Technical Service Training chnici Information ‘New Product Introduction 00/229 Scorpio 95‘The illustrations, technical information, data and descriptive text in this issue, to the best of our knowledge, were correct at he time of going to print. The right to change prices, specifi- cations, equipment and maintenance instructions at any time without notice, is reserved as part of Ford policy of continuous development and improvement No part ofthis publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic, mechanical, photocopying, recording, translating or by other means without prior permission of Ford-Wierke Aktiengesellscha’t. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. © 1994 FORD-WERKE AKTIENGESELLSCHAFT Service Training Programmes D-P/GK-11 Printed in Germany = (GB) Printed on chlorine-free bleached paper.FOREWORD The new Scorpio *95 will be available in the course of the “95 model year in a saloon (notchback) and an estate version. The saloon version has a completely new body. A 4x4 version will not be available. ‘There is a choice of two V6 and two 4-cylinder petrol engines and one diesel engine. The V6 24V Cosworth engine i mission and "Servotronic” speed-sensitive power steering ‘The 2,0 litre DOHC 16V engine is available optionally with the fully electronic A4LDE automatic trans- available as standard with the fully electronic A4LDE automa mission, ‘The 2.0 lite DOHC 8V engine and the TCI diesel engine arc only available with the MT 75 manual trans- mission. The 2.9 litre V6 12V engine is only available with the partially electronic A4LDe automatic transmission — the LHD version is not available in all countries because of the stringent exhaust emission standards. ‘The interior trim of the Scorpio *95 is even more comfortable than that of its predecessor and now includes a speed-sensitive air conditioning system with automatic temperature control, The introduction of polyellipsoid headlamps means even greater safety, In addition, two air bags, seat belt locks, tensioners and improved side impact protection are provided as standard to protect the occupants. Anti-theft protection has also been increased with the introduction of the passive anti-theft system (PATS). Particular account was taken of environmental problems during the development of the new Seorpio. This brochure has been produced to provide you with comprehensive information on all the new technical features and modifications. Please remember that our training literature has been prepared solely for FORD- DEALER TRAINING PURPOSES. Repair and adjustment operations must alway’ be carried out according to instructions and specifications in the workshop literature. Please make extensive use of the training courses offered by the Ford Care Institute in order to gain extensive knowledge in both theory and practice. Service Training 1CONTENTS Contents Page FOREWORD CONTENTS 2 LITERATURE/VIDEO OVERVIEW ... . 6 GENERAL 7 ENGINES V6 24V Cosworth Engine 9 Modifications in Det View of front of engine — external . 10 View of left-hand side of engine ~ internal . 12 Camshaft drive 13 Cylinder heads; Cylinder head covers; Pistons 14 Inlet system: EGR system 15 Plenum chamber; Butterfly valve 16 VIS system 7 VIS system (continued) 18 Fuel system 19 Exhaust manifolds 20 Engine lubricating circuit ... 1 Cooling system de Engine mountings 23 2,0 litre DOHC Engines 24 2.0 litre DOHC 8V engine; 2,0 litre DOHC 16V engine: Technical Data... 6000000000 25 The following modifications apply to both engines 26 Modifications to the DOHC 8V engine 30 Modifications to the DOHC 16V engine 35 TCI Diesel 2 View of front of engine 4B View of flywheel end of engine 44 Cylinder heads and camshaft drive 45 Cylinder head: Glow plugs 46 Parts mounted on the cylinder heads, 47 Service TrainingCONTENTS Contents Page Belt drive 48 Belt tension setting: Belt removal; Belt fitment . . 49 Belt tension adjustment/replacement 50 Engine mountings Sl 2,9 litre V6 Engine (150 PS) 52 ENGINE MANAGEMENT General; EEC V module 533 2,0 lite DOHC 8V and 16¥ engine with manual Wansmission 54 2.0 litre DOHC 16¥ engine with automatic transmission... 55 V6 24V Cosworth engine ... 56 COOLING SYSTEM New features and modifications . 37 FUEL SYSTEM Fuel tank — 4 Porn ars 58 New features and modifications . “ =” Differences between DOHC and 24V engines .. 59 EXHAUST SYSTEM New features and modifications 61 TRANSMISSION AND CLUTCH MT-75 manual transmission; A4LDE automatic transmission 63 Hydraulic clutch operation 64 Pedal box 6 Dual-mass flywheel . 66 ZF hydraulic torsional damper (HTD) 68 AALDE transmission oi! cooler 7 Service Training 3CONTENTS Contents Page CHASSIS ‘Wheels and tyres n New wheel designs B Front axle ” New features and modifications; Subframe 75 Rear axle "0 New features and modifications: Trailing arms 7 STEERING New features and modifications .... . B ZF Servotronic power steering 80 ABS/TCS New features and modifications; ABS . 82 TES vi oe nennien : 83 ABS/TCS control unit 84 Front brakes 85 BODY/EXTERIOR TRIM New features and modifications; Dimensions 86 Auxiliary brake light; Rear light strip . 88 High-strength sheet steels and coated panels 89 ctrically operated exterior door mirrors; Headlamps 2 Windscreen washers and headlamp washers 904 Front side member sectional repair 95 INTERIOR TRIM Instrument panel 90 New features and modifications: Steering column remote radio control; Speed control 97 Interior air distribution 98 Self-regulating air conditioning; Interior lights . 99 Electrically operated windows: New driver’s seats with memory function... . 100 Service TraiCONTENTS Contents Page ELECTRICS New features and modifications: Bodywork electronics system (Multiplex) - 101 Radio frequency remote control cee 101 Modular wiring loom system .......600004 cece 102 Fuse boxes sive wo , 6 08 eso cee 103 SAFETY AND SECURITY Driver's and passenger’s air bags; Seat belts; Self-dimming interior mitror saree eg 10K Auxiliary brake light; Fuel tank filler... 0.4... . ceeteecceeeeeeeeeeeses | 10H Passive anti-theft system (PATS) with key coding , a wien: Gace ee 105 Central and double locking with anti-theft alarm system . . 105 ENVIRONMENTAL COMPATIBILITY Recycling; Emission standards; CFC-free refrigerant sexx 106 TECHNICAL DATA New spezial tools for the Scorpio "95; Engine data ...6.0.600ccccecees Pe) Fill capacities: Servicing and specifications .... 108 Vehicle data ~ saloon: Vehicle data ~estate ..... 109 Servicing and inspection points in the engine compartment .......6666060.600000008 110 Front suspension settings (at kerb weight) .......... oe eae 12 ABBREVIATIONS Be ae 5 113 Service Training 5LITERATURE/VIDEO OVERVIEW Technicians Information: ~ Scorpio with V6 24V Cosworth Engine, CG 7349 = Scorpio '92, CG 7459 = Escort RS 2000, CG 7436 ~ Scorpio '94, CG 7507 Technical a Service Training a ~ Transit 95, CG 7537 - A4LDE Automatic Transmission, CG 7539 New Produet Introduction | saraze ~ MT-75 Transmission and 4x4 Drive, Scorpio "95 CG 7511/8 - ABS/TCS, CG 7493 - EEC V and On-board Diagnostics, CG 7543 Service Microfiche: ~ Scorpio 95 Parts Microfiche: ~ Scorpio "95 6 Service TrainingGENERAL Ata Glance Vehicle variants B_ The Scorpio *95 is available in a saloon and an estate version, Engines @ Modified 2.9 litre V6 24V Cosworth engine. Modified 2.0 litre DOLIC L6V engine Modified 2.0) litre DOHC 8V engine. Modified 2.5 litre D1 turbocharged diesel engine, Carry-over 2.9 litre V6 engine only in con junction with partially electronic autormatic transmission A4LDe (LHD version not in all countries available). BW New EEC V engine management system. ‘Transmissions New A4LDE automatic transmission, DB Modified M175 manual transmission with new hydraulic clutch mechanism Chassis @ New four-hole steel and aluminium wheels. New wheel trim caps for steel wheels, Changed tyre sizes. New front axle with subframe, veur axle, Steering B__ New stezring column adjustable for height and reach. @ New steering gear, BD New "ZF servotronic” speed-sensilive power steering only available with the 2.9 litre V6 24V Cosworth engine. ABS/TCS: @ New vacuum-controlled Mk IV GT ABS with integral modale. BD TCS with special ABS modulator ay standard swith 24V variants, optional with DOHC variants. Body/Exterior trim B New doy for saloon D_ Modified body for estate. Interior trim B__ New instrument panel New radio control function lever on the steering column New soats with electrical adjustment and position memory gs optional equipment. New interior trim ‘New air conditioning with automatic tempera- ture control for driver's und passenger's side, available as optional equipment, @ xevponarnuargaen Service TrainingGENERAL Electries Modular wiring loom system. Ignition key with remote control for central? double locking, luggage compartment lid release and personal identification, New body electronics system (Multiplex), Safety and Security Driver's and passenger's air bags as standard equipment. Modified front scat belt height adjustment, New self-dimming interior mirror, New auxiliary brake light. New fuel tank filler providing inereased safety in the event of lateral impact or eollision, Passive anti-theft system (PATS) with key coding. Central and double locking with anti-theft alarm system, Environmental compat ty The Scorpio “95 is 83% recyclable; the metals are 98% reusable, ‘The DOHC and 24V en; °96 EEC emission standard, ines comply with the ‘The 2,9 litre V6 and diesel engines comply with the °93 BEC emission standard. Air conditioning systems with CPC-free refrigerantENGINES V6 24V COSWORTH V6 24V Cosworth Engine ‘The revised V6 24V Cosworth engine for the Scorpio "95 has the engine code BOB. Ithas the following new or modified components: ‘+ Modified intake system with carry-over throttle housing, + Camshaft drive with two simplex chains instead of one duplex chain. + Modified eylinder block with modified front cover to match the new camshaft drive. + Both cylinder heads have been shortened at the rear end for reasons of space. © Modified sump with new oil dipstick and tube. + Repositioned oil filter. + Repositioned thermostat housing. + New exhaust manifolds with new gaskets and heat shields. + New extended EEC engine management system with sequential multipoint fuel injection (SFD. New double fuel rail with new (twin spray) injectors. New platinum spark plugs, modified HT leads and repositioned ignition coil. New improved HO2S sensors mounted on the exhaust manifolds. New VIS solenoid-operated vacuum valve. New fuel system line routing. New cooling fans Modified radiator. New drive belts for auxiliaries New valves and lines for the evaporative emission control system. Service TrainingV6 24V COSWORTH ENGINES Modifications in detail: View of front of engine — external sT/180/01 Plenum chamber Flap valve in inlet manifold ‘Timing cover Heat shield Water pump ‘Thermostat anne Crankshaft pulley/vibration damper Sump Oil cooler Oj! filter Exhaust manifold Ignition coil 10 Service TrainingENGINES V6 24V COSWORTH View of front of engine ~ internal sv/taoioe ® 1 Plenum chamber 3 Crankshaft 2 Oil dipstick 9 O'l baffle 3 Inlet camshafts 10 Sump 4) Exhaust camshafts 1 Oil filter 5 Heat shield 12. Oil cooler 6 Mounting for HO2S sensor 13 Oil filter connector 7 Exhaust manifold Service Training ahV6 24V COSWORTH ENGINES ‘View of left-hand side of engine — internal sv/19003 ® 1 Air intake 6 Exhaust manifold 2 Camshatt sprocket 7 Sump 3 Camshatt 8 Crankshaft timing sprocket 4 Oil dipstick 9 Timing chains 5. Heat shield 12 Service TrainingENGINES V6 24V COSWORTH Camshaft drive + Camshatt drive by means of two independent timing chains. + New sprockets for the camshafts, crankshalt and jackshaft to match the new camshaft drive. + "Two hydraulically operated chain tensioners ensure constant muintenance-free adjustarent of the timing chain tension. New guides for the timing chains Now camshaft profile, Reference cam for CID sensor on the left- hand exhaust camshalt. New valve springs. sT/180104 Right-hand camshaft sprockets Right-hand timing ehain Guicle For right-hand timing chain Tensioner for left-hand timing chain Left-hand camshaft sprockets 6 ¥ 8 9 Left-hand timing chain Guide for left-hand timing chain Two sprockets on crankshaft ‘Tonsioner for right-hand timing chain Service Training 13V6 24V COSWORTH Cylinder heads + The cylinder heads have been shortened for clearance reasons and modified camshaft drives. «The inlet ports have been modified because of the new injectors. © Cast mounting bosses for the ignition coil on the right-hand cylinder head. © Mounting hole for the CID sensor on the left- hand cylinder head. Cylinder head covers ‘+ The cylinder head covers have been adapted t the new cylinder heads. Pistons + The gap of the second piston ring has been in creased for improved emissions, ENGINES q 2 3 a i i HOLS) i Lf OS woe OO 1 Cylinder head 2 Exhaust side Mounting for exhaust valves 4 Timing case Mounting for inlet valves 6 Inlet side Mounting for spark plugs sT/180/ 06 Right-hand cylinder head cover shown 14 Service TrainingENGINES V6 24V COSWORTH Inlet system © New air cleaner and resonator ST/180107 1 Aireleaner 2 Resonator EGR system © New EGR valve and tines. Plenum chamber EGR valve Connection for DPFE sensor Exhaust manifold Heat shicld Differential pressure measutin, Connection from FGR valve to plenum chamber 3) Mass air flow seasor Service Training 15V6 24V COSWORTH ENGINES Plenum chamber * — Modified plenum chamber with new air * VIS butterfly valve (VIS = variable inlet ducting and carry-over throttle housing, system) in the plenum chamber. A B G8 sT/B0!09 w A Plenum chamber in situ 1 Plenum chamber B Plenum chamber removed 2 Butterfly valve Butterfly valve The butterfly valve is operated by the VIS ‘actuator which receives @ vacuum controlled by the VIS vacuum regulator: Plenum chamber ‘Vacuum connection Butterfly valve Square butterfly plate we sT/180/10 + 16 Service TrainingENGINES V6 24V COSWORTH Y Cosworth engine is equipped with a VIS system. A butterfly valve between the two parts w/the plenum chamber ereates 4 variable intake system which operates as follows: ne speeds and no load the butterfly i 00 revémin the valve is | lt rding to the engine load, eis open. Up to and 5000 rev/min the buterfly = yes opened. From 5000 rev/min it is clo- 20 200 oh shows the torque curve when the 180 00008000400 SND enno sTe0it S system is operating, emis controlled inte EEC V engine pony valve - cent system, 2 Butterfly valve closed air inde 2. Butterfly valve with VIS actuator Service Training 17V6 24V COSWORTH ENGINES VIS system (continued) + ‘The VIS system varies the length of the inlet . passage according to the engine load and engine speed by means of the butterfly valve, * The VIS vacuum regulator is switched by the EEC V module. ‘The torque curve is improved at low engine speeds and at higher engine speeds the resonance characteristics of the inlet passage are altered to achieve beter charging. { € Q OOO} a 2) @ sTieoi3 1 DPFE sensor 5 Vacuum reservoir 2. Butterfly valve (VIS system) 6 Vacuum regulator (EGR system) 3. Vacuum connections 7 Fuel vapour return valve 4 VIS actuator 18 Service TrainingENGINES V6 24V COSWORTH n spray) injectors with the fuel + Noservicing or adjustments should be carried connection at the side. out. system now comprises two fuel rails J injectors and pressure 5 Fuel retum 6 Pressure regulator ie Fuel supply ecting hose Service Training 19V6 24V COSWORTH ENGINES Exhaust manifolds New thin walled exhaust manifolds with new + HO2S sensors mounted on the exhaust gaskets and heat shields. manifolds. ST/1B0/15 Exhaust manifold on left-hand side of engine shown 1 Exhaust manifold 3 Plug 2 Heat shield 4 Mounting for HO2S sensor 20 Service Trainin,ENGINES V6 24V COSWORTH uit ine lubricating * Oil cooler and oil filter repositioned to accommodate the modified exhaust system + Modified sump because of the oil filer comection. Connector Sump Connection to coolant circuit Oil filer Oil cooler Connection to side of engine Connection to vil filter/oil cooler whee sT1a0i16 Service Training 21V6 24V COSWORTH ENGINES Cooling system New water pump and lines, ‘The thermostat housing is now “freely suspended” between the water hoses from the radiator and water pump and controls inlet temperature. The coolant coming from the radiator is mixed in the thermostat housing before it passes into the engine The inlet temperature control reduces temperature fluctuations in the engine andl thus thas an advantageous effect on exhaust emissions, sT/80i7 Water outlet manifold Water pump New thermostat housing sTigoie Coolant circuit (thermoytat closed) eww e Coolant expansion tank Radiator Ther Water pump jostat Cylinder block Cylinder head ne oil cooler Heater radiator 22ENGINES, V6 24V COSWORTH Engine mountings + The engine mountings have been modified on Note: ‘The engine supports must be mounted both sides in line with the changed installation to the front side memibers first, with conditions. care to the location pins {all engines). ‘The installation mark at the rear +The rear mounting is located on the AALDE, mounting on the automatic trans- automatic transmission and has been adapted tnission must point forwards, lo the new installation conditions. sto w¥ Lefichand engine mounting 4 Installation mark Right-hand engine mounting Rear mounting on AST.DE automatic tans- mission Service Training 23DOHC ENGINES ENGINES DOHC 8V DOHC 16V s1/180/20 24 Service TrainingENGINES. DOHC ENGINES 2,0 litre DOHC Engines available with 8V and 16V varia ‘The Scorpio “95 is ts of the 2,0 litre DOHC engine, Both engine variants are based on the same cylinder block and differ mainly in the cylinder head. Both engines most the requirements of the strict American CAA emission standard and the EBC emission standard planned for 1996, 2,0 litre DOHC 8Y engine + Engine code NSD. The DOHC 8V engine was used in the Granada’ Scorpio: for the new Scorpio model, the low-speed Lorque has been improved. ‘Technical Data 2.0 litre DOHC 16V engine + Engine code NSA. ‘The DOHC 16V engine is a development of the DOHC engine alreudy used in the RS 2000 and is now available in the Scorpio for the first time. Above all, improvements have been made to the idling characteristics and the torque al engine speeds of between 2000 and 3000 rev/min, this ha~ ving been achieved by means of a new type of va~ riable inlet system (VIS). DOHC 8Y DOHC 16 Capacity 1998 cm* Bore 86 mm Stroke 86 mm Power output (nominal) 85 KW (115 PS) 100 KW (136 PS) Max. torque 167 Nm 175 Nm at revémin 2500 t/min 4200 L/min Torque at 1500 Iémin 148 Nm 142.Nm Service Training 25DOHC ENGINES ENGINES ‘The following modifications apply to both engint Modified cylinder block. New pistons with raised compression rings; the piston crown was modified to reduce the compression from 10,3 t0 98. New compression rings and modified piston pins New cylinder head gaskets: multi-layer steel gaskets replace the existing soft gaskets. Cylinder head cover made of aluminium instead of pla New cylinder head cover gasket, Modified upper and lower front covers Platinum spark plugs used with « gap of Imm, New fuel rail fitted with modified pressure regulating valve, New engine management system (EEC V) with sequential multipoint fuel injection (SFD. New camshaft position sensor (CID). Modified crankshaft position sensor. New oil dipstick tube sealed with an O-ring «: the cylinder block; the O-ring need not be renewed when the oil dipstick tube is remow and refitted, Modified oil intake pipe. Modified sump and modified bate. New oil filter. New drive belts for auxiliaries. Modified rear starter motor mounting. Modified radial oil seals New improved HO2S sensor. Exhaust gas recirculation (EGR) working on the DPFE principle. New coolant expansion tank and new lines in the cooling system. 26 Service TrainingENGINES DOHC ENGINES Sump +The shape of the sump has heen changed to allow for the repositioned steering. + ‘The oil battle has been redesigned to match the sump. + ‘The oil intake pipe has been fitted with an additional stiffener, + There is no longer a seal on the oil strainer. CID sensor + The camshaft position sensor (CID) is ‘mounted on the cylinder head cover. Itis required for the sequential electronic fuel injection (SEFI) for cylinder identification. ST/80/21 " ae Sump sTig0122. 1 CID sensor (DOHC 16V shown) 27DOHC ENGINES ENGINES Crankease ventilation + The crankease ventilation system is the same + The DOHC 16V engine has two connections ‘on 8V and 16V engine variants. just in front of the inlet ports. Between cylin- der nos. I and 2 and eylinder nos. 3 and 4 ‘+ Both engines have new connecting hoses to therdiiennoensetiontinthe-form ofa ep 1 she inlet manifolds the inlet manifold gasket so that the crankcase fumes can be directed into all the cylinders. sTi8023 wy A DOHC 8V 1 Crankcase breather valve B DOHC 16V 2 Connection to inlet manifold 28 Service TrainingENGINES DOHC ENGINES EGR system + The EGR system on both DOHC engines remains unchanged. + The location is identical on both engines. sTBoi24 1 EGR valve connection 2 Vacuum connections ta DPFE sensor Service Training 29DOHC 8V ENGINES Modifications to the DOHC 8 engine Cylinder head + Modified inlet ports. + Two additional studs for the exhaust manifold for improved sealing. * Optimised combustion chamber design for improved exhaust emissions. * Modified camshafts with different timings. +The cylinder heads fitted in production do not have the oil splash pipe for the camshafts. * The distributor drive has been eliminated due to the distributorless EDIS ignition system, ‘+ Modified press-fit between the valve guide and cylinder head. + New valve springs; the outer valve springs are of oval cross-section. + Sodium-cooled exhaust valves. Note: ‘Sodium-cooled valves must be recycled in a specific way. sT/180/25 1 Cylinder head 2 Valve springs 3. Exhaust valve 30 Service TrainingENGINES DOHC 8V Inlet system and mixture preparation + New inlet manifold made of plastic with 1 gasket for each inlet port and for the water outlet. + New idle speed control valve mounted on the inlet manifold, New throitle housing similar to that on Zetee engines; passage cross-section 50 mm, 87/180/26 * 1 Throttle housing 2. Inlet manifold + Modified fuel rail with new fuel pressure regulator. + Double-jet injectors with the fuel supply connection at the side, similar to that used on the DOHC 16V variant 1 Fuel rail 2 Injectors (4 off) 3. Fuel pressure regulator 3. Idle speed control valve sTis027 Service Training 31DOHC 8V ENGINES ‘Vacuum connections ~ overview A sT/180/28 & A Diagram showing vacuum connections B_ Component locations Fuel pressure regulator EGR system solenoid valve Fuel vapour return valve (VMV) EGR valve DPFE sensor wena 32 Service TrainingENGINES DOHC 8V : mr 1 [28 Pian sT/180/29 Service Training 33DOHC 8Vv ENGINES Exhaust system + New exhaust manifold. + New steel gasket (2 off) EDIS ignition system + Distributorless ignition system; the operating principle is the same as the Known system on the RS 2000. + The front cover ition coils are mounted on the upper Engine mountings + The front mountings of the DOHC 8V engine are not identical to those of the 16V engine, + ‘The rear mounting on the manual trans- nission is the same for both engin the DOHC 8V engine is only available with manual transmission, ST/180/30 1 Exhaust manifold 2. Steel gasket sT/180/31 1 Ignition coil for cylinder nos. | and 4 2. Ignition coil for cylinder nos. 2 and 3 sT18092 1 Front engine mountings 2 Rear mounting 3. Crossmember 34 Service TrainingENGINES DOHC 16V Modifications to the DOHC 16¥ engine Engine mountings + At the front the DOHC 16V engine has transmissions. With automatic tansmission hydraulic mountings. (ake care of the installation mark The rear ‘mounting for manual transmission is identical +The rear mounting (on the transmission) is to that used with the DOHC 8V engine. different for manual and automatic STH80/83, 1 Hydraulic engine mountings at the front 4 Crossmember 2 Mounting for MT-75 manual transmission 5. Installation mark 3. AMLDE aulomatic transmission Service Training 35DOHC 16V ENGINES Cylinder head + Modified inlet ports + New inlet valve seats * Changed press fit for the valve guides + Repositioned inlet manifold locating sleeve. Camshafts with different timings. * Modified inlet valves, + New cylinder head cover with camshaft position sensor (CID). + Sodium-cooled exhaust valves — taken from the RS 2000, Note: Sodium-cooled valves must be recycled in a specific way. ST/NB094 DOHC 16Y cylinder head 36 Service TrainingENGINES DOHC 16V Exhaust system + New exhuust manifold. + New steel gasket Inlet system and mixture preparation + New throttle housing with two throttle plates for the separate inlets for cylinder nos, 1 and 4 and cylinder nos. 2 and 3. +The idle speed control valve is mounted on the throttle housing + New throttle position sensor, + New inlet manifold made of aluminium. + New plastic thermal insulator and gasket unit © The inict manifold gasket and water passage gasket have been climinared; they are now part of the thermal insulator, ST/180136 Exhaust manifold 1 2 Steel gasket sT/180136 L Throtile housing: 2. kde speed control valve 3. Throttle position sensor sT180°87 8 1 Inlet manifold 2. Thermal insulator and gasket unit Service TrainingDOHC 16V ENGINES VIS system (variable inlet system) ‘The VIS system varies the inlet passage according to the engine load and engine speed. This produces signi ‘ant improvements in the low-speed torque of the DOHC 16V engine. The heart of the VIS system is a butterfly valve in the inlet manifold which separates the inlets of cylinder nos. 1 and 4 from those of cylinder nos. 2 and 3 at low engine speeds, At higher engine speeds and engine load the butter- fly valve opens and connects the inlets, This alters better the inlet resonance characteristics, allowin; charging. Before the throttle housing there is a resonator which affects the resonance characteristics. The butterfly valve is operated by a VIS actuator which receives vacuum controlled by the VIS vacuum regulator. The vacuum regulator receives @ signal from the EEC V module. An additional vacuum reservoir ensures that there is always sufficient vacuum when the butterfly valve is operated; the volume in the vacuum hoses ‘would otherwise be insufficient to operate the VIS actuator completely. s1/180/38 Cylinder head VIS butterfly valve Throttle plates, 4 Resonator 5) Mass air flow (MAP) sensor 6 Air cleaner box 38 Service TréENGINES DOHC 16V VIS butterfly valve The butterfly valve of the VIS system is located on the inlet manifold. sT180/39 8 1 VIS butterfly valve 2 VIS actuator Inlet Tines, STH80N40 w 1 Aircleaner box 3 Resonator 2 Mass air flow (MAF) sensor 39 Service TrainingDOHC 16V ENGINES ‘Vacuum connections ~ overview 1 ST/180/41 A. Diagram showing vacuum connections B_ Component locations Vacuum reservoir VIS vacuum regulator Non-return valve EGR system solenoid valve Fuel vapour return valve (VMV) VIS actuator Fuel pressure regulator EGR valve DPFE sensor 40 Service TrainingDOHC 16V ENGINES 4 Service TrainingTCI DIESEL ENGINES TCI Diesel Engine code 25B. + Intercooler unchanged from MY *94 Rearranged belt drive idler and tensioning + Repositioned glow plugs, hence modified pulleys. cylinder head and cylinder head cover. Re-routed cooling system and fuel system li- + Rocker arms each secured with two studs, nes, Larger sump with cooling fins and two drain plugs. ST/I59/05 ‘TCI Diesel engine MY '94 shown 42 Service TrainirENGINES TCI DIESEL View of front of engine & sT/19044 & 1 Thermostat housing 7 Vacuum pump connection (EGR system) 2 Automatic belt tensioner 8° Crankshaft pulley/vibration damper 3° Bracket for idler pulley 9 Power steering oil pump 4 Idler pulley or air conditioning compressor 10 Tensioning pulley 3 Akernator 11 Water pump 6 Idler pulley ~ Service Training 43 aTCI DIESEL ENGINES View of flywheel end of engine ad nel [ = ST/180/45 1 Connection for coolant hose 6 Oil drain plugs 2 Connection for oil pipe (supply to rocker arms) ——-7_-Rear sump retaining bolts 3 Dual-mass flywheel 8 Crankshaft position/speed sensor 4 Transmission intermediate flange 9 Crankease breather/oil separator 5 Clutch pressure plate Note: Both oil drain plugs must be unscrewed to drain all the engine oil 44 Service TrainingENGINES TCI DIESEL Cylinder heads and camshaft drive $7/180 /46 wv 1 Cylinder head cover Spacer (front) 2 Retaining belt 9 Thrust clement/spacer 3. Oil filler cap 10 Glow plug sealing ph 4 Cylinder head gasket LL Thrust clement (fuel injection pump side) 5 Spacer (rear) 12 Inner cylinder head bolts 6 Individual cylinder heads 13 Thrust element (inlevexhaust side) 7 Outer cylinder head bolt 14 Connection for crankcase breather Service Training 45TCI DIESEL ENGINES Cylinder head ‘+ The cylinder head and the cylinder head cover have been modified to accommodate the second stud and the repositioned glow plug, Rocker arm assembly Studs Valve assembly Inlet port Exhaust port Cylinder head gasket Scaling plug for glow plug bore Engine coolant temperature (ECT) sensor, temperature gauge sender gauge or threaded plug New glow plug as sT/180147 Glow plugs + New glow plugs fitted in a new position. + The bores of the old glow plugs have been sealed with inoperative glow plugs to preserve the proven flow conditions in the swirl chamber. Cylinder head New glow plug Injector Inoperative glow plug Swirl chamber UReN y sT/i80ra8 46 Service TrainingENGINES TCI DIESEL Parts mounted on the cylinder heads, + Minor modifications have been made to the = The exhaust and inlet manifold gaskets must inlet manifold and exhaust manifold, always be renewed when repairs are made s1/180/49 1 Inlet manifold 5) Rear engine lifting eye 2 BGR valve 6 Exhaust manifol 3. Exhaust manifold 7 Inlet manifold gasket (single gasket) 4 Turbocharger Service Training 47TC! DIESEL ENGINES Belt drive + Rearranged belt drive idler and tensioning pulleys, at s1/180%50 Water pump Idler pulley Air conditioning compressor or idler pulley Alternator Idler pulley 6 Crankshaft pulley/vibration damper Urene Opening for proprietary tool 8. Tensioning mechanism 9 Retaining bolt 10 Automatic belt tensioner 11 Power steering oil pump 12. Tensioning pulley 48 Service Trainin:ENGINES TCI DIESEL Belt tension setting Belt removal + Slacken the retaining bolt (2), insert a proprietary tool (square) in the opening provided (1) und move the tensioning ‘mechanism (2) to the position shown (see illustration). Belt fitment + Fit the belt over the pulleys in the following order (6), (5). (12), (43, AD), (3), (1) and (23, + Insert the proprietary tool (square) in the opening (7) and turn the tensioning mechanism (8) anti-clockwise until the distance X between the centres of the bolt heads of the automatic belt tensioner (10) is 82 mm, + Tighten the retaining bolt (9) to the specified torque, ©The belt is run in after a roud test of at least Smiles (5 km). © Cheek the setting X af the automatic belt tensioner (10) and rectify the belt tension as, necessary sT/180/51 Opening for proprictary too! (square) Tensioning mechanism Retaining bolt 10 WW Distance between centres of bolt heads Water pump laler pulley Air conditioning compressor or idler pulley Alternator Tiler pulley Crankshaft pulley/vibration damper Opening for proprietary tool (square) Tensioning meckanisn Retaining bolt Automatic belt tensioner Power steering oil pump Tensioning pulley Service Training 49TCI DIESEL ENGINES Belt tension adjustment/replacement + The distance X between the centres of the bolt heads of the automatic belt tensioner (1) should be checked during an engine inspection, + Ifthe distance X is more than 91 mm, curry out the following operations: — Slacken the retaining bolt (4), insert the proprietary tool in the opening (2) and turn the tensioning mechanism (3) anti-clock- svise as far as the stop (see illustration), — Tighten the retaining bolt (4) to the specified torque. Note: For inspections always follow the in- structions given in the Service Booklet for cars. This applies both when adjusting and renewing the drive belt pos Din Be Distance between centres of bolt heads Automatic belt tensioner Opening for proprietary tool ‘Tensioning mechanism Retaining bolt 50 Service TrainingENGINES TCI DIESEL Engine mountings + The engine mouatings have been modified on ~The rear mounting is located on the MI-75 both sides in line with the changed installation transmission and has been adapted to the new conditions, installation conditions ST/180%54 1 Leli-hand engine mounting 3. Rear mounting on MT-75 transmission 2. Right-hand engine mounting Service Training 512,9 LITRE V6 ENGINE 2,9 litre V6 Engine (150 PS) * Engine code BRG electronic automatic transmission A4LDe until further notice. + ‘The proven 2.9 litre V6 engine is available unchanged, ie. with engine management + With respect to the stringent exhaust emission EEC IV. in the Scorpio but only with partially standards the LHD version will not be available in all countries. & sT/180/55 52 Service TrainingENGINE MANAGEMENT General A dotailed description of the complete engine man “EEC V and On-board Diagnostics”, EEC V module All the petrol engines in the Scorpio "95 are equip- ped with the new BEC V module, This new engine ‘management module has a larger memory and handles a larger number of input and output si- gnals than its predecessor, the BEC IV, It also works faster, This module was required in order to comply with the new '96 EEC exhaust emission requirements, As its prima lates the fuelling, ignition timing and various other function, the BEC V module regu- ‘engine functions to optimise the exhaust emis- sions, fuel consumption and engine power, In addition, the EEC V module has the following lasks: + Ikconirols the new fully electronic A4LDE automatic transmission. The module controls the shift timing according to the vehicle speed and engine load. The driver selects normal, winter of sport driving programmes manually. + Italso forms part of the passive anti-theft system (PATS) in that it prevents the engine starting by switching off the fuel supply. gement system is to be found in publication CG 7543 Atmonitors the mass air flow (MAF) s to regulate fuelling Te controls the sequential multipoint fucl injection system for improved fuelling control. It controls the quantity of fuel injected when stuting the engine in order to obtain quicker starting. Italso controls the exhaust gas recirculation system (EGR) to improve the exhaust emissions. It provides improved control of the fuel and air mixture by means of modified HO2S sensors upstream and downstream of the catalytic converter, It monitors the operation of the power steering to correct the engine speed. Tt monitors the operation of the clutch pedal and the transmission neutral position Trregulates the variable inlet system of the 16V and 24V engines to improve engine power ouiput and exhaust emissions. Service Training 53ENGINE MANAGEMENT 2,0 litre DOHC 8V and 16V engine wi manual transmission ST/18056 1 FEC V module 2 Baltery junction box 3. Fuel pump relay 4 Injector valve 1-4 5 Tdle speed control valve 6 Vehicle speed sensor (VSS) 7 EGR system valve solenoid 8 Canister purge solenoid valve (EVAP) ‘Mass air flow (MAF) sensor 10 ul 2 B 14 15 16 17 18 Inlet air control valve (VIS Instrument cluster Octane adjust plu Inertia switch Fuel pump. Air conditioning Engine cooling fan Engine cooling fan Crankshatt position/spe= V only S) sensor 54Se ee aan Sooo eee 19 20 21 22 23 mw 25 26 27 EDIS module Ignition coil A Ignition coil B Spark plugs Ienition switch Diagnostic system Ignition transformer capacitor (DIS); 8V only HO2S sensor Power steering pressure switch 28 29 30 31 32 33 34 35 36 Engine coolant temperature (E« Air charge temperature (ACT) sensor Throttle position sensor (TPS) Exhaust pressure transducer (EPT) sensor ‘Camshaft position sensor Clutch operation switch (CAA) ‘Transmission switch Second cooling fan motor Shorting bar connector sensor Service Trainin:2,0 litre DOHC 16V engine with automatic transmission ST/180157 EEC V module Battery junction box Fuel pump relay Injector valve 1 —4 Idle speed control valve ‘Vehicle speed sensor (VSS) EGR system valve solenoid Canister purge solenoid valve (EVAP) ‘Mass air flow (MAF) sensor Inlet air control valve (VIS); 16V only Borrausuns ul 12 13 14 15 16 vv 18 19 20 Instrument cluster Octane adjust plug Tnertia switch Fuel pump Air conditioning, Engine cooling fan motor ne cooling fan relay Crankshatt position/speed ( EDIS module Ignition coil A PS) sensor Service TrainingENGINE MANAGEMENT Ignition coil B Spark plugs Ignition switch Diagnostic system HO2S sensor Power steering pressure switch Engine coolant temperature (ECT) sensor Air charge temperature (ACT) sensor Throttle position sensor (TPS) 32 35 36 37 38 39 40 4l Exhaust pressure transducer (EPT) sensor Camshaft position sensor Second cooling fan motor Shorting bar connector Transmission hardware unit Instrument interface module Gearshift lever unit Barometric absolut pressure (BAP) sensor Gearbox position sensor 55ENGINE MANAGEMENT V6 24V Cosworth engine ST/180168 FEC V module u 2 Battery junetion box 12 Fuel pump relay 13 4° Injector valve 1-6 14 5 Idle speed control valve 15 Vehicle speed sensor (VSS) 16 EGR system valve solenoid 7 S Canister purge solenoid valve (EVAP) 18 Mass air flow (MAF) sensor 19 Inlet air control valve (VIS) Instrument cluster Octane adjust plug Tnertia switch Fuel pamp Air conditioning Engine cooling fan motor Engine cooling fan relay Crankshaft position/speed (CPS) sensor EDIS module 5623 24 25 26 7 28 29 30 Spark plugs Ignition switch Diagnostic system Ignition transformer capacitor (DIS) HO2S sensor Power steering pressure switch Engine coolant temperature (ECT) sensor Air charge temperature (ACT) sensor ‘Throttle position sensor (TPS) 31 32 35 36 37 38 39 aL 40 Exhaust pressure transducer (EPT) sensor Camshaft position sensor Second cooling fan motor Shorting bar connector Transmission hardware unit Instrument interface module Gearshift lever unit Gearbox position sensor Ignition transformer Service TrainingCOOLING SYSTEM New features and modifications +The main components of the cooling system + When combined with automatic transmission of the Sccrpio "9S are a new radiztor, new there is a transmission oil cooler heside the vooling fans, a new coolant expansion tank radiator. and thermostatic valve. © The new radiator hoses are different on al * These components are the same on all the engines, as is the position of the thermostatic petzol engincs, The expansion tank is different valve. ‘on the diesel engine 1/1809 a DOHC engine shown 1 Radiator 3 Coolant expansion tank 2 Cooling fan 4 Thermostatic valve Service Training STFUEL SYSTEM Fuel tank S7/18060 OF a rf OY DOHC version shown 1 Fuel tank 5 Line of evaporative emission control system 2. Fuel pump 6 Fuel feed line 3. Puel filter 7 Fuel return line 4 Carbon canister 8 Fuel tank filler 58 Service TrainingFUEL SYSTEM ‘New features and modifications + Puel tank has improved protection against corrosion. + New fuel gauge for petrol engines. + New fuel lines because of the modified routing, + New evaporative emission control system, yalye and lines as on the Escort. + Fuel filter for petrol engines as on the Mondeo. Differences hetween DOHC and 24V engines * On vehicles with a DOHC engine, the fuel lines are located on the left-hand side of the vehicle, + On vehicles with a 24V engine, the [uel lines re on the right-hand side of the vehicle, Fuel pre-heater and filler for diesel e mounted on the engine. New fuel tank filler affording greater safety i the event of a Tateral impact or collision ‘Turbine-type fuel pump for petrol engines and new resistive fuel gauge. 70 litre lank. ‘With both engine variants, the line of the eva- parative emission control system (EVAP) is located on the left-hand side of the vehicle, Service Training 59EXHAUST SYSTEM Service TrainingEXHAUST SYSTEM New features and modifications + Additional front resonator for the 16V engine. = Two rear mufflers us on the MY °92 4 es. Cosworth for all pewrol en + New catalytic converter with 100% active surface, two catalytic converters for the 24V engine Key to illustration on page 60: A 2aV engine B DOHC engines C Diesel engine 1 Catalytic converter 2 Front muffler 5 Rear muffler toRe Modified exhaust pipes with three-year warranty against perforation by corrosion, The exhaust systems fitted to the petrol engines are suspended from the floor assembly at eight points. The exhaust system, used with the diesel engine is suspended from the floor assembly at six points Middle muller Ausiliury muffler Bracket used with MT-75 transmission Bracket used with A4LDE transmission Front muffler with diesel catalyst Service Trai 61TRANSMISSION AND CLUTCH stii80/62 w A MT-75 transmission B_AALDE transmission 62 Service TrainingTRANSMISSION AND CLUTCH MZT-75 manual transmission The MT-75 manual transmission is available swith the 2,0 litre DOHC engines and the 2,5 lite turbocharged diesel engine Modified flywiee! housing due to the hydraulic clutch operating mechanisin and the duial-mass flywheel A4LDE automatic tr ‘The A4LDE is a new, fully electronic auto~ mati transmission. A detailed description is to be found in Technicians Information CG 7539 “ALDE Automatic Transmission”. ‘The automatic transmission is available optionally with the 2,0 litre DOHC 16V engine and as standarel with the V6 24V engine ‘The EEC V module automatically reduces the engine lorque while changing up to produce a smoother gear change, ‘The MT-75 transmission has a new reversing fight switch with built in recognition of the neutral position — Different ratios in 3rd (1.436:1) and Sth gear (0,76:1) when used with DOHC 16¥ enigines. With the sport driving programme the trans mission changes up later and changes down earlier o produce optimum acevleration, With the economy driving programme the transmission changes up as early as possible 10 improve fuel consumption If the driver’s door is opened when the engine is switched off and the selector lever is le: any position other than P, an audible warning in is sounded. Selector quadrant Anew sclector quadrant with a shorter selecte lever is used in the Scorpio “95 for the AALDE transmission. The overdrive lock-out switch | which can be used to stop the transmission changing up to 4th gear, is located on the selector lever ‘The new AdLDE wansmission has an @> a) 2 ) 0 @ @ ® fe OFF: additional winter driving programme which 81/80/63 can be selected by the driver manually by means of a switeh in the quadrant. I; Sélecloc love: This driving programme locks out Ist gearin —-2-_-Reverse shift lock selector lever position D lo prevent the wheels 3 Overdrive lock-out switch spinning when pulling aay. a Switch for winter driving programme Switch for sport driving programme Switch for economy driving programme Service Training 63TRANSMISSION AND CLUTCH Hydraulic clutch operation * All Scorpio "95 variants with manual tran: mission are equipped with a hydraulic cluteh operating mechanism, The hydraulic eluteh mechanism was introduced on the operatin; Granada/Scorpio °94 in conjunetion with the 2.5 litre turbocharged diesel engine. + New clutch pedal with master eylinder and clutch pedal switch Advantages of hydraulic clutch operation: + Reduced pedal effort and shorter pedal travel, ire life of which remain constant over the ei the vehicle. ‘The routing of the hydraulic lines can be varied. ‘Smoother pedal operation when declutching, Increased efficiency due to reduced frictional losses, Fewer components and hence savings in weight. Reduced transmission of noise and vibration from the engine. The clutch pedal is self-adjusting. The pedal travel is 140 & 3 m. A 3 ob A ( sT/180/64 = A Hydraulic clutch operation B Mechanical clutch operation 1 Clutch pedal 2. Fluid reservoir a) 4 5 6 Master cylinder Slave cylinder Clutch Cluteh cable 64 Service TrainingTRANSMISSION AND CLUTCH Pedal box + Acluich pedal switch is used for the first time +The signal from the clutch operation switch is in the Scorpio "95. required to ensure a spevified engine idle speed when depressing the clutch pedal ST/180/65 Pedal box — Diesel shown 1 Clutch pedal switch 2 Brake pedal 5. Brake ON/OFF switch (BOO) 3. Choteh operation switeh 6 Master cylinder Service Training 65TRANSMISSION AND CLUTCH Dual-mass flywheel The dual-mass flywheel used in the Granadaf Scorpio 94 with the 2,5 litre turbocharged diesel engine has been adopted unchanged for vehicles with 2,5 litre turbocharged diesel engine of the Scorpio “95. © The du and a secondary flywheel and the spring/ nass flywheel consists of a primary damping system located between them. * The dual-mass flywheel is designed to eliminate engine torque fluctuations as far as possible for even smoother operation of the transmission. The spring/damping yystem is assisted by the division of the mass of the flywheel, Note: ‘The mass of the primary flywheel adds to the ‘moment of inertia of the engine and the secondary flywheel increases the moment of inertia of the transmission, The clutch plate is located between the dual mass flywheel and the transmission, As the torsional damper is located in the dual-mass flywheel and hence in front of the clutch separating point, gear synchronisation is made easier and synchroniser component wear reduced, Note: The dual- ass flywheel is only changed as a unit in service. ST/159/51 A. Working stroke B Other strokes 1 High torque acts on primary flywheel Spring/damping system Secondary flywheel 66 Service TrainingTRANSMISSION AND CLUTCH The dual-mass flywheel in section sTis9/s2 ap. 1 Primary flywheel 8 Counterplate 2 Ring gear 9 Flange 3. Secondary flywheel 10 Balance weights 4 Cover 11 Compression spring, 5 Std 12 Curved spring 6 Bearing 13. Friction segment 7 Counterplate 14 Compression spring Service Traii 67TRANSMISSION AND CLUTCH ‘ZF hydraulic torsional damper (HTD) (2.0 litre DOHC 16V engine with manual transmission) Please note: ‘This hydraulic torsional damper will be posponed for sometime. The introduction date for this system will be announced later on. * The difference to the dual-mass flywheel is that the torque is transmitted by the same principle as an internally geared pump, ie. hydrostatically, and vibration peaks are suppressed in a valve system (limiting over- oad). engine to the rear axle through the trans- mission The special advantages of the hydraulic torsional damper (HTD) are: * Reduction of the noise, vibration and uneven Note: ‘The hydraulic system in the HTD corresponds to the spring/damping system of the dual- ‘mass flywheel and can be described simply as 2 rotating damper between the crankshaft and the transmission. ‘The slip associated with the hydrostatic trans- mission of torque is minimised by centrifu- gally comtrolled regulating valves. ‘The multi-function valves have the primary task of storing energy. ‘When the engine is switched off, the primary and secondary flywheels are connected by means of the centrifugally controlled regula- ting valves (creep inhibitor) to connect the operation produced by the engine over the entire frequency range. Elimination of transmission noises in neutral and when a gear is engaged Reduction of noises when engaging and disengaging the clutch. Reduction of booming noises and vibration at low engine speeds, and when starting and stopping the engine. Improved gear changes due to the elimination of the torsional damper in the clutch plate. Modular system with the same dimensions as for conventional flywheels, allowing the use of standard clutch plates. In Vehicles with 2,0 litre DOHC 8V engine a conventional clutch is further installed, Service TrainingTRANSMISSION AND CLUTCH ‘The hydraulic torsional damper (HTD) in section sT/B0I66 Starter ting gear Low-load damper Multi-function valve Pump pinion 3. Creep inhibitor 6 Primary side (engine) 7 Secondary side (transmission) Service Training 69TRANSMISSION AND CLUTCH Multi-function valve + Overload is also limited by the multi-function valves in that the integral accumulator pistons allow a certain quantity of fluid to pass from the pressure side to the suction side during torque peaks. This eliminates bucking and surges, the so-called bonanza effect. st/180/67 A_ Low engine speeds up to 2000 rev/inin Accumulator piston B_ Maximum torque Centrifugal piston Constrietion Overload control port C High engine speeds above 2400 rev/min D Overload position 70 Service TrainingTRANSMISSION AND CLUTCH AALDE transmission oil cooler + The transmission fluid (ATR) of the A4LDE + From the automatic transtnission the fluid transmission is cooled twice, flows to the oil cooler which is incorporated in the side of the radistor, aud from there to the auxiliary oil cooler sT/180/68 i 1 Automatic tansmission 6 Line from auxiliary oil cooler to automatic 2. Line fiom automatic transmission to oil cooler transmission 3. Radiator with integral oil cooler 7 Oil dipstick Line from oil cooler to auxiliary oil cooler & Air conditioning cooler Auxiliary oil coolerCHASSIS Wheels and tyres + New four-hole patterned wheels of two sizes. + Wheel covers of two types are available for steel wheels. Steel ‘Aluminium Tyres S e 6x1" 6x Is 195/65 RIS H xt om g all except 24V 195/65 RIS V xt om 3 205/60 R @ | oF av 205/60 RIS Z = x 7205/60 RIS H x OFF g all except 24 V 2 205/60 RIS V 2° oF a wv 205/60 RIS V = x X_ standard * depending on engine © optional #9 spare with steel wheel ‘New wheel caps © Wheel covers for 15” rims. sT/180169 118070 72 Service TrainingCHASSIS New wheel designs + Depending on vehicle version and equipment three different alloy wheels are available. sT/er72 steers ® Service Training 73CHASSIS Front axle sT/80i74 74Right-hand drive version shown 1 2 3 4 5 6 7 Steering gear Stabiliser bar Subframe Cross brace Lower suspension arm Spindle carrier ‘McPherson strut Service TrainingCHASSIS New features and modifications + New subframe mounted on the floor + New rear suspension. assembly at four points with a eross brace. simnilar to the Mondeo. Now stabiliser bar with hydraulic bushes. Modi «© New lower suspension arms and spindle LMR in Struts: carriers, hence new suspension geometty Subframe + The lower suspension arms, stabiliser bar, steering gear and the engine (by means of the front engine mountings) are secured to the subframe, + The subframe is centred on the floor assembly by means of pins. ST/1B0/75. a + Atthe rear end the subframe is bolted to the Noor assembly with a transverse brace. Note: The front suspensions settings are to be found in the section “Technical Data” on page 112, Service Training 7CHASSIS Rear axle sT/18076 76Service TrainingCHASSIS New features and modifications + Now geometry. + New trailing arms. + New erossmember with a larger mounting for the running gear and modified fixture for the trailing arms with the uprated 7 44" rear axle assembly + New springs. + New dampers with five diflerent settings. + Stabiliser bar with special mountings. Trailing arms * Different trailing arms for saloon and estate variants, Notes on servieing, © The rear axle assembly is removed and instal- led ia the same way as on the Granada Seorpio "93 Note: ‘The cross br Key to illustration on page 76 \ce must be replaced before replacing the drive sh, New cross brace for additional reinforcement Modified driveshafts. Changed rear axle ratio (3,64:1) for 24V and estate variants, heavy duty rear axle housing. Self-levelling suspension as for the Granada? Scorpio "94 (depending on the model variant) Saloon: Self-regulating adjustment through an additional compressed air system acting on the rear dampers. Estate: Nivomat (self-regulating adjustment through the rear dampers). (On the saloon version the damper is secured ina mounting at the rear end of the wailing am. The rear axle assembly cannot be adjusted. 3. Driveshalt 4 Trailing am 3. Cross brace A. Trailing arm — saloon version Trailing arm — estate version Crossmember Rear axle assembly naw Service Training reeSTEERING New features and modifications + New steering gear for the new steering ‘+ New steering column remote radio control geometry. stalk, & Nei seehomanziues, + Steering wheels as for MY "94, optionally + New height and reach-adjustable steering with speed control buttons and/or in leather column, sT/18077 Right-hand drive variant shown Key to illustration on page 79 Steering gear Cooling loop Power steering pump ~ V6 24V engine Power steering pump ~ Diesel engine A Left-hand drive variant B Right-hand drive variant 1 Power steering fluid reservoir 2 Power steering pump ~ DOHC engine awe 78 Service TrainingSTEERING Service TrainingSTEERING ZF Servotronic power steering ‘The ZF Servotronic is a power steering system the power assistance of which is controlled electronically according to the vehicle speed. Its available in conjunction with 24V engines, Construction + The ZF Servotronic essentially consists of = fluid reservoir (16), — = pump with control valve (14 in detail A), ~ steering gear with valve housing (19, 20), — electronic speedometer (1). ~ special power steering module (2) and ~ electro-hydraulic transducer (3). + The valve housing accommodates ~ torsion bar (10), ' ~ rotary slide valve (12), — control sleeve (13) and — reaction piston (8). Operation without vehicle speed signal + The torsion bar (10) is connected at the top to the rotary slide valve (12) and at the bottom to the pinion (20) and the control sleeve (13), + When the steering wheel is tumed, the rotary slide valve (12) rotates together with the pinion (20), control sleeve (13) and reaction piston (8) in the valve housing (23), + The torsion bar (10) is deformed elastically by the torque transmitted through the steering column, This produces a radial movement of the rotary slide valve (12) in relation to the control sleeve (13). The hydraulic fluid coming from the pump is passed to the appropriate side of the working piston (24) in the steering gear. * The reaction piston (8) remains inoperative. Operation with vehicle speed signal ‘© The effect on the working piston (24) remains the same. + The steering module receives a vehicle speed signal from the electronic speedometer (1) and sends a flow signal corresponding to this speed to the electro-hydraulic transducer (3), Depending on this flow signal, the valve in the electro-hydraulie transducer (3) is opened a greater or lesser mount and opens the hydraulic passages to the reaction piston (8). + On the inside the resetion piston (8) is connected to the rotary slide valve (12) by ‘means of three axial ball guides, On the out- side it is connected to the control sleeve (13) bby means of a ball thread with four turns. + The axial movement of the reaction piston (8) caused by the action of the hydraulic fluid is converted by the ball thread into a radial movement which counteracts the radial move- ment of the rotary slide valve (12) + The valve housing (23) accommodates the reaction limiting valve (4) which has the task of limiting the pressure to the re ion piston. (8) and allowing surplus fluid to pass to the return, 80 Service TrainingsT/190/79 Section through the valve housing Electronic speedometer Power stecring module Electro-hydraulic transducer Reaction limiting valve Control groove —comection to left-hand side of eylinder Wawa > Control groove — connection to 10 right-hand side of eylinder ut Fixed orifices 12 Reaction piston 13 Steering spindle connection 4 ‘Torsion bar Non-return valves Rotary slide valve Control sleeve ‘Vane-type pump: Service TraiSTEERING 15 Pressure and flow limiting valve 20. Pinion 16 Fluid reservoir 21 Right-hand side of cylinder 17 Pressure line 22 Left-hand side of cylinder 18 Retum fine 23. Valve housing 19 Rack 24 Working piston 81ABS/TCS New features and modifications ‘New vacuum-controlled Mk IV GT ABS with integral module. Single-circuit 10” brake servo {except on 24V variants) with integral brake fluid indicator and integral hydraulic fluid reservoir for the clutch. 24¥ variants have a dual-cireuit 8° brake servo with brake Muid indicator as on the Mondeo. New vacuum hoses for diesel variants. Brake master cylinder as on the Mondeo, Modified brake lines and hoses, AL the front intemally ventilated brake dises (260 mm dia.) and wheel brake eylinders as on the Mondeo (except for 24V versions). 24V versions have larger brake dises and wheel brake cylinders than on the Mondeo (278 mm dia.) AL the rear brake discs and wheel brake cylinders as on the Sierra {except for estate and 24V versions). At the rear 24V versions have internally ven= tilted brake dises (273 mm dia.) and wheel brake cylinders as on the Sierra Cosworth. Al the rear estate versions have internally ventilated brake dises (252 mun dis.) as on the Mondeo, Modified brake pads. New brake pedal mounting. New seayor rings. Handbrake taken from the Granada Scorpio "95. ST/180/80 Cable routing for TCS/specd control (V6 24V Cosworth engine shown) Throttle cable for right-hand drive vehicles 2 Throttle cable for lell-hand drive vehicles 3. Throttle plate contral motor 4 Cable to throttle housing 5. Speed contro! unit 6 Cable to throttle housing 82ABS + The new Mk IV GI ABS has been developed ith three control as a split braking system circuits. + The split is as in the past between the front and rear, the front wheels being controlled separately. + Control is independent of the condition of the road surface and vehicle speed. The ABS has an integral electronic control unit which performs the following functions: ABS and TCS modulation calculation of vehicle speed monitoring of all electronic components storage of all faults which oceur A detailed description is to be found in trai- ning publication CG 7493 “Teves Mark IV and Mark IV GI Antilock Braking System”. sT/18081 1 Electronic control unit with valve block 2 Primary brake circuit 3. Secondary brake circuit 4 ABS warning lamp 5 Diagnostic connection 6 Wheel sensor Service TrainingABS/TCS TCs «TCS with special ABS modulator as standard for 24V variants and optional for DOHC variant. = The TCS uses the wheel sensors of the ABS. to monitor the wheel speeds. © Throitle plate control motor with integral throttle position sensor (TPS). «© Whon different wheel speeds are detected at the front and rear axles, the throtile is closed by means of the throttle control motor according to the vehicle speed amd the whee! brake cylinder of the wheel in question is actitated to achieve full traction. Modified TCS switeh in the centre console to switch the TCS on and off. Combined funetion and warning lamp in the instrument panel. Note: A precise description of the operation of the TCS is to be found in publication CG 7493 “ABS/TCS”. i x sT/ig0re2 1. Blecitonie control unit with valve block 2. Primary brake circuit 3. Secondary brake circuit ABS/TCS warning lamp Diagnostic conection Wheel sensor Service Training 83ABS/TCS ABS/TCS control unit + The ABS/TCS control unit consists of a hydraulic contral unit and an electronic control unit + The hydraulic control unit houses the dual- circuit pump and the valve block. The wo represent 2 modified version of the Mk IV braking system, Note: A precise description of the modified ABS is to be found in publication CG 7493 “ABSITCS". ‘The pump housing accommodates a low- pressure accumulator plus one damping chamber for the primary brake circuit and one damping chamber for the secondary brake circuit ‘The electronic control unit controls the solenoid valves in the valve block and continuously monitors the correct operation of all the electronic components. sT/180/83 A. ABS control unit B_ABS/TCS control unit 1 Lines from brake master cylinder 2. Front left-hand brake circuit Front right-hand brake circuit Rear brake circuit Rear left-hand brake circuit Rear right-hand brake circuit 84 Service TrainingBODY/EXTERIOR TRIM Auxiliary brake light + Both body versions of the Scorpio "95 are + On both body versions the auxiliary brake fitted with an auxiliary brake light, On the light is mounted in the middle of the tear saloon the auxiliary brake light is located at window. the bottom of the rear window, on the estate it is located at the top of the rear window. Rear light strip + The saloon version has a rear light strip incorporating all the rear lamps. ST/180/86 # 1 Auxiliary brake light 5. Rear fog light 2. Direction indicator 6 Reversing light 3. Brake light 7 Licence plate light 4 Rear light 88 Service TrainingABS/TCS » Front brakes + Single-piston calliper taken from the Mondeo, No balance weights are used when the brake dises are balanced. True running is obtained by removing material from the brake dise. . * ST/E084 1 Single-piston caliper 3. Material removed during brake disc balancing 2 Wheel sensor Service Training 85BODY/EXTERIOR TRIM New features and modifications The Scorpio "95 has new bodywork with the following external features + New headlamps. + New rear light strip. * New front fenders with integral side direction indicators, + New rear quarter panels. + New front and rear bumpers. © New hood with new radiator grille. * New front and rear doors. + New exterior door mirrors, manually and electrically adjustable + New luggage compartment lid for saloon variants, existing tailgate used for estate In addition, the following design modifications have been made: + Modified front end. + Modified floor pan. + New stiffened rear rocker panels. ‘+ New fender apron panels in the engine compartment. + Side impact protection in the front doors. * Front and rear wheethouse trim panels made of plastic. + Corrosion protection with 6-year warranty against perforation by corrosion. © New design of the roof rack. variants, Dimensions [Dimensions (mm) Saloon Estate [A= max. length 4826 (4926) 4825 (4926) B = Overall width (excluding exterior mirrors) 1760 C= Overall height (at kerb weight) 7 1402 - 1440* 1430 — 1502" D = Wheelbase 2770 _ Front 1448 — 1502* 1478 - 1507* E= Track rear 1495 — 1519" () with tow coupling head * depending on tyre combination 86 Service TrainingBODY/EXTERIOR TRIM SS ad cz & = SS ye > sTi80s Service TrainingBODY/EXTERIOR TRIM High-strength sheet steels and coated panels s1/18087 1 High-strength sheet steel 2 Coated panel Service Training 89BODY/EXTERIOR TRIM ‘ST/18088 2. Coated panel 1 High-strength sheet steel Service Training 90BODY/EXTERIOR TRIM we sT/180189 2 Coated panel Service Training 91BODY/EXTERIOR TRIM Electrically operated exterior door mirrors + When reverse gear is selected, the electrically operated exterior door mirror on the passenger's side is automatically angled Headlamps + The new polyellipsoid headlamps are more compact than conventional reflective headlamps. «The sharp focusing of the light and the elliptical shape of the reflector increase the range of vision and volume of light. This has effects at both short range and long range. + They also ensure even bright illumination of the road on bends. 92 downwards to allow the driver to check the distance from the kerb, o 70 co v0 7 sT/ig0re0 ® Road illumination from conventional reflective headlamps stow ® Road illumination from polyellipsoid headlamps Service TrainingBODY/EXTERIOR TRIM Design and operation + ‘The design of the polyellipsoid headlamp is similar to that of a slide projector. It consists, of a reflector, HI bulb, aperture slide”) and a converging lens, «An uperture inserted between the bulb and the lens produces a precisely defined lightarks boundary. ‘The complex geometry of the reflector means that the light distribution is produced in the object plane and projected complete with the pudark boundary onto the zoad. Thus, a diffusing lens is no longer required _Afier refitting the rear dust cap (in the engine itched compartment) the headlamp can be s from asymmetrical to symmetrical Tight via a lever Therefore ir is not necessary to putan adhesive tape on the headlamp when changing from left (o right-hand traffic. sT/180192 A PSE headlamp B Section through the PSE headlamp 1 Dipped beam (PSE headlamp with H1 bulb) Main beam (A kamp) Parking light Direction indicator und front-fog lamp unit Service Training 93BODY/EXTERIOR TRIM Windscreen washers and headlamp washers + Heated washer jets are available as an option for the windscreen. + Anew high-pressure telescopic headlamp \Washer system is optionally available, When operated (with the headlamps switched on) the washer nozzle extension emerges from the bumper to wash the headlamp with a high- pressure jet from the optimum angle * A combination reservoir for the windscreen/ rear window washers and the headlamp washers. s1/180/93 Rue Washer nozzle for windscreen Heated washer nozzle Washer nozzles for headlamps Washer nozzle extension sT/180/94 ‘A. Reservoir with headlamp washers B_ Reservoir without headlamp washers 1 Pump for windsereen and rear window washers Pump for headlamp washers 94 Service TrainingBODY/EXTERIOR TRIM v Front side member sectional repair On the Scompio “95 a sectional repair to a front side member is made using # modified method. ‘A damaged side member is no longer seplaced by 1 diagonal sandwich structure but by & stepped structure with an offset of approx. 40 mm (see illustration). » »> 81/1805 Distance X = approx, 40 mm > Service Training 95INTERIOR TRIM Instrument panel BOE ST/18096 96A Instrument cluster for petrol engines B__ Instrument cluster for diesel engines 1 Steering wheel with air bag and buttons for speed control system 2. Indicating and warning lights (see instrament cluster) Temperature gauge Lefi-hand direction indicator Trip computer display Main beam warning light Right-hand direction indicator Fuel gauge Auxiliary waming display for open doors and ice 10 Heated windscreen 11 Analogue clock 12 Temperature control for driver's side (AC) 13. Airrecirculating switch 14 Blower switch 15 Airdistribution control 16 Airconditioning switch (A/C) 17. Temperature control for passenger's warwnuey side (A/C) 18 Passenger’s air bag 19° Light switch 20 Headlamp levelling switch 21 Multifunction switch (direction indicators, dipper) 22 Remote radio control stalk 23. Waring lights (see instrument cluster) 24 Hazard flasher switch 25. Warning lights (see instrument cluster) 26 Trip computer function switches 27 Steering/ignition lock 28 Wiper multifunction lever 29 Heated rear window 30. Ashtray/cigarette lighter Note: Refer to the operating 40 20 eS [oonie ‘000 instructions for an explanation \ of the instrument clusters, Service TrainingINTERIOR TRIM New features and modifications + New instrument pane) + New interior rim, + Modified front and rear seats. + New driver's soats with memory function + New electrically operated windows Steering column remote radi control * A steering column remote radio contro! stalk is available as an option + The following fumetions ean be set by means of this stalk: — volume — when the radio is operating: station search, change stored stations and change waveband Speed control + New speed control system with more precise: speed contral, Every time the acceleration or deceleration button is operated, the vehicle speed is increased or reduced by I mph (1.6 kin), + The operation of the speed! control system is indicated by the warning lamp in the instrument panel. + The system can be stopped at any time by means of the buttons in the steering wheel or by depressing the brake or clutch pedal New interior air distribution. ‘New pollen filter system ‘New additional air conditioning system with changed control options ‘New air conditioning heat exchanger. ~ when the CD is operatin: title, next CD. nextiprevious Rauio, cassette or CD operation must be pre- set on the radio. ote: A detailed description is to be found structions, in the Audio Operating 1 On 4 Accelerate 2 Off 5 Decelerate 3 Stop Service Training 97INTERIOR TRIM Interior air distribution © The ventilation system of the Scorpio "95, In addition, the ventilation can be switched to includes a pollen filter similar to that on the air recirculation. Mondeo, st/igoiee 1 Instrument panel 5. Air duct to centre fresh air nozzle 2. Trim for demister nozzles 6 Air duct to fresh air nozzle on passenger's side 3. Heater blower with pollen filter 7 Left-hand windscreen demist nozzle 4. Air duct to fresh air nozzle on driver's side 8 Right-hand windscreen demist nozzle 98 Service TrainingINTERIOR TRIM Self-regulating air conditioning + In addition 1o the known air conditioning system, a self-regulating aic conditioning system is offered as an option, * — The required temperature can be set in- dependently for the driver's side and the passenger's side with a maximum difference of 6°C. ‘The system incorporates five sensors: exterior temperature sensor interior temperuture sensors (3) sun sensor, + The blower is also regulated according (0 the vehicle speed. ©The on/oif buttons for air recirculation and ait conditioning are located on the operating pune], Both buttons are illuminated when actuated. Interior lights “The interior lights now have the following adel nal functions: + The interior Lights are switched on when the ignition is switched off while the headlamps are on, + The interior Tights are switched on when the doors are unlocked with the key or the radio y with double frequency remote control (on locking). sTM1g0199 BEE ‘Temperature control for driver's side On/off bution for air recirculation Blower switch “Temperature sensor Air distribution Onvofi button for air conditioning Femperatuze control for passenger's side When the doors are closed, the interior lights are switched off after a delay of 20 seconds. ‘The interior lights are switched off ewrlier if the ignition is switched on during this 20 second period ar the doors ate locked (only with double locking). Service Training 99INTERIOR TRIM Electrically operated windows + One-touch opening for the windows on the * The electrically operated windows are part of driver's and passenger's side. the global locking function ~ see section entitled "SAFETY AND SECURITY”. New driver’s seats with memory function + The new driver's seats with the memory function are fully adjustable electrically. + Adjustments should only be made while sitting —S_ * The adjusting levers are located on the side of the seat, The seat moves in the direction in ® Q Oy Q OW which the levers are moved. > fo co sti180/100 Move seat forwards and backwards Seat height adjustment Raisc/lower front of seat Raise/lower rear of seat Tilt backrest Adjust lumbar support * ‘The buttons for memorising the driving position are located on the driver's door in front of the stowage pocket. AuEwNH + The driving positions for three drivers can be memorised. + Inaddition to the position of the seat, the positions of the exterior door mizrors are also memorised. Therefore, before memorising the position of the seat, the exterior door mirrors must first be adjusted. + To memorise. first press the memorise button (1) and then the corresponding driver button (2). sT/eo/101 + Press the corresponding driver button (2) to 1 Memorise button call up the position 2. Driver buttons 100 Service Training-w features and modifications © Modular wising loom system. + New modules. + New bodywork electronics system (Multi- plex), Bodywork electronics system (Multiplex) Multiplex is an electronics system for activating several electronically controlled systems. It consists of a number of modules which are comnected to one another and to the corresponding actuating motors and switches. + The number of modules depends on the vehicle model variant ~ four modules at most are required, ‘The following systems are connected through Multiplex: © Central locking. + Double locking. + Luggage compartment lid/tuilgate release. + Radio frequency remote control. ‘The advantages of Multiplex are: + Reduced wiring in critical areas. © Instrument panel wiring loom reduced by approx. 30 wires. = Open system which can be extended easily. New eluich switch (de-activaior switch) to meet Clean Air Act regulations/standards (see page 65). The modules are each connecied with just two wites and located in the immediate vicinity of the system being operated, e.g. in. the driver’s door, under the driver's seat and in the area of the instument panel Anti-thelt alan system, Electrically operated windows. Driver’s seat and exterior door mirrors with, the memory function Fewer components and hence increased reliability. The driver has easy access 10 the operating switches, c.g. the switches for the electrically ‘operated windows of the rear doors are Jocated in the arm rest of the driver’s door, Service TrainingELECTRICS Radio frequency remote control ‘The Scorpio *95 has a radio frequency remote control, ‘The advantage of the radio frequency remote control is that it ean be activated within a radius of 10 m without the need to aim the remote control directly at a particular point ‘The following systems are activated with the remote control: = central locking = double locking — luggage compartment lid/tailgate release. ‘The central locking and anti-theft alarm system are activated by pressing the locking button (2) once. The double loc! the locking button twice. is activated by pressing sT/1g0/102 w Unlocking button Locking button Unlocking button for luggage compartment lidftailgate ‘The luggage compartment lid or tailgate opens automatically when the luggage compartment lid/tailgate unlocking button (3) is pressed. 101ELECTRICS Modular wiring loom system sT/1a0/103 1 Luggage compartment Lock loom 5 Door connecting lead 9 Instrument 2 Luggaye compartment lid loom 6 Centre console lead 10° Central ele 3 Door feect loom 7 Seat heater lead [1 Brake Tight 4 Toterivr light loom 8 Airbag lead 12 Bont light 102Service TrainingElectrical boxes + ‘The central electrical box is located in the engine compartment on the driver's side, ‘The auxiliary electrical box is located in the engine compartment on the passenger's side. RI R} 30 ate] rn7| [rie [BS] I 6. | 37 | 38 Bo 391 40141 ttn 43 46 sT/180/104 al electrical box Fuses 1 Front fog lamps. heated exterior mirrors 2 Left-hand parking light. licence plate light 3. Light switch 4 Right-hand dipped beam, headlamp Jevelli system Left-hand dipped beam 6 Blectrically adjusted seats Wiper motors, screen washer pumps 8 Radio 9 Hor 10__Left-hand main beam 12 1B 1 15 16 19 8 ay “Right-hand main beam Right-hand parking I Ignition lock eur lights, direction indieators, brake Rear fog lamps Electronics Blectronies ‘Dim dipped beam (daytime running lights) Headlamp washers Heater rear window Electrically operated exterior minrors Door locking modules Instrument light Service TrainingELECTRICS B Auxiliary electrical box Fuses Seli ¢ suspension EEC V ignition module Not used Icnition control, ZF servotronic Engine running relay Cooling fan (air conditioning) Not used Engine management Heated windscreen, right-hand side Cooling fan (1/1 + 2) HO2S sensor ‘Heater windscreen, left-hand side Fuel pump Cigarette lighter, electrically heated seats Cooling fan (2) Hazard flashers ABS module ABS pump Supply to central electrical box s Supply to central electrical box LIL Supply to central electrical box. IV _ Diese! pre-heat (glow plug) R21 ignition lock; black R22 Bridge R23 Bridge R24 Air conditioning; green R25 Not used Auxiliary relays (location) R26 Heated seats: yellow (centre console) R27 Electrically operated sunroof; (sunroof) R28 Heater blower motor; yellow (behind glove compartment) R29 Direction indicators; black (adjacent steering column) 30 Touch switches (windows); brown (driver's door) R31 Headlamp washers; blue (behind glove ‘compartient) R32 Diesel preheat; black (engine compartment) R33 Rear wiper interval; orange (adjacent steering column) R34 Engine cooling fan; dark green (engine compartment) R35 Front fog lamps (NL, S); white (under instrument panel) | Relays R36 Power saver (battery); yellow (behind glove | R16 Not used compartment) \ +! R17 Fuel injection pump; green/violet R37 Speed control system; green (behind glove R18 Heated windscreen; black compartment) 19 Engine running relay; brown. R38 Air compressor; yellow (behind glove | R20 Self-levelling suspension; brown compartment) S = MN 24 Interior lighting, audio systems 25. Electrically operated windows 26 Electrically operated windows, front 27 Air bar, ABS, electronic adaptive damping system 28 Electrically operated sunroof 29 Heater blower motor oN / R4 Timing relay, heated windscreen; yellow RS Cooling fan; dark green (black*) RG Starter motor; yellow 7 Hom; brown RS Fuel pump; brown R9_ Dipped beam: white RIO Main beam; white RII EEC V module or diesel cold starting device: Relays ben RI Daytime running light (LHD) or dim dipped _-_-RA2 Rear window inhibitor clreult yellow panel’ eam (RHD): green R13 Bridge | ctrical R> High performance cooling fan: black R14 Daytime running light (S, N, DK. SF); blue switel 3 Air conditioning, blue (brown*) ‘+ in conjunction with diesel engine | ing ma 103SAFETY AND SECURITY This section covers both safety and security. Driver’s and passenger’s air bags ‘+ The driver's and passenger's air bags have = been taken from the Granada/Scorpio "93. Seat belts + Three-point seat belts at the front with belt pre-tensioner and belt locking mechanism as standard. + Modified height adjustment on the B-pillar, sT/180/105 w eat belt height adjustment Self-dimming interior mirror . © The new Scorpio 95 is now fitted with a + The interior mistor is dipped electro- i self-dimming interior mirror. chromatically according to the dazzle. \ © Light sensors measure the ambient light + This function can be deactivated by the levels and dazzle from following vehicles. switch on the interior mirror. Auxiliary brake light + The auxiliary brake light on the saloon is * The auxiliary brake light on the estate is located at the bottom of the rear window. located at the top of the rear window. Fuel tank filler + The new fuel tank filler provides increased safety in the event of lateral impact or collision, lot Service TrainingSAFETY AND SECURITY Note: Passive anti-theft system (PATS) with key coding ‘The passive anti-theft system (PATS) of the Scorpio ‘95 is identical to that in the Transit Important new features : ‘The centzal locking covers the fuel tank filler flap. = Global closing function ~ the electric windows and the sunroof ate closed! when the vehicle is locked = The windows and sunroof can be ‘opened by holding the key in the opening position. — ‘The interior lighting is switched on when the vehicle is unlocked. The central and double locking is uctivated by locking the vehicle from one of the front doors using the key or the radio frequency remote control. Tn addition to the doors and the luggage compartment lid or tailgate, the centea locking also covers the fuel nk filler Hap. The global closing Function will be inzodu 98, This is described in the New Product roduction Brochure CG 7537, Central and double locking with anti-theft alarm system Compared to the systems known to date, the central and double locking has been extended to incorporate the global locking fimetion, ‘The global closing function closes the clecirically operated windows and the electric is locked, This sunroof when the vehie! Junction is activated by holding the key in the closing position of holding down the corresponding fumetion button on the frequency remote coutrol. “The global closing function ean also be used tw open the windows and the sunroof when the vebicle is unlocked, They are opened us Jong as the key is held in the opening position or the corresponding function button on the raclio Frequency remote control is depressed. In adklition, on the Seospie “95 the interior lighting is switched on for approx. 20 secands when the vehicle is unlocked. ata later time. Service Training 105ENVIRONMENTAL COMPATIBILITY When the Scorpio 95 was developed, particular care was taken to ensure that the vehicle design is environ- mentally friendly Recycling * The Scorpio “95 is 83% recyclabl ; the metals are 98% reusable. Possibilities for reusing materials taking the Scorpio "95 with the 2,0 litre DOHC 8V engine for example. Weiaht Material | Chemical | Energy re- | Remaining | Use of recovered BN | recovery | recovery | covery | waste materials Metals 10S 1083 of 2 Rubber 76 | 61 15 __| Energy recovery ‘Components made Laminate-free | of recycled plasties: plastics (removable 49 49, engine covers, cowl in 30 minutes) panel trim, radiator gtille, ete - - : . "| Burning with energy Plastic composites a 7 4 recovery Glass. 4 ce [_ Botile industry Glass composite 28 - a ‘Starting material for | Foam 16 16 a polymer industry icles % a 9 | Buming with energy recovery Liquids 7 21 | All figures in kg 7 Emission standards + The DOHC and 24V engines meet the + The 2,9 litre V6 and diesel engines meet the "96 EEC emission standard "93 EEC emission standard. CFC-free refrigerant + The air conditioning systems are filled with the CFC-free refrigerant R134a. 106 Service TrainingTECHNICAL DATA New spezial tools for the Scorpio *95 16-075, Remover for spring clip atthe clutch» 17-068, Setting gauge, manual lever position master eylinder sensor + 17-067, Guide sleeve, one-way clutch (auto- ‘matie transmission) Engine data. 1 201poHe | 201p0uc | 5.4 2v1v6 | 2.51 Turbo Engine sv lev 29 TV6 24 diesel Capacity 1998 1998 2936 2936 2498 Power oulpur wwiPs)[ ssaisy | 100% | 10050 85.(115) atrevimin] — 5500 6300 5500 42000 Max. torque Nm] 167 229 281 270 acrevimin | — 2500 3500 4200 2200 Required fuel 95 octane Super Unleaded Diesel Max,engine speed revimin] gos ease aan) ois ; ‘continuous) Max, engine speed revimin| 175 6678 sooth 50 0 (intermittend) ° “ . - - elle speed! avin Comrolied by engine management system 850450 (with fa on) Mixture preparation Fuel injection system. Firing order a 1 3-3-6 Spark plugs AGPR AGPR AGRF AGPR _ (Motorcraft) 22PP 22 PP 32C1 22 PPS Electrode yap. mm 10 Ld - Tenition system Fleetronic ignition . ‘Valve clearance Valve cleurance offset by hydraulic tappets: Engine oil Lilter EFL 106 EFL 90 EFL 398 EFL 493 Service Training 107TECHNICAL DATA « Fill capacities . . 2,01 DOHC | 2,01 DOHC 291Vv6 | 251 Turbo Fill capacities (litres) 2.91 V6 sv 16v 2av diesel Engine oil — with filter 45 4.25 4s 66 — without filter 40 40 38 6.0 Manual transmission 12 12 - - i} Automatic transmission - 85 85 95 Rear axle 7" 09 me 13 Power steering Max, mark ~« Cooling system incl. heater 73 15 85 710 4,0 (excl. headlamp washer system) Screen washer system 11,0 (incl. headlamp washer system) Fuel tank 70 Braking system Max, mark Servicing and specifications Note: Refer to the Ford Service Booklet for cars for the service intervals and fluid specifications. ©. 108TECHNICAL DATA o~ Vehicle data - Saloon Transinission MT-75 AALDE. Fini | 2,51 Turbo } 2,01DOHC | 2,01 DOHC | 2,01DOHC 2,91V6 diesel 8Vv 16V 16V 24V Ratios Reverse gear 3,510 3,256 2,110 Ist gear 3,890 3,608 2474 2nd gear 2.084 2,082 L474 3rd gear 1,342 1,430 1,000, 4ih gear 1,000 1,000 0,750 -~ Sth gear 0822 0,829 Final drive 4,090 4270 4.270 3,640 Performance (062 mph (0— 100 knv/h) sec 126 3 128 9d Max. speed mph (km/h) | 120 (193) 120 (193) 129 (207) 121 (194) 140 (22S) atrevAnin 5612 $623 5360 5260 Vehicle data ~ Estate — Transmission MT-75 A4LDF . 251 Turbo | 2,01DOHC | 2.01 DOHC | 2.01 DOHC. 291V6 peipioe diesel 8Vv 16V 16V 24V ”~ Ratios Reverse gear 3.256 3,510 3.256 2,110 Istgear| 3.610 3,890 3.608 2.474 2nd gear 2,082 2,084 1,474 3rdgear] 1.360 1,342 1,000 4th gear 1,000 1,000 0.750 sth gear} 0.736 0,822 Final drive 3,360 4.090 4.270 3,640 Performance 0-62 mph (0 - 100 km/h) see ng 116 13.2 94 Max, speed mph (km/h) | 117 (187) 117 (187) 125 (200) 117 (187) 134 (215) at rev/min 5423 5346 5113 S015 Service Training 109 aTECHNICAL DATA Servicing and inspection points in the engine compartment sT/180108 110Service TrainingTECHNICAL DATA sv180/t07 A. 2,0 lite DOUC 8V engine comparment 4 Battery B_ 2.0 litre DOHC 16V engine compartiment 5 Type plate C 2.9 line V6 engine compartment 6 Automatic transmission fluid dipstick D_ 2,9 litre 24V engine compartment 7 Engine oil filler 2.5 turbo diesel engine compartment 8 Engine oil dipstick 1 Reservoir for sereen washers 9 Brake fluid reservoir 2 Coolant expansion tank 10. Air cleaner 3. Power steering Muid reservoir Note: With the exception of illustration “C”, all the illustrations show left-hand drive vehicles. (On right-hand drive vehicles some of the servicing and inspection pots are on the opposite side. Service Training 111TECHNICAL DATA Front suspension settings (at kerb w Caster and camber Caster Camber Sollwert Toleranz Sollwert Toleranz 483° 4.20° bis 5,67" | -0.45° | 0,65° bis -1,52° DOHC engines oder oder oder oder 4°50" 4°12 bis $40" | 0°27" | 0°39" bis—1°14" 485° 4.20° bis 5,78° | -0,50° | 0,62° bis -1,62° Saloon V6 engines oder oder oder oder asi" 4°17 bis 5°47” | -0°30" | 0°37" bis 1°37" 492° 4.30° bis 5,80° | -0,52° | 057° bis-1,63° Diesel engine oder oder oder oder 4°55 4°18" bis 5°48" | 0°31 0°34" bis 1°38" 4.96° 4,37° bis 5.82° 0,62° bis -1,52° DOHC engines oder oder oder 4°58; 4°22" bis 5°49" 0°37" bis -1°14° 5,03° 4.42° bis 5.87° | -0.50° | 0,62° bis -1,62° Estate V6 engines oder oder oder oder 5°02 4°25" bis 5°52 030° 37’ bis 1°37" 5,20° 4,68° bis 5.98° | -0.62° ° bis -1,68° Diesel engine oder oder oder oder sy ara bis 5°59 | 0°37" | 0°26" bis -1°4” Maximum difference ~ left to right-hand side Caster 1,00° (1°00") Camber 1,25° (1°15") ‘Toe settings All models Permitted tolerance +40.15° (toe-in) to +0,45° (toe-in) 40°09" (toe-in) to +0°27" (toe-in) +1,0 mm (Coe-in) to +3,0 mm (toe-in) Adjustments, if necessary +0,30° (toe-in) 40,15° 40°18" (toe-in) 0°09" 42.0 mm (toe-in) 10mm 12 Service TrainingABBREVIATIONS ASLDE, ABS AIC act Boo cFC cI CPS. DI DOHC DPFE ECT EDIS EEC EGR Automatic 4-speed Lock up OverDrive, Electronic controlled Anti-Lock Braking System Air Conditioning, Air Charge Temperature Sensor Brake On/OLl switch ChloroFluoroCarbon Cylinder Dentification Sensor Crankshalt Position/Speed Sensor Direct Injection Double Overhead Camshatt Delta Pressure Feedback EGR System Engine Coolant Temperature Sensor Electronic Distributorless Tgnition System Electronic Engine Control Exhaust Gas Recirculation ePr EVAP HO2S HTD LHD MAF MT 75 PATS RHD SFI TCs TCT TPS Elceimonie Pressure Transducer Evaporative Emission Control System Heated Oxygen Sensor Hydraulic Torsional Damper Lelt-Hand Drive Mass Air Flow Sensor ‘Manual Transmission with a distance of 75 mm between the shafts rassive Anti Theft System Right- Hand Drive ‘Sequcutial multipoint Fuel Injection Traction Coatiol System urboCharged Intercooled ‘Torattle Position Sensor Variable Inlet System. ‘Vapour Management Valve Vehicle Speed Sensor Service Training 113