Ford Workshop Service and Repair Manuals

Detach the coolant expansion tank from the wheelhouse assembly and position to one side. Remove the bolt. Detach the coolant expansion tank.

Detach the power steering fluid reservoir from the wheelhouse assembly.

NOTE:Using a suitable blanking cap, cap the power steering fluid reservoir. Disconnect the power steering fluid cooler return line from the power steering fluid reservoir.

Place the end of the power steering fluid cooler return line into a suitable container.

Remove the air duct inlet and outlet tubes.

Detach the intercooler air guide from the radiator grille opening panel.

Disconnect the intake air temperature (IAT) sensor electrical connector.

Remove the intercooler.

CAUTION:Isolate the glow plugs to prevent damage to the glow plug electrical connectors. Remove the pre-glow relay fuse from the Battery Junction Box (BJB). Refer to Wiring Diagrams Section -700-01, for schematic and connector information.

Disconnect the glow plug electrical connectors.

Remove the glow plugs.

Disconnect the fuel injection pump electrical connector. Pull out the locking handle. Disconnect the electrical connector.

NOTE:The vehicle must be raised with the wheels clear of the floor to allow the steering wheel to be rotated from lock to lock. Raise and support the vehicle. For additional information, refer to: Jacking (100-02 Jacking and Lifting, Description and Operation) / Lifting (100-02 Jacking and Lifting, Description and Operation).

NOTE:When filling the power steering fluid reservoir, make sure the fluid is clean and not agitated prior to use. The fluid should be poured slowly into the reservoir to minimize the possibility of aeration. The fluid level should be checked with the fluid cold. Fill the power steering fluid reservoir to the MAX mark with the appropriate fluid. For additional information, refer to: Specifications (211-00 Steering System - General Information, Specifications).

CAUTION:Do not continuously crank the engine for more than 30 seconds, as damage to the starter motor may result. While cranking the engine for no more than 30 seconds turn the steering wheel from lock to lock. With the aid of another technician add 1 liter of clean power steering fluid. For additional information, refer to: Specifications (211-00 Steering System - General Information, Specifications).

Wait 60 seconds to allow the starter motor to cool.

CAUTION:Do not continuously crank the engine for more than 30 seconds, as damage to the starter motor may result. While cranking the engine for a further 30 seconds turn the steering wheel from lock to lock. With the aid of another technician add a further 1 liter of clean power steering fluid. For additional information, refer to: Specifications (211-00 Steering System - General Information, Specifications).

When all the fluid has been used, turn the ignition switch to the OFF position.

Remove the blanking cap from the power steering reservoir and connect the power steering fluid cooler return line.

Attach the power steering fluid reservoir to the wheelhouse assembly.

Attach the coolant expansion tank to the wheelhouse assembly. Attach the coolant expansion tank. Install the bolt.

Connect the fuel injection pump electrical connector. Connect the electrical connector. Push in the locking handle.

Install the glow plugs.

Connect the glow plug electrical connectors.

Install the pre-glow relay fuse. Refer to Wiring Diagrams Section -700-01, for schematic and connector information.

Install the intercooler.

Connect the IAT sensor electrical connector.

Attach the intercooler air guide to the radiator grille opening panel.

Install the air duct inlet and outlet tubes.

Lower the vehicle.

Fill the power steering fluid reservoir to the MAX mark with the appropriate fluid. For additional information, refer to: Power Steering System Bleeding (211-00 Steering System - General Information, General Procedures).