1983-1992 Chilton Ford Thunderbird Cougar Repair Manual

Description

This Chilton Ford Thunderbird Cougar 1983-1992 Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1983-1992 Ford Thunderbird/Cougar automobiles.

1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992

1983-1992 Chilton Ford Thunderbird Cougar Repair Manual Table of Contents

GENERAL INFORMATION and MAINTENANCE
How to use this book
Tools and Equipment
Routine Maintenance
ENGINE PERFORMANCE and TUNE-UP
Tune-Up Procedures
Tune-Up Specifications
ENGINE and ENGINE OVERHAUL
Engine Electrical System
Engine Service
Engine Specifications
EMISSION CONTROLS
Emission Controls System and Service
FUEL SYSTEM
Carbureted Fuel System
Carburetor Specifications
Gasoline Fuel Injection System
CHASSIS ELECTRICAL
Heating
Lighting
Air Conditioning
Circuit Protection
Entertainment Systems
Windshield Wipers
Instruments and Switches
DRIVE TRAIN
Manual Transmission
Clutch
Automaiic Transmission
Driveline
Rear Axle
SUSPENSION and STEERING
Front Suspension
Rear Suspension
Steering, Delete this message
BRAKES
Brake Systems
Front Disc Brakes
Rear Drum Brakes
Rear Disc Brakes
Anti-Lock Brakes
BODY
Exterior
Interior
MECHANIC’S DATA
Mechanic’s Data
Glossary
Abbreviations
Index

1983-1992 Chilton Ford Thunderbird Cougar Repair Manual Index of Topics

A
Abbreviations and Symbols, 451 Air cleaner, 10 Air conditioning Blower, 257 Compressor, 258 Condenser, 264 Control panel, 254 Evaporator, 248 Leak testing, 43 Safety precautions, 40 Sight glass check, 42 Alternator
Alternator precautions, 87 Application, 86 Removal and installation, 87 Alignment, wheel, 343, 357 Antenna, 424
Anti-lock brake system, 409 Automatic ride control, 357 Automatic transmission Adjustments, 303 Application chart, 8 Back-up light switch, 311 Filter change, 302 Fluid change, 302 Linkage adjustments, 304 Neutral safety switch, 311 Pan removal, 302 Removal and installation, 312 Auxiliary shaft, 161 Axle Rear, 321
B
Back-up light switch Automatic transmission, 283 Manual transmission, 283 Ball joints Inspection, 337 Removal and installation, 337 Battery Fluid level and maintenance, 28 Jump starting, 30 Removal and installation, 89 Bearings Axle, 322 Driveline, 320 Engine, 159, 166, 169 Wheel, 53, 322 Belts, 31-37 Brakes Anti-lock brake system, 409 Bleeding, 382 Brake light switch, 377 Disc brakes (Front)
Caliper, 386 Pads, 383 Rotor (Disc), 389 Disc brakes (Rear)
Caliper, 398 Pads, 394 Rotor (Disc), 401 Drum brakes (Rear)
Adjustment, 374 Drum, 389 Shoes, 391 Wheel cylinder, 394 Fluid level, 51 Master cylinder, 51, 377 Parking brake Adjustment, 374 Removal and installation, 401 Power booster, 379 Proportioning valve, 381 Specifications, 405
C
Calipers
Overhaul, 388, 399 Removal and installation, 386, 398 Camber, 343, 357 Camshaft Sensor, 75, 84
Camshaft (continued)
Service, 159 Specifications, 96 Capacities Chart, 58 Carburetor
Adjustments, 213 Overhaul, 212
Removal and installation, 212 Specifications, 221 Caster, 343, 357 Catalytic converter, 184, 204 Charging system, 86 Chassis electrical system Circuit protection, 291 Heater and air conditioning, 242 Instrument panel, 279 Lighting, 283
Windshield wipers, 43, 270, 282 Chassis lubrication, 52 Circuit breakers, 291 Circuit protection, 291 Clock, 283 Clutch
Adjustment, 297 Cable, 300
Hydraulic system bleeding, 302 Master cylinder, 302 Removal and installation, 297 Slave cylinder, 302 Coil (ignition), 82 Combination switch, 357 Compression testing, 92 Compressor
Removal and installation, 258 Condenser
Air conditioning, 264 Connecting rods and bearings Service, 166 Specifications, 96 Control arm Lower, 339 Upper, 338 Cooling system, 49 Crankcase ventilation valve, 24, 186 Crankshaft Sensor, 74, 84 Service, 169 Specifications, 96 Crankshaft damper, 154 Cylinder head, 135 Cylinders Honing, 164
D
Disc brakes, 382 Distributor Removal and installation, 83 Door glass, 438 Door lock cylinder, 435 Doors Glass, 438 Lock cylinder, 438
Removal and installation, 419 Regulator, 439 Door trim panel, 430 Drive axle (rear)
Axle shaft, 322 Axle shaft bearing, 322 Fluid recommendations, 49 Halfshaft, 329 Lubricant level, 49 Operation, 321 Pinion oil seal, 329 Ratios, 322
Removal and installation, 329 Driveshaft, 317 Drive Train, 294 Drum brakes, 389
E
EGR valve, 200 Electric cooling fan, 132 Electrical Chassis
Battery, 28, 89 Circuit breakers, 291 Fuses, 291 Fusible links, 291 Heater and air conditioning, 242 Jump starting, 30 Spark plug wires, 63 Engine Alternator, 86 Coil, 82 Distributor, 83 Ignition module, 72, 76, 82 Starter, 89 Electronic Ignition, 64 Emission controls Air pump, 189
Catalytic Converter, 184, 204 Evaporative canister, 26, 188 Exhaust Gas Recirculation (EGR) system, 200 Improved Combustion System (IMCO), 194 Oxygen sensor, 205 PCV valve, 24, 186 Thermactor Air Injector System, 189 Engine Auxiliary shaft, 161 Camshaft, 159 Compression testing, 92 Connecting rods and bearings, 161 Crankshaft, 169 Crankshaft damper, 154 Cylinder head, 135 Exhaust manifold, 119 Fluids and lubricants, 47 Flywheel, 173 Front (timing) cover, 155 Front seal, 157 Identification, 9 Intake manifold, 111, 114 Oil pan, 147 Oil pump, 152
Overhaul tips, 91 Piston pin, 165 Pistons, 161 Rear main seal, 167 Removal and installation, 100 Rings, 161 Rocker cover, 107 Rocker shafts and arms, 109-110 Spark plug wires, 63 Specifications, 94 Supercharger, 125 Thermostat, 110 Timing cover and chain, 155 Turbocharger, 124 Valve guides, 145 Valves, 144 Valve seats, 145 Valve springs, 144 Water pump, 133 Evaporative canister, 26, 188 Evaporator, 248 Exhaust Manifold, 119 Exhaust pipe, 184 Exhaust system, 173
F
Fan, 132 Fasteners, 93 Filters Air, 10 Fuel, 13 Firing orders, 63 Flashers, 293 Flex plate, 173 Fluids and lubricants Automatic transmission, 48 Battery, 28 Chassis greasing, 52 Coolant, 49 Drive axle, 49 Engine oil, 47 Fuel, 46
Manual transmission, 48 Master cylinder Brake, 51 Clutch, 302 Power steering pump, 51 Steering gear, 52 Flywheel and ring gear, 173 Front brakes, 382 Front suspension Ball joints, 337 Description, 334 Lower control arm, 339 Spindles, 340 Springs, 334 Stabilizer bar, 337 Struts, 337
Upper control arm, 337 Wheel alignment, 343 Front wheel bearings, 53, 341
Fuel cap, 28 Fuel injection
Fuel Charging Assembly, 228 Fuel pressure regulator, 235 Fuel pump, 207 Injectors, 239 Throttle body, 229 Throttle position sensor, 238 Fuel filter, 13 Fuel line connections, 22 Fuel pump Electric, 207 Mechanical, 206 Fuel system Carbureted, 212 Gasoline Fuel injection, 220 Fuel tank, 241
Fuses and circuit breakers, 291 Fusible links, 291
G
Gearshift linkage Adjustment Automatic, 304 Manual, 294 Generator (see Alternator)
Glass Door, 438 Stationary, 440 Glossary, 445
H
Halfshaft, 329 Hazard flasher, 293 Headlights, 283 Heater
Blower, 246 Control panel, 247 Core, 242 Heat riser, 31
High mount brake light, 287 Hood, 419 Hoses Coolant, 37, 40 Fuel, 22 How to Use This Book, 1
I
Identification Engine, 9 Model, 5 Serial number, 5 Transmission, 6, 8 Vehicle, 5 Idle speed and mixture adjustment, 79 Ignition Coil, 82 Electronic, 64 Lock cylinder, 359
Ignition (continued)
Module, 72, 76, 82 Switch, 359 Timing, 69, 72 Injectors, fuel, 239 Instrument cluster, 274 Instrument panel Clock, 283 Cluster, 274 Panel removal, 279 Radio, 266
Speedometer cable, 283 Intake manifold, 111, 114
J
Jacking points, 58 Jump starting, 30
L
Lighting Headlights, 283 Signal and marker lights, 286 Lower ball joint, 337 Lower control arm, 339 Lubrication
Automatic transmission, 48 Body, 52 Chassis, 52 Differential, 49 Engine, 47
Manual transmission, 48
N
MacPherson struts, 337 Maintenance intervals, 57 Manifolds Intake, 111, 114 Exhaust, 119 Manual transmission Application chart, 8 Linkage adjustment, 294 Removal and installation, 295 Marker lights, 286 Master cylinder Brake, 377 Clutch, 302 Mechanic’s data, 443 Mirrors, 422, 441 Model identification, 5 Module (ignition), 82 Muffler, 173
Multi-function switch, 357
N
Neutral safety switch, 311
o
Oil and fuel recommendations, 46 Oil and filter change (engine), 47 Oil level check Differential, 49 Engine, 47 Transmission Automatic, 48 Manual, 48 Oil pan, 147 Oil pump, 152
Outside vehicle maintenance Lock cylinders, 52 Door hinges, 53 Trunk lid, 53 Body drain holes, 53 Oxygen sensor, 205
P
Parking brake Adjustment, 374 Cables, 401 Piston pin, 165 Pistons, 161 Pivot pins, 165 PCV valve, 186 Power brake booster, 379 Power seat motor, 442 Power steering gear (rack and pinion) Adjustments, 368 Removal and installation, 372 Power steering pump Fluid level, 51
Removal and installation, 372 Power windows, 440 Preventive Maintenance Charts, 57 Pushing, 56
R
Radiator, 131 Radio, 266 Rear axle Axle shaft, 322 Axle shaft bearing, 322 Fluid recommendations, 49 Lubricant level, 49 Operation, 321 Pinion oil seal, 329 Ratios, 322
Removal and installation, 329 Rear brakes, 389, 394 Rear main oil seal, 167 Rear suspension Alignment, 357 Axle damper, 355 Control arms, 352 Shock absorbers, 351 Springs, 348 Sway bar, 355
Rear wheel bearings, 322 Regulator
Removal and installation, 88 Rings, 161
Rocker arms or shaft, 109-110 Rotor (Brake disc), 389, 401 Routine maintenance, 10
S
Safety notice, 1 Seats, 441
Serial number location, 5 Shock absorbers, 351 Slave cylinder, 302 Spark plugs, 60 Spark plug wires, 63 Speakers, 268 Special tools, 4 Specification Charts Brakes, 405 Camshaft, 96 Capacities, 58 Carburetor, 221
Crankshaft and connecting rod, 96
Fastener markings and torque standards, 93
General engine, 94
Piston and ring, 98
Preventive Maintenance, 57
Torque, 98
Tune-up, 61
Valves, 94
Wheel alignment, 345 Speedometer cable, 283 Spindles, 340 Springs, 334, 348 Stabilizer bar, 337, 355 Starter
Removal and installation, 90 Relay replacement, 90 Steering column, 361 Steering gear (Rack and pinion), 368 Steering linkage, 366 Steering lock, 359 Steering wheel, 357 Stripped threads, 92 Studs (wheel), 331 Supercharger, 125 Suspension Front, 334 Rear, 347 Switches
Back-up light, 283 Blower switch, 247, 257 Headlight, 282 Ignition switch, 358 Multi-function switch, 357 Windshield wiper, 282
T
Thermostat, 110 Throttle body, 229
Tie rod ends, 366 Timing (ignition), 69, 72 Timing cover and chain, 154 Timing cover, 157 Tires
Design, 45 Inflation, 46 Rotation, 45 Storage, 46 Tread depth, 46 Toe-in, 343, 357 Tools, 2
Torque specifications, 98 Towing, 56 Trailer towing, 54 Transmission
Application charts, 8 Automatic, 302 Manual, 294
Routine maintenance, 48 Trunk lid, 429 Trunk lock cylinder, 435 Tune-up
Idle speed, 79 Ignition timing, 69, 72 Procedures, 60 Spark plugs and wires, 60-63 Specifications, 61 Turbocharger, 124 Turn signal flasher, 293 Turn signal switch, 357
U
U-joints Overhaul, 320 Replacement, 321 Upper ball joint, 337 Upper control arm, 338
Y
Valve guides, 145 Valve lash adjustment, 77 Valve seats, 145 Valve service, 144 Valve specifications, 94 Valve springs, 145 Vehicle identification, 5
W
Water pump, 133 Wheel alignment Adjustment, 343 Specifications, 345 Wheel bearings
Front wheel, 53, 341 Rear wheel, 322 Wheel cylinders, 394 Wheels, 46, 331
Wheel studs, 331 Window glass, 438, 440 Window regulator, 439 Windshield wipers Arm, 43, 270 Blade, 43, 270
Linkage, 273 Motor, 270
Windshield wiper switch, 282 Wiring
Spark plug, 63 Trailer, 55, 289