Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

The Ford supplied Sierra 4×4 Supplementary Workshop Manual is a “must have” for any owner of one of these cars. The biggest problem can be actually finding one to purchase. I got lucky and managed to get mine direct from a Ford dealer, brand new for ?8, who was having a clearout. They do appear regularly at autojumbles and it is just a case of keep looking. The manual only covers those items unique to the 4×4 Sierra’s and are to be used in conjunction with the Ford Sierra Workshop Manual. Ford never produced a supplement that covered the 2.9 engine or the later Mark Two model but all the running gear sections are relevant as this never changed during the life of the model

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This manual gives the repair and adjustment procedures for components unique to the Escort Twin Cam model. It includes component illustrations wherever possible, technical specifica-tions, and details of any special tools or equipment that may be required. Information on items common io the rest of the Escort range can be found in the appropriate manual. When the special tools or equipment mentioned are not available, changes may be necessary
to some of the dismantling and reassembly procedures. In certain instances use of special equipment is essential if a satisfactory repair is to be ensured. For this reason we strongly advise owners and operators to allow Ford Dealerships to carry out the more complex repairs, e.g. the overhaul of gearbox or differential assemblies

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6.0L DIESEL FUEL IN ENGINE COOLANT DIAGNOSTICS FORD: 2003-2005 Excursion 2003-2007 F-Super Duty 2004-2008 E-Series ISSUE Some 2003-2005 Excursion, 2003-2007 F-Super Duty and 2004-2008 E-Series vehicles equipped with a 6.OL engine may exhibit fuel in the engine coolant, due to leaks in the cylinder head fuel injector area. Symptoms may include fuel in engine coolant and coolant expulsion from the degas bottle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Inspect the degas bottle for evidence of fuel in engine coolant. If diesel fuel is present, refer to the following Service Procedure. If not, follow normal diagnostics. NOTE IT IS VERY IMPORTANT TO ENSURE A COMPLETE FLUSHING OF THE ENGINE COOLING SYSTEM IS PERFORMED TO REMOVE ALL CONTAMINANTS FOLLOWING REPAIR. 1. Drain coolant from cooling system. 2. Remove all injectors from both cylinder heads. Refer to Workshop Manual (WSM), Section 313-04C. 3. Wipe injector bore clean of oil and fuel then apply a thin layer of bubbly type liquid hand soap, dish soap or laundry soap inside each injector bore. Ensure injector sleeve lip and cylinder head casting are coated with a soap layer. (Adding a small amount of water to the soap aids in creating bubbles) 4. Fit the cooling system pressure tester, refer to WSM, Section 303-03. (Do not add coolant) 5. Apply 5-10 psi (34-69 kPa) of air pressure to sealed cooling system. It is suggested to use a hand operated pressure tester or regulated shop air with tee in degas hose to degas bottle. NOTE MORE THAN 10 PSI (69 kPa) AIR PRESSURE CAN PUSH THE SOAP FROM THE LEAK POINT AND NO BUBBLES WILL BE PRESENT OR CREATED, MAKING DIAGNOSIS DIFFICULT. 6. Inspect each injector bore for bubbles. (A light and mirror or bore-scope may aid in pinpointing a leak location.) If bubbles are observed, determine if bubbles originate from the injector sleeve lip (Figure 1) or cylinder head casting. (Figure 2) Refer to cutaway view of the cylinder head. (Figure 3) a. Replace the injector sleeve if found to be leaking at sleeve lip, refer to WSM 303-04C. b. Replace cylinder head if leaking through casting, refer to WSM 303-01C. c. Flush cooling system, refer to another applicable Technical Service Bulletin (TSB) for proper cooling system flush procedures.

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NOTE: Hydraulic valve lifters are used; no valve adjustment is required. When valve and/or valve seat is machined, valve clearance is reduced and may cause improper valve operation. Different length push rods are available for correcting clearance. Valve lifter must be collapsed to check valve clearance. 1. With valve cover removed, position piston No. 1 at TDC of compression stroke. Completely collapse cylinder No. 1 intake valve lifter and hold valve lifter collapsed. Using feeler gauge, measure clearance between rocker arm and valve stem. 2. Clearance should be within specification. Refer to COLLAPSED VALVE LIFTER CLEARANCE table. Replace push rod, if necessary, to obtain correct clearance. 3. Position crankshaft as specified. See, in this article, VALVE CLEARANCE CHECKING SEQUENCE table, and check appropriate valves. Replace push rods if clearance is not within specification. 4. If push rod(s) is replaced, ensure corresponding cylinder piston is below TDC. It will be necessary to loosen or remove rocker arm to replace push rod. CAUTION: DO NOT operate or crank engine after installing push rod until valve lifter has leaked down to normal operating position. COLLAPSED VALVE LIFTER CLEARANCE

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CAUTION: Use of incompatible bearing lubricant could result in premature lubricant breakdown. The recommended wheel bearing lubricant is the lithium-base grease High Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A. Sodium-base grease is not compatible with lithium-base grease and should not be intermixed. Therefore, before lubricating front or rear wheel bearings (1225), thoroughly clean all old grease from the bearing and front disc brake hub and rotor (1102). If bearing adjustment does not eliminate looseness or rough and noisy operation, clean and inspect the front disc brake hub and rotor and bearings. If bearing cups or the cone and roller assemblies are worn or damaged, replace. Disassembly 1. Raise vehicle and install safety stands. 2. Remove the wheel and tire. Refer to Section 04-04 in the Body, Chassis Manual. 3. Remove the locking hubs. 4. CAUTION: Do not let the disc brake caliper (2B120) hang only by the hose, or damage might occur to the hose or disc brake caliper. Remove the disc brake caliper. Refer to Section 06-03 in the Body, Chassis manual. Securely wire the disc brake caliper to the frame. 5. For vehicles equipped with automatic locking hubs, remove C-ring or snap ring and three-piece thrust washers (spacers). Remove the cam assembly and wheel bearing nut retaining key. Remove wheel bearing retainer (nut) using Hub Nut Wrench T95T-1197-B. Repack the wheel bearings with the specified lubricant (grease). For vehicles with manual locking hubs, remove snap ring, three-piece thrust washers (spacers), the outer lock nut, lockwasher, and inner lock nut using Spanner Locknut Wrench D85T- 1197-A or equivalent. 6. Remove the front disc brake hub and rotor. The front outer wheel bearing will slide out as the hub is removed. 7. Remove the retaining nuts of the front wheel spindle (3105). Carefully remove the front wheel spindle from the knuckle studs and halfshaft (3A329). If necessary, lightly tap the end of the spindle with a rawhide hammer to remove. 8. Clean old grease from the needle bearings and the bore seal of the front wheel spindle. To replace spindle bearing or inner seal, refer to Section 05-03A or Section 05-03B. 9. Clean any old grease or dirt from these parts and replace if signs of excessive wear are noted. Assembly 1. Using High-Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A, thoroughly lubricate the needle bearing and coat the front wheel spindles or face that mates with the seals of the front wheel spindle. 2. Assemble the front wheel spindle over the halfshaft onto the knuckle studs. Tighten the retaining nuts to 68-81 Nm (50-60 lb-ft). 3. Remove the front inner wheel bearing, wheel hub grease seal (1190) from the front disc brake hub and rotor using Bearing Cup Puller T77F-1102-A and Impact Slide Hammer T50T-100-A. Inspect bearings and replace as necessary. 4. Inspect the bearing cups for pits or cracks. If necessary, remove with a drift. If new cups are installed, install new cones and rollers. 5. Lubricate the bearings with High Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford Specification ESA-M1C198-A. Clean all old grease from the front disc brake hub and rotor. Pack the cones and rollers. If a bearing packer is not available, work as much lubricant as possible between the rollers and the cages. 6. Position the front inner wheel bearing in the inner cup and install the new wheel hub grease seal using a hammer, Driver Handle T80T-4000-W and the proper seal installer.