Engine:
Detailed coverage of all engine variants, including diagnosis, repair, overhaul, and tuning for gasoline engines. Specifics for 1.6L, 1.9L, 2.0L (including SOHC, DOHC, and Zetec variants) and potentially diesel engines depending on market.
Fuel System:
Includes fuel delivery, fuel injection systems (EFI, multi-port injection), carburetors (for earlier models), fuel pumps, injectors, pressure regulators, and emissions control systems.
Ignition System:
Distributor-based ignition, electronic ignition systems, spark plugs, coils, timing adjustments, and diagnostic procedures.
Cooling System:
Radiator, water pump, thermostat, hoses, fan operation (mechanical and electric), coolant specifications, and leak diagnosis.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, pipes, gaskets, and emissions routing.
Transmission Manual:
Operation, diagnosis, repair, and overhaul of manual transmissions, including clutch operation, linkage, and gear selection mechanisms.
Transmission Automatic:
Operation, diagnosis, repair, and overhaul of automatic transmissions (e.g., ATX, AXOD, AX4S), including torque converter, valve body, solenoids, and fluid specifications.
Drivetrain:
Front-wheel drive (FWD) system components, including CV axles, drive shafts, differential, and associated seals and bearings.
Suspension Front:
MacPherson strut suspension, control arms, ball joints, sway bar, bushings, springs, shock absorbers, and alignment specifications.
Suspension Rear:
Torsion beam axle, trailing arms, shock absorbers, bushings, and alignment specifications for various generations.
Steering System:
Power steering system (pump, rack, hoses, fluid), manual steering, steering column, and wheel alignment.
Brakes Front:
Disc brake systems, calipers, pads, rotors, brake lines, and bleeding procedures.
Brakes Rear:
Drum brake or disc brake systems (depending on year/trim), shoes, drums, rotors, calipers, brake lines, and bleeding procedures.
Electrical System:
Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems, and accessory circuits.
Body Exterior:
Body panel removal and installation, door mechanisms, hood, trunk, bumpers, mirrors, and trim.
Body Interior:
Dashboard removal and installation, seats, seat belts, interior trim panels, headliner, and HVAC controls.
HVAC System:
Heating, ventilation, and air conditioning (HVAC) system components, including blower motor, heater core, evaporator, refrigerant, and controls.
Safety Restraints:
Seat belt systems, SRS (Supplemental Restraint System) airbags (for later models), and related diagnostic procedures.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, fluid checks and top-offs, tire rotations, brake inspections, and belt replacement.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, often utilizing diagnostic trouble codes (DTCs) for EFI systems.
Component Repair:
Detailed, step-by-step instructions for removing, repairing, overhauling, and reinstalling major and minor components across all systems.
Torque Specifications:
Essential torque values for all critical fasteners, ensuring proper assembly and preventing damage.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for various vehicle configurations and systems, crucial for electrical diagnostics and repairs.
Diagnostic Charts:
Flowcharts and charts to guide technicians through diagnosing specific problems based on symptoms.
Emissions Control Service:
Information on diagnosis and repair of emissions-related components, including EVAP systems, EGR valves, and catalytic converters.
Depth Level:
Comprehensive (covering everything from basic fluid changes to full engine and transmission rebuilds, complex electrical diagnostics, and bodywork repairs).
Diagnostics Complexity:
Advanced diagnostics, including interpretation of sensor data, actuator testing, and on-board diagnostics (OBD-I for earlier models, potentially early OBD-II for late 90s models).
Special Tools:
Identification and usage instructions for specialized tools required for certain procedures, ensuring correct repair methods.
Engine Variants 1981-1997:
1.6L CVH I4, 1.9L CVH I4, 2.0L SPI I4, 2.0L DOHC I4, 2.0L Zetec I4, 1.8L Diesel I4 (market dependent).
Engine Control Systems:
Carbureted systems (early models), Electronic Fuel Injection (EFI), Sequential Electronic Fuel Injection (SEFI), Multi-Port Fuel Injection (MPFI).
Horsepower Range:
Approximately 70 hp to 130 hp, depending on engine and year.
Torque Range:
Approximately 80 lb-ft to 125 lb-ft, depending on engine and year.
Fuel Type:
Unleaded Gasoline (Octane rating as per vehicle specification, typically 87 or 89).
Fuel Tank Capacity:
Typically around 13-14 gallons (49-53 liters).
Spark Plug Type:
Specific spark plug type and gap will vary by engine and ignition system. Examples: Motorcraft AWSF22, Champion RC12YC. (Consult manual for exact part numbers).
Timing Belt Replacement Interval:
For engines with timing belts (e.g., Zetec), typically recommended every 60,000-100,000 miles or 5-7 years. Crucial to verify with manual for specific engine.
Engine Oil And Filter:
Typically every 3,000-5,000 miles or 3-6 months. Later models with synthetic oil may extend this to 7,500-10,000 miles or 6-12 months. Consult manual for specific engine and oil type.
Air Filter Replacement:
Typically every 15,000-30,000 miles or as needed based on driving conditions.
Fuel Filter Replacement:
Typically every 30,000-60,000 miles, especially for earlier models with mechanical fuel pumps. Electronic fuel injection systems may have less frequent recommendations.
Coolant Flush And Replacement:
Every 30,000-50,000 miles or 2-3 years. Use Ford specified coolant (e.g., Ford Premium Gold or similar).
Engine Oil Viscosity:
Commonly 5W-30 or 10W-30 for gasoline engines. Consult manual for specific engine and ambient temperature recommendations.
Brake Fluid Type:
DOT 3 or DOT 4 (typically DOT 3 for most of this era). Check reservoir cap and manual.
Power Steering Fluid:
Ford Power Steering Fluid (e.g., XT-9000-S) or Dexron-III ATF for some models. Consult manual for correct type.
Windshield Washer Fluid:
Automotive windshield washer fluid concentrate mixed with distilled water.
Cv Axle Wear:
Common issue, especially on higher mileage vehicles, leading to clicking noise during turns.
Radiator Leaks And Overheating:
Radiator tanks can degrade and leak; water pump seals can fail, leading to coolant loss and potential overheating.
Ignition Control Module Icm Failure:
A common point of failure in the ignition system, leading to no-spark conditions.
Automatic Transmission Issues:
Some automatic transmissions (e.g., ATX) were known for premature wear or electronic control issues. Fluid changes are critical.
Interior Trim Degradation:
Older plastic interior components can become brittle and crack over time.
Heater Core Leaks:
Heater core can develop leaks, leading to coolant loss and a sweet smell inside the cabin.
Ford Legacy:
Ford Motor Company, a major American automaker with a long history of producing popular and reliable vehicles.
First Generation 1981-1985:
Introduced as a front-wheel-drive replacement for the rear-wheel-drive Pinto and Fiesta. Featured European Escort underpinnings. Available as 3-door and 5-door hatchback.
Second Generation 1986-1990:
Complete redesign. Introduced sedan and wagon body styles. Significant interior and exterior updates. Introduced GT model. Utilized Mazda 323 platform for some components.
Third Generation 1991-1996:
Further refinement and aerodynamic styling. Introduction of the more powerful Zetec engine option. Improved interior ergonomics and safety features. Introduction of the wagon (later named Escort Wagon).
Fourth Generation 1997:
The final model year for the North American Escort, largely a carry-over from the third generation. Replaced by the Focus for the 2000 model year.
Manufacturing Locations:
Primarily Wayne, Michigan, USA; also Hermosillo, Mexico.
Production Years North America:
1981-2003 (though this manual covers up to 1997, with different models phasing out earlier).
