FORD ZL Fairlane and Fairlane Sportsman 1984-1988 Workshop Manual |  PDF Download

The most thorough and complete manual available for the Ford Fairlane ZL range. Detailed steps making it easy for anyone to do repair jobs on their Ford Fairlane 

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This Workshop Manual is for the following 1984-1988 Ford models:

• Ford Fairlane ZL Series
• Ford Fairlane Sportsman ZL Series
• This is an all purpose manual that includes all 1984-1988 Ford Models

The following engines are included:

• 4.1 Litre 6 Cylinder
• 4.1 Litre EFI 6 Cylinder

The following transmissions are included:

• Automatic Transmission Borg Warner 40
• Manual Transmission 3 Speed
• Manual Transmission 4 Speed Borg Warner 0503-XXX
• Manual Transmission 4 Speed Borg Warner 0506-XXX
• Manual Transmission 5 Speed Borg Warner 0507-XXX

Below is an extensive list of topics included:

INTRODUCTION

VEHICLE IDENTIFICATION

BRAKES

General Brake Service, Dual Master Cylinder, Vacuum Brake Booster, Drum Brakes, Front Disc Brake System- P.B.R. Caliper, Front Disc Brake System- Girlock Caliper, Rear Disc Brake System, Parking Brake, Specifications and Special Tools

SUSPENSION-STEERING-WHEELS & TYRES

General Service, Suspension, Power Steering Gear, Manual Steering Gear, Power Steering Pump - and Lines, Steering Columns and Linkage, Wheels, Tyres and Front Hubs, Specifications and Special Tools

REAR AXLE

General Service, Rear Axle- Conventional, Rear Axle - Limited Slip Differential, Specifications and Special Tools

CLUTCH-DRIVELINE

General Clutch Service, Clutch, Specifications and Special Tools

MANUAL TRANSMISSION

ADJUSTMENTS, REMOVAL AND INSTALLATION, REPAIRS

General Transmission Service, 3 Speed Manual Shift, 4 Speed Manual Shift, 5 Speed Manual Shift, Specifications and Special Tools

AUTOMATIC TRANSMISSION

BORG-WARNER MODEL 40

ADJUSTMENTS, REMOVAL AND INSTALLATION, REPAIRS

Fluid level check, Fluid leakage check, Engine idle speed check, Manual linkage check, Downshift cable check, Initial engagement check, Transmission operation checks, Test Preparation, Control .pressure tests, Stall test, Control pressure and engine speed, Road test procedures, Air Pressure checks, Forward clutch Governor, Reverse high clutch (rear), Intermediate servo (front), Low reverse servo (rear), Diagnosis Guide Notes - friction elements/hydraulic valves Transmission Servicing, Preliminary Adjustments - Fluid Level, Accelerator linkage and downshift valve control cable, Downshift valve control cable replacement, Valve body adjustable throttle cam bracket, Manual linkage adjustment, Slow running adjustment, Front Brake Band, Rear Brake Band, Neutral Start Switch, Transmission fluid drain and refill, Oil Cooler Flushing Procedure Neutral Start Switch, Oil Cooler Replacement, Shift Lever/Linkage, Cross Shaft Seal, Extension Housing, Speedo Drive Gear, Governor, Extension Housing Seal/Bush, Oil pan, Valve Body Assembly, Front/Rear Servo Transmission- Dismantle, Valve Bodies, Pump, Front Clutch and Input Shaft, Rear Clutch and Forward Sun Gear, Front Servo, Rear Servo, Governor, Transmission – Reassemble

ENGINE

Six Cylinder Engines with Carburettor

ADJUSTMENTS REPAIRS REMOVAL AND INSTALLATION

Camshaft Lobe Lift, Compression Test, Manifold Vacuum Test, Hydraulic Valve Lifters, Positive Crankcase Ventilation System, Check PCV System Function, Crankshaft End Play, Flywheel Face Runout, Flywheel Ring Gear Runout, Camshaft End Play, Timing Chain Deflection Valve Clearance – Hydraulic, Valve Lifters, Valve Guide Repair, Valve Guide Replacement, Valve Seat Repair, Valves, Valve Seat Insert, Camshaft/Crankshaft, Pistons and Rings, Cylinder Block, Flywheel Ring Gear 

Six Cylinder Engines with Electronic Fuel Injection 

ADJUSTMENTS REPAIRS REMOVAL AND INSTALLATION

Intake Manifold Assembly, Lower Manifold to Intake Tubes Gasket, Plenum Chamber (Upper Manifold) to Intake Tubes Gasket, Valve Rocker Arm Cover, Cylinder Head Removal, Engine Front Support, Specifications and Special Tools

IGNITION SYSTEM 

General Information, Pulse Generator, Electronic Control Unit, Trouble Shooting

ADJUSTMENTS REMOVAL AND INSTALLATION

Ignition Timing, Distributor Spark Advance Spark Plug Wires, Spark Plugs, Secondary Wiring, Coil, Distributor Cap, Rotor, Distributor Vacuum Advance Unit Dual Advance Solid State Distributor (Carburettor Engine) Distributor, Shaft End Float, Shaft Replacement, Distributor Advance Tests Using Tester, Centrifugal Advance, Vacuum Advance Ignition System - EFI - EEC IV Distributor with Thick Film Ignition (TFI) Module 

FUEL SYSTEM

DIAGNOSIS, TESTING, ADJUSTMENTS, REPAIRS

General Fuel System Service (Carburettor Engine) Diagnosis Guide - Fuel Pump, Carburettor, Fuel Tank, Lines and Filter, Fuel Pump Test, Throttle Linkage, Accelerator Pedal – Replace, Accelerator Shaft Assembly – Replace, Accelerator Cable Replacement Initial Idle Speed and Fuel Mixture Adjustments, Idle CO Level - Check and Adjust, Float Level and Max Stroke Air Horn, Throttle Body, Anti Run on Solenoid, Two Stage Idle Switch, Thermo Vacuum Switch

EEC IV Electronic Fuel Injection

DIAGNOSIS, TESTING, ADJUSTMENTS, REPAIRS

Electronic Engine Controls EEC IV, System Input Components and Operation, Engine Operating Modes, Air Intake Tube (Snorkel), Shield- Air Cleaner Duct, Air Cleaner Body or Element, Air Flow Sensor, Fuel Pressure Regulator, Fuel Injector, Idle Speed Control Throttle Position Sensor, Fuel Rail, Engine Temperature Sensor, EGA Valve, Relays, Throttle Body, In Line Filter, Fuel Tank Filter, Fuel Tank, Fuel Pump , Fuel Lines and Repair, EEC Processor

Fuel Pump 

REPAIRS, REMOVAL AND INSTALLATION

Fuel Pump, Fuel Tank, Lines and Filters (Carburettor Engine) Fuel Sender Unit, Fuel Filter- Carburettor, Fuel Tank Filter, Filler Pipe, Fuel Tank, Fuel lines

EVAPORATIVE EMISSION CONTROL SYSTEM

Vapor Vent & Storage System, Service Maintenance, Filler Cap, Carbon Canister, Vapor Lines, Purge Control Valve Testing

COOLING SYSTEM

GENERAL MAINTENANCE, REPAIRS

Coolant Recovery System, Coolant Maintenance, Coolant Level Check, Anti-Freeze Solution, Adjusting Anti-Freeze Protection Level, Draining and Filling the Cooling System, Drive Belts and Pulleys, Fan Replacement, Radiator Hose Replacement, Thermostat Replacement, Water Pump, Pump Overhaul, Radiator, Fan Drive Clutch

CHARGING SYSTEM

DIAGNOSIS, ADJUSTMENTS 

Testing the Charging System, Diagnosis Chart, Output Test Diagnosis, Alternator Tests, Testing the Rotor, Testing the Stator, Testing the Diodes and Rectifier Assembly, Power Diodes, Field Diodes, Heat Sinks, Battery Tests and Conclusions Alternator Drive Belt, Alternator, Regulator, Voltage Regulator Test

STARTING SYSTEM

CLEANING INSPECTION REPAIRS

Bosch Starting System, Testing Starter Components, Adjustment, Repair and replace

LIGHTING & INSTRUMENTS 

DIAGNOSIS, TESTING, ADJUSTMENTS, REMOVAL, INSTALLATION

Lights, Instruments, Turn Indicator, Headlight Switch, Beam Selector, Horn, Windshield Wiper, Oil Pressure, Charge Light Indicator, Tachometer, Voltmeter, Speedometer, Fuel Indicator System, Lighting Systems and Horns, Headlights, Headlight Alignment, Fog Lamp Aim, Headlamp Assembly, Bulb Replacement – Headlight, Park, Driving and Turn Signal, Fog Lamp, Replacement Tail, Stop, Back-Up, Turn Signal Lamp Bulb, License Plate, Back-Up, Luggage Compartment Lamp, Dome, Courtesy, Footwall Bulbs, Control Panel, Instrument Warning, Ignition Key Bulbs, Gear Selector, Glove Box Bulb
Switches, Circuit Breakers and Fuses, Paddle Type Switches, Instrument Cluster Control, Multi-purpose and Wash/Wipe Switches, Fog Lamp Switch, Stoplight Switch, Liftgate Wash/Wipe Switch, Park Brake Warning Switch, Luggage Compartment Light Switch, Ignition Switch/Lock Barrel, Power Door Lock Switch, Power Seat Switch, Power Window Switches, Power Mirror Switch, Boot Release Switch, Wiring Harness and Location
Instruments

INSTRUMENTS

ADJUSTMENTS, REMOVAL AND INSTALLATION

Washer Jet, Cruise Control - Carb Engine, Cruise Control - EFI Engine, Cruise Control Clutch Switch, Windscreen Wiper Blade/Insert, Windscreen Wiper Arm and Blade, Instrument Cluster and Surround, Gauges and Instruments, Turn Indicator Flasher, Temperature Sender Unit, Oil Pressure Switch, Fuel Sender Unit, Wiper Motor and Linkage, Windscreen Washer Pump
Specifications

VENTILATION-HEATING

DIAGNOSIS, TESTING, ADJUSTMENTS REMOVAL, INSTALLATION

Ventilation, Heating, Controls, Footwell Duct, Heater Hose, Fan/Fan Motor, Resistor, Heater Case, Heater Core, Control Assembly, Instrument Panel Air Outlets

AIR CONDITIONING AND ACCESSORIES

DESCRIPTION AND OPERATION

Basic Principles, Evaporator Assembly, Thermostatic Expansion Valve, Compressor, Magnetic Clutch, Compressor Cut Off Switches, Condenser, Receiver-Dryer, Sight Glass

DIAGNOSIS, TESTING, ADJUSTMENTS, REMOVAL, INSTALLATION

Performance Testing, Trouble Shooting Chart, Compressor Drive Belt, Electrical Problems, Use of Sight Glass, Receiver-Dryer Test, Magnetic Clutch Test, Ventilation and Air Cond. System, Oil Check and Charge Procedures, Flush Procedure, Safety Precautions, Heater, Drive Belt Tension, Temperature Control Cam, Discharging the System, Evacuating the System, Compressor, Condenser and Receiver, Expansion Valve, Heater and Air Cond. Case, Heater or Evaporative Core, Refrigerant Lines, Console Air Outlets, Vacuum Reservoir, Thermostat

RADIO AND RADIO TAPE PLAYER

DIAGNOSIS, TESTING, REMOVAL AND INSTALLATION

Diagnosis Guide, Radio Reception, Tuning, Interfering Noise, FM Flutter, Radio and Radio/Stereo Tape, Player Removal, Radio, Radio and Stereo Tape Player, Amplifier, Power Antenna, Power Antenna Mast Replacement, Antenna (Manually Operated), Speaker

BODY, DOORS AND WINDOWS

ADJUSTMENTS, REMOVAL, INSTALLATION

Hood, Latch, Door Alignment Lock Striker, Luggage Compartment Alignment Lock, Liftgate, Hinges, Latch and Striker, Hood/Hood Hinge, Hood Prop/Latch, Doors, Door Latch, Liftgate Hinge, Door Lock Handle/Cylinder, Luggage Comp. Door/Hinge or Torsion Bar, Luggage Comp. Door Latch/Lock, Van Liftgate

FRONT, REAR BUMPERS, GRILLE, EXTERIOR MOULDINGS

REMOVAL AND INSTALLATION

Front Bumper, Rear Bumper – Sedan, Rear Bumper- Wagon, Rear Bumperette- Ute and Van, Grille and Exterior Moulding Installations, Grille, Door Moulding Installation, Roof Moulding

INSTRUMENT PANEL

REMOVAL AND INSTALLATION

Instrument Panel Pad and Centre, Instrument Panel

MANUAL WINDOWS, FIXED GLASS

REMOVAL AND INSTALLATION

Front Door Glass/Regulator, Rear Door Glass – Moveable, Rear Door Window Regulator, Rear Door Stationary Glass, Window Regulator Spring, Windshield Glass, Liftgate Glass, Rear Glass/Weatherstrip – Sedan, Rear Glass - Ute and Van, Van Side Glass, Rear Quarter Glass/Weatherstrip -Wagon, Rear Quarter Glass - Fairlane, LTD, Rear Quarter Glass - Ute and Van, Outside Mirror

POWER WINDOWS

DESCRIPTION, OPERATION, REMOVAL AND INSTALLATION

Circuit Breaker or Relay, Window Regulator and Motor, Switch

POWER AND ILLUMINATED DOOR LOCKS

DESCRIPTION, OPERATION, REMOVAL, INSTALLATION

Illuminated Door Lock, Power Door Lock, Door Wiring, Illuminated Door Lock, Door Lock Actuator Motor, Switch (In Door Pull Handle), Circuit Breaker

ELECTRICALLY OPERATED EXTERNAL MIRROR, LUGGAGE COMPARTMENT LOCK

DESCRIPTION AND OPERATION

Direction Control Switch, Mirror Selection Switch, Electrically Operated Luggage Compartment Lock Release, Remote Control Luggage Compartment, Door Lock Release (Electric), Switch, Solenoid

TRIM AND SEATS

Front Bucket Seats

ADJUSTMENTS, REMOVAL AND INSTALLATION

Release Tie Rod, Front Seat and Seat Track, Front Seat Cushion Cover, Front Seat Back Cover, Recliner Mechanism, Bucket Seat Lumbar Support Mechanism

Front Bench Seat

ADJUSTMENTS, REMOVAL AND INSTALLATION

Front Seat Track Release Tie Rod, Front Seat and Seat Track, Split Bench Seat, Front Seat Cushion Cover, Front Seat Back Cover

Rear Seat

ADJUSTMENTS, REMOVAL AND INSTALLATION

Catch Adjustment, Release Cable Adjustment, Seat Cushion, Seat Back, Seat Cushion Cover, Seat Back Cover, Rear Seat, Centre Arm Rest and Picnic Tray, Rear Seat Cushion- Wagon, Rear Seat Back – Wagon, Rear Seat Hinge, Rear Seat Cushion Cover, Rear Seat Back Cover, Rear Seat back Latch Mechanism

Power Seats

DIAGNOSIS, TESTING, REMOVAL AND INSTALLATION

Noise in Operation, Binding in Operation, Inoperative, Looseness, Slow Operation, Seat Track, Motor and Drive Cables

Door Trims and Headlining

REMOVAL AND INSTALLATION

Door Trim Panels, Headlining – Falcon, Headlining - Fairlane, LTD

LUBRICATION

Lubrication Requirements, Engine Oil, Oil Filter

MAINTENANCE

Battery Fluid, Brake Master Cylinder, Automatic Transmission, Power Steering, Change Engine Oil and Filter, Add Corrosion Inhibitor, Drain and Refill Radiator, Check Cooling System for Leakage, Replace Spark Plugs, Clean and Inspect Spark Plugs, Replace In-line Fuel Filter (EFI), Clean Fuel Filter, Checks and Adjustments of Carburettor and Emission System, Air Cleaner, Check Clutch Cable Adjustment, Check Drive Belts for Condition and Tension, Check Exhaust System for Leakage, Security and Alignment, Remove Drums, Clean and Check Operation and Condition of Brake Assy, Check Front and Rear Disc Brake Pads for Condition and Wear, Repack and Adjust Front Wheel Bearings Adjust Auto Trans Bands, Check Steering Gear and Linkage for Security, Check Brake Hoses for Leakage and Security, Check Rear Axle Fluid Level, Check Manual Transmission Fluid Level, Drain and Refill Manual Transmission, Front Suspension Ball Joints – Lubricate, Clean and Lubricate Front and Rear Door Latches, Renew Brake Fluid, Auto Trans Severe Service, Check Cruise Control Actuator Cable Adjustment, Inspect for Vacuum Leakage, Check and Adjustments of EFI and Emission System

SCHEMATICS

INTRODUCTION

Main Wiring Circuit- Hi Series, Main Wiring Circuit- Lo Series, Electronic Fuel Injection, Engine Compartment, Cigar and Courtesy Lamp, Power Windows and Power Door Locks, Power Mirror, Illuminated Entry, Rear Lamp, Intermittent Windshield Wipers, Rear Window Wiper/Washer (Wagon), Hazard Flasher, Power Seat (LTD), Air Conditioner

HARNESS LOCATION AND IDENTIFICATION

Instrument Panel (Lo Series), Instrument Panel (Lo Series), Instrument Panel (Lo Series), Instrument Panel (Hi Series), Instrument Panel (Hi Series), Instrument Panel (Hi Series), Engine Compartment (Carburettor Engine), Engine Compartment (EFI Engine), Engine Compartment (EFI Engine), Engine Electronic Control (EFI Engine), Front and Rear Door (Near Side), Front and Rear Door (Off Side), Front Door (Off Side- Hi Series), Rear Door (Off Side- Hi Series), Front Door (Near Side - Hi Series), Illuminated Door Entry and Power Door Locks, Centre Console/Power Operated Front Seat, Courtesy Lamp ('C' Pillar), Rear Lamps (Sedans), Rear Lamps (Sedans), Rear Lamps, Rear Lamps and Rear Speakers (Falcon), Rear Lamps and Rear Speakers (Fairlane and LTD)Rear Lamps and Fuel Gauge, Rear Harness Assy. (Wagon), Liftgate/Wiper (Wagon), Back-up Lights/Licence Plate Lamps (Wagon), Rear Harness Assy. (Utility and Van)

EMISSION CONTROL SYSTEMS

EMISSION CONTROL SYSTEMS - CARBURETTOR ENGINE

Exhaust Emission Control Systems, Pollutant Admission to Atmosphere, Description and Application of Emission Components, Positive Crankcase Ventilation, Exhaust Gas Recirculation System, Venturi Vacuum Amplifier Carbon Canister, Spark Port Vacuum, Vacuum Delay/Sustain Valves, Ported Vacuum Switches, Vacuum Line Filters, Vacuum Control Vacuum Switch, Solenoid Operated Vacuum Switch, Low Vacuum Enrichment Device

VACUUM SCHEMATICS

DIAGNOSIS AND TESTING

Functional Checks, Manifold Fittings, PCV System Functional Check, Air Cleaner Temperature Control, Carburettor Adjustments, Two Port Vacuum Switch, Diagnosis Chart, Three Port Vacuum Switch, Exhaust Gas Recirculation System Distributor Component Check, Vacuum Delay Valve Test, Vacuum Controlled, Vacuum Switch, Throttle Nudger Setting, Solenoid Controlled Vacuum Switch

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