operation. 2. If not OK, replace seat belt assembly and repeat Step 1. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! 3. If the retractor of a new seat belt assembly has been bolted into a damaged or distorted mounting area, the new retractor could be warped and may not function. If this is the case, service the sheet metal in the area of the retractor mounting and install a new belt assembly. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Buckle Does Not Latch - All Belts If the tongue will not latch into the buckle securely, a coin or other foreign object may be interfering with proper buckle operation. Remove the object, if possible, and recheck for secure latching. If not OK, replace the belt assembly. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Section 5-Seat Belt Procedure After an Accident NOTE: ALL SEAT BELT ASSEMBLIES INCLUDING RETRACTORS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS THAT ALL SEAT BELT ASSEMBLIES IN USE DURING A COLLISION BE REPLACED UNLESS THE COLLISION WAS MINOR AND THE BELTS SHOW NO DAMAGE AND CONTINUE TO OPERATE PROPERLY. SEAT BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. Before installing the new seat belt assembly, the seat belt attaching areas must be inspected for damage and distortion, and if the attaching points are damaged or distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install the new seat belt assembly in matched sets using the appropriate instructions; then functionally test as described previously in this article. Section 6-Cleaning Belt Webbing Clean the belt webbing with any mild soap solution recommended for cleaning upholstery or carpets; follow instructions provided with the soap. Do not bleach or re-dye the webbing because it may weaken the belt webbing. Section 7-Service Parts The Ford Motor Company stocks replacement parts for all passenger car safety belt systems for which there is nominal demand without regard to the age of vehicle. Beyond this, in the interest of ensuring that the full protection of safety belts is available for all Ford owners, the Company will undertake to provide parts to service the belt system for any Company vehicle if it was originally equipped with safety belts. Seat belt and shoulder assembly part numbers for specific applications can be identified by referring to Body Section 611 of the parts catalog. In general, these assemblies are available with black webbing only once the vehicle is beyond two years out of production. Part orders should be placed through the normal PDC system. WARNING: WHEN REPLACING A SEAT BELT ASSEMBLY, BE SURE TO INSTALL A COMPLETE NEW ASSEMBLY (BUCKLE PORTION AND TONGUE PORTION TOGETHER) AS RECEIVED FROM FORD MOTOR COMPANY. DO NOT REPLACE ONE PART OF A SEAT BELT ASSEMBLY WITHOUT INSTALLING THE ENTIRE SEAT BELT ASSEMBLY. THIS WILL ASSURE THAT THE BUCKLE PORTION IS MANUFACTURED BY THE SAME MANUFACTURER AS THE TONGUE PORTION AND IS COMPATIBLE WITH IT. ALSO BE SURE THAT THE BELTS INSTALLED ARE INTENDED SPECIFICALLY FOR THE VEHICLE IN WHICH THEY ARE BEING INSTALLED. QUICK REFERENCE PARTS LISTING FOR SEAT BELTS, COMFORT CLIPS, AND EXTENDERS Extenders offer eight inches of additional length and can be used in all seating positions. It is necessary to ensure that the manufacturer of the extender being installed is the same as that identified on the seat belt assembly. Part numbers for comfort clips used in the 3-point system, seat belts, extenders are shown below. Quick Reference Part Listing Book Microfiche Section Page Plate Row Column Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 602 Car Seat Belt Extenders 1973-1979 611 2 F4 10 01 and Seat Belts 1973-1979 611 2 M4 9 56 1980- 611 1 F3 23 47 1980- 611 1 M3 23 47 Truck Seat Belt Extenders 1973-1979 600 3 LT2 20 48 and Seat Belts 1980- 600 4 LT2 11 04 All Vehicles Comfort Clips 1973-1979 600 8 F4 9 63 Section 8-Service Recalls Involving Seat Belts Recall # Letter Dated Year Car Line Concern H1B 11/17/1971 1972 Pinto, T-Bird, Light Truck Seat belt or shoulder belt bolt fracture C-2H 7/10/1972 1972 Mark IV Belt retractor won't lock up H-2H 7/10/1972 1972 Thunderbird Belt retractor won't lock up C-3E 7/31/1972 1972 Montego Belt retractor won't lock up H-3E 7/31/1972 1972 Torino Belt retractor won't lock up H-3F 7/31/1972 71-72 F-Series Lt. & Med. Incorrect length shoulder belt - no adjustment H-9D 6/1973 1973 Ford, Pinto, Lt. Truck Seat belt bolt fracture 118 3/20/1974 1974 Torino Retractor remains unlocked 130 8/26/1974 1975 Mercury Mixed part assys. - no seat belt latching 152 2/14/1975 1972 Maverick, Comet Need longer belts 189 4/26/1976 1976 W-Series Belt too short 214 12/4/1976 76-77 Granada, Monarch Shoulder belt weld nut replacement 253 2/22/1978 72-78 L8OO/900, L8000/9000 Belt too short 282 3/30/1978 1978 Pinto, Bobcat, Mustang II Retractor won't lock up 289 8/29/1978 1978 T-Bird, Cougar, LTD II, Ford Retractor won't lock up 298 9/20/1978 1978 F-Series Weld nut replacement 313 10/25/1978 1979 Econolines Possible cut belt by the seat 1536 11/1/1978 1979 Versailles Retractor solenoid drawing constant current, discharging battery 458 3/30/1983 81-82 Escort, Lynx Wagon Shoulder belt anchorage reinforcement 477 12/12/1983 1984 Escort/Lynx (3 dr.), Tempo/ D-ring bolt replacement Topaz (2 dr.), Mustang/Capri, T-Bird/Cougar, LTD/Marquis, Mark VII, Continental, Ford/ Mercury, Lincoln, Ranger, Bronco II, Bronco 477-S 2/23/1984 1984 Bronco, Bronco II, Ranger D-ring covers 489 8/8/1984 81-84 Escort/Lynx, Tempo/Topaz Belt protective spacers Section 9-TSB's Involving Seat Belts TSB # Title Other Information 198 Unauthorized Service Replace belt assembly 81-2-6 Securing Tot Guard Seat belt extender 81-5-3 Seat Belt Discoloration (Red) Truck, Escort/Lynx 1981 81-7-23 Seat Belt Becomes Tight While Driving Seat belt replacement 83-18-15 Seat Belt Rattles Against Trim Seat belt replacement 84-4-4 D-Ring Bind - Restricts Extraction of Belt Addition of spacer 84-11-1 D-Ring Cover Bind - Belt Free Swing D-ring cover replacement 41-50-8 See following page OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Technical Service Bulletins > Safety Belt - Tongue Cover Now Available Seat Belt Latch: Technical Service Bulletins Safety Belt - Tongue Cover Now Available SAFETY BELT - TONGUE COVER SERVICE PART AVAILABILITY Article No. 88-25-2 FORD: 1974-88 ALL LINCOLN-MERCURY: 1974-88 ALL LIGHT-TRUCK: 1974-88 ALL MEDIUM/HEAVY: 1974-88 ISSUE: The safety belt tongue cover is now available for service. It is no longer necessary to replace the entire safety belt assembly in the event a buckle and tongue cover requires service. ACTION: No corrective action is required. Refer to the following application chart for the correct service part number. NOTE: THE SAFETY BELT TONGUE COVERS ARE SERVICED IN A NEUTRAL COLOR AND MUST BE PAINTED TO MATCH. SAFETY BELT TONGUE COVER APPLICATION CHART MODEL YEAR VEHICLE SERVICE PART NO. 1986-88 Taurus/Sable E7DZ-54612A64-A 1974-88 All Other Vehicles E7FZ-61612A64-A PART NUMBER PART NAME CLASS E7DZ-54612A64-A Safety Belt Tongue Cover Package of 4 BM E7FZ-61612A64-A Safety Belt Tongue Cover Package of 4 B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 1050, 1051, 1800 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > System Information > Technical Service Bulletins > Antitheft Devices - Installation Precautions Antitheft and Alarm Systems: Technical Service Bulletins Antitheft Devices - Installation Precautions Article No. 86-3-9 ANTI-THEFT DEVICES (AFTER MARKET) - INSTALLATION/ OPERATING PRECAUTIONS ON VEHICLES EQUIPPED WITH ELECTRONIC ENGINE CONTROLS (EEC) FORD 1978-86 ALL LINCOLN-MERCURY 1978-86 ALL LIGHT TRUCK 1981-86 ALL NOTE: This article is being republished in its entirety to include 1986 models. Installation of "AfterMarket" anti-theft devices such as fuel shutoff and ignition defeating devices may cause no starts, hard starting, stalls, or damage to vehicle components on Ford vehicles equipped with electronic engine controls. Possible damage caused by these devices can result from the following situations: 1. Fuel shutoff devices - Attempting to start the vehicle without disarming this device may cause the fuel injectors to run dry and overheat, which will lead to failure of the injectors. 2. Ignition defeating devices which ground the ignition/tachometer lead - Attempting to start the vehicle without disarming may result in ignition coil failure. Figure 13 In addition, care must be taken when routing underhood after market wiring (see Figure 13 for proper precautions), in order to avoid electromagnetic interference with electronic engine controls. The following precautions must be observed: Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > System Information > Technical Service Bulletins > Antitheft Devices - Installation Precautions > Page 612 1. Ignition tach signal wiring must not be randomly routed through the engine compartment. 2. Add-on wiring must not run parallel to secondary (plug) ignition wires. 3. EEC wiring harness (12A581) must not be altered or cut or rerouted. Failure to observe these warnings may result in damage to vehicle components or drive deterioration. OTHER APPLICABLE ARTICLES: Supersedes 85-7-8 WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Ignition - Coil Durability/Radio Frequency Interference Radio/Stereo: Technical Service Bulletins Ignition - Coil Durability/Radio Frequency Interference Article No. 84-22-8 IGNITION - COIL DURABILITY AND RADIO FREQUENCY INTERFERENCE LIGHT TRUCKS 1985 AND PRIOR YEARS - ALL SERIES MEDIUM/HEAVY TRUCKS 1985 AND PRIOR YEARS - ALL SERIES Relocation of the ignition coil to accomodate the installation of non-Ford engine-mounted equipment may effect the durability of the coil and/or cause a radio frequency interference condition. For these reasons movement of the ignition coil from its original location is not recommended. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Cosmetic Surface Service Procedures Paint: Technical Service Bulletins Paint - Cosmetic Surface Service Procedures Article No. 84-3-3 PAINT - COSMETIC SURFACE SERVICE PROCEDURES FORD ALL CAR LINES - ALL MODEL YEARS LINCOLN-MERCURY ALL CAR LINES - ALL MODEL YEARS LIGHT TRUCKS ALL SERIES - ALL MODEL YEARS The cosmetic paint surface service procedures outlined below are reprinted from Article Number 82-3-3 dated February 18, 1982. Many of these procedures and techniques described have been incorporated along with several other helpful procedures in a video tape which is now available. This video tape describes paint and soft facia service procedures developed by Ford Motor Company Assembly plants to correct minor concerns. After seeing the video tape and with practice, a technician or body shop employee should be able to do the following: ^ Remove most minor dings and dents (without filling and repainting), by using special metal massaging service tools. ^ Remove hood and deck depressions without filling and repainting. ^ Remove trapped dirt particles and still preserve the original paint finish. ^ Service minor scratches that do not cut through into the prime or metal. ^ Service orange peel without repainting. ^ Service sags and runs without repainting. ^ Remove surface stains with a heat gun. ^ Make soft facia services on many punctures and tears in plastic parts without replacement. ^ Service damaged abrasion resistant coating. ^ Properly paint over E-coating. The video tape is titled, "Cosmetic Paint and Surface Repairs" and is available in 3/4 inch Umatic UMC, Order Number 4651-025; or 1/2 inch VHS, Order Number 4651-025. For ordering information refer to the Ford Service Training Aids Catalog or write to: Ford Service Publications Post Office Box 07150 Detroit, Michigan 48207 Exterior paint surface damage or imperfections of a nature where the prime coat does not show can, in most instances, be restored without repainting. The restoration of gloss and luster after the condition has been removed is made possible by new and improved service materials and procedures. The following procedure is applicable to surface conditions such as dirt particles, orange peel, runs, sags, industrial fallout stains, swirl marks, light scratches and other minor imperfections. Usually, these conditions are localized and it is not necessary to restore the entire panel. However, in a case such as dirt particles or scratches in several localized areas, it is recommended that the entire panel be restored to maintain a uniform appearance. FIGURE 5 Preparation Before starting the service, the affected surface must be clean and dry. Mask off adjacent panels, mouldings, stripes and character lines as required (Figure 5). Where applicable, eye protection, face mask and a belt buckle cover should be worn. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Cosmetic Surface Service Procedures > Page 624 Service Procedure The basic concept of the procedure is to remove the defect condition, and then restore the finish to an acceptable appearance. As a general guideline, remember that sanding marks are removed with rubbing compound and the swirl marks evident after buffing are removed by polishing. As an example, light scratches or small dirt particles can be removed with a power buffer and medium buffing compound followed by polishing. Deeper scratches, heavy dirt particles or orange peel must be wet sanded, buffed with compound to remove the sanding marks and then polished to remove the swirl marks from the buffing operation. It is suggested with initial service attempts, that technicians develop a learning cycle by picking a small service area and first try polishing, then buffing and finally wet sanding to remove the condition. When you have determined which method is appropriate, proceed with the remaining area to be serviced and then restore the finish as required. The following outlines the complete procedure and required materials. FIGURE 6 Polishing For removal of very minor scratches, swirl marks and/or to restore luster to a dull finish. Apply a small amount of 3M Final Glaze to the affected panel (Figure 6) and using a suitable electric or air powered polish/buffing wheel (2000 max. rpm) and a 3M Superbuff 2 + 2 Pad, polish the affected area until all swirl marks are gone and desired luster is obtained. When polishing, keep the pad flat against the surface. Do not bear down, the weight of the buffer is sufficient. Add Final Glaze sparingly as needed. Compound For removal of light scratches, small dirt particles, minor grind marks and sanding marks. FIGURE 7 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Cosmetic Surface Service Procedures > Page 625 FIGURE 8 Apply 3M Superduty Rubbing Compound (medium) to the panel and using a clean 2 + 2 pad on the wheel (as noted above) spread the compound evenly and buff the surface until the condition is removed; or in the case of a sanded area, the sanding marks are gone and the luster is restored to an acceptable level for polishing (Figure 7 and Figure 8). When buffing, keep the wheel flat to the surface using light to moderate pressure and long even strokes. Periodically check the finish and add compound as required. When buffing is complete, polish the panel as described above. Sanding For removal of severe conditions such as heavy dirt particles, deep scratches and orange peel. This wet sanding procedure utilizes 3M Ultra Fine Imperial Wetordry Color Sanding Paper to facilitate removal of surface damage. The Ultra Fine paper cuts quickly leaving a uniform finish that requires a minimum of buffing to restore the luster. FIGURE 9 1. Soak the 3M Imperial Wetordry Paper and a 3M Imperial Wetordry Sponge Pad thoroughly in clean water and wrap the paper around the pad as shown in Figure 9. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Cosmetic Surface Service Procedures > Page 626 FIGURE 10 2. Using a clean sponge, wet the area to be sanded. It is essential that the paper be kept wet as sanding proceeds (Figure 10). FIGURE 11 3. Wet sand the affected area with light even pressure on the pad with back and forth strokes (not circular). Do a small area at a time (Figure 11). FIGURE 12 4. Frequently dip the pad and paper in water to wash off sanding residue (Figure 12). Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Cosmetic Surface Service Procedures > Page 627 FIGURE 13 5. Frequently flood or squeegee off the affected surface to check depth of cut and to see if the defect is removed. The amount of paint surface that is being sanded can be judged as the area dulls (Figure 13). FIGURE 14 6. Water wash the affected area to determine if all surface defects have been removed. Note the uniform dull appearance of an evenly sanded panel (Figure 14). If the surface is not uniform, lightly resand the area. FIGURE 15 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Cosmetic Surface Service Procedures > Page 628 7. Wash and squeegee off the panel and check to assure that all defects are removed and sanding is complete. Then proceed with the buffing and polish procedures to restore the luster to the finish. 8. Figure 15 shows a hood panel which has been sanded, buffed and polished on one section to illustrate the effectiveness of the procedure. Runs and Sags The service of runs and sags in nonmetallic paint is covered in the previously released training publication "The Wet Look." This procedure, which consists of shaving the run or sag flush with a commercial single edge razor blade, sanding with a hard block and then compounding, can now be improved by finishing the service with Final Glaze. It is recommended that minor sags and runs be wet sanded with 600 grit paper. If it is necessary to shave them off with a razor blade, first dull the corners with sandpaper to avoid scratching the adjacent panel finish. PART NUMBER PART NAME CLASS 05528 3M Imperial Wetordry Sponge Pad 02021 3M Imperial Wetordry Color Sanding Paper 05955 3M Superduty Rubbing Compound 05957 3M Superduty Paste Compound (if preferred) 05701 3M Superbuff 2 + 2 Pad 05710 3M Superbuff Adaptor (if req'd) 05988 3M Final Glaze 02024 3M Wetordry Tri-M-ite Paper 600 Grit 05519 3M Sanding Block 7" Polisher/Buffer Air or Electric Razor Blade - Industrial Single Edge OTHER APPLICABLE ARTICLES: 82-3-3 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SPP6282 TIME: One Panel 0.4 Hr. - Each additional 0.2 Hr. MATERIAL ALLOWANCE: $.75 per panel DLR. CODING: Basic Part No. As applicable Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Cosmetic Surface Service Procedures > Page 629 Paint: Technical Service Bulletins Paint - Cosmetic Damage From Airborn Materials PAINT COSMETIC DAMAGE FROM AIRBORN MATERIALS Article No. 89-13-3 FORD: 1989 and prior ALL FORD LINES LINCOLN-MERCURY: 1989 and prior ALL LINCOLN-MERCURY LINES LIGHT TRUCK: 1989 and prior ALL LIGHT TRUCK LINES ISSUE: Paint may be damaged from various sources of airborn materials. The two different types are: ^ Inorganic ^ Organic Sometimes it is hard to identify the type of paint damage and know how to remove it. This TSB article gives detailed information and descriptions of both types of airborn materials. It also outlines the service procedures for treating them. ACTION: If service is required, identify the source of damage involved by referring to the following information. Use the following recommended service procedure to correct concerns. INORGANIC AIRBORN MATERIAL The effects of inorganic airborn materials can be seen as: ^ Dark blotches in the paint where the pigment in the paint surface has been attacked ^ Irregular spots that are cracked or etched around the edges and dull in the centers. ^ Small orange colored spots caused by iron particles may appear on the paint surface. Generally, materials that attack a paint film are either acidic or alkaline in nature. Sulfuric and nitric acids, in general, cause extreme damage to automative paint finishes. Even very small concentrations of the same materials can cause chemical spotting damage. Due to evaporation and condensation, these acids can create severe etching "spots" that may eventually crack or lift the paint film after some time in service. Although some automotive finishes are more resistant than others, none are completely immune to these chemicals. The most resistant paints used today are the urethanes because their resin system is least likely to react with chemicals. Air dry coatings are more susceptible to attack only when they are fresh. The longer the paint dries the more resistant it becomes. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Cosmetic Surface Service Procedures > Page 630 Metallic colors are more intolerant to chemicals because aluminum flake is fairly reactive with either an acid or alkali. The following chart contains the most common acid materials found on automotive finishes. The chart shows a color, the corresponding damage appearance and also the chemical causal agent. It is not applicable for Basecoat/Clearcoat finishes. * "Caustic" refers to any alkaline substance that may be "harsh" or "corrosive" depending on strength or concentration. The following "pH" chart show the relationship between acidic and alkaline chemicals and their corresponding pH values. This chart is provided for informational reference only. ORGANIC AIRBORN MATERIALS Organic damage is generally easier to identify. Organic damage is mostly due to tree sap, bird and insect droppings, dead insects (Figure 8) and pollen. Tree sap is easily identified by clear raised drops that may be hard or sticky. Bee or bug dropping spots may appear brownish or yellow in color, about an eighth to a quarter inch in diameter. Dead and decomposing insect bodies are readily visible to the eye. Pollen deposits are small yellow clusters. Each of these items is potentially damaging to any currently available paint system. Other noticeable traits of organic damage are spots that are raised (swelling) micro-crazing (cracked) and pitting, due to pollen eating into the paint film. The active ingredients in most organic contaminants are tannic and formic acids . These acids are found in berries and bodily fluids of insects and birds. Investigations completed at dealerships show that the bright lot lights tend to attract insects. The use of "soft lights" for display and storage lot illumination will help reduce damage resulting from decomposing bugs and droppings by decreasing the number of bugs attracted to these lights. Organic damage is accelerated by heat. During very hot weather conditions, it is important to wash vehicles more often. ORGANIC AND INORGANIC REPAIR PROCEDURES FOR MILD DAMAGE Iron dust particles may imbed themselves into the paint film. On some light colored vehicles after some weathering, tiny dots of rust start to appear. They Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Cosmetic Surface Service Procedures > Page 631 feel rough to the touch and are difficult to remove. The best way to remove these particles is by treating the finish with an oxalic acid-detergent-water wash. Use the following procedure to perform this service repair. NOTE: OXALIC ACID WASH IS ALSO PRE-PACKAGED IN VARIOUS STRENGTHS UNDER VARIOUS BRAND NAMES, IF YOU CHOOSE NOT TO MIX YOUR OWN BATCHES. 1. Wash and degrease the vehicle first, using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent, and a suitable wax and grease remover. If this does not remove all of the iron particles, proceed with the oxalic acid wash. 2. Prepare a quantity of oxalic acid-detergent-water solution as follows: a. Dissolve 6-8 ounces of Oxalic Acid (powder) in one gallon of warm water. b. Add 1-2 tablespoons full of non-alkaline detergent such as Ford Multi Purpose Cleaner. 3. Apply this solution liberally to all affected surfaces of the vehicle with a large sponge. Keep the surface wet until the technician can no longer feel any surface roughness with bare or gloved fingertips. NOTE: IF THIS IS NOT DONE THOROUGHLY, STAINING MAY REDEVELOP IF IRON PARTICLES ARE LEFT BEHIND. 4. Rinse the area with clean water. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS WITH PROLONGED CONTACT. 5. If the iron particles are not totally removed after 2 washings, use one or both of the procedures listed for minor chemical contamination. NOTE: THE USE OF POLISHING (WITH WAX), SANDING WITH MICRO FINE SANDPAPER (1500 GRIT OR GREATER) OR BUFFING WITH VERY LIGHT COMPOUND SHOULD ONLY BE DONE AS A LAST RESORT. CHEMICAL CONTAMINATION Chemical contamination, either acid or alkali, can cause off-color spots and crack the paint film. In the presence of moisture (dew), sulfur contamination will change the color (light/dark) of the paint pigments. (This does not apply to Basecoat/Clearcoat) Since this contamination affects the pigments, lacquers and enamels show no difference in resistance. Production thermal drying and air drying finishes are likely to be spotted. Minor chemical contamination can be removed by using the following step by step procedure. 1. Wash the vehicle first by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent to remove the exterior foreign materials. 2. If the spotting is extensive and on the horizontal surfaces, then machine polish. 3. Apply a light grit polishing compound to the affected surface by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum cutting efficiency. 4. Polish off the spots using a buffer operating at 1700-1800 rpm. Confine polishing to the spotted areas. Repeat as necessary until all spots have been removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all contamination. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Cosmetic Surface Service Procedures > Page 632 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OR SAND OUT, THEN REFINISHING IS REQUIRED. ORGANIC MATERIAL REPAIR PROCEDURE FOR MILD DAMAGE Minor organic damage can be removed by using the following step by step procedure. 1. Wash and degrease the vehicle thoroughly by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent and a wax and grease remover to remove all organics. 2. Inspect the vehicle horizontal surfaces. If spotting or paint film swelling is extensive, use a buffer to repair. 3. Apply a light grit polishing compound to the affected areas by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum efficiency. 4. Polish off the spots or swelling marks using a buffer that operates between 1700-1800 rpm. Polishing should be confined to the affected areas only. Repeat as necessary until all spots or marks are removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE. Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all organics. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OUT, THEN REFINISHING IS REQUIRED. PAINT RECONDITIONING PROCEDURES FOR SEVERE DAMAGE Acrylic enamel single stage or base/clear paint systems should be painted by using the following procedure. 1. .Wash the vehicle with Ford Multi Purpose Cleaner or equivalent to remove all organic materials. 2. Wash the areas to be painted with wax and grease remover. 3. Prepare the area as follows: a. Neutralize the affected areas with baking soda (sodium bicarbonate) and water. b. Rinse the surface off with plain water. c. Wash the panel with a mild soapy detergent. d. Dry the panel completely. NOTE: IF THE DAMAGE IS THROUGH THE TOP COAT FINISH AND INTO THE PRIMERS, THE PANEL MUST BE SANDED DOWN TO BARE METAL OR PLASTIC AND THEN REFINISHED. Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Cosmetic Surface Service Procedures > Page 633 4. Apply a self-etching primer for metal surfaces only. NOTE: A FLEX ADDITIVE MAY BE NECESSARY WHEN WORKING WITH FLEXIBLE PLASTICS Then proceed as follows: a. Let dry per instructions. b. Apply a two component urethane primer surfacer. c. Sand the surface with 400 grit sandpaper to get to proper finish. d. Finish sanding with 600 grit sandpaper. 5. Solvent wash panel with wax and grease remover. Then, tack wipe it. 6. Apply base coat or top coat material per applicable paint system. NOTE: THE USE OF ACRYLIC URETHANE ENAMEL IS HIGHLY RECOMMENDED FOR THIS TYPE OF REPAIR. 7. Apply clear acrylic urethane if you are using a base/clear paint system. WAYS TO MINIMIZE EFFECTS OF AIRBORN MATERIAL DAMAGE During the past year, Ford Motor Company and major paint suppliers have participated in a survey to analyze the effects of airborn materials. This survey was conducted on foreign and domestic vehicles. It resulted in the following interesting conclusions. 1. Keeping the vehicles clean, washing frequently with de-ionized water and drying by hand or mechanical means will help minimize the effects of inorganic and organic materials. 2. Spray washing without rubbing will not totally remove all residue on the surface of the vehicle. Damage could possibly occur over a longer period of time. 3. Care should be taken to not allow any painted vehicle surface to become wet in direct sunlight. (A sprinkler system can cause damage if the vehicles are not dried.) Possible alkaline water or mineral deposit may be the cause. 4. The use of "Soft Lights" for lighting around storage lots and showing areas will minimize the attraction of insects and the possibility of organic damage. 5. Ford Motor Company is piloting a program for a transit/storage coating to be applied on the horizontal surfaces of all vehicles. These coatings have shown good protection to the paint surface. They are clear in color and should be left on the vehicles until they are sold. 6. We are testing many "permanent paint sealants" used by dealers. Until all testing is completed, we cannot give any recommendations for what products to use. Testing has shown that a sealant that allows water to bead up on the vehicle does not help to dissipate the materials on the paint surface. Sheeting of water on the vehicle is highly desirable. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Cruise Control > System Information > Technical Service Bulletins > Speed Control - New Rotunda Tester Information Cruise Control: Technical Service Bulletins Speed Control - New Rotunda Tester Information Article No. 85-1-8 SPEED CONTROL - NEW ROTUNDA TESTER INFORMATION FORD 1974-1985 LINCOLN-MERCURY 1974-1985 LIGHT TRUCKS 1974-1985 Figure 5 - Article No. 85-1-8 A new Rotunda #007-00013 speed control tester is now available for functioning and diagnosing all Ford factory installed speed control systems from 1974 through 1985 model year for both passenger cars and light trucks. The tester (Figure 5) works on vehicles with all combinations of control switches, transmissions, speedometers (electronic and mechanical), brakes, clutches, etc. With three modes of operation (Automatic, Single Scan, and Scan Probe), the mechanic can pinpoint any failure including wiring, vacuum lines, switches, servos, etc. The tester includes a manual with its own specially developed "diagnostic trees" for identifying any failed or marginal part in the speed control system. Service technicians with little or no experience with speed control systems can use this tester to efficiently service the systems. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning 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 > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings Odometer: Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND ODOMETER READINGS Article No. 89-2-7 FORD: 1989 AND PRIOR ALL CAR LINES LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle components or systems. The information in this TSB article is intended to assist technicians in speedometer/odometer concern diagnosis. ACTION: Use the following supplemental information below to assist in speedometer/odometer diagnostics. OPERATION A mechanical analog speedometer displays vehicle speed and the odometer displays total distance traveled. The speedometer/odometer assembly is cable driven by either a transmission or a transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed so that all are identical and have no error in the speedometer head. Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the speedometer/odometer. An electronic signal is sent from a speed sensor to the digital speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle, similar to a cable. Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio and speedometer/odometer drive and driven gears. TIRES Improper tire rolling radius and inflation pressure, temperature and size may contribute to inaccurate system readings. System accuracy testing should be performed after the tires are set at the correct pressure as shown on the safety compliance certification label. The tires should be warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a constant speed within the posted speed limit. AXLE/TRANSAXLE RATIO The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios are available, but usually are not a concern when dealing with speedometer/odometer concerns unless the gear ratio has been changed. WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel drive vehicles have several driven gears with various numbers of teeth available to correct input to the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears for correction. GENERAL DESCRIPTION The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance traveled. Ford Motor vehicles are well within those limits. The speed indication is biased high, except on police vehicles with certified calibration speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the actual speed. This is intended to protect the consumer against violating speed laws. Most customer concerns are related to speedometers reading too high at true speeds between 50 MPH and 65 MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10% greater than true speed. The speedometer head is an instrument which processes information sent to it by the rotating speedometer cable. If the system components send the Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 646 wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the speedometer head odometer, start by checking the accuracy of the odometer even if the customer concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads established at mile increments or a known local course. If roads with mile markers are used, a five mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The odometer should be checked again to verify any corrective action. If the indicated speed error exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of drive gears, parts not splined or loose yoke nuts. If the vehicle has speed control, the speed accuracy can be checked using the verified odometer vs. time. The formula is as follows: 3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES: 60 MPH (96 Km/h) requires 60 seconds to cover one mile 55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile 50 MPH (80 Km/h) requires 72 seconds to cover one mile ARTICLE SUPERSEDED: 84-14-6, date 7/3/84 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2300, 2310, 2400, 2500 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings Speedometer Head: Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND ODOMETER READINGS Article No. 89-2-7 FORD: 1989 AND PRIOR ALL CAR LINES LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle components or systems. The information in this TSB article is intended to assist technicians in speedometer/odometer concern diagnosis. ACTION: Use the following supplemental information below to assist in speedometer/odometer diagnostics. OPERATION A mechanical analog speedometer displays vehicle speed and the odometer displays total distance traveled. The speedometer/odometer assembly is cable driven by either a transmission or a transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed so that all are identical and have no error in the speedometer head. Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the speedometer/odometer. An electronic signal is sent from a speed sensor to the digital speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle, similar to a cable. Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio and speedometer/odometer drive and driven gears. TIRES Improper tire rolling radius and inflation pressure, temperature and size may contribute to inaccurate system readings. System accuracy testing should be performed after the tires are set at the correct pressure as shown on the safety compliance certification label. The tires should be warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a constant speed within the posted speed limit. AXLE/TRANSAXLE RATIO The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios are available, but usually are not a concern when dealing with speedometer/odometer concerns unless the gear ratio has been changed. WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel drive vehicles have several driven gears with various numbers of teeth available to correct input to the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears for correction. GENERAL DESCRIPTION The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance traveled. Ford Motor vehicles are well within those limits. The speed indication is biased high, except on police vehicles with certified calibration speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the actual speed. This is intended to protect the consumer against violating speed laws. Most customer concerns are related to speedometers reading too high at true speeds between 50 MPH and 65 MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10% greater than true speed. The speedometer head is an instrument which processes information sent to it by the rotating speedometer cable. If the system components send the Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 651 wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the speedometer head odometer, start by checking the accuracy of the odometer even if the customer concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads established at mile increments or a known local course. If roads with mile markers are used, a five mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The odometer should be checked again to verify any corrective action. If the indicated speed error exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of drive gears, parts not splined or loose yoke nuts. If the vehicle has speed control, the speed accuracy can be checked using the verified odometer vs. time. The formula is as follows: 3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES: 60 MPH (96 Km/h) requires 60 seconds to cover one mile 55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile 50 MPH (80 Km/h) requires 72 seconds to cover one mile ARTICLE SUPERSEDED: 84-14-6, date 7/3/84 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2300, 2310, 2400, 2500 Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Windows and Glass > Windows > System Information > Technical Service Bulletins > Customer Interest: > 8542 > Feb > 85 > Door/Vent Windows - Excessive Efforts to Open Windows: Customer Interest Door/Vent Windows - Excessive Efforts to Open Article No. 85-4-2 GLASS - DOOR AND VENT WINDOWS - EXCESSIVE EFFORTS TO OPEN - CORRECT LUBRICATING PRODUCT FORD ALL LINCOLN-MERCURY ALL LIGHT TRUCK ALL MEDIUM/HEAVY TRUCK ALL It has been found that the propellant within aftermarket aerosol spray lubricants attacks the weatherstrip flocking adhesive and can cause high friction during glass cycling. To prevent this condition, it is suggested that dealers only use Mini-Vent Lube (Part No. D3AZ-19553-A) or Silicone Lubricant (Jelly) (Part No. COAZ-19553-A) as a lubricant for minimizing door glass or vent window high and/or sticking glass operating afforts. These two aftermarket lubricants are longer lasting and may be applied to the window and vent window weatherstrips during Dealer Prep and/or normal customer service visits. Aerosol sprays should NOT be used. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Windows and Glass > Windows > System Information > Technical Service Bulletins > All Technical Service Bulletins for Windows: > 8542 > Feb > 85 > Door/Vent Windows - Excessive Efforts to Open Windows: All Technical Service Bulletins Door/Vent Windows - Excessive Efforts to Open Article No. 85-4-2 GLASS - DOOR AND VENT WINDOWS - EXCESSIVE EFFORTS TO OPEN - CORRECT LUBRICATING PRODUCT FORD ALL LINCOLN-MERCURY ALL LIGHT TRUCK ALL MEDIUM/HEAVY TRUCK ALL It has been found that the propellant within aftermarket aerosol spray lubricants attacks the weatherstrip flocking adhesive and can cause high friction during glass cycling. To prevent this condition, it is suggested that dealers only use Mini-Vent Lube (Part No. D3AZ-19553-A) or Silicone Lubricant (Jelly) (Part No. COAZ-19553-A) as a lubricant for minimizing door glass or vent window high and/or sticking glass operating afforts. These two aftermarket lubricants are longer lasting and may be applied to the window and vent window weatherstrips during Dealer Prep and/or normal customer service visits. Aerosol sprays should NOT be used. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Windows and Glass > Windows > System Information > Technical Service Bulletins > All Other Service Bulletins for Windows: > 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 > Windows and Glass > Windows > System Information > Technical Service Bulletins > All Other Service Bulletins for Windows: > Page 671 Windows: By Symptom Technical Service Bulletin # 8542 Date: 850221 Door/Vent Windows - Excessive Efforts to Open Article No. 85-4-2 GLASS - DOOR AND VENT WINDOWS - EXCESSIVE EFFORTS TO OPEN - CORRECT LUBRICATING PRODUCT FORD ALL LINCOLN-MERCURY ALL LIGHT TRUCK ALL MEDIUM/HEAVY TRUCK ALL It has been found that the propellant within aftermarket aerosol spray lubricants attacks the weatherstrip flocking adhesive and can cause high friction during glass cycling. To prevent this condition, it is suggested that dealers only use Mini-Vent Lube (Part No. D3AZ-19553-A) or Silicone Lubricant (Jelly) (Part No. COAZ-19553-A) as a lubricant for minimizing door glass or vent window high and/or sticking glass operating afforts. These two aftermarket lubricants are longer lasting and may be applied to the window and vent window weatherstrips during Dealer Prep and/or normal customer service visits. Aerosol sprays should NOT be used. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Technical Service Bulletin # 8542 Date: 850221 Door/Vent Windows - Excessive Efforts to Open Article No. 85-4-2 GLASS - DOOR AND VENT WINDOWS - EXCESSIVE EFFORTS TO OPEN - CORRECT LUBRICATING PRODUCT FORD ALL LINCOLN-MERCURY ALL LIGHT TRUCK ALL MEDIUM/HEAVY TRUCK ALL It has been found that the propellant within aftermarket aerosol spray lubricants attacks the weatherstrip flocking adhesive and can cause high friction during glass cycling. To prevent this condition, it is suggested that dealers only use Mini-Vent Lube (Part No. D3AZ-19553-A) or Silicone Lubricant (Jelly) (Part No. COAZ-19553-A) as a lubricant for minimizing door glass or vent window high and/or sticking glass operating afforts. These two aftermarket lubricants are longer lasting and may be applied to the window and vent window weatherstrips during Dealer Prep and/or normal customer service visits. Aerosol sprays should NOT be used. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford Courier Workshop Manual (L4-2299cc (1982)) Ford Workshop Manuals > Wiper and Washer Systems > 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 > Wiper and Washer Systems > 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 > 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 > 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"