FORD CORTINA Mark 2 Workshop Service Manual | PDF Download

This Ford Workshop Manual has repair and adjustment procedures applicable to all the Ford Cortina Mark 2 range and includes component illustrations wherever possible, technical specifications and details of any tools or equipment that may be required.

Ford Cortina Mark 2 Models covered in this Manual:

• Ford Cortina Standard Models
• Ford Cortina De Luxe Models
• Ford Cortina Super Models
• Ford Cortina GT Models
• Ford Cortina 1600E
• Sedans and Estate Cars
• Right and Left Hand Drive Models

Detailed list of items covered in this manual:

• WHEELS, HUBS AND TYRES
  • WHEEL ASSEMBLIES - ROAD WHEELS - BALANCE
  • FRONT WHEEL STUDS - RENEW
  • FRONT WHEEL HUB ASSEMBLIES - REMOVE AND INSTALL
  • REAR WHEEL STUDS - RENEW
  • BRAKE DISCS - REMOVE AND INSTALL
  • BRAKE DRUMS - REAR - REMOVE AND INSTALL
  • WHEEL BEARINGS - LUBRICATE AND ADJUST
  • WHEEL BEARING CUPS - FRONT WHEELS - RENEW
  • WHEEL BEARINGS - REAR - REMOVE AND INSTALL
• BRAKES
  • BRAKE SERVO UNIT - OVERHAUL
  • FRONT BRAKE CALLIPERS - BOTH - REMOVE AND INSTALL
  • FRONT BRAKE CALLIPER PISTONS AND/OR SEALS - ONE- RENEW
  • FRONT BRAKE CALLIPER PISTONS AND/OR SEALS - RENEW
  • FRONT BRAKE CALLIPER SPLASH SHIELDS - REMOVE AND INSTALL
  • FRONT BRAKE DISCS - REMOVE AND INSTALL
  • BRAKE MASTER CYLINDER - OVERHAUL (SINGLE LINE)
  • BRAKE MASTER CYLINDER - OVERHAUL (DUAL LINE)
  • BRAKE MASTER CYLINDER - OVERHAUL (DUAL LINE WITH SERVO)
  • REAR BRAKE SHOES AND/OR RETRACTING SPRINGS - ALL - RENEW
  • REAR WHEEL CYLINDERS - REMOVE AND INSTALL
  • REAR WHEEL CYLINDERS - OVERHAUL
  • REAR BRAKE CARRIER PLATES – REMOVE AND INSTALL
  • DIFFERENTIAL VALVE ASSEMBLY - OVERHAUL
• STEERING GEAR AND LINKAGE
  • STEERING GEAR - ADJUST
  • STEERING GEAR ASSEMBLY- OVERHAUL
  • FRONT WHEEL TOE-IN AND WHEEL LOCK ANGLES -ADJUST
  • FRONT WHEEL ALIGNMENT - CHECK
  • FRONT WHEEL ALIGNMENT- CHECK AND ADJUST
• REAR AXLE
  • REAR AXLE HOUSING – RENEW
  • REAR AXLE SHAFT AND BEARING ASSEMBLY - REMOVE AND INSTALL
  • REAR AXLE SHAFT OR BEARING AND OIL SEAL - RENEW
  • DIFFERENTIAL ASSEMBLY - REMOVE AND INSTALL
  • DIFFERENTIAL ASSEMBLY - OVERHAUL
  • DRIVE SHAFT UNIVERSAL JOINT - OVERHAUL
  • DRIVE PINION OIL SEAL - RENEW
• FRONT SUSPENSION
  • TRACK CONTROL ARM INNER BUSHES - RENEW
  • TRACK CONTROL ARM ASSEMBLIES - REMOVE AND INSTALL
  • SUSPENSION COIL SPRING - BOTH – REMOVE AND INSTALL
  • BUMP RUBBER - RENEW
  • FRONT SUSPENSION TOP MOUNT ASSEMBLY - RENEW
  • FRONT SUSPENSION UNIT ASSEMBLIES - REMOVE AND INSTALL
  • FRONT SUSPENSION UNITS - OVERHAUL
• REAR SUSPENSION
  • REAR SHOCK ABSORBERS - REMOVE AND INSTALL
  • RADIUS ARMS - REMOVE AND INSTALL
  • REAR LEAF SPRING ASSEMBLIES – REMOVE AND INSTALL
  • REAR SPRING LEAF - RENEW
  • REAR SPRING SHACKLE PLATES AND/OR BUSHES - REMOVE AND INSTALL
  • REAR SPRING FRONT AND REAR BUSHES - RENEW
  • REAR SPRING 'U' BOLTS – REMOVE AND INSTALL
  • SPRING INSULATORS - RENEW (1600E ONLY)
• ENGINE
  • ENGINE- TUNE
  • ENGINE - CHECK COMPRESSION
  • ENGINE ASSEMBLY - REMOVE AND INSTALL
  • CYLINDER ASSEMBLY - REPLACE
  • CYLINDER BLOCK - REPLACE
  • CYLINDER BLOCK - REBORE
  • CYLINDER BLOCK - SLEEVE
  • FRONT COVER AND/OR OIL SEAL - REMOVE AND INSTALL
  • TIMING CHAIN - REMOVE AND INSTALL
  • ENGINE FRONT MOUNTINGS - RENEW
  • VALVES - ALL - REMOVE AND INSTALL
  • DECARBONISE CYLINDER HEAD, PISTONS, RESET AND GRIND VALVES
  • VALVE GUIDES
  • CYLINDER HEAD - REMOVE AND INSTALL
  • CAMSHAFT BEARINGS – RENEW
  • CRANKSHAFT REAR OIL SEAL AND/OR CARRIER - RENEW
  • FLYWHEEL RING GEAR - RENEW
  • VALVE CLEARANCES - ADJUST
  • ROCKER SHAFT AND/OR PUSH RODS – REMOVE AND INSTALL
  • ROCKER SHAFT - OVERHAUL
  • VALVE SPRINGS AND/OR STEM SEALS – ALL RENEW
  • OIL PUMP - OVERHAUL
  • TIMING CHAIN TENSIONER - REMOVE AND INSTALL
  • MAIN BEARING CLEARANCES
  • MAIN BEARING LINERS - CHECK CLEARANCES AND RENEW
  • CONNECTING ROD LINERS - RENEW
  • PISTON RINGS - REMOVE AND INSTALL
  • PISTONS - REMOVE AND INSTALL
  • CONNECTING RODS AND PISTON PINS - REMOVE AND INSTALL
• EXHAUST SYSTEM
  • EXHAUST SYSTEM - RENEW
  • EXHAUST SYSTEM INLET PIPE ASSEMBLY - RENEW
  • EXHAUST SYSTEM OUTLET PIPE ASSEMBLY - RENEW
• CLUTCH AND GEARBOX (MANUAL TRANSMISSION)
  • CLUTCH RELEASE BEARING - RENEW
  • CLUTCH DISC AND/OR PRESSURE PLATE - REMOVE AND INSTALL
  • CLUTCH PILOT BEARING - RENEW
  • SELECTOR MECHANISM - OVERHAUL
  • THIRD/TOP SYNCHRONISER ASSEMBLY - OVERHAUL
  • FIRST/SECOND SYNCHRONISER ASSEMBLY - OVERHAUL
  • MAIN DRIVE GEAR BEARING RETAINER OIL SEAL - RENEW
  • MAIN DRIVE GEAR - REMOVE AND INSTALL
  • COUNTERSHAFT GEAR - REMOVE AND INSTALL
  • REVERSE IDLER GEAR - REMOVE AND INSTALL
  • REVERSE SELECTOR FORK - REMOVE AND INSTALL
  • GEARBOX ASSEMBLY - OVERHAUL
  • EXTENSION HOUSING - REMOVE AND INSTALL
  • COLUMN GEARCHANGE LINKAGE - OVERHAUL
  • CLUTCH HYDRAULIC SLAVE CYLINDER- OVERHAUL
  • CLUTCH HYDRAULIC MASTER CYLINDER - OVERHAUL
• AUTOMATIC TRANSMISSION
  • AUTOMATIC TRANSMISSION ASSEMBLY - REMOVE AND INSTALL
  • FRONT PUMP - REMOVE AND INSTALL
  • FRONT PUMP - OVERHAUL
  • FRONT OR REAR CLUTCHES, PRIMARY SUN GEAR OR FRONT BAND - REMOVE AND INSTALL
  • GEAR SET, ONE-WAY CLUTCH, CENTRE SUPPORT, SUN GEAR AND SHAFT ASSEMBLY AND/OR REAR BAND - REMOVE AND INSTALL
  • PARKING GEAR AND/OR OUTPUT SHAFT - REMOVE AND INSTALL
  • SELECTOR AND PARKING PAWL LEVERS - REMOVE AND INSTALL
  • GEARBOX CASE - RENEW
  • AUTOMATIC TRANSMISSION - OVERHAUL
  • DOWNSHIFT CABLE - RENEW
  • FRONT SERVO - REMOVE AND INSTALL
  • FRONT SERVO - OVERHAUL
  • REAR SERVO - REMOVE AND INSTALL
  • REAR SERVO - OVERHAUL
  • VALVE BODIES ASSEMBLY OR OIL PICK-UP TUBES - REPLACE
  • VALVE BODIES ASSEMBLY - OVERHAUL
  • GOVERNOR ASSEMBLY - REMOVE AND INSTALL
  • GOVERNOR ASSEMBLY – OVERHAUL
  • STARTER INHIBITOR SWITCH - RENEW
• COOLING SYSTEM
  • RADIATOR ASSEMBLY-REMOVE AND INSTALL
  • DRAIN PLUG- REMOVAL AND INSTALL
  • RADIATOR GRILLE- REMOVE AND INSTALL
  • RADIATOR TOP HOSE - RENEW
  • RADIATOR BOTTOM HOSE- RENEW
  • WATER PUMP ASSEMBLY - REMOVE AND INST ALL
  • WATER PUMP- OVERHAUL
  • FAN- REMOVE AND INSTALL
  • FAN BELT- RENEW
  • FAN BELT-ADJUST
• FUEL SYSTEM
  • FUEL SYSTEM AND CARBURETTOR- CLEAN
  • FUEL TANK - REMOVE AND INSTALL
  • FUEL GAUGE TANK UNIT - REMOVE AND INSTALL
  • FUEL GAUGE- REMOVE AND INSTALL
  • FUEL PUMP - REMOVE AND INSTALL
  • FUEL PUMP DIAPHRAGM - RENEW
  • FUEL PUMP MECHANISM - OVERHAUL
  • FUEL PUMP VALVES- RENEW
  • FUEL PUMP DIAPHRAGM AND VALVES- RENEW
  • FUEL PUMP - OVERHAUL
  • CARBURETTOR-OVERHAUL
  • CARBURETTOR- ADJUST
  • CARBURETTOR JETS AND FLOAT CHAMBER - CLEAN
  • AIR CLEANER- REMOVE AND INSTALL
  • CHOKE CONTROL CABLE - RENEW
  • THROTTLE CONTROL ROD - REMOVE AND INSTALL
  • THROTTLE PEDAL ASSEMBLY - REMOVE AND INSTALL
• ELECTRICAL SYSTEM
  • CHARGING SYSTEM
    • GENERATOR ASSEMBLY - REMOVE AND INSTALL
    • GENERATOR PULLEY - REMOVE AND INSTALL
    • GENERATOR BRUSHES - RENEW AND COMMUTATOR - CLEAN
    • GENERATOR ASSEMBLY - OVERHAUL
    • GENERATOR FRONT BEARING - RENEW
    • CHARGING CIRCUIT - TEST AND ADJUST
    • VOLTAGE REGULATOR UNIT - REMOVE AND INSTALL
  • STARTING SYSTEM
    • STARTER MOTOR ASSEMBLY- REMOVE AND INSTALL
    • STARTER MOTOR DRIVE COMPONENTS- REMOVE AND INSTALL
    • STARTER MOTOR BRUSHES - RENEW AND COMMUTATOR - CLEAN
    • STARTER MOTOR - OVERHAUL
    • STARTER SOLENOID - REMOVE AND INSTALL
  • IGNITION SYSTEM
    • IGNITION COIL - REMOVE AND INSTALL
    • DISTRIBUTORAS SEMBLY - REMOVE AND INSTALL
    • GOVERNOR WEIGHTS AND SPRINGS - RENEW
    • VACUUM UNIT- RENEW
    • DISTRIBUTOR - OVERHAUL
    • DISTRIBUTOR ASSEMBLY - TEST AND ADJUST
    • CONTACT BREAKER POINTS - RENEW
    • CONDENSER - RENEW
    • SPARK PLUGS - REMOVE AND INST ALL
    • SPARK PLUGS - CLEAN AND RESET
  • INSTRUMENTS, CONTROLS AND ANCILLARIES
    • INSTRUMENTS, CONTROLS AND ANCILLARIES
    • FUEL GAUGE - REMOVE AND INSTALL
    • INSTRUMENT VOLTAGE REGULATOR - REMOVE AND INSTALL
    • AMMETER - REMOVE AND INSTALL
    • DUAL BRAKE TEST LIGHT AND/OR BULB - REMOVE AND INSTALL
    • OIL PRESSURE GAUGE - REMOVE AND INSTALL
    • TEMPERATURE GAUGE - REMOVE AND INSTALL
    • IGNITION SWITCH AND/OR LOCK BARREL – REMOVE AND INSTALL
    • COMBINED LIGHT SWITCH, PANEL SWITCH, DUAL BRAKE TEST SWITCH AND HAZARD LIGHT SWITCH ASSEMBLY - REMOVE AND INSTALL
    • HEADLAMPS - ALIGN
    • HEADLAMP SEALED BEAM UNITS - REMOVE AND INSTALL
    • COMBINED DIRECTION INDICATOR AND HAZARD WARNING LAMP ASSEMBLY - REMOVE AND INSTALL - (U.S. ONLY)
    • FRONT INDICATOR AND/OR SIDE LAMP ASSEMBLY - REMOVE AND INSTALL
    • DIRECTION INDICATOR, HEADLAMP FLASHER AND HORN SWITCH ASSEMBLY - REMOVE AND INSTALL
    • FLASHER UNIT - REMOVE AND INSTALL
    • COMBINED DIRECTION INDICATOR AND HAZARD WARNING LAMP LENS AND/OR BULB – REMOVE AND INSTALL - (U.S. ONLY)
    • REAR DIRECTION INDICATOR AND/OR STOP/TAIL LAMP BULBS - REMOVE AND INSTALL
    • REAR DIRECTION INDICATOR AND/OR STOP/TAIL LAMP BULBS - REMOVE AND INSTALL
    • REAR LAMP ASSEMBLIES - BOTH - REMOVE AND INSTALL
    • REAR LAMP BEZELS AND/OR LENS - BOTH SIDES - REMOVE AND INSTALL
    • STOP LAMP SWITCH - REMOVE AND INSTALL
    • REAR LICENCE PLATE LAMP - REMOVE AND INSTALL
    • INSTRUMENT PANEL LIGHT SWITCH - REMOVE AND INSTALL
    • INTERIOR LIGHT- REMOVE AND INSTALL
    • HORN - REMOVE AND INSTALL
    • WARNING LIGHT BULB - RENEW
    • FUSE BLOCK ASSEMBLY - REMOVE AND INSTALL
    • CLOCK AND/OR BULB - REMOVE AND INSTALL
    • CIGARETTE LIGHTER ASSEMBLY - REMOVE AND INSTALL
    • SPEEDOMETER HEAD - REMOVE AND INSTALL
    • SPEEDOMETER INNER AND OUTER CABLES – REMOVE AND INSTALL
    • TACHOMETER - REMOVE AND INSTALL
    • WINDSCREEN WIPER ASSEMBLY - REMOVE AND INSTALL
    • WINDSCREEN WIPER MOTOR BRUSHES - RENEW
    • WINDSCREEN WIPER MOTOR OR LINKAGE - RENEW
    • WINDSCREEN WIPER LINKAGE - OVERHAUL
    • WINDSCREEN WIPER MOTOR - OVERHAUL
    • COMBINED WINDSCREEN WIPER AND WASHER SWITCH ASSEMBLY - REMOVE AND INSTALL
    • HEATER CONTROLS ASSEMBLY- REMOVE AND INSTALL
    • HEATER CONTROL CABLES - ADJUST
    • HEATER ASSEMBLY - REMOVE AND INSTALL
    • HEATER RADIATOR - REMOVE AND INSTALL
    • HEATER MOTOR - REMOVE AND INSTALL
    • FACE LEVEL VENT- REMOVE AND INSTALL
    • HEATER CONTROLS BEZEL - REMOVE AND INSTALL
    • HEATER CONTROLS MOUNTING PANEL - REMOVE AND INSTALL
  • WIRING SYSTEM
    • ILLUSTRATIONS OF LOOM CONNECTIONS WIRING DIAGRAMS
    • FACIA PANEL - Standard, De-luxe and Super
    • FACIA PANEL – G.T.
    • Engine Compartment- Right-hand Side
    • Engine Compartment - Left-Hand Side
    • Front Lights
    • WIRING DIAGRAM - R.H.D. AND L.H.D. CARS - STANDARD, DE LUXE AND SUPER MODELS
    • WIRING DIAGRAM - R.H.D AND L.H.D. CARS - G.T. AND 1600 MODELS
• BODYWORK
  • BUMPER BAR - FRONT- REMOVE AND INSTALL
  • BUMPER BAR - REAR - REMOVE AND INSTALL
  • RADIATOR GRILLE - REMOVE AND INSTALL
  • BONNET ASSEMBLY - REMOVE AND INSTALL
  • BONNET STRIKER POST - REMOVE AND INSTALL
  • BONNET LOCK ASSEMBLY - REMOVE AND INSTALL
  • BONNET SAFETY CATCH - REMOVE AND INSTALL
  • BONNET SAFETY CATCH STRIKER PLATE – REMOVE AND INSTALL
  • BONNET STAY - REMOVE AND INSTALL
  • BONNET HINGE - REMOVE AND INSTALL
  • DOOR ASSEMBLY - REMOVE AND INSTALL
  • FRONT DOOR UPPER OR LOWER HINGE - REMOVE AND INSTALL
  • DOOR EXTERIOR HANDLE - REMOVE AND INSTALL
  • DOOR EXTERIOR HANDLE - OVERHAUL
  • DOOR CHECK STRAP - REMOVE AND INSTALL
  • DOOR STRIKER PLATE - REMOVE AND INST ALL
  • DOOR REMOTE CONTROL HANDLE - REMOVE AND INSTALL
  • WINDOW REGULATOR HANDLE- REMOVE AND INSTALL
  • DOOR TRIM PANEL - REMOVE AND INSTALL
  • WINDOW REGULATOR ASSEMBLY - REMOVE AND INSTALL
  • DOOR LOCK ASSEMBLY - REMOVE AND INSTALL
  • DOOR REMOTE CONTROL ASSEMBLY - REMOVE AND INSTALL
  • FIXED VENT WINDOW GLASS AND/OR WEATHERSTRIP - REMOVE AND INSTALL
  • DOOR WINDOW GLASS SILENT CHANNEL – REMOVE AND INSTALL
  • DOOR WINDOW GLASS - REMOVE AND INSTALL
  • LUGGAGE COMPARTMENT LID ASSEMBLY – REMOVE AND INSTALL
  • LUGGAGE COMPARTMENT STRIKER POST – REMOVE AND INSTALL
  • LUGGAGE COMPARTMENT LOCK BARREL - REMOVE AND INSTALL
  • LUGGAGE COMPARTMENT TORSION BARS - REMOVE AND INSTALL
  • LUGGAGE COMPARTMENT HINGES - REMOVE AND INSTALL
  • ESTATE CAR TAILGATE LOCK - REMOVE AND INSTALL
  • TAILGATE DOOR LOCK STRIKER PLATE- REMOVE AND INSTALL
  • TAILGATE DOOR EXTERNAL HANDLE ASSEMBLY - REMOVE AND INSTALL
  • TAILGATE DOOR HINGE AND TORSION BAR ASSEMBLY - REMOVE AND INSTALL
  • WINDSCREEN GLASS AND/OR MOULDING – REMOVE AND INSTALL
  • REAR WINDOW GLASS AND/OR MOULDING – REMOVE AND INSTALL
  • REAR QUARTER WINDOW GLASS AND/OR MOULDING - REMOVE AND INSTALL
  • AEROFLOW EXTERIOR EXTRACTION LOUVRE – REMOVE AND INSTALL (SALOON)
  • AEROFLOW EXTERIOR EXTRACTION LOUVRE – REMOVE AND INSTALL (EST ATE CAR)
  • FRONT PARCEL SHELF - REMOVE AND INSTALL
  • COWL SIDE TRIM PANEL - REMOVE AND INSTALL
  • REAR PARCEL SHELF - REMOVE AND INSTALL
  • REAR QUARTER TRIM PANEL - REMOVE AND INSTALL
  • DRIP RAIL MOULDING - REMOVE AND INSTALL
  • REAR SEAT BACKREST (SALOON) - REMOVE AND INSTALL
  • REAR SEAT BACKREST (ESTATE CAR) - REMOVE AND INSTALL
  • REAR SEAT CUSHION (SALOON) - REMOVE AND INSTALL
  • REAR SEAT CUSHION (ESTATE CAR) - REMOVE AND INSTALL
  • BUCKET SEAT - FRONT - REMOVE AND INSTALL
  • BENCH SEAT ASSEMBLY- REMOVE AND INSTALL
  • INTERIOR MIRROR - REMOVE AND INSTALL
  • SUN VISOR - REMOVE AND INSTALL
  • GLOVE LOCKER LID - REMOVE AND INSTALL
  • HEATER TRIM PANEL - REMOVE AND INSTALL
  • HEADLINING - RENEW (SALOON)
  • HEADLINING - RENEW (ESTATE CAR)
• LUBRICATION AND MAINTENANCE
• SERVICE DATA
• SPECIAL TOOLS

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