|
Manual Coverage
|
|
Systems Covered
|
|
Engine Mechanical:
|
Detailed coverage of engine assembly, disassembly, inspection, and repair for all variants.
|
|
Engine Control System:
|
Diagnosis and repair of the Powertrain Control Module (PCM), sensors, actuators, and fuel injection systems.
|
|
Fuel Service Specifications:
|
Fuel pressure testing, injector service, fuel pump diagnostics, and fuel system cleaning procedures.
|
|
Emission Control:
|
Diagnosis and repair of emissions-related components including the EGR system, catalytic converter, and evaporative emission control (EVAP).
|
|
Intake Exhaust Cooling:
|
Service procedures for intake manifolds, exhaust systems, and the complete cooling system, including radiator, water pump, and thermostat.
|
|
Lube:
|
Lubrication specifications, oil change procedures, and component lubrication points.
|
|
Ignition Starting Charging:
|
Service and diagnosis for the ignition system (coils, plugs), starting system (starter motor, solenoid), and charging system (alternator).
|
|
Automatic Transmission:
|
Detailed repair and overhaul procedures for the 4R70W automatic transmission, including valve body service and torque converter replacement.
|
|
Manual Transmission:
|
Coverage for any manual transmission variants offered, including clutch service and gearshift linkage.
|
|
Transfer Propeller Shaft:
|
Service for driveshafts, universal joints, and related components.
|
|
Drive Shaft:
|
As above, covering rear-wheel drive components.
|
|
Differential:
|
Service and diagnosis for the rear differential, including gear oil specifications and bearing adjustment.
|
|
Axle Suspension:
|
Detailed procedures for front and rear suspension components, including springs, shocks, control arms, ball joints, and bushings.
|
|
Tire Wheel:
|
Wheel alignment specifications, tire rotation procedures, and lug nut torque values.
|
|
Brake Control:
|
Service and diagnosis for the Anti-lock Braking System (ABS), including wheel speed sensors and hydraulic control unit.
|
|
Brake:
|
Complete brake system service, including pad and rotor replacement, caliper overhaul, brake fluid specifications, and bleeding procedures.
|
|
Parking Brake:
|
Adjustment and repair procedures for the parking brake system.
|
|
Steering Column:
|
Service for the steering column, including tilt mechanism and ignition switch.
|
|
Power Steering:
|
Diagnosis and repair of the power steering system, including pump, rack, and hoses.
|
|
Air Condition:
|
Service, diagnosis, and recharging procedures for the air conditioning system.
|
|
Supplemental Restraint System:
|
Service and safety precautions for the airbag system, including module replacement and diagnostic codes.
|
|
Seat Belt:
|
Service and inspection of seat belt retractors and anchors.
|
|
Engine Immobilizer:
|
Information on the factory immobilizer system and its operation.
|
|
Cruise Control:
|
Diagnosis and repair of the cruise control system.
|
|
Wiper Washer:
|
Service for the windshield wiper and washer systems, including motor and linkage.
|
|
Door Lock:
|
Service for power door locks, manual locks, and keyless entry systems.
|
|
Meter Audio Visual:
|
Diagnosis and repair of instrument cluster components, radios, and other audio/visual systems.
|
|
Horn:
|
Service for the horn system.
|
|
Windshield Glass Mirror:
|
Procedures for windshield replacement, glass sealing, and mirror service.
|
|
Instrument Panel:
|
Removal, installation, and service of the instrument panel and its components.
|
|
Seat:
|
Service for manual and power seat adjustments, heating elements, and upholstery.
|
|
Engine Hood Door:
|
Service for hood latches, hinges, and door mechanisms, including window regulators.
|
|
Exterior Interior:
|
Body panel repair, trim replacement, and interior component service.
|
|
Electrical:
|
Comprehensive electrical system troubleshooting, including wiring diagrams for all circuits.
|
|
Multiplex Can Communication:
|
Diagnostic information for vehicle communication networks, if applicable to the 1997 model year (less common for this era).
|
|
Procedures Included
|
|
Maintenance:
|
Routine scheduled maintenance, fluid changes, filter replacements, and inspections.
|
|
Troubleshooting:
|
Diagnostic flowcharts, symptom-based troubleshooting guides, and common fault identification.
|
|
Repair:
|
Step-by-step instructions for component removal, installation, and repair for all major systems.
|
|
Diagnostics:
|
Detailed diagnostic procedures, including use of scan tools, multimeter testing, and component testing.
|
|
Wiring Schematics:
|
Complete and detailed wiring diagrams for all electrical systems, crucial for diagnosing electrical faults.
|
|
Technical Depth
|
|
Depth:
|
Factory-level technical information for complete diagnosis, service, and repair.
|
|
Diagnostic Tools:
|
Information on using diagnostic scan tools (OBD-II), multimeters, and specialized Ford diagnostic equipment.
|
|
Maintenance
|
|
Service Intervals
|
|
Oil Change Interval:
|
Typically every 3,000-5,000 miles or 6 months, depending on driving conditions and oil used. Refer to manual for exact specifications.
|
|
Transmission Fluid Change:
|
Recommended every 30,000-60,000 miles, or as per severe service schedule. Consult manual for specific intervals and fluid type.
|
|
Coolant Change:
|
Typically every 30,000-60,000 miles or 2-4 years.
|
|
Fluid Specifications
|
|
Engine Oil:
|
SAE 5W-30, API SG or SH certified. Capacity approximately 5 quarts with filter.
|
|
Transmission Fluid:
|
Mercon V Automatic Transmission Fluid (ATF). Capacity approximately 13.5 quarts.
|
|
Coolant:
|
Ford Premium Engine Coolant (Green) or equivalent. 50/50 mix with distilled water. Capacity approximately 13.5 quarts.
|
|
Brake Fluid:
|
DOT 3, high-temperature brake fluid.
|
|
Known Issues
|
|
Common Wear Items:
|
Front suspension bushings, ball joints, tie rod ends, and sometimes intake manifold gaskets (though less problematic on later 4.6L Modulars than earlier versions).
|
|
Transmission Shifting:
|
Occasionally, delayed or rough shifting can occur, often related to valve body issues or solenoid pack problems in the 4R70W transmission.
|
