Ford Workshop Service and Repair Manuals

Vehicle in Workshop

When working on a vehicle in the workshop always make sure that:

• the parking brake is applied or the wheels are securely chocked to prevent the vehicle moving forwards or backwards.
• the key is removed from key operated hood locks before any work is carried out around the front of the vehicle.
• if the engine is to be run, there is adequate ventilation, or an extraction hose to remove exhaust fumes.
• there is adequate room to raise the vehicle and remove the wheels, if necessary.
• fender covers are always fitted if any work is to be carried out in the engine compartment.
• the battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is raised.

CAUTION:When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility of a surge of current causing damage to the internal components of the generator.

• if using welding equipment on the vehicle, a suitable fire extinguisher is readily available.

Alternative Fuel

WARNING:When servicing the fuel system always follow the recommended procedures. Failure to follow these instructions may result in personal injury.

If the odor of liquefied petroleum gas (LPG) or compressed natural gas (CNG) is present in the air in the workshop, warn all persons in the area to:

• extinguish all flames and lighted tobacco.
• shut off electrical and air powered equipment.
• evacuate the area.
• ventilate the area.
• contact the fire control authorities.
• remove the vehicle to a dedicated, ventilated area.

Alternative Fuel — Do's

• Do work on the vehicle in a designated area, that is well ventilated and with access restricted to qualified personnel only.
• Install new warning labels to their original locations.
• If possible always isolate the alternative fuel tank, and run the vehicle on the alternative fuel until it automatically switches to its normal fuel prior to taking the vehicle into the workshop service area.
• Only use tested and approved components and pipes when repairing or servicing LPG and CNG systems.

Alternative Fuel — Do Nots

• Do not vent off LPG fuel.
• Do not use shop air pressure to force LPG fuel from the fuel tank.
• Do not use paint drying ovens above 40°C for any alternative fuel vehicle. LPG and CNG fuel tanks must be removed from the vehicle prior to being put into paint drying ovens above 40°C.
• Do not modify the system or install new components that are not designed for gas vehicles.
• Do not evacuate fuel tanks unless there is repair that requires the removal of the fuel tank.
• Do not work on the fuel lines or system components unless the alternative fuel has been evacuated and the pressure in the system reduced to atmospheric or less.
• Do not use anything other than the specified leak detector fluid to trace fuel leaks.

Be aware of situations that may cause the LPG or CNG fuel system to vent off fuel, such as:

• extremely hot days.
• parking by a space heater.
• hoisting a vehicle up near a ceiling heater.

Only fully trained personnel, who are conversant with local standards, are to work on alternative fuel vehicles.

Towing the Vehicle

WARNING:When the vehicle is being towed, the ignition switch must be in position II (steering lock released and warning lamps illuminated). Only then will the steering, turn signal lamps, horn and stop lamps be operational. Failure to follow these instructions may result in personal injury.

NOTE:The removable towing eye (if equipped), has a left-hand thread and must be fully tightened before towing can commence.

When towing is necessary, the vehicle towing eyes should be used. The rope must be securely fastened to the towing eyes and must also be attached to the other vehicle such that the rope will not foul the bodywork.

When a vehicle with automatic transmission is towed, the gear selector must be in position N (Neutral). Never tow a vehicle with automatic transmission at a speed greater than 30 mph (50 km/h) or for a distance greater than 30 miles (50 km). If it is necessary to tow the vehicle a greater distance, the drive wheels must be lifted clear off the ground.

Alternatively the vehicle can be transported on a low loader or a trailer.

Connecting a Slave Battery Using Jumper Cables

WARNING:If the slave battery has recently been charged and is gassing, cover the vent plugs or covers with a damp cloth to reduce the risk of explosion should arcing occur when connecting the jumper cables. Failure to follow these instructions may result in personal injury.

CAUTION:A discharged battery condition may have been caused by an electrical short circuit. If this condition exists there will be an apparently live circuit on the vehicle even when all normal circuits are switched off. This can cause arcing when the jumper cables are connected.

CAUTION:While it is not recommended that the vehicle is jump started, it is recognized that this may occasionally be the only practical way to mobilize a vehicle. In such an instance, the discharged battery must be recharged immediately after jump starting to avoid permanent damage.

• Always make sure that the jumper cables are adequate for the task. Heavy duty cables must be used.
• Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be connected in parallel.
• Always make sure that switched electric circuits are switched off before connecting jumper cables. This reduces the risk of arcing occurring when the final connection is made.

WARNING:Make sure that the ends of the jumper cables do not touch each other or ground against the vehicle body at any time while the cables are attached to the battery. A fully charged battery, if shorted through jumper cables, can discharge at a rate well above 1000 amps causing violent arcing and very rapid heating of the jumper cables and terminals, and can even cause the battery to explode. Failure to follow these instructions may result in personal injury.

Always connect the jumper cables in the following sequence:

• Slave battery positive first and then vehicle battery positive.
• Slave battery negative next and then vehicle ground at least 12 inches (300 mm) from the battery terminal, for example engine lifting eye.

Always reduce the engine speed to idle before disconnecting the jumper cables.

Before removing the jumper cables from the vehicle that had the discharged battery, switch on the heater blower (high) or the heated rear window, to reduce the voltage peak when the cables are removed.

Always disconnect the jumper cables in the reverse order to the connecting sequence and do not short the ends of the cables.

Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in excess of eight hours continuous driving with no additional loads placed on the battery.

Component Cleaning

To prevent the ingress of dirt, accumulations of loose dirt and greasy deposits should be removed before disconnecting or dismantling components or assemblies.

Components should be thoroughly cleaned before inspection prior to reassembly.

Cleaning Methods:

• Dry cleaning.
• Removal of loose dirt with soft or cable brushes.
• Scraping dirt off with a piece of metal or wood.
• Wiping off with a rag.

WARNING:Wear eye protection when cleaning vehicle components with compressed air, a steam cleaner or a power washer. Failure to follow this instruction may result in personal injury.

CAUTION:Compressed air is sometimes 'wet' so use with caution, especially on hydraulic systems.

CAUTION:To prevent damage to the electrical connectors in the engine compartment, do not use a steam cleaner or a power washer to clean the engine compartment.

• Blowing dirt off with compressed air.
• Removal of dry dust using vacuum equipment. This method must always be used to remove friction lining material dust (asbestos particles).
• Steam cleaning.

WARNING:Most solvents require careful handling and some are harmful. Refer to Health and Safety Precautions and to the manufacturers literature for the relevant safety precautions. Failure to follow these instructions may result in personal injury.

Various solvents are available which are suitable for component cleaning. Some components, such as brake hydraulic parts and electrical assemblies should be cleaned only with recommended solvents — refer to Solvents, Sealers and Adhesives or to the section of the manual relevant to the component.

Calibration of Essential Measuring Equipment

WARNING:Equipment, which requires regular calibration, must be calibrated in accordance with the manufacturers instructions. Failure to follow this instruction may result in personal injury or damage to components.

It is of fundamental importance that certain essential equipment, for example torque wrenches, multimeters, exhaust gas analyzers or rolling roads, are regularly calibrated in accordance with the manufacturers instructions.