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Ford Focus 1
General information
Using the manual
About this guide
Health and Precautions
Warning signs on the vehicle
Standard Techniques for Service Stations
Towing a car
Connecting an Auxiliary Battery Using Jumpers
Cleaning and calibration of elements
Solvents, sealants and adhesives
Road test / Roller stand test
Using the jack and lifting the vehicle
Noise, vibration and harshness (NVH)
Diagnosis and verification of noise, vibration and harshness (NVH)
Identification codes
Location of identification codes
Vehicle identification number
Vehicle identification label (typical) or VIN plate
Power unit
Engine
Engine diagnostics and checks
Engine oil leaks
Compression pressure measurement
Oil pressure measurement
Valve train test — static (engine off)
Engine 1.4/1.6 Zetec-SE
Engine Specifications 1.4L/1.6L Zetec-SE
Description and principle of operation of the 1.4L / 1.6L Zetec-SE engine
Valve clearance — adjustment
Intake manifold — removal and installation
Valve cover — removal and installation
Front crankshaft seal — removal and installation
Valve seals — removal and installation
Valves — removal and installation
Camshafts — removal and installation
Camshaft seal — removal and installation
Timing belt — removal and installation
Exhaust manifold — removal and installation
Cylinder head — removal and installation
Oil sump — removal and installation
Removing the engine with a manual transmission
Removing the engine with automatic transmission
Engine disassembly
Cylinder head — disassembly and assembly
Engine assembly
Installing an engine with a manual gearbox
Engine installation with automatic transmission
Engine 1.6/1.8/2.0 Zetec-E
Engine Specifications 1.8L/2.0L/1.6L Zetec-E
Description and principle of operation of the Zetec-E engine
Zetec-E engine design
Valve clearance — adjustment
Intake manifold — removal and installation
Front crankshaft seal — removal and installation
Valve springs — removal and installation
Valve seals — removal and installation
Valves — removal and installation
Camshafts — removal and installation
Camshaft seal — removal and installation
Timing belt — removal and installation
Exhaust manifold — removal and installation
Cylinder head — removal and installation
Oil pump — removal and installation
Rear crankshaft seal — removal and installation
Oil sump — removal and installation
Removing the iB5 manual transmission engine
Removing the MTX-75 Manual Transmission Engine
Removing the engine with automatic transmission
Removing the 1.6L Zetec-E engine
Engine disassembly
Engine assembly
IB5 manual transmission engine installation
MTX-75 Manual Transmission Engine Installation
Engine installation with automatic transmission
Engine installation 1.6L Zetec-E
Engine Duratec ST 2.0 l
Duratec ST 2.0L Engine Specifications
Description and principle of operation of the engine Duratec ST 2.0 l
Intake manifold — removal and installation
Front crankshaft seal — removal and installation
Valve springs — removal and installation
Valve seals — removal and installation
Valves — removal and installation
Camshafts — removal and installation
Timing belt — removal and installation
Exhaust manifold — removal and installation
Cylinder head — removal and installation
Oil sump — removal and installation
Oil pump — removal and installation
Rear crankshaft seal — removal and installation
Removing the engine
Engine disassembly
Engine assembly
Engine installation
Engine Duratec 8V 1.6 l
Engine Specifications Duratec 8V 1.6L
Description and principle of operation of the Duratec 8V 1.6L engine
Intake manifold — removal and installation
Valve cover — removal and installation
Front crankshaft seal — removal and installation
Valve seals — removal and installation
Camshaft — removal and installation
Timing chain — removal and installation
Camshaft pushers — removal and installation
Exhaust manifold — removal and installation
Cylinder head — removal and installation
Oil sump — removal and installation
Oil pump — removal and installation
Rear crankshaft seal — removal and installation
Removing the engine Duratec 8V 1.6L
Engine disassembly Duratec 8V 1.6L
Cylinder head — disassembly and assembly
Engine assembly Duratec 8V 1.6L
Engine installation Duratec 8V 1.6L
Diesel engine 1.8 l
Diesel engine specifications
Description and principle of operation of the engine without fuel injection
Description and principle of operation of a fuel injection engine
Valve clearance — adjustment
Valve cover — removal and installation
Front crankshaft seal — removal and installation
Valve seals — removal and installation
Camshaft — removal and installation
Camshaft seal — removal and installation
Timing belt — removal and installation
Cylinder head — removal and installation
Fuel Injection Cylinder Head
Oil sump — removal and installation
Rear crankshaft seal — removal and installation
Removing the engine
Engine disassembly
Disassembly of a fuel injected engine
Cylinder head — disassembly and assembly
Fuel injection cylinder head — disassembly and assembly
Engine assembly
Fuel injection engine assembly
Engine installation
Engine cooling
Engine Cooling Specifications
Description and principle of operation of engine cooling
Diagnostics and checks of the engine cooling system
Pinpoint tests of the engine cooling system
Checks of elements of the engine cooling system
Drain/fill coolant and bleed
Flushing the cooling system
Backwashing (backflushing) of the cooling system
Thermostat (1.6L Zetec-SE / 1.4L) — removal and installation
Thermostat (1.6L Duratec) — removal and installation
Thermostat (1.8L/2.0L/1.6L Zetec-E) — removal and installation
Thermostat (1.8 l diesel) — removal and installation
Thermostat (Duratec ST 2.0 l) — removal and installation
Thermostat housing (1.8L / 2.0L / 1.6L Zetec-E) — removal and installation
Thermostat housing (1.8 l diesel) — removal and installation
Thermostat housing (Duratec ST 2.0 l) — removal and installation
Water pump (1.6L Zetec-SE / 1.4L) — removal and installation
Water pump (1.8L/2.0L/1.6L Zetec-E) — removal and installation
Water pump housing (1.8L / 2.0L / 1.6L Zetec-E) — removal and installation
Water pump (1.8 l diesel) — removal and installation
Radiator (1.6L Zetec-SE / 1.4L) — removal and installation
Radiator (1.8L/2.0L/1.6L Zetec-E) — removal and installation
Radiator (Duratec ST 2.0 l) — removal and installation
Cooling fan — removal and installation
Cooling fan motor — removal and installation
Motor and cooling fan shroud (1.6L Zetec-SE/1.4L)
Motor and cooling fan shroud (1.8L/2.0L/1.6L Zetec-E)
Expansion tank of the cooling system
Thermostat housing (1.6L Duratec) — removal and installation
Water pump (1.6L Duratec) — removal and installation
Radiator (1.6L Duratec) — removal and installation
Cooling fan motor (1.6L Duratec)
Fuel supply
Specifications (1.6L Zetec-SE/1.4L)
Description and operation principle (1.6L Zetec-SE/1.4L)
Diagnostics and checks (1.6L Zetec-SE/1.4L)
Throttle body (1.6L Zetec-SE/1.4L)
Fuel injectors (1.6L Zetec-SE/1.4L)
Fuel System Wiring Harness (1.6L Zetec-SE/1.4L)
Fuel supply manifold (1.6L Zetec-SE/1.4L)
Fuel pressure regulator (1.6L Zetec-SE/1.4L)
Specifications (1.8L/2.0L/1.6L Zetec-E)
Description and function (1.8L/2.0L/1.6L Zetec-E)
Diagnostics and Checks (1.8L/2.0L/1.6L Zetec-E)
Throttle body (1.8L/2.0L/1.6L Zetec-E)
Fuel injectors (1.8L/2.0L/1.6L Zetec-E)
Fuel System Wiring Harness (1.8L/2.0L/1.6L Zetec-E)
Fuel Supply Manifold (1.8L/2.0L/1.6L Zetec-E)
Fuel pressure regulator (1.8L/2.0L/1.6L Zetec-E)
Specifications (1.8L Diesel)
Description and principle of operation (1.8 l diesel)
Diagnostics and checks (1.8 l diesel)
Fuel injectors (1.8 l diesel)
High pressure fuel pump (1.8L diesel)
Specifications (turbocharger)
Description and principle of operation (turbocharger)
Diagnostics and checks (turbocharger)
Inspection and testing (turbocharger)
Pinpoint tests (turbocharger)
Turbocharger 1.8L Diesel (75 PS/90 PS)
Turbocharger 1.8L fuel injected diesel
Specification (fuel injected diesel)
Description and function (fuel injected diesel)
Diagnostics and Checks (Diesel Fuel Injection)
Cleaning the elements of the fuel injection system (fuel injected diesel)
Fuel injectors (fuel injected diesel)
Fuel supply manifold (fuel injected diesel)
Fuel Pump (Diesel Fuel Injection)
Fuel return line with venturi nozzle
Specifications (Duratec ST 2.0L)
Description and principle of operation (Duratec ST 2.0 l)
Throttle Body (Duratec ST 2.0L)
Fuel system wiring harness (Duratec ST 2.0L)
Fuel supply manifold (Duratec ST 2.0 l)
Specifications (1.6L Duratec)
Description and principle of operation (1.6L Duratec)
Diagnostics and checks (1.6L Duratec)
Throttle body (1.6L Duratec)
Fuel System Wiring Harness (1.6L Duratec)
Fuel supply manifold (1.6L Duratec)
Description and principle of operation of the fuel supply system
Diagnostics and checks of the fuel supply system
Pinpoint tests of the fuel delivery system
Relieving pressure in the fuel supply system
Quick coupler — disconnection and connection
Emptying the fuel tank
Couplings with spring lock — disconnection and connection
Fuel tank and fuel lines
Fuel tank — removal and installation
Fuel pump module — removal and installation
Fuel tank filler pipe — removal and installation
Fuel filter — removal and installation
Fuel filter (1.8 l diesel) — removal and installation
Fuel filter (1.8 l injection diesel) — removal and installation
Inertial Fuel Cutoff Switch (IFS)
Acceleration control (accelerator)
Accelerator pedal — removal and installation
Accelerator cable (1.6L Zetec-SE / 1.4L) — removal and installation
Accelerator cable (1.8L / 2.0L / 1.6L Zetec-E) — removal and installation
Accelerator cable (Duratec ST 2.0 l) — removal and installation
Accelerator cable (1.6L Duratec) — removal and installation
Speed control
Speed control diagnostics and checks
Pinpoint speed control tests
Speed Control Deactivator Switch Adjustment
Speed control cable
Speed Control Cable (Duratec ST 2.0 L)
Speed control system switch
Accessory drive
Accessories Drive Specifications
Description and principle of operation of the accessory drive
Accessory drive diagnostics and checks
Accessory drive belt — removal and installation
Accessory drive belt without tensioner
Accessory drive belt tensioner — removal and installation
Accessory Drive Belt Tensioner (1.8L Diesel)
Accessory Belt Intermediate Pulley
Accessory Drive Belt Intermediate Pulley (1.8L Diesel)
Accessory drive belt (1.6L Duratec)
Accessory Drive Belt Tensioner (1.6L Duratec)
Launch system
Launch System Specifications
Description and principle of operation of the launch system
Diagnostics and checks of the starting system
Launch system pinpoint tests
Starter (1.4L/1.6L/1.8L Diesel)
Starter (1.8L/2.0L/1.6L Zetec-E)
Starter (Duratec ST 2.0 l)
Starter (1.6L Duratec)
Ignition system
Ignition System Specifications 1.4/1.6 Zetec-SE
Description and principle of operation of the ignition system 1.4 / 1.6 Zetec-SE
Diagnostics and checks of the ignition system 1.4 / 1.6 Zetec-SE
Ignition Coil Block 1.4/1.6 Zetec-SE
Spark plug wires 1.4/1.6 Zetec-SE
Ignition System Specifications 1.8/2.0/1.6 Zetec-E
Description and principle of operation of the ignition system 1.8 / 2.0 / 1.6 Zetec-E
Diagnostics and checks of the ignition system 1.8/2.0/1.6 Zetec-E
Ignition Coil Block 1.8/2.0/1.6 Zetec-E
Ignition coil bracket 1.8/2.0/1.6 Zetec-E
Glow Plug System Specifications (1.8L Diesel)
Description and operation of the glow plug system (1.8L diesel)
Diagnosis and checks of the glow plug system (1.8L diesel)
Glow Plug Wire (1.8L Diesel)
Description and principle of operation of the ignition system (Duratec 8V 1.6L)
Diagnostics and checks of the ignition system (Duratec 8V 1.6L)
Air and vapor
Intake air distribution and filtration
Distribution and filtration diagnostics and checks
Air filter inlet pipe
Air filter — removal and installation
Air filter filter element
Fuel vapor control
Fuel vapor control diagnostics and checks
Evaporative carbon filter
Evaporative carbon filter (Duratec ST 2.0L)
Carbon filter purge valve for fuel vapor control system
Carbon filter purge valve for fuel vapor control (Duratec)
Engine management
Specifications for electronic controls
Description and principle of operation of electronic controls
Diagnostics and checks
Camshaft Position Sensor (CMP) (1.6L Zetec-SE/1.4L)
Camshaft Position Sensor (CMP) (1.8L/2.0L/1.6L Zetec-E)
Crankshaft Position Sensor (CKP) (1.6L Zetec-SE/1.4L)
Crankshaft Position Sensor (CKP) (1.8L/2.0L/1.6L Zetec-E)
Crankshaft position sensor (CKR) (1.8 l diesel)
Crankshaft position sensor (CKP) (1.8 l diesel injection)
Power Steering Pressure Switch (PSP) (1.6L Zetec-SE/1.4L)
Power Steering Pressure Switch (PSP) (1.8L/2.0L/1.6L Zetec-E)
Powertrain Control Module (PCM)
Idle Air Control Valve (1.6L Zetec-SE/1.4L)
Idle Air Control Valve (1.8L/2.0L/1.6L Zetec-E)
Mass Air Flow (MAF) Sensor (1.6L Zetec-SE/1.4L)
Mass Air Flow (MAF) Sensor (1.8L/2.0L/1.6L Zetec-E)
Heated oxygen sensor (HO2S) (1.6L Zetec-SE/1.4L)
Heated oxygen sensor (HO2S) (1.8L/2.0L)
Heated oxygen sensor (HO2S) (1.8L/2.0L/1.6L Zetec-E)
Knock sensor (KS) (1.4L/1.6L)
Cylinder Head Temperature Sensor (CNT) (1.6L Zetec-SE/1.4L)
Cylinder head temperature sensor (CNT) (1.8L/2.0L/1.6L Zetec-E)
Cylinder head temperature sensor (CNT) (1.8L diesel)
Clutch Pedal Position Switch (CPP)
Injector Control Module (IDM) (1.8L Diesel)
Fuel Pump Control Module (FPDM) (Duratec ST 2.0L)
Intake manifold duct control (IMRC) actuator
Idling Air Supply Control Valve (IAC)
Exhaust toxicity
Emission Control Specifications (1.8/2.0/1.6 Zetec-E)
Description and principle of operation (1.8/2.0/1.6 Zetec-E)
Diagnostics and checks (1.8/2.0/1.6 Zetec-E)
Positive crankcase ventilation (PCV) hose (1.8/2.0/1.6 Zetec-E)
Positive crankcase ventilation valve (PCV) (1.8/2.0/1.6 Zetec-E)
Emission Control Specifications (1.8L Diesel)
Description and principle of operation (1.8 l diesel)
Diagnostics and checks (1.8 l diesel)
Exhaust Gas Recirculation (EGR) Valve (1.8L Diesel)
Exhaust Gas Recirculation (EGR) Valve (1.8L Injected Diesel)
Line from exhaust manifold to exhaust gas recirculation (EGR) valve
Line from Exhaust Gas Recirculation (EGR) cooler to EGR valve
Exhaust Gas Recirculation (EGR) Cooler (75 PS/90 PS)
Exhaust Gas Recirculation (EGR) Cooler (115 PS)
Oil separator of the crankcase ventilation system
Exhaust system
Exhaust System Specifications
Description and principle of operation
Catalytic converter (1.4L / 1.6L) — removal and installation
Catalytic converter (1.8L/2.0L) — removal and installation
Catalytic converter (1.8 l diesel) — removal and installation
Catalytic converter (Duratec ST 2.0 l) — removal and installation
Automatic gearbox
Automatic transmission specifications
Description and principle of operation of an automatic transmission
Electromagnetic control of synchronized gear shifting
Diagnostics and checks of an automatic transmission
Tables of diagnostic trouble codes
The location of the contacts of the gearbox connectors
Pinpoint tests — car equipped with OSC
Special screening procedures
Inspection for leaks
Symptom Diagnostics
Fluid pan, gasket and filter
Main control valves
Turbine shaft speed sensor (TSS)
Output Shaft Speed Sensor (OSS)
Sealing of the left half shaft
Consolidation of the right semiaxis
Transmission range sensor (TR)
Transmission in a block with a drive axle 1.6L — removal
Transmission in a block with a leading axle 2.0L — removal
Transmission in a block with a driving axle — disassembly
Final drive holder with differential — disassembly and assembly
Pump assembly — disassembly and assembly
Transmission shaft — disassembly and assembly
Forward Clutch — Disassembly and Assembly
Direct and reverse clutch — disassembly and assembly
Direct clutch — disassembly and assembly
Reverse clutch — disassembly and assembly
Planetary gear assembly — disassembly and assembly
Main control valve block — disassembly and assembly
Transmission housing in a block with a drive axle
Torque converter
Checking the torque converter for leaks
Checking the axial clearance of the torque converter
Transmission in a block with a driving axle — assembly
1.6L transaxle transaxle — installation
2.0L Transaxle Transmission — Installation
Description and principle of operation of the gearbox cooling
Diagnosis and checks of transmission cooling
Transmission fluid cooler — removal and installation
Transmission fluid cooler pipelines — removal and installation
Description and principle of operation of external controls
Diagnosis and testing of external controls
Pinpoint tests of external controls
Gear selector cable adjustment
Executive gearshift locking device
Gear selector cable — removal and installation
Gear selection lever — removal and installation
Nest of the lever of a choice of transfers — removal and installation
Gear selector handle — removal and installation
Gear selector — disassembly and assembly
Clutch
Manual transmission specifications
General information about manual transmission
Clutch diagnostics and checks
Pinpoint clutch tests
Clutch control diagnostics and checks
Checking the clutch slave cylinder
Bleeding the iB5 clutch system
Bleeding the MTX-75 Clutch System
Bleeding the clutch system MT285
IB5 shift cable adjustment
MTX-75 Shift Cable Adjustment
Shift Cable Adjustment MT285
IB5 mechanical box clutch
MTX-75 Manual Clutch
MT285 mechanical box clutch
IB5 clutch controls
IB5 clutch master cylinder
IB5 clutch slave cylinder
MTX-75 Clutch Controls
MTX-75 Clutch Master Cylinder
MTX-75 Clutch Slave Cylinder
Mechanical gearbox iB5
IB5 Manual Transmission Specifications
Description and function of iB5
Bearing check
Consolidation of the left semiaxis — removal and installation
Consolidation of the right semiaxis — removal and installation
Gearshift control shaft seal
Vehicle speed sensor (VSS) — removal and installation
Gearbox with drive axle (1.6L Zetec-SE/1.4L) — removal
Gearbox with drive axle (1.8L/1.6L Zetec-E) — removal
Gearbox with drive axle (1.6L) — removal
Gearbox with axle (vehicles up to 07.2000) — dismantling
Gearbox with axle (vehicles after 08.2000) — dismantling
Gear selector plate — disassembly and assembly
Primary shaft — disassembly and assembly
Output shaft — disassembly and assembly
Differential — disassembly and assembly
Gearbox with axle (vehicles up to 07.2000) — assembly
Gearbox with axle (vehicles after 08.2000) — assembly
Drive Axle Transmission (1.6L Zetec-SE/1.4L) — Installation
Drive Axle Transmission (1.8L/1.6L Zetec-E) — Installation
Gearbox with drive axle (1.6L) — installation
External controls iB5
Diagnosis and testing of external controls
Lever gear shift mechanism — removal and installation
Gear shift lever — removal and installation
Gearshift cables — removal and installation
Gear lever — disassembly and assembly
Mechanical gearbox MTX-75
MTX-75 Manual Transmission Specifications
Description and operation of the MTX-75
Bearing check
Consolidation of the left semiaxis — removal and installation
Consolidation of the right semiaxis — removal and installation
Gearbox with drive axle (2.0L) — removal
Gearbox with drive axle (1.8L diesel) — removal
Transmission in a block with a driving axle — disassembly
Gear selector (vehicles up to 07.2000)
Primary shaft — disassembly and assembly
Output shaft (vehicles up to 07.2000) — disassembly and assembly
Output shaft (vehicles after 08.2000) — disassembly and assembly
Differential — disassembly and assembly
Transmission in a block with a driving axle — assembly
Gearbox in block with a leading axle (2.0L) — installation
Transmission in a block with a driving axle (1.8 l diesel) — installation
External Controls MTX-75
Diagnosis and testing of external controls
Lever gear shift mechanism — removal and installation
Gear shift lever — removal and installation
Gearshift cables — removal and installation
Gear lever (vehicles up to 08.2001)
Gear lever (vehicles after 08.2001)
Mechanical gearbox MT285
MT285 Manual Transmission Specifications
Description and principle of operation of MT285
Draining and refilling transmission fluid
Consolidation of the left semiaxis — removal and installation
Consolidation of the right semiaxis — removal and installation
Transmission in a block with a driving axle — removal
Transmission in a block with a driving axle — installation
External controls MT285
Diagnosis and testing of external controls
Lever gear shift mechanism — removal and installation
Gearshift cables — removal and installation
Gear lever — disassembly and assembly
Chassis
Front suspension
Suspension specifications
Diagnostics and suspension check
Pinpoint Suspension Tests
Suspension checks
Rear wheel toe adjustment (15 211 0)
Front wheel toe adjustment (14 117 0)
Estimated suspension height adjustment
Wheel bearing inspection
Rear suspension
Rear Suspension Specifications
Description and principle of operation of the rear suspension
Wheel hub (15 373 0) — removal and installation
Wheel bearing — removal and installation
Wheel bearing — removal and installation
Front lower arm (15 690 0) — removal and installation
Rear lower arm (15 693 0) — removal and installation
Upper arm (15 701 0) — removal and installation
Anti-roll bar (15 752 0)
Wheel fist (15 366 0) — removal and installation
Shock absorber (15 791 0) — removal and installation
Shock absorber — station wagon (15 791 0)
Shock absorber — 3-door/4-door (15 791 0)
Spring (15 621 0) — removal and installation
Spring — 3-door/4-door (15 621 0)
Spring — station wagon (15 621 0)
Cross member — removal and installation
Wheels and tires
Tire inspection and testing
Tire wear and vibration diagnostics
Tire sensitivity to speed and revs
Tire symptoms table
Removal and installation of a wheel
Front axle axles
Front axle specifications
Description and principle of operation
Inspection and testing of the front axle shafts
Left half shaft — removal and installation
Right half shaft — removal and installation
Intermediate shaft — removal and installation
Cover of the inner joint of equal angular velocities (CV joint)
Cover of the external hinge of equal angular speeds (SHRUS)
Left axle shaft — disassembly and assembly
Right axle shaft — disassembly and assembly
Brake system
Description and principle of operation of the brake system
Inspection and testing of the brake system
Table of signs of a malfunction of the brake system
Pinpoint brake tests
Checks of elements of the brake system
Removal of air from the brake system
Removal of air from the brake system under pressure
Checking the brake system for leaks
Checking brake disc runout
Drum Brake Specifications
Description and principle of operation of the drum brake
Brake drum — removal and installation
Brake pads — removal and installation
Wheel cylinder — removal and installation
Brake shield — removal and installation
Front Disc Brake Specifications
Description of front disc brake
Brake pads front disc brake
Brake caliper front disc brake
Brake Disc Front Disc Brake
Brake Disc Front Disc Brake — Duratec ST 2.0 L
Dismantling the front disc brake caliper
Rear Disc Brake Specifications
Description of rear disc brake
Brake caliper rear disc brake
Brake pads rear disc brake
Brake Disc Rear Disc Brake
Rear disc brake plate shield
Description and principle of operation of the parking brake
Inspection and testing of the parking brake
Parking brake pinpoint tests
Parking brake cable adjustment
Parking brake lever
Parking brake cable — removal and installation
Hydraulic brake
Hydraulic Brake Specifications
Description and principle of operation of the hydraulic brake drive
Brake pedal and pedal bracket (manual transmission)
Brake pedal and pedal bracket (automatic transmission)
Master brake cylinder — removal and installation
Master brake cylinder — removal and installation (diesel)
Brake fluid reservoir — removal and installation
Specifications of the vacuum brake booster
Description and principle of operation of the vacuum brake booster
Vacuum brake booster — removal and installation
Vacuum pump of the brake system — removal and installation
Anti-lock braking system
Anti-Lock Specifications
Description and principle of operation of the anti-lock braking system
Diagnostics and checks of the anti-lock system
Hydraulic Control Unit (HCU)
Rear wheel speed sensor
Rear Wheel Speed Sensor Pulse Ring
Description and principle of operation of the directional stability function
The speed sensor of the angular rotation of the car around the vertical axis
Acceleration sensor — removal and installation
Steering
Steering Specifications
Description and principle of operation of the steering
Steering diagnostics and checks
Power Steering System Flush — 1.8L/2.0L/1.4L/1.6L
Power Steering System Flushing — 1.8L Diesel (75 PS/90 PS)
Power Steering System Flushing — 1.8L Diesel (75 PS/90 PS)
Bleeding air from the power steering system
Power steering system purge
Filling the working fluid in the power steering system
Power Steering Specifications
Description of power steering
Power Steering Pump — 1.4L/1.6L (with A/C)
Power Steering Pump — 1.4L/1.6L (No A/C)
Power Steering Pump — 1.8L/2.0L
Power Steering Pump — 1.8L Diesel
Power steering pump — Duratec ST 2.0 l
Power Steering Pump Pulley — 1.8L/2.0L
Power Steering Pump Pulley — 1.4L/1.6L/1.8L Diesel
Pressure line from the power steering pump to the steering gear
Power Steering Working Fluid Cooler
Steering gear — removal and installation
Steering gear bushing — removal and installation
Description of steering column switches
Diagnostics and testing of steering column switches
Steering column switch pinpoint tests
Ignition switch — removal and installation
Steering Gear Description
Tie rod — removal and installation
Tie rod end — removal and installation
Steering gear cover
Steering column description
Steering wheel — removal and installation
Steering column — Vehicles built after 03.2002
Steering column — Vehicles manufactured from 03/2002
Steering column — Duratec ST 2.0 l
Steering column (cars up to 03.2002) — disassembly and assembly
Steering column (vehicles from 03.2002) — disassembly and assembly
Steering column (Duratec ST 2.0 l) — disassembly and assembly
Body and coating
Body panels
General information about the body
Diagnostics and body checks
Tailgate panels
Aligning the position of the hood — removal and installation
Mudguard wing — removal and installation
Bonnet panel grille — removal and installation
Wing — removal and installation
Lockable Body Specifications
Body elements
Rear view mirrors
Rear-view mirrors — diagnostics and checks
Rear view mirrors — Pinpoint tests
Outside mirror — removal and installation
Handles, locks, latches and entry systems
Diagnostics and checks of entry systems
Remote control transmitter programming
Hood latch — removal and installation
Front door latch — removal and installation
Rear door latch — removal and installation
Latch of the raised luggage compartment door
External door handle — removal and installation
Hood lock cylinder — removal and installation
Ignition lock cylinder — removal and installation
Door lock cylinder — removal and installation
Lock cylinder of the lifted luggage compartment door
Tailgate Lock Cylinder (Station wagon)
Internal door latch release handle
Bumper Torque Specification
Front bumper cover — removal and installation
Rear Bumper Cover (3-Door/5-Door)
Rear bumper cover (4-door)
Front bumper — removal and installation
Rear bumper (3-door/4-door/5-door)
Rear bumper (station wagon)
Salon elements
Interior trim
'A' pillar trim panel — removal and installation
'B' pillar trim panel — removal and installation
'C' pillar trim panel — removal and installation
'C' Pillar Trim Panel — 4-Door
Front door trim panel
Rear door trim panel
Trim panel of the rear side of the body
Door sill trim panel
Ceiling trim — removal and installation
Seat Specifications
Description and principle of operation of the seats
Seat diagnostics and checks (vehicles up to 08.2001)
Seat pinpoint tests (vehicles up to 08.2001)
Seat diagnostics and checks (vehicles after 08.2001)
Seat pinpoint tests (vehicles after 08.2001)
Seat diagnostics and checks (Duratec ST 2.0 l)
Seat pinpoint tests (Duratec ST 2.0 l)
Front seat — removal and installation
Front seat back — removal and installation
Front Seat Back (Folding Flat Seat)
Rear seat backrest — removal and installation
Rear Seat Backrest (Split Seat)
Front seat cushion — removal and installation
Rear seat back latch — removal and installation
Rear Seat Back Latch (3-Door/5-Door/Estate)
Front seat cushion — disassembly and assembly
Rear seat cushion (vehicles after 08.2000)
Front seat back — disassembly and assembly
Front seat back (flat seat) — disassembly and assembly
Rear seat back — disassembly and assembly
Rear seat backrest (split seat) — disassembly and assembly
Dashboard — removal and installation
Floor console (vehicles up to 10.2001, manual)
Floor console (vehicles after 10.2001, manual)
Floor console (vehicles up to 10.2001, automatic)
Floor console (vehicles after 10.2001, automatic)
Upper console — removal and installation
Glass, frames and mechanisms
Specifications
Description and principle of operation
Diagnosis and checks (vehicles up to 08.2000)
Pinpoint tests (vehicles up to 08.2000)
Diagnostics and checks (vehicles from 08.2000 to 08.2001)
Pinpoint tests (vehicles from 08.2000 to 08.2001)
Diagnosis and checks (vehicles after 08.2001)
Pinpoint tests (vehicles after 08.2001)
Initializing the door window motor
Front door window glass — removal and installation
Rear door window glass — removal and installation
Rear side window glass (3-door)
Rear side window glass (4-door)
Rear side window glass (5-door)
Rear side window glass (station wagon)
Rear window glass (3-door/5-door)
Rear window glass (4-door)
Rear window glass (station wagon)
Electric motor of window door lifter
Power window front door
Rear window window regulator
Window lifter and front door window motor
Power window lifter and rear door window motor
Windshield — removal and installation
Front door window glass upper guide
Rear window glass upper guide
Windshield wipers and washers
Wiper Specifications
Description and principle of operation of windshield wipers
Wiper diagnostics and checks (vehicles up to 08.2001)
Pinpoint wiper tests (vehicles up to 08.2001)
Checking wiper elements (vehicles up to 08.2001)
Wiper diagnostics and checks (vehicles after 08.2001)
Wiper pinpoint tests (vehicles after 08.2001)
Checking wiper elements (vehicles after 08.2001)
Adjustment of brushes and levers of windshield wipers
Windshield wiper motor — removal and installation
Rear window wiper motor — removal and installation
Windshield washer pump and reservoir
Car sunroof
Torque specification
Diagnostics and checks of the sunroof
Sunroof pinpoint tests
Checking the water drainage system and repairing water leaks
Sunroof alignment
Sunroof motor initialization
Sunroof glass — removal and installation
Sunroof sunroof — removal and installation
Cable and sunroof guide — removal and installation
Sunroof frame — removal and installation
Front drain hose sunroof — removal and installation
Sunroof Rear Drain Hose (4/5-Door/Station)
Sunroof Rear Drain Hose (3-Door)
Sunroof — removal and installation
Sunroof drive motor — removal and installation
Seat belts
Seat Belt Specifications
Description and principle of operation of seat belts
Seat belt diagnostics and checks
Front seat belt retractor
Rear seat belt retractor (3-/5-door)
Rear seat belt retractor (4-door)
Rear seat belt retractor (wagon)
Center rear seat belt retractor
Center rear seat belt retractor (4-door)
Shoulder belt height adjustment mechanism
Seat belt buckle — removal and installation
Seat belt lock and tensioner — removal and installation
Secondary Restraint System Specifications
Auxiliary restraint system — description and principle of operation
Auxiliary restraint system — diagnostics and checks
Restraint System Diagnosis Instructions (up to 08.2002)
Restraint System Diagnosis Instructions (After 08.2002)
Restraint system pinpoint tests (up to 10.2001)
Restraint system pinpoint tests (after 10.2001)
Restraint system pinpoint tests (after 08.2002)
Recycling a deployed airbag
Airbag Recycling — Unusable Car
Recycling a non-deployed airbag
Disposal of airbags and seat belt tensioners
Shock sensor — removal and installation
Side impact sensor — removal and installation
Driver airbag module — removal and installation
Passenger airbag module (vehicles up to 10.2001)
Passenger airbag module (vehicles after 08.2002)
Side airbag module
Clock spring — removal and installation
Restraint Control Module (RCM)
Body repairs
Description and principle of operation
Body protection against corrosion
Repair of plastic parts
Water leaks
Wind noise
Removal of unpainted dents
Noise, vibration and harshness
Clearance checks — general information
Checking underbody clearances
Checking frame and body clearances
Right hood hinge — removal and installation
Left front fender — removal and installation
Hood latch panel — removal and installation
Front cross member — removal and installation
Reinforcement of the wing apron panel — removal and installation
Internal reinforcement of the wing apron panel — removal and installation
Deformable element of the spar — removal and installation
Front side member section — removal and installation
Right front side member and left wing apron panel
Roof panel (4-door) — removal and installation
Roof panel (5-door) — removal and installation
Roof panel (station wagon) — removal and installation
'A' pillar outer panel section and reinforcement
Door half loop — removal and installation
Lower trim panel (3-door)
Lower trim panel (5-door)
Bottom trim panel section (5-door)
Lower trim panel front section (3-door)
Lower trim panel front section (5-door)
Bottom trim panel rear section (5-door)
'B' pillar and reinforcement (3-door)
'B' pillar and reinforcement (5-door)
Subframe Specifications and Mounting System
Cross member — removal and installation
Body Alignment Check
Checking violations of the alignment of the lower part of the body (bottom)
Back elements
Rear Side Body Left Panel (4-Door)
Left panel of the rear side of the body (station wagon)
Rear Side Body Right Panel (3-Door)
Right rear side panel (5-door)
Front Section of Rear Side Body Panel/Side Panel (3-Door)
Rear Left Section of Rear Side Body Panel/Side Panel (3-Door)
Rear Left Side Body Panel/Side Panel Section (5-Door)
Rear Right Section of Rear Side Body Panel/Side Panel (4-Door)
Rear Right Section of Rear Side Body Panel/Side Panel (Estate)
Rear Side Body Inner Panel (3-Door)
Rear Side Body Inner Panel (5-Door)
Rear Side Body Inner Panel and Wheel Arch (4-Door)
Rear side body inner panel and wheel arch (station wagon)
Inner Rear Section of Rear Side Body Panel (3-Door)
Inner Rear Section of Rear Side Body Panel (4-Door)
Inner rear section of rear side panel (station wagon)
Rear Inner Body Rear Side Panel (4-Door)
Water drain panel (4-door)
Water drain panel (5-door)
Water drain panel reinforcement (5-door)
Reinforcement of the water drain panel — station wagon
Inner half rear wheel arch (4-door)
Inner Half Rear Wheel Arch — 5-Door
Inner half of the rear wheel arch (station wagon)
Semi-section rear outer wheel arch (station wagon)
Rear light mounting panel (4-door)
Rear lamp mounting panel (station wagon)
Rear panel (5-door)
Rear panel (station wagon)
Rear panel and reinforcing element (4-door)
Rear panel section (wagon)
Rear panel and cross member (station wagon)
Rear floor panel (5-door)
Right section of rear floor panel (station wagon)
Rear floor panel section (station wagon)
Rear floor panel section (5-door)
Spare wheel recess (station wagon)
Rear spar section (5-door)
Rear spar section (station wagon)
Storage shelf panel (4-door)
Tailgate Hinge (4-Door)
Electrical equipment
Climate control
Climate control specifications
Description and principle of operation of microclimate control
Diagnostics and checks (vehicles produced before 07.2001)
Pinpoint climate control tests (vehicles up to 07.2001)
Diagnostics and checks (vehicles manufactured from 08.2001)
Pinpoint climate control tests (vehicles from 08.2001)
Coupling with spring lock
Adjusting the air gap of the air conditioning clutch
Finding Leaks Using Fluorescent Dye
Electronic leak detection
Adding Coolant Oil
Handling contaminated refrigerant
Cleaning the air distribution system
Utilization of the refrigerant, evacuation and charging of the air conditioning system
Air distribution and purification
Air Conditioning Specifications
Description and principle of operation of air conditioning
Air conditioning compressor — removal and installation
Air conditioning compressor (1.6L) — removal and installation
Clutch and clutch solenoid coil
Evaporator jet — removal and installation
Suction accumulator — removal and installation
Low pressure switch — removal and installation
The core of the condenser (refrigerator) — removal and installation
High pressure switch — removal and installation
Description and operation of controls
Complete climate controls — removal and installation
Controls of a microclimate assy (automatic) — removal and installation
Intake air mixing damper drive
Air distribution cable block
Heating and ventilation
Torque specification
Description and principle of operation
Blower fan motor — removal and installation
Heater and evaporator housing — removal and installation
Heater core — removal and installation
Heater housing — disassembly and assembly
Additional heating specifications
Description and principle of operation of additional heating
Diagnosis and checks of additional heating
Pinpoint additional heating tests
Diagnostics and checks of the electric auxiliary heater
Pinpoint tests for electric auxiliary heater
Additional fuel-powered heater — removal and installation
Additional heater — disassembly and assembly
Instruments and control lamps
Dashboard and instrument panel lighting
Diagnostics and checks of the instrument panel
Dashboard pinpoint tests
Instrument panel — description
Diagnostics and checks of the instrument panel
Instrument Pinpoint Tests
Instrument panel — removal and installation
Instrument panel (Duratec ST 2.0 l) — removal and installation
Combination of oil pressure and oil temperature gauges (Duratec ST 2.0 l)
Sound signal
Diagnostics and checks of a sound signal
Audio Pinpoint Tests
Sound signal — removal and installation
Horn switch — removal and installation
Watches — description and principle of operation
Watches — diagnostics and checks
Watches — Pinpoint Tests
Clock — removal and installation
Information and message center
Information and message center — diagnostics and checks
Information and Message Center — Pinpoint Tests
Message center — removal and installation
Warning devices
Warning devices — diagnostics and checks
Warning Devices — Pinpoint Tests
Assistance with parking
Parking assistance — diagnostics and checks (vehicles up to 10.2001)
Parking assistance — Pinpoint tests (vehicles up to 10.2001)
Parking assistance — diagnostics and checks (vehicles after 10.2001)
Parking assistance — Pinpoint tests (vehicles after 10.2001)
Battery and alternator
Charging system — description and principle of operation
Charging system — diagnostics and checks
Charging system — Pinpoint tests
Accumulator charging
Battery and wire specifications
Battery and wires — description and principle of operation
Battery diagnostics and checks
Disconnecting the battery
Battery — removal and installation
Shelf for battery installation — removal and installation
Battery wires — removal and installation
Battery Shelf (1.6L Duratec)
Battery wires (1.6L Duratec) — removal and installation
Generator Specifications
Description and principle of operation
Generator (1.6L Zetec-SE / 1.4L) — removal and installation
Generator (1.8L/2.0L/2.0L Duratec RS/1.6L Zetec-E) — removal and installation
Generator (1.8 l diesel) — removal and installation
Generator (1.6L Duratec) — removal and installation
Audio system
Diagnostics and checks of the audio system
Audio pinpoint tests
Diagnostics and checks of an audio system without an amplifier
Pinpoint tests of an audio system without an amplifier
Description of the audio system
Audio block — removal and installation
CD player with CD changer
Additional low-frequency amplifier
Antenna Description
Antenna base — removal and installation
Antenna cable LHD — removal and installation
Front door speaker — removal and installation
Rear door speaker — removal and installation
Rear side panel speaker — removal and installation
Subwoofer — removal and installation
Headlights and lighting
Outdoor lighting — description and principle of operation
Headlights (cars up to 08.2001) — diagnostics and checks
Headlights (vehicles up to 08.2001) — Pinpoint tests
Headlights (cars after 08.2001) — diagnostics and checks
Headlights (vehicles after 08.2001) — Pinpoint tests
Headlight range adjustment (up to 08.2001) — diagnostics and checks
Headlight range adjustment (up to 08.2001) — Pinpoint tests
Headlight range adjustment (after 08.2001) — diagnostics and checks
Headlight range adjustment (after 08.2001) — Pinpoint tests
Stop lights (vehicles up to 08.2001) — diagnostics and checks
Stoplights (vehicles before 08.2001) — Pinpoint tests
Stop lights (vehicles after 08.2001) — diagnostics and checks
Stoplights (vehicles after 08.2001) — Pinpoint tests
Direction indicators (vehicles up to 08.2001) — diagnostics and checks
Direction indicators (vehicles before 08.2001) — Pinpoint tests
Direction indicators (vehicles after 08.2001) — diagnostics and checks
Direction indicators (vehicles after 08.2001) — Pinpoint tests
Parking lights (vehicles up to 08.2001) — diagnostics and checks
Parking lights (vehicles up to 08.2001) — Pinpoint tests
Parking lights (vehicles after 08.2001) — diagnostics and checks
Parking lights (vehicles after 08.2001) — Pinpoint tests
Fog lights (vehicles up to 08.2001) — diagnostics and checks
Fog lights (vehicles up to 08.2001) — Pinpoint tests
Fog lights (vehicles after 08.2001) — diagnostics and checks
Fog lights (vehicles after 08.2001) — Pinpoint tests
Reversing lights (vehicles up to 08.2001) — diagnostics and checks
Reversing lights (vehicles up to 08.2001) — Pinpoint tests
Reversing lights (vehicles after 08.2001) — diagnostics and checks
Reversing lights (vehicles after 08.2001) — Pinpoint tests
Headlight adjustment
Headlight adjustment — The vehicle is equipped with: headlights
Headlight support bracket repair
Covering the headlights
Closing headlight areas (cars manufactured before 10.2001)
Closing headlight areas (vehicles manufactured after 10.2001)
Front fog lamp adjustment
High Beam Headlight Bulb
Low Beam Lamp
Headlight assembly — removal and installation
Light switch — removal and installation
Headlight tilt sensor — removal and installation
Headlight range control motor (vehicles up to 10.2001)
Headlight range control motor (vehicles after 10.2001)
Front fog lamp
Interior lighting
Interior lighting — diagnostics and checks
Interior lighting — Pinpoint tests
Daytime running lights (vehicles up to 08.2001)
Daytime running lights (vehicles before 08.2001) — Pinpoint tests
Daytime running lights (vehicles after 08.2001)
Daytime running lights (vehicles after 08.2001) — Pinpoint tests
Power distribution
Communication network (vehicles up to 08.2001)
Communication network (vehicles after 08.2001)
Communication network (vehicles up to 08.2001) — diagnostics and checks
Communication network (vehicles up to 08.2001) — Pinpoint tests
Communication network (vehicles after 08.2001) — diagnostics and checks
Communication network (vehicles after 08.2001) — Pinpoint tests
Module configuration
Electronic Function Group
Active anti-theft system
Active anti-theft system — diagnostics and checks
Active anti-theft system — Pinpoint tests
Passive anti-theft system
Passive anti-theft system — diagnostics and checks
Passive Anti-Theft System — Pinpoint Tests
Transceiver for passive anti-theft system
Telematics — description and principle of operation
Telematics — diagnostics and checks
Telematics — Pinpoint tests
World Positioning System (GPS) Antenna
World System for Mobile Communications (GSM) Antenna
Cell phone — description and principle of operation
Cell phone — diagnostics and checks
Cell Phone — Pinpoint Tests
Cell phone antenna — removal and installation
Handset bracket — removal and installation
Functions controlled by the module (vehicles up to 08.2001)
Functions controlled by the module (vehicles after 08.2001)
Central timer module — diagnostics and checks
Multifunction electronic module (vehicles after 08.2001)
Generic Electronic Module (GEM)
Anti-theft alarm and double door lock module
General electronic module — removal and installation
Ford Focus Turnier 1
General information
Introduction to guide
Car Model Representation
At a glance — an overview of the Focus models
Engine Specifications
Vehicle dimensions
Improvement of Ford Focus 1 models
Workplace equipment
Timely purchase of spare parts
Necessary tools for work
Special purpose tools make the job easier
Professional advice for an amateur mechanic
Tips for visiting the workshop
Safety measures during repair work
Jack for lifting the car
How to securely lift a car
Vehicle Specifications
Car care
Regular car care
Special care products for interior cleaning
Car wash in front of house doors
Car engine wash
Lubrication of hinges and locks
Regular polish care
Severe damage to the varnish reduces the value of the car
Polishing makes minor scratches invisible
This is how larger scratches disappear
Window washer system
Window washer fluid filling
Replacing the wiper rubber pad
Spray nozzle adjustment
Removing the windshield washer nozzle
Removing the wiper arm
Removing the front wiper motor
Removing the rear wiper motor
Help with faulty wipers
Power unit
Engine repair
Description of the engine design
Engine repair in the workshop or do it yourself?
Description of the main engine components
Basic concepts of motor building
Setting the piston of the first cylinder to the TDC position of the compression stroke
Spark plug
Over-revving and engine durability
Compression pressure measurement
Compression pressure drops
V-belt check
Mounting the V-belt
Toothed belt and camshaft
Diagnostics — knocking in the engine compartment
Help with malfunctions of the cylinder head gasket
Lubrication system
Description of the design of the engine lubrication system
New oil filter every oil change
Pressure in the lubrication system
Motor oil is a fluid with many talents
Concepts standards on the topic of oil
Perfectly normal — low oil consumption
Remember to check the oil level regularly
Always change engine oil and oil filter at the same time
Help with malfunctions of the ignition system
Cooling system
Description of the design of the engine cooling system
Cooling system components
Cooling liquid
Checking the cooling system for leaks
Checking the level and adding coolant
Coolant replacement
Repulse the winter — frost protection down to -30°C
Help with malfunctions of the cooling system and thermostat
Engine is losing coolant
Dismantling and checking the thermostat
The engine «boils» — a faulty radiator fan
Removing the radiator fan
Dismantling the radiator
Replacing coolant hoses
Air filter (air intake noise damper)
Cleaning and replacing the air filter insert
Cleaning the air filter insert
Fuel injection (gasoline)
Description of the design of the fuel injection system
General view — EEC-V injection system control
In detail — control of the injection system EEC-V
Invisible assistants — new assistants for the EEC-V injection system
Diagnostics and communication equipment of the injection system EEC-V
Visual inspection of the injection system
Help with malfunctions of the petrol injection system
Uncertainty in the operation of the on-board computer — side air
Checking the idle speed
Blocking idle fluctuations in the system
Checking the idle servomotor
Checking injection valves
Throttle cable replacement
Fuel injection (diesel)
Diesel Fuel Supply System — Basic Design
Excess fuel is returned to the fuel tank
Fuel supply path — this is how fuel enters the injector
Significantly increased hydraulic efficiency — injection pump VP 30
Wheel pulse encoder and angle encoder
Cold start equipment for diesel engine
Injectors — diesel atomization
Repair and correction of the injection system in a diesel engine
Disassembly of nozzles
Visual inspection of the diesel injection system
Help with malfunctions of the diesel injection system
Ignition system
Description of the design of the ignition system
The main components of the ignition system
Ignition coil
Constant High Temperature — Spark Plugs
What does the spark plug face say?
Safety instructions for working on the ignition system
Replacing spark plugs after at least 60,000 km of run
Help with malfunctions of the ignition system
Ignition off
Checking the speed sensor with a multimeter
Checking the pressure sensor
Ignition current measurement
Ignition coil resistance measurement
Removing the ignition module
Diesel pre-glow system
Checking the pre-glow system
Checking the pre-glow relay
Checking glow plugs
Power and exhaust system
General information about the fuel system
The most important structural components of the fuel supply system
Fuel — general information and savings
Checking the ventilation of the fuel tank
Fuel filter replacement (petrol engine)
Fuel filter replacement (diesel engine)
Draining fuel from the fuel tank with a manual pump
Dismantling pipelines and hoses
Troubleshooting the fuel pump
Removing the fuel pump (petrol engine)
Exhaust system design description
Exhaust system tips
Exhaust system check
Exhaust system replacement including catalytic converter
Concepts related to exhaust gases
Reduced exhaust emissions
Transmission
Clutch and drive shafts
Description of the clutch design
Clutch and its nodes
How clutch works
Clutch test
Does the clutch fully disengage?
Driving with Leaky Clutch Hydraulics
Help with clutch problems
Main gear — design description
Main gear and drive shafts
Checking the cuffs of the drive shafts
If the drive shaft makes noise
Dismantling and installation of the drive shaft
Replacement of a cuff of a driving hinge
Mechanical gearbox
Transmission shift control iB5
MTX-75 gearshift control
General information about the gearbox
Five-speed manual transmission
How a manual transmission works
Shift Adjustment
Checking the transmission oil level
Noises in the gearbox
Automatic gearbox
Description of the design of the automatic transmission
Transmission controls
Repairing an automatic transmission is not a job for an amateur
Selector lever cable adjustment
Mechanical release of the selector lever lock
Checking the transmission oil level
Features in handling the automatic transmission 4F27E
Chassis
Car suspension
General Suspension Information
Front suspension units
Rear suspension units
Amateur work on chassis and steering
Checking shock absorbers
Telescopic shock absorber — design description
Checking the bearings of the transverse arms of the independent suspension
Checking the wheel bearing clearance
Wishbone Replacement (Front)
Replacing the suspension strut
Replacing the rear shock absorbers
Steering
Steering and traffic safety are linked
Steering Geometry Concepts
Control Factor — Front Axle Geometry
Regular check of steering free play
Checking the protective collars of the gear rack
Checking the heads and cuffs of the transverse steering rod
Replacement of tie rod heads
Replacement of cuffs of the steering mechanism
Replacement of a rotary steering support
Airbag — work for real professionals
Steering column design
Servo control — general information
Wheels and tires
Tires and rims — general information
Wheels and tires — dimensions
The most important characteristics of tires
Winter tires — professionals in any weather
Practical Tire Saving Tips
Tire pressure check
Wheel replacement
Tire condition check
What can tell the type of tread
Proper wheel storage
Brake system
General information about the brake system
Description of the design of the brake system
The main components of the brake system
Anti-lock brake system
Checking the brake fluid level
Checking the brake system in the workshop
Checking the brake system
Checking the brake booster
Checking the functioning of the brakes
Measuring Disc Brake Lining Wear
Brake pedal and brake lining
Checking brake disc wear
Assistance in case of malfunctions of the brake system
Removal of air from the brake system
Brake fluid — general information
Brake Fluid Replacement
Dismantling the expansion tank from the GTZ
Removing the brake master cylinder
Removing the brake booster
Dismantling the brake hoses
Replacement of linings of brake disks
Removing the brake discs
Restoration of the mobility of the brake caliper and piston
Replacing the rear axle mudguard
Hand brake — general information
Replacing handbrake cables
Handbrake adjustment
Body
Exterior
General information about the car body
Dismantling the door
Door installation
Removing the exterior mirror
Fairing dismantling
Dismantling the hood
Hood installation
Removing the hood lock
Removing the front bumper
Wing dismantling
Rear bumper removal (3-, 4-, 5-door models)
Removing the rear cover
Removing the lock in the back cover
Interior
General information about the car interior
Switches inside the car
Ignition key coding
Controls — general information
Replacing the interior lights
Checking the door contact switch
Trunk Light Replacement
Removing the radio
Dismantling the speaker
Removing the roof antenna
Seat removal
Checking the seat belts
Removing the door trim
Removing the power window side window (front)
Power window not working
Central locking — general information
Removing the door handle
Dismantling the lock drum in the ignition lock
Assistance in case of malfunctions of power windows with electric drive
Help with malfunctions of the central lock
Belt Tensioning Device and Independent Operation
Heating and ventilation
General information about heating and ventilation
Periodic inspection of heating and ventilation
Help with malfunctions of the heating system
Removing the heating and ventilation control module
Air blower — general information
Troubleshooting in the blower
Air blower motor replacement
Removing the heating/AC control
Removing the air circulation damper servomotor
Removing the cables on the air distributor
Electrical equipment
Equipment and devices
Overview of wiring harnesses
General information about on-board electrical equipment
Basic concepts of electrical engineering
Voltage, current and resistance measurement
Instruments and controls
Checking Instruments in the Dashboard Self-Diagnostic Module
Checking the function of the switches
Removing the combined instrument panel
Intertwined wire paths are not always traceable
Fuses in the cabin and engine compartment
Fuses change quickly
Switching relays distribute high operating currents
Location of fuses and relays
Lighting and signaling
External lighting equipment
Light range adjustment
Replacing headlight bulbs
Replacing bulbs in fog lights
Replacing the bulbs in the front direction indicators
Replacement of lamps of lateral indexes of turn
Replacing bulbs in rear lights (hatchback)
Replacing bulbs in the reversing lamp and fog lamp
Replacing the bulbs in the rear lights (with a stepped rear)
Replacing the bulbs in the rear lights (Turnier)
Replacing the soffit lamp in the license plate light
Replacing lamps in an additional brake light (hatchback)
Replacement of lamps in an additional lantern of a stoplight (sedan)
Replacement of interior lighting lamps
Temporary headlight adjustment
Signal equipment
Help with alarm malfunctions
Removing the signal horn
Power devices
Prescription «Order on batteries»
Battery — design description
Battery — concepts and standards
Starter with progressive screw drive
Generator — general information
Checking the acid level in the battery
Caring for battery contacts
Battery check
Starting the engine from the battery of another car
Pushing the car to start the engine
Towing a car to start the engine
Help with battery and alternator malfunctions
Accumulator charging
Removing the battery
Hidden consumers of electricity empty the battery
Checking the voltage regulator
Driving with a faulty alternator
V-belt replacement
V-belt tensioner replacement
Dismantling the generator
Starter removal
Help with starter malfunctions
Electrical circuits
Structure of switching circuits
ZETEC-SE engine cooling with climate control
ZETEC-E engine cooling with climate control
Air Conditioned Endura-DI Engine Cooling
ZETEC-SE starting system with automatic transmission
ZETEC-SE starting system with manual transmission
Engine start system ZETEC-E
Endura-DI Engine Start System
ZETEC-SE engine ignition system
ZETEC-E engine ignition system
Endura-Dl Engine Ignition System
Windshield wipers and washer system with rear window wiper
Windshield wipers and washer system with heated windshield sprayers
Clock / time measurement
External lighting equipment, headlight adjustment
External lighting equipment, manual transmission...
Turnier Exterior Lighting, Clearance Lights...
External lighting equipment without fluorescent lights...
External lighting equipment, fog lamps...
Horn sound signal
LHD speaker wiring diagram
Generator and regulator, ZETEC engines
Alternator and governor, Endura-Dl engines
Ford Focus 2
General information
Vehicle device
General information about the car
Passport data
Car keys
Dashboard
Instrument cluster
Heating (air conditioning) and interior ventilation
Door locks
Door windows
Seat belts
Front seat adjustment
Backseat
Use of child seats
Steering wheel adjustment
Rear view mirrors
Interior lighting
Sun visors
Salon storage boxes
Hood opening
Gearbox control
Roof rack
Owner's manual
Safety regulations
Operating recommendations
Recommendations for traffic safety
What you need to have in the car for everyday use
What you need to have in the car going on a long journey
Vehicle break-in
Vehicle operation during the warranty period
Preparing the car for departure
Refueling a car with gasoline
Using a jack
Towing a car
How to prepare your car for winter
Recommendations for starting the engine in severe frost
Useful winter tips
Recommendations for preparing for technical inspection
List of malfunctions and conditions under which the operation of vehicles is prohibited
Changes to state standards on the permissible content of harmful substances
Faults en route
General engine starting techniques
Faults in the starting system
Checking the ignition system
Checking the engine power system
Fuel Injection System Malfunctions
Idling has disappeared
Interruptions in the engine
Diagnostics of the engine condition by the appearance of spark plugs
The car is jerking
Jerk at the moment of the beginning of the movement
Jerks during acceleration
Jerks in steady motion
The car accelerates badly
Engine stalled while driving
Oil pressure dropped
Checking the lubrication system
Engine overheating
Checking the cooling system
The battery does not charge
Checking electrical equipment
Starting the engine from external current sources
Electrical faults
There was a knock in the engine
Knocks in the suspension and transmission
Possible causes of knocks in the suspension and how to eliminate them
Possible knocks (noises) of the transmission, their causes and solutions
Vibration and bumps in the steering wheel
Possible causes of vibrations and shocks on the steering wheel and how to eliminate them
Problems with the brakes
Bleeding the brake system
Checking the brake system
Wheel puncture
Wheel replacement
Maintenance
General provisions for maintenance
Maintenance safety regulations
Wheel check
Checking the level and adding oil to the lubrication system
Checking the level and topping up the coolant
Checking the level and topping up the brake fluid
Checking the level and topping up the working fluid in the hydraulic booster reservoir
Checking the level and adding fluid to the washer reservoir
Checking external lighting fixtures
A trip to the service station
First maintenance
Checking the accessory drive belt
Checking the A/C Compressor Drive Belt
Checking the timing belt of the gas distribution mechanism
Changing engine oil and oil filter
Cleaning the crankcase ventilation system
Checking the hoses and connections of the cooling system
Check of system of release of the fulfilled gases
Checking the tightness of the fuel lines
Checking and replacing the air filter element
Checking the level and adding oil to the gearbox
Checking the protective covers of the front wheel drives
Checking the technical condition of the front suspension parts on the car
Checking the technical condition of the rear suspension parts on the car
Checking and adjusting wheel alignment
Inspection and testing of the steering on the car
Checking the free play (backlash) of the steering wheel
Checking the tightness of the hydraulic drive of the brakes
Checking the degree of wear of brake pads, discs and drums
Checking the operation of the vacuum brake booster
Checking the effectiveness of the brake system
Checking the parking brake
Battery maintenance
Checking and adjusting the headlights
Body armature lubrication
Cleaning drainage holes
Second maintenance
Replacement and maintenance of spark plugs
Accessory drive belt replacement
Replacing the A/C Compressor Drive Belt
Replacement of the timing belt
Replacement of brake fluid in hydraulic brakes and clutch release
Coolant replacement
Applications
Tightening torques for threaded connections
Overall dimensions (mm) of Ford Focus II cars
Engine specifications and vehicle performance
Air pressure in cold tires
Refueling volumes
Consumables and spare parts
Engine oil
Plastic lubricants
Cooling fluids
Brake fluid
Fuel fine filter
Air filter
Engine Lubrication System Oil Filter
Auto mechanic tips
General safety requirements
Safe vehicle lifting
The main set of tools
Special tools and fixtures
Before starting work
Loosening rusty threaded connections
Loosening damaged nuts
Bolts with hexagon socket head or polygonal head
Removing self-tapping screws with slots and Phillips
Drilling out a broken bolt
Thread cutting
Body Repair Tips
Power unit
Engine repair
Engine design features
Possible engine malfunctions, their causes and remedies
Useful tips about the engine
Cylinder compression check
Removal and installation of a mudguard of the engine
Replacement of the right support of a suspension bracket of the power unit
Replacement of the left support of a suspension bracket of the power unit
Replacing the rear support suspension of the power unit
Setting the piston of the first cylinder to the TDC position of the compression stroke
Removal, installation and troubleshooting of the flywheel
Valve clearance adjustment
Replacing camshafts
Lapping of cylinder head valves
Removal and installation of the engine
Design features of the lubrication system
Removal and installation of the oil pump
Engine seal parts
Replacing the cylinder head cover gasket
Replacing the cylinder head gasket
Replacement of valve stem seals
Replacing camshaft seals
Replacing the crankshaft seals
Replacing the oil sump seal
Replacing the intake pipe gasket
Replacing the gasket of the collector
Cooling system
Features of the design of the cooling system
Possible malfunctions of the cooling system, their causes and solutions
Replacing the cooling system radiator
Removal and installation of the electric fan of the radiator of the engine cooling system, complete with casing
Removal and installation of a broad tank
Water pump replacement
Thermostat replacement
Removal and installation of the electric motor of the radiator fan of the engine cooling system
Replacing the additional resistance of the radiator fan of the engine cooling system
Exhaust system
Design features of the exhaust gas outlet
Replacement of pillows of a suspension bracket of system of release of the fulfilled gases
Replacement of the main and additional mufflers
Removal, installation of the collector and replacement of its gasket
Removal and installation of thermal screens
Supply system
Features of the design of the power system
Checking fuel pressure in the power system
Reducing the pressure in the power system
Removing and installing the air filter and intake silencer
Removal and installation of the fuel pump
Replacing the fuel tank and its filler pipe
Replacing the fuel pressure pulsation compensator
Removal and installation of the fuel rail
Removing, checking and installing injectors
Removal and installation of the throttle assembly
Removing and installing the throttle control pedal
Features of the device of the fuel vapor recovery system
Replacement of an adsorber of system of catching of vapors of fuel
Clutch
Clutch Design Features
Possible clutch malfunctions, their causes and solutions
Checking the travel of the clutch release pedal
Removal and installation of clutch
Replacement of the working cylinder of the clutch release actuator with the clutch release bearing
Clutch Master Cylinder Replacement
Replacement of the pipeline of a hydrodrive of deenergizing of coupling
Removal and installation of the clutch pedal
Bleeding the hydraulic clutch release
Car gearbox
Features of the design of the gearbox
Possible malfunctions of a manual transmission, their causes and solutions
Changing the oil in the gearbox
Replacing gearbox seals
Removal and installation of a transmission
Replacing the transmission control cables
Removal and installation of the scenes of the gear lever
Gearbox control drive adjustment
Front wheel drives
Features of the design of the front wheel drives
Possible malfunctions of the front wheel drives, their causes and solutions
Removal and installation of front wheel drives
Replacement of constant velocity joints
Replacing the intermediate support bearing
Chassis
Front suspension
Design features of the front suspension
Possible malfunctions of the front suspension, their causes and solutions
Removal and installation of a shock-absorber rack
Shock absorber repair
Replacing the upper support of the shock absorber strut
Ball joint replacement
Replacing the front suspension arm
Replacing parts of the front suspension anti-roll bar
Removal and installation of a rotary fist
Replacing the front hub bearing
Removal and installation of a cross-beam of a forward suspension bracket
Rear suspension
Rear suspension design features
Possible malfunctions of the rear suspension, their causes and solutions
Replacing the shock absorber rear suspension
Replacing the rear suspension spring
Replacing the upper arm of the rear suspension
Replacing the front lower arm of the rear suspension
Replacing the rear lower arm of the rear suspension
Rear Suspension Trailing Arm Replacement
Replacing parts of the rear suspension anti-roll bar
Removal and installation of a back nave
Removal and installation of a cross-beam of a back suspension bracket
Steering
Steering design features
Possible malfunctions of a steering with the hydraulic booster
Removal and installation of a casing of a steering column
Removal and installation of a steering wheel
Removal and installation of a steering column
Replacing the outer tie rod end
Bleeding the power steering system
Replacing the power steering reservoir
Steering gear replacement
Power steering pump replacement
Brake system
Features of the brake system
Possible malfunctions of the brake system, their causes and remedies
Bleeding the hydraulic drive of the brake system
Checking the position of the brake pedal
Replacing the reservoir of the main brake cylinder
Replacing the master brake cylinder
Replacing Pressure Regulators
Replacing the vacuum booster
Replacement of brake hoses
Replacement of brake pipes
Removing and installing the brake pedal
Replacing the brake pads of the brake mechanism of the front wheel
Replacing the caliper assembly with the guide pads
Brake disc replacement
Removal and installation of a brake drum
Replacing the brake pads of the brake mechanism of the rear wheel
Replacing the working cylinder of the brake mechanisms of the rear wheels
Parking brake actuator adjustment
Replacing the front parking brake cable
Replacing the rear parking brake cables
Removal and installation of the parking brake lever
Replacing wheel speed sensors
Wheels and tires
Specifications
Wheel marking
Tire marking
Wheel replacement
Wheel nuts
Tire break-in
Tire storage
Wheel balancing
Anti-skid chains
Spare wheel
Tire pressure check
Tire tread check
Checking the valve
Checking the radial and lateral runout of the discs
Body and coating
Body elements
Body design features
Possible body malfunctions, their causes and solutions
Removal and installation of facing of a radiator
Removal and installation of wheel mudguards and fender liner
Removal and installation of a forward bumper
Removal, disassembly and installation of the rear bumper
Removal and installation of a forward wing
Removal and installation of the frame of the engine compartment and the bar of the front bumper
Removal and installation of the grille of the air supply box and the drain shield
Removal and installation of a cowl
Removal, installation and adjustment of the hood lock and its drive
Removal and installation of a cover of the hatch of a bulk pipe of a fuel tank
Removal and installation of the lock of a cover of the hatch of a bulk pipe of a fuel tank
Replacement of the fixed glazing of the body
Removal and installation of the shelf of fastening of the rechargeable battery
Side doors
Removal and installation of an upholstery of a forward door
Front door glass replacement
Replacing the power window of the front door
Replacing the outside handle and front door lock switch
Replacement of the internal handle of a drive of the lock of a forward door
Replacing the front door lock
Replacing the front door opening limiter
Removal and installation of a forward door
Removal and installation of an upholstery of a back door
Rear door glass replacement
Replacing the power window rear door
Rear Door Exterior Handle Replacement
Replacing the inner handle of the tailgate lock actuator
Replacing the rear door lock
Replacing the tailgate opening limiter
Removal and installation of a back door
Tailgate
Replacing tailgate stops
Removal and installation of an upholstery of a door of a back
Removal and installation of a decorative overlay of a door of a back
Removal and installation of a spoiler of a door of a back
Replacing the lock, latch and button for opening the tailgate lock
Removal and installation of a door of a back
Salon elements
Removal and installation of a forward seat
Removal and installation of a back seat
Removal and installation of floor tunnel lining
Removal and installation of an external mirror
Removal and installation of an internal mirror
Instrument panel device
Removal and installation of the instrument panel
Features of the heater and air conditioner
Removal and installation of the heating (air conditioning) and interior ventilation control unit
Removal and installation of the filter for cleaning the air entering the passenger compartment
Handrail Replacement
Replacing sun visors
Removal and installation of facings of salon
Removal and installation of facings of a luggage carrier
Safety system
Design features of the passive safety system
Removal and installation of the driver's airbag
Replacing the front seat belt
Replacing the rear seat belt
Removal and installation of the electronic control unit of the additional passive safety system
Windshield wipers and washers
Replacing the windshield wiper blades
Replacing Windshield Wiper Arms
Removal and installation of a windscreen wiper trapezoid assembly with a gearmotor
Replacing the tailgate window wiper blade
Tailgate Window Wiper Arm Replacement
Replacing the windshield wiper gearmotor
Replacing the tailgate window wiper motor
Removal and installation of a washer glass of a wind window
Body Care
Car wash
Polishing of the paintwork
Engine wash
Anti-corrosion body protection
Preparation and anti-corrosion treatment of body cavities
Body sealing
Caring for trim panels made of polymer materials
Upholstery and carpet care
Electrical equipment
Instruments and motors
Design features of electrical equipment
Diagnostics of malfunctions of onboard electrical equipment
Replacing the front door power window motor
Removal and installation of the electric motor of a heater
Replacement of additional resistance of the heater electric fan
Electric heating of glass of a window of a back (back door)
Replacing the control unit for power windows and power mirrors
Location of fuses and relays and their replacement
Removal and installation of mounting blocks
Design features of the instrument cluster
Removal and installation of a combination of devices
Battery and alternator
Battery design features
Possible battery malfunctions, their causes and solutions
Removing and installing the battery
Charging the battery
Generator Design Features
Possible malfunctions of the generator, their causes and remedies
Removal and installation of the generator
Alternator pulley replacement
Starter design features
Possible starter malfunctions, their causes and remedies
Removal and installation of a starter
Starter repair
Egnition lock
Design features of the ignition switch
Checking the ignition switch (lock)
Replacing the contact group of the ignition switch (lock)
Replacing the ignition switch (lock) cylinder
Removal and installation of the switch (lock) of ignition
Engine management
Features of the design of the engine management system
Possible malfunctions of the engine management system, their causes and remedies
Checking the ignition coil
Removal and installation of the ignition coil
Removal and installation of the electronic engine control unit
Check and replacement of gauges of a control system of the engine
Headlights and lighting
Lighting Design Features
Lamp replacement
Headlight Replacement
Replacing the electric headlight corrector
Replacement of a lateral lantern of the index of turn
Rear light replacement
Replacement of a lantern of a light of a backing light
Fog lamp replacement
Replacement of an additional brake light
Replacing license plate lights
Interior lamp replacement
Replacing the trunk light
Replacing paddle shifters
Removal and installation of a sound signal
Switches and sensors
Replacing the outdoor lighting control unit
Replacing Instrument Panel Switches
Hazard Switch Replacement
Removing and installing the antenna
Replacing the oil pressure warning light sensor
Checking and replacing the fuel gauge sensor
Replacing the pressure sensor in the power steering system
Checking and replacing the reverse light switch
Stoplight Switch Replacement
Replacing Cruise Control Switches
Replacing the Parking Brake Warning Light Switch
Emergency fuel shutoff button
Schematic diagrams
Scheme 1. Wiper and windshield washer connections
Diagram 2. Battery Charging System Connections
Scheme 3. Connections of the hydraulic drive system of the brake system
Diagram 4. Connections of the ventilation, heating and air conditioning system
Diagram 5. Connections of the engine start system
Scheme 6a. Speed Control Connections
Scheme 6b. Speed Control Connections
Scheme 7a. Engine management connections
Scheme 7b. Engine management connections
Scheme 7c. Engine management connections
Scheme 7d. Engine management connections
Scheme 7d. Engine management connections
Scheme 7e. Engine management connections
Scheme 7g. Engine management connections
Scheme 8a. Air conditioning connections
Scheme 8b. Air conditioning connections
Diagram 9 Power Steering System Connections
Scheme 10a. Anti-Lock Braking System (ABS) Connections
Scheme 10b. Anti-Lock Braking System (ABS) Connections
Scheme 11. Connections of the dynamic stabilization system of the car
Ford Mondeo 1
General information
Car care
Car wash
Care of the lacquer coating
Anti-corrosion protection of the bottom and preservation of car cavities
Interior upholstery care
Starting the engine from the auxiliary battery
Towing a car
Features of towing cars with automatic transmission
Starting the engine by towing
Vehicle lifting
Car Repair Tools
Maintenance
Vehicle maintenance plan
Resetting the service interval indicator
General information about maintenance
Engine and exhaust system
Engine oil change
Visual check for oil leaks
Checking the engine oil level
Checking the coolant level
Visual inspection of the cooling system for leaks
Checking antifreeze
Diesel engine: checking and adjusting valve clearances
Replacing spark plugs and checking electrical components
Replacing the Air Filter Insert
Fuel filter replacement
Checking and replacing the V-belt and toothed belt
Diesel: Tightening turbocharger and intake manifold bolts
Diesel engine: CVT filter replacement
Replacing the pulse air filter
Visual inspection of the exhaust system
Clutch, gearbox and final drive
Visual control of transmission tightness
Checking the rubber cuff of the cardan shaft
Automatic transmission: checking the oil level
Clutch linkage adjustment
Brakes, tires and wheels
Checking the brake fluid level
Checking the thickness of the brake linings
Visual inspection of the brake lines
Brake Fluid Replacement
Tire tread depth check
Tire pressure check
Tire valve check
Steering and front axle
Checking the anti-dust caps of steering rods and axle joints
Checking the clearance of the axle joint
Checking the tie rod bellows
Steering clearance check
Checking the oil level in the power steering
Electrical system
Checking the battery
Body and interior of the car
Troubleshooting
Engine Troubleshooting
Diagnostics of malfunctions in the oil circulation system
Diagnostics of malfunctions in the engine cooling system
Diagnostics of malfunctions of system of injection of gasoline
Table of diagnostics of malfunctions of the diesel fuel injection system
Clutch Troubleshooting
Diagnostics of malfunctions of the brake system
Tire Fault Diagnosis
Diagnostics of malfunctions of interior heating
Diagnosis of faults in the battery
Diagnostics of malfunctions of the generator
Starter Troubleshooting
Diagnosis of malfunctions of wiper blades
Power unit
Engine repair
General information on engine repair
The most important engine specifications
DOHC Gasoline Engine — Design Description
OHC turbocharged diesel engine
Removal and installation of the engine
Removal, installation and tension of a toothed belt (gasoline)
Removal and installation of camshafts (gasoline)
Removal and installation of the cylinder head, seal replacement
Timing Belt Drive — Diesel Engine
Removal and installation of a gear belt (diesel)
Timing adjustment, toothed belt tension (diesel)
Removal and installation of a head of the block of cylinders (diesel)
Removal and installation of the vacuum pump (diesel)
Camshaft/valve drive in a diesel engine
Removal and installation of the camshaft
Removal and installation of valves
Replacement of oil seals
Checking the valve guides
Lapping of valve seats
Checking and adjusting valve clearances (diesel)
Cylinder compression check
Removing, installing and tensioning the V-belt
Cooling and lubrication system
Engine lubrication system — general information
Oil circulation circuit
Oil pressure check
Checking the hydraulic switch
Removal and installation of the oil pallet
Coolant circuit
Antifreeze poured into the radiator
Coolant replacement
Checking the cooling system for leaks
Removal, installation and check of the thermostat
Thermal switch test (diesel)
Removal and installation of the fan motor
Removal and installation of a radiator
Removal and installation of the pump of a cooling liquid
Ignition system
General information about the ignition system
Safety precautions when working with an electronic ignition system
Checking the ignition wires
Checking and replacing the ignition coil
Checking and replacing the pulse encoder
Fuel quality adjustment
Spark plugs — general information
Spark plugs for Ford Mondeo
Fuel/exhaust systems
General information about the fuel system
Requirements for cleanliness when working with the fuel system
Fuel quantity sensor, removal and installation of the fuel pump
Removal and installation of the fuel tank
Removing the fuel tank in an all-wheel drive model
Replacing the fuel pump safety switch
Removal and installation of the relay of system of injection of fuel
Removal and installation of the air filter and suction pipe
Removal and installation of gas draft
Throttle adjustment
Exhaust gas exhaust system
Exhaust system catalyst functions
Handling vehicles equipped with catalytic converters
Removal and installation of system of release of the fulfilled gases
Removal and installation of an additional muffler
Fuel injection (gasoline)
Schematic representation of the fuel injection system
Engine regulation
Auto-diagnosis of ignition and fuel injection systems
Checking jets
Removal and installation of jets and fuel pressure regulator
System troubleshooting in the ignition and fuel injection system
Fuel injection (diesel)
Schematic representation of a diesel fuel injection system
Working principle of diesel engine
Measures to improve the composition of exhaust gases
Exhaust turbocharger
Driving in winter with a diesel engine
Bleeding air from the fuel system
Preheating system/removal and installation of glow plugs
Removal and installation of jets
Checking, removing and installing the electrical disconnect device
Checking and adjusting the idle speed
Vacuum hoses for brake booster and exhaust gas recirculation
Transmission
Clutch and drive shafts
Clutch — design description
Removal, installation and clutch check
Removing, installing and checking the clutch release bearing
Clutch test
Clutch control
Drive Shafts — Design Description
Removal and installation of power shafts
Removal and installation of cuffs of cardan shafts
Car gearbox
Removal and installation of a transmission
Adjustment of a drive of a gear change
Automatic transmission
Mode Selector Cable Adjustment
Four-wheel drive cars
Filling and changing gear oil
Chassis
Suspension
Front Axle — Design Description
Removal and installation of a forward shock-absorber rack
Front shock absorber
Dismantling the front shock absorber
Checking and Disposing of the Front Shock Absorber
Removal and installation of transverse levers of a forward suspension bracket
Removal and installation of a rotary fist
Front wheel bearing
Rear Axle — Design Description
Rear axle suspension — design description
Removal and installation of a back shock-absorber rack
Dismantling the rear shock absorber, shock absorber
Rear axle of Mondeo Turnier
Wheel alignment
Steering
Steering — design description
Removal and installation of a steering wheel
Steering wheel adjustment
Removal and installation of a tip of steering draft
Removal and installation of rubber cuffs of a steering
Removal and installation of the power steering pump
Removing air from the hydraulic steering system
Brake system
General information about the brake system
Specifications of the brake system
Removal and installation of front brake pads
Checking the thickness of the brake disc
Removal and installation of a forward brake disk
Removal and installation of brake shoes of back disk brakes
Removal and installation of a bracket and a support of back brakes
Removal and installation of a back brake disk
Removal and installation of the rear brake drum and brake shoes
Removal and installation of the wheel brake cylinder
Wheel Brake Cylinder Repair
Brake fluid — description and safety measures
Removal of air from the brake system
Brake pipes and brake hoses
Replacing the brake pipe and brake hose
Checking the vacuum brake booster and vacuum pipe
Parking brake — design description
Removal and installation of the parking brake lever
Removal and installation of the brake light switch
Anti-lock braking system (ABS)
Traction control system (TCS)
Wheels and tires
General information about wheels and tires
Dimension of wheels and tires, tire pressure
Wheel designation
Tire designation
Wheel replacement
Rules of tire operation
Anti-skid chains
Incorrect tire wear
Body
Exterior
General information about the car body
Removal and installation of a forward bumper
Removal and installation of a back bumper
Removal and installation of a forward mudguard
Removal and installation of a radiator grille
Removal and installation of the air grille
Removal and installation of an external mirror
Replacing moldings
Removal and installation of the engine hood
Removal and installation of a cable of a drive of the lock of a cowl
Removal and installation of the lock of a cowl
Leveling and varnishing works
Elimination of damage from stone impacts
Elimination of body deformation and removal of shells from corrosion
Body preparation for varnishing
Body painting process
Interior
Removal and installation of a covering of a roof of salon
Removal and installation of an internal covering
Removal and installation of a forward seat
Removal and installation of a back seat
Removal and installation of a back of a back seat
Removal and installation of the average console
Removal and installation of an internal rear-view mirror
Doors, locks and windows
Windshield
Removal and installation of a door
Removal and installation of the lock rod
Door trim — design description
Removal and installation of a covering of a door
Removal and installation of the external door handle and door lock
Removal and installation of the lock of a forward door
Removal and installation of the external handle of a back door
Removal and installation of the core of the door lock
Removal and installation of the internal door handle
Removal and installation of door glass
Removal and installation of a window regulator
Removal and installation of a back cover of a luggage carrier
Removal and installation of a covering of a cover of a luggage carrier
Removing and installing the trunk lid
Removal and installation of the trunk lid lock
Removal and installation of the trunk lid lock core
Removal and installation of the tank hatch
Central lock — design description
Removal and installation of the sunroof
Heating system
Heating system — design description
Fan switch and temperature controller
Removal and installation of the anti-dust filter
Removal and installation of the fan
Removal and installation of additional heating resistance
Removal and installation of the right ventilation nozzle
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
Measuring instruments
Measurement technique
Installing additional electrical accessories
Fault detection in electrical equipment
Checking switches for current flow
Relay test
Checking the wiper motor
Checking the device of flashing light signals
Checking the brake signal
Checking the rear window heater
Removal and installation of a sound signal
Replacing fuses
Location of fuses and relays
Anti-theft alarm device
Removal and installation of the dashboard
Removal and installation of devices
Removal and installation of takhoval
Steering column switch, turn signal relay
Removal and installation of the radio receiver
Removing and installing the loudspeaker
Removing and installing the antenna
Power devices
Removing and installing the battery
Maintenance-free batteries
Charging the battery
Checking the battery
Battery self-discharge
General information about the generator
Safety precautions when working on the generator
Removal and installation of the generator
Checking the alternator charging voltage
Replacement of carbon brushes of the generator, voltage regulator
General information about the starter
Check, removal and installation of the traction relay
Removal and installation of a starter
Lighting and signaling
Lighting and light signaling system
Table of incandescent lamps
Headlight Bulb Replacement
Replacing the front turn signal bulb
Replacing the rear light bulb
Replacing the license plate lamp
Replacing the lamp of the lamp of the engine compartment and glove box
Replacing the bulb of the lamp in the cabin, reading lamp, trunk lamp
Headlight adjustment
Removal and installation of a headlight
Removal and installation of headlight glass
Removal and installation of a fog lamp, replacement of a lamp
Removal and installation of a back lantern
Removal and installation of the engine of regulation of range of lighting
Windshield wipers and washers
Replacing wiper rubber
Removal, installation and adjustment of a nozzle for washing of glasses
Washer reservoir, pump and fluid level sensor
Front wiper — design description
Removal and installation of the front wiper motor
Removal and installation of the mechanism of screen wipers
Removal and installation of the rear wiper motor
Electrical circuits
Instructions for using electrical circuits
Description of the engine adjustment system (with manual transmission)
Description of the central locking system (central locking)
Headlight Wiring Diagram
Engine tuning (with manual transmission)
Brake light wiring diagram
Fog lights and fog lights
Flashing direction indicators
Wiring diagram for interior lighting
Glass cleaner and washer
Heated windshield and rear window
Heating electrical circuit
Seat heating wiring diagram
Wiring diagram for cigarette lighter and clock
Electrical diagram of the horn
Ford Mondeo 1 and 2
General information
User guide
Breaking in a new car
Front panel
Dashboard
Graphic display
Instrument panel switches and controls
Clock and trip computer
Heating and ventilation system
Air conditioner control
Cigarette lighter, ashtray and glove box
Elements of the steering column and steering column switches
Interior light control. top hatch
Warning parking system
Controls on the doors
Console Hardware
Luggage compartment
Keys and locks
Security alarm
Seat adjustment
Seat belts
Airbag
Features of starting the engine
Traction control system
Self-adjusting rear suspension
Driving a car with an automatic transmission
Roof rack
Limited drive mode
Filling the fuel system
Fuel supply interrupter
Forced stop of parking mode
Vehicle data
Basic dimensions and weights
Vehicle identification
General Repair Tips
Jacking up the car
Tools and fixtures
Checking the technical condition
Checks performed from the driver's seat
Checks performed with the vehicle on the ground
Checks on a raised vehicle with spinning wheels
Vehicle Exhaust System Check
Repair on the road
Major Hazards in Service
If the engine does not start
Starting the engine from an auxiliary battery
Wheel replacement
Car smudges and stains
Towing a car
Weekly checks
Checkpoints under the hood
Engine oil level
Fluid level in the hydraulic steering system
Fluid level in the brake system and clutch
Washer fluid level
Coolant level
Wiper blades
Tire condition and pressure
Types of tire wear
Checking the battery
Bulbs and fuses
Lubricants, fluids and tire pressure
Periodic maintenance
Maintenance specification
Engine compartment of a 4-cylinder engine
Underhood space of a 6-cylinder engine
Bottom front view of a model with a 4-cylinder engine
Bottom front view of the V-engine model
Bottom rear view of Sedan and Hatchback model
Bottom view of the back of the station wagon model
Periodic Maintenance Procedures
Engine oil and filter change
Maintenance and battery charging
Checking and replacing the accessory drive belts
Checking the Fluid Level in an Automatic Transmission
Check for fluid leaks and the condition of the hoses under the hood
Checking the electrical wiring of the engine compartment
Checking the air conditioning system
Checking the oil level in a manual transmission
Steering, suspension and wheel checks
Checking the rubber boots of the drive shafts and CV joints
Exhaust system check
Checking the bottom and pipeline of the brake and fuel systems
Checking the brake system
Checking wheel nuts
Road test
Replacing the dust filter of the ventilation system
Air filter replacement
Forced crankcase ventilation system
Automatic transmission fluid change
Replacing the brake and coolant
Replacing spark plugs 4-cylinder engine
Expansion tank cap check
Fuel filter replacement
Replacing the spark plugs of a 6-cylinder engine
Troubleshooting
Troubleshooting Tips
Engine malfunctions
Cooling system malfunctions
Malfunctions of the power supply system and exhaust gases
Clutch malfunctions
Manual Transmission Malfunctions
Automatic transmission malfunctions
Malfunctions of driving shafts
Brake system malfunctions
Suspension and steering problems
Electrical system malfunctions
Engine
4 cylinder engines
Specifications and tightening torques
General information about the engine
Repair operations performed without removing the engine
Compression test
Top dead center of cylinder #1
Removal and installation of a cover of a head of the block of cylinders
Removal and installation of an inlet collector
Removal, inspection and installation of the exhaust manifold
Removal and installation of the crankshaft pulley
Timing belt covers of the timing mechanism
Timing belt of the timing mechanism
Tensioner and timing belt pulleys
Replacement of a cuff of a camshaft
Camshafts and hydraulic lash adjusters
Checking and adjusting valve clearances
Removal and installation of a head of the block of cylinders
Removal and installation of the pallet
Removal, inspection and installation of the oil pump
Removal and installation of an oil cooler
Removal and installation of the oil level sensor
Oil pressure indicator sensor
Replacement of a cuff of a cranked shaft
Removal and installation of the flywheel / faceplate
Inspection and replacement of engine and transmission mounts
6 cylinder engines
Specifications and tightening torques
General information about the engine
Repair operations performed without removing the engine
Compression test
Top dead end of cylinder #1
Removal and installation of a cover of a head of the block of cylinders
Removal and installation of an inlet collector
Removal and installation of a final collector
Removal and installation of the crankshaft pulley
Valve Timing Cover (MGR)
Removal and installation of a chain of the gas distribution mechanism
Replacement of a cuff of a camshaft
Camshafts, hydraulic gap compensators and rocker arms
Removal and installation of a head of the block of cylinders
Removal and installation of the pallet
Removal, inspection and installation of the oil pump
Removal and installation of an oil cooler
Oil pressure indicator sensor
Replacement of a cuff of a cranked shaft
Removal, inspection and installation of the flywheel / faceplate
Inspection and replacement of engine and transmission mounts
Removal and repair
Technical requirements of a 4-cylinder engine
Technical requirements of a 6-cylinder engine
Using the information in this chapter
General information about engine repair
Power block removal methods and precautions
Removal and installation of the power block (4-cylinder)
Removal and installation of the power block (6-cylinder)
Engine disassembly sequence
Dismantling of a head of the block of cylinders
Cylinder head control and valve train
Cylinder head assembly
Removal of connecting rod and piston groups
Removing the crankshaft
Cleaning and Inspection of the Cylinder Block/Crankcase
Inspection of connecting rod and piston groups
Crankshaft Inspection
Inspection of main and connecting rod bearings
Engine Assembly Sequence
Installation of piston rings
Installation and control of the clearance of the main bearings of the crankshaft
Setting and checking the clearance of connecting rod bearings
First run after repair
Cooling system
Specifications and tightening torques
General information about refrigeration, heating and air conditioning
General information about antifreeze
Disconnecting and replacing cooling system hoses
Removal, check and installation of the thermostat
Removal and installation of the electric radiator fan
Removal and installation of sensors of the cooling system
Removal and installation of a radiator and an expansion tank
Removal and installation of the pump of system of cooling
Removal and installation of components of heating / ventilation systems
Heater/air conditioning control units
Air conditioning system
Removal and installation of components of the air conditioning system
Fuel/exhaust systems
Specifications and tightening torques
General information and precautions
Elimination of pressure in the fuel system
Fuel lines and connections — general information
Air cleaner assembly and intake duct components
Removing, installing and adjusting the accelerator cable
Removing and installing the gas pedal
Checking the fuel pump/fuel pressure
Fuel pump/fuel gauge sensor
Removal, inspection and installation of the fuel tank
Removing and installing roll valves
Removal and installation of the fuel cut-off switch
Information about the fuel injection system
Checking and diagnosing the fuel injection system
Removal and installation of components of the fuel injection system
General information and replacement of exhaust system components
Emission management
Specifications and tightening torques
General information about the emission management system
Description of emission control systems
Inspection and replacement of emission control system components
Catalytic Converter Precautions
Starting and charging systems
Specifications and tightening torques
General information and precautions
Removing and installing the battery
General information and precautions of the loading system
Checking the loading system
Removal and installation of the generator
Brushes and alternator voltage regulator
Starting System — General Information and Precautions
Trigger System Check
Removal and installation of a starter
Replacement brushes and starter solenoid
Ignition system
Specifications and tightening torques
General information and precautions
Checking the ignition system
Check, removal and installation of the ignition coil
Removal and installation of the ignition module
Ignition advance check
Transmission
Clutch
Specifications and tightening torques
Description and testing of clutch
Clutch adjustment
Removal and installation of the clutch cable
Removal and installation of the master cylinder
Removal and installation of the clutch pedal
Removing, checking and installing clutch components
Removing and installing clutch release bearing
Removal and installation of an axis and plugs of deenergizing of coupling
Elimination of air in the clutch hydraulic system
Mechanical gearbox
Specifications and tightening torques
General information about manual transmission
Adjustment of the mechanism of a gear change
Mechanism and shift lever
Removal and installation of a gear wheel of a drive of a speedometer
Cuff replacement
Removal and installation of the reverse light switch
Removal and installation of manual transmission
Manual Transmission Repair
Automatic gearbox
Specifications and tightening torques
General information about automatic transmission
Troubleshooting
Removal, installation and adjustment of a cable of the selector
Removing and installing the selector assembly
Removal and installation of a gear wheel of a drive of a speedometer
Selector lever position sensor
Removal and installation of automatic transmission
Transmission repair
Drive shafts
Specifications and tightening torques
General information about drive shafts
Removal and installation of drive shafts
Case inner CV joint of the drive shaft
Cover of the outer CV joint of the drive shaft
Inspection and replacement of the hinges of the drive shafts
Chassis
Brake system
Specifications and tightening torques
General information about the brake system
Replacing the front brake pads
Removal, repair and installation of a support of a forward brake
Inspection, removal and replacement of the front brake disc
Removal, inspection and installation of the rear brake drum
Replacing the rear drum brake pads
Removal, repair and installation of the rear brake wheel cylinder
Replacing the rear disc brake pads
Removal, repair and installation of the rear brake caliper
Removal and installation of the master cylinder
Removing and installing the brake pedal
Servo brake pedal connector
Inspection, removal and installation of pipelines and hoses
Elimination of air from the hydraulic system
Check, removal and installation of the block of the vacuum servo amplifier
Vacuum hose and vacuum booster check valve
Removal and installation of the pressure limiting valve (without ABS)
Removal and installation of the pressure limiting valve (with ABS)
Removal and installation of the ABS hydraulic modulator
Check, removal and installation of the ABS wheel sensor
Removal and installation of the ABS relay box
Traction Control Throttle Actuator
Removal and installation of the brake light switch
Removal and installation of the hand brake lever
Removal and installation of cables of a manual brake
Suspension
Specifications and tightening torques
General Suspension Information
Removal and installation of knot of a rotary fist and a nave
Inspection and replacement of the front hub and bearings
Removal and installation of a rack of a forward suspension bracket
Front suspension strut repair
Front stabilizer bar
Removal, repair and installation of the lower arm of the front suspension
Replacing the ball joint of the lower arm of the front suspension
Inspection and replacement of the rear hub and bearings (Sedan and Hatchback)
Removal and installation of a support of an axis of a back suspension bracket (Sedan and Hatchback)
Removal and installation of the rear suspension strut (Sedan and Hatchback)
Rear Suspension Strut Repair (Sedan and Hatchback)
Rear Anti-roll Bar (Sedan and Hatchback)
Rear Lower Arms (Sedan and Hatchback)
Removal and installation of the jet lever (Sedan and Hatchback)
Removal and installation of a rear suspension beam (Sedan and Hatchback)
Inspection and replacement of the rear hub and bearings (Universal)
Removal and installation of a support of an axis of a back suspension bracket (Universal person)
Removal and installation of the rear suspension shock absorber (Universal)
Rear stabilizer bar (Universal)
Rear Suspension Coil Spring (Station wagon)
Rear Lower Arm Rear Suspension (Station wagon)
Front Lower Rear Suspension Arm (Station wagon)
Rear Upper Arm (Station wagon)
Rear Suspension Reaction Arm (Station wagon)
Removal and installation of a beam of a back suspension bracket (Universal person)
Steering
Removal and installation of a steering wheel
Removal, inspection and installation of the steering column
Removal and installation of an elastic coupling of a steering column
Steering gear with hydraulic booster (4-cylinder)
Steering gear with hydraulic booster (6-cylinder)
Replacement of rubber covers of the steering mechanism
Bleeding hydraulic steering system
Removal and installation of the steering hydraulic pump
Radiator of hydraulic steering system working fluid
Replacing the tie rod end switch
Wheel setup and steering angles
Steering tightening torques
Body
Exterior
Tightening torques for body elements
General information about the body
Body and bottom maintenance
Repair of minor body damage
Repair of serious damage to the body
Removal and installation of bumpers
Removal and installation of a radiator grille
Removal, installation and adjustment of a cowl
Cable and hood opening lever
Removal, installation and adjustment of the lock of a cowl
Removal and installation of glass of a back door
Removal and installation of a door
Removal and installation of an external mirror
Removing and installing the trunk lid
Removal and installation of trunk lid lock components
Removal and installation of a door of a back
Removal and installation of basic racks of a door of a back
Removal and installation of components of the lock of a door of a back
Windshield and fixed windows
Removal and installation of moldings and stickers
General information and sunroof adjustment
Interior
Carpet and upholstery care
Removal and installation of the panel of internal facing of a door
Removal and installation of a window regulator of a door
Removal and installation of the door handle and lock components
Removal and installation of an internal mirror
Components of the central locking system
Removal and installation of seats
Removal and installation of seat belts
Removal and installation of panels of internal facing
Removal and installation of the central console
Removal and installation of the ceiling panel
Removal and installation of a glove box
Removing and installing the front panel
Removal and installation of the wheel arch locker
Fuel filler flap and opening cable
Electrical equipment
Fuses, relays and bulbs
General information about electrical equipment
Troubleshooting in electrical circuits
Checking and replacing fuses, relays and timers
Removal and installation of switches
Replacing light bulbs (outdoor lights)
Replacing light bulbs (indoor lights)
Removal and installation of blocks of external lamps
Headlight Beam Adjustment
Removal and installation of the electric motor of system of an inclination of a headlight
Removal and installation of the instrument panel
Removal and installation of components of the panel of devices
Removal and installation of a cable of a drive of a speedometer
Removing and installing the watch
Removal and installation of a sound signal
Removal and installation of wiper arms
Windshield wiper motor and drive mechanism
Tailgate Wiper Motor Assembly
Additional vehicle parameter monitoring system
General information about the anti-theft alarm system
General information about the speed control system
Windshield/tailgate washer components
Radio/audio cassette player
Radio/CD Player Amplifier
CD Player
Removing and installing speakers
Removing and installing the radio antenna
Removal and installation of blocks of airbags of safety
Removal and installation of the airbag control device
Airbag Power Supply wiring Drum
Sensor based parking system
GPS navigation system
Removal and installation of electric components of seats
Electrical circuits
Ford Mondeo 2
General information
User guide
Description of cars
Vehicle identification
General repair instructions
Working conditions and tools
Vehicle lifting
Specifications
Torque Specifications
Maintenance and care
Car maintenance and care
Spare parts
Checking the engine oil level
Checking the brake fluid level
Checking the brake signals
Checking the lighting system
Tire pressure check
Checking the coolant level
Checking the oil level in an automatic transmission
Checking the oil level in a manual transmission
Checking the accessory drive belt
Parking brake adjustment
Lubricants, sealants
Recommendations for working with threaded connections
Accumulator battery
Airbag system
Seat belt pretensioner
Wheels and rims
General description
Types of rims
Wheel disks
Tires
Wheel replacement
Winter tires
Tire pressure check
Extended tire life
Tire condition check
Causes of tire wear
Tire storage
Power unit
V16 engine
Removing the engine
Engine installation
Engine disassembly
Engine assembly
Removal and installation of a head of the block of cylinders (on the engine in the car)
Dismantling of a head of the block of cylinders
Repair of a head of the block of cylinders and valves
Cylinder head assembly
Removing pistons
Disassembly of pistons and connecting rods
Checking the technical condition of pistons and connecting rods
Assembly of pistons and connecting rods
Installation of pistons and connecting rods
Cylinder block
Checking the crankshaft
Rear seal ring and crankshaft flange
Camshafts and timing mechanism
Removal and installation of a gear drive belt
Measuring the axial clearance (backlash) of the camshaft
Cylinder compression check
Engine malfunctions
Replacing the front crankshaft oil seal (produced before May 1998)
Removal and installation of camshafts (release before May 1998)
Camshaft oil seals (produced before May 1998)
Duratec VE
Duratec 2.5 liter VE engine
Removal and installation of the left cover of a head of the block of cylinders
Removal and installation of the right cover of a head of the block of cylinders
Removal and installation of the upper intake manifold
Replacement of sealing rings of a camshaft
Removal and installation of the left exhaust manifold
Removal and installation of the right exhaust manifold
Removal and installation of the oil pan
Replacement of a back sealing ring of a cranked shaft
Engine disassembly
Engine assembly
Lubrication system
General information about the lubrication system
Engine oil selection
Checking the engine oil level
Oil consumption
Change of oil
Oil pump replacement
Oil filter replacement
Oil pressure check
Oil pan replacement
Oil leaks
Lubrication system malfunctions
Cooling system
General information about the cooling system
Coolant replacement
Radiator Cooling Fan Replacement
Radiator replacement
Checking the radiator cap and radiator
Fluid Pump Replacement
Thermostat replacement
Thermostat check
Thermostat malfunctions
Checking the cooling system
Coolant hoses
Radiator of the cooling system
Power systems
General information about the power supply and exhaust system
Precautions when working with the power supply system
Air filter replacement
Fuel filter replacement
Checking the operation of the fuel pump
Fuel pump replacement
Throttle cable adjustment
General information about the injection system
Injection System Precautions
Exhaust gas neutralization
Neutralization of exhaust gases of gasoline engines
Exhaust gas recirculation (AGR) system
Ignition system
General information about the ignition system
Precautions when working with the ignition system
Replacing the engine control unit
Spark plug
Diagnostics of the ignition system
Exhaust system
Exhaust gas exhaust system
Removal and installation of system of release of the fulfilled gases
Catalytic Converter Handling Precautions
Removal and installation of catalytic converter
Lambda probe
Transmission
Clutch
General information about the clutch
Clutch test
Removing the clutch
Clutch installation
Removing and installing clutch master cylinder
Removal and installation of the clutch slave cylinder
Removal of air from the hydraulic clutch
Clutch pedal free play adjustment
Mechanical gearbox
Manual Transmission
Removal and installation of a manual transmission
Checking the oil level in a manual transmission
Transmission malfunctions
Automatic gearbox
Automatic transmission
Removal and installation of an automatic transmission
Checking the oil level in an automatic transmission
Wheel drives
General information about wheel drives
Checking the technical condition of the wheel drive shafts
Wheel Drive Shaft Precautions
Removal and installation of the drive shaft on the right side of the car
Removal and installation of an intermediate shaft
Removal and installation of the wheel drive shaft on the left side of the car
Wheel drive repair
Thrust bearing replacement
Internal radial o-rings
Chassis
Front suspension
General information about the front suspension
Removing the wheel bearing
Removing the steering knuckle
Installing the steering knuckle
Removal and installation of the left transverse suspension arm
Removal and installation of the right transverse lever
Removal and installation of the stabilizer bar
Removal and installation of a shock-absorber rack
Removal and installation of forward springs
Installation of a convergence of wheels
Rear suspension (sedan)
Rear suspension (sedan body)
Removal and installation of the rear suspension assembly
Removal and installation of the forward trailing arm of a suspension bracket
Removal and installation of the rear trailing arm suspension
Removal and installation of the stabilizer bar
Rear suspension
Rear suspension
Removal and installation of the rear suspension assembly
Removal and installation of the transverse lever and coil springs
Removal and installation of the front and rear side arms
Removal and installation of the upper suspension arm
Removal and installation of shock absorbers
Removal and installation of jet drafts
Removal and installation of a nave of a wheel
Removal and installation of the stabilizer bar
Removal and installation of naves of back wheels
Rear wheel alignment
Steering
General steering information
Removal and installation of the steering mechanism
Checking the technical condition of the cuffs of the gear rack
Checking the technical condition of the cuffs and tips of the transverse steering rods
Steering Clutch Replacement
Bleeding the power steering drive
Power steering pump replacement
Removal and installation of a steering wheel
Brake system
General information about the brake system
Brake design
General description of the braking system
Replacing the front brake pads
Removal and installation of the front brake caliper
Dismantling the front brake caliper
Removal and installation of a forward brake disk
Removing the rear drum brake pads
Installing the rear drum brake pads
Removal and installation of the brake cylinder of drum brakes
Replacing the rear disc brake pads
Removal and installation of the rear disc brake caliper
Removal and installation of a back disk of the brake mechanism
Removal and installation of the main brake cylinder
Repair of the main brake cylinder
Brake booster
Anti-lock braking system (ABS)
Removal and installation of the ABS hydraulic block
ABS sensor replacement (front wheels)
ABS sensor replacement (rear wheels)
Replacing the front parking brake cables
Replacing the rear parking brake cables
Traction control
Removal and installation of the regulating electric motor
Brake service
Checking the brake fluid level
Brake Fluid Replacement
Checking the brake system
Checking the brake system for leaks and damage
Checking the brake pads
Bleeding the brake system
Electrical equipment
Battery and alternator
Accumulator battery
Checking the battery
Battery characteristic
Definition of a faulty consumer
Generator Handling Precautions
Checking the installed generator
Removal and installation of the generator
Generator repair
Generator brush replacement
Typical generator malfunctions
Starter
Starter check (on a car)
Removal and installation of a starter
Starter repair
Alternator drive belt
Light and appliances
Checking the wiper and alarm system
Removing and installing the wiper motor (front)
Removal and installation of a screen wiper (in front)
Wiper Bearing Replacement
Removal and installation of the wiper motor (rear)
Outdoor Lighting
Replacing headlight bulbs
Replacing parking light bulbs
Removal and installation of headlights
Headlight adjustment
Control and measuring devices
Electrical circuits
Ford Mondeo 3
General information
Introduction to the guide
Introduction to service manual repair
Help system view
First Look at the Mondeo Model Program
Car engine family
Car dimensions
Model development
Workplace equipment
Workplace equipment
Take care of spare parts in a timely manner
Tools — basic equipment
Special tools and accessories
A matter of experience — professional advice for amateurs
Tips for attending the workshop
Safety first
A practical lifting tool — a jack
Car care
Car care products
Internal cleaning — dirt has no chance
Outdoor sink
Engine wash
To keep everything in motion, contact the lubrication service
If you want to save material values — take care of the coloring
Lacquer care
Decrease in product value — ugly color defects
Elimination of defects from stone impacts
Polishing small scratches
Elimination of large scratches
Installation for glass washing
Checking the windshield wiper and washer
Pouring water into the washer
Wiper blade rubber replacement
Windshield washer nozzle installation
Installation and dismantling of the washer nozzle
Dismantling and installation of the wiper arm
Dismantling and installation of the front wiper motor
Dismantling and installation of the rear wiper motor
Help with malfunctions
Starter malfunctions
Battery and alternator faults
Malfunctions of the gasoline injection system
Brake malfunctions
Diesel injection system malfunctions
Power window malfunctions
Heating system malfunctions
Cooling system malfunctions
Clutch malfunctions
Engine and system malfunctions
Brake signal faults
Wiper malfunctions
Lubrication system malfunctions
Thermostat malfunctions
Malfunctions of the sound and light alarm system
Wiper blade failures
Malfunctions of the central locking system
Spark Plug Malfunctions
Cylinder Head Gasket Faults
Power unit
Engine repair
The device and characteristics of engines
Make in the workshop or do it yourself
Engine cranking
Compression ratio
Compression measurement
Checking drive belts
Mounting drive belts
Determining the location of the malfunction by listening — noises in the engine compartment
Lubrication system
Engine lubrication system device
The role of engine oil for the engine
Checking the engine oil level
Changing engine oil and oil filter
Oil bubbles on the engine
Cooling system
Engine cooling system device
Cooling liquid
Checking the cooling system for leaks
Checking and topping up the coolant
Coolant replacement
Adding frost protection
Dismantling and checking the thermostat — only when the engine is cold
First aid — close the thermal switch
Removing the cooling fan
Dismantling and installation of the radiator
Replacing coolant hoses
Air filter (intake muffler)
Cleaning and replacing the filter cartridge
Fuel injection system
Fuel injection system device
Sometimes it is rational to carry out a visual inspection of the injection system
Checking the intake system for leaks
Idling speed check
Fluctuations at idle — a systematic phenomenon
Checking the idle control valve
Injector test
Replacing the thrust of the gas pedal (using the example of Duratec-HE)
Diesel engine fuel supply — basic design
Visual inspection of the diesel injection system
Ignition system
Ignition system device
Ignition coil
High temperature resistant spark plugs
Replacing spark plugs — after 60,000 kilometers
Checking with a universal device – speed sensor
With the help of an assistant, no problem — checking the pressure sensor
Well-coordinated work — checking the current in the ignition system
Measuring the resistance on the ignition coil
Removing the ignition unit
Diesel engine preheating device
Checking the preheating device
Checking the preheat relay
Checking glow plugs
Fuel system
Fuel system device
Fuel types and handling
Tank Ventilation and Ventilation Check
Fuel filter replacement (petrol engine)
Fuel filter replacement (diesel engine)
Emptying the tank without fuel pump
Dismantling pipelines and hoses (general instructions)
Troubleshooting the fuel pump
Dismantling and installation of the fuel pump (gasoline engine)
Exhaust gas exhaust system
Exhaust System Tips
The question of cost — full repair or partial replacement
Low Exhaust Gas — ASU
Exhaust gas neutralization
Transmission
Gear box device
Clutch device
Clutch test
Does the clutch fully disengage?
Five-speed manual transmission
Gear shift adjustment
Checking the transmission oil level (manual transmission)
Automatic in combination with 2.0-litre Duratec-HE engine
Checking the transmission oil level (automatic transmission)
Main gear
Checking the cuffs of the drive shafts
Dismantling and installation of the drive shaft / control arm suspension
Replacing the cuffs of the cardan joint
Chassis
Chassis
Chassis device
Front axle Mondeo
Front axle geometry
Checking shock absorbers after two sets of tires are worn out
Regular check of steering wheel free play
Checking the protective collars of the gear rack
Checking the tie rod ends and cuffs
Control Arm Bearing Check
Checking the wheel bearing clearance
Replacing the front wishbone
Dismantling and installation of shock absorber
Replacement of tie rod ends
Replacement of cuffs of the steering mechanism
Steering swivel replacement
Dismantling and installation of the rear suspension strut
Shock absorber replacement (station wagon)
Power steering gear
Tires and wheels
Air pressure is best checked on cold tires
Wheel replacement
Tire condition check
Brake system
Brake system device
Checking the brake fluid level
Checking the brake system
Checking the brake booster
Functional check of the brakes
Measuring Disc Brake Pad Wear
Checking Disc Brake Wear
Bleeding the brake system
Brake Fluid Replacement
Dismantling the compensation tank of the main brake cylinder
Dismantling and installation of the main brake cylinder
Dismantling and installation of the brake booster
Dismantling and installation of brake hoses
Replacing disc brake pads
Replacing brake discs
Replacement of protective cuffs of a support and the piston of the brake mechanism
Parking brake
Replacing the parking brake cable
Body
Interior
Car interior device
Ventilation and heating
Periodically check heating and ventilation systems
Removing the heating and ventilation control unit
Fan
Fan Troubleshooting
Fan motor replacement
Replacing interior lamps
Switch
Ignition key coding
Checking the door contact switch
Removing the radio
Dismantling the speaker
Dismantling the outdoor antenna
It is not recommended to dismantle the front seats yourself
Removing the rear seat back
Removing the front door trim
Removing the side windows / power window
Power window
Power window motor setting
Removing the door handle
Removing the steering lock
Exterior
Description of the car body
Dismantling and installation of the door
Door adjustment
Dismantling and installation of an external rear-view mirror
Dismantling and installation of the fairing
Dismantling and installation of the hood
Engine Hood Adjustment
Dismantling and installation of the bumper cover (front)
Dismantling and installation of wings
Dismantling and installation of the bumper cover (rear)
Dismantling and installation of the trunk lid
Trunk lid adjustment
Dismantling and installation of the rear door lock
Electrical equipment
Light and appliances
Description of electrical equipment
Contact Care
Starting the engine «from the side» with a wire
Car pushing
Towing a car
Identification of secret consumers of electricity
Replacing drive belts
Replacing the Belt Pinch Roller
Outdoor Lighting
Replacing incandescent lamps
Headlight adjustment «in front of the wall»
Signaling devices
Checking the brake light switch
Checking the beep
Instruments and controls
Function test of the circuit breaker
Removing and installing the combined instrument panel
It's not always easy to follow the «winding» wires
Fuses in passenger compartment and engine compartment
Replacing fuses
Distributes high operating currents — switching relay
Fuse and relay layout
Battery and alternator
Battery and starter
Generator
Checking the electrolyte level in the battery
Checking the battery
Charging the battery
Replacing the battery
Checking the voltage regulator
Dismantling and installation of the generator
Starter Replacement
Schematic diagrams
The structure of electrical circuits
Engine cooling circuits
Fuel System Wiring Diagrams
Electrical diagrams of the diesel starting system
Motor Control Circuits
Electric circuits for heating and air conditioning
Electric circuits of the generator and regulator
Wiring diagrams for outdoor lighting, headlights
Horn Wiring Diagrams
Electrical circuits of the clockwork
Windscreen wiper and washer circuit diagrams
Ford Mondeo 4
General information
User guide
General information about the car
Passport data of the car
Cruise control system
On-board computer
Power unit
Engine repair
Features of the design and repair of the duratec-v15 engine with a volume of 2.5 liters
Checking compression in the cylinders of the duratec-v15 engine with a volume of 2.5 liters
Replacing the timing belt of the duratec-v15 engine with a volume of 2.5 liters
Replacing the crankshaft seals of the duratec-v15 engine with a volume of 2.5 liters
Replacing the cylinder head gasket for the 2.5L duratec-v15 engine
Replacing the camshafts and sealing the cylinder head cover of the duratec-v15 engine with a volume of 2.5 liters
Replacing the oil sump seal of the duratec-v15 engine with a volume of 2.5 liters
Features of the design and repair of the 2.2 l duratorq-tdci engine
Checking compression in the cylinders of the 2.2 l duratorq-tdci engine
Timing belt replacement for 2.2L duratorq-tdci engine
Replacing the crankshaft seals on the 2.2L duratorq-tdci engine
2.2L Duratorq-tdci Cylinder Head Cover Seal Replacement
2.2L duratorq-tdci cylinder head gasket replacement
Replacing the camshafts of the 2.2L duratorq-tdci engine
2.2L duratorq-tdci engine oil seal replacement
Removal and installation of a decorative casing of the engine
Cylinder compression check
Removal and installation of a mudguard and crankcase protection
Replacement of the right support of a suspension bracket of the power unit
Replacement of the left support of a suspension bracket of the power unit
Replacing the rear support suspension of the power unit
Cleaning the crankcase ventilation system
Setting the piston of the first cylinder to the TDC position of the compression stroke
Valve clearance adjustment
Checking and replacing the accessory drive belt
Checking and replacing the timing belt of the duratec ti-vct engine with a volume of 1.6 liters
Replacing the timing chain of duratec-he engines with a volume of 2.0 and 2.3 liters
Removal, troubleshooting and installation of the flywheel
Replacing the cylinder head cover gasket
Replacing the cylinder head gasket
Replacement of oil scraper caps
Replacing camshaft seals
Replacing the crankshaft seals
Replacing the oil sump seal
Replacing the intake pipe gasket
Replacing the gasket of the collector
Replacing camshafts
Removal and installation of the engine
Lubrication system
Lubrication system
Changing engine oil and oil filter
Removal and installation of the oil pump
Oil pump repair
Checking the level and adding oil to the lubrication system
Cooling system
Cooling system
Coolant replacement
Replacing the cooling system radiator
Water pump replacement
Removal and installation of the thermostat
Removal and installation of a broad tank
Checking the level and topping up the coolant
Exhaust system
Exhaust gas exhaust system
Replacement of pillows of a suspension bracket of system of release of the fulfilled gases
Removal and installation of the collector and replacement of its gasket
Removal and installation of the main and additional mufflers
Removal and installation of thermal screens
Supply system
Supply system
Checking the pressure in the engine power system
Reducing the pressure in the engine power system
Replacing the air filter element
Removing and installing the air filter and intake silencer
Removal, repair and installation of the fuel module
Fuel tank replacement
Removal and installation of the fuel rail
Removing, checking and installing injectors
Removal and installation of the throttle assembly
Removing and installing the throttle control pedal
Checking the engine power system
Fuel Injection System Malfunctions
Fuel vapor recovery
Evaporative Emission System
Removal and installation of an adsorber of system of catching of steams of fuel
Transmission
Clutch
Clutch
Checking the travel of the clutch release pedal
Removal and installation of clutch
Replacement of the working cylinder of the clutch release actuator with the clutch release bearing
Clutch Master Cylinder Replacement
Replacement of the pipeline of a hydrodrive of deenergizing of coupling
Removal and installation of the clutch pedal
Bleeding the hydraulic clutch release
Car gearbox
Transmission
Changing the oil in a manual transmission or fluid in an automatic transmission
Replacing gearbox seals
Removal and installation of a transmission
Replacing the transmission control cables
Removal and installation of the scenes of the gear lever
Gearbox control drive adjustment
Checking the fluid level in an automatic transmission
Wheel drives
Front wheel drives
Removal and installation of front wheel drives
Replacement of constant velocity joints
Replacing the intermediate support bearing
Chassis
Front suspension
Front suspension
Checking the technical condition of the front suspension parts on the car
Removal and installation of a shock-absorber rack
Shock absorber repair
Replacing the upper support of the shock absorber strut
Ball joint replacement
Replacing the front suspension arm
Replacing parts of the front suspension anti-roll bar
Removal and installation of a rotary fist
Replacing the front hub bearing
Removing and installing front suspension subframe
Checking and adjusting wheel alignment
Rear suspension
Rear suspension
Checking the technical condition of the rear suspension parts on the car
Replacing the shock absorber rear suspension
Replacing the rear suspension spring
Replacing the upper arm of the rear suspension
Replacing the front lower arm of the rear suspension
Replacing the rear lower arm of the rear suspension
Rear Suspension Trailing Arm Replacement
Replacing parts of the rear suspension anti-roll bar
Replacing the rear wheel hub
Removal and installation of a cross-beam of a back suspension bracket
Steering
Steering
Inspection and testing of the steering on the car
Checking the free play (backlash) of the steering wheel
Removal and installation of a casing of a steering column
Removal and installation of a steering wheel
Removal and installation of a steering column
Replacing the outer tie rod end
Tie rod replacement
Bleeding the power steering system
Replacing the power steering reservoir
Steering gear replacement
Power steering pump replacement
Checking the level and topping up the working fluid in the power steering reservoir
Brake system
Brake system
Checking the position of the brake pedal
Checking the operation of the vacuum brake booster
Checking the degree of wear of brake pads and discs
Bleeding the hydraulic drive of the brake system
Brake Fluid Replacement
Replacing the reservoir of the main brake cylinder
Replacing the master brake cylinder
Replacing the vacuum booster
Replacement of brake hoses
Replacement of brake pipes
Removing and installing the brake pedal
Replacing the brake pads of the brake mechanism of the front wheel
Front wheel brake caliper replacement
Replacing the brake disc of the front wheel brake mechanism
Replacing the brake pads of the brake mechanism of the rear wheel
Rear wheel brake caliper replacement
Replacing the brake disc of the rear wheel brake mechanism
Parking brake actuator adjustment
Replacing the front parking brake cable
Replacing the rear parking brake cables
Removal and installation of the parking brake lever
Checking the level and topping up the brake fluid in the reservoir of the hydraulic brake system and clutch release
Body
Exterior
General information about the body
Removal and installation of a forward bumper
Removal and installation of wheel mudguards and fender liner
Removal and installation of a back bumper
Removal and installation of a forward wing
Removal and installation of a cowl
Removal, installation and adjustment of the hood lock and its drive
Removal and installation of facing of a box of an air inlet
Removing and installing the trunk lid
Replacing the trunk lid lock
Removing the lining of the trunk lid
Removal and installation of a cover of the hatch of a bulk pipe of a fuel tank
Removal and installation of an external mirror
Interior
Removal and installation of a forward seat
Removal and installation of a back seat
Removal and installation of floor tunnel lining
Removal and installation of an internal mirror
Dashboard
Removal and installation of the instrument panel
Removal and installation of facings of salon
Removal and installation of facings of a luggage carrier
Removal and installation of the shelf of fastening of the rechargeable battery
Doors, locks and windows
Removal and installation of an upholstery of a forward door
Front door glass replacement
Replacing the power window of the front door
Replacing the outside handle and front door lock switch
Replacement of the internal handle of a drive of the lock of a forward door
Replacing the front door lock
Replacing the front door opening limiter
Removal and installation of a forward door
Removal and installation of an upholstery of a back door
Rear door glass replacement
Replacing the power window rear door
Rear Door Exterior Handle Replacement
Replacing the inner handle of the tailgate lock actuator
Replacing the rear door lock
Replacing the tailgate opening limiter
Removal and installation of a back door
Heating and ventilation
Ventilation, heating and air conditioning system
Features of the device of the ventilation system
Features of the heating system device
Features of the air conditioning system
Removing refrigerant from the air conditioning system
Replacement of O-rings
Air conditioning compressor
Removal and installation of the compressor
Drive pulley bearing replacement
Replacing the compressor clutch solenoid
Removal and installation of the condenser
Replacing the filter element of the receiver-drier
Replacing the cabin air filter
Removal and installation of the control unit for the ventilation, heating and air conditioning system
Replacing the pressure sensor
Removal and installation of the sensor of solar illumination
Replacing the outdoor temperature sensor
Activation of the on-board diagnostic system
Reading stored trouble codes
Reading the software version number
Security systems
Passive safety system (srs)
Removal and installation of the driver's airbag
Removal and installation of a pillow of safety of the forward passenger
Removal and installation of a forward seat belt
Removal and installation of a back seat belt
Removal and installation of the electronic control unit of the additional passive safety system
Removal and installation of the side impact sensor
Active safety system (electronic braking control systems)
Removal and installation of the hydroelectronic control unit for anti-lock braking system
Removal and installation of sensors of frequency of rotation of forward wheels
Removal and installation of sensors of frequency of rotation of back wheels
Electrical equipment
Electrical appliances
Electrical equipment
Location of fuses, fuses and relays and their replacement
Removal and installation of mounting blocks
Replacing the contact group of the ignition switch (lock)
Replacing the ignition switch (lock) cylinder
Removal and installation of the switch (lock) of ignition
Replacement and maintenance of spark plugs
Engine management system
Checking the ignition coil
Removal and installation of the ignition coil of the 1.6 l duratec ti-vct engine
Removal and installation of ignition coils for duratec-he and duratec-v15 engines
Replacing the electronic engine control unit
Check and replacement of gauges of a control system of the engine
Replacing paddle shifters
Removal and installation of a sound signal
Removal and installation of a trapezoid and a gearmotor of a screen wiper of a wind window
Removal and installation of a washer glass of a wind window
Replacing the power window control unit and switches
Replacement of motor reducers of electric drives of window regulators
Replacing Power Window Control Modules
Removal and installation of the electric motor of the radiator fan of the engine cooling system
Replacing the engine cooling radiator fan control unit
Removal and installation of the electric motor of the fan of a heater
Replacing the additional resistance of the heater electric fan and damper motors
Removal and installation of a combination of devices
Replacing the control unit for outdoor lighting and illumination of the instrument cluster
Removal and installation of switches of the course stability system (esp), alarm and electrical heating of the windshield and rear windows
Removal and installation of switches of heating of forward seats
Removal and installation of the car radio
Removing and installing speakers of the acoustic system
Replacing the oil pressure warning light sensor
Checking and replacing the fuel gauge sensor
Checking and replacing the reverse light switch
Stoplight Switch Replacement
Replacing the Parking Brake Warning Light Switch
Headlights and lighting
Lighting, light and sound signaling
Lamp replacement
Removal and installation of the multifunctional electronic unit (gem)
Headlight Replacement
Fog Lamp Replacement
Rear light replacement
Replacement of an additional brake light
Replacement of a lateral lantern of the index of turn
Replacing license plate lights
Interior lamp replacement
Battery and alternator
Removing and installing the battery
Generator
Removal and installation of the generator
Checking the ignition system
Generator repair
Starter
Removal and installation of a starter
Starter repair
Ford Escort 3
General information
Maintenance
Hood opening
Ignition switch with anti-theft device
Features of starting the engine
Lubrication system
Cooling system
Supply system
Ignition system and spark plugs
Clutch adjustment and care
Transmission
Steering
Car suspension
Brake system
Vehicle electrical equipment
Replacement of headlights, side lights and signaling lamps
Wheels and tires
Body and layout of the car
Lifting and towing a car
General requirements for car repair
Reference dimensions for checking the floor of the body
Tightening torques for threaded connections
Characteristics
Vehicle data
Operating data
Basic data for adjustments and monitoring
Passport data
Engine
Disassembly and assembly
Removal and installation of the power unit
Disassembly and assembly of engines of all models except GLA
Disassembly, inspection and assembly of the GLA engine
The device and check of the block of cylinders
Connecting rod and piston group
Crankshaft
Cylinder head (except GLA model)
GLA engine cylinder head
Cooling system
Features of the cooling system device
Coolant replacement
Removal and installation of a radiator
Electric fan replacement
Removal and installation of the water pump
Removal and installation of the thermostat
Lubrication system
Features of the lubrication system device
Engine lubrication system for all models except GLA
GLA engine lubrication system
Oil pressure check
Oil filter replacement
Supply system
Power supply system for carburetor engines
Fuel tank
Fuel pump
Air filter
Ford carburetor
Ford Carburetor Maintenance
Removal and installation of the Ford carburetor
Dismantling and checking the technical condition
Ford Carburetor Adjustments
Replacing the dispensing needle
Needle valve replacement
Removal and installation of air spool actuator
Weber carburetor
Weber carb settings
Exhaust gas exhaust system
Fuel injection «K-Jetronic»
The principle of operation and features of the device
Fuel pump and filter
Pressure accumulator
Air flow meter
Fuel dispenser and regulator
Valves and nozzles
Forced idling device
Checking and adjusting the elements of the fuel injection system
Removal and installation of elements of the injection system
Possible malfunctions of the fuel injection system
Transmission
Clutch
Device Features
Removal and installation of a conducted disk of coupling
Replacing the clutch release bearing
Clutch cable replacement
Escort RS 1600 I Pedal Freeplay Adjustment
Mechanical gearbox
Device Features
Removal and installation of mechanical transmission
Disassembly of the four-speed gearbox
Assembly of a four-speed gearbox
Removal and installation of the gear change drive
Assembly features of a five-speed gearbox
Hydromechanical box
General information about the hydromechanical box
Device Features
Removing the hydromechanical gearbox
Installing a hydromechanical gearbox
Checking the hydromechanical transmission assembly
Starter Interlock Switch Adjustment
Hydromechanical transmission test
Test in motion
Possible malfunctions, their causes and methods of elimination
Drive shafts
Features of the wheel drive device
Front wheel drive replacement
Disassembly of the wheel drive shaft
Chassis
Front suspension
Device Features
Features of the front suspension «Escort RS 1600 i»
Checking and adjusting the angles of the front wheels
Hub bearing replacement
Removal and installation of a rack of a forward suspension bracket
Dismantling and assembling the suspension strut
Removal and installation of the lower suspension arm
Removal and installation of the stabilizer bar
Rear suspension
Device Features
Rear wheel alignment
Removal and installation of the rear suspension assembly
Removal and installation of suspension spring
Shock absorber replacement
Removal and installation of the suspension arm
Removal and installation of stretch marks
Removal and installation of the hub
Replacing wheel bearings
Removal and installation of a pin
Steering
Device Features
Removing the steering gear
Steering gear installation
Disassembly of the steering mechanism of cars produced before May 1983
Assembling the steering gear of cars manufactured before May 1983
Disassembly of the steering gear on cars produced since May 1983
Assembling the steering mechanism of vehicles produced since May 1983
Checking the torque of the drive gear
Removal and installation of a steering shaft
Brake system
Device Features
Replacing the brake pads of the front wheel
Removal and installation of the brake mechanism of a forward wheel
Replacing the brake pads of the rear wheel
Removal and installation of the brake mechanism of a back wheel
Removal of air from the hydraulic actuator
Removal and installation of the master cylinder
Disassembly and assembly of the master cylinder
Removal and installation of the vacuum amplifier
Parking brake adjustment
Electrical equipment
Starting and charging system
Electrical equipment diagram
Accumulator battery
Generator device
Generator repair
Disassembly and assembly of the generator
Starter device
Starter repair
Ignition system
General information about ignition
Ignitions for GLA, GMA and GPA engines
Vacuum ignition timing control
Removal and installation of the distributor
Replacing contacts
Contact gap adjustment
Setting the ignition timing
Contactless ignition system
Checks and repairs of the non-contact ignition system
Ignition «Escort RS 1600»
Device Features
Removal and installation of the crankshaft position sensor
Checking the electrical connections of the ignition system
Check of installation of the initial moment of ignition
Light and appliances
Features of the lighting and signaling device
Headlight adjustment
Windshield wiper and washer
Wiper operation
Removal and installation of a screen wiper
Rear window wiper and headlight washer
Electric motors of fans
Power windows and central locking
Control devices
Schematic diagrams
Electrical equipment of cars «Escort» 1980-1982
Wiring diagram for Escort devices 1980-1982
Charging, starting and control devices «Escort» 1980-1982
Power windows, door locks and lighting «Escort» 1980-1982
Exterior lighting for Escort cars from 1980-1982
Clearance light and direction indicators «Escort» 1980-1982
Interior lighting for Escort cars 1980-1982
Ventilation, cleaners and washers «Escort» 1980-1982
Control lamps of cars «Escort» 1980-1982
Systems for charging, starting and operating the Escort engine 1983-1985
Power windows, door locks and lighting «Escort» 1983-1985
Exterior lighting of Escort cars produced in 1983-1985
Direction indicators for Escort cars 1983-1985
Interior lighting for Escort cars 1983-1985
Ventilation, cleaners and washers of glasses «Escort» 1983-1985
Control lamps for Escort cars 1983-1985
Escort fuel injection system 1983-1985
Schematic diagram of the electrical equipment of Orion cars
System for charging, starting and operating the engine of the Orion car
Wiring diagram of the exterior lighting of the car «Orion»
The connection diagram of the direction indicators of the car «Orion»
Ventilation, cleaners and washers «Orion»
Wiring diagram for the interior lighting of the Orion car
Scheme of connection of control lamps of the car «Orion»
Power windows and heated rear window «Orion»
Central blocking of car door locks «Orion»
Orion fuel injection system
Ford Escort 4
General information
User manual
Design features Ford Escort 4
Fuel consumption, l/100 km
The speed of movement on the gears
Equipped and gross vehicle weight
Vehicle dimensions
Periodic vehicle inspections and maintenance
Vehicle identification
Warning signs in text
Control of external rear-view mirrors with the electric drive
Front seats — adjustment
Steering column lock / ignition lock
Dashboard
Instrument cluster
Control levers on the steering column
Manual transmission
Heating and ventilation
Analog and digital clock
Fuel computer
Door locks — opening and locking
Manhole with mechanical drive
Power-down windows
Increasing the volume of the luggage compartment
Windshield wipers and washers
Vehicle lifting
Engine starting
Features of car operation
Repair dimensions of bodies
Maintenance
The location of the units in the engine compartment
Operating materials and fluids
Maintenance interval
Primary and Secondary Maintenance Activities
Oil and oil filter change (10,000 km/12 months)
Check for tightness of hoses and fluid leakage (10,000 km / 12 months)
Checking the idle speed and the quality of the fuel mixture (10,000 km / 12 months)
Checking the components of the ignition system (10,000 km / 12 months)
Lubrication of contacts of the breaker of the distributor of ignition (10000 km/12 months)
Breaker contact gap adjustment (10,000 km/12 months)
Ignition timing with contact breaker (10,000 km / 12 months)
Replacing spark plugs on an RS Turbo engine (10,000 km / 12 months)
Checking the front brake pads (10,000 km / 12 months)
Checking the rear brake pads (10,000 km / 12 months)
Checking the front suspension and steering (10,000 km / 12 months)
Shock absorber check (10,000 km / 12 months)
Checking the condition of seat belts (10,000 km / 12 months)
Alternator drive belt (10,000 km / 12 months)
Valve clearance adjustment (20,000 km / 12 months)
Checking the oil level in the gearbox (20,000 km / 12 months)
Replacing breaker contacts (20,000 km / 12 months)
Checking the oil level in a manual transmission (20,000 km / 12 months)
Checking the level of transmission fluid in the automatic transmission (20,000 km / 12 months)
Checking the protective cover of the drive shaft (20,000 km / 12 months)
Coolant change (40,000 km/24 months)
Replacing the air filter element (40,000 km / 24 months)
Replacing the filter of the crankcase ventilation system (40,000 km / 24 months)
Replacing the fuel filter on engines with a fuel injection system (40,000 km / 24 months)
Replacing the toothed belt on CVH engines (60,000 km / 36 months)
CVH brake component check (60,000 km/36 months)
Brake fluid change (60,000 km/36 months)
Gasoline engines
OHV engine repair
General OHV engine data
Main parameters of OHV engines
Cylinder Head — Specifications
Engine Block — Specifications
Crank Mechanism — Specifications
Gas distribution system — specifications
Fuel System — Specifications
Ignition system — specifications
Lubrication system — specifications
Cooling System — Specifications
Tightening torques for threaded connections
General view of the OHV engine and engine compartment
Valve clearance adjustment
Removing the cylinder head
Dismantling of a head of the block of cylinders
Check and repair of a head of the block of cylinders
Cylinder head assembly
Installing the cylinder head
Replacement of a forward sealing ring of a cranked shaft
Pistons and connecting rods — removal
Pistons and connecting rods — check and repair
Pistons and connecting rods — installation
Removing the engine
Engine disassembly
Engine repair
Engine assembly
Engine installation
Cylinder compression check
CVH engine repair
General CVH engine data
Main parameters of CVH engines
Cylinder Head — Specifications
Engine Block — Specifications
Crank Mechanism — Specifications
Gas distribution system — specifications
Fuel System — Specifications
Contact ignition system — specifications
Non-contact ignition system — specifications
Lubrication system — specifications
Cooling System — Specifications
Tightening torques for threaded connections
General view of the CVH engine and engine compartment
Toothed belt replacement
Removing the cylinder head
Dismantling of a head of blocks of cylinders
Check and repair of a head of the block of cylinders
Hydraulic valve lifters
Cylinder head assembly
Installing the cylinder head
Replacement of a sealing ring of a camshaft
Replacement of a forward sealing ring of a cranked shaft
Oil sump replacement
Pistons and connecting rods — removal, inspection and installation
Removing the engine
Engine disassembly
Engine repair
Engine assembly
Engine installation
Cylinder compression check
Fuel system
Fuel system — general information
FORD VV carburetor with variable diffuser section
Main dosing system
Idle system
Removal and installation of the carburetor
Idle speed and CO content
Idling valve
Starting device — removal and installation
Speed increase device
Jet needle — removal and installation
Float chamber needle valve
Accelerator cable — removal, installation and adjustment
Trigger cable — removal, installation and adjustment
Fuel pump — removal, inspection and installation
Fuel tank — removal and installation
Air supply thermostat
Air filter — removal and installation
Weber 2V carburetor
Weber 2V carburetor — design description
Removal and installation of the carburetor
Carburetor cover — removal
Idle speed and CO content
Automatic starter — removal and installation
Air damper gap adjustment
Speed increase device
Float chamber needle valve
KE-Jetronic injection system
The location of the elements of the fuel injection system on the car
K-Jetronic fuel injection system — principle of operation
KE-Jetronic fuel injection system — design description
Starting nozzle — check
Thermal time switch
Idle speed
CO content adjustment
Temperature controller
Auxiliary dosing device
Fuel pump — removal and installation
Fuel filter — removal
Air filter — removal and installation
Turbocharger — removal and installation
Lambda probe — removal, installation and check
CFI injection system
CFI fuel injection system — design description
Throttle valve — general information
Injectors — general information
Pressure regulator — general information
Injection system sensors — general information
Operation of the central injection system
Removal and installation of an injector
Safety precautions when working with the injection system
Diagnosis of malfunctions of the injection system
Ignition system
Ignition system — general information
Contact ignition system — general information
Ignition distributor — removal and installation
Vacuum Ignition Advance Controller
Capacitor — removal and installation
Adjusting the gap between the breaker contacts
Replacing breaker contacts
Checking the ignition timing
Diagnosis of malfunctions of the contact ignition system
Contactless ignition system — general information
Contactless ignition distributor
Contactless ignition switch
Electronic ignition system without ignition distributor
Diesel engines
Engine repair
View of the engine compartment and specifications
Cylinder Head — Specifications
Engine Block — Specifications
Crank Mechanism — Specifications
Gas distribution system — specifications
Fuel System — Specifications
Lubrication system — specifications
Cooling System — Specifications
Tightening torques for threaded connections
Working principle of diesel engine
Engine adjustment
Removal and installation of a toothed belt (engine 1.6 l)
Removal and installation of a toothed belt (engine 1.8 l)
Removing the cylinder head
Cylinder head repair
Installing the cylinder head and adjusting the valve timing
1.6 liter engine disassembly
Checking engine parts 1.6 liters
1.6 liter engine assembly
Differences in the assembly of the engine with a displacement of 1.8 liters
Fuel system
General information about the fuel system
Nozzles — removal, inspection and installation
Checking the tightness of the atomizer nozzle
Adjustment of the initial injection pressure
Glow plugs — check
Cylinder compression check
Removal of air and water from the fuel system
Engine stop device
Fuel filter replacement
Accelerator cable — removal and installation
High pressure pump
High pressure fuel pump — design description
Rotary pump — general information
Piston distributor — general information
Solenoid valve — general information
Centrifugal governor and injection regulator
Setting the injection timing of the fuel pump
Checking the maximum speed and delay time
Idle speed adjustment
Air filter replacement
Cooling and lubrication system
Technical characteristics of the cooling system
Cooling system tightening torques
Coolant replacement
Radiator fan motor — removal and installation
Thermostat — removal, inspection and installation
Temperature sensor for turning on the fan
Removal and installation of the water pump
Removal and installation of a radiator
Technical characteristics of the lubrication system
Lubrication system tightening torques
Engine lubrication system — design description
Oil pressure check
Removal and installation of an oil crankcase
Removal and installation of the oil pump
Engine oil change
Oil filter replacement
Engine ventilation system
Lubrication system malfunctions
Exhaust system — design description
Removal and installation of system of release of the fulfilled gases
Rear muffler replacement
Cars with a catalyst — general information
Transmission
Clutch
Clutch specifications
Removing the clutch
Clutch test
Clutch installation
Removal and installation of release bearing
Removal and installation of the clutch cable
Free play adjustment
Basic clutch malfunctions
Mechanical gearbox
Gearbox — general information
Gearbox Specifications
Maintenance of a four-speed manual transmission
Removing the four-speed manual transmission
Installation of a four-speed manual transmission
Dismantling a four-speed manual transmission
Assembly of a four-speed manual transmission
Gearshift mechanism of a four-speed manual transmission
Removing the five-speed manual transmission
Dismantling a five-speed manual transmission
Gearshift mechanism of a five-speed manual transmission
Automatic gearbox
Technical characteristics of the automatic transmission FORD ATX
Removal and installation of transmission FORD ATX
Gearbox controls FORD ATX
Checking the parking brake box FORD ATX
Checking the oil level in the FORD ATX box
Towing a car with an automatic transmission
The main malfunctions of the FORD ATX gearbox
Technical characteristics of the automatic transmission FORD CTX
Removing and installing transmission FORD CTX
FORD CTX Gearbox Shift Rod
Drive shafts
Description of the design of drive shafts
Tightening torques for threaded connections
Removing drive shafts
Installation of drive shafts
Disassembly of drive shafts
Assembly of drive shafts
Inner Hinge Protective Boot Replacement
Replacement of a protective cover of the external hinge
Joint housing seal
Drive shaft failures
Chassis
Suspension and wheels
Front suspension — design description
Specifications of the front suspension
Front suspension tightening torques
Removal and installation of a forward amortization rack
Removal and installation of the front shock absorber and spring
Removal and installation of a forward spherical support
Removal and installation of the forward stabilizer
Removal and installation of the front extension
Removal and installation of bearings of a forward nave
Rear suspension — design description
Rear Suspension Specifications
Removal and installation of a back amortization rack
Removal and installation of the rear suspension arm and spring
Removal and installation of rear jet thrust
Removal and installation of bearings of a back nave
Tire designation
Designation of disks of wheels
Steering
Description of the steering structure
Steering Specifications
Tightening torques for threaded connections
Removal and installation of the steering mechanism
Removal and installation of a steering column
Removal and installation of a steering wheel
Removal and installation of a tip of steering draft
Brake system
General information about the brake system
Specifications of the brake system
Tightening torques for threaded connections
Removal and installation of front brake pads
Removal and installation of a forward support of brakes and a brake disk
Removal and installation of rear brake pads
Removal and installation of back working brake cylinders
Master brake cylinder — removal and installation
Vacuum brake booster — removal and installation
Removal of air from the brake system
Parking brake adjustment
Replacing the parking brake cables
Anti-Lock Braking System — Design Description
Brake system maintenance
The main malfunctions of the brake system
Body
Body elements
General information about the car body
Radiator grill — removal
Hood opening cable — removal and installation
Front bumper — removal and installation
Rear bumper — removal and installation
Trunk lid (Orion) — removal and installation
Upholstery of the ceiling — removal and installation
Front seats — removal and installation
Rear seats — removal and installation
Outside mirror — removal and installation
Interior mirror — removal and installation
Air control panel
Heating control cable adjustment
Heater fan — removal
Doors, locks and windows
Description of the door structure
Removal and installation of a lateral door
Removal and installation of an upholstery of a door
Removal and installation of the door lock
Removal and installation of the door lock cylinder
Door installation adjustment
Removal and installation of door glass
Removal and installation of a back door
Removal and installation of the internal handle of opening of a door
Electrical equipment
Equipment and devices
Technical characteristics of electrical equipment
Fuses and relays
Removal and installation of the generator
V-belt tension adjustment
Replacing the brushes of the generator and Bosch voltage regulator
Replacing the brushes of the generator and Lucas voltage regulator
Motorola Alternator and Voltage Regulator Replacement Brushes
Main generator malfunctions
Starter design features
Removal and installation of a starter
The main malfunctions of the starter
Removal and installation of a combination of devices
Removal and installation of measuring instruments
Removal and installation of switches
Removal and installation of the switch of fires of braking
Lighting system
Replacing headlight bulbs
Headlight adjustment
Removal and installation of headlights
Replacing side light and turn signal bulbs
Removal and installation of the forward index of turns
Replacing tail light bulbs
Removal and installation of a back lantern
License plate light bulb replacement
Replacing the interior light bulb
Electrical circuits
General description and symbols on electrical diagrams
Starting system, battery, fan, sensors
Ignition systems (carbureted engines up to 1995)
Ignition system (engines 1.6 CVH and automatic transmission until 1995)
Ignition and fuel injection systems (engines 1.3 CFI until 1995)
Ignition and fuel injection systems (engines 1.4 CFI until 1995)
Engine management system 1.6 EF
Zetec engine management system (16V)
Exterior lighting, side light, brake and reversing lamps
Exterior lighting, direction indicators, fog light
Interior lighting system
Horn, defrosters, power mirrors
Central locking, power windows, windshield and headlight washers
Starting system, battery, fan, horn
Pilot lamps and gauges, position lighting
Head lights, rear fog lamp
Direction indicators, brake lights and reversing lights
Interior lighting system, cigarette lighter, windshield washer
Windshield and rear window heaters, interior heater fan
Windshield and rear window cleaners, windshield washer
CFI engine management system
SEFI engine management system
Ford Escort 5
General information
User manual
Vehicle identification
Opening the car hood
Car dashboard
Car instrument cluster
Steering column lock / ignition lock
Front and rear fog light switch
Heated windshield switch
Rear window heating switch
Clock analog and digital
Headlight range corrector
Multifunctional light and turn switch
Wiper/ Washer switch
Car keys and locks
Door lock system
Car door position
Central locking with double locking system
Car anti-theft system
Power outside mirrors
Rear side windows (three-door version)
Power side windows
Car interior lighting
Car front seats
Manual transmission
Automatic transmission
Starting the car engine
Driving a car of various configurations
Heating and ventilation of the car
Car air conditioner
Maintenance
Filling capacities and specification of liquids
Consumable specifications and specifications
Car service intervals
Checks every 400 km or weekly
Vehicle fluid leaks
Weekly checkpoints
Checking the coolant level
Checking the engine oil level
Checking the brake fluid level
Fluid level for the power steering mechanism
Incandescent lamps and fuses
Checking the wiper blades
Engine compartment
Bottom view of the front and rear of the car
Auxiliary drive belt
Fuel supply hoses
Checking the air conditioning system
Changing engine oil and filter
Clutch pedal stroke adjustment (post-1996 models)
Checking the oil level in a manual transmission
Checking and adjusting idle speed and mixture quality
Checking the front suspension
Checking the rear suspension
Drive shaft protective rubber boots
Checking the brake system
Checking the oil level in an automatic transmission
Replacing spark plugs
Coolant replacement
Replacing the air filter element
Exhaust emission control systems
Replacing transmission fluid in an automatic transmission
Handbrake adjustment
Fuel filter replacement
Engine
HCS and Endura-E engines
Technical specifications
General information
Compression test
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover
Valve clearances
Valve mechanism of the cylinder head
Cylinder head
Crankshaft pulley
Camshaft timing chain cover
Camshaft drive chain
Oil pan
Oil pump
Oil pump repair
Replacement of sealing rings of a cranked shaft
Power unit suspension
Flywheel
CVH and PTE engines
Technical specifications
General information
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover
Valve clearances
Crankshaft pulley
Timing belt cover
Toothed belt
Toothed belt tensioner and pulleys
Replacement of a sealing ring of a camshaft
Camshaft, levers and pushrods
Cylinder head
Oil pan
Oil pump
Oil pump disassembly
Crankshaft sealing rings
Zetec and Zetec-E engines
Technical specifications
General information
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover
Crankshaft pulley
Timing belt cover
Toothed belt
Toothed belt tensioner and pulleys
Replacement of sealing rings of a camshaft
Camshafts and hydraulic tappets
Cylinder head
Oil pan
Oil pump
Replacing crankshaft oil seals
Flywheel or drive plate
Power unit suspension
Gasoline engines
Technical specifications
Removing the engine with gearbox
Engine removal and installation (HCS and Endura-E engines)
Removal and installation of CVH and PTE engines
Removal and installation of Zetec and Zetec-E engines
Engine repair
Removing the cylinder head
Cylinder head assembly
Camshaft and hydraulic tappets (HCS and Endura-E engines)
Pistons and connecting rods
Crankshaft
Engine block
Main and connecting rod bearings
Engine Assembly Sequence
Piston rings
Crankshaft main bearings
Installation of pistons and connecting rods
Starting the engine after a major overhaul
Diesel engines
Technical specifications
Checking and adjusting valve clearance
Fuel filter replacement
Nozzles
Fuel pump adjustment
BOSCH fuel pump
Fuel pump CAV Roto diesel
Removal and installation of the fuel pump
Cylinder head
Engine disassembly
Checking Engine Parts
Checking the clearances of the crankshaft and connecting rods
Checking piston rings and piston clearance in the cylinder
Engine assembly
Removal and installation of the oil pump
Oil pressure check
Removal and installation of the pump of a cooling liquid
Coolant replacement
Diesel engines (since 1992)
Fuel pump adjustment
Idle speed adjustment
Fuel pump
Turbocharger
FORD EDC Electronic Engine Control
Exhaust system
Fuel heater
Fuel filter
Bleeding air from the fuel system
Fuel pump cable adjustment
The design and operation of the FORD EDC electronic engine control
FORD EDC Electronic Engine Control Power Supply
Sensors
Executive devices
Turbocharger — removal and installation
Air radiator
Exhaust Gas Recirculation System
Exhaust gas recirculation valve
Vacuum control valve for Bosch fuel pump 1.8 D engine
Cooling and heating
Technical specifications
General information
Antifreeze
Coolant hoses
Thermostat
Radiator fan
Electrical sensors of the cooling system
Radiator and expansion tank
Water pump for HCS and Endura-E engines
Water pump for CVH and PTE engines
Water pump for Zetec and Zetec-E engines
Heater fan
Heater control panel
Air conditioning system
Carburetors
Technical specifications
General information
Air filter
Accelerator cable (manual transmissions)
Cam Control Cable on CTX Automatic Transmission Models
Accelerator pedal
Air flap control cable
Fuel pump
Fuel tank
Fuel level sensor
Check valve
Fuel tank filling pipe
Weber TLDM carburetor
Weber TLDM carburetor fast idle speed adjustment
Weber TLDM carburetor needle valve and float
Weber TLDM Carburetor Choke Damper
Removal and installation of the Weber TLDM carburetor
Weber TLDM carburetor repair
Weber TLD carburetor
Fast idle speed adjustment on a Weber TLD carburetor
Weber TLD carburetor needle valve and float
Weber TLD carburetor auto choke adjustment
Removal and installation of the automatic air damper of the Weber TLD carburetor
Removal and installation of the Weber TLD carburetor
Disassembly and assembly of the Weber TLD carburetor
Removal and installation of an inlet collector
CFI fuel injection
Technical specifications
General information
Relieve pressure in the fuel system
Fuel lines
Air filter
Accelerator cable
Fuel pump
Fuel tank
Fuel level sensor, fuel pump
Fuel pump circuit breaker
Checking the fuel injection system
Elements of the fuel injection system
Intake manifold
EFI fuel injection
Specifications
General information
Air filter
Accelerator cable
Fuel pump
Fuel tank
Elements of the fuel injection system
Intake manifold
SEFI fuel injection
Technical specifications
General information
Air filter
Accelerator cable
Fuel pump
Fuel tank
Elements of the fuel injection system
Intake manifold
Exhaust system
Technical specifications
General information
Exhaust system repair
Removing the exhaust manifold
Catalyst
Elements of the crankcase ventilation system
Fuel Evaporation Control System
Exhaust Gas Re-burning System
Air pulsation system
Charging and starting system
Technical specifications
General information
Electrical circuits
Battery
Removing and installing the battery
Checking the charging system
Removal and installation of the generator
Cleaning the generator and replacing the voltage regulator
Checking the engine start system
Removal and installation of a starter
Ignition system
Technical specifications
General information
Checking the ignition system
Ignition coil
Ignition block for engines with carburetor
Ignition unit on the fuel injection system
Crankshaft rotation angle sensor
Transmission
Clutch
Technical specifications
General information
Clutch cable
Clutch pedal
Removing the clutch
Clutch Release Bearing
Clutch release shaft and bushing
Mechanical gearbox
Technical specifications
General information
Shift rod adjustment
Removal and installation of the lever and draft of a gear change
Speedometer drive gear
Replacement of O-rings
Reversing light switch
Removal and installation of gearbox B5 or iB5
Manual transmission МТХ-75
Automatic gearbox
Technical specifications
General information
Gearshift thrust
Gear shift mechanism
Speedometer drive gear
Removal and installation of an automatic transmission
Drive shafts
Technical specifications
General information
Removal and installation of power shafts
Inner Hinge Protective Boot Replacement
Replacement of a protective cover of the external hinge
Drive shaft failures
Chassis
Brake system
Technical specifications
General information
Replacing the front brake pads
Replacing the front caliper
Replacing the front brake disc
Rear brake drum
Replacing the rear brake pads
Replacing the rear working brake cylinder
Rear brake shield
Replacing the rear brake pads on disc brakes
Rear brake caliper
Rear Brake Disc
Master brake cylinder
Brake pedal
Brake pedal link
Brake lines and hoses
Bleeding the brake system
Vacuum brake booster
Vacuum line for brake booster
Handbrake working mechanism (disc brakes)
Hand brake lever
Front handbrake cable
Rear handbrake cable
Brake pressure control valve
Pressure regulator (VAN·models)
Pressure regulator position adjustment (VAN·models)
Anti-Lock Braking System (ABS)
Removal and installation of elements of system ABS
Car suspension
Technical specifications
General information
Rounded fist
Replacing front wheel bearings (23 spline hub)
Replacing front wheel bearings (25 spline hub)
Front suspension strut
Front suspension shock absorber
Stabilizer bar of the front suspension
Lower front suspension wishbone
Front cross member
Rear hub bearing replacement
Rear suspension struts
Rear suspension strut repair
Rear axle
Replacing rear axle bushings
Rear shock absorbers (Combi and Van models)
Rear coil springs on combi models
Rear leaf spring on Van models
Rear axle (Van models)
Steering
Technical specifications
Steering wheel
Steering column
Steering column repair
Replacement of rubber protective covers of the steering mechanism
Steering gear
Steering gear with hydraulic booster
Power steering pump
Bleeding the power steering system
Steering rod tip
Wheel alignment
Body
Technical specifications
General information
Body Care
Caring for upholstery and rugs
Repair of minor body damage
Repair of severe damage to the body
Bumpers
Hood
Bonnet lock cable
Hood lock
Door upholstery
Door glass
Power window
Door lock, lock cylinder and handles
Doors
Outside rear view mirror
Interior rear view mirror
Trunk lid
Trunk lid lock
Backdoor
Rear door lock
Block of the system of central blocking of doors
Windshield
Overlays and emblems
Checking and adjusting the sunroof
Seats
Seat belts
Interior trim
Dashboard
Center console
Wheel arch liners
Radiator grille
Electrical equipment
Light and appliances
Fuses
Car relay
Incandescent lamps
General information and precautions
Open Circuit Detection
Fuses and relays
Switches
External lighting bulbs
Interior lighting lamps
External lighting devices
Headlight adjustment
Instrument cluster
Elements of the instrument cluster
Speedometer drive cable
Cigarette lighter
Watch
Sound signal
Wiper arms
Wiper motor and traction
Wiper arm drive
Rear door wiper
Windshield washer
Radio receiver
Loudspeakers
Radio antenna
Anti-theft system
Schematic diagrams
Information for the schemes of cars manufactured before 1996
Diagram 1. Starting, charging, cooling systems, alarms and indicators (before 1995)
Diagram 2. Ignition system (all carburetor models) (until 1995)
Diagram 3. Ignition system (1.6L CVH engines with automatic transmission) (until 1995)
Diagram 4. Ignition and engine management system 1.3 l CFI (until 1995)
Diagram 5. Ignition and engine management system 1.4 l CFI (until 1995)
Diagram 6. Ignition and engine management system 1.6L EFi (until 1995)
Diagram 7. Zetec ignition and engine management system (16V) (until 1995)
Diagram 8. External lighting — side light, brake lights, reverse (before 1995)
Diagram 9. External lighting — fog and main lights (until 1995)
Diagram 10. Interior interior lighting (until 1995)
Diagram 11. Alarm system, heating, glass and mirror heating (until 1995)
Figure 12. Window cleaner and washer system, central locking and power windows (before 1995)
Information for car diagrams made since 1996
Diagram 2. Starting, charging, cooling systems, alarms and indicators (since 1996)
Diagram 3. Hazard lamps, indicators, rear light and license plate light (since 1996)
Diagram 4. Exterior lighting and fog lights and lamps (since 1996)
Diagram 5. Direction indicators, brake lights and reversing lights (since 1996)
Diagram 6. Interior lighting of the passenger compartment, cigarette lighter, clock and heater (since 1996)
Diagram 7. Window heaters and heater fan (since 1996)
Diagram 8. Front and rear windscreen wipers and washers (since 1996)
Diagram 9. CFI fuel injection system (since 1996)
Diagram 10. SEFI fuel injection system (since 1996)
Ford Fiesta 2
General information
Characteristics
Identification data
Engine specification
Engine Power System Specification
Fuel injection device specification
Ignition system specification
Specification of starter and alternator
Gearbox and Clutch Specification
Suspension and brake specification
Bulbs, fuses and relays
Engine tightening torques 1.1
Engine tightening torques 1.4i/1.6i
Diesel engine tightening torques 1.8
Transmission tightening torques
Suspension and brake tightening torques
Maintenance
General instructions for repairs
Proper vehicle lifting
Engine
Disassembly and assembly
Description and location of engines
Removing the engine from the car
Installing the engine on a car
Engine disassembly 1.1
1.4i/1.6i Engine Dismantling (Petrol Injection)
Disassembly of the diesel engine 1.8
Engine assembly — general data
Engine assembly 1.1
1.4i/1.6i Engine Assembly (Petrol Injection)
Diesel engine assembly 1.8
Block head
Head camshaft inspection
Removal and installation of a head of the block of the engine 1.1
Removal and installation of heads of blocks of engines 1.4i/1.6i
Removal and installation of a head of the block of the diesel engine 1.8
Dismantling of a head of the block of the petrol engine
Checking and repairing the block head and its parts
1.8 diesel engine block head inspection and repair
Checking the camshaft
Connecting rod and piston group
Checking the crankshaft
Checking the connecting rods
Piston check
Installation of pistons with connecting rods in engines 1.1 / 1.4i
Checking the motor housing
Flywheel check
Lubrication system
Description of the lubrication system
Oil pump check
Oil filter replacement
Gas distribution system
Engine timing check 1.1
Checking the gas distribution of engines 1.4i / 1.6i
Checking the camshaft of a diesel engine 1.8
Cooling system
Description of the cooling system
Removing the water pump in the engine 1.1
Installing the water pump in the engine 1.1
Removing the water pump in the 1.4i / 1.6i engine
Water pump installation in 1.4i/1.6i engines
Removing the water pump in a diesel engine 1.8
Installing a water pump in a 1.8 diesel engine
Thermostat replacement
Replacing the radiator and coolant
Supply system
Description of the power system
Repair and adjustment of the carburetor
Removal and installation of the carburetor
Dismantling the carburetor
Carburetor washing
Petrol injection system in 1.1i/1.4i/1.6i engines
Removal and installation of the sensor of temperature of a cooling liquid
Removing the Electric Throttle Motor
Installing a new electric motor
Removal and installation of the pressure regulator
Removing and installing damper potentiometer
Removal and installation of the nozzle
Removing and installing the CFJ
Removal and installation of the fuel pump
Fuel filter replacement
Control unit replacement
Replacing the lambda probe
Removal and installation of other sensors
Exhaust gas exhaust system
Diesel power system
Description of the diesel fuel supply system
Nozzle replacement
Replacement of injection pump
Installation of injection pump
Fuel filter replacement
Replacing spark plugs
Engine idle speed adjustment
Ignition system
Description of ignition control
Replacing the coolant temperature sensor
Removal and installation of the ignition coil
Removal and installation of the engine speed sensor
Ignition and injection control system in 1.4i/1.6i engines
Removal and installation of the distributor of ignition
Removal and installation of the ignition control module
Spark Plugs and Starter Plugs
Transmission
Clutch
Description and test of clutch operation
Removal and installation of clutch
Clutch cable replacement
Mechanical gearbox
Description of the five-speed manual transmission
Removal and installation of a transmission
Gearbox disassembly
Disassembly of the secondary shaft of the box
Assembly of a secondary shaft of a box
Differential disassembly
Gearbox Assembly
Automatic gearbox
Automatic transmission device
Removing the automatic transmission
Installing an automatic transmission
Checking the oil level
Replacing the hand cable
Replacing the cam starter cable
Replacement of the switch of blocking of an automatic transmission
Drive shafts
Description of drive shafts
Half shaft replacement
Installing the half shaft
Suspension and chassis
Front suspension
Description of the front wheel suspension
Front wheel bearing replacement
Replacing the front arm
Ball joint replacement
Removal and installation of a suspension column
Disassembly and assembly of the suspension column
Rear suspension
Description of the rear wheel suspension
Removal and installation of a back axis
Replacing and adjusting the backlash of the rear wheel bearings
Replacing the rear shock absorber
Replacement of rear suspension rubber bushings
Steering
Description of gear steering
Removal and installation of the steering mechanism
Replacement of rubber covers of the steering mechanism
Removal and installation of a steering column
Removal and installation of a steering shaft
Wheel installation
Brake system
Description of the braking system
Handbrake adjustment
Replacing disc brake pads
Replacing drum brake pads
Removal and installation of a support of a forward brake
Removal and installation of a brake disk
Replacing the rear brake cylinder
Replacing the handbrake cable
Replacing the master brake cylinder
Replacing the brake pressure regulator
Removal and installation of the vacuum brake booster
Bleeding the brake system and changing the brake fluid
Removal and installation of the pressure control valve
Removal and installation of the adjusting unit
Electrical equipment
Equipment and devices
General battery information
Checking the operation of the generator
Checking the regulated voltage
Removal and installation of the generator
Checking the operation of the starter
Starter Replacement
Headlights and wipers
Removal and installation of the front window wiper motor
Heating and ventilation
Removal and installation of a heater
Removal and installation of the heater fan
Replacing fuses and relays
Electrical equipment diagrams
Short description
List of conditional elements
List of grounding nodes
List of solder joints
Wiring diagram of the power system
Wiring diagram of the engine start and battery charging system
Circuit diagram engine 1.1 (HSS-Valencia)
Schematic diagram engine 1.4 (CVH)
Schematic diagram of the engine 1.4 Fiesta XR2i
Schematic diagram engine 1.6 (CVH)
Schematic diagram diesel 1.8
Schematic diagram of the lighting system
Schematic diagram of auxiliary equipment
Ford Fiesta 4
General information
Characteristics
General information about Ford Fiesta cars
Using the manual
General information about the car
Fiesta car lineup
Line of car engines
Appendix 1. Technical data and specifications
Volumes of operating fluids
Working conditions and tools
Purchase of spare parts
Workplace
Main working tool
Special tools and fixtures
Professional advice for a mechanic
Car delivery for repair
Vehicle lifting
Car care
Interior cleaning
Car wash
Car wash outside
Engine wash
Lubrication of hinges and assemblies
Paintwork care
Elimination of damage from stone impacts
Polishing small scratches
Removing deep scratches
Windshield wiper and washer
Checking the windshield wiper and washer
Filling fluid into the windshield washer reservoir
Brush replacement
Windshield washer jet adjustment
Removing jets
Removing the wiper arm
Removing the windshield wiper motor
Removing the rear window motor
Possible malfunctions of the wiper brush drive mechanism, their causes and methods of elimination
Power unit
Engine repair
General information about the engine
Rated speed of the crankshaft and the service life of the engine
Engine compression
Poly V-belt check
Diagnosis of the engine by knocking from the engine compartment
Determination of bearing or bushing damage
Possible malfunctions of spark plugs, their causes and features
Possible malfunctions caused by damage to the cylinder head gasket
Lubrication system
General information about the lubrication system
Oil pressure in the lubrication system
Engine oil
Checking the engine oil level
Changing engine oil and oil filter
Possible malfunctions of the lubrication system, their causes and methods of elimination
Cooling system
General information about the cooling system
Cooling liquid
Checking the tightness of the cooling system
Checking the level and topping up the coolant
Coolant replacement
Fiesta car engine protection from frost down to -30°С
Removing and checking the thermostat
Radiator fan
Troubleshooting the Radiator Fan
Removing the radiator fan
Removing the radiator
Replacing the cooling system hoses
Possible malfunctions of the cooling system
Possible thermostat malfunctions and their causes
Air filter
Air filter and sound absorber
Preheating of the intake air
Symptoms of Intake Air Preheating Malfunctions
Fuel injection system
General information about the fuel injection system
Main systems and elements of fuel injection EEC-V
Checking the fuel injection system
Elimination of unstable idle speed of the engine crankshaft
Check of the executive engine of idling
Checking the injectors
Accelerator cable
Accelerator Cable Replacement on Endura-E Engine Vehicles
Replacing the accelerator cable on vehicles with Zetec engines
Accelerator cable adjustment
1.8D Diesel Engine Injection System
Visual inspection of the diesel injection system
Air-fuel mixture adjustment
Replacing the accelerator cable
Air filter replacement
Possible malfunctions of the fuel injection system
Possible malfunctions of the diesel fuel injection system
Ignition system
General information about the ignition system
Electronic control unit
Ignition timing adjustment
Ignition coil
Spark plug
Every 45,000 km — removal, inspection and replacement of spark plugs
Temporarily changing the ignition timing to correct the octane number of the fuel
Turning off the ignition, checking the ignition unit and high-voltage wires
Checking the engine speed sensor with a universal measuring device
Checking the pressure sensor
Checking the secondary voltage of the ignition system
Checking the Primary Ignition Circuit in Conventional Ignition Systems
Ignition coil resistance measurement
Removing the ignition block
Possible malfunctions of the engine and ignition system
Supply system
General information about the fuel supply system
The most important elements of the power system
Types of fuel and work with it
Checking the fuel tank vent valve
Replacing the fuel filter on vehicles with gasoline engines
Replacing the fuel filter on vehicles with diesel engines
Removing water from the fuel filter of vehicles with diesel engines
Draining fuel from the tank without a hand pump
Removing fuel lines and hoses
Malfunctions of the electric fuel pump
Removing the fuel pump on vehicles with gasoline engines
Exhaust system
General information about the exhaust system
Recommendations for replacing the exhaust system
Checking the technical condition of the suspension elements and the exhaust system
Replacing the exhaust system, including the catalytic converter
Reducing the toxicity of exhaust gases
Transmission
General information about the transmission
General information about the clutch
Clutch test
Incomplete clutch disengagement
Five-speed gearbox
Adjustment of the mechanism of a gear change
Checking the transmission oil level
Adding transmission oil
CTX continuously variable automatic transmission
Checking the fluid level in the CTX automatic transmission
Replacing the working fluid and filter in an automatic transmission CTX
Main gear
Checking the protective covers of the hinges of equal angular speeds of the drive shafts
Removing the wheel drive shaft
Replacement of protective covers of hinges of equal angular speeds
Possible clutch malfunctions
Possible malfunctions of the CTX automatic transmission
Chassis
Car suspension
General Suspension and Steering Information
Front suspension
Rear suspension
Front suspension geometry
Checking shock absorbers
Checking the bushings of the transverse arm of the independent front suspension
Checking wheel bearing play
Removing the front control arm
Installing the front wishbone
Removing the shock absorber
Wheel bearing replacement
Removing the rear shock absorber
Replacement of bearings of a nave of a back wheel
Steering
Steering play check
Checking the protective covers of the steering mechanism
Checking ball joints and dust-protective covers of tie rod ends
Replacement of spherical joints of tips of steering draughts
Replacement of mud-protective covers of steering rods
Steering knuckle replacement
Installing the steering knuckle
Removing the steering wheel
Coil Spring Replacement
Power steering
Wheels and tires
Wheel and tire sizes
Tire design and marking
Wheel replacement
Tire condition check
Brake system
General information about the brake system
Checking the hydraulic drive of the brake system
Checking the vacuum brake booster
Anti-lock braking system (ABS), BTCS and EBD
Fiesta braking system
Diagnostics and repair of the brake system
Checking the brake fluid level
Checking the brake system
Measuring the thickness of the brake pads of the front disc brakes
Checking the condition of the brake discs
Measuring the lining thickness of the rear drum brake pads
Removing air from the brake system (bleeding)
Brake Fluid Replacement
Removing the brake fluid reservoir from the brake master cylinder
Removing the brake master cylinder
Removing the vacuum brake booster
Removing the vacuum pump on vehicles with diesel engines
Removing the brake hose
Replacing disc brake pads
Removing the brake disc
Checking the caliper piston and replacing the piston protection ring
Removing the brake drum
Replacing the brake pads on the rear drum brakes
Removing the wheel brake cylinder
Parking brake
Replacing the parking brake cables
Parking brake adjustment
Possible malfunctions of the brake system
Body
Interior
General information about the car interior
Checking the operation of heating and ventilation
Removing the heating and ventilation control unit
Car interior fan
Car interior switches
Key encoding
Removing the switch from the instrument panel
Replacing interior lamps
Checking the door contact switch
Trunk Light Bulb Replacement
Removing the radio
Removing the speakers
Removing the outdoor antenna
Front seats
Backseat
Rear seat back
Removing the door upholstery
Removal of a window regulator of a glass of a door
Central locking
Removing the door handle
Removing the door lock cylinder
Possible heating malfunctions
Possible malfunctions of power windows
Possible malfunctions of the central lock
Exterior
General information about the car body
Belt pre-tensioning mechanism
Removing the door
Removing the rear view mirror
Rear view mirror replacement
Removing the hood
Removing the front bumper
Wing removal
Wing installation
Removing the rear bumper
Removing the trunk lid
Removing the lock cylinder from the trunk lid
Removing the trunk lid lock
Electrical equipment
Light and appliances
General information about electrical equipment
Secret consumers of electrical energy
V-ribbed belt replacement
Outdoor Lighting
Replacing headlight bulbs
Replacing the turn signal lamp
Parking light bulb replacement
Replacement of a lamp of the lateral repeater of indexes of turn
Fog Light Bulb Replacement
Rear combination lamps
Courier Rear Combination Lamps
Headlight lens replacement
Replacing the license plate light bulb
Temporary headlight adjustment
Signaling devices
Checking the brake light switch
Checking the beep
Instrumentation and controls
Checking switches
Removing the instrument cluster
Replacing indicator lamps
Removing gauges
Electrical circuits
Fuses in passenger compartment and engine compartment
Replacing fuses
Relays and control circuits
Possible malfunctions of the emergency light signaling and direction indicators
Possible malfunctions of brake lights
Schematic diagrams of electrical equipment
Battery and alternator
Battery and starter
Generator device
Checking the electrolyte level in the battery and cleaning the terminals
Checking the state of charge of the battery
Starting the engine with a dead battery
Charging the battery
Removing the battery
Checking the voltage regulator
Removing the generator
Removing the starter
Possible battery and alternator malfunctions
Possible starter malfunctions
Ford Taurus 1 and 2
General information
Characteristics
Vehicle number identification
Conventions
Unit conversion table
Adjusting parameters of vehicle systems
Maintenance
Jacking and towing
General vehicle specifications
Introduction to Maintenance
Maintenance Schedule
Fluid level checks
Tires and chamber pressure control
Checking the fluid level in the power steering
Checking the Fluid Level in an Automatic Transmission
Changing engine oil and filter
Clutch pedal adjustment
Checking and replacing pipelines located under the hood
Checking, adjusting and replacing the drive belt
Air filter replacement
PCV valve and crankcase breather check
Fuel system check
Fuel filter replacement
Checking the cooling system
Exhaust system check
Tire change
Checking shock absorbers
Steering and suspension check
Brake check
Lubrication of the automatic transmission control rod
Checking the oil level in a manual transmission
Checking and disassembling the rear wheel bearing (yes, 1989)
Replacing spark plugs
Checking and replacing spark plug wires
Maintenance of the cooling system (draining, flushing, filling)
Changing the fluid and filter in an automatic transmission
Troubleshooting
Engine Diagnostics
Diagnostics of the electrical equipment of the engine
Fuel system diagnostics
Cooling system diagnostics
Clutch Diagnostics
Diagnosis of a manual transmission
Automatic transmission diagnostics
Axial drives and CV joints
Brake Diagnostics
Suspension and steering diagnostics
Engine
Four-cylinder engine
Engine Specifications and Torques
General information
Repair operations allowed with the engine not removed
Removal and installation of a cover of the valvate mechanism
Removing, checking and installing valve levers and push rods
The location of the top dead center (TDC) of the piston No. 1
Replacing valve springs, gaskets and retainers
Measuring Camshaft Lobe Wear
Removal and installation of an inlet collector
Removal and installation of a final collector
Removal and installation of heads of the block of cylinders
Valve lifters — removal, inspection and installation
Removal and installation of the oil pan
Oil pump — removal and installation
Checking and replacing the engine suspension and shock absorbers
Six-cylinder engine
Engine Specifications and Torques
Repair operations available with the engine not removed
Removing and installing valve covers
Removal, installation and adjustment of valve levers and push rods
Replacing springs, retainers, valve seals
Removal and installation of an inlet collector
Exhaust manifolds — removal and installation
Removal and installation of heads of the block of cylinders
Replacing the front crankshaft oil seal
Removing and installing the camshaft drive chain cover
TDC location for piston No. 1
Removal and installation of the camshaft drive chain and sprockets
Valve lifters — removal, inspection, installation
Removal and installation of the oil pan
Oil pump and oil receiver — removal and installation
Checking and replacing the engine shock absorber suspension
Overhaul
Specifications of the four-cylinder engine
3.0LV6 engine specifications
3.8LV6 engine specifications
General information
Cylinder compression test
General information about overhaul
Engine — removal and installation
Engine Overhaul — Disassembly Sequence
Dismantling of a head of the block of cylinders
Cylinder heads — cleaning and inspection
Bulkhead of a head of the block of cylinders
Removing and installing flywheel or drive plate
Replacement of crankshaft oil seals
Front cover, camshaft drive chain and sprocket
Camshaft, balancer shaft and bearings
Removing pistons and connecting rods
Removing the crankshaft
Cleaning the engine block
Checking the engine block
Cylinder honing
Checking pistons and connecting rods
Checking the crankshaft
Checking the main and connecting rod bearings
Engine Assembly Sequence
Installation of piston rings
Installing the crankshaft and checking the oil clearance of the main bearings
Installation of pistons and connecting rods, checking the oil clearance in the connecting rod bearing
Starting and running in the engine after overhaul
Cooling system
Torque Specifications
Cooling, heating, air conditioning systems
General information about antifreeze
Thermostat replacement
Electric fan — description, check and replacement of elements
Removal and installation of a radiator
Checking and replacing the cooling fan thermostat
Removal and installation of a tank of a cooling liquid
Water pump check
Water pump — removal and installation
Maintenance of air conditioning and heating systems
Removal and installation of the heater and air conditioner control unit
Replacing the motor and resistance of the heater and air conditioner
Replacing the Heater Radiator
Removal and installation of the compressor of the air conditioner
Removal and installation of the condenser of the air conditioner
Air conditioning accumulator and pressure switch
Fuel/exhaust systems
Specifications
General information about the fuel and exhaust system
Relieve the pressure of the fuel system
Replacement of fuel lines and pipeline connections
Fuel pump check
Gas tank — removal and installation
General information on cleaning and repairing the gas tank
Removal and installation of the fuel pump
Removing and installing the air cleaner housing
Removal and installation of throttle connection elements
Fuel injection system — general information
Measurement of pressure in the fuel injection system
Replacing elements of the central fuel injection (CFI) system
Replacement of elements (EFI) of electronic fuel injection system
Replacement of elements of the EFI system (for engines 3.8LV6)
Exhaust System Replacement
Engine electrics
Specifications and general information
Removing and installing the battery
Checking and replacing battery wires
General information about the ignition system
Checking the ignition system
Ignition circuit and coil — checking and replacing the coil
Distributor — removal and installation
Checking and adjusting the ignition timing
Electronic ignition unit check and replacement
Checking and replacing the hall sensor stator distributor block
Power supply system — general information and safety
Checking the power supply system
Generator — removal and installation
Replacement of alternator brushes (EVR type)
Replacing the External Voltage Regulator (EVR)
Replacement of alternator brushes (type IAR) / voltage regulator
Starting system — general information
Checking the engine and starter circuit
Removal and installation of the starter motor
Removal and installation of the starter relay
Emission control
General information
Electronic engine control system (EEC — IV)
Exhaust gas re-burning (EGR) system
Manifold Air Intake Control System
Evaporative emission control system
Efficient crankcase ventilation system
Intake air temperature control system
Catalytic converter
Transmission
Mechanical gearbox
Manual transmission specifications
General information about manual transmission
Changing the oil in a manual transmission
Removal and installation of the gear shift handle
Removal and installation of manual transmission
General information on gearbox overhaul
Replacing the sealing ring of the speedometer drive mechanism
Automatic gearbox
Torque specification
General information about automatic transmission
General diagnostics of automatic transmission
Removal and installation of the automatic transmission drive mechanism
Removal and installation of an automatic transmission
Adjustment of the automatic transmission drive mechanism
Throttle valve (TV) control mechanism adjustment
Checking and replacing the gearbox suspension
Replacing and adjusting the neutral start sensor
Clutch and drives
Specifications
General information
Checking clutch operation
Coupling — removal, check and installation
Thrust bearing and its fork — removal, inspection and installation
Removal and installation of the clutch cable
Internal starter/clutch switch
Checking axle drives, CV joints and covers
Removal and installation of axial drives
Replacing the housing of the axial drive and bulkhead SHRUS
Replacing differential seals
Chassis
Brake system
Specifications
General information and safety
Front brake pads — replacement
Front disc brake caliper — removal and installation
Front brake disc — check, removal and installation
Brake drum — removal, inspection and installation
Replacing the rear brake shoes
Wheel cylinder — removal, reassembly and installation
Master cylinder — removal, reassembly and installation
Brake Pressure Control Valves
Hoses and pipelines of the brake system — check and replacement
Bleeding the hydraulic system of the brakes
Parking brake adjustment
Replacing the parking brake cables
Parking brake pedal — removal and installation
Removal and installation of a brake pedal
Brake booster — removal, installation and adjustment
Brake light switch — removal and installation
General information about the ABS system and rear disc brakes
Replacing the rear brake pads
Rear disc brake caliper — removal and installation
Rear brake disc — check, removal and installation
Car suspension
Torque specification
General information
Front anti-roll bar, arm and bushings
Ball joints — check and replacement
Front jet thrust and elastic hinge — removal and installation
The forward lever — removal, check and installation
Front shock absorber and coil spring unit — removal and installation
Front shock absorber block — replacement
Swivel fist and hubs — removal and installation
Front hub and bearing assembly — removal and installation
Rear stabilizer bar and bushings — removal and installation
Rear shock absorber and coil spring unit — removal and installation
Rear shock absorber block (sedan) — replacement
Rear wishbones (sedan) — removal and installation
Jet thrust and hinge pads (sedan) — removal and installation
Wheel fist — removal and installation
Rear shock absorbers (station wagon) — removal and installation
Upper rear suspension arms (station wagon) — removal and installation
Rear coil spring (station wagon) — removal and installation
Lower arm rear suspension (station wagon) — removal and installation
Trailing arm (station wagon) — removal and installation
Rear fist (station wagon) — removal and installation
Replacing the rear wheel bearings (1990 and later)
Steering
General information
Steering wheel — removal and installation
Intermediate shaft — removal and installation
Steering gear — removal and installation
Power steering pump — removal and installation
Replacing the power steering pump reservoir
Bleeding the power steering system
Tie rod ends — removal and installation
Replacing steering gear covers
Wheels and tires — general information
Front wheel adjustment — general information
Body
Repair and maintenance
Torque specification
General information and care
Hood — removal, installation, adjustment
Front wing insert — removal and installation
Removal and installation of the lock and cable of the lock of a cowl
Door — removal, installation, adjustment
Trunk lid — removal, installation, adjustment
Tailgate (station wagon) — removal, installation, adjustment
Bumpers — removal and installation
Removal and installation of the door decorative panel
Door lock and its drives — removal and installation
Outside mirror — removal and installation
Dashboard trim panels — removal and installation
Center console — removal and installation
Door glass — removal, installation and adjustment
Automatic shoulder belts — general information
Electrical equipment
General information
Diagnostics of malfunctions of electrical equipment
Connectors — general information
Fuses — general information
Fusible connecting links — general information
Circuit breakers — general information
Replacing the multifunction switch
Replacing the blocking (locking) cylinder of the ignition key
Replacement switch and wiper motor
Replacing the turn signal and emergency breaker
Replacing the headlight switch and dimmer / rheostat
Headlights — removal and installation
Lamp replacement
Radio and speakers — removal and installation
Checking and replacing the radio antenna
Dashboard — removal and installation
Instrument block — removal and installation
Repair and replacement of the rear window heater and switch
Sound signal — check and replacement
Checking the cruise control system
Electrical circuits
Ford Fusion
General information
Vehicle device
General information about the car Ford Fusion
Passport data of the car
Car keys
Instruments and controls
Instrument cluster
Trip computer
Heating (air conditioning) and interior ventilation
Door locks — opening and locking
Power window control
Seat belts on the front seats
Seat belts on the rear seats
Front seat adjustment
Rear seats
Use of child seats
Steering wheel adjustment
Rear view mirrors
Interior lighting
Sun visors
Bonnet — opening and closing
Gearbox control
User manual
Safety regulations
Operating recommendations
Recommendations for traffic safety
Vehicle break-in
Vehicle operation during the warranty period
Preparing the car for departure
Refueling a car with gasoline
Using a jack
Towing a car
Faults on the way
General engine starting techniques
Faults in the starting system
Checking the ignition system
Checking the engine power system
Fuel Injection System Malfunctions
Idling has disappeared
Interruptions in the engine
Diagnostics of the engine condition by the appearance of spark plugs
The car is jerking
The car accelerates badly
Engine stalled while driving
Oil pressure dropped
Engine overheating
Checking the cooling system
The battery does not charge
Checking electrical equipment
Starting the engine from external current sources
Electrical faults
There was a knock in the engine
There were knocks in the suspension and transmission
Possible causes of knocks in the suspension and how to eliminate them
Possible knocks (noises) of the transmission, their causes and solutions
Vibration and bumps in the steering wheel
Brake system malfunctions
Bleeding the brake system
Checking the brake system
Puncture and wheel replacement
Maintenance
Maintenance Schedule
Safety regulations
Wheel check
Checking the level and adding oil to the engine
Checking the level and topping up the coolant
Checking the level and topping up the fluid in the reservoir of the brake system and clutch
Checking the level and adding fluid to the steering reservoir
Checking the level and adding fluid to the washer reservoir
Checking external lighting fixtures
Checking the accessory drive belt
Checking the power steering pump drive belt
Checking the timing belt of the gas distribution mechanism
Changing engine oil and oil filter
Cleaning the crankcase ventilation system
Checking the hoses and connections of the cooling system
Check of system of release of the fulfilled gases
Checking the tightness of the fuel lines
Checking and replacing the air filter element
Fuel filter replacement
Checking the level and adding oil to the gearbox
Checking the protective covers of the front wheel drives
Checking the technical condition of the front suspension parts on the car
Checking the technical condition of the rear suspension parts on the car
Checking and adjusting wheel alignment
Inspection and testing of the steering on the car
Checking the free play (backlash) of the steering wheel
Checking the tightness of the hydraulic drive of the brakes
Checking the degree of wear of brake pads, discs and drums
Checking the operation of the vacuum brake booster
Checking the effectiveness of the brake system
Checking the parking brake
Battery maintenance
Checking and adjusting the headlights
Body armature lubrication
Cleaning drainage holes
Replacement and maintenance of spark plugs
Accessory drive belt replacement
Replacing the power steering pump drive belt
Replacing the timing belt and its tension roller
Replacement of brake fluid in hydraulic brakes and clutch release
Coolant replacement
Tightening torques for threaded connections
Lamps used on the car
Fuels and lubricants and operating fluids
Tips for the car owner
Purchase of spare parts
A trip to the service station (SRT)
How to prepare your car for winter
Recommendations for starting the engine in severe frost
What is useful to buy for the winter
Useful winter tips
Recommendations for preparing for technical inspection
List of malfunctions and conditions under which the operation of vehicles is prohibited
Changes to state standards
Safety precautions when carrying out repair work
Tools for car repair and maintenance
Before starting work
Restoration of threaded connections
Body Repair Tips
Power unit
Engine repair
Engine design features
Possible engine malfunctions, their causes and remedies
Useful tips for engine repair
Cylinder compression check
Removal and installation of a mudguard of the engine
Replacement of the right support of a suspension bracket of the power unit
Replacement of the left support of a suspension bracket of the power unit
Replacing the rear support suspension of the power unit
Setting the piston of the first cylinder to the TDC position of the compression stroke
Removal, installation and troubleshooting of the flywheel
Replacing the cylinder head cover gasket
Replacing the cylinder head gasket
Replacement of valve stem seals
Replacing camshaft seals
Replacing the crankshaft seals
Replacing the oil sump seal
Replacing the intake pipe gasket
Replacing the gasket of the collector
Valve clearance adjustment
Cylinder head — general information
Replacing camshafts
Lapping of valves
Removal and installation of the engine
Lubrication and cooling system
Design features of the engine lubrication system
Removal and installation of the oil pump
Oil pump repair
Features of the design of the engine cooling system
Removal and installation of the electric fan of the radiator of the cooling system
Replacing the cooling system radiator
Removal and installation of the water pump
Removal and installation of the thermostat
Removal and installation of a broad tank
Supply system
Design features of the engine power system
Checking the pressure in the power system
Reducing the pressure in the power system
Removal and installation of the air filter
Fuel tank replacement
Fuel pump replacement
Checking and replacing the fuel pressure regulator
Removing, checking and installing fuel injectors
Removal and installation of the fuel rail
Removal and installation of the throttle assembly
Removal and installation of an accelerator pedal
Exhaust and vapor recovery
Exhaust system design features
Replacement of pillows of a suspension bracket of system of release of the fulfilled gases
Removal and installation of the collector
Replacement of the main and additional mufflers
Removal and installation of thermal screens
Features of the device of the fuel vapor recovery system
Replacement of an adsorber of system of catching of vapors of fuel
Transmission
Clutch
Clutch Design Features
Possible clutch malfunctions, their causes and solutions
Checking the travel of the clutch release pedal
Removal and installation of clutch
Replacement of the working cylinder of a drive of deenergizing of coupling with the bearing
Clutch Master Cylinder Replacement
Replacement of pipelines of a hydrodrive of deenergizing of coupling
Removal and installation of the clutch pedal
Bleeding the hydraulic clutch release
Car gearbox
Features of the design of the gearbox
Changing the oil in the gearbox
Replacing gearbox seals
Removal and installation of a transmission
Replacing the transmission control cables
Removal and installation of the scenes of the gear lever
Gearbox control drive adjustment
Front wheel drives
Design features of drive shafts
Possible malfunctions of the front wheel drive
Removal and installation of front wheel drives
Replacement of ball joints of equal angular velocities
Replacing the intermediate support bearing
Chassis
Front suspension
Design features of the front suspension
Possible malfunctions of the front suspension
Removal and installation of a shock-absorber rack
Shock absorber repair
Replacing the upper support of the shock absorber strut
Shock absorber ball joint replacement
Replacing the front suspension arm
Replacing the anti-roll bar of the front suspension
Removal and installation of a rotary fist
Replacing the front hub bearing
Removal and installation of a cross-beam of a forward suspension bracket
Rear suspension
Rear suspension design features
Possible malfunctions of the rear suspension
Replacing the shock absorber rear suspension
Replacing the rear suspension spring
Replacing silent blocks of rear suspension arms
Replacing the rear hub bearing
Replacing the rear suspension beam
Steering
Steering design features
Possible malfunctions of a steering with the hydraulic booster
Removal and installation of a steering wheel
Removal and installation of a steering column
Replacing the outer tie rod end
Tie rod replacement
Bleeding the power steering system
Replacing the power steering reservoir
Steering gear replacement
Power steering pump replacement
Brake system
Features of the brake system
Possible malfunctions of the brake system
Bleeding the hydraulic drive of the brake system
Checking the position of the brake pedal
Master brake cylinder — general information
Replacing the reservoir of the main brake cylinder
Replacing the master brake cylinder
Vacuum brake booster — general information
Replacing the vacuum brake booster
Replacement of hoses and tubes of the hydraulic drive of the brakes
Replacement of brake hoses
Replacement of brake pipes
Replacing the brake pads of the brake mechanism of the front wheel
Replacing the caliper assembly with the guide pads
Brake disc replacement
Rear wheel brakes — general information
Removal and installation of a brake drum
Replacing the brake pads of the brake mechanism of the rear wheel
Replacing the working cylinder of the brake mechanisms of the rear wheels
Parking brake actuator adjustment
Replacing the rear parking brake cables
Wheels and tires
Wheel marking
Tire marking
Wheel replacement
Wheel nuts
Tire break-in
Tire storage
Wheel balancing
Anti-skid chains
Spare wheel
Tire pressure check
Tire tread check
Checking the valve
Checking the radial and lateral runout of the discs
Body
Exterior
Body design features
Possible body malfunctions
Removal and installation of facing of a radiator
Removal and installation of wheel mudguards and fender liner
Removal and installation of the front bumper and its bar
Removal and installation of a back bumper
Removal and installation of a forward wing
Removal and installation of a lattice of a box of an air inlet
Removal and installation of a cowl
Removal, installation and adjustment of the lock of a cowl
Removal and installation of an external mirror
Removal and installation of an arm of the shelf of fastening of the storage battery
Interior
Removal and installation of a forward seat
Removal and installation of a back seat
Removal and installation of floor tunnel lining
Design features of the passive safety system
Removal and installation of the driver's airbag
Replacing the front seat belt
Replacing the rear seat belt
Electronic control unit for additional passive safety system
Removal and installation of an internal mirror
Design features of the instrument panel
Removal and installation of the instrument panel
Design features of the heater and air conditioner
Control unit for the heating, air conditioning and ventilation system
Removal and installation of the filter for cleaning the air entering the passenger compartment
Replacing handrails in the cabin
Replacing the glasses compartment
Replacing sun visors
Removal and installation of facings of salon
Removal and installation of casings of a steering column
Removal and installation of facings of a luggage carrier
Doors, locks and windows
Removal and installation of an upholstery of a forward door
Front door glass replacement
Replacing the power window of the front door
Replacing the outside handle and front door lock
Replacement of the internal handle of a drive of the lock of a forward door
Replacing the front door opening limiter
Removal and installation of a forward door
Removal and installation of an upholstery of a back door
Rear door glass replacement
Replacing the power window rear door
Replacing the outside handle and tailgate lock
Replacing the inner handle of the tailgate lock actuator
Replacing the tailgate opening limiter
Removal and installation of a back door
Replacing tailgate stops
Removal and installation of an upholstery of a door of a back
Removal and installation of a decorative overlay of a door of a back
Replacing the tailgate lock
Removal and installation of a door of a back
Removal and installation of a cover of the hatch of a bulk pipe of a fuel tank
Removal and installation of the lock of a cover of the hatch of a bulk pipe of a fuel tank
Windscreen wiper — general information
Replacement wiper blades
Replacement of levers and drafts of a screen wiper of a wind window
Windshield wiper trapezoid assembly with gearmotor
Tailgate window wiper — general information
Replacing the tailgate window wiper blade
Tailgate Window Wiper Arm Replacement
Replacement of the fixed glazing of the body
Body сare
Car body wash
Body paint polishing
Anti-corrosion body protection
Preparation and anti-corrosion treatment of hidden cavities
Body sealing
Upholstery and carpet care
Car engine wash
Electrical equipment
Equipment and devices
Features of the design of electrical equipment
Diagnostics of malfunctions of onboard electrical equipment
Location and replacement of fuses, fuses and relays
Replacing the windshield wiper gearmotor
Replacing the tailgate window wiper motor
Removal and installation of a washer glass of a wind window
Replacing the front door power window motor
Electric motor of the radiator fan of the cooling system
Removal and installation of the heater electric fan
Heater recirculation damper motor
Replacement of additional resistance of the heater electric fan
Electric heating of glass of a door of a back
Design features of the instrument cluster
Removal and installation of a combination of devices
Removing and installing speakers of the acoustic system
Removal and installation of the car radio
Removing and installing the antenna
Removal and installation of the remote control of the audio system
Removal and installation of the cigarette lighter cartridge
Electronic anti-theft remote control system
Control of the electronic anti-theft system
Replacing the battery in the remote control
Removal and installation of the electronic anti-theft system control unit
Design features of the immobilizer
Additional functions of the immobilizer
Engine electrics
Battery design features
Possible battery problems
Removing and installing the battery
Charging the battery
Generator Design Features
Possible generator malfunctions
Removal and installation of the generator
Generator repair
Starter design features
Possible starter malfunctions
Removal and installation of a starter
Starter repair
Checking the ignition switch (lock)
Replacing the contact group of the ignition switch (lock)
Replacing the ignition switch (lock) cylinder
Removal and installation of the switch (lock) of ignition
Features of the design of the engine management system
Possible malfunctions of the engine management system
Checking the ignition coil
Removal and installation of the ignition coil
Replacing the electronic engine control unit
Check and replacement of gauges of a control system of the engine
Lighting and signaling
Design features of lighting and signaling
Replacing lamps in lighting devices
Headlight Replacement
Replacement of a lateral lantern of the index of turn
Replacing the front fog lamp
Rear light replacement
Replacement of an additional brake light
Replacing license plate lights
Replacing the front dome light
Replacing the rear dome light
Replacing the trunk light
Replacing paddle shifters
Removal and installation of a sound signal
Switches and sensors
Replacing the outdoor lighting control unit
Replacing Instrument Panel Switches
Hazard Switch Replacement
Replacing the exterior mirror control unit
Replacing the Power Trunk Lock Switch
Checking and replacing the fuel gauge sensor
Replacing the pressure sensor in the power steering system
Checking and replacing the reverse light switch
Stoplight Switch Replacement
Clutch Position Sensor Replacement
Brake Pedal Position Sensor Replacement
Replacing the Parking Brake Warning Light Switch
Fuel Switch Replacement
Replacing wheel speed sensors
Replacing the shock sensor
Electrical circuits
Scheme 1. Block diagram of the car
Scheme 2. Engine management system
Scheme 3. Power system
Scheme 4. Engine start system for cars with a manual gearbox
Scheme 5. Charging system
Scheme 6. Ignition system
Scheme 7. Car audio system
Scheme 8. Cooling system
Scheme 9. Robotic gearbox
Scheme 10. Anti-lock braking system (ABS) and dynamic stabilization system (ESP)
Scheme 11. Diagnostic connector
Scheme 12. Anti-theft system
Scheme 13. Illumination of the combination and instrument panel
Scheme 14. Instrument cluster and steering column switches
Diagram 15. Sound signal
Scheme 16. Clock in the car
Scheme 17. Heating and ventilation system
Diagram 18. Air conditioning system
Scheme 19. Interior lighting
Scheme 20. Dimensional lighting for driving during the day (DRL system)
Scheme 21. Fog lights
Scheme 22. Block headlights of a car
Scheme 23. Outline lighting and license plate lighting
Scheme 24. Reversing lights for cars with manual transmission
Scheme 25. Car brake lights
Scheme 26. Direction indicators
Scheme 27. Rear fog lights
Scheme 28. External rear-view mirrors
Scheme 29. Car windscreen washer
Scheme 30. Heated glass of the tailgate and mirrors
Scheme 31. Lock drive
Scheme 32. Central lock
Diagram 33. Heated seats
Ford Scorpio 1
General information
User manual
Vehicle identification
Instrument panel and instrument cluster
Control levers on the steering column
Car keys
Doors — opening and locking
Steering column lock / ignition lock
Manual transmission
Automatic transmission
Power windows with electric drive
Steering wheel adjustment
Front seats
Interior lighting
Electric outside rear-view mirrors
Increasing the volume of the luggage compartment
Windshield wipers and washers
Vehicle lifting
Towing a car
Engine starting
Starting a gasoline engine
Diesel engine start
Features of car operation
Maintenance
Car maintenance intervals
Maintenance every 10,000 km or once a year
Maintenance every 40,000 km
Maintenance every 60,000 km or 2 years
Checking the engine oil level
Changing engine oil and filter
Locations of possible engine oil leaks and their identification
Checking the level and replacing the coolant
Checking the tightness of the cooling system
Spark plug
Air filter replacement
Fuel filter replacement
Replacing the crankcase ventilation valve
Checking fluid in the air conditioning system
Checking the oil level in the gearbox
Checking the oil level in the rear axle
Check of a condition of a protective cover of a power shaft
Adjusting the brake band in an automatic transmission
Checking the condition of the front and rear brake pads
Checking the level and replacing the brake fluid
Suspension condition check
Checking the Fluid Level in the Power Steering System
Cleaning the drain for condensate from the air conditioner
Engine Oil Recommendations
Filling tanks and operating fluids
Power unit
Petrol engines OHC
Specifications for OHC engines
Engine adjustment
Repair without removing the engine
Removal and installation of a gear belt
Removing the cylinder head
Dismantling and assembly of a head of the block of cylinders
Installing the cylinder head
Removal and installation of the oil pan
Replacement of a forward sealing ring of a cranked shaft
Replacement of a back sealing ring of a cranked shaft
Replacing engine mounts
Removal and installation of the engine
Engine disassembly
Identification of interacting parts
Engine Assembly
Pistons replacement
Removal and installation of an intermediate shaft
Gas distribution system
Starting the engine after a major overhaul
OHC engine lubrication system
Crankcase ventilation system
Petrol engines DOHC
Specifications for DOHC engines
Repair without removing the engine
Timing chain and sprockets
Cylinder head — design description
Removing the cylinder head
Dismantling and assembly of a head of the block of cylinders
Checking the cylinder head
Checking the valve guides
Processing of valve seats in the cylinder head
Cylinder head assembly
Installing the cylinder head
Removal and installation of a back sealing ring of a cranked shaft
Removing the engine
Additional operations for removing the engine on vehicles with automatic transmission
Additional operations for removing the engine from the gearbox
Engine installation
Engine disassembly
Cylinders — wear check
Inspection and restoration of pistons and piston rings
Piston pins and connecting rods
Crankshaft — check and installation
Main and connecting rod bearings
Flywheel — check and installation
Engine Assembly
Starting the engine after a major overhaul
Crankcase ventilation system
Removal and installation of an oil crankcase
Removal and installation of the oil pump
Oil pump disassembly
Petrol engines V6
View of the engine compartment of the V6 engine
Specifications of V6 engines
Repair without removing the engine
Removing the engine
Engine disassembly
Checking the degree of wear of engine parts
Rocker axle assembly
Valve lifters and push rods
Camshaft — wear check
Cylinder heads
Cylinders — wear check
Inspection and restoration of pistons and piston rings
Piston pins and connecting rods — check
Crankshaft — check
Main and connecting rod bearings
Distribution gears — check
Flywheel — check and installation
Lubrication system — general information
Oil pump — removal and installation
Crankcase ventilation system
Engine assembly — general information
Installing the crankshaft
Installing the camshaft
Installation of pistons and connecting rods
Oil pump installation
Flywheel Installation
Installing the gear and timing cover
Installing the oil pan, water pump and crankshaft pulley
Removal and installation of the oil heat exchanger
Cylinder heads, rocker shafts and intake manifold
Valve clearance adjustment
Auxiliary engine parts
Engine installation
Removing the engine 2.4 and 2.9 liters
2.4 and 2.9 liter engine cylinder heads
Replacing the timing chain drive 2.4 and 2.9 liters
Adjusting the valve clearance of the engine 2.4 and 2.9 liters
Engine oil pump 2.4 and 2.9 liters
Ignition and control
Ignition and engine management systems — general information
Specifications of the ignition system
ESC II Ignition System — Design Description
EEC IV ignition system — design description
Ignition distributor
Checking the ignition timing
Ignition unit (models with fuel injection system)
Ignition coil
Fuel trap on carbureted engines
The engine control unit
Carburetor stepper motor
Intake manifold heater for engines with a carburetor
Engine management relay
Setting the ignition timing and idle speed
RPM and crankshaft position sensor
Air temperature sensor
Fuel temperature sensor
Vehicle speed sensor
Manifold absolute pressure (MAP) sensor
Diesel engines
Diesel engines — general information
Specifications of diesel engines
Repair without removing the engine
Checking and adjusting valve clearances
Fuel System — Design Description
Nozzles — removal, inspection and installation
Glow plugs — check
Cylinder compression check
Bleeding air from the fuel system
Removal and installation of the fuel pump
Checking and adjusting idle speed
Idle speed cable — removal and installation
Removing the cylinder head
Installing the cylinder head
Check and repair of a head of the block of cylinders
Removal and installation of the engine
Engine disassembly
Engine assembly — general information
Installing the rear main bearing
Installation of side seals
Assembling the piston-rod assembly
Selection of pistons by cylinder diameter
Assembly of the drive system of the gas distribution system
Further steps for assembling the engine
Turbocharger — removal and installation
Oil pump — removal and installation
Oil pressure check
Draining fluid from the cooling system
Filling the system and removing air
Cooling system fan
Removing and installing the fan clutch
Removal and installation of the thermostat
Typical engine malfunctions
Cooling system
Specifications of the cooling system
Coolant drain
Flushing the cooling system
Filling the cooling system
Removal and installation of a radiator
Removal and installation of the thermostat
Removal and installation of a fan with a hydraulic clutch
Removal and installation of the electric fan
Coolant pump — removal and installation
Coolant temperature sensor
DOHC Engine Drive Belt
Drive belt tensioner
Supply system
General information about the fuel system
Fuel System Specifications
Fuel used for the car
Unleaded gasoline engines V6, 2.4 and 2.9 liters
Removal and installation of the air filter
Checking the thermostat
Fuel pump — removal and installation
Replacing the fuel filter on engines with a fuel injection system
Removal and installation of the fuel tank
Removal and installation of the gauge of measurement of level of fuel
Removal and installation of the inertial fuel supply switch
Removal and installation of an accelerator pedal
Removal and installation of an accelerator cable
Fuel steam separator
Removal and installation of an inlet collector
Carburetors
Pierburg carburetor — design description
Idle speed and mixture adjustment (Pierburg)
Throttle damper adjustment of the first chamber (Pierburg)
Air damper starting gap adjustment (Pierburg)
Removal and installation of the Pierburg carburetor
Pierburg carburetor disassembly
Pierburg carburetor assembly
Fast idle adjustment (Pierburg)
Pierburg 2V carburetor changes since September 1986
Weber 2V carburetor — design description
Idle speed and mixture adjustment (Weber 2V)
Removal and installation of the Weber 2V carburetor
Assembly and adjustment of the Weber 2V carburetor
Air damper gap adjustment (Weber 2V)
Intermediate clearance adjustment (Weber 2V)
WEBER 2V TLD carburetor — design description
Removal and installation of the Weber 2V TLD carburetor
Idle and mixture adjustment (Weber 2V TLD)
Float Chamber Needle Valve (Weber 2V TLD)
Secondary Chamber Throttle Actuator Vacuum Device (Weber 2V TLD)
Economizer Valve Diaphragm Replacement (Weber 2V TLD)
Automatic Launcher (Weber 2V TLD)
Fast idle speed control (Weber 2V TLD)
Removing and installing throttle damper (Weber 2V TLD)
Weber 2V TLD Carburetor Adjustment
Fuel injection
Fuel injection system — design description
Adjustment of turns of idling and quality of a mix
Removal and installation of the throttle position sensor
Removal and installation of the valve of management of turns of idling
Removal and installation of air flow meters
Removal and installation of fuel injectors
Removal and installation of the temperature sensor of the fuel line
Removal and installation of the fuel pressure regulator
Removal and installation of the throttle body on a DOHC engine
Removal and installation of the oxygen sensor (HEGO)
Removal and installation of a coal adsorber
Removal and installation of the solenoid valve of the coal adsorber
Transmission
Clutch
Clutch specifications
Removing the clutch
Clutch test
Clutch installation
Replacing the needle bearing of the clutch shaft
Clutch cable replacement
Clutch pedal mechanism
Clutch Pedal Replacement
Removal and installation of release bearing
Free play adjustment
Manual gearbox «N»
Specifications of mechanical box «N» type
Description of the design of the mechanical transmission type «N»
Removal and installation of a transmission
Gears and shafts of the gearbox — description of the design
Disassembly of a manual transmission
Assembling a manual transmission
Gearshift Mechanism — Design Description
Dismantling of a secondary shaft of a transmission
Assembly of a secondary shaft of a transmission
Disassembly and assembly of the block gears of the intermediate shaft
Manual gearbox «MT 75»
Technical characteristics of the mechanical box type «MT 75»
Description of the design of the mechanical transmission type «MT 75»
Removing the gearbox
Installing the gearbox
Transmission housing — design description
Gearshift Mechanism — Design Description
Gearbox disassembly
Gears and shafts of the gearbox — description of the design
Replacing bearings in the gearbox
Checking the reverse gear axle
Primary and secondary shafts — disassembly and assembly
Gearbox Assembly
Automatic gearbox «A4LD»
Specifications of automatic transmission
Description of the automatic transmission
Checking the oil level in the gearbox
Checking and flushing the hydrokinetic gearbox
Checking the oil pressure while the gearbox is running
Engine overload test by hydrokinetic transmission
Front planetary brake band adjustment
Removal and installation of the vacuum regulator
Rear planetary hydraulic booster
Centrifugal Oil Pressure Regulator
Replacing the rear o-ring
Removal and installation of the mechanism of a choice of transfers
Removal and installation of draft of a choice of transfers
Kick-down cable adjustment
Kick-down cable adjustment (with solenoid valve)
Removal and installation of a transmission
Automatic transmission malfunctions
Rear axle and drive shafts
Technical characteristics of cardan and drive shafts
Removal and installation of cardan shaft
Repair of the intermediate bearing of the cardan shaft
Removal and installation of the rear axle
Disassembly and assembly of the rear axle
Disassembly of the rear axle differential
Rear axle differential assembly
Adjustment of bearings of gear wheels of the main transfer
Main gear adjustment
Assembly and adjustment of the main gear
Replacement of a sealing ring of a gear wheel of the main transfer
Removal and installation of power shafts
Disassembly and assembly of drive shafts
Chassis
Steering
Steering Specifications
Removal and installation of steering gear
Disassembly and assembly of the steering gear
Removal and installation of a steering wheel
Steering wheel centering
Removal and installation of the lock of blocking of a steering column
Removal and installation of a steering column
Disassembly and assembly of the steering shaft
Power steering
Technical characteristics of the steering with power steering
Removal and installation of steering gear
Disassembly and assembly of the CAM GEAR steering gear
Disassembly and assembly of ZF steering gear
Removal and installation of a steering column
Disassembly and assembly of the steering column
Removal and installation of the pump of the amplifier of a steering
Dismantling and assembly of the pump of the hydraulic booster
Replacing and adjusting the tension of the drive belt
Replacement of protective covers of the steering mechanism
Bleeding air from the power steering system
Front suspension
Specifications of the front suspension
Description of the design of the front suspension
Front suspension beam — removal and installation
Removal and installation of a rack of a forward suspension bracket
Dismantling and assembling the suspension strut
Removal and installation of the stabilizer
Replacing the metal-rubber bushing of the lever
Removal and installation of a rotary fist
Checking the installation of the front wheels
Replacing wheel bearings
Designation of tires and wheel rims
Rear suspension
Rear Suspension Specifications
Description of the design of the rear suspension
Replacing the rear shock absorber
Suspension spring replacement
Removal and installation of the suspension arm
Replacing the metal-rubber bushing of the rear axle beam
Removal and installation of the stabilizer
Replacing wheel bearings
Ride height adjustment system (clearance)
Removal and installation of the compressor
Height sensor replacement
Brake system
Specifications of the brake system
Replacing the front brake pads
Replacing the front caliper
Replacing the front brake disc
Description of the design of the rear brakes
Replacing the rear brake pads
Removal and installation of a back support
Replacing the rear brake disc
Handbrake adjustment
Removal of air from the brake system
Description of the design of the anti-lock braking system
Checking the functioning of the ABS
Removal and installation of hydraulic control unit ABS
Removal and installation of a brake pedal
Removal and installation of the ABS hydraulic unit accumulator
Removal and installation of the pump and engine of the ABS hydraulic unit
Replacing the front wheel speed sensor
Replacing the rear wheel speed sensor
Body
Exterior
Washing and body care
Removal and installation of a cowl
Removal and installation of a cable of a cowl
Removal and installation of the insulating panel of a cowl
Removal and installation of a radiator grille
Removal and installation of the cylinder of the lock of a mouth of the gulf of fuel
Removal and installation of a cover of the hatch
Removal and installation of a windshield and motionless glasses
Removal and installation of decorative slips of a windscreen
Removal and installation of decorative slips of glass of a back door
Removal and installation of emblems
Front bumper height adjustment
Removal and installation of bumpers
Removal and installation of bumper pads
Removing and installing the front spoiler
Interior
Removal and installation of an upholstery of a ceiling
Removal and installation of an internal rear-view mirror
Removal and installation of the instrument panel
Removal and installation of the center console
Removal and installation of the upper console
Removal and installation of the rear shelf (Salon models)
Removing and installing the front seat
Removal and installation of seat belts of forward seats
Removal and installation of seat belts of a back seat
Removal and installation of the rear seat
Doors, locks and windows
Removal and installation of doors
Door position adjustment
Removal and installation of the panel of an internal upholstery of doors
Removal and installation of external door handles
Removal and installation of the door lock cylinder
Removal and installation of the door lock
Removal and installation of a door seal
Removal and installation of glass doors
Removal and installation of the mechanism of a window regulator
Removal and installation of decorative lateral overlays of doors
Removal and installation of decorative overlays of a frame of glasses of a door
Removal and installation of external rear-view mirrors
Removal and installation of a back door
Removal and installation of the tailgate lock cylinder
Removal and installation of the lock of a back door
Removal and installation of a gas-filled emphasis of a door of a luggage carrier
Removing, installing and adjusting the trunk lid (Salon models)
Removal and installation of the trunk lid lock (Salon models)
Heating and ventilation
Heating and ventilation system — general information
Removal and installation of the heater control unit
Removal and installation of heater control cables
Removal and installation of a heater
Disassembly and assembly of the heater
Removal and installation of heater air ducts
Air conditioner — general information
Air Conditioner Service
Compressor drive belt
Condenser fan — removal and installation
Thermostat — removal and installation
Heater water valve
Electrical equipment
Equipment and devices
Technical characteristics of onboard electrical equipment
Fuses and relays
Electronic control units
Central locking system
Direction indicator system
Fuel computer
Additional control system — general information
The main malfunctions of the starter
Rear window wiper
Replacement and adjustment of windshield washer nozzles
Removal and installation of a combination of devices
External and internal lighting
Replacement of other electrical equipment
Removal and installation of switches, motors and sensors
Additional control system — removal and installation
Removal and installation of the radio receiver
Removing and installing loudspeakers
Anti-theft alarm system
Power devices
Generator — Safety Measures and Verification
Removal and installation of the generator
Disassembly and assembly of the generator
Replacement of generator brushes and voltage regulator
Main generator malfunctions
V-belt tension adjustment
Removal and installation of a starter
Disassembly and assembly of the starter
Electrical circuits
Scheme of the electrical power circuit
Diagram of the electrical circuit for charging and starting the engine
Diagram of the electrical circuit for charging and starting the engine (all engines)
Diagram of the electrical circuit of the engine management system 1.8 l
2.0L OHC engine management circuit diagram with carburetor
2.0L OHC Engine Control Loop Diagram with Injection
Diagram of the electrical circuit of the engine management system 2.8 l
Scheme of the electrical circuit of outdoor lighting
Loop diagram of signaling, turns and control systems
Scheme of the electrical circuit of internal lighting
Wiper and washer drive circuit diagram
Outline diagram of the central door locking system
Electric window drive circuit diagram
Anti-lock braking system (ABS) circuit diagram
Circuit Diagram of AWS Additional Control System
Scheme of the electrical circuit for connecting the radio receiver
Diagram of the electrical circuit of the diesel engine
Sunroof drive electrical circuit diagram
Scheme of the electrical circuit for turning on the heater fan
Ford Scorpio 2
General information
Car care
Car wash
Paintwork care
Anti-corrosion protection of the bottom of the body and hidden internal cavities
Seat upholstery care
Facilitation of starting the engine
Towing a car
Starting the engine by pushing the vehicle (emergency start)
Vehicle lifting
List of tools for maintenance and repair
Maintenance
Maintenance card
General information about maintenance
Engine and exhaust system
Engine oil change
Visual control of oil leakage
Checking the engine oil level
Checking the coolant level
Coolant replacement
Visual control of the tightness of the cooling system
Checking the concentration of antifreeze
Checking and adjusting valve clearances
Tightening the intake manifold bolts
Spark plugs, checking connections and ignition distributor caps
Replacing the Air Filter Element
Fuel filter replacement
Checking and replacing the V-ribbed belt and toothed belt
Replacing the crankcase ventilation valve
Visual inspection of the exhaust system
Checking the refrigerant level in the air conditioning system
Gearbox and final drive
Visual control of transmission tightness
Manual Transmission — Checking the Oil Level
Automatic Transmission — Checking the Oil Level
Checking the oil in the final drive of axles and in the transfer case
Checking the rubber covers of cardan shafts
Automatic Transmission — Band Brake Adjustment
Brakes, tires and wheels
Checking the brake fluid level
Checking the thickness of the brake linings
Visual inspection of brake pipes
Brake Fluid Replacement
Checking the tire tread pattern
Checking tire inflation pressure
Chamber valve check
Steering and front axle
Checking the dust caps on the tie rod ends
Checking ball joints for clearance
Checking the rubber boots of the steering mechanism
Checking the steering for the absence of gaps
Checking the oil level in the power steering reservoir
Electrical system
Checking the battery
Body and interior equipment
Treatment of drains for moisture condensate
Lubrication of locks
Visual control of all seat belts
Replacing the replaceable element of the fine air filter
Power unit
Engine repair
General information about engines
Vehicle identification
The most important characteristics of engines for Ford Scorpio cars
Removal and installation of the lower casing of a motor compartment
Removal and installation of the engine
Removal, installation and adjustment of a gear belt
Removal and installation of a head of cylinders (gasoline OHC engine)
Removal and installation of a head of cylinders (engine DOHC)
Removing and installing cylinder heads (V6 OHV engine)
Removal and installation of a camshaft (OHC engine)
Removal and installation of valves (OHC engine)
Removal and installation of valves (DOHC engine)
Removal and installation of valves (engine V6 OHV)
Replacing valve stem seals (petrol engine)
Replacing valve stem seals (diesel engine)
Checking the valve guides
Lapping of valves
Checking and adjusting valve clearances
Cylinder compression check
Removing, installing and tensioning the V-belt and V-ribbed belt
Engine Troubleshooting
Lubrication system
General information about engine oil
Recommended Viscosity Grades for Motor Oils
Engine oil consumption
Engine oil circulation
Oil pressure check
Checking the hydraulic switch
Removal and installation of the oil pan
Oil Circulation Troubleshooting
Cooling system
Coolant circulation
Coolant — basic information
Coolant replacement
Checking the cooling system for leaks
Removal and installation of the thermostat (OHC engine)
Removing and installing thermostat (DOHC engine)
Removing and installing thermostat (V6 engine)
Removal and installation of the thermostat (diesel engine)
Thermostat check
Removal and installation of the cooling fan
Removal and installation of the pump of a cooling liquid
Removal and installation of a radiator
Diagnosis of malfunctions of the cooling system
Ignition system
General information about the ignition system
Operation of the ignition system
Safety precautions when working on the ignition system
Checking the ignition distributor cap / high voltage wires
Checking the ignition coil
Removal and installation of the distributor of ignition
Removal and installation of the control unit of the ignition system
Checking and adjusting the ignition timing
Removal and installation of spark plugs
Spark plug technology
Diagnostics of malfunctions of system of ignition
Supply system
General information about the power system
Safety and cleanliness when working on fuel systems
Removing, installing and checking the fuel level sensor
Removal and installation of the fuel tank
Removal and installation of the electric fuel pump
Removal, installation and check of the mechanical fuel pump
Removal and installation of the air filter (cars up to 8/94)
Removing and installing the air filter (vehicles from 9/94)
Removal and installation of gas thrust (vehicles from 9/94)
Throttle adjustment
Check, removal and installation of the relay of the fuel pump
Carburetors
General information about the carburetor
Carburetor adjustment
Faults in the fuel supply
Carburetor Pierburg 2V — design description
Weber 2V-ISC Carburetor — Design Description
Checking and adjusting idle speed and CO content
Checking and adjusting the CO content
Removal and installation of the carburetor
Technical characteristics of carburetors
Carburetor Troubleshooting
Injection system (gasoline)
Diagram of the electronic engine control system EEC V
General information about the fuel injection system
Safety regulations for working with the injection system
Operation of the petrol injection system
Injection sensors
SEFI injection system (engines from 9/94)
Checking valve injectors
Removal and installation of the fuel manifold and valve injectors
Diagnostics of malfunctions of system of injection of gasoline
Injection system (diesel)
General information about the fuel injection system
Working principle of diesel engine
General information about the turbocharger
Bleeding air from the fuel system
Checking and adjusting the idle speed
Removal and installation of draft of increase in frequency of rotation at idle
Removal and installation of nozzles
Preheating system
Checking the heating system, removing and installing glow plugs
Characteristics of the diesel injection system
Diagnosis of malfunctions of the injection system of a diesel engine
Exhaust system
Exhaust system (gasoline up to 8/94) — design description
Exhaust system (petrol since 9/94) — design description
Exhaust system (diesel) — design description
Removal and installation of system of release of the fulfilled gases
Checking the exhaust system for leaks
Removal and installation of the subsequent muffler
Operation of the catalytic converter
Handling vehicle catalytic converters
Transmission
Clutch
Description of the clutch design
Removal, installation and clutch check
Removal and installation of a cable of a drive of coupling
Removing, installing and checking the clutch release bearing
Removal of air from the hydraulic clutch
Clutch Troubleshooting
Car gearbox
General information about the gearbox
Removing the N·manual transmission (pre-1988 models)
Removing the manual transmission MT-75
Installation of a manual transmission
All Wheel Drive — Design Description
Automatic transmission
Chassis
Front suspension
Description of the design of the front suspension
Removal and installation of an amortization rack
Removal and installation of a rotary support
Shock absorber device
Dismantling of a shock-absorber rack, removal and installation of the shock-absorber
Shock absorber check
Removal and installation of the transverse lever
Removal and installation of the stabilizer (models up to 8/94)
Removal and installation of the stabilizer (models from 9/94)
Determination of chassis parameters
Rear suspension
General information about the rear suspension
Removal and installation of cardan shaft
Removal and installation of the rear shock absorber
Removal and installation of the stabilizer
Removal and installation of a nave of a back wheel
Removal and installation of the bearing of a nave of a wheel
Removal and installation of the cardan shaft of the rear axle
Disassembly of the cardan shaft, replacement of corrugated covers
Steering
Description of the steering structure
Safety precautions when handling the airbag
Removal and installation of a steering wheel
Steering wheel adjustment
Removal and installation of a tip of cross steering draft
Removal and installation of a corrugated cover of the steering mechanism
Power steering pump (gasoline, up to 8/94)
Power steering pump (petrol, from 9/94)
Power steering pump (diesel)
Removal of air from a hydraulic drive of the amplifier of a steering mechanism
Brake system
General information about the brake system
Anti-lock braking system (ABS)
Front disc brake caliper
Removing and installing front disc brake pads
Rear disc brake caliper
Removing and installing rear disc brake pads
Checking the thickness and lateral runout of the brake discs
Brake shoe guide with front brake caliper
Brake shoe guide with rear brake caliper
Removal and installation of a brake disk
Checking the brake booster
Replacing the pipeline and brake hose
Brake Fluid — Safety Precautions
Removal of air from the hydraulic drive of the brake system
Handbrake adjustment
Removal and installation of a cable of a manual brake
Removal and installation of the switch of a signal of braking
Specifications of the brake system
Brake fault diagnosis
Wheels and tires
General information about wheels and tires
Designations of tires and disk wheels
Wheel replacement and balancing
Tire care rules
Anti-skid chains
Incorrect tire wear
Elimination of vibrations of the steering wheel / front of the car
Tire Fault Diagnosis
Body
Exterior
General information about the car body Scorpio I
Removal and installation of the front bumper (Scorpio I)
Front bumper adjustment (Scorpio I)
Removal and installation of the rear bumper (Scorpio I)
Removal and installation of a radiator grille (Scorpio I)
Removal and installation of the fairing grille (Scorpio I)
Removal and installation of a decorative overlay (Scorpio I)
Removal and installation of draft of the lock of a cowl (Scorpio I)
Removal, installation and adjustment of the hood (Scorpio I)
Removal and installation of an external mirror (Scorpio I)
General information about the car body Scorpio II
Removal and installation of the front bumper (Scorpio II)
Removal and installation of the rear bumper (Scorpio II)
Removal and installation of a radiator grille (Scorpio II)
Removal and installation of the fairing grille (Scorpio II)
Removal and installation of facing of a forward wheel arch (Scorpio II)
Removal and installation of draft of the lock of a cowl (Scorpio II)
Removal and installation of an external mirror (Scorpio II)
Interior
Removal and installation of a ware box (Scorpio I)
Removal and installation of the center console (Scorpio I, up to 1/92)
Removal and installation of the center console (Scorpio I, after 1/92)
Removing and installing the front seat (Scorpio I)
Removal and installation of a back seat (Scorpio I)
Seat belt tensioner (Scorpio II)
Precautions when working with the seat belt tensioner
Removing and installing the front seat (Scorpio II)
Doors, locks and windows
Removal and installation of a cover of a luggage compartment (Scorpio I)
Removal and installation of a back door (Scorpio I)
Removal and installation of the lock of a back door (Scorpio I)
Removal and installation of a door (Scorpio I)
Door adjustment (Scorpio I)
Removal and installation of facing of a door (Scorpio I)
Removal and installation of the door lock cylinder (Scorpio I)
Removal and installation of the door lock (Scorpio I)
Windshield (Scorpio I)
Removal and installation of window glass (Scorpio I)
Removal and installation of the crank mechanism of the window lifter (Scorpio I)
Removal and installation of a cover of a luggage compartment (Scorpio II)
Lock cylinder, trunk lid lock (Scorpio II)
Removal and installation of facing of a door (Scorpio II)
Removal and installation of the lock and the external handle of a door (Scorpio II)
Removal and installation of the door lock cylinder (Scorpio II)
Removal and installation of window glass (Scorpio II)
Removal and installation of lateral facing of a luggage compartment (Scorpio II)
Removal and installation of a cover of a niche of a mouth of a fuel tank (Scorpio II)
Central locking system (Scorpio II)
Heating system
General information about the interior heating system
Removal and installation of the heating system control unit (up to 1/92)
Removal and installation of the heating system control unit (after 1/92)
Removal and installation of the heater fan switch
Removal and installation of the heater fan
Diagnosis of malfunctions of the heating system
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
Measuring instruments
Measurement technique
Installation of additional components of the electrical system
Troubleshooting in the electrical system
Electronic anti-theft system
Ignition key coding for anti-theft system
Checking the heating of the rear window and windshield
Replacing fuses
Location of relays and fuses
Instrument panel — design description
Removal and installation of the instrument panel
Removal and installation of devices
Removal and installation of the speed sensor
Steering column and hazard warning switches
Removal and installation of the light switch and incandescent lamp
Removal and installation of switches of the control panel
Removal and installation of the radio receiver
Entering the radio code
Removing and installing the loudspeaker
Headlights and lighting