Manual Coverage
|
Systems Covered
|
Powertrain:
|
Engine mechanical, fuel system, ignition system, cooling system, lubrication, exhaust system, emissions control, automatic transmission (e.g., 4R70W).
|
Chassis:
|
Suspension (front and rear), steering system (including power steering), braking system (front and rear, ABS), wheels, and tires.
|
Electrical:
|
Wiring schematics, battery, charging system, starting system, lighting, instruments, gauges, power accessories, body control modules, multiplex communication systems.
|
Body And Interior:
|
Body panels, doors, windows, glass, mirrors, seats, interior trim, HVAC system, safety restraint systems (airbags, seatbelts), cruise control, windshield wipers and washers.
|
Diagnostics:
|
On-Board Diagnostics (OBD-II) system diagnostics, fault code retrieval and interpretation, sensor testing, actuator testing.
|
HVAC:
|
Air conditioning system (refrigerant handling, compressor, condenser, evaporator, controls), heater system (heater core, blower motor, controls).
|
Emissions Control:
|
Catalytic converter, oxygen sensors, EGR system, evaporative emission control system, diagnostic procedures for emissions-related faults.
|
Interior Systems:
|
Door locks (manual and power), seat adjustment mechanisms, airbag system components, interior lighting, instrumentation and related sensors.
|
Fuel System:
|
Fuel pump replacement, fuel filter replacement, fuel injector service, fuel pressure testing.
|
Procedures Included
|
Diagnostic Procedures:
|
Troubleshooting guides, fault code diagnosis, symptom-based troubleshooting.
|
Repair Procedures:
|
Step-by-step instructions for component removal, installation, and overhaul.
|
Maintenance Procedures:
|
Scheduled maintenance, fluid changes, filter replacements, inspections.
|
Specifications And Tolerances:
|
Torque specifications, clearances, fluid capacities, resistance values, diagnostic readings.
|
Engine Overhaul:
|
Detailed procedures for engine disassembly, inspection, repair, and reassembly, including cylinder head removal/installation, piston and connecting rod service, crankshaft service.
|
Brake System Service:
|
Front and rear brake pad replacement, caliper service, rotor replacement, brake fluid flush and bleeding, ABS component diagnosis and replacement.
|
Suspension And Steering:
|
Front and rear suspension component replacement (shocks, struts, ball joints, control arm bushings, sway bar links), power steering pump and gear replacement, alignment specifications.
|
Bodywork:
|
Panel removal and installation, door and trunk lid adjustment, glass replacement, interior trim removal and installation.
|
Ignition System:
|
Spark plug replacement, ignition coil service, diagnostic procedures for misfires.
|
Technical Depth
|
Depth:
|
Comprehensive; covers routine maintenance to complex diagnostics and full component rebuilds, including wiring diagrams and component locations.
|
Wiring Schematics:
|
Complete, detailed color-coded wiring schematics for all electrical systems, including powertrain control, lighting, body electronics, and accessories.
|
Diagnostic Tools:
|
Information on required diagnostic tools, including scan tools for OBD-II data and specialized Ford diagnostic equipment.
|
Specific Part Numbers:
|
Includes references to OEM part numbers where applicable for critical components.
|
Maintenance
|
Service Intervals
|
Oil Change Interval:
|
Every 5,000 miles or 6 months, whichever comes first, with synthetic blend oil.
|
Transmission Fluid Change:
|
Every 30,000 - 60,000 miles, depending on driving conditions.
|
Coolant Change:
|
Initial change at 100,000 miles, then every 50,000 miles.
|
Fluid Specifications
|
Engine Oil Spec:
|
SAE 5W-30, API Certified
|
Coolant Spec:
|
Ford Premium Engine Coolant (Green) or equivalent meeting Ford specification ESE-M97B44-A
|
Brake Fluid Spec:
|
DOT 3 (or DOT 4 if specified by Ford for certain applications)
|
Known Issues
|
Common Issues:
|
Rear main seal leaks, intake manifold gasket leaks (on earlier modular engines, less common by '98), suspension component wear (bushings, ball joints), potential for carbon buildup in intake ports.
|
Police Interceptor Specific Maintenance:
|
Cooler transmission fluid and oil, more frequent brake inspections, heavier-duty suspension components may require different inspection intervals.
|