Ford Escort Complete Workshop Service Repair Manual 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1

Chapter 1 Routine maintenance and servicing Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Alternator drivebelt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . .27 Automatic transmission selector mechanism check . . . . . . . . . . . .28 Battery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Brake components check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Contact breaker points adjustment - models with contact breaker distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Contact breaker points renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Crankcase emission control filter renewal . . . . . . . . . . . . . . . . . . . .35 Distributor lubrication - models with contact breaker distributor . .12 Driveshaft check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Exhaust manifold nut check - RS Turbo models . . . . . . . . . . . . . . . .9 Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Fluid level checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Front brake disc pad check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Fuel filter renewal - fuel injection engines . . . . . . . . . . . . . . . . . . . .36 Hinge and lock check and lubrication . . . . . . . . . . . . . . . . . . . . . . .31 Idle speed and mixture adjustment . . . . . . . . . . . . . . . . . . . . . . . . .10 Ignition system components check . . . . . . . . . . . . . . . . . . . . . . . . .11 Ignition timing check - models with contact breaker distributor . . .14 Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Manual transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . .26 Oil filler cap cleaning - OHV and HCS engines . . . . . . . . . . . . . . . . .7 Rear brake shoe lining check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Roadwheel check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Spark plug renewal - RS Turbo models . . . . . . . . . . . . . . . . . . . . . .15 Suspension and steering check . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Turbocharger-to-manifold nut check - RS Turbo models . . . . . . . .23 Tyre checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Valve clearance adjustment - OHV and HCS engines . . . . . . . . . . .21 1•1 Easy, suitable for novice with little experience Fairly easy, suitable for beginner with some experience Fairly difficult, suitable for competent DIY mechanic Difficult, suitable for experienced DIY mechanic Very difficult, suitable for expert DIY or professional Degrees of difficulty Contents 1

Engine Oil filter type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C104 Valve clearances (cold): OHV engines: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.008 in) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.59 mm (0.023 in) HCS engines: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.008 in) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.32 mm (0.012 in) Cooling system Recommended antifreeze concentration . . . . . . . . . . . . . . . . . . . . . . . . 45% by volume Fuel system Idle speed: Carburettor models: All except Weber 2V TLDM carburettor . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpm Weber 2V TLDM carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 to 800 rpm Bosch K-Jetronic fuel injection models . . . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpm Bosch KE-Jetronic fuel injection models: 1985 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 to 900 rpm 1986 models onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 920 to 960 rpm Electronic Fuel Injection (EFI) models . . . . . . . . . . . . . . . . . . . . . . . . . 900 ± 50 rpm Idle mixture CO content: Bosch K-Jetronic fuel injection models . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.5 % Bosch KE-Jetronic fuel injection models: 1985 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.75% 1986 models onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.1% Electronic Fuel Injection (EFI) models . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 ± 0.25% (cooling fan running) Air filter element type: 1.1 litre and 1.3 litre OHV engines . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W153 1.1 litre and 1.3 litre HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W225 1.1 litre and 1.3 litre CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W127 1.4 litre CVH engine: Carburettor engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W179 Central Fuel Injection (CFI) engines . . . . . . . . . . . . . . . . . . . . . . . . Champion W201 1.6 litre CVH engine (except XR3 models): Up to 1986 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W169 1986 to October 1988 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W201 October 1988 on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W226 1.6 litre CVH engine (XR3 models) . . . . . . . . . . . . . . . . . . . . . . . . . Champion W201 Ignition system Contact breaker points gap: Bosch distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 0.50 mm (0.016 to 0.02 in) Lucas distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 0.59 mm (0.016 to 0.023 in) Dwell angle (contact breaker ignition system) . . . . . . . . . . . . . . . . . . . . 48º to 52º Ignition timing *: OHV engines: Up to 1984 (contact breaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12º BTDC at idle speed 1984-on (contact breaker) and all electronic ignition . . . . . . . . . . . . . 6º BTDC at idle speed CVH engines (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12º BTDC at idle speed * Note: Ignition timing on models with either a Distributorless Ignition Sytem (DIS) or a programmed ignition system (ESC) cannot be adjusted. Refer to Chapter 5, Part B for further information. Spark plugs: Type: OHV and HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RS9YCC or RS9YC CVH engines: Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7YCC or RC7YC Bosch K-Jetronic fuel injection and Electronic Fuel Injection (EFI) models . . . . . . . . . . . . . . . . . . . . . . . Champion C6YCC or RC6YC Bosch KE-Jetronic fuel injection models . . . . . . . . . . . . . . . . . . . . Champion C61YC Central Fuel Injection (CFI) models . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7YCC or RC7YC4 Electrode gap: All except HCS and CFI models: RS9YCC, RC7YCC, C6YCC spark plugs . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.032 in) RS9YC, RC7YC, RC6YC, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 mm (0.028 in) HCS and CFI models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.039 in) 1•2 Servicing Specifications

Servicing Specifications 1•3 1 Brakes Minimum front brake disc pad thickness . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in) Minimum rear brake shoe lining thickness . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.04 in) Tyres Tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See “Weekly checks” on page 0•16 Torque wrench settings Nm lbf ft Exhaust manifold nuts - RS Turbo models . . . . . . . . . . . . . . . . . . . . . . . 14 to 17 10 to 13 Turbocharger-to-manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 to 26 15 to 19 Spark plugs: OHV and HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 to 20 10 to 15 CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 38 18 to 28 Seat belt anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 to 41 21 to 30 Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 to 100 52 to 74 Capacities Engine oil (drain and refill) OHV engine: With filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 litres (5.7 pints) Without filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.75 litres (4.8 pints) CVH engine: Carburettor engines with filter change: Pre-July 1982 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75 litres (6.6 pints) July 1982 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50 litres (6.2 pints) Carburettor engines without filter change: Pre-July 1982 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50 litres (6.2 pints) July 1982 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 litres (5.7 pints) Fuel-injected engines with filter change . . . . . . . . . . . . . . . . . . . . . . . 3.85 litres (6.8 pints) Fuel-injected engines without filter change . . . . . . . . . . . . . . . . . . . . 3.60 litres (6.3 pints) Fuel tank All models (except XR3i and Van) pre-May 1983 . . . . . . . . . . . . . . . . . . 40 litres (8.8 gallons) All other models (except Van) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 litres (10.6 gallons) Van . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 litres (11.0 gallons) Cooling system 1.1 litre OHV engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 litres (11.8 pints) 1.1 litre CVH engine: With small radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 litres (11.0 pints) With large radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 litres (12.6 pints) 1.3 litre OHV engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 litres (12.5 pints) 1.3 litre CVH engine: Pre-1986 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 litres (12.5 pints) 1986 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 litres (13.3 pints) 1.4 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 litres (13.3 pints) 1.6 litre CVH engine: Pre-1986 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 litres (12.1 pints) 1986 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 litres (13.7 pints) Transmission 4-speed manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 litres (4.9 pints) 5-speed manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 litres (5.5 pints) Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 litres (13.9 pints) The maintenance intervals in this manual are provided with the assumption that you, not the dealer, will be carrying out the work. These are the minimum maintenance intervals recommended by the manufacturer for vehicles driven daily. If you wish to keep your vehicle in peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, because it enhances the efficiency, performance and resale value of your vehicle. If the vehicle is driven in dusty areas, used to tow a trailer, or driven frequently at slow speeds (idling in traffic) or on short journeys, more frequent maintenance intervals are recommended. When the vehicle is new, it should be serviced by a factory- authorised dealer service department, in order to preserve the factory warranty. Ford Escort maintenance schedule

1•4 Maintenance schedule Every 6000 miles (10 000 km) or 6 months – whichever comes first In addition to all the items in the 250 mile (400 km) service, carry out the following: m Renew the engine oil and filter (Section 6) m On OHV and HCS engines, remove and clean the oil filler cap (Section 7) m Check the hoses, hose clips and visible joint gaskets for leaks and any signs of corrosion or deterioration (Section 8) m Visually check the fuel pipes and hoses for security, chafing, leaks and corrosion (Section 8) m Check the fuel tank for leaks and any sign of damage or corrosion (Section 8) m On RS Turbo models check the tightness of the exhaust manifold retaining nuts (Section 9) m Check and if necessary adjust the idle speed and mixture settings (Section 10) m Clean the distributor cap, coil tower and HT leads and check for tracking (Section 11) m On contact breaker point distributors lubricate the distributor shaft and cam (Section 12) m On contact breaker point distributors check and if necessary adjust the points gap (dwell angle), then check the ignition timing (Sections 13 and 14) m On RS Turbo models renew the spark plugs (Section 15) m Check the front disc pad thickness (Section 16) m Check the rear brake shoe lining thickness (Section 17) m Check the steering and suspension components for any signs of damage and wear (Section 18) m Check the security of the front suspension lower arm balljoint (Section 18) m Check the seat belt webbing for cuts or damage and check the seat belt operation (Section 19) m Carefully inspect the paintwork for damage and the bodywork for corrosion (Chapter 11) m Check the condition and adjustment of the alternator drivebelt (Section 20) Every 12 000 miles (20 000 km) or 12 months - whichever comes first In addition to all the items in the 6000 mile (10 000 km) service, carry out the following: m On OHV and HCS engines check and if necessary adjust the valve clearances (Section 21) m Check the exhaust system condition and security (Section 22) m On RS Turbo models check the tightness of the turbocharger-to-manifold nuts (Section 23) m Renew the spark plugs (Sections 24 and 15) m On contact breaker point distributors renew the contact breaker points (Section 25) m Check and if necessary top-up the manual transmission oil (Section 26) m Check the automatic transmission fluid level - where applicable (Section 27) m Check the operation of the automatic transmission selector mechanism (Section 28) m Check the driveshafts for damage or distortion and check the condition of the constant velocity joint bellows (Section 29) m Inspect the roadwheels for damage (Section 30) m Check the tightness of the roadwheel bolts (Section 30) m Lubricate all hinges, door locks, check straps and the bonnet release mechanism (Section 31) m Check the operation of all door, tailgate, bonnet release and window regulator components (Section 31) m Carry out a road test (Section 32) Every 36 000 miles (60 000 km) or 3 years - whichever comes first In addition to all the items listed in the previous services, carry out the following: m On CVH engines renew the timing belt (Section 37) m Make a thorough inspection of all brake components and rubber seals for signs of leaks, general deterioration and wear (Section 38) m Renew the brake fluid (Section 39) Every 24 000 miles (40 000 km) or 2 years - whichever comes first In addition to all the items in the 12 000 mile (20 000 km) and 6000 mile (10 000 km) services, carry out the following: m Renew the coolant (Section 33) m Renew the air cleaner element (Section 34) m On CVH engines renew the crankcase emission control filter (Section 35) m On fuel-injected engines renew the fuel filter (Section 36) Every 250 miles (400 km) or weekly m See "Weekly checks"

Maintenance - Component location 1•5 1 1 Fuse and relay box 2 Windscreen wiper motor 3 Engine oil dipstick 4 Carburettor 5 Fuel pump 6 Battery negative terminal 7 Brake master cylinder reservoir 8 Distributor 9 Ignition coil 10 Washer reservoir 11 Thermostat housing 12 Oil filler cap 13 Vehicle identification plate 14 Engine tuning decal 15 Cooling system expansion tank 16 Suspension strut top mounting Engine and under bonnet component location on 1986 1.4 litre models (air cleaner removed for clarity) 1 Fuse and relay box 2 Windscreen wiper motor 3 Crankcase emission control filter 4 Engine oil dipstick 5 Throttle housing 6 Inlet manifold 7 Throttle position sensor 8 Charge air temperature sensor 9 Distributor 10 Brake master cylinder reservoir 11 Battery negative terminal 12 Ignition coil 13 Fuel filter 14 Washer reservoir 15 Air cleaner 16 Fuel distributor 17 Inlet air hose 18 Turbocharger 19 Vehicle identification plate 20 Engine tuning decal 21 Cooling system expansion tank 22 Suspension strut top mounting Engine and under bonnet component locations on 1986 RS Turbo models

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Ford Escort Complete Workshop Service Repair Manual 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1

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