Ford - Escort Mk1 - Workshop Manual - 1968 - 2004

Page 1 NEWTON COMMERCIAL FORD ESCORT Mk1 & Mk2 CARPET SET FITTING INSTRUCTIONS Please read these instructions carefully to give an idea of the sequence of events. When removing clips, screws, bolts etc. please remember to put them in a plastic bag, label & store them safely for re-use. (Take plenty of pictures to remind you how things fitted). REMOVE OLD CARPET 1 Mk1- Tilt seat forward, undo bolts on rear of cross member. Lower seat, undo bolts at top of cross member, pull locking handle to release & remove seat from car. Mk2 - Undo seat bolts & remove front seats. Remove the mounting brackets & inserts from the frame legs – store safely. 3 2 Mk1 - Unscrew gear knob, remove lower seat belt fixings. (Place belts on rear seat) Mk2 - Unscrew gear knob, remove lower seat belt fixings. (Place inertia reel units on rear seat) All Models - Remove rear tunnel seat belt fixings (Note which hand). Mk1 – Remove seat wear plates from the rear floor. NOTE. The plate with the upstand next to the tunnel has the upstand itself facing towards the outside of the car. 4 Remove securing screws on the centre console where fitted. Lift the console sideways to expose the wiring for the clock & radio. Mark all wires with tape then disconnect & remove console from the vehicle. 5 Remove centre securing screw at the bottom of the rear seat base – allowing the rear base to lift out of the way. 6. Remove sill plates. 7. Remove front scuttle panels (This may require removal of under dash shelf/glove box assembly if fitted). 8. Lift the old carpet out of the car (may need some effort over the handbrake boot). 9. Finally remove any old underfelt & clean/repair the floor as necessary Page 2 FIT NEW UNDERFELT – Some trimming is required to achieve best fit. 1 2 3 FRONT TUNNEL Lift the gear lever boot base up so that it is clear of the hole in the tunnel. Make sure felt is located centrally on tunnel top. Locate the front tunnel felt over the gear lever so that the lower rear corners sit on the cross member. (If you need to re-position the hole. Mark using a felt tip pen & cut to shape) Identify all parts of the kit. This picture shows a Mk2 front tunnel with a centre console. Using scissors, cut slots for the console mounting tabs, allowing the felt to sit flat. For cars with no centre console, the felt will simply lay flat over the tunnel. 4 5 6 REAR TUNNEL Locate rear tunnel felt over the handbrake, lightly glue the top front section centrally onto tunnel top. 8 Using a bradawl, locate the 2 seat belt mounting holes at the rear top of tunnel. Cut holes approx. 35mm diameter using scissors 9 Lightly spray glue the tunnel top in place, then lightly glue the sides. Mk1 – Fold felt over sides of tunnel. Slit at each end of bracket. 7 Mk1 – Slit along the middle of the bracket to make an upper & lower flap. 11 10 Mk1 - Seat locking bracket. Mk1 – Trim back the top edge so that when it is pushed behind the bracket, it will sit flat on the tunnel top & sides. 12 Lightly glue down the top & sides of rear tunnel. (Mk2 shown) Mk1 – Trim the bottom edge in line with the bottom edge of the bracket. This allows space for the carpet. 14 13 Tunnel felt finished. (Mk2 shown) All Cars - Lay the front footwell felts in place. Rear edge to cross member & butt up to tunnel felt. – No overlaps On driver’s side, fold back the front edge up to steering column. Page 3 15 17 16 All Cars - Slit centrally to edge of column then cut a hole. Push felt behind the pedal area & trim as required. All Cars - Mark & trim the tunnel felt if there is any overlap. Lightly glue the felt over wheel arch and front of floor area. All Cars - Lay the rear floor felts in place. No overlap with tunnel felt – lightly glue in place. Using the bradawl Mk1 – Locate the fixing holes for the seat wear plates, cut small holes to clear. Mk2 - Locate the 4 seat mount holes in the floor. Mark & cut out approx. 25mm holes in the felt FITTING NEW MOULDED CARPET SET 3 2 1 Measure the distance from the front of the handbrake gaiter to the centre of the gear lever. (In neutral) – Measure on the carpet set the same distance from the front of the handbrake hole. Cut a cross (approx. 50mm) at the centre point. Locate carpet over handbrake & gear lever. Push carpet forward until it locates over the cross member. Locate the position of the centre console brackets. Using a knife carefully cut a slot on the INSIDE of the brackets, allowing the carpet to sit flat on the tunnel. Pull gear lever boot down & locate its lower flange into the tunnel hole. Then push the carpet edge under the boot so that no raw edges of carpet are showing. Carefully cut out the hole for the Gear Lever. 5 4 6 Mk1 - Find the seat locking bracket – cut down the centre & a small cut at each end to create two flaps. Mk1 – In a similar fashion to the underfelt, trim back the top flap so that it sits flat on the tunnel top. 8 Mk1 – Trim the underside flap to sit up against the tunnel side & under the bracket. Glue the carpet to the underside of the bracket. 9 7 Pull the bottom edge of the hand brake gaiter through the carpet hole. You may find the use of a large flat screwdriver helps to hold the carpet edge down. Note: If the gaiter does not sit evenly, the carpet may need slight trimming. The gaiter should sit evenly in its hole, as shown above. Using a bradawl, locate the seat belt mounts behind the handbrake. Carefully cut holes approx. 10mm diameter, then re-fit the seat belt mounts. Page 4 10 12 11 Mk1 – Find fixing screw hole positions for seat wear brackets using a bradawl. Cut approx.. 10mm holes with scissors or a knife. Mk1 – Re-fit the wear plates. 14 13 Mk1 – Locate the seat mounting holes on cross member, using a bradawl. Cut the holes with a knife or scissors. 15 Locate using a bradawl & cut the 8 seat mounting holes using a knife Re-fit the centre console as necessary & gear knob. (Mk2 shown) Re-fit front scuttle panels and under dash shelf/ glovebox assemblies. (Mk1 shown) (Mk2 shown) 17 18 16 All models - The under door sill carpet edge should just touch the rubber door seal. If it is too tall make sure the carpet is tight up to the tunnel, then trim as necessary. Offer up the metal sill plates, use a bradawl to locate the centre mounting holes then screw plates into place. Happy Motoring! Your new carpet set fitting is now complete. Re-fit the front seats. All models - Locate & cut holes for lower seat belt mounts & screw belts in place. (Check seat belt operation) Push the rear seat base back into position & re-fit the central retaining screw.