3•1

Chapter 3
Cooling, heating and air conditioning systems
Contents
Air conditioning system - component renewal . . . . . . . . . . . . . . . . . .21 General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . . .1
Coolant pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .9 Heater controls - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .17
Coolant pump/alternator drivebelt(s) - checking, renewal and Heater motor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .20
tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Heater unit - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Coolant pump/alternator drivebelt tensioner (DOHC models with Heater unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .18
power steering) - removal and refitting . . . . . . . . . . . . . . . . . . . . . .11 Radiator - inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Cooling fan switch - removal and refitting . . . . . . . . . . . . . . . . . . . . .14 Radiator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Cooling system - draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Temperature gauge sender - removal and refitting . . . . . . . . . . . . . .16
Cooling system - filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Thermostat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Cooling system - flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Thermostat - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Electric cooling fan - removal and refitting . . . . . . . . . . . . . . . . . . . . .13 Thermo-viscous cooling fan (SOHC models) - removal and refitting .12
Expansion tank and coolant level sensor - removal and refitting . . . .15

Degrees of difficulty
Easy, suitable for Fairly easy, suitable Fairly difficult, Difficult, suitable for Very difficult,
novice with little for beginner with suitable for competent experienced DIY suitable for expert
experience some experience DIY mechanic mechanic DIY or professional

3
Specifications
System type
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised, with belt-driven coolant pump, crossflow radiator,
thermo-viscous fan, thermostat, and expansion tank
CVH and DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised, with belt-driven coolant pump, crossflow radiator,
electric fan, thermostat, and expansion tank

Thermostat
Nominal temperature rating (fully open):
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88ºC (190º F)
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100ºC (212ºF)
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102ºC (216ºF)
Opening temperature:
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC (185 to 192ºF)
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88ºC (190ºF)
CVH (R6A type) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC (185 to 192ºF)
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC (185 to 192ºF)

Expansion tank cap opening pressure

SOHC models:
Up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 to 1.1 bar (12 to 16 lbf/in2)
From 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.25 bar (15 to 18 lbf/in2)
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.25 bar (15 to 18 lbf/in2)
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.4 bar (15 to 20 lbf/in2)
Coolant mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Specifications
System capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Specifications

Drivebelt tensions
Air conditioning system compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm (0.4 in) deflection at the midpoint of the belt’s longest run
under firm thumb pressure
Coolant pump/alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm (0.4 in) deflection midway between coolant pump and
alternator (or power steering pump) pulleys under firm thumb pressure
3•2 Cooling, heating and air conditioning systems

Torque wrench settings Nm lbf ft

Radiator upper mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 to 25 15 to 18
Radiator lower mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 12 6 to 9
Coolant pump bolts:
SOHC models:
M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 21 13 to 15
M10 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 to 42 26 to 31
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8
CVH (R6A type) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 to 10 5 to 7
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 to 28 15 to 21
Thermostat housing bolts:
SOHC/DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 20 13 to 15
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8
CVH (R6A type) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 12 6 to 9
Cooling fan shroud-to-radiator nuts/bolts . . . . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8
Coolant pump pulley bolts:
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 to 28 15 to 21
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 15 to 18
Coolant pump/alternator drivebelt tensioner bolt:
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 to 30 17 to 22
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 to 97 52 to 72
Cooling fan blades-to-fan hub bolts (SOHC models) . . . . . . . . . . . . . . . 8 to 10 6 to 7
Air conditioning compressor-to-bracket bolts . . . . . . . . . . . . . . . . . . . . 65 to 75 48 to 55
Air conditioning compressor bracket-to-engine bolts:
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 92 63 to 68
M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 to 120 81 to 89
Air conditioning condenser fan assembly-to-condenser bolts:
Models up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 to 3 1 to 2
Models from 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8
Air conditioning condenser securing bolts (models from 1987) . . . . . . . 27 to 33 20 to 24

temperature and engine speed. The fan is the coolant passes from the thermostat
1 General information and therefore only operating when required, and housing to the expansion tank, but the main
precautions compared with direct-drive type fans circulation is through the inlet manifold,
represents a considerable improvement in fuel automatic choke (where applicable), and
economy, drivebelt wear and fan noise. heater matrix, finally returning to the coolant
General information The electrically-operated fan is switched on pump. When the coolant reaches a
The cooling system is of pressurised type, by a temperature sensor mounted in the predetermined temperature, the thermostat
and consists of a front mounted radiator, thermostat housing when the temperature opens and hot water passes through the top
coolant pump, cooling fan, wax type reaches a predetermined level. The fan is hose to the top of the radiator. As the coolant
thermostat, and an expansion tank. therefore only operating when required, and like circulates through the radiator, it is cooled by
The radiator matrix is manufactured from the thermo-viscous fan, offers a considerable the flow of air to the vehicle’s forward motion,
honeycombed metal, and the end tanks are advantage over direct-drive type fans. supplemented by the action of the cooling fan
made of plastic. On automatic transmission A thermostat is fitted. Its purpose is to where necessary. By the time it reaches the
models, the right-hand end tank incorporates ensure rapid engine warm-up by restricting bottom of the radiator the coolant is cooled,
the transmission fluid cooler. the flow of coolant to the engine when cold and the cycle is repeated. Circulation of
The coolant pump is located on the front and also to assist in regulating the normal coolant continues through the expansion
face of the engine block, and is belt-driven. operating temperature of the engine. tank, inlet manifold, automatic choke (where
The pump is of the impeller type. The expansion tank incorporates a pressure applicable) and heater at all times, the heater
The cooling fan draws cold air over the cap which effectively pressurises the cooling temperature being controlled by an air flap.
radiator matrix to assist the cooling process system as the coolant temperature rises, An air conditioning system is available as
when the forward speed of the vehicle is too thereby increasing the boiling point of the an optional extra on certain models. In
low to provide sufficient cooling airflow, or the coolant. The tank also has a further degas conjunction with the heater, the system
ambient temperature is unusually high. SOHC function. Any accumulation of air bubbles in the enables any reasonable air temperature to be
models have a thermo-viscous fan, whereas coolant is returned to the tank and released in achieved inside the vehicle; it also reduces
CVH and DOHC models have an the air space, thus maintaining the efficiency of the humidity of the incoming air, aiding
electrically-operated fan. the coolant. The pressure cap also incorporates demisting even when cooling is not required.
The thermo-viscous fan is controlled by the a vacuum relief valve which prevents a vacuum The refrigeration side of the air conditioning
temperature of the air behind the radiator. forming in the system as it cools. system functions in a similar way to a
When the air temperature reaches a The system functions as follows. Cold domestic refrigerator. A compressor, belt-
predetermined level, a bi-metallic coil coolant in the bottom of the radiator circulates driven from the crankshaft pulley, draws
commences to open a valve within the unit, through the bottom hose to the coolant pump refrigerant in its gaseous phase from an
and silicon fluid is fed through a system of where the pump impeller pushes the coolant evaporator. The compressed refrigerant
vanes. Half the vanes are driven directly by through the passages within the cylinder passes through a condenser where it loses
the coolant pump, and the remaining half are block, cylinder head and inlet manifold. After heat and enters its liquid phase. After passing
connected to the fan blades. The vanes are cooling the cylinder bores, combustion through the dehydrator, which acts as a
arranged so that drive is transmitted to the fan chambers and valve seats, the coolant reservoir and filter to extract moisture from
blades in relation to the viscosity of the silicon reaches the underside of the thermostat the circuit, the refrigerant returns to the
fluid, and this in turn depends on ambient which is initially closed. A small proportion of evaporator where it absorbs heat from the air
 Cooling, heating and air conditioning systems 3•3

passing over the evaporator fins on its way to

the vehicle interior. The refrigerant becomes a
gas again and the cycle is repeated.
Various subsidiary controls and sensors
protect the system against excessive
temperature and pressures. Additionally,
engine idle speed is increased when the
system is in use to compensate for the
additional load imposed by the compressor.
Precautions
Air conditioning refrigerant
Although the refrigerant is not itself toxic, in
the presence of a naked flame (or a lighted 5.9 Unscrew the fan shroud/radiator 5.10a Radiator and cooling fan shroud
cigarette) it forms a highly toxic gas. Liquid retaining nuts upper mountings
refrigerant spilled on the skin will cause
A Radiator mounting nut
frostbite. If refrigerant enters the eyes, rinse
them with a dilute solution of boric acid and B Shroud securing screw
seek medical advice immediately. 5 Radiator - removal and refitting C Shroud securing clips
In view of the above points, and of the need D Radiator top hose clip
for specialised equipment for evacuating and 11 On all later models, the radiator is secured
recharging the system, any work which Removal to the engine compartment front panel using
requires the disconnection of a refrigerant line 1 Disconnect the battery negative lead.
must be left to a specialist. clips and locking pegs. To release the top of
2 Drain the cooling system. the radiator, work through the cut-outs in the
Do not allow refrigerant lines to be exposed 3 If not already done, disconnect the bottom
to temperatures above 230°F (110°C) - eg engine compartment front panel and remove
hose from the radiator. the two radiator upper locking pegs (see
during welding or paint drying operations and
4 Disconnect the top hose and the expansion illustration). Working under the front of the
do not operate the air conditioning system if it
tank hose from the radiator.
is known to be short of refrigerant, or further vehicle, remove the two radiator lower
5 On automatic transmission models, place a
damage may result. mounting bolts. Support the radiator from
suitable container beneath the fluid cooler
Antifreeze mixture pipe connections at the radiator. Unscrew the underneath. Squeeze the upper radiator
Antifreeze mixture is poisonous. Keep it out union and plug the upper pipe, then repeat locking pegs to release them from the engine
of reach of children and pets. Wash splashes the procedure on the lower pipe. compartment front panel and lower the
off skin and clothing with plenty of water. 6 Apply the handbrake, jack up the front of radiator assembly from the vehicle.
Wash splashes off vehicle paintwork to avoid the vehicle and support on axle stands (see 3
discolouration.
Refitting
“Jacking and Vehicle Support”).
Antifreeze/water mixture must be renewed 7 To improve access, remove the cooling fan 12 Refitting is a reversal of removal, bearing
at the specified intervals to preserve its anti- shroud as follows, according to model. in mind the following points.
corrosive properties. In climates where 8 On SOHC models, remove the four 13 Refill the cooling system.
antifreeze protection is unnecessary, a retaining clips and unscrew the two retaining 14 On automatic transmission models, check
corrosion inhibitor may be used instead - screws, then withdraw the upper section of and if necessary top-up the transmission fluid
consult a Ford dealer. Never run the engine the fan shroud. Unclip and remove the lower level.
for long periods with plain water as coolant. section of the shroud.
Only use the specified antifreeze as inferior 9 On CVH and DOHC models, unclip the
brands may not contain the necessary wiring connector from the fan motor(s) then
6 Radiator - inspection and
corrosion inhibitors, or may break down at cleaning
unscrew the retaining nuts and washers, and
high temperatures. Antifreeze containing
withdraw the fan shroud(s) and cooling fan
methanol is particularly to be avoided, as the 1 If the radiator has been removed because
assembly(s) (see illustration).
methanol evaporates.
10 On early models, unscrew and remove the of suspected blockage, reverse-flush it.
The specified mixture is 45 to 50%
antifreeze and 50 to 55% clean soft water (by upper radiator mounting nuts and washers 2 Clean dirt and debris from the radiator fins
volume). Mix the required quantity in a clean (see illustration). Unscrew and remove the using an air jet or water and a soft brush. Be
container. lower mounting bolts and washers and careful not to damage the fins or cut your
withdraw the radiator from under the vehicle fingers.
(see illustration).
2 Cooling system - draining

Refer to Chapter 1, Section 46.

3 Cooling system - flushing

Refer to Chapter 1, Section 46.

4 Cooling system - filling

5.10b Lower radiator mounting bolt 5.11Removing a radiator upper locking peg
Refer to Chapter 1, Section 46.
3•4 Cooling, heating and air conditioning systems

7.4a Radiator top hose connection at 7.4b Disconnect the expansion tank hose 7.6a Prise out the retaining clip . . .
thermostat housing from the thermostat housing

7.6b . . . and extract the thermostat . . . 7.6c . . . and sealing ring 7.9 Thermostat flow direction markings
(arrowed)
3 A radiator specialist can perform a “flow housing situated at the front of the cylinder cooling fan switch on the thermostat housing
test” on the radiator to establish whether an head (see illustrations). situated at the front of the inlet manifold.
internal blockage exists. 5 Unscrew the two securing bolts and 12 Disconnect the automatic choke hose,
4 A leaking radiator must be referred to a remove the housing and gasket. radiator top hose and expansion tank hose
specialist for permanent repair. Do not 6 Using a screwdriver, prise the retaining clip from the thermostat housing. Where
attempt to weld or solder a leaking radiator, from the housing, and extract the thermostat applicable, take care not to strain the wiring
as damage to the plastic parts may result. and sealing ring (see illustrations). which is routed around the housing. If
5 In an emergency, minor leaks from the 7 Refitting is a reversal of removal, bearing in necessary, disconnect the wiring connector
radiator can be cured by using a sealant. mind the following points. (see illustrations).
8 Clean the housing and the mating face of 13 Unscrew the three securing bolts and
the cylinder head. Check the thermostat remove the housing and gasket (see
7 Thermostat - removal and sealing ring for condition and renew it if illustration).
refitting necessary. Use a new gasket when refitting 14 Lift the thermostat from the housing, and
the housing. carefully prise out the sealing ring.
1 Disconnect the battery negative lead. 9 The thermostat wax capsule must face into 15 Refitting is a reversal of removal, bearing
2 Drain the cooling system. the cylinder head with the flow direction arrow in mind the following points.
3 Proceed as follows according to model: facing forward (see illustration). 16 Clean the housing and the mating face of
10 Refill the cooling system. the inlet manifold. Check the thermostat
SOHC models
sealing ring for condition and renew it if
4 Disconnect the radiator top hose and CVH models
necessary. Use a new gasket when refitting
expansion tank hose from the thermostat 11 Disconnect the wiring plug from the the housing.

7.12a Disconnect the automatic choke 7.12b . . . the radiator top hose . . . 7.12c . . . and the expansion tank hose
hose . . .
 Cooling, heating and air conditioning systems 3•5

7.13 Removing the thermostat housing and 7.17 Correct orientation of thermostat with 7.20a Disconnect the coolant hoses . . .
gasket flow direction arrow pointing towards
pressure relief valve
17 Note that the thermostat wax capsule 2 Gradually heat the water, and using a
must face into the inlet manifold, with the flow necessary to prise the thermostat out, take thermometer with a range of at least 100ºC,
direction arrow pointing forward, in line with care not to damage the surface of the housing note the temperature at which the thermostat
the pressure relief valve in the housing (see in the inlet manifold. starts to open.
illustration). 24 Refitting is a reversal of removal, bearing 3 Remove the thermostat from the water and
18 Refill the cooling system. in mind the following points. check that it is fully closed when cold.
25 Ensure that the O-ring seal is correctly
DOHC models 4 Renew the thermostat if the opening
fitted around the edge of the thermostat.
temperature is not as given in the
19 On fuel injection models, for access to the 26 When fitting the thermostat to the inlet
thermostat housing loosen the clips and manifold, ensure that the relief valve is located Specifications, or if the unit does not fully
remove the air inlet tube which connects the in the 12 o’clock position (see illustration). close when cold.
plenum chamber to the inlet manifold. 27 Tighten the thermostat housing securing
20 Disconnect the coolant hoses from the bolts to the specified torque. 9 Coolant pump - removal and
thermostat housing (see illustrations). 28 Refill the cooling system. refitting
21 Disconnect the wiring plug from the
cooling fan switch mounted in the thermostat
1 Disconnect the battery negative lead.
housing (see illustration). 8 Thermostat - testing 2 Drain the cooling system.
22 Unscrew the three securing bolts, and
withdraw the thermostat housing (see 3 Proceed as follows according to model:
illustration). 1 To test the thermostat, suspend it by a SOHC models 3
23 Manipulate the thermostat from the inlet piece of string in a container of water (see
manifold, and recover the O-ring. If it is illustration). 4 Disconnect the heater and radiator bottom
hoses from the coolant pump.
5 Remove the thermo-viscous fan (Section 12).
6 If not already done, remove the coolant
pump drivebelt, then unscrew the four
retaining bolts and remove the coolant pump
pulley. If necessary, the pulley can be
prevented from turning using a strap wrench.

Holding the pulley can be

improvised using an old
drivebelt, and a suitable
socket and wrench.

7.20b . . . from the thermostat housing 7.21 Disconnect the cooling fan switch 7 Unbolt and remove the timing belt cover.
wiring plug

7.22 Withdrawing the thermostat housing 7.26 Thermostat relief valve (arrowed) 8.1 Testing the thermostat opening
should be in the 12 o’clock position temperature
3•6 Cooling, heating and air conditioning systems

9.8 Location of the alternator adjusting 9.15 Disconnect the coolant elbow from 9.20 Remove the timing belt tensioner
link under the right-hand retaining bolt the coolant pump
8 Unscrew the three retaining bolts and 14 Refill the cooling system. DOHC models
remove the coolant pump and gasket from the
front of the cylinder block. Note that on CVH models Note: Before proceeding, take note of the
following modifications: On models up to May
certain models, the alternator adjusting link is 15 Unscrew the two securing nuts, and
disconnect the coolant elbow from the 1990, the coolant hoses were connected to the
secured by the right-hand retaining bolt (see
illustration). left-hand side of the coolant pump (see coolant pump housing as shown (see
9 If the coolant pump is faulty, it must be illustration). illustration). On models from May 1990, the
renewed, as it is not possible to obtain 16 Remove the timing belt. heater hose (A) and the expansion tank hose (B)
individual components. 17 Unscrew the camshaft sprocket bolt and connections were swapped over. If the hoses
10 Before refitting, clean the mating faces of withdraw the distributor drive sleeve. are disconnected on earlier models,they should
the coolant pump and cylinder block. 18 Screw the camshaft sprocket bolt part be reconnected as on later models, ie connect
11 Refitting is a reversal of removal, bearing way back into the end of the camshaft, and the heater hose to connection “B”, and connect
in mind the following points. using a suitable puller, pull the sprocket from the expansion tank hose to connection “A”.
12 Use a new gasket, and tighten the the camshaft. This will prevent the possibility of noises from
retaining bolts to the specified torque. 19 Remove the plastic rear timing belt cover. the heater matrix due to air in the system.
13 Before fitting the coolant pump pulley, 20 Unscrew the two retaining bolts, and 29 On fuel injection models, for access to the
ensure that the timing belt cover support bolt remove the timing belt tensioner (see coolant pump, remove the air inlet hose,
is located in its hole in the pump. illustration). plenum chamber, and air cleaner lid as an
21 Unscrew the four securing bolts, and assembly.
withdraw the coolant pump (see illustration). 30 Remove the coolant pump/alternator
22 If the coolant pump is faulty it must be drivebelt.
renewed, as it is not possible to obtain 31 If the pump pulley is to be removed, it is
individual components. easiest to do this with the pump in position, as
23 Before refitting, clean the mating faces of follows. Prevent the pulley from rotating using
the coolant pump and cylinder block. a strap wrench and unscrew the four pulley
24 Refitting is a reversal of removal, bearing securing bolts. Withdraw the pulley.
in mind the following points. 32 Position a suitable container beneath the
25 Use a new gasket, and tighten the coolant pump, to catch the coolant which will
securing bolts to the specified torque. be released as the pump is removed. Unscrew
26 Before refitting the camshaft sprocket the five securing bolts, and withdraw the pump
bolt, the threads must be coated with sealer from the housing in the cylinder block (see
9.21 Withdraw the coolant pump (Loctite 74 or 274, or Omnifit 30M blue), as the illustration). Recover the O-ring seal.
bolt acts as an oil seal for the hollow 33 Before refitting, clean the mating faces of
camshaft. Do not forget to fit the distributor the coolant pump and the cylinder block.
drive sleeve. 34 Refitting is a reversal of removal, bearing
27 Correctly tension the timing belt. in mind the following points.
28 Refill the cooling system. 35 Use a new O-ring seal (see illustration).

9.29 Coolant pump housing hose

connections
A Heater hose connection - up to May 1990
B Expansion tank hose connection - up to
May 1990 9.32 Withdrawing the coolant pump from 9.35 Coolant pump O-ring (arrowed)
C Bottom radiator hose the cylinder block (engine removed)
 Cooling, heating and air conditioning systems 3•7

36 Tighten the coolant pump securing bolts,

and where applicable the pump pulley
securing bolts, to the specified torque.
37 On completion, refill the cooling system.

10 Coolant pump/alternator
drivebelt(s) - checking, renewal
and tensioning

Refer to Chapter 1, Section 21.

11 Coolant pump/alternator
drivebelt tensioner (DOHC 11.3 Withdrawing the coolant 11.7 Alternator/coolant pump drivebelt
models with power steering) pump/alternator drivebelt tensioner tensioner indicator position
assembly. Note lug (A) on tensioner which Inset shows tensioner at maximum
- removal and refitting
engages with hole (B) in mounting bracket adjustment
assembly. Refit the upper mounting bolt, and 4 If required, the fan blades can be separated
Removal tighten the upper bolt and lower through-bolt. from the fan hub by unscrewing the four
1 Remove the alternator drivebelt. 6 Fit the drivebelt by reversing the removal securing bolts.
2 Loosen the alternator lower mounting procedure, and release the tensioner to
through-bolt, then remove the alternator tension the drivebelt. Refitting
upper mounting bolt and swing the alternator 7 Observe the tensioner indicator, which 5 Refitting is a reversal of removal, but where
away from the engine. should be central in its slot (see illustration). applicable, take care not to overtighten the
3 Unscrew the central securing bolt, and bolts securing the fan blades to the fan hub,
withdraw the drivebelt tensioner assembly 12 Thermo-viscous cooling fan as thread damage may require the whole unit
(see illustration). to be renewed. Where applicable, refit and
(SOHC models) - removal and tension the drivebelt.
Refitting refitting
4 Commence refitting by positioning the
tensioner on the cylinder block, ensuring that 13 Electric cooling fan - removal
the lug on the rear of the tensioner bracket Removal and refitting
engages with the corresponding hole in the 1 Disconnect the battery negative lead.
cylinder block. Tighten the securing bolt. 2 Remove the four retaining clips and
5 Swing the alternator into position, to align unscrew the two retaining screws, then CVH models 3
the upper mounting bolt hole with the withdraw the upper section of the fan shroud 1 Disconnect the battery negative lead.
corresponding hole in the drivebelt tensioner (see illustrations). Unclip the wiring connector from the fan
3 The cooling fan hub nut must now be motor then unscrew the retaining nuts and
unscrewed from the coolant pump drive washers. Withdraw the fan shroud and
flange. A thin cranked 32.0 mm (1.25 in AF) cooling fan assembly (see illustration).
spanner with a jaw thickness not exceeding 2 To remove the fan blades, prise the
5.0 mm (0.2 in) will be required (see securing clip from the end of the motor shaft
illustration). Alternatively, if two of the (see illustration).
coolant pump pulley bolts are removed, a
3 The motor can be separated from the fan
normal thickness spanner can be used. Note
shroud by unscrewing the three securing nuts
that the fan hub nut has a left-hand thread, (ie
and bolts.
it is undone in a clockwise direction.) If the
pulley turns as the nut is undone, remove the 4 Where two cooling fans are fitted, both fans
drivebelt, and clamp an old drivebelt round are secured to the fan shroud in the same
the pulley to restrain it, using self-locking manner.
pliers. Tap the spanner with a mallet if 5 Refitting is a reversal of removal, but when
required to remove the nut. refitting the fan blades, ensure that the
12.2a Remove the retaining clips followed direction of rotation arrow faces away from
by the screws . . . the motor, towards the radiator.

12.3 Modified spanner required for

removing the thermo-viscous cooling fan
12.2b . . . and withdraw the upper section 13.1 Withdrawing the fan shroud and
of the fan shroud X = 25.0 mm (1.0 in) Y = 12.0 mm (0.5 in) cooling fan assembly
3•8 Cooling, heating and air conditioning systems

12 The motor can be separated from the fan

shroud by unscrewing the three securing nuts
and bolts.
13 Where two cooling fans are fitted, both are
secured to the shroud in the same manner.
14 Refitting is a reversal of removal, but
when fitting the fan blades, ensure that the
drive dog on the motor shaft engages with the
slot in the rear of the fan blades.

14 Cooling fan switch - removal

and refitting
13.2 Fan blade securing clip and direction 14.1 Disconnecting the wiring plug from
On CVH models, the cooling fan switch is
of rotation arrow the cooling fan switch
located on the right-hand side of the
DOHC models thermostat housing (see illustration). On 5 Unscrew the expansion tank securing
DOHC models, the switch is located in the screws, and tilt the tank so that the coolant
6 Disconnect the battery negative lead.
end of the thermostat housing. runs to the sealed end.
7 To provide additional clearance when Removal and refitting of the switch is as 6 Disconnect and plug the lower hose.
removing the cooling fan shroud assembly described for the temperature gauge sender. 7 Drain the expansion tank into the container
(which is removed from below the vehicle),
and remove the tank.
apply the handbrake, then jack up the front of
15 Expansion tank and coolant 8 Where applicable, the coolant level sensor
the vehicle and support it securely on axle
can be removed from the tank by unscrewing
stands (see “Jacking and Vehicle Support”). level sensor - removal and
the collar from the sensor, then withdrawing
8 Disconnect the wiring plug(s) from the refitting the spacer, sensor and seal (see illustration).
motor(s), and where applicable, unclip the
Renew the seal if necessary. Note that the
wiring from the fan shroud.
Removal sensor can only be fitted in one position (see
9 Unclip the expansion tank hose from the
illustration).
fan shroud. 1 With the engine cold, slowly unscrew the
10 Unscrew the two nuts securing the fan expansion tank cap to release any remaining Refitting
shroud to the top of the radiator, then tilt the pressure from the cooling system. Remove 9 Refitting is a reversal of removal.
top of the shroud away from the radiator, and the cap. 10 On completion, top-up the coolant level to
lift the shroud to release the lower securing 2 Place a suitable container beneath the the maximum mark, then refit the expansion
clips. Withdraw the assembly from below the expansion tank. tank cap and run the engine at a fast idling
vehicle. 3 Disconnect and plug the upper hose. speed for several minutes. Check the
11 To remove the fan blades, prise the 4 Where applicable, disconnect the coolant expansion tank for leaks, then stop the engine
securing clip from the end of the motor shaft. level sensor wiring plug. and if necessary top-up the coolant level.

16 Temperature gauge sender

- removal and refitting

Removal
1 On SOHC models, the temperature gauge
sender is located on the front left-hand side of
the cylinder head, just in front of the inlet
manifold. On CVH models, the sender is
located on the front face of the inlet manifold,
next to the thermostat housing. On DOHC
models, the sender is located at the front of
15.8a Removing the coolant level sensor 15.8b Fitting the coolant level sensor
the inlet manifold (see illustration).
from the expansion tank

16.1 Temperature gauge sender location 16.3a Disconnect the temperature gauge 16.3b Disconnect the temperature gauge
(arrowed) sender wiring - SOHC sender wiring - CVH
 Cooling, heating and air conditioning systems 3•9

2 With the engine cold, slowly unscrew the

expansion tank cap to release any remaining
pressure from the cooling system, then refit
the cap.
3 Disconnect the wiring from the sender
terminal (see illustrations).
4 Unscrew and remove the sender, and
temporarily plug the aperture.
Refitting
5 Refitting is a reversal of removal, but smear
a little sealing compound on the sender unit
threads before fitting.
6 On completion, check and if necessary top- 17.5 Heater control cable lower end fittings 17.9 Heater control panel illumination bulb
up the coolant level. (arrowed) wiring loom correctly routed

around the wiring loom over a length of on the engine compartment bulkhead, then
17 Heater controls - removal and
approximately 330.0 mm (13.0 in) starting disconnect and plug them (see illustration).
refitting from the bulbholder. Route the loom, ensuring Alternatively, the hoses can be secured high
that it is located in the two retaining clips, enough to prevent the coolant from draining.
Removal bend it over and secure it to the bulbholder 4 To prevent unnecessary spillage of coolant
with insulating tape as shown (see when the heater unit is removed, blow into the
1 Disconnect the battery negative lead.
illustration). This procedure will prevent the upper heater pipe until all the coolant has
2 Remove the securing screws and unclip the
wiring loom from chafing against the heater been expelled through the lower pipe.
lower and upper steering column shrouds.
control levers. 5 Remove the two securing screws and
3 Remove the four securing screws and
10 When reconnecting the control cables to withdraw the heater pipe cover from the
withdraw the instrument panel surround. Note
the heater, move the control levers on the bulkhead (see illustration). Recover the
that the bottom right-hand screw is covered
control panel to the fully up position, then gasket.
by a plastic panel which must be prised out.
attach the cables to the clips on the heater. 6 Working inside the vehicle, remove the
4 Remove the passenger side lower facia
The cable ends should project from the clips passenger side lower facia panel.
panel.
by between 0 and 4.0 mm (0 and 0.16 in). The 7 Disconnect the ends of the two control
5 Where necessary for improved access,
cables are adjusted automatically by moving cables from the heater by removing the two
detach the two vent hoses from the left-hand
the control levers fully downwards. It is retaining screws.
side of the heater, then detach the lower ends
possible that considerable resistance may 8 Detach the five vent hoses from the heater. 3
of the two control cables from the heater by
have to be overcome when moving the control 9 Unscrew the two mounting bolts, and move
removing the retaining screws (see
levers. the heater to the rear until the pipes are clear
illustration).
of the bulkhead, then withdraw the heater to
6 Unscrew the three securing screws, and
18 Heater unit - removal and the left. If necessary, remove the lower facia
remove the heater control panel by sliding it bracket (see illustration).
through the facia panel and withdrawing it refitting
downwards. Disconnect the wiring from the Refitting
control panel illumination bulb. 10 Refitting is a reversal of removal, but
7 If necessary, the bulb can be removed with
Removal
adjust the control cables by moving the levers
its holder. 1 Disconnect the battery negative lead.
on the control panel to the top and then the
2 If the coolant is still hot, release the
Refitting bottom stops. Considerable resistance may
pressure in the system by slowly unscrewing
be encountered when moving the levers
8 Refitting is a reversal of removal, bearing in the expansion tank cap. Place a thick rag over
towards the bottom stops, which should be
mind the following points. the cap to prevent scalding as the pressure is
overcome.
9 When reconnecting the wiring to the control released.
11 On completion, top-up the coolant level.
panel illumination bulb, wrap insulating tape 3 Note the location of the two heater hoses

18.3 Location of heater hoses on engine 18.5 Heater pipe cover 18.9 Withdrawing the heater
compartment bulkhead
3•10 Cooling, heating and air conditioning systems

19.1a Remove the securing screws . . . 19.1b . . . and withdraw the heater matrix 19.3 Heater “up/down” control lever must
be aligned as shown before removal
Note that the cross marks are for right-hand
a chemical cleaner to clear the inner passage
drive vehicles
of the matrix. Renew the components as
19 Heater unit - overhaul necessary. 6 Unscrew the two motor securing nuts, and
5 Reassembly is a reversal of dismantling. withdraw the motor assembly (see illustration).
1 With the heater unit removed from the 7 Unclip the casing halves, then prise open
vehicle, remove the two securing screws and 20 Heater motor - removal and the motor retaining strap using a screwdriver,
withdraw the heater matrix from the casing or if necessary a drift.
refitting 8 Detach the wiring from the motor, then
(see illustrations).
2 Cut the heater casing gasket in line with the remove the motor and fan wheels from the
casing joint, then use two suitable Removal casing.
screwdrivers to prise off the retaining clips 1 Disconnect the battery negative lead. Refitting
and separate the casing halves. Withdraw the 2 Where necessary, unclip the brake servo 9 Refitting is a reversal of removal.
lower part of the casing to the side. vacuum hose for improved access.
3 Remove the air flap valves, then press the 3 On models from 1987, unclip the
control levers from the casing. Note that the windscreen washer hoses and wiring from the 21 Air conditioning system -
“up/down” control lever can only be removed motor cover, and secure them to the component renewal
when the marks are aligned as shown (see bodywork out of the way.
illustration). 4 Unscrew the two securing bolts from the 1 Only those items which can be renewed
4 Clean all components and hose through the motor cover, pull off the rubber moulding, without discharging the system are described
matrix to remove any debris. If necessary use then withdraw the cover (see illustration). here (see illustration). Other items must be
5 Disconnect the wiring from the motor, and dealt with by a Ford dealer or air conditioning
detach the earth lead from its bracket. specialist.

20.4 Unscrew the securing bolts and

withdraw the heater motor cover

21.1 Layout of air conditioning system components

1 De-ice thermostat 6 Pressure switch

2 Evaporator 7 Sight glass
3 Expansion valve 8 Dehydrator/collector
20.6 Heater motor and wiring 4 Compressor 9 Cooling fan
5 Compressor clutch 10 Condenser
 Cooling, heating and air conditioning systems 3•11

9 Disconnect the fan wiring connector at the

side of the condenser.
10 Remove the three securing bolts and
withdraw the fan assembly. Turn the frame to
position the fan wiring on the dehydrator side
to avoid damaging the wiring. Take care also
not to damage the condenser fins or tube.
11 To remove the fan blades from the motor,
remove the retaining nut and circlip. The nut
has a left-hand thread, ie, it is undone in a
clockwise direction.
12 With the blades removed, the motor can
be unscrewed from the frame.
21.4 Typical air conditioning compressor 13 Reassemble and refit in the reverse order 21.17 Air conditioning condenser fan
mounting and pivot bolts (arrowed) of dismantling and removal. wiring connector location (arrowed) -
Models from 1987 models from 1987
Compressor drivebelt
14 Disconnect the battery negative lead. 23 Disconnect any vacuum hoses,
2 Disconnect the battery negative lead.
15 Remove the bonnet lock. windscreen washer hoses and electrical
3 On SOHC models, remove the thermo-
16 Unclip the guard from the fan frame. wiring as necessary, then unscrew the four
viscous cooling fan.
17 Disconnect the fan wiring connector (see securing bolts and on models up to 1987 the
4 Slacken the compressor mounting and
illustration). single nut, and remove the right-hand plenum
pivot bolts, move the compressor towards the
18 Apply the handbrake, jack up the front of chamber cover plate from the bulkhead.
engine and remove the old drivebelt (see
the vehicle and support on axle stands (see 24 Disconnect the thermostat from the
illustration).
“Jacking and Vehicle Support”). evaporator casing and withdraw it. Also
5 Fit the new drivebelt, position the
19 Unscrew the two lower condenser withdraw the thermostat probe from the
compressor to achieve the correct belt
securing bolts and disengage the condenser casing.
tension, then tighten the mounting and pivot
from the top of the radiator by releasing the 25 Refitting is a reversal of removal.
bolts.
three clips.
6 On SOHC models, refit the thermo-viscous Heating/air conditioning controls
cooling fan. 20 Unscrew the four securing bolts and
detach the fan assembly from the condenser. 26 The procedure is similar to that described
7 Reconnect the battery negative lead. for the heater controls but additionally the
Withdraw the fan assembly from underneath
Condenser fan and motor the vehicle. vacuum hoses must be disconnected from
21 Proceed as described in paragraphs 11 to the control unit vacuum valve during removal,
Models up to 1987 and reconnected when refitting.
13 inclusive. 3
8 Disconnect the battery negative lead, and
remove the radiator grille. On Ghia models, De-ice thermostat
remove the front bumper. 22 Disconnect and remove the battery.
3•12 Notes