Werkstatthandbuch Book 2 · Seiten 1–100

Volume3,4,&5 Electrical,Body,&Maintenance

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

GROUP AND PART INDEX VOLUME 3 ELECTRICAL IDENTIFICATION CODES GROUP 30 CHARGING SYSTEM GROUP 31 10000 IDENTIFICATION CODES - 30-01 LIGHTING SYSTEMALTERNATOR - Flectro-Mechanical Regulator 31-40

GROUP AND PART INDEX CONT’D. LVOLUME 3 ELECTRICAL I I 34-30 WIRING HARNESS - Dash-to-Headlight Junction 34-10 - Dash Panel-to-Engine 34-20 - Instr

foreword... This 1978 Car Shop Manual has been prepared to provide information covering normal service repairs and maintenance for 1978 Ford Passenger Cars manufactured in the United States and Canada. It is divided into five volumes, each covering a specific major area: Volume 1 - Chassis Volume 3 - Electrical Volume 5 - Maintenance and Volume 2 - Engine Volume 4 - Body Lubrication. Information in each volume is divided into Groups covering a general system. The table of contents on the cover of each volume indicates the Group title number and volume in which each Group is located. For 1978, the basic part number for components covered in the Groups is also included in parenthesis after the Group number. Example:

30-00-1 Identification Codes 30-00-1 GROUP IDENTIFICATION CODES 30 PART Car Identification Codes 30-01 GENERAL DESCRIPTION OFFICIAL VEHICLE IDENTIFICATION NUMBER The official Vehicle Identification Number 500,001-Mercury, Cougar, Zephyr, Monarch VIN Fig. 1 for title and registration purposes is and Mercury Bobcat. stamped on a metal tab that is fastened to the 800,001- Lincoln Continental and Continental instrument panel close to the windshield on the Mark V. driver’s side of the car and is visible from outside. The remaining information on the V.C.

30-01-2 Car Identification Codes 30-01-2 8563H1OOOO1 MED. BY FORD MOTOR co. IN u.S.A. I VEHICLE IDENTIFICATION NUMBER I MFD. BY FORD MOTOR CO. IN U.S.A. DATE 08/77 GVWR 5892 DATE: 08;77 GVWR 6538 UASR I:RONr 2964 REAR 2928 GAWR: FRONT 2964. REAR 3375 THIS VEHICLE 1.NLFA JL’REI FOR EXPOR1 ONLY ON DATE THIS VEHICLE CONFORMS TO ALE SUO%N ABOVE:

30-01-3 Car identification Codes 30-01-3 IDENTIFICATION CODES DISTRICT CODES DISTRICT CODES ASSEMBLY PLANT CODES LINCOLN-MERCURY FORD Code Letter Districe Code Divrrict Code 0 intricl A Atlanea 00 Special 00 Special B Dakeille Canada 11 Bostor Ii Bos

_____ 30-01-4 Car Identification Codes 30-01-4 BODY SERIAL AND STYLE CODES Body Body Body Body Serial Style Serial Style Vehicle Code Code Body Type Model Vehicle Code Code Body Type Model PINTO ID 620 2-Dr. Sedan Base COUGAR 92 530 4-Or, Pillar Hardlop Cougar 11 64 B 3Dr. Sedan Base 91 65D

31-01-1 Charging System 31-01-1 GROUP CHARGING SYSTEM 31 PART TITLE PART NO. PART TITLE PART NO. Alternator Electra-Mechanical Regulator 31-40 Charging System General Service 31-01 Alternator Electronic Regulator 31-43 FED Rear Terminal Alternator 31-10 Alternator Transistorized Regulator 31-42 EED Side Terminal Alternator 31-12 Batteries 31-02 PART Charging System General Service 31-01 Applies to All M

31-01-2 Charging System General Service 31-01-2 THUNDERBIRD, LINCOLN CONTINENTAL. FORD, MERCURY. LTD II, FAIRMONT, &MJSTANG II AIC cOUGAR AND CONTINENTAL MARK V ZEPHYR, GRANADA. MONARDI. J1431 2F VERSAILLES, PINTO AND DOeCAT FIG. 1 Fuse Link Installation "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford

31-01-3 Charging System General Servtce 31-01-3 DIAGNOSIS CHARGING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE RESOLUTION * Battery does not stay charged - * Battery * Test battery, replace if necessary engine starts OK * oo or warn alternator belt s Adjust or replace belt * Damaged wiring or Cables * Service as required * Alternator * Test, repair or replace as required * Regulator * Test, replace if necessary

__________ __ ____________________ 31-01-4 Charging System General Service 31-01-4 GENERALCHARGINGSVSTEMTEST I I PRELIMINARY CHECKS . FUSE LINK . BATTERY TERMINALS AND CABLE CLAMPS S WIRING CONNECTIONS AT ALTERNATOR. REGULATOR AND ENGINE * ALTERNAT

31-01-5 Charging System General Service 31-01-5 TESTING A Voltmeter 0 to 20 volt sCale, ohmmeter, jumper With ignition switch on engine running charge wire and a test light 12 volt ore the only tools required indicator-Alternator lamp is off. to perform on accurate check of the complete charging 1. If the charge indicator lamp does not come on with system. The meters should be calibrated once a year the ignition key in the on position and the engineand the dote of calibration stamped on the meter face. not running, check the I wiring circuit ignition It is recommended that this practice be follo

31-01-6 Charging System General Service 31-01-6 INDICATE RETWEEN METED SHOULDNo Load Test 4 AND 250 OHMS 1. Then, start the engine and increase speed to approximately 1500 rpm. With no other electrical A LOWER load foot off brake pedal and car doors closed, READINGINDICATES A the voltmeter pointer should move upwa

CO C 31-01-7 Charging System General Service 31-01-7 JUMPER WIRE CONNECTED JUMPER WIRE TO ALTERNATOR TO ALTERNATOR "BAT AND ‘FLD’ TERMINALS B AT" AND "F LD " TERMINA LS REGULATOR PLUG REMOVED

31-01-8 Charging System General Service 31-01-8 BENCH TESTS Rectifier Short or Grounded and Stator Grounded FIELD FRONT Test TERMINAL These tests are performed with an 02-0364 tester or equivalent. Set the "Multiply By" knob at 10, and calibrate the ohmmeter as directed inside the instrument cover. 1. Contact one ahmeter probe to the alternator BAT terminal Fig. 5 and the other probe to the STA terminal rear blade terminal. Then, reverse the ohmmeter probes and repeat the test. A reading of about 60 ohms should be obtained in one direction and no needle movement with the probes reversed. A read

31-01-9 Charging System General Service 31-01-9 CONTACT EACH TERMINAL CONTACT EACH TERMINAL CONTACT DIODE FLATE Ji 211-IF CONTACT TERMINAL SCREW .11567-in FIG. 7 Diode Test-Rear Terminal Alternator FIG. 8 Diode Test-Side Terminal Alternator Except 61-Ampere touching the rotor shaft, or that excess solder is notRotor Open or Short Circuit Test grounding

_______ ____________ ___ 31-01-10 Charging System General Service 31-01-10 3. Disconnect the fuse link and/or fuse link eyelet NOTE: The charge Indicator fight circuit must be terminal from the battery terminal of the starter tested with a test lamp containing a trade number relay. On the Thunderbird, Lincoln Continental and 97 bulb. the Continental Mark V, the fuse link is looped outside of the wire harness behind the point at Disconnect the regulator connector from the which the harness is clipped to the right rocker regulator. Turn the ignition switch to RUN position. Touch one test probe fr

31-01-11 Charging System General Service 31-01-11 WIRING ASSEMBLY-FUSE LINK WITH INSULATION STRIPPED BOTH ENDS BUTT CONNECTOR -WIRING SPLICE D3AZ-14A526-H # 14GAUGE WIRE-9.00"+,bQ LENGTH GREEN INSULATION D3AZ-14A526.J 1$ GAUGE WIRE 9,00" ± .50 LENGTH ORANGE INSULATION AS PEO’D. D3AZ-l4526-K # 17 GAUGE WIRE - 9.00" ±50 LENGTH YELLOW INSULATION AS REO’D, SPECIAL USED WITH AIR CONDITIONING SYSTEM 03AZ14A526-L #18 GAUGE WIRE -900+ -50 LENGTH RED INSULATION AS REO’D D3AZ-14A526-M # 2OGALJGE WIRE -9.00" ± .50 LENGTH BLUE INSULATION AS REDO.

31-02-1 Batteries 31-02-1 PART Batteries 31-02 Applies to All Models SUBJECT PAGE SUBJECT PAGE TESTING 021 SPECIFICATIONS 02-2 CK3360-2B TESTING CAUTION: Hydrogen and oxygen gases are generator set, even when cranking loads are relatively produced during normal battery operation. This light. Extensive starting motor damage is more likely if gas mixture can explode if flames, sparks or l

3 1-02-2 Batteries 3 1-02-2 2. Turn the voltmeter selector switch to the 20-volt 8. If the difference between any two cells is more than position. 50 points 0.050, the battery is not satisfactory for service and should be replaced. 3. Connect both positive test leads to the positive battery post and both negative leads to the 9. If the difference between cells is less than 50 points negative battery post. The voltmeter clips must 0.050, the battery should be charged according contact the battery posts and not the high-rate to the charging schedule in the Specifications d

31-10-1 E.E.D. Rear Terminal Alternator 31-10-1 PART ESEID. RearTerminal Alternator 31-10 Applies to All Models SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 10-1 REMOVAL AND INSTALLATION 10-3 TESTING 10-2 DISASSEMBLY AND OVERHAUL 10-5 ADJUSTMENTS SPECIFICATIONS AND Belt Adjustment 10-2 SPECIAL TOOLS 10-7

31-10-2 E.E.D. Rear Terminal Alternator 31-10-2 BATTERY TERMINAL OF STARTER RELAY J1ZU52K FIG. 2 Alternator Charging System-Ammeter If an ammeter is used in the charging system Fig.through the regulator A terminal and is metered to the 2, the regulator I terminal and the alternator statoralternator field. terminal are not used. When the ignition

31-10-3 E.E.D. Rear Terminal Alternator 31-10-3 REMOVAL AND INSTALLATION CAUTION: Exercise care. Do not permit flames, Installationsparks or lighted tobacco near battery. 1. Position the alternator to the engine, and install the Removal spacer if used and the alternator mounting bolt I. Disconnect the battery ground cable. Tighten the bolt to a snug position. 2. Loosen the alternator mounting bolts and remove 2. Install the adjustment arm to alternator attaching the adjustment arm alternator attaching bolt. bolt. Disengag

31-10-4 E.E.D. Rear Terminal Alternator 31-10-4 STATOR FRONT HOUSING REAR HOUSING 10336 10333 RECTIFIER ASSEMBLY 10304 REAR BEARING FRONT BEARING 1OA304

31-10-5 E.E.D. Rear Terminal Alternator 31-10-5 on the shaft and into the groove. Do not open the 7. Place the brush springs, brushes, brush terminal and ring with snap ring pliers as permanent terminal insulator in the brush holder and hold the damage will result brushes in position by inserting a piece of stiff wire in the brush holder as shown in Fig. 8. SQUARE STATOR TERMINAL INSULATOR - PART OF 0304 KIT r-.

31-10-6 E.E.D. Rear Terminal Alternator 31-10-6 ALIGN SQUARE INSULATOR WITII SQIIAFF HOLE IN DIOUL PLAIN THE UROUND STUD IS FULLY INSTALLED INTO RECTIFIER WHEN BUILT. DO NOT REMOVE OROUND SCREW FXCEPT TO REPAIR STATOR OH REPLACE SCREW OR WASHER NEUTRAL LEAD

31-10-7 EE.D. Rear Terminal Alternator 31-10-7 SPECIFICATIONS ALTERNATOR Slip-Ring Brush I I Field Turning Length Pulley I - i Inches T

31-12-1 E.E.D. Side Terminal Alternator 31-12-1 PART E.E.D. Side Terminal Alternator 31-12 Applies to All Models SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 12-1 MAJOR REPAIR OPERATIONS Brush Replacement 12-5 TESTING 12-2 Overhaul 123 Rectifier Replacement 12-5 ADJUSTMENTS Belt Adjustment

31-12-2 E.E.D. Side Terminal Alternator 31-12-2 BATTERY TERMINAL OF STORTER RELAY SLIP RiNGS SLIP RINGS INDICATOR LIGHT AMMETER J1637.24 FIG. 2 90-Ampere Side Terminal Alternator Charging System TESTING ON VEHICLE TESTS Check the alternator drive belt and adjust t to specification, if necessary, before proceeding with any tests. Do not run the engine with the battery disconnected. Refer to Part 31-01 for Charging System Diagnosis and Test Procedures. ADJUSTMENTS

31-12-3 E.E.D. Side Terminal Alternator 31-12-3 3. Remove the electrical connectors from the alternator Fig. 3. The stator and field connectors are the push-on blade type with a lock that engages with the alternator housing. Depress the lock tab BATTERY and pull the connector straight off the terminals to TERMINAL TERMINALFIELD prevent damage to them and the connector. 4. Remove the alternator attaching bolt, and remove the alternator. BLACK UHANUE Installation 1. Position the alternator to the engine, and install the spacer if used and the alternator attaching bolt. Tighten the bolt

31-12-4 E.E.D. Side Terminal Alternator 31-12-4 11. Remove the two terminal nuts and insulator from outside the housing, and remove the rectifier from the housing. 12. Remove two screws attaching the brush holder to the housing and remove the brushes and holder. 13. Remove any sealing compound from the rear housing and brush ho

31-12-5 E.E.D. Side Terminal Alternator 31-12-5 8. Place the two rectifier insulators an the bosses 3. Unsolder and disengage the brush holder from inside the housing Fig. 8. the rear housing. Remove brushes and springs from brush holders. 4. Remove the two brush holder attaching screws and lift the brush holder from the rear housing. BRUSH 5. Remove any sealing compound from the rear HOLDER housing and brush holder.

31-12-6 E.E.D. Side Terminal Alternator 31-12-6 3. Place the insulator on the BAT large terminal of 8. position the stator in the rear housing and align the the rectifier, and position the rectifier in the rear scribe marks. Press the three stator leads on the housing. Place the outside insulator on the BAT rectifier pins and solder securely Fig. 6: Work terminal, and install the nuts on the BAT and GRD quickly to prevent overheating the rectifier. terminals finger tight. 9. Position the rotor and front housing into the stator 4. Install but do not tighten the four rectifier attaching and rear housing. Align the scribe marks, install and screws.

31-40-1 Alternator Electro-Mechanical Regulator 31-40-1 PART Alternator Electro-Mechanical 31-40 Regulator Applies to All Models SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 40-1 ADJUSTMENTS 40-2 TESTING REMOVAL AND INSTALLATION 40-2 Voltage Regulation Calibration Test 40-1 C

31-40-2 Alternator Electro-Mechanical Regulator 31-40-2 than 2,0 volts higher than base voltage, turn on the regulated voltage. Disconnect regulator and check headlamps and heater blower. The full lead voltage alternator and wirin$ harness by placing a jumper should be at least 0.5 volt above the base voltage. wire from "A" to "F" terminals. Check for voltage If the voltage is less than 0.5, find cause of under- at "S" and "1" terminals. Voltage at "S" terminal voltage condition. Replace the regulator if the should be 1/2 voltage reading of "1" terminal. If voltage drop is greater than 1/2 volt below the alternator and harness are okay, replace regulator. ADJUSTMENTS The electra-mechanical regulator is factory calibrated and sealed and is not

31-42-1 Alternator Transistorized Regulator 31-42-1 Alternator Transistorized 31-42 Regulator Applies to All Models SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 42-1 REMOVAL AND INSTALLATION 42-1 ADJUSTMENTS 42-1 CK3364-2B DESCRIPTION AND OPERATION The transistorized voltage regulator controls the sistors and diodes rather than by a vibrating alternator voltage output in a similar manner to an armature relay. The volta

"This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

31-43-1 Alternator Electronic Regulator 31-43-1 PART Alternator Electronic Regulator 31-43 SUBJECT PAGE SUBJECT PAGE DESCRIPTION 43-1 REMOVAL AND INSTALLATION 43-4 CK3544-2A DESCRIPTION The electrical charging systems incorporate a new INDICATOR LAMP REGULATORS Figure 1 electronic voltage regulator. These regulators are Closing the ignition switch energizes the warning100% solid state, consisting of transistors, diodes, and resistors. The working func

31-43-2 Alternator Electronic Regulator 31-43-2 AMMETER REGULATORS Figure 2 the new system, will have a slightly reduced out The operating principle for the regulator used in put. The older model alternator with the 3.8Ohm field will be used as replacement for vehicles withammeter equipped vehicles is much the same as the indicator lamp type. electra-mechanical and electronic regulators. Only the older model will be serviced. 2. Never use an electra-mechanical 77 and prior REGULATOR APPLICATION -

31-43.3 Alternator Electronic Regulator 31-43-3 TO 500 OHM RESISTO9 CHARGING SYSTEM WITH ELECTRONIC REGULATOR AND WARNING LAMP INOICATOR Mffl INDICATOR LAMP V ELECTRUErL REGULATOR CHOKE a V GROUND STARTER MOTOR RELAY

31-43-4 Alternator Electronic Regulator 31-43-4 NAL STUD AT ALTERNATOR AND NOT THE REGULATOR WITH THE IGNITION SWITCH ON GROUND STUD. WILL DESTROY THE REGULATOR. ALWAYS DISCONNECT THE CONNECTOR PLUG BE SURE TO DISCONNECT ELECTRIC CHOKE WIRE FROM THE REGULATOR BEFORE CHECKING AL- FROM STATOR TERMINAL OR ALTERNATOR TERNATOR OUTPUT WITH TEST PROBES OR A WHEN TROUBLE-SHOOTING CHARGING SYS JUMPER WIRE. TEM. CHECK ELECTRIC CHOKE WIRE FOR A ALWAYS DISCONNECT THE CONNECTOR PLUG GROUND CONDITION. FROM THE REGULATOR BEFORE REMOVING THE NEVER ATTEMPT TO POLARIZE OR TEST THE AL- REGULATOR MOUNTING SCREWS. REMOVING TERNATOR BY GROUNDING THE FIELD CIRCUIT, THE CO

32-01-1 Lighting System 32-01-1 GROUP LIGHTING SYSTEM 32 PART TITLE PART NO. PART TITLE PART NO. AUTOMATIC HEADLAMP DIMMER .. -. * . . . 32-15 LAMP DELAY SYSTEM AUTO LAMP 32-12 HEADLAMP COVERS 32-06 LIGHTING SYSTEM GENERAL SERVICE. 32-01 HEADLAMP SYSTEM 32-02 PARKING, REAR AND MARKER LAMPS 32-20 ILLUMINATED ENTRY 32-80 TURN SIGNAL AND HAZARD FLASHER. 32-40 INTERIOR LAMPS 3260 CK3366-2B

32-01-2 Lighting System General Service 32-01-2 DIAGNOSING ELECTRICAL - LAMPS CONDITION POSSIBLE CAUSE RESOLUTION Head Lamps I * All exterior lamps do not light a Loose wiring connections a Check and secure connections at head lamp switch and dash panel connector * Open wiring a Check power to and from

32-01-3 Lighting System General Service 32-01-3 ELECTRICAL - LAMPS I CONDITION POSSIBLE CAUSE RESOLUTION Back-up Lamps a Back-up lamps - both lamps a Fuse burnt out a Check a circuit that shares the same do not function fuse. Replace fuse a Back-up amp switch out of a Adjust switch adjustment a Damaged back-up lamp switch a Replace switch

32-01-4 Lighting System General Service 32-01-4 - LAMPS ELECTRICAL CONDITION POSSIBLE CAUSE RESOLUTION Stop Lamps a Stop Lamps do not light a Fuse burn out or CR. open a Replace fuse or C.B. If device blows again check for short circuit. a Problem in turn signal circuit a Repair turn signal circuit or

32-01-5 Lighting System General Service 32-01-5 COURTESY LAMPS DO NOT TURN COURTESY LAMPS DOES NOT ON WHEN ONE DOOR IS OPENED. COME ON WHEN HEADLAMP SWITCI OK WHEN OTHER DOORS ARE IS TURNED COUNTERCLOCKWISE OPEN ED. TO STOP. VEHICLES WITH ONLY ONE COURTESY LIGHT.

32-02-1 Headlamp System 32-02-1 PART Headlamp System 32-02 Applies to All Models SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION ADJUSTMENTS Autolamp 02-2 Headlamp Aim 02-2 Automatic Headlamp Dimmer 02-2 Dimmer Switch 02-2 REMOVAL AND INSTALLATION Headlamps 02-1 Headlamp Bulb 02-2 Headlamps ON Indicator 02-1 H

32-02-2 Headlamp System 32-02-2 The indicator lamp and/or buzzer is connected between the left-hand front courtesy lamp switch and o relay. The relay completes the indicating circuit and ground when energized by the toil/park lamp feed from the headlamp switch. AUTOMATIC HEADLAMP DIMMER The automatic headlamp dimmer is a driver-operated electronic device which automatically switches the car headlamp beams in response to light from an OISTI BUTDR VALVLapproaching car, or light from the taillamps of a vehiclebeing overtaken. Refer to Part 32-15 for Service KNOB RELEASE/BLFTI ON K2160-1B Procedures. DIMMER SWITCH Switching of the head

32-02-3 Headlamp System 32-02-3 HEADLAMP BEAnING HEADLAMP BULB - 138160 112 REOD ASSY- 13007 -- N2 yII HEADLAMP ADJUSTER SCREW -- AND NUT 13A093 IS REGal ‘7 I

32-02-4 Headlamp System 32-02-4 4. Connect the wiring assembly plug to the new 2. Install the knob and shaft assembly. headlamp bulb and place the bulb in position. 3. Connect the battery ground cable. locating the bulb glass tabs in the positioning slots. 5. Attach the bulb retainer ring to the assembly with the retainer ring screws. LTD II, COUGAR, FAIRMONT, ZEPHYR AND LINCOLN CONTINENTAL LINCOLN CONTINENTAL EOIJIPPED6. If so equipped, place the headlamp door in position WITH POTENTIOMETER REFER TO 32-12 and install the mounting screws. If equipp

32-02-5 Headlamp System 32-02-5 THUNDERBIRD AND CONTINENTAL MARK V WIRING ASSEMBLY 14401 Remove the cluster trim panel, as outlined in Group 33. Remove the switch mounting plate. Remove the bezel nut and disconnect the multiple connector. Then, remove the vacuum lines if so equipped and remove the switch. HEADLAMPS-ON INDICATOR 1. It is available on all cars except Fairmont and Zephyr. 2. It utilizes the key warning buzzer and requires a relay. 3. In addition to the buzzer, the lamps -on indicator utilizes an instrument panel tamp on Mustang and Lincoln Continental. On console-equipped Granada, Monarch and Versailles, the lamp is

32-06-1 Headlamp Covers 32-06-1 PART Headlamp Covers 32-06 Applies Ta Mercury, Ford LTD Landau, Lincoln Continental, Continental Mark V and Thunderbird SUBJECT PAGE SUBJECT PACE DESCRIPTION AND OPERATION Headlamp Covers -- Standard O6- Vacuum Test Probe 06-6 Headlamp Covers Autolamp 06-1 TESTING REMOVAL AND INSTALLATION Covers Will Not Close 06-6 Vacuum Motor 06-7 Covers Will Not Open 06-6 Vacuum Reservoir

3246-2 Headlamp Covers 32-06-2 1 CHECK VALVE MANIFOLD SOURCE HEADLAMP SWITCH VIEW-ba 2 By-PASS VALVE* 38035 **r-- 3

32-06-3 Headlamp Covers 3246-3 FIG. 2 Headlamp Covert and Vacuum System-Continental Mark V "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

32-06-4 Headlamp Covers 32-06-4 FIG. 3 Headlamp Covers and Vacuum System-Lincoln Continental "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

32-06-5 Headlamp Covers 3246-5 IREWc WASHER ASSY - - 5703D-S36 2 REOD. L.H. SIDE PART OF PNL- ASSY. - RAD. GRILLE OPENING FIG. 4 Headlamp Covers and Vacuum System-Thunderbird "This publication contains material that is reproduced and distributed under a license to Detro

32-06-6 Headlight Covers 3246-6 TESTING HEADLAMP COVER VACUUM SYSTEM LEAK TEST VACUUMT77 L 901TEST0-A TOOL A leak test on any part or component of the headlamp cover vacuum system, can be accomplished with the use of the vacuum test probe. Refer to Vacuum Test Probe for fabrication. Io perform the leak test, 3/16CONNECTORTEE plug the probe into the system at the desred point. The 310REDUCERTO 10 4 WAy 3/1$ reading on the gauge should momentarily fall below the preset value of 14 inches of vacuum, If there are no /1E SPLICE leaks in that part of the system being checked, the

32-06-7 Headlamp Covers 32-06-7 2. Check for leaks and kinks or obstructions through 9. If a leak is found, replace the check valve. the check valve from the intake manifold. 10. If no leak was indicated check the headlamp switch, 3. If any irregularities are found, repair or replace the hoses, connectors and motors in the open circuit hose between the intake manifold and the check green hose for kinks or obstructions. valve. 11. If kinks or obstructions are found, replace or repair 4. If no irregularities are encountered, disconnect the as necessary. reservoir hose at the check valve. Check the hose 12. If no kinks or

32-12-1 Headlamp Delay System Autolamp 32-12-1 PART -- Headlamp Delay System Autolamp 32-12 SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 12.1 REMOVAL AND INSTALLATION Complete Checkout Procedure 12-] DIAGNOSIS 12-3 Headlamp Switch and/or Potentiometer 12-4 ADJUS

© © © VACUUM PC BOARD VACUUM F.C. BOARU P.C. BOARD I SOURCE SOURCE CLCSE: OFHN CLOSE OPEN CLOSE OPEN TO SOURCE TO SOURCE TO SOURCE 54 0- I-

32-12-3 Headlamp Delay System Autolamp 32-72-3 VACUUM GAUGES C-CLOSE V-VACUUM 0-OPEN HI/L COVER SOLENOID VACUUM

32-12-4 Headlamp Delay System Autolamp 32-12-4 b. There should be no continuity between blade a. Vacuum should show at nipple C-no vacuum 54 and any other blade. Ground blade 502 to atO. blade 54 to discharge capacitator before b. Light should glow for 30-60 seconds, then go checking. out. 2. Attach vacuum gauges to nipple C and 0. Apply c. Trap vacuum at nipple V-vacuum at nipple C 15 inch vacuum to nippe V. shou’d hod br 1 minute. a. Vacuum should show at nipple C; no vacuum d. Nipple 0 should be open to atmosphere. atO.

32-12-5 Headlamp Delay System Autolamp 32-12-5 6- Disconnect all wires and remove the headlamp Installation switch. 1. Assemble the headlamp switch to the 7. Remove the bracket from the headlamp switch potentiometer, and/or the potentiometer to the Continental Mark V only. headlamp switch. 8. Remove the nut and washer from the potentiometer or headlamp switch Fig. 4J. NOTE: When 2. Then1 secure with nut and washer Fig. 6. assembling, notice that the top straight edge of the potentiometer is located under the two 90 degree 3. Position the bracket to the headlamp switch tabs on the headlamp switch bracket Fig. 5.

32-12-6 Headlamp Delay System Autolamp 32-12-6 5CR EW-42366-52 SCREW 6 REoulneol HEADLAMP COVER CONTRDL ASSEMBLY COVER WIRING 14401 WIRiNG INSTRUMENT

32-12-7 Headlamp Delay System Autolamp 32-12-7 COMPLETE CHECKOUT PROCEDURE FIGS. 6-9 1. Remove sensor amplifier bracket from the lower terminal pins in the amplifier wiring connector to instrument panel support bracket and separate the make sure they are properly installed and in wiring connector from the sensor amplifier. position. 2. Before proceeding with the Circuit Checkout Procedure on the following pages, check all USE A SCREW DRIVER TO TURN THE AD

32-12-8 Headlamp Delay System Autolamp 32-12-8 AUTOLAMP ION/OFF DELAY SYSTEMI OPERATION TAIL LAMP CIRCUIT TEST AND RESULT 12 VOLT TEST LIGHT WITH MANUAL HEADLAMP SWITCH IN PARK OR FULL "ON" POSITION, VOLTAGE SHOULD BE MEASURED AT AUTOLAMP CONNECTOR CIRCUITS NOS 14 AND 14A1 THIS CHECKS FOR CORRECTWIRING TO TAIL

32-12-9 Headlamp Delay System Autolamp 32-12-9 AUTOLAMP ON/OPP DELAY SWITCHI HEADLAMP CIRCUIT BREAKER OPERATION 12 VOLT TEST LIGHT TEST AND RESULT TEST FOR POWER FEED FROM THE HEADLIGHT SWITCH CIRCUIT BREAKER AT AUTOLAMP CONNECTOR, CIRCUIT NO. 221 OR 221A1. NOT

32-12-10 Headlamp Delay System Autolamp 32-12-10 HEADLAMP CIRCUIT CONNECT A 32 VOLT TEST LIGHT BETWEEN TERMINAL NO.12 OR 13 AND A GOOD GROUND 12 VOLT OR WITH MANUAL HEADLAMP SWITCH IN FULL ON P031- TEST LIGHT TION, VOLTAGE SHOULD BE MEASURED AT AUTO. LAMP CONNECTOR. THIS CHECKS FOR CORRECT WIRING TO HEADLAMP CIRCUIT CIRCUIT NO.15 OR

32-15-1 Automatic Headlamp Dimmer 32-15-1 PART Automatic Headlamp Dimmer 32-15 Applies to Continental Mark V and Lincoln Continental SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 15-1 REMOVAL AND INSTALLATION Driver Sensitivity Control 15-4 TESTING 15-1 Foot Dimmer Switch 15-4 Power Relay 15-4 ADJUSTMENTS

32-15-2 Automatic Headlamp Dimmer 32-15-2 of the operation of the unit may lead an owner to c. Disconnect the sensor-amplifier cable at the in-line believe an adjustment or port replacement is necessary. connector. Fabricate a test lamp with a socket and a No. 53 bulb and 2 pieces of wire. Ground one The following checks should be performed, in test lamp lead and touch the other to the yellowsequence, to determine the cause and correction of terminal in the female connector. The test lamptrouble and to eliminate unnecessary service work. This

32-15-3 Automatic Headlamp Dimmer 32-15-3 e.Connect one test lamp lead to battery voltage and c-Complete continuity of the white wire can be touch the other lead to the grey-yellow dot 505 checked by disconnecting the sensor-amplifier terminal in the connector. Operate the foot switch cable from the interconnecting harness at the in two or three times. The test bulb should light in one line connector. Using a test lamp No. 53 bulb, position of the foot switch and the headlights connect one lead to battery voltage and touch the should be on lower beam for both positions of the other to the white terminal in the in-line connector. foot switch. If not, check for loose connections at Pu

32-15-4 Automatic Headlamp Dimmer 32-15-4 REMOVAL AND INSTALLATION SENSOR-AMPLIFIER If the automatic headlamp dimmer malfunctions and cannot be removed for repair immediately, manual operation of the heodlamps may be obtained at the foot dimmer switch, in most cases, by removing the fuse from the fuse holder. The fuse holder is located in the wiring harness near the headlamp switch. Should the car have to be driven with the sensor- amplifier unit removed, manual headlamp beam operation with the foot dimmer switch will be obtained. If both the sensor-amplifier unit and the power relay are removed, manual operation with the foot dimmer switch may be obtained by replacing the override type foot dimmer switch with a standard foot dimmer switch, and plugging the standard car wirin

32-15-5 Automatic Headlamp Dimmer 32-15-5 Installation 1. Position the power relay to the brake pedal BRAKE PEDALSUPPORT support. The terminals of the relay must point down and rearward the vehicle. Install the two attaching screws, 2. Connect the two plug connectors to the power relay. P

32-20-1 Parking, Rear and Marker Lamps 32-20-1 PANT Parking, Rear and Marker Lamps 32-20 Applies to All Models SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 20-1 REMOVAL AND INSTALLATION Cont’d. License Plate Lamp 20-13 REMOVAL AND INSTALLATION Marker Lamps 20-8 Back-up Lamps 20-13 Parking Lamps 20-2 Back-up Lamp Switch 20-1

32-20-2 Parking, Rear and Marker Lamps 32-20-2 REMOVAL AND INSTALLATION PARKING LAMPS remove the screws that retain the headlamp door. Remove screws retaining parking lamp assembly. PullFord the lamp frontwards and remove lamp sockets. The front parking lamps are located in the fender. Cougar and VersaillesTo replace the bulb, remove the door from the lamp assembly. Three screws attach the door. The parking lamps are located in the outboard side of the headlamp doors. To replace the bulb or parking To replace the lamp assembly, unplug the w

32-20-3 Parking, Rear and Marker Lamps 32-20-3 FIG. 3 Parking Lamp Installation-Fairmont Shown Zephyr Similar assembly to the door or grille assembly. Remove the lamp. To install clips, push inward. Locking boss must snap into boss opening. Ta replace the parking lamp body assembly remove the socket from the parking lamp body, remove the two SPRING SliT screws retaining the lamp body to the grille and remove the lamp body assembly. To install, position the lamp body to the grille and install the two retaining screws Fig. 4. Then, install the socket to the lamp body assembly. Lincoln Continental To replace parking lamp bulb, remove door attaching screws and remove the lens and bulb. The front parking

32-20-4 Parking, Rear and Marker Lamps 32-20-4 NUTS AOJUSTINO RING hIEAD LAMP BULB - 13007 WIRE RETAINER LOCATOR RING 13015 PARKING LAMP

32-20-5 Parking, Rear and Marker Lamps 32-20-5 be smoothed to within 1/64-inch of the normal 3. Firmly press, for ten seconds, the replacement lens surface. into position, assuring that the butyl tape seals the lens to the body around the entire perimeter. Do Installation not apply pressure to the middle of the lens. 1. Locate position of the water drainage notches on 4. Reassemble the bezel to the lamp body and tighten bottom edge of new lens assembly.

32-20-6 Parking, Rear and Marker Lamps 32-20-6 BULBS 13465 LAMP ASSEMBLY NUTS 13464 RH. 313556-SIlO 13405 L.H. LICENSE PLATE LAMP WIRING K3217-1A FIG. 8 Rear Lamp Installation-Ford-Except Station Wagons FIG. 10 Rear Lamp Installation-Ford and Mercury Station Wagons FIG. 9 Rear Lamp Installation-Mercury Except DOOR15513-AABACK-UPIRMJ LAMP

32-20-7 Parking, Rear and Marker Lamps 32-20-7 Pinto end Bobcat-Station Wagons Mustang II To remove the bulbs, Fig. 13 remove the lamp From inside the luggage compartment, remove 4 assembly from vehicle and twist the socket bulb sockets from the lamp body and the 6 door-to- counterclockwise and remove from lamp body. body attaching nuts from the studs. Remove the lamp To remove the lamp body, remove the six retaining body from inside the luggage compartment, and the screws and disengage the sockets. Remove the lamp door from the outer side of the back panel. Refer to rig. body assembly. 16. Pinto, Bobcat, Fairmont and Zephyr-Except To replace the lens, remove the 8 ph

32-20-8 Parking, Rear and Marker Lamps 32-20-8 2. From under rear bumper, remove two screws 3. Install the compartment trim cover. retaining the rear sight shield to both rear lamps. 4. Check the operation of the lights. 3. From inside the luggage compartment, remove the rear lamp trim panel, rear and back-up lamp MARKER LAMPS sockets. Remove retaining nuts from both rear Front lamps and center reflector. 4. With assistance from another person, lift both rear 1. Reach behind the fender and disengage the bulb socket from the lamp body. lamps and center reflector from the vehicle and place on a clean b

32-20-9 Parking, Rear and Marker lamps 32-20-9 SIDE MARKER LAMP BULB K2766-2E FIG. 14 Rear Lamp Installation-Fairniont and Zephyr FRONT or VEHICLE N UT STUD

32-20-10 Parking, Rear and Marker Lamps 32-20-10 B U LB LICENSE PLATE LAMP ASSEMBLY SCREW NUT DOOR K3220-24 FIG. 16 Rear Lamp Installation-Mustang II TORQUE NUTS VIEW 4 2545 IN-LBS LAMP ASSEMBLY

32-20-11 Parking, Rear and Marker lamps 32-20-11 STOP LAMP SWITCH All Except Granada. Versailles and Monarch With 1. Disconnect the wire harness at the connector from Vacuum-Powered Brakes the switch. The mechanical stop lamp switch assembly is 2. Remove the hairpin retainer, slide the stop lamp installed on the pin of the brake pedal arm, so that it switch, the push rod and the nylon washers and straddles the master cylinder push rod Fig. 22. The bushing away from the pedal, and remove the switch assembly is a slip fit on the pedal arm pin, and switch Fig. 22. thus, the switch assembly moves with the pedal arm 3. Position the switch, push rod, and bushing and whenever the brake

32-20-12 Parking, Rear and Marker Lamps 32-20-12 IC 2385-0 FIG. 20 Rear Marker Lamp Installation "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or dist

32-20-13 Parking, Rear and Marker Lamps 32-20-13 LICENSE PLATE LAMP Floor Or Console Mounted-Automatic Transmission All Except Ford and Mercury Station Wagon Vehicles equipped with a floor or console-mounted To replace the license lamp assembly, remove the automatic transmission still have a neutral start switch.two lamp body retaining screws and remove the lamp On these vehicles, the back-up lamp switch is anassembly. Remove the socket and the bulb, from the integral pa

32-20-14 Parking, Rear and Marker Lamps 32-20-14 wires. Make sure switch is inside shift mechanism boot REAR LAMP WIRING-FLAT FLEXIBLE and that reverse shift lever directly activates switch Open Circuit Conditions-Fairmant, Zephyr. LTD IIplunger. and Cougar 1. Locate the open circuit.4-Speed-Pinto. Bobcat and Mustang II 2. Disconnect the negative battery cable from the Place the shift control lever in neutral and raise the battery. vehicle on a hoist. Disconnect the electrical connector

32-20-15 Parking, Rear and Marker Lamps 32-20-15 TO FRONT OF VEHICLE FLANGE t NOTE: BUSHING F LANGE TO BE ASSEMBLED ON OPPOSITE SIDE OF PUSH ROD FROM DIMPLE IN SWITCH FRAME BRAKE

32-40-1 Turn Signal and Hazard Flasher 32-40-1 PART Turn Signal and Hazard Flasher 32-40 Applies to All Models SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 40-1 REMOVAL AND INSTALLATION Cont’d. Turn Signal/Hazard Flasher REMOVAL AND INSTALLATION Switch and Wire Assembly 40-2 Flasher Units 40-1 CK3313-2B DESCRIPTION AND OPERATION TURN SIGNAL A

32-40-2 Turn Signal and Hazard Flasher 32-40-2 the unit 90 degrees counterclockwise to disengage it 3. Remove the turn signal switch lever by unscrewing from the mounting slot. To install, lock the flasher in it from the steering column. place by inserting the tab in the slot and rotating 90 4. Remove the shroud trom under the steering coumn. degrees clockwise. Reconnect the wiring plug. 5. Disconnect the steering column wiring connector plugs from the bracket as shown in Fig. 2, andTURN SIGNAL/HAZARD FLASHER SWITCH remove the screws th

32-40-3 Turn Signal and Hazard Flasher 32-40-3 FIG. 2 Column Wire Connectors Typical I lET OETAININO TABS TO SEPARATE CONNECTOR 14t89 SI EEVE-WIPE - - CONNECTOR MALE -,-- 14A459 -- SLEEVE VIEWA WIRE CONNECTOR

32-60-1 Interior Lamps 32-60-1 PART Interior Lamps 32-60 Applies to All Models SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION REMOVAL ANO INSTALLATION Cont’d. Dome and Map Lamp Combination 60-1 Dome Lamp 60-2 Dome Lamp Switch 60-3 ALMOVAL AND INSTALLATION Glove Compartment Lamp 60-4 Cargo LamQs

32-60-2 Interior Lamps 32-60-2 PUSH ON FRONT Of VEHICLE VISOR HANOLE TO CAVIl’, RELEASE MAR INOT ON FAIHMONT LAMP - ANO ZERHYP REMOVE THE LENS TO CHANUE I I-lb BULU 3231-lU FIG. 2 Door Courtesy and Map Lamps-Pinto,

32-60-3 Interior Lamps 32-60-3 COURTESY AND MAP LAMP body see Fig. 6. Using a pair of long-nosed pliers, COMBINATION slide the bulb out of its socket. Be careful not to grip the bulb tightly; it could break. Wear eye pro- Ceiling Mounted-Pinto, Bobcat, Mustang II, tection. Fairmont and Zephyr MAP LAMP AND SWITCH To remove map lamp, push retainer forward. To Lincoln Continental remove bulb first remove lens by unscrewing it from the barrel; then push bulb in and turn counterclockwise. To The map lamp mounted in the ce

32-60-4 Interior Lamps 32-60-4 in the pillar and connect the switch to the connector Fig. 2. Lift the lever cover assembly and replace the bulb. 7. Then, twist the wiring and switch six turns 3. Position the cover to the floor and install the four counterclockwise, push the wiring and connector back cover retaining screws. through the mounting hole and screw the switch into the pillar until it is seated. Close and open the door to Console Mounted assure that the courtesy lamp and ignition key warning buzzer systems are operating properly. 1. Remove the finish panel from the console. 2. Remove the quadra

32-80-1 Illuminated Entry 32-80-1 PART Illuminated Entry 32-80 All Except Pinto, Bobcat, Mustang II, Fairmont and Zephyr SUBJECT PAGE SUBJECT PAGE DESCRIPTION 80-1 DIAGNOSIS 80-2 REMOVAL ANO INSTALLATION 80-4 DESCRIPTION The illuminated entry system is intended to assistvehicle entry during the hours of darkness by providing 1234 7 illumination of the door lock cylinder, so it may be easily located for key insertion. The vehicle inte

32-80-2 Illuminated Entry 32-80-2 The door lock cylinder is unique to this system. It is rectangular in shape and common to all illuminated entry vehicles. A light-emitting diode LED. provides 14A524the light source to a lens system built into the cylinder. WIRINCASSY. RETAINER Normal operating voltage for the L.E.D. is 3 volts. A resistor built into the harness protects the L.E.D., and is impartant when checking the lock cylinder illumination that 12 volts is applied only to the connector terminals. If the resistor is by-passed and 12 volts is applied to the wires betw

32-80-3 Illuminated Entry 32-80-3 OPERATION RESULT Step 1 - Connect a 12 volt lest light between I ermlnal Whether ignition is No. B and a good ground "On’’ or ‘‘Ott," the test ighl should glow. It not, trace