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Ford Focus 1
General information
Using the manual
About this Guide
Health protection and precautions
Warning signs located on the vehicle
Standard technical practices 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 a jack and lifting the car
Noise, vibration and harshness (NVH)
Noise, Vibration and Harshness (NVH) Diagnostics and Testing
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
Measuring compression pressure
Measuring oil pressure
Checking the valve mechanism — static (engine off)
Engine 1.4/1.6 Zetec-SE
1.4L/1.6L Zetec-SE Engine Specifications
Description and operating principle 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 pan — removal and installation
Removing the engine with a manual transmission
Removing the engine with automatic transmission
Disassembling the engine
Cylinder head — disassembly and assembly
Engine assembly
Installing an engine with a manual transmission
Installing an engine with an automatic transmission
Engine 1.6/1.8/2.0 Zetec-E
1.8L/2.0L/1.6L Zetec-E Engine Specifications
Description and operating principle 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 pan — removal and installation
Removing the engine with a manual transmission iB5
Removing the engine with a manual transmission MTX-75
Removing the engine with automatic transmission
Removing the 1.6L Zetec-E engine
Disassembling the engine
Engine assembly
Installing an engine with a manual transmission iB5
Installing an engine with a manual transmission MTX-75
Installing an engine with an automatic transmission
Installing 1.6L Zetec-E Engine
Engine Duratec ST 2.0 l
Duratec ST 2.0L Engine Specifications
Description and operating principle of the Duratec ST 2.0 l engine
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 pan — removal and installation
Oil pump — removal and installation
Rear Crankshaft Seal — Removal and Installation
Removing the engine
Disassembling the engine
Engine assembly
Engine installation
Engine Duratec 8V 1.6 l
Duratec 8V 1.6L Engine Specifications
Description and operating principle 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 tappets — removal and installation
Exhaust manifold — removal and installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Rear Crankshaft Seal — Removal and Installation
Removing the Duratec 8V 1.6L engine
Disassembling the Duratec 8V 1.6L engine
Cylinder head — disassembly and assembly
Duratec 8V 1.6L Engine Assembly
Installing the Duratec 8V 1.6L engine
Diesel engine 1.8 l
Diesel Engine Specifications
Description and operating principle of the engine without fuel injection
Description and operating principle 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
Cylinder head of a fuel injected engine
Oil pan — removal and installation
Rear Crankshaft Seal — Removal and Installation
Removing the engine
Disassembling the engine
Disassembling a fuel injected engine
Cylinder head — disassembly and assembly
Fuel Injected Cylinder Head — Disassembly and Assembly
Engine assembly
Fuel injection engine assembly
Engine installation
Engine cooling
Engine Cooling System Specifications
Description and principle of operation of engine cooling
Diagnostics and testing of the engine cooling system
Pinpoint tests of the engine cooling system
Checking the engine cooling system components
Draining/filling coolant and bleeding air
Flushing the cooling system
Backwashing (counter-current flushing) 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
Electric motor and cooling fan housing (1.6L Zetec-SE/1.4L)
Electric motor and cooling fan housing (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 operating 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 injection 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 operating principle (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 Delivery 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 operating principle (1.8 l diesel)
Diagnostics and checks (1.8 l diesel)
Fuel injectors (1.8 l diesel)
High pressure fuel pump (1.8 l diesel)
Specifications (turbocharger)
Description and principle of operation (turbocompressor)
Diagnostics and checks (turbocharger)
Inspection and testing (turbocharger)
Pinpoint tests (turbocharger)
Turbocharger 1.8 l diesel (75 PS/90 PS)
Turbocharged 1.8L Diesel with Fuel Injection
Specification (diesel with fuel injection)
Description and operating principle (diesel with fuel injection)
Diagnostics and checks (diesel with fuel injection)
Cleaning of fuel injection system components (diesel with fuel injection)
Fuel injectors (diesel fuel injection)
Fuel Supply Manifold (Diesel Fuel Injection)
Fuel pump (diesel with fuel injection)
Fuel return line with Venturi nozzle
Specifications (Duratec ST 2.0L)
Description and operating principle (Duratec ST 2.0 l)
Throttle Body (Duratec ST 2.0L)
Fuel Delivery System Wiring Harness (Duratec ST 2.0L)
Fuel Supply Manifold (Duratec ST 2.0L)
Specifications (1.6L Duratec)
Description and operating principle (1.6L Duratec)
Diagnostics and checks (1.6L Duratec)
Throttle Body (1.6L Duratec)
Fuel Delivery System Wiring Harness (1.6L Duratec)
Fuel Supply Manifold (1.6L Duratec)
Description and operating principle of the fuel supply system
Diagnostics and testing of the fuel supply system
Pinpoint tests of the fuel supply system
Relieving pressure in the fuel supply system
Quick coupling — disconnection and connection
Emptying the fuel tank
Spring Lock Couplings — Disconnecting and Connecting
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 diesel with injection) — removal and installation
Inertial Fuel Shutoff 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 tests
Pinpoint speed control tests
Adjusting the Speed Control System Deactivator Switch
Speed control cable
Speed control cable (Duratec ST 2.0L)
Speed control system switch
Accessory drive
Accessory Drive Specifications
Description and operating principle of the accessory drive
Diagnostics and checks of accessory drive
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 Drive Belt Idler Pulley
Accessory Drive Belt Idler Pulley (1.8L Diesel)
Accessory Drive Belt (1.6L Duratec)
Accessory Drive Belt Tensioner (1.6L Duratec)
Launch system
Launch System Specifications
Description and operating principle of the launch system
Diagnostics and testing of the starting system
Pinpoint tests of the launch system
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 operating principle of the ignition system 1.4/1.6 Zetec-SE
Diagnostics and testing 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 operating principle of the ignition system 1.8/2.0/1.6 Zetec-E
Diagnostics and testing of 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 operating principle of the glow plug system (1.8L diesel)
Diagnostics and testing of glow plug system (1.8L diesel)
Glow Plug Wire (1.8L Diesel)
Description and operating principle of the ignition system (Duratec 8V 1.6L)
Diagnostics and testing of the ignition system (Duratec 8V 1.6L)
Air and vapor
Distribution and filtration of intake air
Diagnostics and testing of distribution and filtration
Air filter inlet pipe
Air filter — removal and installation
Air filter element
Fuel vapor control
Diagnostics and fuel vapor control checks
Carbon filter for fuel vapor control system
Carbon filter for fuel vapor control system (Duratec ST 2.0 l)
Fuel Evaporative Control System Carbon Canister Purge Valve
Fuel Evaporative Canister Purge Valve (Duratec)
Engine management
Electronic Control Specifications
Description and operating principle 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 (CPS) (1.6L Zetec-SE/1.4L)
Crankshaft Position Sensor (CPS) (1.8L/2.0L/1.6L Zetec-E)
Crankshaft position sensor (CPS) (1.8 l diesel)
Crankshaft Position Sensor (CPS) (1.8L Diesel with Injection)
Power Steering Pressure (PSP) Switch (1.6L Zetec-SE/1.4L)
Power Steering Pressure (PSP) Switch (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 (CHT) (1.6L Zetec-SE/1.4L)
Cylinder Head Temperature Sensor (CHT) (1.8L/2.0L/1.6L Zetec-E)
Cylinder Head Temperature Sensor (CHT) (1.8 l diesel)
Clutch Pedal Position Switch (CPP)
Injector Control Module (IDM) (1.8L Diesel)
Fuel Pump Control Module (FPDM) (Duratec ST 2.0L)
Intake Manifold Runner Control (IMRC) actuator
Idling Air Supply Control Valve (IAC)
Exhaust toxicity
Emissions reduction specifications (1.8/2.0/1.6 Zetec-E)
Description and operating principle (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)
Emissions reduction specifications (1.8L diesel)
Description and operating principle (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 Diesel Injection)
Pipe from the exhaust manifold to the exhaust gas recirculation (EGR) valve
Piping from the exhaust gas recirculation (EGR) cooler to the EGR valve
Exhaust Gas Recirculation (EGR) Cooler (75 PS/90 PS)
Exhaust Gas Recirculation (EGR) Cooler (115 PS)
Engine crankcase ventilation system oil separator
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 operating principle of automatic transmission
Electromagnetic control of synchronized gear shifting
Automatic transmission diagnostics and testing
Diagnostic Trouble Code Tables
Gearbox connector pinout
Pinpoint tests — car equipped with OSC
Special verification procedures
Inspection for leaks
Diagnostics by fault sign
Fluid pan, gasket and filter
Main control valves
Turbine Shaft Speed Sensor (TSS)
Secondary Shaft Speed Sensor (OSS)
Left axle shaft seal
Right axle shaft seal
Transmission Range (TR) Sensor
Gearbox in block with driving axle 1.6L — removal
Gearbox in block with leading axle 2.0L — removal
Gearbox in block with driving axle — disassembly
Main gear holder with differential — disassembly and assembly
Pump assembly — disassembly and assembly
Transfer shaft — disassembly and assembly
Forward Clutch — Disassembly and Assembly
Direct and reverse clutch — disassembly and assembly
Direct Drive Clutch — Disassembly and Assembly
Reverse clutch — disassembly and assembly
Planetary gear assembly — disassembly and assembly
Main control valve block — disassembly and assembly
Gearbox housing in block with drive axle
Torque converter
Checking the torque converter for leaks
Checking the axial clearance of the torque converter
Gearbox in block with driving axle — assembly
Gearbox in block with driving axle 1.6L — installation
Gearbox in block with driving axle 2.0L — installation
Description and operating principle of gearbox cooling
Diagnostics and testing of gearbox cooling
Transmission Fluid Cooler — Removal and Installation
Transmission Fluid Cooler Lines — Removal and Installation
Description and operating principle of external controls
Diagnostics and testing of external controls
Pinpoint tests of external controls
Adjusting the gear selector lever cable
Gearshift locking actuator
Gear Selector Lever Cable — Removal and Installation
Gear Selector Lever — Removal and Installation
Gear Selector Lever Socket — Removal and Installation
Gear Selector Lever Handle — Removal and Installation
Gear Selector Lever — Disassembly and Assembly
Clutch
Manual Transmission Specifications
General information about manual transmission
Clutch diagnostics and testing
Pinpoint clutch tests
Diagnostics and testing of clutch controls
Checking the clutch slave cylinder
Bleeding the iB5 Clutch System
Bleeding the MTX-75 Clutch System
Bleeding the Clutch System MT285
Adjusting the iB5 Shift Cable
Adjusting the MTX-75 Shift Cable
Adjusting the MT285 Shift Cable
Clutch of manual transmission iB5
Clutch for manual transmission MTX-75
Clutch for manual transmission MT285
IB5 Clutch Controls
Clutch Master Cylinder iB5
Clutch slave cylinder iB5
MTX-75 Clutch Controls
Clutch Master Cylinder MTX-75
MTX-75 Clutch Slave Cylinder
Mechanical gearbox iB5
IB5 Manual Transmission Specifications
Description and operating principle of iB5
Checking bearings
Left axle shaft seal — removal and installation
Right axle shaft seal — removal and installation
Gear shift control shaft seal
Vehicle Speed Sensor (VSS) — Removal and Installation
Gearbox with driving axle (1.6L Zetec-SE/1.4L) — removal
Gearbox with leading axle (1.8L/1.6L Zetec-E) — removal
Gearbox with driving axle (1.6L) — removal
Gearbox with axle (cars up to 07.2000) — disassembly
Gearbox with axle (cars after 08.2000) — disassembly
Gear Selector Plate — Disassembly and Assembly
Primary shaft — disassembly and assembly
Secondary shaft — disassembly and assembly
Differential — disassembly and assembly
Gearbox with axle (cars up to 07.2000) — assembly
Gearbox with axle (cars after 08.2000) — assembly
Gearbox with leading axle (1.6L Zetec-SE/1.4L) — installation
Gearbox with leading axle (1.8L/1.6L Zetec-E) — installation
Gearbox with leading axle (1.6L) — installation
External controls of the iB5
Diagnostics and testing of external controls
Gear shift lever mechanism — removal and installation
Gear Shift Lever — Removal and Installation
Gear Shift Cables — Removal and Installation
Gear Shift Lever — Disassembly and Assembly
Mechanical gearbox MTX-75
MTX-75 Manual Transmission Specifications
Description and operating principle of MTX-75
Checking bearings
Left axle shaft seal — removal and installation
Right axle shaft seal — removal and installation
Gearbox with driving axle (2.0L) — removal
Gearbox with driving axle (1.8L diesel) — removal
Gearbox in block with driving axle — disassembly
Gear selection mechanism (vehicles up to 07.2000)
Primary shaft — disassembly and assembly
Secondary shaft (cars up to 07.2000) — disassembly and assembly
Secondary shaft (cars after 08.2000) — disassembly and assembly
Differential — disassembly and assembly
Gearbox in block with driving axle — assembly
Transmission in block with driving axle (2.0L) — installation
Gearbox in block with driving axle (1.8 l diesel) — installation
External controls MTX-75
Diagnostics and testing of external controls
Gear shift lever mechanism — removal and installation
Gear Shift Lever — Removal and Installation
Gear Shift Cables — Removal and Installation
Gear shift lever (cars up to 08.2001)
Gear shift lever (cars after 08.2001)
Mechanical gearbox MT285
MT285 Manual Transmission Specifications
Description and operating principle of MT285
Draining and filling transmission fluid
Left axle shaft seal — removal and installation
Right axle shaft seal — removal and installation
Gearbox in block with driving axle — removal
Gearbox in block with driving axle — installation
External controls MT285
Diagnostics and testing of external controls
Gear shift lever mechanism — removal and installation
Gear Shift Cables — Removal and Installation
Gear Shift Lever — Disassembly and Assembly
Chassis
Front suspension
Suspension specifications
Diagnostics and testing of suspension
Pinpoint tests of suspension
Checking suspension components
Rear wheel alignment adjustment (15 211 0)
Front wheel alignment (14 117 0)
Adjusting the calculated suspension height
Inspection of wheel bearings
Rear suspension
Rear Suspension Specifications
Description and operating principle of the rear suspension
Wheel hub (15 373 0) — removal and installation
Wheel bearing — removal and installation
Wheel hub 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 knuckle (15 366 0) — removal and installation
Shock absorber (15 791 0) — removal and installation
Shock absorber — universal (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 — universal (15 621 0)
Cross member — removal and installation
Wheels and tires
Inspection and testing of tires
Tire wear and vibration diagnostics
Tire sensitivity to speed and rotation frequency
Table of signs of tire failure
Removing and installing a wheel
Front axle axles
Front Axle Shaft Specifications
Description and principle of operation
Inspection and testing of front axle shafts
Left axle shaft — removal and installation
Right axle shaft — removal and installation
Intermediate shaft — removal and installation
Inner constant velocity joint (CV joint) boot
Outer constant velocity joint (CV joint) boot
Left axle shaft — disassembly and assembly
Right axle shaft — disassembly and assembly
Brake system
Description and operating principle of the braking system
Inspection and testing of the brake system
Table of signs of brake system malfunction
Pinpoint tests of the brake system
Checking the brake system components
Bleeding the brake system
Bleeding air from the brake system under pressure
Checking the brake system for leaks
Checking the brake disc runout
Drum Brake Specifications
Description and operating principle of a 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
Front Disc Brake Description
Front Disc Brake Pads
Front Disc Brake Caliper
Front disc brake disc
Front Disc Brake Disc — Duratec ST 2.0L
Disassembling the front disc brake caliper
Rear Disc Brake Specifications
Description of the rear disc brake
Rear Disc Brake Caliper
Rear Disc brake pads
Rear disc brake disc
Rear Disc Brake Disc Shield
Description and principle of operation of the parking brake
Inspection and testing of the parking brake
Parking Brake Pinpoint Tests
Adjusting the parking brake cable
Parking brake control lever
Parking brake cable — removal and installation
Hydraulic brake
Hydraulic brake drive specifications
Description and operating principle of 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
Brake Booster Specifications
Description and operating principle of the vacuum brake booster
Vacuum brake booster — removal and installation
Brake system vacuum pump — removal and installation
Anti-lock braking system
Anti-lock braking system specifications
Description and operating principle of the anti-lock braking system
Diagnostics and testing of the anti-lock braking system
Hydraulic Control Unit (HCU)
Rear wheel speed sensor
Rear wheel speed sensor pulse ring
Description and operating principle of the stability control function
Speed sensor for angular rotation of the vehicle around the vertical axis
Acceleration sensor — removal and installation
Steering
Steering Specifications
Description and operating principle of the steering control
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 (115 PS)
Bleeding the Power Steering System
Purge the power steering system
Filling the power steering system with working fluid
Power Steering Specifications
Description of power steering
Power steering pump — 1.4L/1.6L (with air conditioning)
Power steering pump — 1.4L/1.6L (without air conditioning)
Power Steering Pump — 1.8L/2.0L
Power Steering Pump — 1.8L Diesel
Power Steering Pump — Duratec ST 2.0L
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 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
Pinpoint tests of steering column switches
Ignition Switch — Removal and Installation
Description of the steering drive
Steering rod — removal and installation
Tie Rod End — Removal and Installation
Steering gear housing
Steering column description
Steering wheel — removal and installation
Steering column — Cars produced up to 03.2002
Steering column — Cars produced from 03/2002
Steering column — Duratec ST 2.0 l
Steering column (cars up to 03.2002) — disassembly and assembly
Steering column (cars 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
Rear body panels
Alignment of the hood — removal and installation
Mudguard — Removal and Installation
Hood Panel Grille — Removal and Installation
Wing — removal and installation
Specifications of lockable body elements
Body elements
Rear view mirrors
Rear view mirrors — diagnostics and checks
Rearview Mirrors — Pinpoint Tests
Outside mirror — removal and installation
Handles, Locks, Latches and Entry Systems
Diagnostics and testing of entry systems
Programming the remote control transmitter
Hood Latch — Removal and Installation
Front Door Latch — Removal and Installation
Rear Door Latch — Removal and Installation
Luggage compartment liftgate latch
External door handle — removal and installation
Hood Lock Cylinder — Removal and Installation
Ignition Lock Cylinder — Removal and Installation
Door Lock Cylinder — Removal and Installation
Luggage compartment lift door lock cylinder
Luggage compartment lift door lock cylinder (station wagon)
Interior Door Latch Release Handle
Bumper Tightening Torque Specifications
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
Rear side trim panel
Door sill trim panel
Ceiling lining — removal and installation
Seat specifications
Description and operating principle of the seats
Diagnostics and checks of seats (cars up to 08.2001)
Pinpoint tests of seats (cars up to 08.2001)
Diagnostics and checks of seats (cars after 08.2001)
Pinpoint tests of seats (cars after 08.2001)
Seat diagnostics and testing (Duratec ST 2.0 l)
Pinpoint tests seats (Duratec ST 2.0 l)
Front seat — removal and installation
Front seat back — removal and installation
Front seat back (folding flat seat)
Rear seat back — removal and installation
Rear seat back (split seat)
Front seat cushion — removal and installation
Rear Seat Back Latch — Removal and Installation
Rear Seat Back Latch (3-Door/5-Door/Wagon)
Front seat cushion — disassembly and assembly
Rear seat cushion (cars 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 back (split seat) — disassembly and assembly
Instrument panel — removal and installation
Floor console (cars up to 10.2001, manual transmission)
Floor console (cars after 10.2001, manual transmission)
Floor console (cars up to 10.2001, automatic transmission)
Floor console (cars after 10.2001, automatic transmission)
Upper console — removal and installation
Glass, frames and mechanisms
Specifications
Description and principle of operation
Diagnostics and checks (cars up to 08.2000)
Pinpoint tests (cars up to 08.2000)
Diagnostics and checks (cars from 08.2000 to 08.2001)
Pinpoint tests (cars from 08.2000 to 08.2001)
Diagnostics and checks (cars after 08.2001)
Pinpoint tests (cars after 08.2001)
Initialization of the electric motor of the window lifter of the door
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 for window lift door
Front door window lifter
Rear door window lifter
Front door window lifter and window lifter motor
Rear door window lifter and window lifter motor
Windshield — removal and installation
Upper guide for front door window glass
Upper guide for rear door window glass
Windshield wipers and washers
Windscreen Wiper Specifications
Description and operating principle of windshield wipers
Diagnostics and testing of windshield wipers (cars up to 08.2001)
Pinpoint tests of windscreen wipers (cars up to 08.2001)
Checking windshield wiper elements (vehicles up to 08.2001)
Diagnostics and testing of windshield wipers (cars after 08.2001)
Pinpoint tests of windscreen wipers (cars after 08.2001)
Checking windshield wiper elements (cars after 08.2001)
Adjusting the windshield wiper blades and arms
Windshield wiper motor — removal and installation
Rear Window Wiper Motor — Removal and Installation
Windshield washer pump and reservoir
Car sunroof
Tightening torque specification
Sunroof diagnostics and testing
Sunroof Pinpoint Tests
Checking the water drainage system and eliminating water leaks
Checking the position of the roof hatch
Initializing the sunroof drive motor
Sunroof Glass — Removal and Installation
Sunroof Curtain — Removal and Installation
Roof Sunroof Cable and Guide — Removal and Installation
Sunroof Frame — Removal and Installation
Front Sunroof Drain Hose — Removal and Installation
Rear Sunroof Drain Hose (4/5-Door/Wagon)
Rear Sunroof 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
Diagnostics and testing of seat belts
Front seat belt retractor mechanism
Rear seat belt retractor (3-/5-door)
Rear Seat Belt Retractor (4-Door)
Rear seat belt retractor mechanism (station wagon)
Central rear seat belt retractor mechanism
Rear center seat belt retractor (4-door)
Shoulder belt height adjustment mechanism
Seat belt buckle — removal and installation
Seat belt buckle and tensioner — removal and installation
Auxiliary Restraint System Specifications
Auxiliary restraint system — description and operating principle
Auxiliary restraint system — diagnostics and testing
Instructions for diagnostics of the restraint system (before 08.2002)
Instructions for diagnostics of the restraint system (after 08.2002)
Pinpoint tests of the auxiliary restraint system (before 10.2001)
Pinpoint tests of the auxiliary restraint system (after 10.2001)
Pinpoint tests of the auxiliary restraint system (after 08.2002)
Disposal of a deployed airbag
Airbag disposal — unserviceable vehicle
Disposal of an undeployed 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
Protection of the body from corrosion
Repair of plastic parts
Water leaks
The sound of the wind
Removing 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
Inner reinforcement of the wing apron panel — removal and installation
Deformable element of the side member — removal and installation
Front side member section — removal and installation
Right front spar 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
Section and reinforcement of the outer panel of the 'A' pillar
Half door hinge — removal and installation
Lower trim panel (3-door)
Lower trim panel (5-door)
Lower Trim Panel Section (5-Door)
Front section of lower trim panel (3-door)
Front section of lower trim panel (5-door)
Rear section of the lower trim panel (5-door)
B-Pillar and Reinforcement (3-Door)
B-Pillar and Reinforcement (5-Door)
Subframe and mounting system specifications
Cross member — removal and installation
Checking for body misalignment
Checking for misalignment of the lower part of the body (bottom)
Back elements
Left side panel of the rear body (4-door)
Left side panel of the rear body (station wagon)
Right side panel of the rear body (3-door)
Right side panel of the rear body (5-door)
Front section of rear quarter panel/side panel (3-door)
Rear left section of rear quarter panel/side panel (3-door)
Rear left section of rear quarter panel/side panel (5-door)
Rear right section of rear quarter panel/side panel (4-door)
Rear right section of rear quarter panel/side panel (estate)
Rear side interior panel (3-door)
Rear side interior panel (5-door)
Rear side interior panel and wheel arch (4-door)
Rear quarter panel interior and wheel arch (station wagon)
Inner rear section of rear quarter panel (3-door)
Inner rear section of rear side panel (4-door)
Inner rear section of rear quarter panel (station wagon)
Rear inner panel of the rear side part of the body (4-door)
Water Drain Panel (4-Door)
Water Drain Panel (5-Door)
Reinforcement of the water drain panel (5-door)
Water Drain Panel Reinforcement — Universal
Inner half of rear wheel arch (4-door)
Inner half of rear wheel arch — 5-door
Inner half of rear wheel arch (station wagon)
Half section of the rear outer wheel arch (station wagon)
Tail Light Mounting Panel (4-Door)
Rear Light Mounting Panel (Wagon)
Rear panel (5-door)
Rear panel (station wagon)
Rear panel and reinforcement (4-door)
Rear panel section (station wagon)
Rear panel and cross member (station wagon)
Rear floor panel (5-door)
Right section of rear floor panel (estate)
Rear Floor Panel Section (Wagon)
Rear Floor Panel Section (5-Door)
Spare wheel well (station wagon)
Rear side member section (5-door)
Rear side member section (station wagon)
Storage Shelf Panel (4-Door)
Trunk lid hinge (4-door)
Electrical equipment
Climate control
Climate control specifications
Description and operating principle of microclimate control
Diagnostics and checks (cars manufactured before 07.2001)
Pinpoint tests of microclimate control (cars up to 07.2001)
Diagnostics and checks (cars manufactured since 08.2001)
Pinpoint tests of microclimate control (cars from 08.2001)
Spring Lock Coupling
Adjusting the air gap of the air conditioning system clutch
Finding Leaks Using Fluorescent Dye
Electronic leak detection
Adding cooling oil
Handling contaminated refrigerant
Cleaning the air distribution system
Refrigerant recovery, vacuuming and refilling of air conditioning systems
Air distribution and purification
Air Conditioning Specifications
Description and operating principle of air conditioning
Air conditioning compressor — removal and installation
Air conditioning compressor (1.6L) — removal and installation
Clutch and electromagnetic clutch coil
Evaporator jet — removal and installation
Suction tank — removal and installation
Low pressure relay — removal and installation
Condenser (refrigerator) core — removal and installation
High pressure relay — removal and installation
Description and operating principle of controls
Microclimate control assemblies — removal and installation
Microclimate control units in assembly (automatic) — removal and installation
Intake air mixing flap drive
Air distribution control cable block
Heating and ventilation
Tightening torque specification
Description and principle of operation
Blower 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 operating principle of additional heating
Diagnostics and testing of additional heating
Pinpoint tests of additional heating
Diagnostics and testing of electric additional heater
Pinpoint tests of electric auxiliary heater
Additional fuel-fired heater — removal and installation
Additional heater — disassembly and assembly
Instruments and control lamps
Instrument panel and dashboard lighting
Diagnostics and testing of the instrument panel
Pinpoint tests of the instrument cluster
Instrument cluster — description
Diagnostics and checks of the instrument panel
Pinpoint tests of the instrument cluster
Instrument cluster — removal and installation
Instrument cluster (Duratec ST 2.0 l) — removal and installation
Combination of oil pressure and oil temperature indicators (Duratec ST 2.0 l)
Sound signal
Diagnostics and testing of the sound signal
Pinpoint tests of the sound signal
Sound signal — removal and installation
Horn Switch — Removal and Installation
Watch — description and principle of operation
Watches — diagnostics and checks
Watch — Pinpoint tests
Watch — 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 tests
Warning Devices — Pinpoint Tests
Parking assistance
Parking assistance — diagnostics and checks (cars up to 10.2001)
Parking assistance — Pinpoint tests (vehicles up to 10.2001)
Parking assistance — diagnostics and checks (cars after 10.2001)
Parking assistance — Pinpoint tests (cars after 10.2001)
Battery and alternator
Charging system — description and operating principle
Charging system — diagnostics and checks
Charging System — Pinpoint Tests
Charging the battery
Battery and Wire Specifications
Battery and wires — description and operating principle
Battery diagnostics and testing
Disconnecting the battery
Battery — removal and installation
Battery shelf — removal and installation
Battery Cables — Removal and Installation
Battery shelf (1.6L Duratec)
Battery Cables (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 System Pinpoint Tests
Diagnostics and testing of the audio system without an amplifier
Pinpoint tests of audio system without 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
LHD Antenna Cable — 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 operating principle
Headlights (cars up to 08.2001) — diagnostics and checks
Headlights (cars up to 08.2001) — Pinpoint tests
Headlights (cars after 08.2001) — diagnostics and checks
Headlights (cars after 08.2001) — Pinpoint tests
Headlight leveling (before 08.2001) — diagnostics and checks
Headlight range correction (before 08.2001) — Pinpoint tests
Headlight aiming correction (after 08.2001) — diagnostics and checks
Headlight level correction (after 08.2001) — Pinpoint tests
Brake lights (cars before 08.2001) — diagnostics and checks
Brake Lights (vehicles up to 08.2001) — Pinpoint Tests
Brake lights (cars after 08.2001) — diagnostics and checks
Brake Lights (Cars after 08.2001) — Pinpoint Tests
Direction indicators (vehicles up to 08.2001) — diagnostics and checks
Direction indicators (vehicles up to 08.2001) — Pinpoint tests
Direction indicators (cars after 08.2001) — diagnostics and checks
Direction indicators (cars 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 (cars after 08.2001) — diagnostics and checks
Parking lights (cars after 08.2001) — Pinpoint tests
Fog lights (cars up to 08.2001) — diagnostics and checks
Fog lights (vehicles up to 08.2001) — Pinpoint tests
Fog lights (cars after 08.2001) — diagnostics and checks
Fog lights (cars 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 (cars after 08.2001) — diagnostics and checks
Reversing lights (cars after 08.2001) — Pinpoint tests
Headlight adjustment
Headlight adjustment — The vehicle comes with: headlights
Headlight support bracket repair
Covering headlight areas
Covering headlight sections (cars manufactured before 10.2001)
Covering headlight sections (cars manufactured after 10.2001)
Adjusting the front fog lights
Front high beam headlight bulb
Low beam headlight bulb
Headlight assembly — removal and installation
Light switch — removal and installation
Headlight leveling sensor — removal and installation
Headlight leveling motor (vehicles up to 10.2001)
Headlight leveling motor (vehicles after 10.2001)
Front fog light
Interior lighting
Interior Lighting — Diagnostics and Checks
Interior Lighting — Pinpoint Tests
Daytime running lights (vehicles before 08.2001)
Daytime running lights (vehicles up to 08.2001) — Pinpoint tests
Daytime running lights (cars after 08.2001)
Daytime running lights (cars after 08.2001) — Pinpoint tests
Power distribution
Communication network (vehicles up to 08.2001)
Communication network (cars after 08.2001)
Communication network (vehicles up to 08.2001) — diagnostics and checks
Communication network (vehicles before 08.2001) — Pinpoint tests
Communication network (cars after 08.2001) — diagnostics and checks
Communication network (cars after 08.2001) — Pinpoint tests
Configuration of modules
Electronic Function Group
Active anti-theft system
Active Anti-Theft System — Diagnostics and Tests
Active Anti-Theft System — Pinpoint Tests
Passive anti-theft system
Passive Anti-Theft System — Diagnostics and Tests
Passive Anti-Theft System — Pinpoint Tests
Passive anti-theft system transceiver
Telematics — description and operating principle
Telematics — diagnostics and testing
Telematics — Pinpoint tests
Global Positioning System (GPS) Antenna
Worldwide Mobile Communication System (GSM)Antenna
Cell phone — description and operating principle
Cell phone — diagnostics and checks
Cell Phone — Pinpoint Tests
Cell Phone Antenna — Removal and Installation
Telephone handset bracket — removal and installation
Functions controlled by the module (vehicles up to 08.2001)
Functions controlled by the module (cars after 08.2001)
Central Timer Module — Diagnostics and Tests
Multifunctional electronic module (cars after 08.2001)
General 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
Presentation of the car model
At a glance — an overview of Focus models
Engine specifications
Overall dimensions of the car
Improving Ford Focus 1 models
Workplace equipment
Timely purchase of spare parts
Tools required for work
Special purpose tools make work easier
Professional tips for the amateur mechanic
Tips for visiting the workshop
Safety precautions during repair work
Car lifting jack
How to lift a car safely
Technical characteristics of the car
Car care
Regular car maintenance
Special care products for interior cleaning
Car wash in front of the house door
Car engine wash
Lubrication of hinges and locks
Regular care of varnish
Severe damage to the paintwork reduces the value of the car
Polishing makes small scratches invisible
This is how larger scratches disappear
Windscreen washer system
Filling with windshield washer fluid
Replacing the rubber wiper pad
Adjusting the sprinkler nozzles
Removing the windshield washer nozzle
Removing the windshield wiper arm
Removing the front wiper motor
Removing the rear wiper motor
Help with windshield wiper problems
Power unit
Engine repair
Description of engine design
Engine repair in a workshop or do it yourself?
Description of the main engine components
Basic concepts of engine building
Setting the piston of the first cylinder to the TDC position of the compression stroke
Spark plugs
Over-revving and engine durability
Measuring compression pressure
Compression pressure decreases
Checking the V-belt
Installation of V-belt
Timing belt and camshaft
Diagnostics — knocking in the engine compartment
Help with cylinder head gasket problems
Lubrication system
Description of the design of the engine lubrication system
New oil filter at every oil change
Lubrication system pressure
Motor oil is a liquid with many talents
Concepts of standards on the topic of oil
Absolutely normal — low oil consumption
Don't forget to measure the oil level regularly
Always change the engine oil and oil filter at the same time
Help with ignition system malfunctions
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
Replacing the coolant
Resist winter — protection from frost down to -30°C
Help with cooling system and thermostat problems
The engine is losing coolant
Removing and checking the thermostat
The engine «boils» — a faulty radiator fan
Removing the radiator fan
Removing 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 fuel injection system design
General overview — EEC-V injection system control
In detail — EEC-V injection system control
Invisible assistants – new assistants of the EEC-V injection system
Diagnostics and communication equipment of the EEC-V injection system
Visual inspection of the injection system
Help with petrol injection system faults
Uncertainty in the operation of the on-board computer — secondary air
Checking the idle speed
Blocking of idle speed oscillations by the system
Checking the idle servo motor
Checking injection valves
Replacing the throttle cable
Fuel injection (diesel)
Diesel Fuel Supply System — Basic Design
Excess fuel is returned to the fuel tank
Fuel Delivery Path — This is how fuel gets to the injector
Significantly increased hydraulic efficiency — VP 30 injection pump
Pulse sensor wheel and angle sensor
Equipment for starting a cold diesel engine
Injectors — Diesel fuel atomization
Repair and correction of the injection system in a diesel engine
Disassembling injectors
Visual inspection of the diesel engine injection system
Help with diesel injection system faults
Ignition system
Description of the ignition system design
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
Replace spark plugs at least every 60,000 km
Help with ignition system malfunctions
Ignition off
Checking the RPM sensor with a multimeter
Checking the pressure sensor
Ignition current measurement
Measuring the resistance of the ignition coil
Removing the ignition module
Diesel pre-heating system
Checking the pre-heating 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 fuel tank ventilation
Replacing the fuel filter (petrol engine)
Replacing the fuel filter (diesel engine)
Draining fuel from the fuel tank using a hand pump
Dismantling of pipelines and hoses
Troubleshooting a Fuel Pump
Removing the fuel pump (petrol engine)
Description of the exhaust system design
Tips for working on the exhaust system
Checking the exhaust system
Replacement of the exhaust system, including the catalytic converter
Concepts related to exhaust gases
Reducing toxicity of exhaust gases
Transmission
Clutch and drive shafts
Description of the clutch design
Clutch and its components
This is how the clutch works
Checking the clutch
Does the clutch disengage completely?
Driving with leaky clutch hydraulics
Help with clutch problems
Main gear — design description
Main gear and drive shafts
Checking the drive shaft seals
If the drive shaft makes noise
Dismantling and installation of the drive shaft
Replacing the drive joint cuff
Mechanical gearbox
IB5 Gearbox Shift Control
Gearbox shift control MTX-75
General information about the gearbox
Five-speed manual transmission
This is how a manual transmission works
Gear shift adjustment
Checking the transmission oil level
Noises in the gearbox
Automatic gearbox
Description of the design of the automatic transmission
Transmission controls
Automatic transmission repair is not a job for amateurs
Adjusting the selector lever cable
Mechanical release of the selector lever lock
Checking the transmission oil level
Features of handling the automatic transmission 4F27E
Chassis
Car suspension
General information about the suspension
Front suspension units
Rear suspension units
Amateur work on the chassis and steering
Checking shock absorbers
Telescopic shock absorber — design description
Checking the bearings of the wishbones of the independent suspension
Checking the wheel bearing clearance
Replacing the wishbone (front)
Replacing the shock absorber strut
Replacing rear shock absorbers
Steering
Steering and driving safety are linked
Steering Geometry Concepts
Control factor — front axle geometry
Regularly check the steering free play
Checking the toothed rack protective cuffs
Checking the heads and seals of the tie rod
Replacing the tie rod ends
Replacing the steering gear cuffs
Replacing the steering swivel support
Airbag — a job for real professionals
Steering column design
Servo control — general information
Wheels and tires
Tires and Rims — General Information
Wheels and tires — sizes
Key characteristics of tires
Winter tires — professionals in any weather
Practical tips for saving tires
Checking tire pressure
Wheel replacement
Checking the condition of the tires
What the type of tread can tell you
Proper storage of wheels
Brake system
General information about the braking system
Description of the brake system design
Main components of the braking 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 operation of the brakes
Measuring wear on disc brake linings
Brake pedal and brake pad
Checking brake disc wear
Help with brake system problems
Bleeding the brake system
Brake fluid — general information
Replacing brake fluid
Removing the expansion tank from the brake master cylinder
Removing the master brake cylinder
Removing the brake booster
Removing brake hoses
Replacing brake disc linings
Removing brake discs
Restoring the mobility of the brake caliper and piston
Replacing the rear axle mudguard
Handbrake — General Information
Replacing handbrake cables
Adjusting the handbrake
Body
Exterior
General information about the car body
Door dismantling
Installing a door
Removing the external viewing mirror
Removing the fairing
Removing the hood
Installing the hood
Removing the hood lock
Removing the front bumper
Wing dismantling
Removing the rear bumper (3-, 4-, 5-door models)
Removing the back cover
Removing the lock in the back cover
Interior
General information about the car interior
Switches in the car interior
Ignition key coding
Controls — General Information
Replacement of interior lights
Checking the door contact switch
Replacement of trunk light
Dismantling the radio receiver
Removing the speaker
Removing the roof antenna
Removing the seats
Checking seat belts
Removing door trim
Removing the side window regulator (front)
The electric window does not work
Central locking — general information
Removing the door handle
Removing the ignition lock drum
Help with power window problems
Help with central locking problems
Belt tensioner and independent work
Heating and ventilation
General information about heating and ventilation
Periodic check of heating and ventilation
Help with heating system malfunctions
Removing the heating and ventilation control module
Air blower — general information
Troubleshooting the Air Blower
Replacing the air blower motor
Dismantling the heating/AC control unit
Removing the air circulation flap servomotor
Removing the cables on the air distributor
Electrical equipment
Equipment and devices
Wiring Harness Overview
General information about on-board electrical equipment
Basic concepts of electrical engineering
Measuring voltage, current and resistance
Instruments and controls
Checking the instruments in the instrument panel self-diagnostic module
Checking the operation of switches
Dismantling the combination instrument
Intertwined wire paths are not always traceable
Fuses in the passenger compartment and engine compartment
Fuses are replaced quickly
Switching relays distribute high operating currents
Location of fuses and relays
Lighting and signaling
External lighting equipment
Adjusting the light range
Replacing headlight bulbs
Replacing bulbs in fog lights
Replacing the bulbs in the front turn signals
Replacing side turn signal bulbs
Replacing the bulbs in the rear lights (hatchback)
Replacing the bulbs in the reversing light and fog light
Replacing the bulbs in the rear lights (with a stepped rear section)
Replacing the bulbs in the rear lights (Turnier)
Replacing the spotlight bulb in the license plate light
Replacing bulbs in additional brake light (hatchback)
Replacing the bulbs in the additional brake light (sedan)
Replacing interior lighting bulbs
Temporary headlight adjustment
Signaling equipment
Help with alarm malfunctions
Dismounting the alarm horn of the beep
Power devices
Order «Order on batteries»
Battery — design description
Battery — concepts and standards
Starter with reciprocating screw drive
Generator — General Information
Checking the acid level in the battery
Caring for battery contacts
Checking the battery
Jump starting the engine from another car's battery
Pushing the car to start the engine
Towing a car to jump start the engine
Help with battery and generator problems
Charging the battery
Removing the battery
Hidden power consumers drain battery
Checking the voltage regulator
Driving with a faulty alternator
Replacing the V-belt
Replacing the V-belt tension roller
Dismantling the generator
Removing the starter
Help with starter problems
Electrical circuits
Structure of switching circuits
Engine cooling ZETEC-SE with air conditioning
Engine cooling ZETEC-E with air conditioning
Endura-DI engine cooling with climate control
ZETEC-SE starting system with automatic transmission
ZETEC-SE starting system with manual transmission
ZETEC-E engine starting system
Endura-DI Engine Starting System
ZETEC-SE engine ignition system
ZETEC-E engine ignition system
Endura-Dl Engine Ignition System
Windscreen wipers and washer system with rear window wiper
Windscreen wipers and washer system with heated windscreen sprayers
Clock / time measurement
External lighting equipment, headlight adjustment
External lighting equipment, manual transmission...
Turnier exterior lighting equipment, marker lights...
External lighting equipment without daylight lamps...
External lighting equipment, fog lights...
Horn of sound signal
LHD Speaker Wiring Diagram
Generator and regulator, ZETEC engines
Generator and regulator, Endura-Dl engines
Ford Focus 2
General information
Vehicle device
General information about the car
Passport details
Car keys
Instrument panel
Instrument cluster
Heating (air conditioning) and ventilation of the passenger compartment
Door locks
Door window lifters
Seat belts
Adjusting the position of the front seats
Back seat
Using child seats
Adjusting the position of the steering wheel
Rear view mirrors
Interior lighting
Sun visors
Interior storage compartments
Opening the hood
Gearbox control
Roof rack
Owner's manual
Safety regulations
Operating recommendations
Traffic safety recommendations
What you need to have in your car for everyday use
What you need to have in your car when going on a long journey
Running in a car
Operation of the vehicle during the warranty period
Preparing the car for departure
Filling up a car with petrol
Using a jack
Towing a car
How to prepare your car for winter
Recommendations for starting the engine in severe frost
What is useful to buy for winter
Useful winter tips
Recommendations for preparation for technical inspection
List of faults and conditions under which operation of vehicles is prohibited
Changes to state standards for permissible content of harmful substances
Faults en route
General techniques for starting an engine
Malfunctions in the starting system
Checking the ignition system
Checking the engine fuel system
Fuel injection system faults
Idle speed is gone
Engine misfires
Diagnosis of engine condition by the appearance of spark plugs
The car moves in jerks
A jerk at the start of movement
Jerks during acceleration
Jerks during steady motion
The car accelerates poorly
The engine stalled while driving
Oil pressure dropped
Checking the lubrication system
Engine overheating
Checking the cooling system
The battery is not recharging
Checking electrical equipment
Starting the engine from external power sources
Electrical equipment faults
There was a knocking noise in the engine
Knocking in suspension and transmission
Possible causes of knocking in the suspension and ways to eliminate them
Possible transmission knocks (noises), their causes and methods of elimination
Vibration and shock on the steering wheel
Possible causes of vibrations and shocks on the steering wheel and ways to eliminate them
Brake problems
Bleeding the brake system
Checking the brake system
Tire puncture
Wheel replacement
Maintenance
General Provisions for Maintenance
Safety rules for maintenance
Checking the wheels
Checking the level and adding oil to the lubrication system
Checking the level and adding coolant
Checking the level and topping up the brake fluid
Checking the level and adding working fluid to the power steering reservoir
Checking the level and adding fluid to the washer reservoir
Checking external lighting fixtures
Trip to the service station
First maintenance
Checking the accessory drive belt
Checking the air conditioning compressor drive belt
Checking the timing belt
Changing engine oil and oil filter
Cleaning the crankcase ventilation system
Checking the cooling system hoses and connections
Checking the exhaust system
Checking the tightness of fuel lines
Checking and replacing the air filter element
Checking the level and adding oil to the gearbox
Checking the front wheel drive protective covers
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 angles
Inspection and testing of the steering system on the vehicle
Checking the free play (play) of the steering wheel
Checking the tightness of the hydraulic brake drive
Checking the degree of wear of brake pads, discs and drums
Checking the operation of the brake booster
Checking the efficiency of the braking system
Checking the parking brake
Battery Maintenance
Checking and adjusting headlights
Lubrication of body fittings
Cleaning drainage holes
Second maintenance
Replacement and maintenance of spark plugs
Replacement of auxiliary drive belt
Replacing the air conditioning compressor drive belt
Replacing the timing belt
Replacing brake fluid in hydraulic brake and clutch release systems
Replacing the coolant
Applications
Tightening torques for threaded connections
Overall dimensions (mm) of Ford Focus II cars
Technical characteristics of engines and performance indicators of cars
Cold Tire Pressure
Filling volumes
Consumables and spare parts
Motor oil
Plastic lubricants
Cooling fluids
Brake fluid
Fine fuel filter
Air filter
Engine lubrication system oil filter
Auto mechanic tips
General safety requirements
Safe car lifting
Basic set of tools
Special tools and devices
Before you start working
Unscrewing rusty threaded connections
Unscrewing damaged nuts
Hexagon socket or hexagon head bolts
Removing self-tapping screws with straight and Phillips slots
Drilling out a broken bolt
Thread cutting
Auto Body Repair Tips
Power unit
Engine repair
Engine design features
Possible engine malfunctions, their causes and solutions
Useful tips about the engine
Checking the compression in the cylinders
Removing and installing the engine mudguard
Replacing the right powertrain suspension support
Replacing the left support of the powertrain suspension
Replacing the rear support of the powertrain suspension
Setting the piston of the first cylinder to the TDC position of the compression stroke
Removal, installation and inspection of the flywheel
Adjusting valve clearances
Replacing camshafts
Grinding of cylinder head valves
Removing and installing the engine
Features of the lubrication system design
Removing and installing the oil pump
Engine seal parts
Replacing the cylinder head cover gasket
Replacing the cylinder head gasket
Replacing valve stem seals
Replacing camshaft seals
Replacing crankshaft seals
Replacing the oil pan seal
Replacing the intake manifold gasket
Replacing the catalytic converter gasket
Cooling system
Design features of the cooling system
Possible malfunctions of the cooling system, their causes and methods of elimination
Replacing the cooling system radiator
Removal and installation of the electric fan of the radiator of the engine cooling system in assembly with the casing
Removing and installing the expansion tank
Replacing the water pump
Replacing the thermostat
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 system
Replacing the exhaust system suspension cushions
Replacing the main and additional mufflers
Removal, installation of the catalytic converter and replacement of its gasket
Removal and installation of thermal screens
Supply system
Features of the power supply system design
Checking the fuel pressure in the fuel system
Reducing pressure in the fuel system
Removing and installing the air filter and intake noise muffler
Removing and installing the fuel pump
Replacing the fuel tank and its filler pipe
Replacing the fuel pressure pulsation compensator
Removing and installing the fuel rail
Removal, inspection and installation of injectors
Removing and installing the throttle assembly
Removing and installing the throttle pedal
Features of the fuel vapor recovery system
Replacing the fuel vapor recovery system canister
Clutch
Clutch design features
Possible clutch malfunctions, their causes and solutions
Checking the Clutch Release Pedal Travel
Removing and installing the clutch
Replacing the clutch release drive slave cylinder with the clutch release bearing
Replacing the clutch release master cylinder
Replacing the clutch release hydraulic line
Removing and installing the clutch pedal
Bleeding the clutch release hydraulic drive
Car gearbox
Gearbox design features
Possible malfunctions of a manual gearbox, their causes and methods of elimination
Gearbox oil change
Replacing gearbox seals
Removing and installing the gearbox
Replacing gearbox control cables
Removing and installing the gearbox control lever linkage
Adjusting the gearbox control drive
Front wheel drives
Design features of front wheel drives
Possible faults of front wheel drives, their causes and methods of elimination
Removing and installing front wheel drives
Replacement of constant velocity joints
Replacing the intermediate support bearing
Chassis
Front suspension
Features of the front suspension design
Possible faults of the front suspension, their causes and methods of elimination
Removing and installing the shock absorber strut
Shock absorber strut repair
Replacing the upper shock absorber strut support
Replacing the ball joint
Replacing the front suspension arm
Replacing the front suspension stabilizer bar components
Removing and installing the steering knuckle
Replacing the front hub bearing
Removing and installing the front suspension crossmember
Rear suspension
Features of the rear suspension design
Possible malfunctions of the rear suspension, their causes and methods of elimination
Replacing the rear shock absorber
Replacing the rear suspension spring
Replacing the upper arm of the rear suspension
Replacing the front lower control arm of the rear suspension
Replacing the rear lower control arm of the rear suspension
Replacing the rear suspension trailing arm
Replacing the rear suspension stabilizer bar components
Removing and installing the rear hub
Removing and installing the rear suspension crossmember
Steering
Features of the steering design
Possible malfunctions of the power steering
Removing and installing the steering column cover
Removing and installing the steering wheel
Removing and installing the steering column
Replacing the outer tie rod end
Bleeding the power steering system
Replacing the power steering fluid reservoir
Replacing the steering gear
Replacing the power steering pump
Brake system
Features of the brake system
Possible malfunctions of the brake system, their causes and methods of elimination
Bleeding the hydraulic brake system
Checking the brake pedal position
Replacing the brake master cylinder reservoir
Replacing the master brake cylinder
Replacing pressure regulators
Replacing the vacuum booster
Replacing brake hoses
Replacing brake pipes
Removing and installing the brake pedal
Replacing the brake pads of the front wheel brake mechanism
Replacing the caliper assembly with the pad guide
Replacing the brake disc
Removing and installing the brake drum
Replacing the brake pads of the rear wheel brake mechanism
Replacing the rear wheel brake slave cylinder
Adjusting the parking brake drive
Replacing the front parking brake cable
Replacing the rear parking brake cables
Removing and installing the parking brake lever
Replacing wheel speed sensors
Wheels and tires
Technical specifications
Wheel rim markings
Tire markings
Wheel replacement
Wheel nuts
Tire running-in
Tire storage
Wheel balancing
Anti-skid chains
Spare wheel
Checking tire pressure
Checking the tire tread
Checking the valve
Checking the radial and lateral runout of the discs
Body and coating
Body elements
Features of the body design
Possible body malfunctions, their causes and methods of elimination
Removing and installing the radiator grille
Removing and installing wheel mudguards and fender liners
Removing and installing the front bumper
Removal, disassembly and installation of the rear bumper
Removing and installing the front wing
Removing and installing the engine compartment frame and the front bumper beam
Removing and installing the air intake box grille and water drain shield
Removing and installing the hood
Removal, installation and adjustment of the hood lock and its drive
Removing and installing the fuel tank filler pipe hatch cover
Removing and installing the fuel tank filler pipe hatch lock
Replacement of fixed body glazing
Removing and installing the battery mounting shelf
Side doors
Removing and installing the front door trim
Front door glass replacement
Replacing the front door window regulator
Replacing the outside handle and front door lock switch
Replacing the inner handle of the front door lock drive
Replacing the front door lock
Replacing the front door opening limiter
Removing and installing the front door
Removing and installing the rear door trim
Rear door glass replacement
Replacing the rear door window regulator
Replacing the outer rear door handle
Replacing the inner handle of the rear door lock actuator
Replacing the rear door lock
Replacing the rear door opening limiter
Removing and installing the rear door
Tailgate
Replacing the tailgate stops
Removing and installing the rear door trim
Removing and installing the decorative trim on the tailgate
Removing and installing the rear door spoiler
Replacement of the lock, latch and button for opening the rear door lock
Removing and installing the tailgate
Salon elements
Removing and installing the front seat
Removing and installing the rear seat
Removing and installing the floor tunnel lining
Removing and installing the outside mirror
Removing and installing the interior mirror
Instrument panel design
Removing and installing the instrument panel
Features of the heater and air conditioner
Removal and installation of the control unit for the heating (air conditioning) and ventilation system
Removing and installing the incoming air filter
Replacing handrails
Replacing sun visors
Removal and installation of interior trim
Removing and installing trunk trims
Safety system
Design features of the passive safety system
Removing and installing 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
Windshield wiper blade replacement
Replacing windshield wiper arms
Removal and installation of windshield wiper linkage assembly with gear motor
Replacing the rear window wiper blade
Replacing the rear window wiper arm
Windscreen wiper motor gearbox replacement
Replacement of the rear window wiper motor
Removing and installing the windshield washer
Body Care
Car wash
Polishing of paintwork
Engine wash
Anti-corrosion protection of the body
Preparation and anti-corrosion treatment of hidden cavities of the body
Body sealing
Care of interior trim panels made of polymeric materials
Caring for upholstery and carpets
Electrical equipment
Instruments and motors
Features of the design of electrical equipment
Diagnostics of faults of on-board electrical equipment
Replacing the front door window lift motor
Removing and installing the heater electric motor
Replacing the additional resistance of the heater electric fan
Electric heating of the rear window glass (rear door)
Replacement of the control unit for electric windows and electric mirrors
Location of fuses and relays and their replacement
Removal and installation of mounting blocks
Features of the instrument cluster design
Removing and installing the instrument cluster
Battery and alternator
Battery design features
Possible battery malfunctions, their causes and solutions
Removing and installing the battery
Charging the battery
Design Features of the Generator
Possible generator malfunctions, their causes and methods of elimination
Removing and installing the generator
Replacing the generator pulley
Features of the starter design
Possible starter malfunctions, their causes and solutions
Removing and installing the starter
Starter repair
Egnition lock
Features of the ignition switch design
Checking the ignition switch (lock)
Replacing the ignition switch (lock) contact group
Replacing the ignition switch cylinder
Removing and installing the ignition switch (lock)
Engine management
Design features of the engine management system
Possible malfunctions of the engine management system, their causes and methods of elimination
Checking the ignition coil
Removing and installing the ignition coil
Removal and installation of the electronic engine control unit
Checking and replacing engine management system sensors
Headlights and lighting
Features of lighting design
Replacing lamps
Headlight replacement
Replacing the headlight beam corrector
Replacing the side turn signal light
Replacing the rear light
Replacing the reverse light
Replacing the fog light
Replacing an additional brake light
Replacing license plate lights
Replacement of interior light
Replacement of the trunk light
Replacing steering column switches
Removing and installing the horn
Switches and sensors
Replacing the external lighting control unit
Replacing the instrument panel switches
Replacing the hazard warning switch
Removing and installing the antenna
Replacing the oil pressure warning light sensor
Checking and replacing the fuel level indicator sensor
Replacing the pressure sensor in the power steering system
Checking and replacing the reverse light switch
Replacing the brake light switch
Replacing Cruise Control Switches
Replacing the Parking Brake Indicator Light Switch
Emergency fuel shut-off button
Schematic diagrams
Diagram 1. Windscreen wiper and washer connections
Scheme 2. Connections of the battery charging system
Scheme 3. Connections of the hydraulic drive system of the brake system
Scheme 4. Connections of ventilation, heating and air conditioning systems
Scheme 5. Connections of the engine starting system
Diagram 6a. Speed control system connections
Scheme 6b. Speed control system connections
Diagram 7a. Engine management system connections
Scheme 7b. Engine control system connections
Scheme 7v. Engine management system connections
Scheme 7g. Engine control system connections
Scheme 7d. Engine control system connections
Scheme 7e. Engine management system connections
Scheme 7zh. Engine control system connections
Diagram 8a. Air conditioning system connections
Scheme 8b. Air conditioning system connections
Diagram 9. Power steering system connections
Diagram 10a. Anti-lock braking system (ABS) connections
Scheme 10b. Anti-lock braking system (ABS) connections
Scheme 11. Connections of the vehicle dynamic stabilization system
Ford Mondeo 1
General information
Car care
Car wash
Care of varnish coating
Anti-corrosion protection of the underbody and preservation of vehicle cavities
Caring for upholstery in the car interior
Starting the engine from an auxiliary battery
Towing a car
Features of towing cars with automatic transmission
Starting the engine by towing
Lifting a car
Car Repair Tools
Maintenance
Vehicle maintenance plan
Resetting the service interval indicator
General information about maintenance
Engine and exhaust system
Engine oil change
Visual inspection for oil leaks
Checking the engine oil level
Checking the coolant level
Visual inspection of the cooling system for leaks
Antifreeze check
Diesel engine: checking and adjusting valve clearances
Replacing spark plugs and checking electrical components
Replacing the air filter insert
Replacing the fuel filter
Checking and replacing the V-belt and toothed belt
Diesel: Tightening the turbocharger and intake manifold bolts
Diesel Engine: Replacing CVT Filter
Replacing the pulse air filter
Visual inspection of the exhaust system
Clutch, gearbox and final drive
Visual inspection of transmission tightness
Checking the rubber seal of the cardan shaft
Automatic transmission: checking the oil level
Adjusting the clutch rod
Brakes, tires and wheels
Checking the brake fluid level
Checking the thickness of brake pads
Visual inspection of brake lines
Replacing brake fluid
Checking the tread depth of your tires
Checking the air pressure in the tires
Checking the tire valve
Steering and front axle
Checking the dust caps of the steering rods and axle joints
Checking the axle joint clearance
Checking the tie rod bellows
Checking the steering clearance
Checking the Power Steering Oil Level
Electrical equipment system
Checking the battery
Car body and interior
Troubleshooting
Engine fault diagnostics
Diagnosing faults in the oil circulation system
Diagnostics of faults in the engine cooling system
Diagnostics of faults of the petrol injection system
Diesel Fuel Injection System Fault Diagnosis Table
Diagnosing Clutch Faults
Diagnostics of brake system faults
Diagnosis of tire faults
Diagnostics of interior heating faults
Diagnostics of faults in the battery
Generator fault diagnostics
Starter fault diagnostics
Diagnosing Windscreen Wiper Blade Faults
Power unit
Engine repair
General information on engine repair
The most important technical characteristics of engines
DOHC Gasoline Engine — Design Description
OHC turbocharged diesel engine
Removing and installing the engine
Removing, installing and tensioning the timing belt (petrol)
Removing and installing camshafts (petrol)
Removing and installing the cylinder head, replacing the seal
Toothed Belt Drive — Diesel Engine
Removing and installing a toothed belt (diesel)
Adjusting the valve timing mechanism, tensioning the toothed belt (diesel)
Removing and installing the cylinder head (diesel)
Removing and installing a vacuum pump (diesel)
Camshaft/valve drive in a diesel engine
Removing and installing the camshaft
Removing and installing valves
Replacing the valve stem seals
Checking the valve guides
Lapping valve seats
Checking and adjusting valve clearances (diesel)
Checking the compression in the cylinders
Removing, installing and tensioning the V-belt
Cooling and lubrication system
Engine lubrication system — general information
Oil circulation circuit
Checking oil pressure
Checking the hydraulic switch
Removing and installing the oil pan
Coolant circuit
Antifreeze poured into the radiator
Replacing the coolant
Checking the cooling system for leaks
Removing, installing and checking the thermostat
Checking the thermal switch (diesel)
Removing and installing the fan motor
Removing and installing the radiator
Removing and installing the coolant pump
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 sensor
Adjustment to fuel quality
Spark plugs — general information
Spark plugs for Ford Mondeo
Fuel/exhaust systems
General information about the fuel system
Cleanliness requirements when working with the fuel system
Fuel quantity sensor, fuel pump removal and installation
Removing and installing the fuel tank
Removing the fuel tank in a four-wheel drive model
Replacing the fuel pump safety switch
Removing and installing the fuel injection system relay
Removing and installing the air filter and intake pipe
Removing and installing the gas rod
Adjusting the gas thrust
Exhaust gas exhaust system
Functions of the exhaust system catalyst
Handling vehicles equipped with catalytic converters
Removal and installation of the exhaust system
Removing and installing an additional muffler
Fuel injection (gasoline)
Schematic representation of the fuel injection system
Engine operation regulation
Auto diagnostics of ignition and fuel injection systems
Checking the jets
Removing and installing jets and fuel pressure regulator
System troubleshooting for ignition and fuel injection systems
Fuel injection (diesel)
Schematic representation of the diesel fuel injection system
How a diesel engine works
Measures to improve the composition of exhaust gases
Exhaust gas turbocharger
Driving in winter with a diesel engine
Removing air from the fuel system
Preheating system/removal and installation of glow plugs
Removing and installing jets
Checking, removing and installing an electrical disconnect device
Checking and adjusting the idle speed
Brake booster vacuum and EGR hoses
Transmission
Clutch and drive shafts
Clutch — design description
Removal, installation and testing of the clutch
Removing, installing and checking the clutch release bearing
Checking the clutch
Clutch adjustment
Drive shafts — design description
Removing and installing drive shafts
Removing and installing cardan shaft seals
Car gearbox
Removing and installing the gearbox
Adjusting the gear shift drive
Automatic transmission
Adjusting the mode selector lever cable
All-wheel drive vehicles
Filling and replacing transmission oil
Chassis
Suspension
Front Axle — Design Description
Removing and installing the front shock absorber strut
Front shock absorber strut
Disassembling the front shock absorber strut
Checking and disposing of the front shock absorber
Removing and installing the front suspension wishbones
Removing and installing the steering knuckle
Front wheel hub bearing
Rear Axle — Design Description
Rear Axle Suspension — Design Description
Removing and installing the rear shock absorber strut
Disassembling the rear shock absorber strut, shock absorber
Rear axle of the Mondeo Turnier
Wheel alignment angles
Steering
Steering — design description
Removing and installing the steering wheel
Adjusting the steering wheel position
Removing and installing the steering rod end
Removing and installing rubber steering cuffs
Removing and installing the power steering pump
Bleeding the hydraulic steering system
Brake system
General information about the braking system
Technical characteristics of the brake system
Removing and installing front brake pads
Checking the thickness of the brake disc
Removing and installing the front brake disc
Removing and installing rear disc brake pads
Removing and installing the rear brake caliper and bracket
Removing and installing the rear brake disc
Removing and installing the rear brake drum and brake shoes
Removing and installing the wheel brake cylinder
Wheel brake cylinder repair
Brake fluid — description and safety precautions
Bleeding the brake system
Brake lines and brake hoses
Replacing the brake pipe and brake hose
Checking the brake booster and vacuum line
Parking brake — design description
Removing and installing the parking brake lever
Removing and installing the brake light switch
Anti-lock braking system (ABS)
Traction Control System (TCS)
Wheels and tires
General information about wheels and tires
Wheel and tire size, tire pressure
Wheel designation
Tyre designation
Wheel replacement
Rules for using tires
Anti-skid chains
Incorrect tire wear
Body
Exterior
General information about the car body
Removing and installing the front bumper
Removing and installing the rear bumper
Removing and installing the front mudguard
Removing and installing the radiator grille
Removing and installing the air grille
Removing and installing the outside mirror
Replacing moldings
Removing and installing the engine hood
Removing and installing the hood lock drive cable
Removing and installing the hood lock
Straightening and varnishing works
Repairing damage from rock strikes
Elimination of body deformation and removal of corrosion pits
Preparing the body for varnishing
The process of varnishing the car body
Interior
Removing and installing the roof trim
Removing and installing interior trim
Removing and installing the front seat
Removing and installing the rear seat
Removing and installing the rear seat back
Removing and installing the center console
Removing and installing the interior rearview mirror
Doors, locks and windows
Windshield
Removing and installing the door
Removing and installing the lock rod
Door paneling — design description
Removing and installing door trim
Removing and installing the outside door handle and door lock
Removing and installing the front door lock
Removing and installing the outer rear door handle
Removing and installing the door lock core
Removing and installing the inner door handle
Removing and installing door glass
Removing and installing the window regulator
Removing and installing the rear trunk lid
Removing and installing the trunk lid trim
Removing and installing the trunk lid
Removing and installing the trunk lid lock
Removing and installing the trunk lid lock core
Removing and installing the fuel tank hatch
Central lock — design description
Removing and installing the roof hatch
Heating system
Heating system — design description
Fan switch and temperature controller
Removing and installing the dust filter
Removing and installing the fan
Removing and installing additional heating resistance
Removing and installing the right ventilation nozzle
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
Measuring instruments
Measurement technique
Installation of additional electrical accessories
Detecting faults in electrical equipment
Checking switches for current flow
Checking the relay
Checking the windshield wiper motor
Checking the flashing light device
Checking the brake light
Checking the rear window defroster
Removing and installing the horn
Replacing fuses
Location of fuses and relays
Anti-theft alarm device
Removing and installing the instrument panel
Removal and installation of devices
Removing and installing the tachometer
Steering column switch, turn signal relay
Removing and installing the radio
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
Self-discharge of the battery
General information about the generator
Safety precautions when working with a generator
Removing and installing the generator
Checking the generator charging voltage
Replacement of generator carbon brushes, voltage regulator
General information about the starter
Checking, removing and installing the traction relay
Removing and installing the 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 light bulb
Replacing the engine compartment and glove box light bulb
Replacement of interior light bulb, reading light, trunk light
Headlight adjustment
Removing and installing headlights
Removing and installing headlight glass
Removing and installing fog lights, replacing the bulb
Removing and installing the rear light
Removing and installing the motor for adjusting the lighting range
Windshield wipers and washers
Replacing windshield wiper rubber
Removing, installing and adjusting the windshield washer nozzle
Windscreen washer reservoir, pump and fluid level sensor
Front windshield wiper — design description
Removing and installing the front wiper motor
Removing and installing the windshield wiper mechanism
Removing and installing the rear wiper motor
Electrical circuits
Instructions for using electrical diagrams
Description of the engine control system (with manual transmission)
Description of the central locking system (central lock)
Electrical diagram of headlights
Engine adjustment (with manual transmission)
Electrical diagram of brake lights
Fog lights and fog lamps
Flashing direction indicators
Electrical diagram of interior lighting
Glass cleaning and washing device
Heated windshield and rear window
Electrical heating circuit
Electrical diagram of seat heating
Electrical diagram of the cigarette lighter and clock
Electrical diagram of the sound signal
Ford Mondeo 1 and 2
General information
User guide
Running in a new car
Front panel
Instrument panel
Graphic display
Instrument panel switches and controls
Clock and trip computer
Heating and ventilation system
Air Conditioning Control
Cigarette lighter, ashtray and storage compartment
Steering column elements and steering column switches
Interior Light Control. Upper Sunroof
Parking Warning System
Controls on the doors
Equipment on the console
Luggage compartment
Keys and locks
Security alarm
Seat adjustment
Seat belts
The airbag
Features of engine starting
Traction control system
Self-adjusting rear suspension
Driving a car with automatic transmission
Roof rack
Limited control mode
Filling the fuel system
Fuel cut-off switch
Forced deactivation of parking mode
Vehicle data
Main dimensions and weights
Vehicle identification
General tips for carrying out repairs
Lifting a car with a jack
Tools and accessories
Checking the technical condition
Checks performed from the driver's seat
Checks performed on a vehicle standing on the ground
Checks on a raised vehicle with rotating wheels
Checking the exhaust system of a car
Repair on the road
Main types of danger during maintenance
If the engine does not start
Starting the engine from an auxiliary battery
Wheel replacement
Car stains and stains
Towing a car
Weekly checks
Check points under the hood
Engine oil level
Steering hydraulic fluid level
Brake and clutch fluid level
Washer fluid level
Coolant level
Windscreen wiper blades
Tire condition and pressure
Types of tire wear
Checking the battery
Light bulbs and fuses
Lubricants, fluids and tire pressure
Periodic maintenance
Technical Service Specification
Underhood space of a 4-cylinder engine
Engine compartment of a 6-cylinder engine
Bottom view from the front of the model with a 4-cylinder engine
Bottom front view of V-engine model
Bottom rear view of the Sedan and Hatchback models
Bottom rear view of the Station Wagon model
Periodic maintenance procedures
Engine oil and filter change
Maintenance and charging of the battery
Checking and replacing accessory drive belts
Checking the Automatic Transmission Fluid Level
Checking for fluid leaks and hose condition under the hood
Checking the engine compartment wiring
Checking the air conditioning system
Checking the oil level in a manual transmission
Checking the steering, suspension and wheels
Checking the rubber boots of the drive shafts and CV joints
Checking the exhaust system
Checking the bottom and pipeline of the brake and fuel systems
Checking the brake system
Checking the tightening of wheel nuts
Road test
Replacing the dust filter of the ventilation system
Replacing the air filter
Forced crankcase ventilation system
Automatic Transmission Fluid Replacement
Replacement of brake and coolant fluid
Replacing spark plugs on a 4-cylinder engine
Checking the expansion tank cap
Replacing the fuel filter
Replacing spark plugs on a 6-cylinder engine
Troubleshooting
Troubleshooting Tips
Engine malfunctions
Cooling system malfunctions
Malfunctions of the fuel and exhaust system
Clutch faults
Manual transmission faults
Automatic transmission faults
Drive shaft faults
Brake system malfunctions
Suspension and steering faults
Electrical system faults
Engine
4 cylinder engines
Technical requirements and tightening torques
General information about the engine
Repair operations performed without removing the engine
Compression check
Top dead center of cylinder #1
Removing and installing the cylinder head cover
Removing and installing the intake manifold
Removal, inspection and installation of the exhaust manifold
Removing and installing the crankshaft pulley
Timing belt covers of the timing mechanism
Timing belt of the timing mechanism
Timing Belt Tensioner and Toothed Pulleys
Replacing the camshaft seal
Camshafts and hydraulic valve lifters
Checking and adjusting valve clearances
Removing and installing the cylinder head
Removing and installing the pallet
Removal, inspection and installation of the oil pump
Removing and installing an oil radiator
Removing and installing the oil level sensor
Oil pressure indicator sensor
Replacing the crankshaft seal
Removing and installing the flywheel/faceplate
Inspection and replacement of engine and transmission mounts
6 cylinder engines
Technical requirements and tightening torques
General information about the engine
Repair operations performed without removing the engine
Compression check
Upper dead center of cylinder No. 1
Removing and installing the cylinder head cover
Removing and installing the intake manifold
Removing and installing the exhaust manifold
Removing and installing the crankshaft pulley
Timing mechanism cover (TMC)
Removing and installing the timing chain
Replacing the camshaft seal
Camshafts, hydraulic valve lifters and rocker arms
Removing and installing the cylinder head
Removing and installing the pallet
Removal, inspection and installation of the oil pump
Removing and installing an oil radiator
Oil pressure indicator sensor
Replacing the crankshaft seal
Removal, inspection and installation of flywheel/faceplate
Inspection and replacement of engine and transmission mounts
Removal and repair
Technical requirements of 4-cylinder engine
Technical requirements of 6-cylinder engine
Using the information in this chapter
General information about engine repair
Methods of removing the power unit and precautions
Removal and installation of the power unit (4-cylinder)
Removal and installation of the power unit (6-cylinder)
Engine disassembly sequence
Disassembling the cylinder head
Cylinder head inspection and valve mechanism
Cylinder head assembly
Removing connecting rod and piston groups
Removing the crankshaft
Cleaning and inspection of the cylinder block/crankcase
Inspection of connecting rod and piston groups
Inspection of the crankshaft
Inspection of main and connecting rod bearings
Engine assembly sequence
Installing piston rings
Installation and control of crankshaft main bearing clearance
Installation and control of connecting rod bearing clearance
First launch after repair
Cooling system
Technical requirements and tightening torques
General information about cooling, heating and air conditioning
General information about antifreeze
Disconnecting and replacing cooling system hoses
Removing, checking and installing the thermostat
Removing and installing an electric radiator fan
Removing and installing cooling system sensors
Removing and installing the radiator and expansion tank
Removing and installing the cooling system pump
Removal and installation of heating/ventilation system components
Heater/Air Conditioning Control Units
Air conditioning system
Removal and installation of air conditioning system components
Fuel/exhaust systems
Technical requirements and tightening torques
General information and precautions
Relieving 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 the tilt valves
Removing and installing the fuel cut-off switch
Fuel injection system information
Checking and diagnosing the fuel injection system
Removal and installation of fuel injection system components
General information and replacement of exhaust system components
Emission management
Technical requirements and tightening torques
General information about the emission control system
Description of emission control systems
Checking and replacing emission control system components
Catalytic Converter — Precautions
Starting and charging systems
Technical requirements and tightening torques
General information and precautions
Removing and installing the battery
General information and precautions for the loading system
Checking the loading system
Removing and installing the generator
Generator brushes and voltage regulator
Starting System — General Information and Precautions
Checking the launch system
Removing and installing the starter
Replacing the brushes and starter solenoid
Ignition system
Technical requirements and tightening torques
General information and precautions
Checking the ignition system
Checking, removing and installing the ignition coil
Removing and installing the ignition module
Checking the ignition timing
Transmission
Clutch
Technical requirements and tightening torques
Description and testing of the clutch
Clutch adjustment
Removing and installing the clutch cable
Removing and installing the master cylinder
Removing and installing the clutch pedal
Removal, inspection and installation of clutch components
Removing and installing the clutch release bearing
Removing and installing the clutch release shaft and sleeve
Removing air from the clutch hydraulic system
Mechanical gearbox
Technical requirements and tightening torques
General information about manual transmission
Adjusting the gear shift mechanism
Gear shift mechanism and lever
Removing and installing the speedometer drive gear
Replacing the cuff
Removing and installing the reverse light switch
Removing and installing manual transmission
Manual Transmission Repair
Automatic gearbox
Technical requirements and tightening torques
General information about automatic transmission
Troubleshooting
Removing, installing and adjusting the selector cable
Removing and installing the selector unit
Removing and installing the speedometer drive gear
Selector lever position sensor
Removal and installation of automatic transmission
Transmission repair
Drive shafts
Technical requirements and tightening torques
General information about drive shafts
Removing and installing drive shafts
Inner CV joint cover of the drive shaft
Outer CV joint cover of the drive shaft
Inspection and replacement of drive shaft joints
Chassis
Brake system
Technical requirements and tightening torques
General information about the braking system
Replacing the front brake pads
Removal, repair and installation of the front brake caliper
Inspection, removal and replacement of the front brake disc
Removal, inspection and installation of the rear brake drum
Replacing the rear drum brake shoes
Removal, repair and installation of the rear brake wheel cylinder
Replacing rear disc brake pads
Removal, repair and installation of the rear brake caliper
Removing and installing the master cylinder
Removing and installing the brake pedal
Brake pedal servo amplifier connection
Inspection, removal and installation of pipelines and hoses
Removing air from the hydraulic system
Checking, removing and installing the vacuum servo booster unit
Vacuum hose and check valve of vacuum servo booster
Removing and installing the pressure limiting valve (without ABS)
Removing and installing the pressure limiting valve (with ABS)
Removal and installation of the ABS hydraulic modulator
Checking, removing and installing the ABS wheel sensor
Removing and installing the ABS relay box
Throttle actuator of the traction control system
Removing and installing the brake light switch
Removing and installing the handbrake lever
Removing and installing handbrake cables
Suspension
Technical requirements and tightening torques
General information about the suspension
Removing and installing the steering knuckle and hub assembly
Inspection and replacement of the front hub and bearings
Removing and installing the front suspension strut
Front suspension strut repair
Front cross 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)
Removing and installing the rear suspension axle support (Sedan and Hatchback)
Removing and installing the rear suspension strut (Sedan and Hatchback)
Rear Suspension Strut Repair (Sedan and Hatchback)
Rear Anti-Roll Bar (Sedan and Hatchback)
Lower Rear Suspension Arms (Sedan and Hatchback)
Removing and installing the torque arm (Sedan and Hatchback)
Removing and installing the rear suspension beam (Sedan and Hatchback)
Inspection and replacement of rear hub and bearings (Station wagon)
Removing and installing the rear suspension axle support (Station wagon)
Removing and installing the rear shock absorber (Station wagon)
Rear anti-roll bar (Universal)
Rear Suspension Coil Spring (Wagon)
Rear Lower Control Arm (Wagon)
Front Lower Arm Rear Suspension (Wagon)
Upper control arm rear suspension (station wagon)
Rear Suspension Reactive Arm (Wagon)
Removing and installing the rear suspension beam (station wagon)
Steering
Removing and installing the steering wheel
Removal, inspection and installation of the steering column
Removing and installing the steering column elastic coupling
Power steering (4-cylinder)
Power steering (6 cylinder)
Replacing the rubber boots of the steering gear
Bleeding the hydraulic steering system
Removing and installing the hydraulic power steering pump
Radiator of working fluid of the hydraulic system of steering
Replacing the tie rod end
Wheel alignment and steering angles
Steering tightening torques
Body
Exterior
Tightening torques for body elements
General information about the body
Body and underbody maintenance
Repair of minor body damage
Repair of serious body damage
Removing and installing bumpers
Removing and installing the radiator grille
Removal, installation and adjustment of the hood
Hood release cable and lever
Removing, installing and adjusting the hood lock
Removing and installing rear door glass
Removing and installing the door
Removing and installing the outside mirror
Removing and installing the trunk lid
Removing and installing trunk lid lock components
Removing and installing the tailgate
Removing and installing the tailgate support pillars
Removing and installing tailgate lock components
Windshield and fixed glass
Removal and installation of moldings and stickers
General information and adjustment of the sunroof
Interior
Carpet and Upholstery Care
Removing and installing the interior door trim panel
Removing and installing the door window lifter
Removing and installing door handle and lock components
Removing and installing the interior mirror
Components of the central locking system
Removing and installing seats
Removing and installing seat belts
Removal and installation of interior trim panels
Removing and installing the central console
Removing and installing the ceiling remote control
Removing and installing the glove box
Removing and installing the front panel
Removing and installing the wheel arch liner
Fuel tank filler flap and its opening cable
Electrical equipment
Fuses, relays and bulbs
General information about electrical equipment
Troubleshooting Electrical Circuits
Checking and replacing fuses, relays and timers
Removing and installing switches
Replacing light bulbs (exterior lighting fixtures)
Replacing light bulbs (interior lighting fixtures)
Removal and installation of external lamp units
Headlight beam adjustment
Removing and installing the headlight tilt motor
Removing and installing the instrument panel
Removing and installing instrument panel components
Removing and installing the speedometer drive cable
Removing and installing the watch
Removing and installing the horn
Removing and installing windshield wiper arms
Windshield wiper motor and drive mechanism
Rear Door 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 Glass Washer Components
Radio receiver/audio cassette player
Radio/CD Player Amplifier
CD Player
Removing and installing speakers
Removing and installing the radio antenna
Removal and installation of airbag units
Removing and installing the airbag control unit
Airbag Power Supply Wiring Drum
Parking system by sensors
GPS navigation system
Removing and installing electrical components of seats
Electrical diagrams
Ford Mondeo 2
General information
User guide
Description of cars
Vehicle identification
General repair instructions
Working conditions and tools
Lifting a car
Technical specifications
Tightening torque specifications
Maintenance and care
Car maintenance and care
Spare parts
Checking the engine oil level
Checking the brake fluid level
Checking the brake lights
Checking the lighting system
Checking tire pressure
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
Adjusting the parking brake
Lubricants, sealants
Recommendations for working with threaded connections
The rechargeable battery
Airbag system
Seat belt pretensioning system
Wheels and rims
General description
Types of wheel rims
Wheel rims
Tires
Wheel replacement
Winter tires
Checking tire pressure
Extending the life of your tires
Checking the condition of the tires
Causes of tire wear
Tire storage
Power unit
V16 engine
Removing the engine
Engine installation
Disassembling the engine
Engine assembly
Removing and installing the cylinder head (on the engine in the car)
Disassembling the cylinder head
Repair of cylinder head and valves
Cylinder head assembly
Removing the pistons
Disassembling pistons and connecting rods
Checking the technical condition of pistons and connecting rods
Assembly of pistons and connecting rods
Installing pistons and connecting rods
Cylinder block
Checking the crankshaft
Rear oil seal ring and crankshaft flange
Camshafts and valve timing
Removing and installing a toothed drive belt
Measuring the axial clearance (play) of the camshaft
Checking the compression in the cylinders
Engine malfunctions
Replacing the front crankshaft oil seal (manufactured before May 1998)
Removal and installation of camshafts (produced before May 1998)
Camshaft seals (manufactured before May 1998)
Duratec VE
2.5-liter Duratec VE engine
Removing and installing the left cylinder head cover
Removing and installing the right cylinder head cover
Removing and installing the upper intake manifold
Replacing camshaft sealing rings
Removing and installing the left exhaust manifold
Removing and installing the right exhaust manifold
Removing and installing the oil pan
Replacing the rear crankshaft seal ring
Disassembling the engine
Engine assembly
Lubrication system
General information about the lubrication system
Selecting engine oil
Checking the engine oil level
Oil consumption
Oil change
Replacing the oil pump
Replacing the oil filter
Checking oil pressure
Replacing the oil pan
Oil leaks
Lubrication system malfunctions
Cooling system
General information about the cooling system
Replacing the coolant
Replacing the radiator cooling fan
Replacing the radiator
Checking the radiator cap and radiator
Replacing the liquid pump
Replacing the thermostat
Checking the Thermostat
Thermostat malfunctions
Checking the cooling system
Cooling system 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
Replacing the air filter
Replacing the fuel filter
Checking the operation of the fuel pump
Replacing the fuel pump
Adjusting the throttle cable
General information about the injection system
Precautions when working with the injection system
Neutralization of exhaust gases
Neutralization of exhaust gases of gasoline engines
Exhaust Gas Recirculation (EGR) System
Ignition system
General information about the ignition system
Precautions when working with the ignition system
Replacing the engine control unit
Spark plugs
Ignition system diagnostics
Exhaust system
Exhaust gas exhaust system
Removal and installation of the exhaust system
Precautions when handling a catalytic converter
Removing and installing the catalytic converter
Lambda probe
Transmission
Clutch
General information about the clutch
Checking the clutch
Removing the clutch
Clutch installation
Removing and installing the clutch master cylinder
Removing and installing the clutch hydraulic drive slave cylinder
Bleeding the Clutch Hydraulic Drive
Adjusting the free travel of the clutch pedal
Mechanical gearbox
Manual transmission
Removal and installation of a manual gearbox
Checking the oil level in a manual transmission
Gearbox malfunctions
Automatic gearbox
Automatic transmission
Removal and installation of 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
Precautions when working with wheel drive shafts
Removing and installing the drive shaft on the right side of the vehicle
Removing and installing the intermediate shaft
Removing and installing the drive shaft on the left side of the vehicle
Wheel drive repair
Replacing thrust bearings
Inner radial sealing rings
Chassis
Front suspension
General information about the front suspension
Removing the wheel bearing
Removing the steering knuckle
Installing the steering knuckle
Removing and installing the left wishbone
Removing and installing the right wishbone
Removing and installing the anti-roll bar
Removing and installing the shock absorber strut
Removing and installing front springs
Wheel alignment
Rear suspension (sedan)
Rear suspension (sedan body)
Removing and installing the rear suspension assembly
Removing and installing the front trailing arm
Removing and installing the rear trailing arm
Removing and installing the anti-roll bar
Rear suspension
Rear suspension
Removing and installing the rear suspension assembly
Removing and installing the wishbone and coil springs
Removing and installing front and rear side arms
Removing and installing the upper suspension arm
Removing and installing shock absorbers
Removal and installation of jet rods
Removing and installing the wheel hub
Removing and installing the anti-roll bar
Removing and installing rear wheel hubs
Adjusting the rear wheel alignment angles
Steering
General information about steering
Removing and installing the steering gear
Checking the technical condition of the toothed rack cuffs
Checking the technical condition of the cuffs and ends of the transverse steering rods
Replacing the steering gear coupling
Bleeding the power steering drive
Replacing the power steering pump
Removing and installing the steering wheel
Brake system
General information about the brake system
Brake design
General description of the braking system
Replacing the front brake pads
Removing and installing the front brake caliper
Disassembling the front brake caliper
Removing and installing the front brake disc
Removing the rear drum brake shoes
Installing rear drum brake shoes
Removing and installing the brake cylinder of drum brakes
Replacing rear disc brake pads
Removing and installing the rear disc brake caliper
Removing and installing the rear brake disc
Removing and installing the master brake cylinder
Repair of the main brake cylinder
Brake booster
Anti-lock braking system (ABS)
Removing and installing the ABS hydraulic unit
Replacing the ABS sensor (front wheels)
Replacing the ABS sensor (rear wheels)
Replacing the front parking brake cables
Replacing the rear parking brake cables
Traction control system
Removing and installing the adjusting electric motor
Brake service
Checking the brake fluid level
Replacing brake fluid
Checking the brake system
Checking the brake system for leaks and damage
Checking brake pads
Bleeding the brake system
Electrical equipment
Battery and alternator
The rechargeable battery
Checking the battery
Battery characteristics
Determination of a faulty consumer
Precautions when handling the generator
Checking the installed generator
Removing and installing the generator
Generator repair
Replacing generator brushes
Typical generator faults
Starter
Checking the starter (on the car)
Removing and installing the starter
Starter repair
Generator drive belt
Light and appliances
Checking the windshield wiper and alarm system
Removing and installing the windshield wiper motor (front)
Removing and installing the windshield wiper (front)
Replacing the wiper bearing
Removing and installing the windshield wiper motor (rear)
Outdoor lighting
Replacing headlight bulbs
Replacing parking light bulbs
Removing and installing headlights
Headlight adjustment
Control and measuring instruments
Electrical diagrams
Ford Mondeo 3
General information
Introduction to the guide
Introduction to the service repair manual
Presentation of the help system
First look at the Mondeo model range
Family of car engines
Dimensions of cars
Development of models
Technical specifications
Workplace equipment
Workplace equipment
Take care of spare parts in a timely manner
Tools — Basic Equipment
Special tools and accessories
A Matter of Experience – Advice from a Professional for Amateurs
Tips for those attending the workshop
Safety first
A practical lifting tool is a jack
Car care
Car care products
Internal cleaning — dirt doesn't stand a chance
External wash
Engine wash
To keep everything moving, call in a lubrication service
If you want to preserve your material assets, take care of the paintwork
Care of varnish
Decreasing the value of the product — ugly paint defects
Elimination of defects from stone impacts
Polishing of small scratches
Removing large scratches
Glass washing machine
Checking the windshield wiper and washer
Filling the windshield washer with water
Replacing the wiper blade rubber
Installing a Windshield Washer Nozzle
Installation and removal of the windshield washer nozzle
Removing and installing the windshield wiper arm
Removing and installing the front windshield wiper motor
Removing and installing the rear wiper motor
Help with malfunctions
Starter malfunctions
Battery and generator faults
Malfunctions of the petrol injection system
Brake malfunctions
Diesel injection system faults
Electric window lift malfunctions
Heating system malfunctions
Cooling system malfunctions
Clutch faults
Engine and system faults
Brake light malfunctions
Windscreen wiper malfunctions
Lubrication system malfunctions
Thermostat malfunctions
Malfunctions of the sound and light signaling system
Windscreen wiper blade malfunctions
Central locking system malfunctions
Spark plug faults
Cylinder head gasket faults
Power unit
Engine repair
Design and characteristics of engines
Make it in a workshop or do it yourself
Cranking the engine
Compression ratio
Measuring the compression ratio
Checking drive belts
Installation of drive belts
Determining the location of the fault by listening — noises in the engine compartment
Lubrication system
Engine lubrication system device
The Role of Motor 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
Replacing the coolant
Adding freeze protection
Removing and checking the thermostat — only when the engine is cold
First aid — short-circuit the thermal switch
Removing the cooling system fan
Dismantling and installation of the radiator
Replacing coolant hoses
Air filter (intake noise muffler)
Cleaning and replacing the filter cartridge
Fuel injection system
Fuel injection system device
Sometimes it makes sense to conduct a visual inspection of the injection system
Checking the intake system for leaks
Checking the idle speed
Idle oscillations are a systematic phenomenon
Checking the idle speed control valve
Checking the injector
Replacing the gas pedal rod (using Duratec-HE as an example)
Diesel Engine Fuel Supply — Basic Design
Visual inspection of the diesel engine injection system
Ignition system
Ignition system device
Ignition coil
High Temperature Resistant — Spark Plugs
Replace spark plugs — after 60,000 kilometers
Checking with a universal device — rotation 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 resistance on the ignition coil
Dismantling the ignition unit
Diesel engine preheating device
Checking the preheating device
Checking the preheating relay
Checking glow plugs
Fuel system
Fuel system device
Fuel types and handling
Checking the ventilation and airing of the tank
Replacing the fuel filter (petrol engine)
Replacing the fuel filter (diesel engine)
Emptying the tank without a fuel pump
Dismantling pipelines and hoses (general instructions)
Fuel Pump Troubleshooting
Removing and installing the fuel pump (petrol engine)
Exhaust gas exhaust system
Tips for working with the exhaust system
The question of cost — complete repair or partial replacement
Low exhaust gas — ASU
Neutralization of exhaust gases
Transmission
Gearbox device
Clutch device
Checking the clutch
Does the clutch disengage completely?
Five-speed manual transmission
Gear shift adjustment
Checking the transmission oil level (manual transmission)
Automatic transmission in combination with the 2.0-liter Duratec-HE engine
Checking the transmission oil level (automatic transmission)
Main gear
Checking the drive shaft seals
Removing and installing the drive shaft/transverse control arm
Replacing the universal joint seals
Chassis
Chassis
Chassis design
Front axle Mondeo
Front axle geometry
Checking shock absorbers after wearing two sets of tires
Regularly check the steering wheel free play
Checking the toothed rack protective cuffs
Checking the tie rod ends and seals
Checking the wishbone bearing
Checking the wheel bearing clearance
Replacing the front wishbone
Dismantling and installation of shock absorber struts
Replacing the tie rod ends
Replacing the steering gear cuffs
Replacing the steering gear pivot bearing
Removal and installation of the rear shock absorber strut
Replacing the shock absorber (station wagon)
Power steering gear
Tires and wheels
It is better to check the air pressure on cold tires
Wheel replacement
Checking the condition of the tires
Brake system
The structure of the braking system
Checking the brake fluid level
Checking the brake system
Checking the brake booster
Checking the brakes for functionality
Measuring the wear of disc brake pads
Checking the wear of the disc brake mechanism
Bleeding the brake system
Replacing brake fluid
Removing the master brake cylinder expansion tank
Removal and installation of the master brake cylinder
Dismantling and installation of the brake booster
Removing and installing brake hoses
Replacing disc brake pads
Replacing brake discs
Replacing the protective cuffs of the caliper and piston of the brake mechanism
Parking brake
Replacing the parking brake cable
Body
Interior
Car interior design
Ventilation and heating
Check heating and ventilation systems from time to time
Dismantling the heating and ventilation control unit
Fan
Troubleshooting a Fan
Replacing the fan motor
Replacing interior lamps
Switch
Ignition Key Coding
Checking the door contact switch
Dismantling the radio receiver
Removing the speaker
Dismantling the outdoor antenna
It is not recommended to remove the front seats yourself
Removing the backrest of the rear seats
Removing the front door trim
Removing side windows/window lifter
Window lifter
Adjusting the window lift motor
Removing the door handle
Removing the steering lock
Exterior
Description of the car body
Dismantling and installation of the door
Door adjustment
Removing and installing the outside rearview mirror
Removal and installation of the fairing
Dismantling and installation of the hood
Adjusting the engine hood
Removing and installing the bumper cover (front)
Dismantling and installation of wings
Removing and installing the bumper cover (rear)
Removing and installing the trunk lid
Adjusting the trunk lid
Removing and installing the rear door lock
Electrical equipment
Light and appliances
Description of electrical equipment
Contact care
Starting the engine «from the side» with a wire
Pushing a car
Towing a car
Identifying secret electricity consumers
Replacing drive belts
Replacing the belt pressure roller
Outdoor lighting
Replacing incandescent lamps
Adjusting headlights «in front of the wall»
Signaling devices
Checking the brake light switch
Checking the sound signal
Tools and control devices
Checking the operation of the switch
Dismantling and installation of the combined instrument
It's not always easy to follow the «winding» paths of wires
Fuses in the passenger compartment and engine compartment
Replacing fuses
Distributes high operating currents — changeover relay
Layout of fuses and relays
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
Structure of electrical circuits
Electrical diagrams of engine cooling
Electrical diagrams of the fuel system
Electrical diagrams of the diesel starting system
Electrical diagrams of engine control
Electrical diagrams of heating and air conditioning
Electrical diagrams of the generator and regulator
Electrical circuits for exterior lighting, headlights
Electrical circuits of the sound signal
Electrical diagrams of the clock mechanism
Electrical diagrams of the windshield wiper and washer system
Ford Mondeo 4
General information
User guide
General information about the car
Vehicle Passport Data
Cruise control system
On-board computer
Power unit
Engine repair
Features of the design and repair of the 2.5 l duratec-v15 engine
Checking the compression in the cylinders of the 2.5L duratec-v15 engine
Replacing the timing belt of the 2.5L duratec-v15 engine
Replacing crankshaft seals on a 2.5L duratec-v15 engine
Replacing the cylinder head gasket of the 2.5L duratec-v15 engine
Replacing camshafts and cylinder head cover seals for a 2.5L duratec-v15 engine
Replacing the oil pan seal of the 2.5L duratec-v15 engine
Features of the design and repair of the 2.2 l duratorq-tdci engine
Checking the compression in the cylinders of the 2.2L duratorq-tdci engine
Replacing the timing belt of the 2.2L duratorq-tdci engine
Replacing the crankshaft seals of the 2.2L duratorq-tdci engine
Replacing the cylinder head cover seals on a 2.2L duratorq-tdci engine
Replacing the cylinder head gasket of the 2.2L duratorq-tdci engine
Replacing camshafts on a 2.2L duratorq-tdci engine
Replacing the oil pan seal on a 2.2L duratorq-tdci engine
Removing and installing the decorative engine cover
Checking the compression in the cylinders
Removing and installing mudguard and engine crankcase protection
Replacing the right powertrain suspension support
Replacing the left support of the powertrain suspension
Replacing the rear support of the powertrain suspension
Cleaning the crankcase ventilation system
Setting the piston of the first cylinder to the TDC position of the compression stroke
Adjusting valve clearances
Checking and replacing the accessory drive belt
Checking and replacing the timing belt of the 1.6L Duratec Ti-VCT engine
Replacing the timing chain of the 2.0 and 2.3 L duratec-he engines
Removal, defect detection and installation of the flywheel
Replacing the cylinder head cover gasket
Replacing the cylinder head gasket
Replacing valve stem seals
Replacing camshaft seals
Replacing crankshaft seals
Replacing the oil pan seal
Replacing the intake manifold gasket
Replacing the catalytic converter gasket
Replacing camshafts
Removing and installing the engine
Lubrication system
Lubrication system
Changing engine oil and oil filter
Removing and installing the oil pump
Oil pump repair
Checking the level and adding oil to the lubrication system
Cooling system
Cooling system
Replacing the coolant
Replacing the cooling system radiator
Replacing the water pump
Removing and installing the thermostat
Removing and installing the expansion tank
Checking the level and adding coolant
Exhaust system
Exhaust gas exhaust system
Replacing the exhaust system suspension cushions
Removing and installing the catalytic converter and replacing its gasket
Removal and installation of main and additional mufflers
Removal and installation of thermal screens
Supply system
Power supply system
Checking the pressure in the engine fuel system
Decreased pressure in the engine fuel system
Replacing the air filter element
Removing and installing the air filter and intake noise muffler
Removal, repair and installation of the fuel module
Replacing the fuel tank
Removing and installing the fuel rail
Removal, inspection and installation of injectors
Removing and installing the throttle assembly
Removing and installing the throttle pedal
Checking the engine fuel system
Fuel injection system faults
Fuel vapor recovery
Fuel vapor recovery system
Removing and installing the fuel vapor recovery system canister
Transmission
Clutch
Clutch
Checking the Clutch Release Pedal Travel
Removing and installing the clutch
Replacing the clutch release drive slave cylinder with the clutch release bearing
Replacing the clutch release master cylinder
Replacing the clutch release hydraulic line
Removing and installing the clutch pedal
Bleeding the clutch release hydraulic drive
Car gearbox
Transmission
Changing the oil in a manual transmission or the working fluid in an automatic transmission
Replacing gearbox seals
Removing and installing the gearbox
Replacing gearbox control cables
Removing and installing the gearbox control lever linkage
Adjusting the gearbox control drive
Checking the level of working fluid in the automatic transmission
Wheel drives
Front wheel drives
Removing and installing 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
Removing and installing the shock absorber strut
Shock absorber strut repair
Replacing the upper shock absorber strut support
Replacing the ball joint
Replacing the front suspension arm
Replacing the front suspension stabilizer bar components
Removing and installing the steering knuckle
Replacing the front hub bearing
Removing and installing the front suspension subframe
Checking and adjusting wheel alignment angles
Rear suspension
Rear suspension
Checking the technical condition of the rear suspension parts on the car
Replacing the rear shock absorber
Replacing the rear suspension spring
Replacing the upper arm of the rear suspension
Replacing the front lower control arm of the rear suspension
Replacing the rear lower control arm of the rear suspension
Replacing the rear suspension trailing arm
Replacing the rear suspension stabilizer bar components
Replacing the rear wheel hub
Removing and installing the rear suspension crossmember
Steering
Steering control
Inspection and testing of the steering system on the vehicle
Checking the free play (play) of the steering wheel
Removing and installing the steering column cover
Removing and installing the steering wheel
Removing and installing the steering column
Replacing the outer tie rod end
Replacing the steering rod
Bleeding the power steering system
Replacing the power steering fluid reservoir
Replacing the steering gear
Replacing the power steering pump
Checking the level and adding working fluid to the power steering reservoir
Brake system
Brake system
Checking the brake pedal position
Checking the operation of the brake booster
Checking the degree of wear of brake pads and discs
Bleeding the hydraulic brake system
Replacing brake fluid
Replacing the brake master cylinder reservoir
Replacing the master brake cylinder
Replacing the vacuum booster
Replacing brake hoses
Replacing brake pipes
Removing and installing the brake pedal
Replacing the brake pads of the front wheel brake mechanism
Replacing the front wheel brake caliper
Replacing the brake disc of the front wheel brake mechanism
Replacing the brake pads of the rear wheel brake mechanism
Replacing the rear wheel brake caliper
Replacing the brake disc of the rear wheel brake mechanism
Adjusting the parking brake drive
Replacing the front parking brake cable
Replacing the rear parking brake cables
Removing and installing the parking brake lever
Checking the level and adding brake fluid to the reservoir of the hydraulic drives of the brake system and clutch release
Body
Exterior
General information about the body
Removing and installing the front bumper
Removing and installing wheel mudguards and fender liners
Removing and installing the rear bumper
Removing and installing the front wing
Removing and installing the hood
Removal, installation and adjustment of the hood lock and its drive
Removing and installing the air intake box lining
Removing and installing the trunk lid
Replacement of the trunk lid lock
Removing the trunk lid trims
Removing and installing the fuel tank filler pipe hatch cover
Removing and installing the outside mirror
Interior
Removing and installing the front seat
Removing and installing the rear seat
Removing and installing the floor tunnel lining
Removing and installing the interior mirror
Instrument panel
Removing and installing the instrument panel
Removal and installation of interior trim
Removing and installing trunk trims
Removing and installing the battery mounting shelf
Doors, locks and windows
Removing and installing the front door trim
Front door glass replacement
Replacing the front door window regulator
Replacing the outside handle and front door lock switch
Replacing the inner handle of the front door lock drive
Replacing the front door lock
Replacing the front door opening limiter
Removing and installing the front door
Removing and installing the rear door trim
Rear door glass replacement
Replacing the rear door window regulator
Replacing the outer rear door handle
Replacing the inner handle of the rear door lock actuator
Replacing the rear door lock
Replacing the rear door opening limiter
Removing and installing the rear door
Heating and ventilation
Ventilation, heating and air conditioning system
Features of the ventilation system
Features of the heating system
Features of the air conditioning system
Removing refrigerant from the air conditioning system
Replacing the sealing rings
Air conditioning compressor
Removing and installing the compressor
Replacing the drive pulley bearing
Replacing the compressor clutch solenoid
Removing and installing the condenser
Replacing the filter element of the receiver-dryer
Replacing the cabin air filter
Removal and installation of the ventilation, heating and air conditioning system control unit
Replacing the pressure sensor
Removing and installing the solar light sensor
Replacing the outside air temperature sensor
Activation of the on-board diagnostic system
Reading recorded fault codes
Reading the software version number
Security systems
Passive safety system (srs)
Removing and installing the driver's airbag
Removing and installing the front passenger airbag
Removing and installing the front seat belt
Removing and installing the rear seat belt
Removal and installation of the electronic control unit of the additional passive safety system
Removing and installing the side impact sensor
Active safety system (electronic braking control systems)
Removal and installation of the hydroelectronic control unit of the anti-lock braking system
Removing and installing front wheel speed sensors
Removing and installing rear wheel speed sensors
Electrical equipment
Electrical appliances
Electrical equipment
Location of fuses, fuse links and relays and their replacement
Removal and installation of mounting blocks
Replacing the ignition switch (lock) contact group
Replacing the ignition switch cylinder
Removing and installing the ignition switch (lock)
Replacement and maintenance of spark plugs
Engine management system
Checking the ignition coil
Removing and installing ignition coil for 1.6L duratec ti-vct engine
Removing and installing ignition coils for duratec-he and duratec-v15 engines
Replacing the electronic engine control unit
Checking and replacing engine management system sensors
Replacing steering column switches
Removing and installing the horn
Removing and installing the windshield wiper linkage and gear motor
Removing and installing the windshield washer
Replacing the electric window control unit and switches
Replacement of electric window lifter motors
Replacing window lifter control modules
Removal and installation of the electric motor of the radiator fan of the engine cooling system
Replacing the radiator fan control unit of the engine cooling system
Removing and installing the heater fan motor
Replacement of additional resistance of the heater electric fan and electric motors of the damper drives
Removing and installing the instrument cluster
Replacing the control unit for external lighting and instrument cluster illumination
Removing and installing switches for the electronic stability program (ESP), hazard warning lights and heated windshields and rear windows
Removing and installing front seat heating switches
Removing and installing a car radio
Removing and installing speakers of the acoustic system
Replacing the oil pressure warning light sensor
Checking and replacing the fuel level indicator sensor
Checking and replacing the reverse light switch
Replacing the brake light switch
Replacing the Parking Brake Indicator Light Switch
Headlights and lighting
Lighting, light and sound signaling
Replacing lamps
Removing and installing the multifunctional electronic unit (gem)
Headlight replacement
Replacing the fog light
Replacing the rear light
Replacing an additional brake light
Replacing the side turn signal light
Replacing license plate lights
Replacement of interior light
Battery and alternator
Removing and installing the battery
Generator
Removing and installing the generator
Checking the ignition system
Generator repair
Starter
Removing and installing the starter
Starter repair
Ford Escort 3
General information
Maintenance
Opening the hood
Ignition switch with anti-theft device
Features of engine starting
Lubrication system
Cooling system
Power supply system
Ignition system and spark plugs
Clutch adjustment and maintenance
Transmission
Steering control
Car suspension
Brake system
Electrical equipment of the car
Replacement of headlights, parking lights and alarms
Wheels and tires
Car body and layout
Lifting and towing a car
General requirements for car repair
Reference dimensions for checking the body floor
Tightening torques for threaded connections
Characteristics
Vehicle details
Operational data
Basic data for adjustments and control
Passport details
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 model engine
The device and inspection of the cylinder block
Connecting rod and piston group
Crankshaft
Cylinder head (except GLA model)
Cylinder head of the GLA engine
Cooling system
Features of the cooling system
Replacing the coolant
Removing and installing the radiator
Replacing the electric fan
Removing and installing the water pump
Removing and installing the thermostat
Lubrication system
Features of the lubrication system
Engine lubrication system for all models except GLA
Engine lubrication system of the GLA model
Oil pressure control check
Replacing the oil filter
Supply system
Fuel system of carburetor engines
Fuel tank
Fuel pump
Air filter
Ford Carburetor
Ford Carburetor Maintenance
Removing and installing a Ford carburetor
Disassembly and technical condition check
Ford Carburetor Adjustments
Replacing the dosing needle
Replacing the needle valve
Removing and installing the pneumatic drive of the air valve
Weber carburetor
Weber Carburetor Adjustments
Exhaust system
Fuel injection «K-Jetronic»
Operating principle and features of the device
Fuel pump and filter
Pressure accumulator
Air flow meter
Fuel dispenser and regulator
Valves and injectors
Forced idling device
Checking and adjusting the fuel injection system components
Removal and installation of injection system components
Possible malfunctions of the fuel injection system
Transmission
Clutch
Features of the device
Removing and installing the clutch slave disc
Replacing the clutch release bearing
Replacing the clutch cable
Adjusting the free travel of the pedal «Escort RS 1600 I»
Mechanical gearbox
Features of the device
Removal and installation of a manual transmission
Disassembling a four-speed gearbox
Assembly of a four-speed gearbox
Removing and installing the gear shift drive
Features of assembly of a five-speed gearbox
Hydromechanical box
General information about the hydromechanical gearbox
Features of the device
Removing the hydromechanical gearbox
Installation of a hydromechanical gearbox
Checking the hydromechanical transmission assembly
Adjusting the starter interlock switch
Testing of hydromechanical transmission
Test in motion
Possible malfunctions, their causes and methods of elimination
Drive shafts
Features of the wheel drive device
Front Wheel Drive Replacement
Disassembling the wheel drive shaft
Chassis
Front suspension
Features of the device
Features of the front suspension of the «Escort RS 1600 i»
Checking and adjusting the front wheel alignment angles
Replacing hub bearings
Removing and installing the front suspension strut
Disassembly and assembly of suspension strut
Removing and installing the lower suspension arm
Removing and installing the anti-roll bar
Rear suspension
Features of the device
Rear wheel alignment angles
Removing and installing the rear suspension assembly
Removing and installing the suspension spring
Replacing the shock absorber
Removing and installing the suspension arm
Removing and installing the stretch
Removing and installing the hub
Replacing hub bearings
Removing and installing the trunnion
Steering
Features of the device
Removing the steering gear
Installing the steering gear
Disassembly of the steering mechanism of cars produced before May 1983
Assembly of steering gear for cars manufactured before May 1983
Disassembling the steering gear on cars produced since May 1983
Assembly of steering gear for cars produced since May 1983
Checking the drive gear rotation torque
Removing and installing the steering shaft
Brake system
Features of the device
Replacing the front brake pads
Removing and installing the front wheel brake mechanism
Replacing the rear wheel brake pads
Removing and installing the rear wheel brake mechanism
Removing air from the hydraulic drive
Removing and installing the master cylinder
Disassembly and assembly of the master cylinder
Removing and installing the vacuum booster
Adjusting the parking brake
Electrical equipment
Starting and charging system
Electrical equipment diagram
Battery
Generator device
Generator repair
Disassembly and assembly of the generator
Starter device
Starter repair
Ignition system
General information about ignition
Ignition of engines of GLA, GMA and GPA models
Vacuum ignition advance regulator control
Removing and installing the distributor
Replacing contacts
Adjusting the gap between contacts
Setting the ignition timing
Contactless ignition system
Checks and repairs of contactless ignition system
Ignition «Escort RS 1600»
Features of the device
Removing and installing the crankshaft position sensor
Checking the electrical connections of the ignition system
Checking the initial ignition timing setting
Light and appliances
Features of lighting and signaling devices
Headlight adjustment
Windscreen wiper and washer
Windshield wiper operation
Removing and installing the windshield wiper
Rear window wiper and headlight washer
Fan motors
Electric windows and central locking
Control devices
Schematic diagrams
Electrical equipment of Escort cars 1980-1982
Wiring diagram for Escort 1980-1982 devices
Charging, starting and control devices «Escort» 1980-1982
Escort 1980-1982 Power Windows, Door Locks and Lighting
Exterior lighting for Escort cars manufactured in 1980-1982
Side lights and direction indicators «Escort» 1980-1982
Interior lighting for Escort cars 1980-1982
Ventilation, wipers and washers for Escort 1980-1982
Escort 1980-1982 Control Lights
Charging, starting and engine operation systems «Escort» 1983-1985
Power windows, door locks and lighting «Escort» 1983-1985
Exterior lighting for Escort cars manufactured in 1983-1985
Direction indicators for Escort cars 1983-1985
Interior lighting for Escort cars 1983-1985
Ventilation, wipers and washers of glass «Escort» 1983-1985
Control lamps of cars «Escort» 1983-1985
Fuel injection system of Escort cars 1983-1985
Schematic diagram of the electrical equipment of the Orion cars
Charging, starting and engine operation system of the Orion car
Wiring diagram for exterior lighting of the Orion car
Wiring diagram of the direction indicators of the Orion car
Ventilation, glass cleaners and washers «Orion»
Wiring diagram for interior lighting of the Orion car
Wiring diagram for control lamps of the Orion car
Orion power windows and heated rear window
Central locking of car doors «Orion»
Fuel injection system of the Orion car
Ford Escort 4
General information
User manual
Design Features of Ford Escort 4
Fuel consumption, l/100 km
Speed of movement in gears
Curb and gross vehicle weight
Overall dimensions of cars
Periodic inspections and maintenance of the car
Vehicle identification
Warning signs in text
Electrically adjustable exterior rear view mirrors
Front seats — adjustment
Steering column lock / ignition switch
Instrument panel
Instrument cluster
Steering column control levers
Manual gearbox
Heating and ventilation
Analog and digital clocks
Fuel computer
Door locks — opening and blocking
Mechanically operated hatch
Power lowering windows
Increased luggage compartment volume
Windscreen wipers and washers
Lifting a car
Starting the engine
Features of vehicle operation
Body repair dimensions
Maintenance
Location of units in the engine compartment
Operating materials and fluids
Maintenance intervals
Primary and secondary maintenance activities
Oil and oil filter change (10,000 km/12 months)
Checking the tightness of hoses and fluid leakage (10,000 km/12 months)
Checking idle speed and fuel mixture quality (10,000 km/12 months)
Checking ignition system components (10,000 km/12 months)
Lubrication of ignition distributor breaker contacts (10,000 km/12 months)
Adjusting the gap of the breaker contacts (10,000 km/12 months)
Ignition timing with contact breaker (10,000 km/12 months)
Replacing spark plugs on RS Turbo engine (10,000 km/12 months)
Checking the front brake pads (10,000 km/12 months)
Checking 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 gearbox oil level (20,000 km/12 months)
Replacement of breaker contacts (20,000 km/12 months)
Checking the oil level in a manual transmission (20,000 km/12 months)
Checking the transmission fluid level in the automatic transmission (20,000 km/12 months)
Checking the drive shaft protective cover (20,000 km/12 months)
Coolant replacement (40,000 km/24 months)
Replacing the air filter element (40,000 km/24 months)
Replacement of the crankcase ventilation filter (40,000 km/24 months)
Replacing the fuel filter on engines with a fuel injection system (40,000 km/24 months)
Replacing the timing belt on CVH engines (60,000 km/36 months)
Checking the components of the CVH brake system (60,000 km/36 months)
Brake fluid replacement (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
Valve timing 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
Adjusting valve clearances
Removing the cylinder head
Disassembling the cylinder head
Checking and repairing the cylinder head
Cylinder head assembly
Installing the cylinder head
Replacing the front crankshaft seal ring
Pistons and connecting rods — removal
Pistons and connecting rods — inspection and repair
Pistons and connecting rods — installation
Removing the engine
Disassembling the engine
Engine repair
Engine assembly
Engine installation
Checking the compression in the cylinders
CVH engine repair
General data of the CVH engine
Main parameters of CVH engines
Cylinder Head — Specifications
Engine Block — Specifications
Crank mechanism — specifications
Valve timing system — specifications
Fuel System — Specifications
Contact ignition system — specifications
Contactless Ignition System — Specifications
Lubrication system — specifications
Cooling system — specifications
Tightening torques for threaded connections
General view of the CVH engine and engine compartment
Replacing the timing belt
Removing the cylinder head
Disassembling the cylinder head
Checking and repairing the cylinder head
Hydraulic valve lifters
Cylinder head assembly
Installing the cylinder head
Replacing the camshaft sealing ring
Replacing the front crankshaft seal ring
Replacing the oil pan
Pistons and connecting rods — removal, inspection and installation
Removing the engine
Disassembling the engine
Engine repair
Engine assembly
Engine installation
Checking the compression in the cylinders
Fuel system
Fuel system — general information
FORD VV carburetor with variable diffuser section
Main dosing system
Idle system
Removing and installing the carburetor
Idle speed and CO content
Idle control valve
Starter — removal and installation
Speed increaser device
Jet Needle — Removal and Installation
Float chamber needle valve
Accelerator cable — removal, installation and adjustment
Starter cable — removal, installation and adjustment
Fuel pump — removal, inspection and installation
Fuel tank — removal and installation
Air supply system thermostat
Air filter — removal and installation
Weber 2V carburetor
Weber 2V Carburetor — Design Description
Removing and installing the carburetor
Carburetor Cover — Removal
Idle speed and CO content
Automatic starting device — removal and installation
Adjusting the air damper clearance
Speed increaser device
Float chamber needle valve
KE-Jetronic injection system
Location of fuel injection system components on a vehicle
K-Jetronic fuel injection system — operating principle
KE-Jetronic fuel injection system — design description
Starting injector — check
Thermal time switch
Idle speed
Adjusting CO content
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 testing
CFI injection system
CFI fuel injection system — design description
Throttle valve — general information
Injectors — General Information
Pressure regulator — general information
Fuel injection system sensors — general information
Functioning of the central injection system
Removing and installing the injector
Safety precautions when working with the injection system
Diagnostics of injection system faults
Ignition system
Ignition system — general information
Contact ignition system — general information
Ignition distributor — removal and installation
Vacuum ignition timing regulator
Capacitor — removal and installation
Adjusting the gap between the breaker contacts
Replacing breaker contacts
Checking the ignition timing angle
Diagnostics of faults of contact ignition system
Contactless ignition system — general information
Contactless ignition system distributor
Contactless ignition system switch
Electronic ignition system without distributor
Diesel engines
Engine repair
View of the engine compartment and technical specifications
Cylinder Head — Specifications
Engine Block — Specifications
Crank mechanism — specifications
Valve timing system — specifications
Fuel System — Specifications
Lubrication system — specifications
Cooling system — specifications
Tightening torques for threaded connections
How a diesel engine works
Engine adjustment
Removing and installing the timing belt (1.6L engine)
Removing and installing the timing belt (1.8L engine)
Removing the cylinder head
Cylinder head repair
Installing the cylinder head and adjusting the valve timing
Disassembling a 1.6 liter engine
Checking 1.6 liter engine parts
Assembly of 1.6 liter engine
Differences in the assembly of an engine with a working volume of 1.8 liters
Fuel system
General information about the fuel system
Injectors — removal, inspection and installation
Checking the tightness of the nozzle sprayer
Adjusting the initial injection pressure
Glow Plugs — Checking
Checking the compression in the cylinders
Removing air and water from the fuel system
Engine stop device
Replacing the fuel filter
Accelerator cable — removal and installation
High pressure pump
High pressure fuel pump — design description
Rotary pump — general information
Distributor piston — general information
Solenoid valve — general information
Centrifugal regulator and injection regulator
Setting the injection timing of the fuel pump
Checking the maximum number of revolutions and delay time
Adjusting the idle speed
Replacing the air filter
Cooling and lubrication system
Technical characteristics of the cooling system
Cooling system tightening torques
Replacing the coolant
Radiator Fan Motor — Removal and Installation
Thermostat — Removal, Checking and Installation
Temperature sensor for fan activation
Removing and installing the water pump
Removing and installing the radiator
Technical characteristics of the lubrication system
Tightening torques of the lubrication system
Engine lubrication system — design description
Checking oil pressure
Removing and installing the oil pan
Removing and installing the oil pump
Engine oil change
Replacing the oil filter
Engine crankcase ventilation system
Lubrication system malfunctions
Exhaust system — design description
Removal and installation of the exhaust system
Replacing the rear muffler
Vehicles with a catalytic converter — general information
Transmission
Clutch
Clutch specifications
Removing the clutch
Checking the clutch
Clutch installation
Removing and installing the release bearing
Removing and installing the clutch cable
Adjusting the free play
Main clutch faults
Mechanical gearbox
Gearbox — General Information
Gearbox specifications
Maintenance of a four-speed manual transmission
Removing a four-speed manual transmission
Installation of a four-speed manual transmission
Disassembling a four-speed manual transmission
Assembly of a four-speed manual transmission
Gear shift mechanism of a four-speed manual transmission
Removing a five-speed manual transmission
Disassembling a five-speed manual transmission
Gear shift mechanism of a five-speed manual transmission
Automatic gearbox
Technical characteristics of the automatic transmission FORD ATX
Removal and installation of gearbox FORD ATX
FORD ATX Gearbox Control Mechanisms
Checking the parking brake of the FORD ATX gearbox
Checking the oil level in the FORD ATX gearbox
Towing a car with an automatic transmission
Main faults of FORD ATX gearbox
Technical characteristics of the automatic transmission FORD CTX
Removal and installation of gearbox FORD CTX
Gear shift rod FORD CTX box
Drive shafts
Description of the design of drive shafts
Tightening torques for threaded connections
Removing drive shafts
Installation of drive shafts
Disassembling drive shafts
Assembly of drive shafts
Replacing the inner hinge protective cover
Replacing the outer hinge protective cover
Hinge housing seal
Drive shaft faults
Chassis
Suspension and wheels
Front suspension — design description
Front suspension specifications
Front suspension tightening torques
Removing and installing the front shock absorber strut
Removing and installing the front shock absorber and spring
Removing and installing the front ball joint
Removing and installing the front stabilizer
Removing and installing the front strut
Removing and installing front hub bearings
Rear suspension — design description
Rear suspension specifications
Removing and installing the rear shock absorber strut
Removing and installing the rear suspension arm and spring
Removing and installing the rear jet rod
Removing and installing rear hub bearings
Tyre designation
Wheel rim designation
Steering
Description of the steering design
Technical characteristics of the steering system
Tightening torques for threaded connections
Removing and installing the steering gear
Removing and installing the steering column
Removing and installing the steering wheel
Removing and installing the steering rod end
Brake system
General information about the braking system
Technical characteristics of the brake system
Tightening torques for threaded connections
Removing and installing front brake pads
Removing and installing the front brake caliper and brake disc
Removing and installing rear brake pads
Removing and installing rear wheel brake cylinders
Master Brake Cylinder — Removal and Installation
Vacuum brake booster — removal and installation
Bleeding the brake system
Adjusting the parking brake
Replacing the parking brake cables
Anti-lock braking system — design description
Maintenance of the brake system
Main faults of the brake system
Body
Body elements
General information about the car body
Radiator grille — removal
Hood release cable — removal and installation
Front bumper — removal and installation
Rear bumper — removal and installation
Trunk lid (Orion) — removal and installation
Headlining — Removal and Installation
Front seats — removal and installation
Rear seats — removal and installation
Outside mirror — removal and installation
Interior mirror — removal and installation
Air supply control panel
Adjusting the heating control cables
Heater Fan — Removal
Doors, locks and windows
Description of door construction
Removing and installing the side door
Removing and installing door trim
Removing and installing the door lock
Removing and installing the door lock cylinder
Adjusting the door installation
Removing and installing door glass
Removing and installing the rear door
Removing and installing the interior door opening handle
Electrical equipment
Equipment and devices
Technical characteristics of electrical equipment
Fuses and relays
Removing and installing the generator
Adjusting the V-belt tension
Replacing the generator brushes and voltage regulator Bosch
Replacing the Generator Brushes and Voltage Regulator Lucas
Motorola Generator and Voltage Regulator Brush Replacement
Main generator faults
Features of the starter design
Removing and installing the starter
Main faults of the starter
Removing and installing the instrument cluster
Removal and installation of measuring instruments
Removing and installing switches
Removing and installing the brake light switch
Lighting system
Replacing headlight bulbs
Headlight adjustment
Removing and installing headlights
Replacing the parking light and turn signal bulbs
Removing and installing the front turn signal
Replacing the rear light bulbs
Removing and installing the rear light
Replacing the license plate light bulb
Replacing the interior light bulb
Electrical circuits
General description and symbols on electrical diagrams
Starting system, battery, fan, sensors
Ignition systems (carburetor engines before 1995)
Ignition system (1.6 CVH engines and automatic transmissions before 1995)
Ignition and fuel injection systems (1.3 CFI engines before 1995)
Ignition and fuel injection systems (1.4 CFI engines before 1995)
Engine management system 1.6 EF
Zetec Engine Management System (16V)
External lighting, side lights, brake lights and reversing lights
External lighting, direction indicators, fog light
Interior lighting system
Horn, heated glass, electric mirrors
Central locking, power windows, windscreen and headlight washers
Starting system, battery, fan, horn
Control lamps and sensors, side lights
Headlamps, rear fog lamps
Direction indicators, brake lights and reversing lights
Interior lighting system, cigarette lighter, windshield washer
Windscreen and rear window defrosters, interior heater fan
Windscreen and rear window wipers, windscreen washer
CFI engine management system
SEFI engine management system
Ford Escort 5
General information
User manual
Vehicle identification
Opening the hood of the car
Car dashboard
Car instrument cluster
Steering column lock / ignition switch
Front and rear fog light switch
Windscreen heating switch
Rear window defroster switch
Analog and digital watches
Headlight leveling corrector
Multifunctional light and turn signal switch
Windscreen wiper/washer switch
Car keys and locks
Door locking system
Position of the car door
Central locking with double locking system
Anti-theft system of the car
Electrically adjustable exterior mirrors
Rear side windows (three-door version)
Electric side windows
Car interior lighting
Front seats of the car
Manual gearbox
Automatic transmission
Starting the car engine
Driving a car of various configurations
Heating and ventilation of the car
Car air conditioning
Maintenance
Filling capacities and specification of liquids
Consumables specifications and technical characteristics
Frequency of car maintenance
Checks every 400 km or weekly
Liquid leaks from the car
Weekly Check Points
Checking the coolant level
Checking the engine oil level
Checking the brake fluid level
Power steering fluid level
Incandescent lamps and fuses
Checking the windshield wipers
Engine compartment of the engine
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
Adjusting the Clutch Pedal Stroke (Models After 1996)
Checking the oil level in a manual transmission
Checking and adjusting idle speed and mixture quality
Checking the front suspension
Checking the rear suspension
Protective rubber covers for the drive shaft
Checking the brake system
Checking the oil level in an automatic transmission
Replacing spark plugs
Replacing the coolant
Replacing the air filter element
Exhaust emission control systems
Replacing transmission fluid in an automatic transmission
Adjusting the handbrake
Replacing the fuel filter
Engine
HCS and Endura-E engines
Technical specifications
General information
Compression check
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover
Valve clearances
Cylinder head valve mechanism
Cylinder head
Crankshaft pulley
Camshaft timing chain cover
Camshaft drive chain
Oil pan
Oil pump
Oil pump repair
Replacing the crankshaft sealing rings
Powertrain 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
Timing Belt Tensioner and Pulleys
Replacing the camshaft sealing ring
Camshaft, levers and tappets
Cylinder head
Oil pan
Oil pump
Disassembling the oil pump
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
Timing Belt Tensioner and Pulleys
Replacing camshaft sealing rings
Camshafts and hydraulic tappets
Cylinder head
Oil pan
Oil pump
Replacing the crankshaft oil seal rings
Flywheel or drive plate
Powertrain suspension
Gasoline engines
Technical specifications
Removing the engine together with the gearbox
Engine Removal and Installation (HCS and Endura-E Engines)
Removal and installation of CVH and RTE 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 cylinder block
Main and connecting rod bearings
Engine assembly sequence
Piston rings
Crankshaft main bearings
Installing pistons and connecting rods
Starting the engine after major repairs
Diesel engines
Technical specifications
Checking and adjusting valve clearance
Replacing the fuel filter
Nozzles
Fuel pump adjustment
Fuel pump BOSCH
Fuel pump CAV Roto diesel
Removing and installing the fuel pump
Cylinder head
Disassembling the engine
Checking engine parts
Checking the crankshaft and connecting rod clearances
Checking piston rings and piston clearance in the cylinder
Engine assembly
Removing and installing the oil pump
Checking oil pressure
Removing and installing the coolant pump
Replacing the coolant
Diesel engines (since 1992)
Fuel pump adjustment
Adjusting the idle speed
Fuel pump
Turbocharger
FORD EDC Electronic Engine Control Unit
Exhaust system
Fuel heater
Fuel filter
Removing air from the fuel system
Adjusting the fuel pump cable
Design and operation of electronic engine control FORD EDC
Electrical power supply of electronic engine control FORD EDC
Sensors
Executive devices
Turbocharger — removal and installation
Air radiator
Exhaust gas recirculation system
Exhaust gas recirculation valve
Bosch fuel pump vacuum control valve for 1.8 D engine
Cooling and heating
Technical specifications
General information
Antifreeze
Cooling system 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 RTE 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)
Eccentric control cable on models with automatic transmission STX
Accelerator pedal
Air damper control cable
Fuel pump
Fuel tank
Fuel level sensor
Check valve
Fuel tank filler pipe
Weber TLDM Carburetor
Weber TLDM Carburetor Fast Idle Speed Adjustment
Weber TLDM Carburetor Needle Valve and Float
Weber TLDM Carburetor Choke Damper
Removing and installing the Weber TLDM carburetor
Weber TLDM carburetor repair
Weber TLD Carburetor
Adjusting the Fast Idle Speed on a Weber TLD Carburetor
Weber TLD Carburetor Needle Valve and Float
Adjusting the automatic choke of the Weber TLD carburetor
Removing and installing the automatic air damper of the Weber TLD carburetor
Removing and installing the Weber TLD carburetor
Disassembly and assembly of the Weber TLD carburetor
Removing and installing the intake manifold
CFI fuel injection
Technical specifications
General information
Relieving pressure in the fuel system
Fuel lines
Air filter
Accelerator cable
Fuel pump
Fuel tank
Fuel level sensor, fuel pump
Automatic fuel pump switch
Checking the fuel injection system
Fuel injection system components
Intake manifold
EFI fuel injection
Technical specifications
General information
Air filter
Accelerator cable
Fuel pump
Fuel tank
Fuel injection system components
Intake manifold
SEFI fuel injection
Technical specifications
General information
Air filter
Accelerator cable
Fuel pump
Fuel tank
Fuel injection system components
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
Removing and installing the generator
Cleaning the generator and replacing the voltage regulator
Checking the engine starting system
Removing and installing the starter
Ignition system
Technical specifications
General information
Checking the ignition system
Ignition coil
Ignition unit for engines with carburetor
Ignition unit on the fuel injection system
Crankshaft angle sensor
Transmission
Clutch
Technical specifications
General information
Clutch cable
Clutch pedal
Removing the clutch
Clutch release bearing
Clutch release shaft and sleeve
Mechanical gearbox
Technical specifications
General information
Adjusting the gear shift rod
Removing and installing the gear shift lever and rod
Speedometer drive gear
Replacing the sealing rings
Reverse light switch
Removing and installing a B5 or iB5 gearbox
Mechanical gearbox MTX-75
Automatic gearbox
Technical specifications
General information
Gear shift rod
Gear shift mechanism
Speedometer drive gear
Removal and installation of automatic transmission
Drive shafts
Technical specifications
General information
Removing and installing drive shafts
Replacing the inner hinge protective cover
Replacing the outer hinge protective cover
Drive shaft faults
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 rear brake pads
Replacing the rear wheel brake cylinder
Rear brake shield
Replacing rear brake pads on disc brakes
Rear brake caliper
Rear brake disc
Master brake cylinder
Brake pedal
Brake pedal rod
Brake lines and hoses
Bleeding the brake system
Vacuum brake booster
Brake booster vacuum line
Handbrake operating mechanism (disc brakes)
Handbrake lever
Front handbrake cable
Rear handbrake cable
Brake pressure regulating valve
Pressure regulator (VAN models)
Adjusting the pressure regulator position (VAN models)
Anti-lock braking system (ABS)
Removal and installation of ABS system components
Car suspension
Technical specifications
General information
Steering knuckle
Replacing the front hub bearings (23 spline hub)
Replacing the front hub bearings (25 spline hub)
Front suspension strut
Front suspension shock absorber
Front suspension anti-roll bar
Front suspension lower cross member
Front cross beam
Replacing rear hub bearings
Rear shock absorbers
Repair of rear shock absorber strut
Rear axle
Replacing rear axle bushings
Rear shock absorbers (Combi and Van models)
Rear coil springs on estate models
Rear leaf spring on Van models
Rear axle (Van models)
Steering
Technical specifications
Steering wheel
Steering column
Steering column repair
Replacing the rubber protective covers of the steering gear
Steering gear
Power steering
Power steering pump
Bleeding the power steering system
Steering link rod end
Wheel alignment angles
Body
Technical specifications
General information
Car body care
Caring for upholstery and carpets
Repair of minor body damage
Repair of severe body damage
Bumpers
Hood
Hood lock cable
Hood lock
Door trim
Door glass
Window lifter
Door lock, lock cylinder and handles
Doors
Outside rear view mirror
Interior rear view mirror
Trunk lid
Trunk lid lock
Back door
Rear door lock
Central door locking system unit
Windshield
Overlays and emblems
Checking and adjusting the hatch
Seats
Seat belts
Interior trim
Instrument panel
Central 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
Indoor lighting lamps
External lighting devices
Headlight adjustment
Instrument cluster
Elements of the instrument cluster
Speedometer drive cable
Cigarette lighter
Watch
Sound signal
Windscreen wiper arms
Windscreen wiper motor and rods
Windscreen wiper arm drive
Rear door wiper
Windscreen washer
Radio receiver
Loudspeakers
Radio receiver antenna
Anti-theft system
Schematic diagrams
Information on diagrams of cars manufactured before 1996
Diagram 1. Starting, charging, cooling systems, alarms and indicators (before 1995)
Diagram 2. Ignition system (all carburetor models) (before 1995)
Diagram 3. Ignition system (CVH 1.6L engines with automatic transmission) (before 1995)
Diagram 4. Ignition and engine management system 1.3L CFI (before 1995)
Diagram 5. Ignition and engine management system 1.4L CFI (before 1995)
Diagram 6. Ignition and engine management system 1.6L EFi (before 1995)
Diagram 7. Zetec ignition and engine management system (16V) (before 1995)
Diagram 8. External lighting — side lights, brake lights, reverse lights (before 1995)
Diagram 9. External lighting — fog and main lights (before 1995)
Diagram 10. Interior lighting (before 1995)
Diagram 11. Alarm system, heating, heated glass and mirrors (before 1995)
Diagram 12. Windscreen wiper and washer system, central locking and power windows (before 1995)
Information on diagrams of cars manufactured since 1996
Diagram 2. Starting, charging, cooling systems, alarms and indicators (since 1996)
Diagram 3. Hazard warning lights, indicators, rear light and number plate light (since 1996)
Diagram 4. External 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. Glass 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 specifications
Engine Power System Specification
Fuel injection device specification
Ignition system specification
Starter and Generator Specification
Gearbox and Clutch Specification
Suspension and brake specifications
Light bulbs, fuses and relays
Engine tightening torques 1.1
Engine tightening torques 1.4i/1.6i
Tightening torques for diesel engine 1.8
Gearbox tightening torques
Suspension and brake tightening torques
Maintenance
General instructions for carrying out repairs
Correct lifting of the car
Engine
Disassembly and assembly
Description and location of engines
Removing the engine from the car
Installing the engine on a car
Disassembling the engine 1.1
Dismantling 1.4i/1.6i engines (with petrol injection)
Disassembling a 1.8 diesel engine
Engine assembly — general information
Engine assembly 1.1
Assembly of 1.4i/1.6i engines (with petrol injection)
Assembly of diesel engine 1.8
Block head
Inspection of the camshaft of the cylinder head
Removing and installing the engine cylinder head 1.1
Removal and installation of cylinder heads of 1.4i/1.6i engines
Removal and installation of the cylinder head of a 1.8 diesel engine
Disassembling the cylinder head of a gasoline engine
Checking and repairing the cylinder head and its parts
Checking and repairing the cylinder head of a 1.8 diesel engine
Checking the camshaft
Connecting rod and piston group
Checking the crankshaft
Checking the connecting rods
Checking the pistons
Installation of pistons with connecting rods in 1.1/1.4i engines
Checking the engine body
Checking the flywheel
Lubrication system
Description of the lubrication system
Checking the oil pump
Replacing the oil filter
Gas distribution system
Checking the engine timing 1.1
Checking the valve timing of 1.4i/1.6i engines
Checking the camshaft of a 1.8 diesel engine
Cooling system
Description of the cooling system
Removing the water pump in the 1.1 engine
Installing a water pump in a 1.1 engine
Removing the water pump in the 1.4i/1.6i engine
Installing a water pump in 1.4i/1.6i engines
Removing the water pump in a 1.8 diesel engine
Installing a water pump in a 1.8 diesel engine
Replacing the thermostat
Replacing the radiator and coolant
Supply system
Description of the power supply system
Carburetor repair and adjustment
Removing and installing the carburetor
Disassembling the carburetor
Carburetor cleaning
Petrol injection system in engines 1.1i/1.4i/1.6i
Removing and installing the coolant temperature sensor
Removing the electric throttle control motor
Installing a new electric motor
Removing and installing the pressure regulator
Removing and installing the throttle potentiometer
Removing and installing the injector
Removing and installing the CFJ device
Removing and installing the fuel pump
Replacing the fuel filter
Replacing the control device
Replacing the lambda probe
Removal and installation of other sensors
Exhaust gas discharge system
Diesel power system
Description of the diesel fuel supply system
Replacing the injector
Replacement of fuel injection pump
Installation of fuel injection pump
Replacing the fuel filter
Replacing spark plugs
Adjusting the engine idle speed
Ignition system
Description of ignition control
Replacing the coolant temperature sensor
Removing and installing the ignition coil
Removing and installing the engine speed sensor
Ignition and injection control system in 1.4i/1.6i engines
Removing and installing the ignition distributor
Removing and installing the ignition control module
Spark plugs and starting plugs
Transmission
Clutch
Description and testing of clutch operation
Removing and installing the clutch
Replacing the clutch control cable
Mechanical gearbox
Description of the five-speed manual transmission
Removing and installing the gearbox
Disassembling the gearbox
Disassembling the secondary shaft of the box
Assembly of the secondary shaft of the box
Disassembling the differential
Gearbox assembly
Automatic gearbox
Automatic transmission device
Removing the automatic transmission
Installation of automatic transmission
Checking the oil level
Replacing the manual control cable
Replacing the cam starter cable
Replacing the automatic transmission lock switch
Drive shafts
Description of drive axles
Replacing the axle shaft
Installing the axle shaft
Suspension and chassis
Front suspension
Description of front wheel suspension
Replacing the front wheel bearing
Replacing the front control arm
Replacing the ball joint
Removing and installing the suspension column
Disassembly and assembly of the suspension column
Rear suspension
Description of rear wheel suspension
Removing and installing the rear axle
Replacement and adjustment of rear wheel bearing clearance
Replacing the rear shock absorber
Replacing rubber bushings of the rear suspension
Steering
Description of the gear steering mechanism
Removing and installing the steering gear
Replacing the rubber boots of the steering gear
Removing and installing the steering column
Removing and installing the steering shaft
Wheel installation
Brake system
Description of the brake system
Adjusting the handbrake
Replacing disc brake pads
Replacing drum brake shoes
Removing and installing the front brake caliper
Removing and installing the brake disc
Replacing the rear brake cylinder
Replacing the handbrake cable
Replacing the master brake cylinder
Replacing the brake pressure regulator
Removal and installation of the brake booster
Bleeding the brake system and replacing brake fluid
Removing and installing the pressure regulating valve
Removing and installing the adjustment unit
Electrical equipment
Equipment and devices
General information about the battery
Checking the generator operation
Checking the regulated voltage
Removing and installing the generator
Checking the starter operation
Starter replacement
Headlights and windshield wipers
Removing and installing the windshield wiper motor
Heating and ventilation
Removing and installing the heater
Removing and installing the heater fan
Replacing fuses and relays
Electrical equipment diagrams
Brief description
List of conditional elements
List of grounding nodes
List of soldered units
Electrical diagram of the power supply system
Electrical diagram of the engine starting and battery charging system
Schematic diagram of the engine 1.1 (HSS-Valencia)
Schematic diagram of the engine 1.4 (CVH)
Schematic diagram of the 1.4 Fiesta XR2i engine
Schematic diagram of the engine 1.6 (CVH)
Schematic diagram of 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
Car engine lineup
Appendix 1. Technical data and characteristics
Volumes of operating fluids
Working conditions and tools
Purchase of spare parts
Workplace
Main working tool
Special tools and accessories
Professional tips for mechanics
Submitting a car for repair
Lifting a car
Car care
Interior cleaning
Car wash
Car wash outside
Engine wash
Lubrication of joints and assemblies
Care of the paintwork
Repairing damage from rock strikes
Polishing of small scratches
Removing deep scratches
Windscreen wiper and washer
Checking the windshield wiper and washer
Filling the windshield washer reservoir with fluid
Replacing brushes
Adjusting the windshield washer jets
Removing the jets
Removing the windshield wiper arm
Removing the windshield wiper gear motor
Removing the rear window gear motor
Possible malfunctions of the windshield wiper drive mechanism, their causes and methods of elimination
Power unit
Engine repair
General information about the engine
Nominal crankshaft speed and engine service life
Engine compression
Checking the poly V-belt
Engine diagnostics based on knocking sounds from the engine compartment
Determining bearing or liner 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
Motor 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 adding coolant
Replacing the coolant
Protecting the Fiesta engine from frost down to -30°C
Removing and checking the thermostat
Radiator fan
Troubleshooting the Radiator Fan
Removing the radiator fan
Removing the radiator
Replacing cooling system hoses
Possible malfunctions of the cooling system
Possible thermostat malfunctions and their causes
Air filter
Air filter and sound-absorbing pipe
Preheating of intake air
Symptoms of intake air preheating malfunctions
Fuel injection system
General information about the fuel injection system
Main systems and components of the EEC-V fuel injection
Checking the fuel injection system
Elimination of unstable engine crankshaft speed at idle
Checking the idle speed actuator
Checking the injectors
Accelerator cable
Replacing the accelerator cable on vehicles with Endura-E engines
Replacing the accelerator cable on cars with Zetec engines
Adjusting the accelerator cable
Diesel engine injection system 1.8D
Visual inspection of the diesel engine injection system
Adjusting the air-fuel mixture supply
Replacing the accelerator cable
Replacing the air filter
Possible malfunctions of the fuel injection system
Possible malfunctions of the fuel injection system of a diesel engine
Ignition system
General information about the ignition system
Electronic control unit
Adjusting the ignition timing angle
Ignition coil
Spark plugs
Every 45,000 km – removal, inspection and replacement of spark plugs
Temporary change of ignition timing to adjust fuel octane number
Turning off the ignition, checking the ignition unit and high-voltage wires
Checking the engine crankshaft 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
Measuring the resistance of the ignition coil
Removing the ignition unit
Possible engine and ignition system malfunctions
Supply system
General information about the fuel supply system
The most important elements of the power supply system
Fuel types and handling
Checking the fuel tank ventilation valve
Replacing the fuel filter on cars with gasoline engines
Replacing the fuel filter on cars with diesel engines
Removing water from the fuel filter of cars with diesel engines
Draining fuel from the tank without a hand pump
Removing fuel lines and hoses
Electric Fuel Pump Malfunctions
Removing the fuel pump on cars with gasoline engines
Exhaust system
General information about the exhaust system
Recommendations for replacing the exhaust system
Checking the technical condition of suspension elements and exhaust system
Replacement of the exhaust system, including the catalytic converter
Reducing toxicity of exhaust gases
Transmission
General information about transmission
General information about the clutch
Checking the clutch
Incomplete clutch disengagement
Five-speed gearbox
Adjusting the gear shift mechanism
Checking the transmission oil level
Topping up transmission oil
Continuously variable automatic transmission STX
Checking the level of working fluid in the automatic transmission STX
Replacement of working fluid and filter in automatic transmission STX
Main gear
Checking the protective covers of the constant velocity joints of the drive shafts
Removing the wheel drive shaft
Replacement of constant velocity joint protective boots
Possible clutch malfunctions
Possible malfunctions of the automatic transmission STX
Chassis
Car suspension
General information about suspension and steering
Front suspension
Rear suspension
Front suspension geometry
Checking shock absorbers
Checking the bushings of the transverse arm of the independent front suspension
Checking the play of wheel hub bearings
Removing the front suspension wishbone
Installing the front suspension wishbone
Removing the shock absorber strut
Replacing the wheel hub bearing
Removing the rear shock absorber
Replacing the rear wheel hub bearings
Steering
Checking the steering play
Checking the steering gear protective covers
Checking ball joints and dust covers of tie rod ends
Replacing ball joints of steering rod ends
Replacing the steering rod mudguards
Replacing the steering knuckle
Installing the steering knuckle
Removing the steering wheel
Replacing the coil spring
Power steering
Wheels and tires
Wheel and tire sizes
Construction and marking of tires
Wheel replacement
Checking the condition of the tires
Brake system
General information about the braking system
Checking the hydraulic drive of the brake system
Checking the brake booster
Anti-lock braking system (ABS), BTCS and EBD
Fiesta car 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 thickness of the brake shoe linings of the rear drum brakes
Removing air from the brake system (bleeding)
Replacing brake fluid
Removing the brake fluid reservoir from the brake master cylinder
Removing the master brake cylinder
Removing the 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 protective ring
Removing the brake drum
Replacing brake pads on rear drum brakes
Removing the wheel brake cylinder
Parking brake
Replacing the parking brake cables
Adjusting the parking brake
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 lighting bulbs
Checking the door contact switch
Replacement of the trunk light bulb
Removing the radio
Removing the speakers
Removing the external antenna
Front seats
Back seat
Backrest of the rear seat
Removing the door trim
Removing the door glass window regulator
Central lock
Removing the door handle
Removing the door lock cylinder
Possible heating malfunctions
Possible malfunctions of electric 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
Replacing the rear view mirror
Removing the hood
Removing the front bumper
Removing the wing
Installing the wing
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
Replacing the poly V-belt
Outdoor lighting
Replacing headlight bulbs
Replacing the turn signal lamp
Replacing the parking light bulb
Replacing the side turn signal repeater bulb
Replacing the fog light bulb
Rear combination lights
Rear combination lights for Courier cars
Replacing headlight lenses
Replacing the license plate light bulb
Temporary headlight adjustment
Signaling devices
Checking the brake light switch
Checking the sound signal
Control and measuring instruments and controls
Checking switches
Removing the instrument cluster
Replacing indicator lamps
Removing measuring instruments
Electrical circuits
Fuses in the passenger compartment and engine compartment
Replacing fuses
Relays and control circuits
Possible malfunctions of hazard warning lights 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 battery charge level
Starting an engine with a discharged battery
Charging the battery
Removing the battery
Checking the voltage regulator
Removing the generator
Removing the starter
Possible faults of the battery and generator
Possible starter malfunctions
Ford Taurus 1 and 2
General information
Characteristics
Vehicle identification number
Conventional designations
Unit Conversion Table
Adjustment parameters of vehicle systems
Maintenance
Jacking and towing
General specifications of the car
Introduction to Maintenance
Maintenance schedule
Checking fluid levels
Tires and tire pressure monitoring
Checking the power steering fluid level
Checking the fluid level in the automatic transmission
Changing engine oil and filter
Adjusting the clutch pedal
Checking and replacing under-hood pipes
Checking, adjusting and replacing the drive belt
Replacing the air filter
Checking the PCV valve and crankcase ventilation filter
Checking the fuel system
Replacing the fuel filter
Checking the cooling system
Checking the exhaust system
Changing tires
Checking shock absorbers
Checking the steering and suspension
Checking the brakes
Automatic transmission control rod lubrication
Checking the oil level in a manual transmission
Checking and disassembling the rear wheel bearing (up to 1989)
Replacing spark plugs
Checking and replacing spark plug wires
Maintenance of the cooling system (draining, flushing, filling)
Automatic transmission fluid and filter replacement
Troubleshooting
Engine diagnostics
Diagnostics of engine electrical equipment
Fuel system diagnostics
Cooling system diagnostics
Clutch diagnostics
Diagnostics of a manual transmission
Automatic transmission diagnostics
Axle drives and CV joints
Brake diagnostics
Suspension and steering diagnostics
Engine
Four-cylinder engine
Engine Specifications and Tightening Torques
General information
Repair operations permitted with the engine still in place
Removal and installation the valve cover
Removal, checking and installation valve levers and push rods
Location of top dead center (TDC) of piston No. 1
Replacing valve springs, gaskets and retainers
Measuring Camshaft Cam Wear
Removal and installation the intake manifold
Removal and installation the exhaust manifold
Removal and installation cylinder heads
Valve lifters — removal, inspection and installation
Removal and installation the oil pan
Oil pump — removal and installation
Checking and replacing the engine suspension and shock absorbers
Six-cylinder engine
Engine Specifications and Tightening Torques
Repair operations available with the engine still in place
Removal and installation valve covers
Removal, installation and adjustment of valve levers and push rods
Replacement of springs, retainers, valve seals
Removal and installation the intake manifold
Exhaust manifolds — removal and installation
Removal and installation cylinder heads
Replacing the front crankshaft oil seal
Removal and installation the camshaft drive chain cover
TDC location for piston #1
Removal and installation the camshaft drive chain and sprockets
Valve tappets — removal, inspection, installation
Removal and installation the oil pan
Oil pump and oil receiver — removal and installation
Checking and replacing the engine shock absorber suspension
Overhaul
Four-cylinder engine specifications
3.0LV6 Engine Specifications
3.8LV6 Engine Specifications
General information
Checking cylinder compression
General information about major repairs
Engine — removal and installation
Engine overhaul — disassembly sequence
Disassembling the cylinder head
Cylinder heads — cleaning and inspection
Cylinder head overhaul
Removal and installation the flywheel or drive plate
Replacing crankshaft seals
Front cover, camshaft drive chain and sprockets
Camshaft, balance shaft and bearings
Removal pistons and connecting rods
Removal 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
Installing piston rings
Installing the crankshaft and checking the oil clearance of the main bearings
Installing pistons and connecting rods, checking the oil clearance in the connecting rod bearing
Starting and running in the engine after major repairs
Cooling system
Tightening torque specifications
Cooling, heating, air conditioning systems
General information about antifreeze
Replacing the thermostat
Electric fan — description, checking and replacement of elements
Removal and installation the radiator
Checking and replacing the cooling system fan thermostat
Removal and installation the coolant reservoir
Checking the water pump
Water pump — removal and installation
Air conditioning and heating systems maintenance
Removal and installation 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 the air conditioning compressor
Removal and installation the air conditioner condenser
Air conditioner accumulator and pressure switch
Fuel/exhaust systems
Specifications
General information about the fuel and exhaust system
Relieving fuel system pressure
Replacement of fuel lines and pipeline connections
Checking the fuel pump
Gas tank — removal and installation
General information on cleaning and repairing the gas tank
Removal and installation the fuel pump
Removal and installation the air cleaner housing
Removal and installation throttle connection elements
Fuel injection system — general information
Measuring pressure in the fuel injection system
Replacing components of the central fuel injection (CFI) system
Replacing components (EFI) of the electronic fuel injection system
Replacing EFI system components (for 3.8LV6 engines)
Replacement of exhaust system components
Engine electrics
Specifications and General Information
Removal and installation the battery
Checking and replacing battery cables
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 angle
Electronic ignition unit check and replacement
Checking and replacing the Hall sensor stator distributor block
Power supply system — general information and safety precautions
Checking the power supply system
Generator — removal and installation
Replacing the generator brushes (type EVR)
Replacing the External Voltage Regulator (EVR)
Replacing the generator brushes (type IAR) / voltage regulator
Starting system — general information
Checking the engine and starter electrical circuit
Removal and installation the starter motor
Removal and installation the starter relay
Emission control
General information
Electronic Engine Control System (EEC — IV)
Exhaust Gas Recirculation (EGR) System
Manifold Air Intake Control System
Fuel 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 oil in manual transmission
Removal and installation the gear shift handle
Removal and installation of manual transmission
General information on gearbox overhaul
Replacing the speedometer drive mechanism sealing ring
Automatic gearbox
Tightening 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 automatic transmission
Adjusting the automatic transmission drive mechanism
Adjusting the Throttle Valve (TV) Control Mechanism
Checking and replacing the gearbox suspension
Replacing and adjusting the neutral start sensor
Clutch and drives
Specifications
General information
Checking the clutch operation
Clutch — removal, inspection and installation
Thrust bearing and its fork — removal, inspection and installation
Removal and installation the clutch cable
Internal starter/clutch switch
Checking axle drives, CV joints and covers
Removal and installation of axial drives
Replacement of the axle drive housing and CV joint overhaul
Replacing differential seals
Chassis
Brake system
Specifications
General information and safety precautions
Front brake pads — replacement
Front Disc Brake Caliper — Removal and Installation
Front brake disc — inspection, removal and installation
Brake drum — removal, inspection and installation
Replacing rear brake shoes
Wheel cylinder — removal, overhaul and installation
Master cylinder — removal, overhaul and installation
Brake pressure control valves
Brake system hoses and lines — inspection and replacement
Bleeding the brake hydraulic system
Adjusting the parking brake
Replacing the parking brake cables
Parking brake pedal — removal and installation
Removal and installation the 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 rear brake pads
Rear Disc Brake Caliper — Removal and Installation
Rear brake disc — inspection, removal and installation
Car suspension
Tightening torque specification
General information
Front anti-roll bar, control arm and bushings
Ball joints — inspection and replacement
Front Torque Rod and Elastic Joint — Removal and Installation
Front arm — removal, inspection and installation
Front shock absorber and coil spring assembly — removal and installation
Front shock absorber unit — replacement
Steering knuckle 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 unit (sedan) — replacement
Rear wishbones (sedan) — removal and installation
Jet thrust and ball joint cushions (sedan) — removal and installation
Wheel knuckle — removal and installation
Rear shock absorbers (station wagon) — removal and installation
Upper Rear Suspension Arms (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 knuckle (station wagon) — removal and installation
Replacing 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 the steering gear covers
Wheels and tires — general information
Front Wheel Alignment — General Information
Body
Repair and maintenance
Tightening torque specification
General information and care
Hood — removal, installation, adjustment
Front fender liner — removal and installation
Removal and installation the hood lock and cable
Door — removal, installation, adjustment
Trunk lid — removal, installation, adjustment
Tailgate of bodies (station wagon) — removal, installation, adjustment
Bumpers — removal and installation
Removal and installation 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 electrical equipment faults
Connectors — General Information
Fuses — General Information
Fusible Links — General Information
Circuit Breakers — General Information
Replacing the multifunction switch
Replacing the ignition key lock cylinder
Replacing the wiper switch and motor
Replacing the turn signal and hazard warning flasher
Headlight Switch and Dimmer/Rheostat Replacement
Headlights — removal and installation
Replacing lamps
Radio and speakers — removal and installation
Checking and replacing the radio antenna
Instrument panel — removal and installation
Instrument cluster — removal and installation
Repair and replacement of rear window heater and switch
Sound signal — check and replacement
Checking the cruise control system
Electrical diagrams
Ford Fusion
General information
Vehicle device
General information about the Ford Fusion
Vehicle Passport Data
Car keys
Instruments and controls
Instrument cluster
Trip computer
Heating (air conditioning) and ventilation of the passenger compartment
Door locks — opening and blocking
Window lift control
Seat belts on the front seats
Seat belts in the rear seats
Adjusting the position of the front seats
Rear seats
Using child seats
Adjusting the position of the steering wheel
Rear view mirrors
Interior lighting
Sun visors
Hood — opening and closing
Gearbox control
User manual
Safety regulations
Operating recommendations
Traffic safety recommendations
Running in a car
Operation of the vehicle during the warranty period
Preparing the car for departure
Filling up a car with petrol
Using a jack
Towing a car
Faults on the way
General techniques for starting an engine
Malfunctions in the starting system
Checking the ignition system
Checking the engine fuel system
Fuel injection system faults
Idle speed is gone
Engine misfires
Diagnosis of engine condition by the appearance of spark plugs
The car moves in jerks
The car accelerates poorly
The engine stalled while driving
Oil pressure dropped
Engine overheating
Checking the cooling system
The battery is not recharging
Checking electrical equipment
Starting the engine from external power sources
Electrical equipment faults
There was a knocking noise in the engine
Knocking noises appeared in the suspension and transmission
Possible causes of knocking in the suspension and ways to eliminate them
Possible transmission knocks (noises), their causes and methods of elimination
Vibration and shock on the steering wheel
Brake system malfunctions
Bleeding the brake system
Checking the brake system
Puncture and replacement of a wheel
Maintenance
Maintenance schedule
Safety regulations
Checking the wheels
Checking the level and adding oil to the engine
Checking the level and adding coolant
Checking the level and adding fluid to the brake and clutch reservoir
Checking the level and adding fluid to the power 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 cooling system hoses and connections
Checking the exhaust system
Checking the tightness of fuel lines
Checking and replacing the air filter element
Replacing the fuel filter
Checking the level and adding oil to the gearbox
Checking the front wheel drive protective covers
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 angles
Inspection and testing of the steering system on the vehicle
Checking the free play (play) of the steering wheel
Checking the tightness of the hydraulic brake drive
Checking the degree of wear of brake pads, discs and drums
Checking the operation of the brake booster
Checking the efficiency of the braking system
Checking the parking brake
Battery Maintenance
Checking and adjusting headlights
Lubrication of body fittings
Cleaning drainage holes
Replacement and maintenance of spark plugs
Replacement of auxiliary drive belt
Replacing the power steering pump drive belt
Replacing the timing belt and its tension roller
Replacing brake fluid in hydraulic brake and clutch release systems
Replacing the coolant
Tightening torques for threaded connections
Lamps used in the car
Fuels and lubricants and operating fluids
Tips for the car owner
Purchase of spare parts
Trip to the service station (STO)
How to prepare your car for winter
Recommendations for starting the engine in severe frost
What is useful to buy for winter
Useful winter tips
Recommendations for preparation for technical inspection
List of faults and conditions under which operation of vehicles is prohibited
Changes to state standards
Safety precautions during repair work
Tools for car repair and maintenance
Before you start working
Restoration of threaded connections
Auto Body Repair Tips
Power unit
Engine repair
Features of engine design
Possible engine malfunctions, their causes and solutions
Useful tips for engine repair
Checking the compression in the cylinders
Removal and installation the engine mudguard
Replacing the right powertrain suspension support
Replacing the left support of the powertrain suspension
Replacing the rear support of the powertrain suspension
Setting the piston of the first cylinder to the TDC position of the compression stroke
Removal, installation and inspection of the flywheel
Replacing the cylinder head cover gasket
Replacing the cylinder head gasket
Replacing valve stem seals
Replacing camshaft seals
Replacing crankshaft seals
Replacing the oil pan seal
Replacing the intake manifold gasket
Replacing the catalytic converter gasket
Adjusting valve clearances
Cylinder head — general information
Replacing camshafts
Lapping valves
Removal and installation the engine
Lubrication and cooling system
Design features of the engine lubrication system
Removal and installation the oil pump
Oil pump repair
Features of the design of the engine cooling system
Removal and installation the electric fan of the radiator of the cooling system
Replacing the cooling system radiator
Removal and installation the water pump
Removal and installation the thermostat
Removal and installation the expansion tank
Supply system
Features of the design of the engine power supply system
Checking the pressure in the fuel system
Reducing pressure in the fuel system
Removal and installation the air filter
Replacing the fuel tank
Replacing the fuel pump
Checking and replacing the fuel pressure regulator
Removal, inspection and installation of fuel injectors
Removal and installation the fuel rail
Removal and installation the throttle assembly
Removal and installation the accelerator pedal
Exhaust and vapor recovery
Design features of the exhaust system
Replacing the exhaust system suspension cushions
Removal and installation the catalytic converter
Replacing the main and additional mufflers
Removal and installation of thermal screens
Features of the fuel vapor recovery system
Replacing the fuel vapor recovery system canister
Transmission
Clutch
Clutch design features
Possible clutch malfunctions, their causes and solutions
Checking the Clutch Release Pedal Travel
Removal and installation the clutch
Replacing the clutch release drive slave cylinder with bearing
Replacing the clutch release master cylinder
Replacing the clutch release hydraulic lines
Removal and installation the clutch pedal
Bleeding the clutch release hydraulic drive
Car gearbox
Gearbox design features
Gearbox oil change
Replacing gearbox seals
Removal and installation the gearbox
Replacing gearbox control cables
Removal and installation the gearbox control lever linkage
Adjusting the gearbox control drive
Front wheel drives
Design features of drive shafts
Possible faults of front wheel drives
Removal and installation front wheel drives
Replacing constant velocity ball joints
Replacing the intermediate support bearing
Chassis
Front suspension
Features of the front suspension design
Possible faults of the front suspension
Removal and installation the shock absorber strut
Shock absorber strut repair
Replacing the upper shock absorber strut support
Replacing the shock absorber strut ball joint
Replacing the front suspension arm
Replacing the front suspension stabilizer bar
Removal and installation the steering knuckle
Replacing the front hub bearing
Removal and installation the front suspension crossmember
Rear suspension
Features of the rear suspension design
Possible faults of the rear suspension
Replacing the rear shock absorber
Replacing the rear suspension spring
Replacing the silent blocks of the rear suspension arms
Replacing the rear hub bearing
Replacing the rear suspension beam
Steering
Features of the steering design
Possible malfunctions of the power steering
Removal and installation the steering wheel
Removal and installation the steering column
Replacing the outer tie rod end
Replacing the steering rod
Bleeding the power steering system
Replacing the power steering fluid reservoir
Replacing the steering gear
Replacing the power steering pump
Brake system
Features of the brake system
Possible malfunctions of the brake system
Bleeding the hydraulic brake system
Checking the brake pedal position
Master Brake Cylinder — General Information
Replacing the brake master cylinder reservoir
Replacing the master brake cylinder
Brake booster — general information
Replacing the brake booster
Replacement of hydraulic brake hoses and tubes
Replacing brake hoses
Replacing brake pipes
Replacing the brake pads of the front wheel brake mechanism
Replacing the caliper assembly with the pad guide
Replacing the brake disc
Rear wheel brakes — general information
Removal and installation the brake drum
Replacing the brake pads of the rear wheel brake mechanism
Replacing the rear wheel brake slave cylinder
Adjusting the parking brake drive
Replacing the rear parking brake cables
Wheels and tires
Wheel rim markings
Tire markings
Wheel replacement
Wheel nuts
Tire running-in
Tire storage
Wheel balancing
Anti-skid chains
Spare wheel
Checking tire pressure
Checking the tire tread
Checking the valve
Checking the radial and lateral runout of the discs
Body
Exterior
Features of the body design
Possible bodywork faults
Removal and installation the radiator grille
Removal and installation wheel mudguards and fender liners
Removal and installation the front bumper and its bar
Removal and installation the rear bumper
Removal and installation the front wing
Removal and installation the air intake box grille
Removal and installation the hood
Removal, installing and adjusting the hood lock
Removal and installation the outside mirror
Removal and installation the battery shelf bracket
Interior
Removal and installation the front seat
Removal and installation the rear seat
Removal and installation the floor tunnel lining
Design features of the passive safety system
Removal and installation the driver's airbag
Replacing the front seat belt
Replacing the rear seat belt
Electronic control unit of additional passive safety system
Removal and installation the interior mirror
Features of the instrument panel design
Removal and installation the instrument panel
Design features of the heater and air conditioner
Control unit for heating, air conditioning and ventilation of the passenger compartment
Removal and installation the incoming air filter
Replacing handrails in the cabin
Replacing the glasses compartment
Replacing sun visors
Removal and installation of interior trim
Removal and installation steering column covers
Removal and installation trunk trims
Doors, locks and windows
Removal and installation the front door trim
Front door glass replacement
Replacing the front door window regulator
Replacing the outside handle and lock of the front door
Replacing the inner handle of the front door lock drive
Replacing the front door opening limiter
Removal and installation the front door
Removal and installation the rear door trim
Rear door glass replacement
Replacing the rear door window regulator
Replacing the outside handle and rear door lock
Replacing the inner handle of the rear door lock actuator
Replacing the rear door opening limiter
Removal and installation the rear door
Replacing the tailgate stops
Removal and installation the rear door trim
Removal and installation the decorative trim on the tailgate
Replacing the tailgate lock
Removal and installation the tailgate
Removal and installation the fuel tank filler pipe hatch cover
Removal and installation the fuel tank filler pipe hatch lock
Windscreen wiper — general information
Replacing windshield wiper blades
Replacing windshield wiper arms and rods
Windscreen wiper trapezoid assembly with gear motor
Rear Window Wiper — General Information
Replacing the rear window wiper blade
Replacing the rear window wiper arm
Replacement of fixed body glazing
Body сare
Car body wash
Polishing of the body paintwork
Anti-corrosion protection of the body
Preparation and anti-corrosion treatment of hidden cavities
Body sealing
Caring for upholstery and carpets
Car engine wash
Electrical equipment
Equipment and devices
Features of the design of electrical equipment
Diagnostics of faults of on-board electrical equipment
Location and replacement of fuses, fuse links and relays
Windscreen wiper motor gearbox replacement
Replacement of the rear window wiper motor
Removal and installation the windshield washer
Replacing the front door window lift motor
Electric motor of the radiator fan of the cooling system
Removal and installation the heater electric fan
Heater recirculation flap motor
Replacing the additional resistance of the heater electric fan
Electric heating of the rear door glass
Features of the instrument cluster design
Removal and installation the instrument cluster
Removal and installation speakers of the acoustic system
Removal and installation a car radio
Removal and installation the antenna
Removal and installation the audio system remote control
Removal and installation the cigarette lighter socket
Electronic anti-theft system remote control
Electronic anti-theft system control
Replacing the battery in the remote control
Removal and installation the electronic anti-theft system control unit
Features of the immobilizer design
Additional functions of the immobilizer
Engine electrics
Features of the battery design
Possible faults of the battery
Removal and installation the battery
Charging the battery
Design Features of the Generator
Possible generator faults
Removal and installation the generator
Generator repair
Features of the starter design
Possible starter malfunctions
Removal and installation the starter
Starter repair
Checking the ignition switch (lock)
Replacing the ignition switch (lock) contact group
Replacing the ignition switch cylinder
Removal and installation the ignition switch (lock)
Design features of the engine management system
Possible malfunctions of the engine management system
Checking the ignition coil
Removal and installation the ignition coil
Replacing the electronic engine control unit
Checking and replacing engine management system sensors
Lighting and signaling
Features of the lighting and signaling design
Replacing lamps in lighting fixtures
Headlight replacement
Replacing the side turn signal light
Front Fog Light Replacement
Replacing the rear light
Replacing an additional brake light
Replacing license plate lights
Replacing the front interior light
Replacing the rear interior light
Replacement of the trunk light
Replacing steering column switches
Removal and installation the horn
Switches and sensors
Replacing the external lighting control unit
Replacing the instrument panel switches
Replacing the hazard warning switch
Replacing the control unit for exterior mirrors
Replacing the electric trunk lock switch
Checking and replacing the fuel level indicator sensor
Replacing the pressure sensor in the power steering system
Checking and replacing the reverse light switch
Replacing the brake light switch
Replacing the clutch pedal position sensor
Replacing the brake pedal position sensor
Replacing the Parking Brake Indicator Light Switch
Replacing the fuel switch
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 supply system
Scheme 4. Engine starting system for cars with manual transmission
Diagram 5. Charging system
Scheme 6. Ignition system
Scheme 7. Car audio system
Scheme 8. Cooling system
Diagram 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
Scheme 15. Sound signal
Scheme 16. Clock in the car interior
Scheme 17. Heating and ventilation system
Scheme 18. Air conditioning system
Scheme 19. Interior lighting of the salon
Scheme 20. Daytime driving lights (DRL system)
Scheme 21. Fog lights
Scheme 22. Car headlights
Scheme 23. Side lights and number plate illumination
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 windshield washer
Scheme 30. Heating of the rear door glass and mirrors
Scheme 31. Lock drive
Scheme 32. Central lock
Scheme 33. Seat heating
Ford Scorpio 1
General information
User manual
Vehicle identification
Instrument panel and instrument cluster
Steering column control levers
Car keys
Doors — opening and locking
Steering column lock / ignition switch
Manual gearbox
Automatic transmission
Electric power windows
Adjusting the position of the steering wheel
Front seats
Interior lighting
Electrically adjustable exterior rear view mirrors
Increased luggage compartment volume
Windscreen wipers and washers
Lifting a car
Towing a car
Starting the engine
Starting a gasoline engine
Starting a diesel engine
Features of vehicle operation
Maintenance
Frequency of vehicle maintenance
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 plugs
Replacing the air filter
Replacing the fuel filter
Replacing the engine crankcase ventilation valve
Checking the fluid in the air conditioning system
Checking the gearbox oil level
Checking the oil level in the rear axle
Checking the condition of the drive shaft protective cover
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
Checking the condition of the suspension
Checking the Power Steering Fluid Level
Cleaning the air conditioner condensate drain
Recommendations for motor oils
Filling tanks and operating fluids
Power unit
Petrol engines OHC
Technical characteristics of OHC engines
Engine adjustment
Repairs that do not require engine removal
Removal and installation the timing belt
Removal the cylinder head
Disassembly and assembly of the cylinder head
Installing the cylinder head
Removal and installation the oil pan
Replacing the front crankshaft seal ring
Replacing the rear crankshaft seal ring
Replacing engine mounts
Removal and installation the engine
Disassembling the engine
Identification of interacting parts
Engine assembly
Replacing pistons
Removal and installation the intermediate shaft
Gas distribution system
Starting the engine after major repairs
OHC engine lubrication system
Crankcase ventilation system
Petrol engines DOHC
DOHC Engine Specifications
Repairs that do not require engine removal
Timing chain and sprockets
Cylinder head — design description
Removal the cylinder head
Disassembly and assembly of the cylinder head
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 the rear crankshaft seal ring
Removal the engine
Additional operations for engine removal on vehicles with automatic transmission
Additional operations for removing the engine with gearbox
Engine installation
Disassembling the engine
Cylinders — Checking for wear
Checking and restoring pistons and piston rings
Piston pins and connecting rods
Crankshaft — Checking and Installing
Main and connecting rod bearings
Flywheel — Checking and Installing
Engine assembly
Starting the engine after major repairs
Crankcase ventilation system
Removal and installation the oil pan
Removal and installation the oil pump
Disassembling the oil pump
Petrol engines V6
View of the engine bay of a V6 engine
Technical characteristics of V6 engines
Repairs that do not require engine removal
Removal the engine
Disassembling the engine
Checking the degree of wear of engine parts
Rocker arm axle assembly
Valve tappets and tappet rods
Camshaft — Checking for Wear
Cylinder heads
Cylinders — Checking for wear
Checking and restoring pistons and piston rings
Piston pins and connecting rods — inspection
Crankshaft — Check
Main and connecting rod bearings
Timing gears — check
Flywheel — Checking and Installing
Lubrication system — general information
Oil pump — removal and installation
Crankcase ventilation system
Engine assembly — general information
Installing the crankshaft
Installing the camshaft
Installing pistons and connecting rods
Installing an oil pump
Installing the flywheel
Installing the timing gear and cover
Installing the oil pan, water pump and crankshaft pulley
Removal and installation the oil heat exchanger
Cylinder heads, rocker shafts and intake manifold
Adjusting valve clearances
Engine Auxiliary Parts
Engine installation
Removal the 2.4 and 2.9 liter engine
Cylinder heads for 2.4 and 2.9 liter engines
Replacing the timing chain 2.4 and 2.9 liters
Adjusting the valve clearance of the 2.4 and 2.9 liter engine
Oil pump for 2.4 and 2.9 liter engines
Ignition and control
Ignition and engine management systems — general information
Technical characteristics of the ignition system
Ignition system ESC II — design description
Ignition system EEC IV — design description
Ignition distributor
Checking the ignition timing angle
Ignition unit (models with fuel injection system)
Ignition coil
Fuel trap on engines with carburetor
Engine control unit
Carburetor stepper motor
Device for heating the intake manifold of engines with a carburetor
Engine Management System Relay
Setting the ignition timing and idle speed
Crankshaft speed and position sensor
Air temperature sensor
Fuel temperature sensor
Vehicle speed sensor
Manifold Absolute Pressure (MAP) Sensor
Diesel engines
Diesel engines — general information
Technical characteristics of diesel engines
Repairs that do not require engine removal
Checking and adjusting valve clearances
Fuel system — design description
Injectors — removal, inspection and installation
Glow Plugs — Checking
Checking the compression in the cylinders
Removal air from the fuel system
Removal and installation the fuel pump
Checking and adjusting idle speed
Idle Speed Increase Cable — Removal and Installation
Removal the cylinder head
Installing the cylinder head
Checking and repairing the cylinder head
Removal and installation the engine
Disassembling the engine
Engine assembly — general information
Installing the rear main bearing
Installing side seals
Assembling the piston-connecting rod unit
Selection of pistons by cylinder diameter
Assembly of the timing drive
Further steps for engine assembly
Turbocharger — removal and installation
Oil pump — removal and installation
Checking oil pressure
Draining the cooling system
Filling the system and removing air
Cooling system fan
Removal and installation the fan clutch
Removal and installation the thermostat
Typical engine faults
Cooling system
Technical characteristics of the cooling system
Draining the coolant
Flushing the cooling system
Filling the cooling system
Removal and installation the radiator
Removal and installation the thermostat
Removal and installation a fan with a hydraulic clutch
Removal and installation an electric fan
Coolant pump — removal and installation
Coolant temperature sensor
DOHC Engine Drive Belt
Drive belt tensioning mechanism
Supply system
General information about the fuel system
Fuel system specifications
Fuel used for the car
Unleaded petrol for V6 engines, 2.4 and 2.9 litres
Removal and installation 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 the fuel tank
Removal and installation the fuel level sensor
Removal and installation the inertial fuel supply switch
Removal and installation the accelerator pedal
Removal and installation the accelerator cable
Fuel steam separator
Removal and installation the intake manifold
Carburetors
Pierburg carburetor — design description
Adjusting the idle speed and mixture quality (Pierburg)
Adjusting the throttle damper of the first chamber (Pierburg)
Adjusting the starting clearance of the air damper (Pierburg)
Removal and installation a Pierburg carburetor
Disassembling the Pierburg carburetor
Assembling a Pierburg carburetor
Fast Idle Adjustment (Pierburg)
Changes to the Pierburg 2V carburetor from September 1986
Weber 2V Carburetor — Design Description
Adjusting idle speed and mixture quality (Weber 2V)
Removal and installation the Weber 2V carburetor
Assembly and adjustment of the Weber 2V carburetor
Adjusting the air damper clearance (Weber 2V)
Adjusting the intermediate stage clearance (Weber 2V)
WEBER 2V TLD Carburetor — Design Description
Removal and installation the Weber 2V TLD carburetor
Adjusting idle speed and mixture quality (Weber 2V TLD)
Float chamber needle valve (Weber 2V TLD)
Secondary Throttle Valve Vacuum Drive (Weber 2V TLD)
Replacing the economizer valve diaphragm (Weber 2V TLD)
Automatic starting device (Weber 2V TLD)
Fast Idle Speed Adjustment (Weber 2V TLD)
Removal and installation the throttle damper (Weber 2V TLD)
Weber 2V TLD Carburetor Adjustment
Fuel injection
Fuel injection system — design description
Adjusting idle speed and mixture quality
Removal and installation the throttle position sensor
Removal and installation the idle speed control valve
Removal and installation air flow meters
Removal and installation fuel injectors
Removal and installation the fuel line temperature sensor
Removal and installation the fuel pressure regulator
Removal and installation the throttle body on a DOHC engine
Removal and installation the oxygen sensor (HEGO)
Removal and installation the carbon adsorber
Removal and installation the carbon adsorber electromagnetic valve
Transmission
Clutch
Clutch specifications
Removal the clutch
Checking the clutch
Clutch installation
Replacing the clutch shaft needle bearing
Replacing the clutch cable
Clutch pedal mechanism
Replacing the clutch pedal
Removal and installation the release bearing
Adjusting the free play
Manual gearbox «N»
Technical characteristics of the mechanical gearbox type «N»
Description of the design of the mechanical transmission type «N»
Removal and installation the gearbox
Gearbox gears and shafts — design description
Disassembling a manual gearbox
Assembly of a manual gearbox
Gear shift mechanism — design description
Disassembling the secondary shaft of the gearbox
Assembly of the secondary shaft of the gearbox
Disassembly and assembly of the intermediate shaft gear block
Manual gearbox «MT 75»
Technical characteristics of the mechanical gearbox type «MT 75»
Description of the design of the mechanical transmission type «MT 75»
Removal the gearbox
Gearbox installation
Gearbox housing — design description
Gear shift mechanism — design description
Disassembling the gearbox
Gearbox gears and shafts — design description
Replacing bearings in the gearbox
Checking the reverse gear pinion shaft
Primary and secondary shafts — disassembly and assembly
Gearbox assembly
Automatic gearbox «A4LD»
Automatic transmission specifications
Description of the operation of an automatic transmission
Checking the gearbox oil level
Checking and flushing the hydrokinetic gearbox
Checking oil pressure while the gearbox is running
Hydrokinetic transmission engine overload test
Adjusting the front planetary gear brake band
Removal and installation the vacuum regulator
Rear planetary gear hydraulic booster
Centrifugal oil pressure regulator
Replacing the rear sealing ring
Removal and installation the gear selection mechanism
Removal and installation the gear selector rod
Adjusting the Kick-down Mechanism Cable
Kick-down cable adjustment (with electromagnetic valve)
Removal and installation the gearbox
Automatic transmission faults
Rear axle and drive shafts
Technical characteristics of the cardan and drive shafts
Removal and installation the propeller shaft
Repair of intermediate bearing of cardan shaft
Removal and installation the rear axle
Disassembly and assembly of the rear axle
Disassembling the rear axle differential
Rear axle differential assembly
Adjusting the main gear bearings
Adjusting the main gear
Assembly and adjustment of the main gear
Replacing the final drive gear seal ring
Removal and installation drive shafts
Disassembly and assembly of drive shafts
Chassis
Steering
Technical characteristics of the steering system
Removal and installation the steering gear
Disassembly and assembly of the steering gear
Removal and installation the steering wheel
Steering wheel centering
Removal and installation the steering column lock
Removal and installation the steering column
Disassembly and assembly of the steering shaft
Power steering
Technical characteristics of the power steering
Removal and installation the steering gear
Disassembly and assembly of the CAM GEAR steering gear
Disassembly and assembly of the ZF steering gear
Removal and installation the steering column
Disassembly and assembly of the steering column
Removal and installation the power steering pump
Disassembly and assembly of the power steering pump
Replacing and adjusting the tension of the drive belt
Replacing the steering gear protective covers
Bleeding the Power Steering System
Front suspension
Front suspension specifications
Description of the front suspension design
Front suspension beam — removal and installation
Removal and installation the front suspension strut
Disassembly and assembly of suspension strut
Removal and installation the stabilizer
Replacing the metal-rubber bushing of the lever
Removal and installation the steering knuckle
Checking the installation of the front wheels
Replacing wheel hub bearings
Designation of tires and wheel rims
Rear suspension
Rear suspension specifications
Description of the rear suspension design
Replacing the rear shock absorber
Replacing the suspension spring
Removal and installation the suspension arm
Replacing the metal-rubber bushing of the rear axle beam
Removal and installation the stabilizer
Replacing wheel hub bearings
Ground clearance adjustment system
Removal and installation the compressor
Replacing the height sensor
Brake system
Technical characteristics of the brake system
Replacing the front brake pads
Replacing the front caliper
Replacing the front brake disc
Description of the rear brake design
Replacing rear brake pads
Removal and installation the rear caliper
Replacing the rear brake disc
Adjusting the handbrake
Bleeding the brake system
Description of the design of the anti-lock braking system
Checking the operation of ABS
Removal and installation of the ABS hydraulic control unit
Removal and installation the brake pedal
Removal and installation the ABS hydraulic unit accumulator
Removal and installation of the pump and motor of the ABS hydraulic unit
Replacing the front wheel speed sensor
Replacing the rear wheel speed sensor
Body
Exterior
Car body wash and care
Removal and installation the hood
Removal and installation the hood cable
Removal and installation the hood insulation panel
Removal and installation the radiator grille
Removal and installation the fuel filler neck lock cylinder
Removal and installation the hatch cover
Removal and installation of windshield and fixed glass
Removal and installation decorative windshield trims
Removal and installation decorative trims on the rear door glass
Removal and installation of emblems
Adjusting the front bumper installation height
Removal and installation bumpers
Removal and installation bumper pads
Removal and installation the front spoiler
Interior
Removal and installation the headlining
Removal and installation the interior rearview mirror
Removal and installation the instrument panel
Removal and installation the center console
Removal and installation the upper console
Removal and installation the rear shelf (Salon models)
Removal and installation the front seat
Removal and installation front seat belts
Removal and installation rear seat belts
Removal and installation the rear seat
Doors, locks and windows
Removal and installation doors
Adjusting the door position
Removal and installation the interior door trim panel
Removal and installation exterior door handles
Removal and installation the door lock cylinder
Removal and installation the door lock
Removal and installation the door seal
Removal and installation door glass
Removal and installation the window lift mechanism
Removal and installation decorative side door trims
Removal and installation decorative trims on door glass frames
Removal and installation exterior rearview mirrors
Removal and installation the rear door
Removal and installation the trunk door lock cylinder
Removal and installation the rear door lock
Removal and installation the gas-filled tailgate strut
Removal, installing and adjusting the trunk lid (Salon models)
Removal and installation the trunk lid lock (Salon models)
Heating and ventilation
Heating and ventilation system — general information
Removal and installation the heater control unit
Removal and installation heater control cables
Removal and installation the heater
Disassembly and assembly of the heater
Removal and installation of heater air ducts
Air Conditioner — General Information
Air Conditioner Maintenance
Compressor drive belt
Condenser Fan — Removal and Installation
Thermostat — removal and installation
Heater water valve
Electrical equipment
Equipment and devices
Technical characteristics of on-board electrical equipment
Fuses and relays
Electronic control units
Central locking system
Direction indicator system
Fuel computer
Additional control system — general information
Main faults of the starter
Rear window wiper
Replacement and adjustment of windshield washer nozzles
Removal and installation the instrument cluster
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 the radio
Removal and installation speakers
Anti-theft alarm system
Power devices
Generator — Safety precautions and testing
Removal and installation the generator
Disassembly and assembly of the generator
Replacing the generator brushes and voltage regulator
Main generator faults
Adjusting the V-belt tension
Removal and installation the starter
Disassembling and assembling the starter
Electrical circuits
Electrical power supply circuit diagram
Electrical circuit diagram for charging and starting the engine
Electrical circuit diagram for charging and starting the engine (all engines)
Electrical circuit diagram of the engine management system 1.8L
2.0L OHC Carb Engine Management System Circuit Diagram
2.0L OHC Fuel Injected Engine Management System Circuit Diagram
2.8L Engine Management System Electrical Circuit Diagram
Outdoor lighting electrical circuit diagram
Circuit diagram of signaling, turning and control systems
Interior lighting electrical circuit diagram
Windscreen wiper and washer drive circuit diagram
Central door locking system circuit diagram
Electrical circuit diagram of the window lift drive
Anti-lock braking system (ABS) circuit diagram
AWS Additional Control System Circuit Diagram
Electrical circuit diagram of the radio receiver connection
Electrical circuit diagram of a diesel engine
Electrical circuit diagram of the sunroof drive
Electrical circuit diagram for switching on the heater fan
Ford Scorpio 2
General information
Car care
Car wash
Care of the paintwork
Anti-corrosion protection of the underbody and hidden internal cavities
Seat Cushion Upholstery Care
Making engine starting easier
Towing a car
Starting the engine by pushing the car (emergency start)
Lifting a car
List of tools for maintenance and repair
Maintenance
Maintenance card
General information about maintenance
Engine and exhaust system
Engine oil change
Visual inspection of oil leaks
Checking the engine oil level
Checking the coolant level
Replacing the coolant
Visual inspection of the cooling system for leaks
Checking the concentration of antifreeze
Checking and adjusting valve clearances
Tightening the intake manifold mounting bolts
Spark plugs, checking connections and distributor cap
Replacing the air filter element
Replacing the fuel filter
Checking and replacing the poly V-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 inspection of gearbox tightness
Manual transmission — checking the oil level
Automatic transmission — checking the oil level
Checking the oil in the main gear of the bridges and in the transfer case
Checking the rubber boots of the cardan shafts
Automatic Transmission — Band Brake Adjustment
Brakes, tires and wheels
Checking the brake fluid level
Checking the thickness of brake pads
Visual inspection of brake lines
Replacing brake fluid
Checking the tire tread pattern
Checking tire inflation pressure
Checking the chamber valve
Steering and front axle
Checking the tie rod end dust caps
Checking ball joints for clearances
Checking the rubber boots of the steering gear
Checking the steering for play
Checking the oil level in the power steering reservoir
Electrical equipment system
Checking the battery
Body and interior equipment
Cleaning of drains for moisture condensate
Lubrication of locks
Visual inspection 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 the lower engine compartment casing
Removal and installation the engine
Removal, installing and adjusting the timing belt
Removal and installation the cylinder head (OHC petrol engine)
Removal and installation the cylinder head (DOHC engine)
Removal and installation cylinder heads (V6 OHV engine)
Removal and installation the camshaft (OHC engine)
Removal and installation valves (OHC engine)
Removal and installation valves (DOHC engine)
Removal and installation valves (V6 OHV engine)
Replacing valve stem seals (petrol engine)
Replacing valve stem seals (diesel engine)
Checking the valve guides
Lapping valves
Checking and adjusting valve clearances
Checking the compression in the cylinders
Removal, installation and tensioning of V-belts and poly V-belts
Engine fault diagnostics
Lubrication system
General information about motor oil
Recommended viscosity grades of motor oils
Engine oil consumption
Circulation of engine oil
Checking oil pressure
Checking the hydraulic switch
Removal and installation the oil pan
Diagnosing oil circulation problems
Cooling system
Coolant circulation
Coolant — Basic Information
Replacing the coolant
Checking the cooling system for leaks
Removal and installation thermostat (OHC engine)
Removal and installation the thermostat (DOHC engine)
Removal and installation the thermostat (V6 engine)
Removal and installation the thermostat (diesel engine)
Checking the Thermostat
Removal and installation the cooling system fan
Removal and installation the coolant pump
Removal and installation the radiator
Diagnostics of cooling system faults
Ignition system
General information about the ignition system
Operation of the ignition system
Safety precautions when working with the ignition system
Checking the distributor cap/high voltage wires
Checking the ignition coil
Removal and installation the ignition distributor
Removal and installation of the ignition system control unit
Checking and adjusting the ignition timing angle
Removal and installation spark plugs
Spark Plug Technique
Ignition system fault diagnostics
Supply system
General information about the power supply system
Safety and cleanliness when working with fuel supply systems
Removal, installing and checking the fuel level sensor
Removal and installation the fuel tank
Removal and installation an electric fuel pump
Removal, installation and testing of mechanical fuel pump
Removal and installation the air filter (cars up to 8/94)
Removal and installation the air filter (cars from 9/94)
Removal and installation the gas rod (cars from 9/94)
Adjusting the gas thrust
Checking, removing and installing the fuel pump relay
Carburetors
General information about the carburetor
Carburetor adjustment
Malfunctions in fuel supply
Carburetor Pierburg 2V — design description
Weber 2V-ISC Carburetor — Design Description
Checking and adjusting idle speed and CO content
Checking and adjusting CO content
Removal and installation the carburetor
Technical characteristics of carburetors
Carburetor fault diagnostics
Injection system (gasoline)
Schematic diagram of the electronic engine control system EEC V
General information about the fuel injection system
Safety rules when working with the injection system
Operation of the gasoline injection system
Injection system sensors
SEFI injection system (engines from 9/94)
Checking the valve injectors
Removal and installation of fuel manifold and valve injectors
Diagnostics of faults of the petrol injection system
Injection system (diesel)
General information about the fuel injection system
How a diesel engine works
General information about turbocharger
Removal air from the fuel system
Checking and adjusting the idle speed
Removal and installation the idle speed increase rod
Removal and installation injectors
Preheating system
Checking the heating system, removing and installing glow plugs
Characteristics of the diesel engine injection system
Diagnostics of faults of the injection system of a diesel engine
Exhaust system
Exhaust system (petrol up to 8/94) — design description
Exhaust system (petrol from 9/94) — design description
Exhaust system (diesel) — design description
Removal and installation of the exhaust system
Checking the exhaust system for leaks
Removal and installation the subsequent muffler
Operation of the catalytic converter
Handling of catalytic converters in vehicles
Transmission
Clutch
Description of the clutch design
Removal, installation and testing of the clutch
Removal and installation the clutch cable
Removal, installing and checking the clutch release bearing
Bleeding the Clutch Hydraulic Drive
Diagnosing Clutch Faults
Car gearbox
General information about the gearbox
Removal the N manual transmission (models before 1988)
Removal the MT-75 manual gearbox
Installation of a manual gearbox
All-wheel drive — design description
Automatic transmission
Chassis
Front suspension
Description of the front suspension design
Removal and installation the shock absorber strut
Removal and installation the swivel support
Shock absorber strut device
Disassembling the shock absorber, removing and installing the shock absorber
Checking the shock absorber
Removal and installation the transverse arm
Removal and installation the stabilizer (models up to 8/94)
Removal and installation the stabilizer (models from 9/94)
Definition of chassis parameters
Rear suspension
General information about the rear suspension
Removal and installation the propeller shaft
Removal and installation the rear shock absorber
Removal and installation the stabilizer
Removal and installation the rear wheel hub
Removal and installation the wheel hub bearing
Removal and installation the rear axle propeller shaft
Disassembling the cardan shaft, replacing the corrugated covers
Steering
Description of the steering design
Safety precautions when handling an airbag
Removal and installation the steering wheel
Adjusting the position of the steering wheel
Removal and installation the tie rod end
Removal and installation the steering gear bellows
Power steering pump (petrol, up to 8/94)
Power steering pump (petrol, since 9/94)
Power steering pump (diesel)
Bleeding the power steering hydraulic system
Brake system
General information about the braking system
Anti-lock braking system (ABS)
Front Disc Brake Caliper
Removal and installation front disc brake pads
Rear Disc Brake Caliper
Removal and installation rear disc brake pads
Checking the thickness and lateral runout of brake discs
Brake shoe guide with front brake caliper
Brake shoe guide with rear brake caliper
Removal and installation the brake disc
Checking the brake booster
Replacing the brake line and hose
Brake fluid — safety precautions
Bleeding air from the hydraulic brake system
Adjusting the handbrake
Removal and installation the handbrake cable
Removal and installation the brake light switch
Technical characteristics of the brake system
Brake fault diagnostics
Wheels and tires
General information about wheels and tires
Tyre and wheel designations
Wheel replacement and balancing
Rules for tire care
Anti-skid chains
Incorrect tire wear
Elimination of vibrations of the steering wheel / front of the car
Diagnosis of tire faults
Body
Exterior
General information about the body of the Scorpio I car
Removal and installation the front bumper (Scorpio I)
Front bumper adjustment (Scorpio I)
Removal and installation the rear bumper (Scorpio I)
Removal and installation the radiator grille (Scorpio I)
Removal and installation the fairing grille (Scorpio I)
Removal and installation decorative trim (Scorpio I)
Removal and installation the bonnet lock rod (Scorpio I)
Removal, installation and adjustment of the hood (Scorpio I)
Removal and installation the outside mirror (Scorpio I)
General information about the Scorpio II car body
Removal and installation the front bumper (Scorpio II)
Removal and installation the rear bumper (Scorpio II)
Removal and installation the radiator grille (Scorpio II)
Removal and installation the fairing grille (Scorpio II)
Removal and installation front wheel arch trim (Scorpio II)
Removal and installation the hood lock rod (Scorpio II)
Removal and installation the outside mirror (Scorpio II)
Interior
Removal and installation the glove box (Scorpio I)
Removal and installation the center console (Scorpio I, up to 1/92)
Removal and installation the center console (Scorpio I, after 1/92)
Removal and installation the front seat (Scorpio I)
Removal and installation the rear seat (Scorpio I)
Seat Belt Tensioner (Scorpio II)
Safety precautions when working with the seat belt tensioner
Removal and installation the front seat (Scorpio II)
Doors, locks and windows
Removal and installation the trunk lid (Scorpio I)
Removal and installation the rear door (Scorpio I)
Removal and installation the rear door lock (Scorpio I)
Removal and installation the door (Scorpio I)
Door adjustment (Scorpio I)
Removal and installation door trim (Scorpio I)
Removal and installation the door lock cylinder (Scorpio I)
Removal and installation the door lock (Scorpio I)
Windscreen (Scorpio I)
Removal and installation window glass (Scorpio I)
Removal and installation the window lift crank mechanism (Scorpio I)
Removal and installation the trunk lid (Scorpio II)
Lock cylinder, trunk lid lock (Scorpio II)
Removal and installation door trim (Scorpio II)
Removal and installation the lock and outer door handle (Scorpio II)
Removal and installation the door lock cylinder (Scorpio II)
Removal and installation window glass (Scorpio II)
Removal and installation the side trim of the luggage compartment (Scorpio II)
Removal and installation the fuel tank filler cap (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 the heater fan switch
Removal and installation the heater fan
Diagnostics of heating system faults
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
Measuring instruments
Measurement technique
Installation of additional components of the electrical equipment system
Troubleshooting electrical equipment
Electronic anti-theft system
Ignition key coding for anti-theft system
Checking the rear window and windshield heating
Replacing fuses
Location of relays and fuses
Instrument cluster — design description
Removal and installation the instrument panel
Removal and installation of devices
Removal and installation the speed sensor
Steering column and hazard warning light switches
Removal and installation a light switch and incandescent lamp
Removal and installation control panel switches
Removal and installation the radio
Entering the radio code
Removal and installation the loudspeaker
Headlights and lighting
General information about the lighting system
Table of lamps
Replacement of incandescent lamps for outdoor lighting (up to 8/94)
Replacing exterior light bulbs (after 8/94)
Replacing interior lighting bulbs
Removal and installation headlights (up to 8/94)
Removal and installation headlights (after 8/94)
Removal and installation the headlight diffuser
Electric motor for headlight beam angle adjustment system
Headlight adjustment
Removal and installation the rear light
Windshield wipers and washers
Replacing the rubber band of the windshield wiper blade
Adjustment, removal and installation of window washer nozzles
Checking the windshield washer pump and headlight lenses
Replacing the windshield washer pump and headlight lenses
Front windshield wiper system
Removal and installation the front wiper linkage system
Removal and installation the front windshield wiper motor
Rear window cleaning system
Removal and installation the rear window wiper motor
Checking and adjusting the angle of the windshield wiper blade
Diagnosing Windscreen Wiper Blade Rubber Band Faults
Power devices
Removal and installation the battery
Instructions for maintenance-free battery
Charging the battery
Checking the battery
Storage of the battery
Spontaneous discharge of the battery
Diagnosis of battery malfunctions
Generator from BOSCH — design description
Safety precautions when working with an alternator
Checking the generator voltage
Removal and installation the generator
Replacing and checking the generator brushes and voltage regulator
Generator fault diagnostics
BOSCH starter — design description
Removal and installation the starter
Starter fault diagnostics
Electrical circuits
Introduction to electrical circuits and letter symbols
Scheme 1. Power supply system of electrical circuits
Scheme 2. Charging and starting system I — all engines
Scheme 3. Charging and starting system II — DOHC engine (injection)
Scheme 4. Engine management system, gasoline injection system
Scheme 5. Outdoor lighting
Scheme 6. Control lamps and signaling devices
Scheme 7. Instrument panel, glove compartment, luggage compartment lighting
Scheme 8. Window glass cleaning and washing system
Ford Sierra
General information
User manual
Introduction to the Operation and Repair Manual
Vehicle identification data
Lifting a car
Towing a car
Instrument cluster and controls
Hood — opening and closing
Starting the engine
Lighting and signaling
Replacing light bulbs
Ventilation and heating of the passenger compartment
Doors — opening and locking
Sunroof and roof rack
Seats and headrests
Rear view mirrors
Seat belt fastening indicator light
Wheel replacement
Maintenance
Engine compartment of a car
Adjusting valve clearances
Checking and replacing oil and oil filter
Coolant — Checking and Replacing
Gasoline Engine Maintenance
Fuel system of diesel engines
Manual transmission
Automatic transmission
Checking the condition of the hinge covers
Checking the power steering pump drive belt
Checking the brake fluid level
Handbrake lever
Electrical equipment
Tires — checking condition and pressure control
Operating fluids
Tires, body size and fuel consumption
Vehicle weights and transmission ratios
Filling volumes and liquids used
Gasoline engines
Engine repair
Technical characteristics of gasoline engines
Tightening torques for threaded connections
Adjusting valve clearances
Description of the design of the gasoline engine ONS
Removal and installation the timing belt
Removal the cylinder head
Disassembly and assembly of the cylinder head
Installing the cylinder head
Removal and installation the engine
Disassembling the engine
Identification of interacting parts
Engine assembly
Replacing pistons
Removal and installation the intermediate shaft — removal and installation
Gas distribution system
Ignition system
Technical characteristics of the ignition system
Ignition system — general information
Hall Effect Pulse Sensor
Ignition Distribution — Design Description
Ignition system switch
Notes on the operation of the ignition system
Setting the ignition timing
Ignition System Fault Identification
Removal and installation the ignition distributor
Fuel system
Fuel system specifications
Ford variable diffuser carburetor
Removal and installation a Ford carburetor
Disassembly, inspection and assembly of the Ford carburetor
Adjusting idle speed and CO content (Ford carburetor)
Adjusting the starting device (Ford carburetor)
Adjusting the throttle cable (Ford carburetor)
Removal and installation the needle shaft (Ford carburetor)
Vacuum Regulator Diaphragm (Ford Carburetor)
Weber 32/36 DGAV Carburetor — Design Description
Removal and installation a Weber carburetor
Adjusting the float position (Weber carburetor)
Adjusting the starting choke (Weber carburetor)
Checking and adjusting the automatic starting device (Weber carburetor)
Adjusting idle speed and CO content (Weber carburetor)
Cooling and lubrication system
Technical characteristics of the lubrication system
Technical characteristics of the cooling system
Engine lubrication system — design description
Checking oil pressure
Replacing the oil filter
Oil pump repair
Draining and filling the cooling system
Removal and installation the radiator
Removal and installation the fan
Coolant pump — removal and installation
Replacing the cooling system thermostat
Powertrain suspension
Exhaust gas exhaust system
Changes 1984-1986
Changes in the design of the car from 1984 to 1986
Main engine parameters
Cylinder Head — Specifications
Engine Block — Specifications
Crank mechanism — specifications
Crankshaft — Specifications
Valve timing system — specifications
Engine mount — removal and installation
Draining and filling the cooling system
Ford carburetor with variable diffuser cross-section
Weber carburetors — design and adjustment
Pierburg carburetor — design and adjustment
Fuel injection system
Ignition system — specifications
Clutch — Description of changes
Four-speed manual transmission
Five-speed manual transmission
Technical characteristics of the automatic transmission Ford A 4 LD
Maintenance and repair of automatic transmission Ford A 4 LD
Changes in the design of the automatic transmission
Drive shaft and rear axle
Power steering system
Front suspension
Rear suspension
Front brake system
Turning on the dim headlights
Generator bracket mounting bolt
Fuses and relays
Changes 1987-1989
Changes in the design of the car from 1987 to 1989.
OHC Engine — Description of Changes
CVH 1.8 liter engine — technical characteristics
CVH 1.8 liter engine adjustment
Ignition system of the CVH 1.8 liter engine
Valve timing system of the CVH 1.8 liter engine
Assembly of the CVH 1.8 liter engine
DOHC Engine Specifications
DOHC engine ignition system
DOHC engine fuel injection system
2.0L DOHC Engine EEC IV System Diagram
Checking and adjusting the EEC IV system of the DOHC engine
DOHC Engine Troubleshooting
Checking the elements of the EEC IV system
DOHC Engine Timing System
DOHC Engine Cylinder Head
Disassembling a DOHC engine
DOHC Engine Assembly
DOHC engine lubrication system
Clutch specifications
N-type five-speed manual transmission
Technical characteristics of the gearbox type MT 75
Removal and installation of gearbox type MT 75
Disassembling the gearbox type MT 75
Checking and repairing parts of the MT 75 type gearbox
Assembly of gearbox type MT 75
Automatic transmission
Front suspension
Technical characteristics of the brake system
Maintenance and repair of the brake system
Adjusting the handbrake
Bleeding the brake system
Anti-lock braking system
Checking the operation of ABS
Hydraulic brake control unit — removal and installation
Wheel speed sensor
Generator and starter — technical characteristics
General data and characteristics of the car
Changes 1990-1993
Changes in the design of the car from 1990 to February 1993.
DOHC Engine Specifications
DOHC Engine Cylinder Head
DOHC Engine Timing System
Engine injection system type N9C
Clutch — Description of changes
Drive shaft and rear axle
Power steering system
Connecting fuses and relays
General data and characteristics of the car
Diesel engines
Engine repair
Technical characteristics of diesel engines
Tightening torques for threaded connections
Checking and adjusting valve clearances
Checking the compression in the cylinders
Cylinder head — design description
Removal and installation the cylinder head
Checking and repairing the cylinder head
Removal and installation the engine
Disassembly, repair and assembly of the engine
Installing the rear main bearing
Assembling the piston-connecting rod unit
Assembly of the timing drive
Further assembly of the engine
Fuel system
Fuel system specifications
Fuel system — general information
Rotary high pressure fuel pump
Injectors — removal, inspection and installation
Checking the tightness of the nozzle sprayer
Adjusting the initial injection pressure
Glow plugs
Removal air from the fuel system
Fuel Filter — Description and Water Removal
Fuel pump, fuel injection start setting
Adjusting the idle speed
Cooling and lubrication system
Technical characteristics of the lubrication system
Oil pump — removal and installation
Checking oil pressure
Engine cooling system — design description
Draining the cooling system
Filling the cooling system and removing air
Removal and installation the fan clutch
Thermostat — removal and installation
Changes 1988-1993
Changes in the design of the car from 1988 to 1993.
Repair of 2.3 liter diesel engine
Technical characteristics of the 1.8 liter engine
Cylinder head of the 1.8 liter engine
1.8 liter engine cylinder block
Crank mechanism of the 1.8 liter engine
1.8 liter engine valve timing system
1.8 liter engine lubrication system
Engine cooling system 1.8 liter
Fuel system of the 1.8 liter engine
Tightening torques for 1.8 liter engine
Engine tuning 1.8 liter
Fuel filter — removal and installation
Removal and installation injectors
Fuel pump — removal and installation
Removal and installation a turbocharger
Removal the cylinder head
Cylinder head repair
Cylinder head, valve timing adjustment
Removal and installation the engine
Disassembling a diesel engine
Checking engine parts
Checking the crankshaft and connecting rod clearances
Assembly of a diesel engine
Diesel engine lubrication system
Diesel engine cooling system
Clutch — Description of changes
Mechanical five-speed gearbox type MT 75
Drive shaft and rear axle
Steering system
Front suspension — checking and adjustment
Brake system — description of changes
Electrical Equipment — Description of Changes
General data and characteristics of the car
Transmission
Clutch
Description of the clutch design
Clutch specifications
Removal and installation the clutch
Replacing the needle bearing
Replacing the clutch cable
Clutch pedal mechanism
Replacing the clutch pedal — removal and installation
Clutch release bearing
Mechanical gearbox
Technical characteristics of the gearbox (4-speed)
Removal and installation of gearbox (4-speed)
Disassembly and assembly of gearbox (4-speed)
Disassembly and assembly of gearbox type A and B (4-speed)
Disassembly and assembly of gearbox type C (4-speed)
Technical characteristics of the gearbox (5-speed)
Removal and installation of gearbox (5-speed)
Disassembly and assembly of gearbox (5-speed)
Disassembly and assembly of gear block (5-speed)
Automatic gearbox
Automatic transmission Ford C 3 — design description
Automatic transmission specifications
Automatic transmission maintenance and repair
Checking the gearbox oil level
Checking and cleaning the hydrokinetic transmission
Checking oil pressure while the gearbox is running
Hydrokinetic transmission engine overload test
Checking the box while driving
Adjusting the front planetary gear brake band
Removal and installation the gearbox
Removal and installation the kick-down cable
Removal and installation the engine safety start relay
Box malfunctions and methods of their elimination
Cardan and rear axle
Propeller shaft and rear axle — general information
Technical characteristics of the cardan shaft and rear axle
Removal and installation the propeller shaft
Repair of intermediate bearing
Removal and installation the rear axle
Disassembly and assembly of the rear axle
Disassembling and assembling the differential
Adjusting the main gear bearings
Adjusting the main gear
Assembly and adjustment of the main gear
Replacing the final drive gear seal ring
Removal and installation of drive axle shafts
Disassembly and assembly of drive axle shafts
Chassis
Steering
Description of the steering design
Technical characteristics of the power steering
Removal and installation the steering gear
Disassembly and assembly of the steering gear
Removal and installation the steering column
Disassembling and assembling the steering wheel
Steering with power steering
Power steering — design description
Technical characteristics of the power steering
Removal and installation the steering gear
Removal and installation the hydraulic pump
Disassembly and assembly of the CAM GEAR steering gear
Disassembly and assembly of the ZF steering gear
Removal and installation the steering column
Disassembling and assembling the steering wheel
Bleeding the steering system
Front suspension
Front suspension specifications
Removal and installation the front suspension strut
Disassembly and assembly of suspension strut
Removal and installation the stabilizer
Replacing the metal-rubber bushing of the lever
Removal and installation the steering knuckle
Checking the installation of the front wheels
Replacing the front wheel hub bearings
Rear suspension
Rear suspension specifications
Replacing the rear shock absorber
Replacing the suspension spring — removal and installation
Removal and installation the suspension arm
Replacing the metal-rubber bushing of the suspension beam
Replacing the rear wheel hub bearings
Brake system
Technical characteristics of the brake system
Replacing the front brake pads
Replacing the front caliper
Replacing the front brake disc
Front Caliper Repair
Removal and installation the brake drum
Replacing rear brake pads
Replacing the rear brake cylinder
Removal and installation the master brake cylinder
Bleeding the brake system
Adjusting the handbrake
Body and electrical
Body elements and doors
Car body wash and treatment
Elements of the bonnet and front part of the body
Hood cable — removal and installation
Hood adjustments
Interior door trim — removal and installation
Adjusting the door lock closing
Interior Door Handle — Removal and Installation
Door Lock Cylinder — Removal and Installation
Door lock — removal and installation
Front seat — removal and installation
Electrical equipment
Technical characteristics of on-board electrical equipment
Relays and fuses
Removal and installation the generator
Disassembly and assembly of the generator
Adjusting the V-belt tension
Starter — design description
Windscreen wiper, indicator assembly and headlights
Removal and installation the instrument cluster
Headlight adjustment
Heating and ventilation system — removal and installation
Fan Motor — Removal and Installation
Electrical circuits
Electrical power supply circuit diagram
Electrical circuit diagram of the charging and starter
Electrical circuit diagram of a diesel engine
Outdoor lighting electrical circuit diagram
Fog Light Electrical Circuit Diagram
Instrument cluster electrical circuit diagram
Interior Lighting Electrical Circuit Diagram
Electrical circuit diagram of heating, ventilation, windshield wipers
Central door locking electrical circuit diagram
Electrical circuit diagram for side door glass control
Ford Transit 2
General information
User manual
About this guide
About the Ford Transit (diesel)
Introduction to the Car Manual
Breaking in a new car
Low dashboard
High dashboard
Instrument panel (option 1)
Instrument panel (option 2)
High instrument panel (option 1)
Instrument panel (option 3)
Instrument panel (option 4)
Control levers
Heating and ventilation
Interior equipment
Starting the engine
Brakes — abs
Automatic transmission
Towing a trailer
Care and maintenance
Opening the hood
Car windshield washer
What to do in an emergency — towing
Fuel filter water settling sensor (diesel only)
Fuel system (diesel)
Fuel injection system fuse switch
Reconnecting the fuse
Engines with a control unit (2.0 l, 2.5 l turbodiesel)
Batteries — general information
Jump starting using another car's battery
Changing a wheel
Spare wheel
Installing the jack
Removal the wheel
Wheel installation
Storing a spare tire
Replacing lamps
Fuses and relays
Fuel consumption
Dimensions of the car
Fuel, oils, liquids
Jacking, towing and wheel changing
Radio blocking system in case of theft
Maintenance
Maintenance and care — specifications
Lubricants, liquids and containers
Purchasing spare parts and identification numbers
Ford Transit Diesel Service Schedule
Maintenance and Care — introduction
Checking fluid levels (daily/monthly)
Check tire treads and pressure (daily)
Checking the power steering fluid level (monthly)
Inspection of windshield and rear window wipers/washers (daily/monthly)
Electrical system check (every 10,000 km or 6 months)
Checking, servicing and charging the battery (every 10,000 km or 6 months)
Seat belt inspection (every 10,000 km or 6 months)
Inspection and replacement of drive belts (every 10,000 km or 6 months)
Inspection and replacement of hoses in the engine compartment (every 10,000 km or 6 months)
Changing engine oil and oil filter (every 10,000 km or 6 months)
Checking and cleaning the oil filler cap (every 10,000 km or 6 months)
Draining sediment from the fuel filter (every 10,000 km or 6 months)
Check steering, suspension and wheels (every 10,000 km or 6 months)
Brake check (every 10,000 km or 6 months)
Checking the engine compartment wiring (every 20,000 km or 12 months)
Checking the air conditioning system (monthly/every 20,000 km or 12 months)
Check and lubricate the hood and doors (every 20,000 km or 12 months)
Kingpin and steering bush lubrication — models with independent front suspension (every 20,000 km or 12 months)
Checking the oil level in a manual transmission (every 20,000 km or 12 months)
Clutch cable lubrication (every 20,000 km or 12 months)
Lubrication of the sliding joint of the overdrive transmission and the propeller shaft (every 20,000 km or 12 months)
Lubrication of automatic transmission rods and levers (every 20,000 km or 12 months)
Lubrication and adjustment of parking brake rods and levers (every 20,000 km or 12 months)
Checking the universal joint and intermediate bearing of the propeller shaft (every 20,000 km or 12 months)
Inspection of the condition of the underbody and fuel and brake system pipelines (every 20,000 km or 12 months)
Exhaust system inspection (every 20,000 km or 12 months)
Checking the rear axle oil level (every 20,000 km or 12 months)
Checking and adjusting the rear brake pressure regulator (every 20,000 km or 12 months)
Checking the tightening torque of wheel nuts (every 20,000 km or 12 months)
Trial tests after service or repair (every 20,000 km or 12 months)
Checking the automatic transmission fluid level (every 20,000 km or 12 months)
Checking and adjusting normal idle speed and idle reduction mode (every 20,000 km or 12 months)
Replacing the air filter element (every 40,000 km or 2 years)
Fuel filter replacement (every 40,000 km or 2 years)
Technical data
Special tools and devices
Troubleshooting
Troubleshooting — general information
Engine fault diagnostics
Cooling system
Fuel system and exhaust system
Diagnosing clutch faults
Manual transmission
Automatic transmission
Cardan shaft
Rear axle
Brake system
Suspension and steering
Electrical system
Power unit
Engine in the car
Engine Repair Specifications
General information about engine repair
Repair operations that can be performed without removing the engine from the vehicle
Compression test and leak test
Setting piston No. 1 to top dead center (TDC)
Cylinder head valve cover — removal and installation
Timing Belt Cover — removal and installation
Timing Belt — removal, inspection, installation and tensioning
Timing Belt Pulleys and Timing Belt Tensioner — removal and installation
Valve clearances — checking and adjusting
Valve train drive — removal, inspection, installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Oil pump — disassembly, inspection and assembly
Crankshaft seals — replacement with new ones
Flywheel — removal, inspection and installation
Engine Mounts — inspection and replacement
Engine overhaul
Removal and overhaul — specifications
Removal and overhaul — general information
Engine overhaul — general information
Engine Removal — methods and precautions
Engine (non-turbocharged) — removal and installation
Engine (turbocharged) — removal and installation
Engine (non-turbocharged) with gearbox — removal and installation
Engine (turbocharged) and gearbox — removal and installation
Engine overhaul — disassembly procedure
Cylinder head — disassembly
Cylinder head and valve train components — cleaning and inspection
Cylinder head assembly
Cylinder head — inspection, installation
Connecting rod and piston group — removal
Crankshaft — removal
Cylinder block and crankcase — cleaning and inspection
Connecting rod and piston group — inspection
Crankshaft — inspection
Main and connecting rod bearings — inspection
Engine Overhaul — assembly sequence
Piston rings — installation
Crankshaft — shaft installation and main bearing clearance check
Connecting rod and piston group — installation and checking of the working clearance in the connecting rod lower head bearings
Engine — test run after major overhaul
Cooling and heating
Ventilation, Heating and Cooling Systems — technical data
General information and precautions
Coolant system hoses — disconnecting and replacing
Cooling system expansion tank — removal and installation
Radiator — removal, inspection and installation
Cooling fan clutch — removal and installation
Coolant Temperature Sensor — removal, inspection, and installation
Thermostat — removal, checking, and installation
Water pump — removal and installation
Heating and ventilation systems — general information
Heating and Ventilation Components — removal and installation
Heating and ventilation system deflectors — removal and installation
Air Conditioning System — general information and precautions
Fuel and exhaust system
Emission Control System — technical data
General information and precautions
Fuel system — filling with fuel and bleeding air
Air filter — removal and installation
Maximum engine speed — checking and adjustment
Thermostatic idle speed sensor — removal, installation and adjustment
Solenoid valve — description, removal and installation
High-pressure fuel pump — removal and installation
Fuel injection advance — testing methods and adjustment methods
Fuel injection advance — checking and adjustment
Fuel injectors — inspection, removal and installation
Fuel injector delivery pipes — removal and installation
Fuel filter — removal and installation
Accelerator cable — removal, installation and adjustment
Accelerator pedal — removal and installation
Fuel level sensor — removal and installation
Fuel tank — removal, maintenance and installation
Fuel pump — removal and installation
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Turbocharging — description and precautions
Turbocharging — removal and installation
Turbocharging — inspection and repair
Exhaust system — basic information and replacement of components
Exhaust emission control systems — general information
Emission Control Systems — checking and replacing parts
Lucas Epic Electronic Fuel Injection System — description and precautions
Lucas Epic System Sensors — general information, inspection, removal, and installation
Intercooling — basic information, removal and installation
Engine electrical equipment
Engine electrical equipment — technical requirements
Engine Electrical Systems — general information and precautions
Battery — removal and installation
Charging system — testing
Alternator — removal and installation
Alternator Brushes and Regulator — inspection and replacement
Launch system — testing
Starter — removal and installation
Starter — replacing brushes
Low oil pressure sensor — removal and installation
Engine preheating system — description and testing
Glow Plug — removal and installation
Transmission
Clutch
Clutch — technical data
Clutch — general information
Clutch cable — removal and installation
Clutch pedal — removal and installation
Clutch — removal, inspection and installation
Clutch release mechanism — removal, inspection and installation
Clutch cable — adjustment
Automatic clutch system components — removal and installation
Manual gearbox
Manual transmission — technical data
Manual transmission — general information
Gearbox control lever — removal and installation
Oil seals — replacement
Reverse Light Switch — removal and installation
Speedometer Drive Gear — removal and installation
Manual transmission mounts — inspection and replacement
Manual transmission — removal and installation
Manual Transmission Overhaul — general information
Overdrive — general information
Overdrive Switch — removal and installation
Overdrive Lock Switch — removal and installation
Overdrive Solenoid Valve — removal and installation
Overdrive gear — removal and installation
Automatic gearbox
Automatic transmission — technical data
Automatic transmission — general information
Brake bands — adjustment
Downshift cable (kick-down) — regulation
Downshift Cable — removal and installation
Gear Shift Lever Cable — removal, installation and adjustment
Gear shift mechanism — removal and installation
Locking switch — removal, installation and adjustment
Oil seals — replacement
Vacuum diaphragm — removal and installation
Servomechanism — removal and installation
Vacuum regulator — testing and adjustment
Vacuum regulator — removal and installation
Speedometer Drive Pinion — removal and installation
Automatic transmission — removal and installation
Automatic transmission overhaul — general information
Cardan and rear axle
Cardan shaft and rear axle — technical data
Driveshaft and rear axle — general information
Cardan shaft — description
Cardan shaft (two links) — removal and installation
Cardan shaft (three-section type) — removal and installation
Replacement of the center support bearing of the propeller shaft
Elastic quibo type hinge — removal and installation
Rear Axle — description
Rear axle — removal and installation
Rear axle half shafts — removal and installation
Rear Hub and Bearing (H-Type Axle) — removal, disassembly and installation
Rear Hub and Bearing (G-Type Axle) — removal, disassembly and installation
Pinion Oil Seals (All Axle Types) — renewal
Differential housing (type «H») — removal and installation
Differential (G-type axle) — overhaul
Chassis
Brake system
Brake system — basic information
Technical data — general information
Hydraulic system — air removal
Hydraulic tubes and hoses — inspection, removal and installation
Front disc brakes — replacement
Front Brake Caliper — removal and installation
Front brake caliper — disassembly
Front Brake Disc — inspection, removal and installation
Drum brake shoes — replacement
Rear wheel brake cylinder — removal, disassembly and installation
Master cylinder — removal and installation
Master cylinder — disassembly
Vacuum booster — inspection, removal and installation
Vacuum pump — removal and installation
Parking brake adjustment
Parking brake lever and drive rod — removal and installation
Parking brake cable — removal and installation
Brake pressure regulating valve — description, removal and installation
Rear Axle Load-Sensing Valve (LAV) — general information
Brake pedal — removal and installation
Anti-lock Braking System (ABS) — basic information
Anti-lock braking system components — removal and installation
Steering system
Front Steering and Suspension Specifications
Front Wheel Steering and Suspension — general information
Steering wheel — removal and installation
Steering column — removal and installation
Steering column — removal, inspection and assembly
Rack and Pinion Steering Gear — removal, disassembly and installation
Tie Rod End Ball Joint — removal and installation
Replacement of protective rubber steering gear boots
Screw-and-nut steering gear — removal, disassembly and installation
Steering gear of the screw-and-nut type — adjustment of the steering arm shaft preload
Steering knuckle of the steering gear of the «screw-nut» type — removal and installation
Steering gear longitudinal tie rod of the «screw-nut» type — removal and installation
Power steering pump — removal and installation
Power steering — removal and installation
Power Steering Tubes and Hoses — removal and installation
Power Steering — bleeding
Wheel installation — general information
Front suspension
Front Wheel Hub (IFS Models) — removal, installation and adjustment
Front Hub Bearings (IFS Models) — replacement
Front steering knuckle (IFS models) — removal and installation
Independent front suspension coil spring — removal and installation
Lower (transverse) arm of independent front suspension — removal and installation
Front Lower Control Arm Bushing (IFS Models) — replacement
Front Lower Control Arm Bracket Bushing (IFS Models) — replacement
Front Lower Arm Ball Joint (IFS Models) — removal and installation
Front Anti-Roll Bar (IFS Models) — removal and installation
Front Shock Absorber (IFS) — removal and installation
Front wheel hub (dependent front suspension) — removal, installation and adjustment
Steering knuckle (dependent front suspension) — removal and installation
Front axle beam (dependent front suspension) — removal and installation
Front dependent suspension leaf spring — removal and installation
Front suspension travel limiting buffer (front dependent suspension) — removal and installation
Front anti-roll bar (front dependent suspension) — removal and installation
Front shock absorber (front dependent suspension) — removal and installation
Rear axle leaf spring — removal and installation
Rear shock absorber — removal and installation
Body
Exterior
Body — technical data
Body — general information
Body and subframe
Carpet and Upholstery Care
Minor body damage — repair
Serious body damage — repair
Hood — removal, installation and adjustment
Hood Lock and Cable Replacement
Hood safety latch — removal and installation
Exterior mirrors and related parts — removal and installation
Front bumper — removal and installation
Rear bumper — removal and installation
Radiator grille — removal and installation
Windshield Grille — removal and installation
Interior
Instrument panel — removal and installation
Interior body trim — removal and installation
Headlining — removal and installation
Seats — removal and installation
Seat belts — removal and installation
Doors, locks and windows
Interior door trim — removal and installation
Front Door Parts — removal and installation
Front door — removal, installation, adjustment
Sliding Side Door Parts — removal and installation
Sliding side door — removal, installation and adjustment
Rear Door Parts — removal and installation
Rear doors — removal, installation and adjustment
Tailgate Parts — removal and installation
Tailgate — removal and installation
Front door window regulator and glass — removal and installation
Front door fixed glass — removal and installation
Sliding glass and frame — removal and installation
Sliding glass and frame — disassembly and assembly
Rear opening window — removal and installation
Windshield and fixed glass — removal and installation
Electrical equipment
Equipment and devices
Vehicle electrical equipment — technical data
General information and precautions
Electrical Circuit Troubleshooting — general information
Fuses and relays — general information
Switches — removal and installation
Instrument cluster (models without tachograph) — removal and installation
Instrument cluster instruments and bulbs (models without a tachograph) — removal and installation
Tachograph — removal and installation
Fuel and temperature gauge (models with tachograph) — removal and installation
Control lamp unit (models with tachograph) — removal and installation
Speedometer Cable — removal and installation
Cigarette lighter — removal and installation
Watch — removal and installation
Checking and adjusting low beam headlights
Exterior Light Bulbs and Parking Lights — replacement
Light bulbs (interior lighting) — replacement
External lighting fixtures — removal, installation
Horn — removal and installation
Windshield wiper arms — removal and installation
Windshield wiper motor and drive mechanism — removal and installation
Windshield wiper arm pivot shaft housing — removal and installation
Headlight and windshield washer reservoir — removal and installation
Rear Door Wiper Elements — removal and installation
Radio and car stereo — removal and installation
CD player — removal and installation
Radio antenna — removal and installation
Power amplifier — removal and installation
Speakers — removal and installation
Airbags — removal and installation
Airbag control unit — removal and installation
Passive anti-theft system — general information and replacement of components
Possible malfunctions of automotive electronics
Electrical circuits
Schematic 1. Information on the use of electrical diagrams for models before 1992
Scheme 2. Starting, charging, cold start, overdrive and headlight systems — models before 1992
Scheme 3. Tachograph and instrument cluster — models manufactured before 1992
Scheme 4. External lighting devices — models manufactured before 1992
Scheme 5. Interior lighting, windshield wipers and washers — models before 1992
Scheme 6. Horn, heater fan, cigarette lighter, radio, and rear window defroster — pre-1992 models
Schematic 7. Information on the use of electrical diagrams for 1992-1995 models
Scheme 8. Starting, charging, cold start and manifold heating systems for 1992-1995 models
Heated manifold, downshift mechanism, tachograph and instrument cluster (1992-1995 models)
Engine Management System and Anti-Lock Braking System (ABS) (1992-1995 models)
Exterior Lighting (1992-1995 Models)
Scheme 15. Washers and wipers — models manufactured in 1992-1995
Scheme 16. Rear window defroster, headlight washers, windshield defroster, cigarette lighter — 1992-1995 models
Scheme 17. Downshift control («kick-down»), heater fan and radio receiver-models 1992-1995
Scheme 18. Information on the use of electrical circuits for models manufactured since 1995
Scheme 19. Starting and charging system — models since 1995
Scheme 20. Cold start, fuel shut-off valve and manifold heater — models from 1995.
Scheme 21. Turbocharged diesel engine control system — models from 1995.
Scheme 22. Diagnostic connector, anti-lock braking system (ABS) and traction control system (TCS) (models from 1995).
Scheme 23. Automatic clutch and automatic transmission — models from 1995
Scheme 24. Side and tail lights, brake lights, reversing lights and license plate lights — models from 1995
Scheme 25. Headlights — models manufactured since 1995
Scheme 26. Indicator lamps for fog lights and headlights, direction indicators and hazard warning lights — models from 1995
Scheme 27. Indicator lamps and direction indicators — models from 1995
Scheme 28. Windscreen wipers, washers and horn — models from 1995
Scheme 29. Cigarette lighter, clock and interior lighting — models from 1995
Scheme 30. Windshield defrosters and heater fan — models from 1995
Scheme 31. Central locking system and electric windows — models from 1995
Scheme 32. Power mirrors, audio system and airbags — models from 1995
General information
Using the manual
About this Guide
Health protection and precautions
Warning signs located on the vehicle
Standard technical practices 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 a jack and lifting the car
Noise, vibration and harshness (NVH)
Noise, Vibration and Harshness (NVH) Diagnostics and Testing
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
Measuring compression pressure
Measuring oil pressure
Checking the valve mechanism — static (engine off)
Engine 1.4/1.6 Zetec-SE
1.4L/1.6L Zetec-SE Engine Specifications
Description and operating principle 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 pan — removal and installation
Removing the engine with a manual transmission
Removing the engine with automatic transmission
Disassembling the engine
Cylinder head — disassembly and assembly
Engine assembly
Installing an engine with a manual transmission
Installing an engine with an automatic transmission
Engine 1.6/1.8/2.0 Zetec-E
1.8L/2.0L/1.6L Zetec-E Engine Specifications
Description and operating principle 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 pan — removal and installation
Removing the engine with a manual transmission iB5
Removing the engine with a manual transmission MTX-75
Removing the engine with automatic transmission
Removing the 1.6L Zetec-E engine
Disassembling the engine
Engine assembly
Installing an engine with a manual transmission iB5
Installing an engine with a manual transmission MTX-75
Installing an engine with an automatic transmission
Installing 1.6L Zetec-E Engine
Engine Duratec ST 2.0 l
Duratec ST 2.0L Engine Specifications
Description and operating principle of the Duratec ST 2.0 l engine
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 pan — removal and installation
Oil pump — removal and installation
Rear Crankshaft Seal — Removal and Installation
Removing the engine
Disassembling the engine
Engine assembly
Engine installation
Engine Duratec 8V 1.6 l
Duratec 8V 1.6L Engine Specifications
Description and operating principle 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 tappets — removal and installation
Exhaust manifold — removal and installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Rear Crankshaft Seal — Removal and Installation
Removing the Duratec 8V 1.6L engine
Disassembling the Duratec 8V 1.6L engine
Cylinder head — disassembly and assembly
Duratec 8V 1.6L Engine Assembly
Installing the Duratec 8V 1.6L engine
Diesel engine 1.8 l
Diesel Engine Specifications
Description and operating principle of the engine without fuel injection
Description and operating principle 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
Cylinder head of a fuel injected engine
Oil pan — removal and installation
Rear Crankshaft Seal — Removal and Installation
Removing the engine
Disassembling the engine
Disassembling a fuel injected engine
Cylinder head — disassembly and assembly
Fuel Injected Cylinder Head — Disassembly and Assembly
Engine assembly
Fuel injection engine assembly
Engine installation
Engine cooling
Engine Cooling System Specifications
Description and principle of operation of engine cooling
Diagnostics and testing of the engine cooling system
Pinpoint tests of the engine cooling system
Checking the engine cooling system components
Draining/filling coolant and bleeding air
Flushing the cooling system
Backwashing (counter-current flushing) 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
Electric motor and cooling fan housing (1.6L Zetec-SE/1.4L)
Electric motor and cooling fan housing (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 operating 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 injection 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 operating principle (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 Delivery 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 operating principle (1.8 l diesel)
Diagnostics and checks (1.8 l diesel)
Fuel injectors (1.8 l diesel)
High pressure fuel pump (1.8 l diesel)
Specifications (turbocharger)
Description and principle of operation (turbocompressor)
Diagnostics and checks (turbocharger)
Inspection and testing (turbocharger)
Pinpoint tests (turbocharger)
Turbocharger 1.8 l diesel (75 PS/90 PS)
Turbocharged 1.8L Diesel with Fuel Injection
Specification (diesel with fuel injection)
Description and operating principle (diesel with fuel injection)
Diagnostics and checks (diesel with fuel injection)
Cleaning of fuel injection system components (diesel with fuel injection)
Fuel injectors (diesel fuel injection)
Fuel Supply Manifold (Diesel Fuel Injection)
Fuel pump (diesel with fuel injection)
Fuel return line with Venturi nozzle
Specifications (Duratec ST 2.0L)
Description and operating principle (Duratec ST 2.0 l)
Throttle Body (Duratec ST 2.0L)
Fuel Delivery System Wiring Harness (Duratec ST 2.0L)
Fuel Supply Manifold (Duratec ST 2.0L)
Specifications (1.6L Duratec)
Description and operating principle (1.6L Duratec)
Diagnostics and checks (1.6L Duratec)
Throttle Body (1.6L Duratec)
Fuel Delivery System Wiring Harness (1.6L Duratec)
Fuel Supply Manifold (1.6L Duratec)
Description and operating principle of the fuel supply system
Diagnostics and testing of the fuel supply system
Pinpoint tests of the fuel supply system
Relieving pressure in the fuel supply system
Quick coupling — disconnection and connection
Emptying the fuel tank
Spring Lock Couplings — Disconnecting and Connecting
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 diesel with injection) — removal and installation
Inertial Fuel Shutoff 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 tests
Pinpoint speed control tests
Adjusting the Speed Control System Deactivator Switch
Speed control cable
Speed control cable (Duratec ST 2.0L)
Speed control system switch
Accessory drive
Accessory Drive Specifications
Description and operating principle of the accessory drive
Diagnostics and checks of accessory drive
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 Drive Belt Idler Pulley
Accessory Drive Belt Idler Pulley (1.8L Diesel)
Accessory Drive Belt (1.6L Duratec)
Accessory Drive Belt Tensioner (1.6L Duratec)
Launch system
Launch System Specifications
Description and operating principle of the launch system
Diagnostics and testing of the starting system
Pinpoint tests of the launch system
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 operating principle of the ignition system 1.4/1.6 Zetec-SE
Diagnostics and testing 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 operating principle of the ignition system 1.8/2.0/1.6 Zetec-E
Diagnostics and testing of 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 operating principle of the glow plug system (1.8L diesel)
Diagnostics and testing of glow plug system (1.8L diesel)
Glow Plug Wire (1.8L Diesel)
Description and operating principle of the ignition system (Duratec 8V 1.6L)
Diagnostics and testing of the ignition system (Duratec 8V 1.6L)
Air and vapor
Distribution and filtration of intake air
Diagnostics and testing of distribution and filtration
Air filter inlet pipe
Air filter — removal and installation
Air filter element
Fuel vapor control
Diagnostics and fuel vapor control checks
Carbon filter for fuel vapor control system
Carbon filter for fuel vapor control system (Duratec ST 2.0 l)
Fuel Evaporative Control System Carbon Canister Purge Valve
Fuel Evaporative Canister Purge Valve (Duratec)
Engine management
Electronic Control Specifications
Description and operating principle 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 (CPS) (1.6L Zetec-SE/1.4L)
Crankshaft Position Sensor (CPS) (1.8L/2.0L/1.6L Zetec-E)
Crankshaft position sensor (CPS) (1.8 l diesel)
Crankshaft Position Sensor (CPS) (1.8L Diesel with Injection)
Power Steering Pressure (PSP) Switch (1.6L Zetec-SE/1.4L)
Power Steering Pressure (PSP) Switch (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 (CHT) (1.6L Zetec-SE/1.4L)
Cylinder Head Temperature Sensor (CHT) (1.8L/2.0L/1.6L Zetec-E)
Cylinder Head Temperature Sensor (CHT) (1.8 l diesel)
Clutch Pedal Position Switch (CPP)
Injector Control Module (IDM) (1.8L Diesel)
Fuel Pump Control Module (FPDM) (Duratec ST 2.0L)
Intake Manifold Runner Control (IMRC) actuator
Idling Air Supply Control Valve (IAC)
Exhaust toxicity
Emissions reduction specifications (1.8/2.0/1.6 Zetec-E)
Description and operating principle (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)
Emissions reduction specifications (1.8L diesel)
Description and operating principle (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 Diesel Injection)
Pipe from the exhaust manifold to the exhaust gas recirculation (EGR) valve
Piping from the exhaust gas recirculation (EGR) cooler to the EGR valve
Exhaust Gas Recirculation (EGR) Cooler (75 PS/90 PS)
Exhaust Gas Recirculation (EGR) Cooler (115 PS)
Engine crankcase ventilation system oil separator
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 operating principle of automatic transmission
Electromagnetic control of synchronized gear shifting
Automatic transmission diagnostics and testing
Diagnostic Trouble Code Tables
Gearbox connector pinout
Pinpoint tests — car equipped with OSC
Special verification procedures
Inspection for leaks
Diagnostics by fault sign
Fluid pan, gasket and filter
Main control valves
Turbine Shaft Speed Sensor (TSS)
Secondary Shaft Speed Sensor (OSS)
Left axle shaft seal
Right axle shaft seal
Transmission Range (TR) Sensor
Gearbox in block with driving axle 1.6L — removal
Gearbox in block with leading axle 2.0L — removal
Gearbox in block with driving axle — disassembly
Main gear holder with differential — disassembly and assembly
Pump assembly — disassembly and assembly
Transfer shaft — disassembly and assembly
Forward Clutch — Disassembly and Assembly
Direct and reverse clutch — disassembly and assembly
Direct Drive Clutch — Disassembly and Assembly
Reverse clutch — disassembly and assembly
Planetary gear assembly — disassembly and assembly
Main control valve block — disassembly and assembly
Gearbox housing in block with drive axle
Torque converter
Checking the torque converter for leaks
Checking the axial clearance of the torque converter
Gearbox in block with driving axle — assembly
Gearbox in block with driving axle 1.6L — installation
Gearbox in block with driving axle 2.0L — installation
Description and operating principle of gearbox cooling
Diagnostics and testing of gearbox cooling
Transmission Fluid Cooler — Removal and Installation
Transmission Fluid Cooler Lines — Removal and Installation
Description and operating principle of external controls
Diagnostics and testing of external controls
Pinpoint tests of external controls
Adjusting the gear selector lever cable
Gearshift locking actuator
Gear Selector Lever Cable — Removal and Installation
Gear Selector Lever — Removal and Installation
Gear Selector Lever Socket — Removal and Installation
Gear Selector Lever Handle — Removal and Installation
Gear Selector Lever — Disassembly and Assembly
Clutch
Manual Transmission Specifications
General information about manual transmission
Clutch diagnostics and testing
Pinpoint clutch tests
Diagnostics and testing of clutch controls
Checking the clutch slave cylinder
Bleeding the iB5 Clutch System
Bleeding the MTX-75 Clutch System
Bleeding the Clutch System MT285
Adjusting the iB5 Shift Cable
Adjusting the MTX-75 Shift Cable
Adjusting the MT285 Shift Cable
Clutch of manual transmission iB5
Clutch for manual transmission MTX-75
Clutch for manual transmission MT285
IB5 Clutch Controls
Clutch Master Cylinder iB5
Clutch slave cylinder iB5
MTX-75 Clutch Controls
Clutch Master Cylinder MTX-75
MTX-75 Clutch Slave Cylinder
Mechanical gearbox iB5
IB5 Manual Transmission Specifications
Description and operating principle of iB5
Checking bearings
Left axle shaft seal — removal and installation
Right axle shaft seal — removal and installation
Gear shift control shaft seal
Vehicle Speed Sensor (VSS) — Removal and Installation
Gearbox with driving axle (1.6L Zetec-SE/1.4L) — removal
Gearbox with leading axle (1.8L/1.6L Zetec-E) — removal
Gearbox with driving axle (1.6L) — removal
Gearbox with axle (cars up to 07.2000) — disassembly
Gearbox with axle (cars after 08.2000) — disassembly
Gear Selector Plate — Disassembly and Assembly
Primary shaft — disassembly and assembly
Secondary shaft — disassembly and assembly
Differential — disassembly and assembly
Gearbox with axle (cars up to 07.2000) — assembly
Gearbox with axle (cars after 08.2000) — assembly
Gearbox with leading axle (1.6L Zetec-SE/1.4L) — installation
Gearbox with leading axle (1.8L/1.6L Zetec-E) — installation
Gearbox with leading axle (1.6L) — installation
External controls of the iB5
Diagnostics and testing of external controls
Gear shift lever mechanism — removal and installation
Gear Shift Lever — Removal and Installation
Gear Shift Cables — Removal and Installation
Gear Shift Lever — Disassembly and Assembly
Mechanical gearbox MTX-75
MTX-75 Manual Transmission Specifications
Description and operating principle of MTX-75
Checking bearings
Left axle shaft seal — removal and installation
Right axle shaft seal — removal and installation
Gearbox with driving axle (2.0L) — removal
Gearbox with driving axle (1.8L diesel) — removal
Gearbox in block with driving axle — disassembly
Gear selection mechanism (vehicles up to 07.2000)
Primary shaft — disassembly and assembly
Secondary shaft (cars up to 07.2000) — disassembly and assembly
Secondary shaft (cars after 08.2000) — disassembly and assembly
Differential — disassembly and assembly
Gearbox in block with driving axle — assembly
Transmission in block with driving axle (2.0L) — installation
Gearbox in block with driving axle (1.8 l diesel) — installation
External controls MTX-75
Diagnostics and testing of external controls
Gear shift lever mechanism — removal and installation
Gear Shift Lever — Removal and Installation
Gear Shift Cables — Removal and Installation
Gear shift lever (cars up to 08.2001)
Gear shift lever (cars after 08.2001)
Mechanical gearbox MT285
MT285 Manual Transmission Specifications
Description and operating principle of MT285
Draining and filling transmission fluid
Left axle shaft seal — removal and installation
Right axle shaft seal — removal and installation
Gearbox in block with driving axle — removal
Gearbox in block with driving axle — installation
External controls MT285
Diagnostics and testing of external controls
Gear shift lever mechanism — removal and installation
Gear Shift Cables — Removal and Installation
Gear Shift Lever — Disassembly and Assembly
Chassis
Front suspension
Suspension specifications
Diagnostics and testing of suspension
Pinpoint tests of suspension
Checking suspension components
Rear wheel alignment adjustment (15 211 0)
Front wheel alignment (14 117 0)
Adjusting the calculated suspension height
Inspection of wheel bearings
Rear suspension
Rear Suspension Specifications
Description and operating principle of the rear suspension
Wheel hub (15 373 0) — removal and installation
Wheel bearing — removal and installation
Wheel hub 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 knuckle (15 366 0) — removal and installation
Shock absorber (15 791 0) — removal and installation
Shock absorber — universal (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 — universal (15 621 0)
Cross member — removal and installation
Wheels and tires
Inspection and testing of tires
Tire wear and vibration diagnostics
Tire sensitivity to speed and rotation frequency
Table of signs of tire failure
Removing and installing a wheel
Front axle axles
Front Axle Shaft Specifications
Description and principle of operation
Inspection and testing of front axle shafts
Left axle shaft — removal and installation
Right axle shaft — removal and installation
Intermediate shaft — removal and installation
Inner constant velocity joint (CV joint) boot
Outer constant velocity joint (CV joint) boot
Left axle shaft — disassembly and assembly
Right axle shaft — disassembly and assembly
Brake system
Description and operating principle of the braking system
Inspection and testing of the brake system
Table of signs of brake system malfunction
Pinpoint tests of the brake system
Checking the brake system components
Bleeding the brake system
Bleeding air from the brake system under pressure
Checking the brake system for leaks
Checking the brake disc runout
Drum Brake Specifications
Description and operating principle of a 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
Front Disc Brake Description
Front Disc Brake Pads
Front Disc Brake Caliper
Front disc brake disc
Front Disc Brake Disc — Duratec ST 2.0L
Disassembling the front disc brake caliper
Rear Disc Brake Specifications
Description of the rear disc brake
Rear Disc Brake Caliper
Rear Disc brake pads
Rear disc brake disc
Rear Disc Brake Disc Shield
Description and principle of operation of the parking brake
Inspection and testing of the parking brake
Parking Brake Pinpoint Tests
Adjusting the parking brake cable
Parking brake control lever
Parking brake cable — removal and installation
Hydraulic brake
Hydraulic brake drive specifications
Description and operating principle of 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
Brake Booster Specifications
Description and operating principle of the vacuum brake booster
Vacuum brake booster — removal and installation
Brake system vacuum pump — removal and installation
Anti-lock braking system
Anti-lock braking system specifications
Description and operating principle of the anti-lock braking system
Diagnostics and testing of the anti-lock braking system
Hydraulic Control Unit (HCU)
Rear wheel speed sensor
Rear wheel speed sensor pulse ring
Description and operating principle of the stability control function
Speed sensor for angular rotation of the vehicle around the vertical axis
Acceleration sensor — removal and installation
Steering
Steering Specifications
Description and operating principle of the steering control
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 (115 PS)
Bleeding the Power Steering System
Purge the power steering system
Filling the power steering system with working fluid
Power Steering Specifications
Description of power steering
Power steering pump — 1.4L/1.6L (with air conditioning)
Power steering pump — 1.4L/1.6L (without air conditioning)
Power Steering Pump — 1.8L/2.0L
Power Steering Pump — 1.8L Diesel
Power Steering Pump — Duratec ST 2.0L
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 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
Pinpoint tests of steering column switches
Ignition Switch — Removal and Installation
Description of the steering drive
Steering rod — removal and installation
Tie Rod End — Removal and Installation
Steering gear housing
Steering column description
Steering wheel — removal and installation
Steering column — Cars produced up to 03.2002
Steering column — Cars produced from 03/2002
Steering column — Duratec ST 2.0 l
Steering column (cars up to 03.2002) — disassembly and assembly
Steering column (cars 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
Rear body panels
Alignment of the hood — removal and installation
Mudguard — Removal and Installation
Hood Panel Grille — Removal and Installation
Wing — removal and installation
Specifications of lockable body elements
Body elements
Rear view mirrors
Rear view mirrors — diagnostics and checks
Rearview Mirrors — Pinpoint Tests
Outside mirror — removal and installation
Handles, Locks, Latches and Entry Systems
Diagnostics and testing of entry systems
Programming the remote control transmitter
Hood Latch — Removal and Installation
Front Door Latch — Removal and Installation
Rear Door Latch — Removal and Installation
Luggage compartment liftgate latch
External door handle — removal and installation
Hood Lock Cylinder — Removal and Installation
Ignition Lock Cylinder — Removal and Installation
Door Lock Cylinder — Removal and Installation
Luggage compartment lift door lock cylinder
Luggage compartment lift door lock cylinder (station wagon)
Interior Door Latch Release Handle
Bumper Tightening Torque Specifications
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
Rear side trim panel
Door sill trim panel
Ceiling lining — removal and installation
Seat specifications
Description and operating principle of the seats
Diagnostics and checks of seats (cars up to 08.2001)
Pinpoint tests of seats (cars up to 08.2001)
Diagnostics and checks of seats (cars after 08.2001)
Pinpoint tests of seats (cars after 08.2001)
Seat diagnostics and testing (Duratec ST 2.0 l)
Pinpoint tests seats (Duratec ST 2.0 l)
Front seat — removal and installation
Front seat back — removal and installation
Front seat back (folding flat seat)
Rear seat back — removal and installation
Rear seat back (split seat)
Front seat cushion — removal and installation
Rear Seat Back Latch — Removal and Installation
Rear Seat Back Latch (3-Door/5-Door/Wagon)
Front seat cushion — disassembly and assembly
Rear seat cushion (cars 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 back (split seat) — disassembly and assembly
Instrument panel — removal and installation
Floor console (cars up to 10.2001, manual transmission)
Floor console (cars after 10.2001, manual transmission)
Floor console (cars up to 10.2001, automatic transmission)
Floor console (cars after 10.2001, automatic transmission)
Upper console — removal and installation
Glass, frames and mechanisms
Specifications
Description and principle of operation
Diagnostics and checks (cars up to 08.2000)
Pinpoint tests (cars up to 08.2000)
Diagnostics and checks (cars from 08.2000 to 08.2001)
Pinpoint tests (cars from 08.2000 to 08.2001)
Diagnostics and checks (cars after 08.2001)
Pinpoint tests (cars after 08.2001)
Initialization of the electric motor of the window lifter of the door
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 for window lift door
Front door window lifter
Rear door window lifter
Front door window lifter and window lifter motor
Rear door window lifter and window lifter motor
Windshield — removal and installation
Upper guide for front door window glass
Upper guide for rear door window glass
Windshield wipers and washers
Windscreen Wiper Specifications
Description and operating principle of windshield wipers
Diagnostics and testing of windshield wipers (cars up to 08.2001)
Pinpoint tests of windscreen wipers (cars up to 08.2001)
Checking windshield wiper elements (vehicles up to 08.2001)
Diagnostics and testing of windshield wipers (cars after 08.2001)
Pinpoint tests of windscreen wipers (cars after 08.2001)
Checking windshield wiper elements (cars after 08.2001)
Adjusting the windshield wiper blades and arms
Windshield wiper motor — removal and installation
Rear Window Wiper Motor — Removal and Installation
Windshield washer pump and reservoir
Car sunroof
Tightening torque specification
Sunroof diagnostics and testing
Sunroof Pinpoint Tests
Checking the water drainage system and eliminating water leaks
Checking the position of the roof hatch
Initializing the sunroof drive motor
Sunroof Glass — Removal and Installation
Sunroof Curtain — Removal and Installation
Roof Sunroof Cable and Guide — Removal and Installation
Sunroof Frame — Removal and Installation
Front Sunroof Drain Hose — Removal and Installation
Rear Sunroof Drain Hose (4/5-Door/Wagon)
Rear Sunroof 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
Diagnostics and testing of seat belts
Front seat belt retractor mechanism
Rear seat belt retractor (3-/5-door)
Rear Seat Belt Retractor (4-Door)
Rear seat belt retractor mechanism (station wagon)
Central rear seat belt retractor mechanism
Rear center seat belt retractor (4-door)
Shoulder belt height adjustment mechanism
Seat belt buckle — removal and installation
Seat belt buckle and tensioner — removal and installation
Auxiliary Restraint System Specifications
Auxiliary restraint system — description and operating principle
Auxiliary restraint system — diagnostics and testing
Instructions for diagnostics of the restraint system (before 08.2002)
Instructions for diagnostics of the restraint system (after 08.2002)
Pinpoint tests of the auxiliary restraint system (before 10.2001)
Pinpoint tests of the auxiliary restraint system (after 10.2001)
Pinpoint tests of the auxiliary restraint system (after 08.2002)
Disposal of a deployed airbag
Airbag disposal — unserviceable vehicle
Disposal of an undeployed 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
Protection of the body from corrosion
Repair of plastic parts
Water leaks
The sound of the wind
Removing 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
Inner reinforcement of the wing apron panel — removal and installation
Deformable element of the side member — removal and installation
Front side member section — removal and installation
Right front spar 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
Section and reinforcement of the outer panel of the 'A' pillar
Half door hinge — removal and installation
Lower trim panel (3-door)
Lower trim panel (5-door)
Lower Trim Panel Section (5-Door)
Front section of lower trim panel (3-door)
Front section of lower trim panel (5-door)
Rear section of the lower trim panel (5-door)
B-Pillar and Reinforcement (3-Door)
B-Pillar and Reinforcement (5-Door)
Subframe and mounting system specifications
Cross member — removal and installation
Checking for body misalignment
Checking for misalignment of the lower part of the body (bottom)
Back elements
Left side panel of the rear body (4-door)
Left side panel of the rear body (station wagon)
Right side panel of the rear body (3-door)
Right side panel of the rear body (5-door)
Front section of rear quarter panel/side panel (3-door)
Rear left section of rear quarter panel/side panel (3-door)
Rear left section of rear quarter panel/side panel (5-door)
Rear right section of rear quarter panel/side panel (4-door)
Rear right section of rear quarter panel/side panel (estate)
Rear side interior panel (3-door)
Rear side interior panel (5-door)
Rear side interior panel and wheel arch (4-door)
Rear quarter panel interior and wheel arch (station wagon)
Inner rear section of rear quarter panel (3-door)
Inner rear section of rear side panel (4-door)
Inner rear section of rear quarter panel (station wagon)
Rear inner panel of the rear side part of the body (4-door)
Water Drain Panel (4-Door)
Water Drain Panel (5-Door)
Reinforcement of the water drain panel (5-door)
Water Drain Panel Reinforcement — Universal
Inner half of rear wheel arch (4-door)
Inner half of rear wheel arch — 5-door
Inner half of rear wheel arch (station wagon)
Half section of the rear outer wheel arch (station wagon)
Tail Light Mounting Panel (4-Door)
Rear Light Mounting Panel (Wagon)
Rear panel (5-door)
Rear panel (station wagon)
Rear panel and reinforcement (4-door)
Rear panel section (station wagon)
Rear panel and cross member (station wagon)
Rear floor panel (5-door)
Right section of rear floor panel (estate)
Rear Floor Panel Section (Wagon)
Rear Floor Panel Section (5-Door)
Spare wheel well (station wagon)
Rear side member section (5-door)
Rear side member section (station wagon)
Storage Shelf Panel (4-Door)
Trunk lid hinge (4-door)
Electrical equipment
Climate control
Climate control specifications
Description and operating principle of microclimate control
Diagnostics and checks (cars manufactured before 07.2001)
Pinpoint tests of microclimate control (cars up to 07.2001)
Diagnostics and checks (cars manufactured since 08.2001)
Pinpoint tests of microclimate control (cars from 08.2001)
Spring Lock Coupling
Adjusting the air gap of the air conditioning system clutch
Finding Leaks Using Fluorescent Dye
Electronic leak detection
Adding cooling oil
Handling contaminated refrigerant
Cleaning the air distribution system
Refrigerant recovery, vacuuming and refilling of air conditioning systems
Air distribution and purification
Air Conditioning Specifications
Description and operating principle of air conditioning
Air conditioning compressor — removal and installation
Air conditioning compressor (1.6L) — removal and installation
Clutch and electromagnetic clutch coil
Evaporator jet — removal and installation
Suction tank — removal and installation
Low pressure relay — removal and installation
Condenser (refrigerator) core — removal and installation
High pressure relay — removal and installation
Description and operating principle of controls
Microclimate control assemblies — removal and installation
Microclimate control units in assembly (automatic) — removal and installation
Intake air mixing flap drive
Air distribution control cable block
Heating and ventilation
Tightening torque specification
Description and principle of operation
Blower 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 operating principle of additional heating
Diagnostics and testing of additional heating
Pinpoint tests of additional heating
Diagnostics and testing of electric additional heater
Pinpoint tests of electric auxiliary heater
Additional fuel-fired heater — removal and installation
Additional heater — disassembly and assembly
Instruments and control lamps
Instrument panel and dashboard lighting
Diagnostics and testing of the instrument panel
Pinpoint tests of the instrument cluster
Instrument cluster — description
Diagnostics and checks of the instrument panel
Pinpoint tests of the instrument cluster
Instrument cluster — removal and installation
Instrument cluster (Duratec ST 2.0 l) — removal and installation
Combination of oil pressure and oil temperature indicators (Duratec ST 2.0 l)
Sound signal
Diagnostics and testing of the sound signal
Pinpoint tests of the sound signal
Sound signal — removal and installation
Horn Switch — Removal and Installation
Watch — description and principle of operation
Watches — diagnostics and checks
Watch — Pinpoint tests
Watch — 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 tests
Warning Devices — Pinpoint Tests
Parking assistance
Parking assistance — diagnostics and checks (cars up to 10.2001)
Parking assistance — Pinpoint tests (vehicles up to 10.2001)
Parking assistance — diagnostics and checks (cars after 10.2001)
Parking assistance — Pinpoint tests (cars after 10.2001)
Battery and alternator
Charging system — description and operating principle
Charging system — diagnostics and checks
Charging System — Pinpoint Tests
Charging the battery
Battery and Wire Specifications
Battery and wires — description and operating principle
Battery diagnostics and testing
Disconnecting the battery
Battery — removal and installation
Battery shelf — removal and installation
Battery Cables — Removal and Installation
Battery shelf (1.6L Duratec)
Battery Cables (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 System Pinpoint Tests
Diagnostics and testing of the audio system without an amplifier
Pinpoint tests of audio system without 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
LHD Antenna Cable — 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 operating principle
Headlights (cars up to 08.2001) — diagnostics and checks
Headlights (cars up to 08.2001) — Pinpoint tests
Headlights (cars after 08.2001) — diagnostics and checks
Headlights (cars after 08.2001) — Pinpoint tests
Headlight leveling (before 08.2001) — diagnostics and checks
Headlight range correction (before 08.2001) — Pinpoint tests
Headlight aiming correction (after 08.2001) — diagnostics and checks
Headlight level correction (after 08.2001) — Pinpoint tests
Brake lights (cars before 08.2001) — diagnostics and checks
Brake Lights (vehicles up to 08.2001) — Pinpoint Tests
Brake lights (cars after 08.2001) — diagnostics and checks
Brake Lights (Cars after 08.2001) — Pinpoint Tests
Direction indicators (vehicles up to 08.2001) — diagnostics and checks
Direction indicators (vehicles up to 08.2001) — Pinpoint tests
Direction indicators (cars after 08.2001) — diagnostics and checks
Direction indicators (cars 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 (cars after 08.2001) — diagnostics and checks
Parking lights (cars after 08.2001) — Pinpoint tests
Fog lights (cars up to 08.2001) — diagnostics and checks
Fog lights (vehicles up to 08.2001) — Pinpoint tests
Fog lights (cars after 08.2001) — diagnostics and checks
Fog lights (cars 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 (cars after 08.2001) — diagnostics and checks
Reversing lights (cars after 08.2001) — Pinpoint tests
Headlight adjustment
Headlight adjustment — The vehicle comes with: headlights
Headlight support bracket repair
Covering headlight areas
Covering headlight sections (cars manufactured before 10.2001)
Covering headlight sections (cars manufactured after 10.2001)
Adjusting the front fog lights
Front high beam headlight bulb
Low beam headlight bulb
Headlight assembly — removal and installation
Light switch — removal and installation
Headlight leveling sensor — removal and installation
Headlight leveling motor (vehicles up to 10.2001)
Headlight leveling motor (vehicles after 10.2001)
Front fog light
Interior lighting
Interior Lighting — Diagnostics and Checks
Interior Lighting — Pinpoint Tests
Daytime running lights (vehicles before 08.2001)
Daytime running lights (vehicles up to 08.2001) — Pinpoint tests
Daytime running lights (cars after 08.2001)
Daytime running lights (cars after 08.2001) — Pinpoint tests
Power distribution
Communication network (vehicles up to 08.2001)
Communication network (cars after 08.2001)
Communication network (vehicles up to 08.2001) — diagnostics and checks
Communication network (vehicles before 08.2001) — Pinpoint tests
Communication network (cars after 08.2001) — diagnostics and checks
Communication network (cars after 08.2001) — Pinpoint tests
Configuration of modules
Electronic Function Group
Active anti-theft system
Active Anti-Theft System — Diagnostics and Tests
Active Anti-Theft System — Pinpoint Tests
Passive anti-theft system
Passive Anti-Theft System — Diagnostics and Tests
Passive Anti-Theft System — Pinpoint Tests
Passive anti-theft system transceiver
Telematics — description and operating principle
Telematics — diagnostics and testing
Telematics — Pinpoint tests
Global Positioning System (GPS) Antenna
Worldwide Mobile Communication System (GSM)Antenna
Cell phone — description and operating principle
Cell phone — diagnostics and checks
Cell Phone — Pinpoint Tests
Cell Phone Antenna — Removal and Installation
Telephone handset bracket — removal and installation
Functions controlled by the module (vehicles up to 08.2001)
Functions controlled by the module (cars after 08.2001)
Central Timer Module — Diagnostics and Tests
Multifunctional electronic module (cars after 08.2001)
General 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
Presentation of the car model
At a glance — an overview of Focus models
Engine specifications
Overall dimensions of the car
Improving Ford Focus 1 models
Workplace equipment
Timely purchase of spare parts
Tools required for work
Special purpose tools make work easier
Professional tips for the amateur mechanic
Tips for visiting the workshop
Safety precautions during repair work
Car lifting jack
How to lift a car safely
Technical characteristics of the car
Car care
Regular car maintenance
Special care products for interior cleaning
Car wash in front of the house door
Car engine wash
Lubrication of hinges and locks
Regular care of varnish
Severe damage to the paintwork reduces the value of the car
Polishing makes small scratches invisible
This is how larger scratches disappear
Windscreen washer system
Filling with windshield washer fluid
Replacing the rubber wiper pad
Adjusting the sprinkler nozzles
Removing the windshield washer nozzle
Removing the windshield wiper arm
Removing the front wiper motor
Removing the rear wiper motor
Help with windshield wiper problems
Power unit
Engine repair
Description of engine design
Engine repair in a workshop or do it yourself?
Description of the main engine components
Basic concepts of engine building
Setting the piston of the first cylinder to the TDC position of the compression stroke
Spark plugs
Over-revving and engine durability
Measuring compression pressure
Compression pressure decreases
Checking the V-belt
Installation of V-belt
Timing belt and camshaft
Diagnostics — knocking in the engine compartment
Help with cylinder head gasket problems
Lubrication system
Description of the design of the engine lubrication system
New oil filter at every oil change
Lubrication system pressure
Motor oil is a liquid with many talents
Concepts of standards on the topic of oil
Absolutely normal — low oil consumption
Don't forget to measure the oil level regularly
Always change the engine oil and oil filter at the same time
Help with ignition system malfunctions
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
Replacing the coolant
Resist winter — protection from frost down to -30°C
Help with cooling system and thermostat problems
The engine is losing coolant
Removing and checking the thermostat
The engine «boils» — a faulty radiator fan
Removing the radiator fan
Removing 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 fuel injection system design
General overview — EEC-V injection system control
In detail — EEC-V injection system control
Invisible assistants – new assistants of the EEC-V injection system
Diagnostics and communication equipment of the EEC-V injection system
Visual inspection of the injection system
Help with petrol injection system faults
Uncertainty in the operation of the on-board computer — secondary air
Checking the idle speed
Blocking of idle speed oscillations by the system
Checking the idle servo motor
Checking injection valves
Replacing the throttle cable
Fuel injection (diesel)
Diesel Fuel Supply System — Basic Design
Excess fuel is returned to the fuel tank
Fuel Delivery Path — This is how fuel gets to the injector
Significantly increased hydraulic efficiency — VP 30 injection pump
Pulse sensor wheel and angle sensor
Equipment for starting a cold diesel engine
Injectors — Diesel fuel atomization
Repair and correction of the injection system in a diesel engine
Disassembling injectors
Visual inspection of the diesel engine injection system
Help with diesel injection system faults
Ignition system
Description of the ignition system design
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
Replace spark plugs at least every 60,000 km
Help with ignition system malfunctions
Ignition off
Checking the RPM sensor with a multimeter
Checking the pressure sensor
Ignition current measurement
Measuring the resistance of the ignition coil
Removing the ignition module
Diesel pre-heating system
Checking the pre-heating 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 fuel tank ventilation
Replacing the fuel filter (petrol engine)
Replacing the fuel filter (diesel engine)
Draining fuel from the fuel tank using a hand pump
Dismantling of pipelines and hoses
Troubleshooting a Fuel Pump
Removing the fuel pump (petrol engine)
Description of the exhaust system design
Tips for working on the exhaust system
Checking the exhaust system
Replacement of the exhaust system, including the catalytic converter
Concepts related to exhaust gases
Reducing toxicity of exhaust gases
Transmission
Clutch and drive shafts
Description of the clutch design
Clutch and its components
This is how the clutch works
Checking the clutch
Does the clutch disengage completely?
Driving with leaky clutch hydraulics
Help with clutch problems
Main gear — design description
Main gear and drive shafts
Checking the drive shaft seals
If the drive shaft makes noise
Dismantling and installation of the drive shaft
Replacing the drive joint cuff
Mechanical gearbox
IB5 Gearbox Shift Control
Gearbox shift control MTX-75
General information about the gearbox
Five-speed manual transmission
This is how a manual transmission works
Gear shift adjustment
Checking the transmission oil level
Noises in the gearbox
Automatic gearbox
Description of the design of the automatic transmission
Transmission controls
Automatic transmission repair is not a job for amateurs
Adjusting the selector lever cable
Mechanical release of the selector lever lock
Checking the transmission oil level
Features of handling the automatic transmission 4F27E
Chassis
Car suspension
General information about the suspension
Front suspension units
Rear suspension units
Amateur work on the chassis and steering
Checking shock absorbers
Telescopic shock absorber — design description
Checking the bearings of the wishbones of the independent suspension
Checking the wheel bearing clearance
Replacing the wishbone (front)
Replacing the shock absorber strut
Replacing rear shock absorbers
Steering
Steering and driving safety are linked
Steering Geometry Concepts
Control factor — front axle geometry
Regularly check the steering free play
Checking the toothed rack protective cuffs
Checking the heads and seals of the tie rod
Replacing the tie rod ends
Replacing the steering gear cuffs
Replacing the steering swivel support
Airbag — a job for real professionals
Steering column design
Servo control — general information
Wheels and tires
Tires and Rims — General Information
Wheels and tires — sizes
Key characteristics of tires
Winter tires — professionals in any weather
Practical tips for saving tires
Checking tire pressure
Wheel replacement
Checking the condition of the tires
What the type of tread can tell you
Proper storage of wheels
Brake system
General information about the braking system
Description of the brake system design
Main components of the braking 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 operation of the brakes
Measuring wear on disc brake linings
Brake pedal and brake pad
Checking brake disc wear
Help with brake system problems
Bleeding the brake system
Brake fluid — general information
Replacing brake fluid
Removing the expansion tank from the brake master cylinder
Removing the master brake cylinder
Removing the brake booster
Removing brake hoses
Replacing brake disc linings
Removing brake discs
Restoring the mobility of the brake caliper and piston
Replacing the rear axle mudguard
Handbrake — General Information
Replacing handbrake cables
Adjusting the handbrake
Body
Exterior
General information about the car body
Door dismantling
Installing a door
Removing the external viewing mirror
Removing the fairing
Removing the hood
Installing the hood
Removing the hood lock
Removing the front bumper
Wing dismantling
Removing the rear bumper (3-, 4-, 5-door models)
Removing the back cover
Removing the lock in the back cover
Interior
General information about the car interior
Switches in the car interior
Ignition key coding
Controls — General Information
Replacement of interior lights
Checking the door contact switch
Replacement of trunk light
Dismantling the radio receiver
Removing the speaker
Removing the roof antenna
Removing the seats
Checking seat belts
Removing door trim
Removing the side window regulator (front)
The electric window does not work
Central locking — general information
Removing the door handle
Removing the ignition lock drum
Help with power window problems
Help with central locking problems
Belt tensioner and independent work
Heating and ventilation
General information about heating and ventilation
Periodic check of heating and ventilation
Help with heating system malfunctions
Removing the heating and ventilation control module
Air blower — general information
Troubleshooting the Air Blower
Replacing the air blower motor
Dismantling the heating/AC control unit
Removing the air circulation flap servomotor
Removing the cables on the air distributor
Electrical equipment
Equipment and devices
Wiring Harness Overview
General information about on-board electrical equipment
Basic concepts of electrical engineering
Measuring voltage, current and resistance
Instruments and controls
Checking the instruments in the instrument panel self-diagnostic module
Checking the operation of switches
Dismantling the combination instrument
Intertwined wire paths are not always traceable
Fuses in the passenger compartment and engine compartment
Fuses are replaced quickly
Switching relays distribute high operating currents
Location of fuses and relays
Lighting and signaling
External lighting equipment
Adjusting the light range
Replacing headlight bulbs
Replacing bulbs in fog lights
Replacing the bulbs in the front turn signals
Replacing side turn signal bulbs
Replacing the bulbs in the rear lights (hatchback)
Replacing the bulbs in the reversing light and fog light
Replacing the bulbs in the rear lights (with a stepped rear section)
Replacing the bulbs in the rear lights (Turnier)
Replacing the spotlight bulb in the license plate light
Replacing bulbs in additional brake light (hatchback)
Replacing the bulbs in the additional brake light (sedan)
Replacing interior lighting bulbs
Temporary headlight adjustment
Signaling equipment
Help with alarm malfunctions
Dismounting the alarm horn of the beep
Power devices
Order «Order on batteries»
Battery — design description
Battery — concepts and standards
Starter with reciprocating screw drive
Generator — General Information
Checking the acid level in the battery
Caring for battery contacts
Checking the battery
Jump starting the engine from another car's battery
Pushing the car to start the engine
Towing a car to jump start the engine
Help with battery and generator problems
Charging the battery
Removing the battery
Hidden power consumers drain battery
Checking the voltage regulator
Driving with a faulty alternator
Replacing the V-belt
Replacing the V-belt tension roller
Dismantling the generator
Removing the starter
Help with starter problems
Electrical circuits
Structure of switching circuits
Engine cooling ZETEC-SE with air conditioning
Engine cooling ZETEC-E with air conditioning
Endura-DI engine cooling with climate control
ZETEC-SE starting system with automatic transmission
ZETEC-SE starting system with manual transmission
ZETEC-E engine starting system
Endura-DI Engine Starting System
ZETEC-SE engine ignition system
ZETEC-E engine ignition system
Endura-Dl Engine Ignition System
Windscreen wipers and washer system with rear window wiper
Windscreen wipers and washer system with heated windscreen sprayers
Clock / time measurement
External lighting equipment, headlight adjustment
External lighting equipment, manual transmission...
Turnier exterior lighting equipment, marker lights...
External lighting equipment without daylight lamps...
External lighting equipment, fog lights...
Horn of sound signal
LHD Speaker Wiring Diagram
Generator and regulator, ZETEC engines
Generator and regulator, Endura-Dl engines
Ford Focus 2
General information
Vehicle device
General information about the car
Passport details
Car keys
Instrument panel
Instrument cluster
Heating (air conditioning) and ventilation of the passenger compartment
Door locks
Door window lifters
Seat belts
Adjusting the position of the front seats
Back seat
Using child seats
Adjusting the position of the steering wheel
Rear view mirrors
Interior lighting
Sun visors
Interior storage compartments
Opening the hood
Gearbox control
Roof rack
Owner's manual
Safety regulations
Operating recommendations
Traffic safety recommendations
What you need to have in your car for everyday use
What you need to have in your car when going on a long journey
Running in a car
Operation of the vehicle during the warranty period
Preparing the car for departure
Filling up a car with petrol
Using a jack
Towing a car
How to prepare your car for winter
Recommendations for starting the engine in severe frost
What is useful to buy for winter
Useful winter tips
Recommendations for preparation for technical inspection
List of faults and conditions under which operation of vehicles is prohibited
Changes to state standards for permissible content of harmful substances
Faults en route
General techniques for starting an engine
Malfunctions in the starting system
Checking the ignition system
Checking the engine fuel system
Fuel injection system faults
Idle speed is gone
Engine misfires
Diagnosis of engine condition by the appearance of spark plugs
The car moves in jerks
A jerk at the start of movement
Jerks during acceleration
Jerks during steady motion
The car accelerates poorly
The engine stalled while driving
Oil pressure dropped
Checking the lubrication system
Engine overheating
Checking the cooling system
The battery is not recharging
Checking electrical equipment
Starting the engine from external power sources
Electrical equipment faults
There was a knocking noise in the engine
Knocking in suspension and transmission
Possible causes of knocking in the suspension and ways to eliminate them
Possible transmission knocks (noises), their causes and methods of elimination
Vibration and shock on the steering wheel
Possible causes of vibrations and shocks on the steering wheel and ways to eliminate them
Brake problems
Bleeding the brake system
Checking the brake system
Tire puncture
Wheel replacement
Maintenance
General Provisions for Maintenance
Safety rules for maintenance
Checking the wheels
Checking the level and adding oil to the lubrication system
Checking the level and adding coolant
Checking the level and topping up the brake fluid
Checking the level and adding working fluid to the power steering reservoir
Checking the level and adding fluid to the washer reservoir
Checking external lighting fixtures
Trip to the service station
First maintenance
Checking the accessory drive belt
Checking the air conditioning compressor drive belt
Checking the timing belt
Changing engine oil and oil filter
Cleaning the crankcase ventilation system
Checking the cooling system hoses and connections
Checking the exhaust system
Checking the tightness of fuel lines
Checking and replacing the air filter element
Checking the level and adding oil to the gearbox
Checking the front wheel drive protective covers
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 angles
Inspection and testing of the steering system on the vehicle
Checking the free play (play) of the steering wheel
Checking the tightness of the hydraulic brake drive
Checking the degree of wear of brake pads, discs and drums
Checking the operation of the brake booster
Checking the efficiency of the braking system
Checking the parking brake
Battery Maintenance
Checking and adjusting headlights
Lubrication of body fittings
Cleaning drainage holes
Second maintenance
Replacement and maintenance of spark plugs
Replacement of auxiliary drive belt
Replacing the air conditioning compressor drive belt
Replacing the timing belt
Replacing brake fluid in hydraulic brake and clutch release systems
Replacing the coolant
Applications
Tightening torques for threaded connections
Overall dimensions (mm) of Ford Focus II cars
Technical characteristics of engines and performance indicators of cars
Cold Tire Pressure
Filling volumes
Consumables and spare parts
Motor oil
Plastic lubricants
Cooling fluids
Brake fluid
Fine fuel filter
Air filter
Engine lubrication system oil filter
Auto mechanic tips
General safety requirements
Safe car lifting
Basic set of tools
Special tools and devices
Before you start working
Unscrewing rusty threaded connections
Unscrewing damaged nuts
Hexagon socket or hexagon head bolts
Removing self-tapping screws with straight and Phillips slots
Drilling out a broken bolt
Thread cutting
Auto Body Repair Tips
Power unit
Engine repair
Engine design features
Possible engine malfunctions, their causes and solutions
Useful tips about the engine
Checking the compression in the cylinders
Removing and installing the engine mudguard
Replacing the right powertrain suspension support
Replacing the left support of the powertrain suspension
Replacing the rear support of the powertrain suspension
Setting the piston of the first cylinder to the TDC position of the compression stroke
Removal, installation and inspection of the flywheel
Adjusting valve clearances
Replacing camshafts
Grinding of cylinder head valves
Removing and installing the engine
Features of the lubrication system design
Removing and installing the oil pump
Engine seal parts
Replacing the cylinder head cover gasket
Replacing the cylinder head gasket
Replacing valve stem seals
Replacing camshaft seals
Replacing crankshaft seals
Replacing the oil pan seal
Replacing the intake manifold gasket
Replacing the catalytic converter gasket
Cooling system
Design features of the cooling system
Possible malfunctions of the cooling system, their causes and methods of elimination
Replacing the cooling system radiator
Removal and installation of the electric fan of the radiator of the engine cooling system in assembly with the casing
Removing and installing the expansion tank
Replacing the water pump
Replacing the thermostat
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 system
Replacing the exhaust system suspension cushions
Replacing the main and additional mufflers
Removal, installation of the catalytic converter and replacement of its gasket
Removal and installation of thermal screens
Supply system
Features of the power supply system design
Checking the fuel pressure in the fuel system
Reducing pressure in the fuel system
Removing and installing the air filter and intake noise muffler
Removing and installing the fuel pump
Replacing the fuel tank and its filler pipe
Replacing the fuel pressure pulsation compensator
Removing and installing the fuel rail
Removal, inspection and installation of injectors
Removing and installing the throttle assembly
Removing and installing the throttle pedal
Features of the fuel vapor recovery system
Replacing the fuel vapor recovery system canister
Clutch
Clutch design features
Possible clutch malfunctions, their causes and solutions
Checking the Clutch Release Pedal Travel
Removing and installing the clutch
Replacing the clutch release drive slave cylinder with the clutch release bearing
Replacing the clutch release master cylinder
Replacing the clutch release hydraulic line
Removing and installing the clutch pedal
Bleeding the clutch release hydraulic drive
Car gearbox
Gearbox design features
Possible malfunctions of a manual gearbox, their causes and methods of elimination
Gearbox oil change
Replacing gearbox seals
Removing and installing the gearbox
Replacing gearbox control cables
Removing and installing the gearbox control lever linkage
Adjusting the gearbox control drive
Front wheel drives
Design features of front wheel drives
Possible faults of front wheel drives, their causes and methods of elimination
Removing and installing front wheel drives
Replacement of constant velocity joints
Replacing the intermediate support bearing
Chassis
Front suspension
Features of the front suspension design
Possible faults of the front suspension, their causes and methods of elimination
Removing and installing the shock absorber strut
Shock absorber strut repair
Replacing the upper shock absorber strut support
Replacing the ball joint
Replacing the front suspension arm
Replacing the front suspension stabilizer bar components
Removing and installing the steering knuckle
Replacing the front hub bearing
Removing and installing the front suspension crossmember
Rear suspension
Features of the rear suspension design
Possible malfunctions of the rear suspension, their causes and methods of elimination
Replacing the rear shock absorber
Replacing the rear suspension spring
Replacing the upper arm of the rear suspension
Replacing the front lower control arm of the rear suspension
Replacing the rear lower control arm of the rear suspension
Replacing the rear suspension trailing arm
Replacing the rear suspension stabilizer bar components
Removing and installing the rear hub
Removing and installing the rear suspension crossmember
Steering
Features of the steering design
Possible malfunctions of the power steering
Removing and installing the steering column cover
Removing and installing the steering wheel
Removing and installing the steering column
Replacing the outer tie rod end
Bleeding the power steering system
Replacing the power steering fluid reservoir
Replacing the steering gear
Replacing the power steering pump
Brake system
Features of the brake system
Possible malfunctions of the brake system, their causes and methods of elimination
Bleeding the hydraulic brake system
Checking the brake pedal position
Replacing the brake master cylinder reservoir
Replacing the master brake cylinder
Replacing pressure regulators
Replacing the vacuum booster
Replacing brake hoses
Replacing brake pipes
Removing and installing the brake pedal
Replacing the brake pads of the front wheel brake mechanism
Replacing the caliper assembly with the pad guide
Replacing the brake disc
Removing and installing the brake drum
Replacing the brake pads of the rear wheel brake mechanism
Replacing the rear wheel brake slave cylinder
Adjusting the parking brake drive
Replacing the front parking brake cable
Replacing the rear parking brake cables
Removing and installing the parking brake lever
Replacing wheel speed sensors
Wheels and tires
Technical specifications
Wheel rim markings
Tire markings
Wheel replacement
Wheel nuts
Tire running-in
Tire storage
Wheel balancing
Anti-skid chains
Spare wheel
Checking tire pressure
Checking the tire tread
Checking the valve
Checking the radial and lateral runout of the discs
Body and coating
Body elements
Features of the body design
Possible body malfunctions, their causes and methods of elimination
Removing and installing the radiator grille
Removing and installing wheel mudguards and fender liners
Removing and installing the front bumper
Removal, disassembly and installation of the rear bumper
Removing and installing the front wing
Removing and installing the engine compartment frame and the front bumper beam
Removing and installing the air intake box grille and water drain shield
Removing and installing the hood
Removal, installation and adjustment of the hood lock and its drive
Removing and installing the fuel tank filler pipe hatch cover
Removing and installing the fuel tank filler pipe hatch lock
Replacement of fixed body glazing
Removing and installing the battery mounting shelf
Side doors
Removing and installing the front door trim
Front door glass replacement
Replacing the front door window regulator
Replacing the outside handle and front door lock switch
Replacing the inner handle of the front door lock drive
Replacing the front door lock
Replacing the front door opening limiter
Removing and installing the front door
Removing and installing the rear door trim
Rear door glass replacement
Replacing the rear door window regulator
Replacing the outer rear door handle
Replacing the inner handle of the rear door lock actuator
Replacing the rear door lock
Replacing the rear door opening limiter
Removing and installing the rear door
Tailgate
Replacing the tailgate stops
Removing and installing the rear door trim
Removing and installing the decorative trim on the tailgate
Removing and installing the rear door spoiler
Replacement of the lock, latch and button for opening the rear door lock
Removing and installing the tailgate
Salon elements
Removing and installing the front seat
Removing and installing the rear seat
Removing and installing the floor tunnel lining
Removing and installing the outside mirror
Removing and installing the interior mirror
Instrument panel design
Removing and installing the instrument panel
Features of the heater and air conditioner
Removal and installation of the control unit for the heating (air conditioning) and ventilation system
Removing and installing the incoming air filter
Replacing handrails
Replacing sun visors
Removal and installation of interior trim
Removing and installing trunk trims
Safety system
Design features of the passive safety system
Removing and installing 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
Windshield wiper blade replacement
Replacing windshield wiper arms
Removal and installation of windshield wiper linkage assembly with gear motor
Replacing the rear window wiper blade
Replacing the rear window wiper arm
Windscreen wiper motor gearbox replacement
Replacement of the rear window wiper motor
Removing and installing the windshield washer
Body Care
Car wash
Polishing of paintwork
Engine wash
Anti-corrosion protection of the body
Preparation and anti-corrosion treatment of hidden cavities of the body
Body sealing
Care of interior trim panels made of polymeric materials
Caring for upholstery and carpets
Electrical equipment
Instruments and motors
Features of the design of electrical equipment
Diagnostics of faults of on-board electrical equipment
Replacing the front door window lift motor
Removing and installing the heater electric motor
Replacing the additional resistance of the heater electric fan
Electric heating of the rear window glass (rear door)
Replacement of the control unit for electric windows and electric mirrors
Location of fuses and relays and their replacement
Removal and installation of mounting blocks
Features of the instrument cluster design
Removing and installing the instrument cluster
Battery and alternator
Battery design features
Possible battery malfunctions, their causes and solutions
Removing and installing the battery
Charging the battery
Design Features of the Generator
Possible generator malfunctions, their causes and methods of elimination
Removing and installing the generator
Replacing the generator pulley
Features of the starter design
Possible starter malfunctions, their causes and solutions
Removing and installing the starter
Starter repair
Egnition lock
Features of the ignition switch design
Checking the ignition switch (lock)
Replacing the ignition switch (lock) contact group
Replacing the ignition switch cylinder
Removing and installing the ignition switch (lock)
Engine management
Design features of the engine management system
Possible malfunctions of the engine management system, their causes and methods of elimination
Checking the ignition coil
Removing and installing the ignition coil
Removal and installation of the electronic engine control unit
Checking and replacing engine management system sensors
Headlights and lighting
Features of lighting design
Replacing lamps
Headlight replacement
Replacing the headlight beam corrector
Replacing the side turn signal light
Replacing the rear light
Replacing the reverse light
Replacing the fog light
Replacing an additional brake light
Replacing license plate lights
Replacement of interior light
Replacement of the trunk light
Replacing steering column switches
Removing and installing the horn
Switches and sensors
Replacing the external lighting control unit
Replacing the instrument panel switches
Replacing the hazard warning switch
Removing and installing the antenna
Replacing the oil pressure warning light sensor
Checking and replacing the fuel level indicator sensor
Replacing the pressure sensor in the power steering system
Checking and replacing the reverse light switch
Replacing the brake light switch
Replacing Cruise Control Switches
Replacing the Parking Brake Indicator Light Switch
Emergency fuel shut-off button
Schematic diagrams
Diagram 1. Windscreen wiper and washer connections
Scheme 2. Connections of the battery charging system
Scheme 3. Connections of the hydraulic drive system of the brake system
Scheme 4. Connections of ventilation, heating and air conditioning systems
Scheme 5. Connections of the engine starting system
Diagram 6a. Speed control system connections
Scheme 6b. Speed control system connections
Diagram 7a. Engine management system connections
Scheme 7b. Engine control system connections
Scheme 7v. Engine management system connections
Scheme 7g. Engine control system connections
Scheme 7d. Engine control system connections
Scheme 7e. Engine management system connections
Scheme 7zh. Engine control system connections
Diagram 8a. Air conditioning system connections
Scheme 8b. Air conditioning system connections
Diagram 9. Power steering system connections
Diagram 10a. Anti-lock braking system (ABS) connections
Scheme 10b. Anti-lock braking system (ABS) connections
Scheme 11. Connections of the vehicle dynamic stabilization system
Ford Mondeo 1
General information
Car care
Car wash
Care of varnish coating
Anti-corrosion protection of the underbody and preservation of vehicle cavities
Caring for upholstery in the car interior
Starting the engine from an auxiliary battery
Towing a car
Features of towing cars with automatic transmission
Starting the engine by towing
Lifting a car
Car Repair Tools
Maintenance
Vehicle maintenance plan
Resetting the service interval indicator
General information about maintenance
Engine and exhaust system
Engine oil change
Visual inspection for oil leaks
Checking the engine oil level
Checking the coolant level
Visual inspection of the cooling system for leaks
Antifreeze check
Diesel engine: checking and adjusting valve clearances
Replacing spark plugs and checking electrical components
Replacing the air filter insert
Replacing the fuel filter
Checking and replacing the V-belt and toothed belt
Diesel: Tightening the turbocharger and intake manifold bolts
Diesel Engine: Replacing CVT Filter
Replacing the pulse air filter
Visual inspection of the exhaust system
Clutch, gearbox and final drive
Visual inspection of transmission tightness
Checking the rubber seal of the cardan shaft
Automatic transmission: checking the oil level
Adjusting the clutch rod
Brakes, tires and wheels
Checking the brake fluid level
Checking the thickness of brake pads
Visual inspection of brake lines
Replacing brake fluid
Checking the tread depth of your tires
Checking the air pressure in the tires
Checking the tire valve
Steering and front axle
Checking the dust caps of the steering rods and axle joints
Checking the axle joint clearance
Checking the tie rod bellows
Checking the steering clearance
Checking the Power Steering Oil Level
Electrical equipment system
Checking the battery
Car body and interior
Troubleshooting
Engine fault diagnostics
Diagnosing faults in the oil circulation system
Diagnostics of faults in the engine cooling system
Diagnostics of faults of the petrol injection system
Diesel Fuel Injection System Fault Diagnosis Table
Diagnosing Clutch Faults
Diagnostics of brake system faults
Diagnosis of tire faults
Diagnostics of interior heating faults
Diagnostics of faults in the battery
Generator fault diagnostics
Starter fault diagnostics
Diagnosing Windscreen Wiper Blade Faults
Power unit
Engine repair
General information on engine repair
The most important technical characteristics of engines
DOHC Gasoline Engine — Design Description
OHC turbocharged diesel engine
Removing and installing the engine
Removing, installing and tensioning the timing belt (petrol)
Removing and installing camshafts (petrol)
Removing and installing the cylinder head, replacing the seal
Toothed Belt Drive — Diesel Engine
Removing and installing a toothed belt (diesel)
Adjusting the valve timing mechanism, tensioning the toothed belt (diesel)
Removing and installing the cylinder head (diesel)
Removing and installing a vacuum pump (diesel)
Camshaft/valve drive in a diesel engine
Removing and installing the camshaft
Removing and installing valves
Replacing the valve stem seals
Checking the valve guides
Lapping valve seats
Checking and adjusting valve clearances (diesel)
Checking the compression in the cylinders
Removing, installing and tensioning the V-belt
Cooling and lubrication system
Engine lubrication system — general information
Oil circulation circuit
Checking oil pressure
Checking the hydraulic switch
Removing and installing the oil pan
Coolant circuit
Antifreeze poured into the radiator
Replacing the coolant
Checking the cooling system for leaks
Removing, installing and checking the thermostat
Checking the thermal switch (diesel)
Removing and installing the fan motor
Removing and installing the radiator
Removing and installing the coolant pump
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 sensor
Adjustment to fuel quality
Spark plugs — general information
Spark plugs for Ford Mondeo
Fuel/exhaust systems
General information about the fuel system
Cleanliness requirements when working with the fuel system
Fuel quantity sensor, fuel pump removal and installation
Removing and installing the fuel tank
Removing the fuel tank in a four-wheel drive model
Replacing the fuel pump safety switch
Removing and installing the fuel injection system relay
Removing and installing the air filter and intake pipe
Removing and installing the gas rod
Adjusting the gas thrust
Exhaust gas exhaust system
Functions of the exhaust system catalyst
Handling vehicles equipped with catalytic converters
Removal and installation of the exhaust system
Removing and installing an additional muffler
Fuel injection (gasoline)
Schematic representation of the fuel injection system
Engine operation regulation
Auto diagnostics of ignition and fuel injection systems
Checking the jets
Removing and installing jets and fuel pressure regulator
System troubleshooting for ignition and fuel injection systems
Fuel injection (diesel)
Schematic representation of the diesel fuel injection system
How a diesel engine works
Measures to improve the composition of exhaust gases
Exhaust gas turbocharger
Driving in winter with a diesel engine
Removing air from the fuel system
Preheating system/removal and installation of glow plugs
Removing and installing jets
Checking, removing and installing an electrical disconnect device
Checking and adjusting the idle speed
Brake booster vacuum and EGR hoses
Transmission
Clutch and drive shafts
Clutch — design description
Removal, installation and testing of the clutch
Removing, installing and checking the clutch release bearing
Checking the clutch
Clutch adjustment
Drive shafts — design description
Removing and installing drive shafts
Removing and installing cardan shaft seals
Car gearbox
Removing and installing the gearbox
Adjusting the gear shift drive
Automatic transmission
Adjusting the mode selector lever cable
All-wheel drive vehicles
Filling and replacing transmission oil
Chassis
Suspension
Front Axle — Design Description
Removing and installing the front shock absorber strut
Front shock absorber strut
Disassembling the front shock absorber strut
Checking and disposing of the front shock absorber
Removing and installing the front suspension wishbones
Removing and installing the steering knuckle
Front wheel hub bearing
Rear Axle — Design Description
Rear Axle Suspension — Design Description
Removing and installing the rear shock absorber strut
Disassembling the rear shock absorber strut, shock absorber
Rear axle of the Mondeo Turnier
Wheel alignment angles
Steering
Steering — design description
Removing and installing the steering wheel
Adjusting the steering wheel position
Removing and installing the steering rod end
Removing and installing rubber steering cuffs
Removing and installing the power steering pump
Bleeding the hydraulic steering system
Brake system
General information about the braking system
Technical characteristics of the brake system
Removing and installing front brake pads
Checking the thickness of the brake disc
Removing and installing the front brake disc
Removing and installing rear disc brake pads
Removing and installing the rear brake caliper and bracket
Removing and installing the rear brake disc
Removing and installing the rear brake drum and brake shoes
Removing and installing the wheel brake cylinder
Wheel brake cylinder repair
Brake fluid — description and safety precautions
Bleeding the brake system
Brake lines and brake hoses
Replacing the brake pipe and brake hose
Checking the brake booster and vacuum line
Parking brake — design description
Removing and installing the parking brake lever
Removing and installing the brake light switch
Anti-lock braking system (ABS)
Traction Control System (TCS)
Wheels and tires
General information about wheels and tires
Wheel and tire size, tire pressure
Wheel designation
Tyre designation
Wheel replacement
Rules for using tires
Anti-skid chains
Incorrect tire wear
Body
Exterior
General information about the car body
Removing and installing the front bumper
Removing and installing the rear bumper
Removing and installing the front mudguard
Removing and installing the radiator grille
Removing and installing the air grille
Removing and installing the outside mirror
Replacing moldings
Removing and installing the engine hood
Removing and installing the hood lock drive cable
Removing and installing the hood lock
Straightening and varnishing works
Repairing damage from rock strikes
Elimination of body deformation and removal of corrosion pits
Preparing the body for varnishing
The process of varnishing the car body
Interior
Removing and installing the roof trim
Removing and installing interior trim
Removing and installing the front seat
Removing and installing the rear seat
Removing and installing the rear seat back
Removing and installing the center console
Removing and installing the interior rearview mirror
Doors, locks and windows
Windshield
Removing and installing the door
Removing and installing the lock rod
Door paneling — design description
Removing and installing door trim
Removing and installing the outside door handle and door lock
Removing and installing the front door lock
Removing and installing the outer rear door handle
Removing and installing the door lock core
Removing and installing the inner door handle
Removing and installing door glass
Removing and installing the window regulator
Removing and installing the rear trunk lid
Removing and installing the trunk lid trim
Removing and installing the trunk lid
Removing and installing the trunk lid lock
Removing and installing the trunk lid lock core
Removing and installing the fuel tank hatch
Central lock — design description
Removing and installing the roof hatch
Heating system
Heating system — design description
Fan switch and temperature controller
Removing and installing the dust filter
Removing and installing the fan
Removing and installing additional heating resistance
Removing and installing the right ventilation nozzle
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
Measuring instruments
Measurement technique
Installation of additional electrical accessories
Detecting faults in electrical equipment
Checking switches for current flow
Checking the relay
Checking the windshield wiper motor
Checking the flashing light device
Checking the brake light
Checking the rear window defroster
Removing and installing the horn
Replacing fuses
Location of fuses and relays
Anti-theft alarm device
Removing and installing the instrument panel
Removal and installation of devices
Removing and installing the tachometer
Steering column switch, turn signal relay
Removing and installing the radio
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
Self-discharge of the battery
General information about the generator
Safety precautions when working with a generator
Removing and installing the generator
Checking the generator charging voltage
Replacement of generator carbon brushes, voltage regulator
General information about the starter
Checking, removing and installing the traction relay
Removing and installing the 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 light bulb
Replacing the engine compartment and glove box light bulb
Replacement of interior light bulb, reading light, trunk light
Headlight adjustment
Removing and installing headlights
Removing and installing headlight glass
Removing and installing fog lights, replacing the bulb
Removing and installing the rear light
Removing and installing the motor for adjusting the lighting range
Windshield wipers and washers
Replacing windshield wiper rubber
Removing, installing and adjusting the windshield washer nozzle
Windscreen washer reservoir, pump and fluid level sensor
Front windshield wiper — design description
Removing and installing the front wiper motor
Removing and installing the windshield wiper mechanism
Removing and installing the rear wiper motor
Electrical circuits
Instructions for using electrical diagrams
Description of the engine control system (with manual transmission)
Description of the central locking system (central lock)
Electrical diagram of headlights
Engine adjustment (with manual transmission)
Electrical diagram of brake lights
Fog lights and fog lamps
Flashing direction indicators
Electrical diagram of interior lighting
Glass cleaning and washing device
Heated windshield and rear window
Electrical heating circuit
Electrical diagram of seat heating
Electrical diagram of the cigarette lighter and clock
Electrical diagram of the sound signal
Ford Mondeo 1 and 2
General information
User guide
Running in a new car
Front panel
Instrument panel
Graphic display
Instrument panel switches and controls
Clock and trip computer
Heating and ventilation system
Air Conditioning Control
Cigarette lighter, ashtray and storage compartment
Steering column elements and steering column switches
Interior Light Control. Upper Sunroof
Parking Warning System
Controls on the doors
Equipment on the console
Luggage compartment
Keys and locks
Security alarm
Seat adjustment
Seat belts
The airbag
Features of engine starting
Traction control system
Self-adjusting rear suspension
Driving a car with automatic transmission
Roof rack
Limited control mode
Filling the fuel system
Fuel cut-off switch
Forced deactivation of parking mode
Vehicle data
Main dimensions and weights
Vehicle identification
General tips for carrying out repairs
Lifting a car with a jack
Tools and accessories
Checking the technical condition
Checks performed from the driver's seat
Checks performed on a vehicle standing on the ground
Checks on a raised vehicle with rotating wheels
Checking the exhaust system of a car
Repair on the road
Main types of danger during maintenance
If the engine does not start
Starting the engine from an auxiliary battery
Wheel replacement
Car stains and stains
Towing a car
Weekly checks
Check points under the hood
Engine oil level
Steering hydraulic fluid level
Brake and clutch fluid level
Washer fluid level
Coolant level
Windscreen wiper blades
Tire condition and pressure
Types of tire wear
Checking the battery
Light bulbs and fuses
Lubricants, fluids and tire pressure
Periodic maintenance
Technical Service Specification
Underhood space of a 4-cylinder engine
Engine compartment of a 6-cylinder engine
Bottom view from the front of the model with a 4-cylinder engine
Bottom front view of V-engine model
Bottom rear view of the Sedan and Hatchback models
Bottom rear view of the Station Wagon model
Periodic maintenance procedures
Engine oil and filter change
Maintenance and charging of the battery
Checking and replacing accessory drive belts
Checking the Automatic Transmission Fluid Level
Checking for fluid leaks and hose condition under the hood
Checking the engine compartment wiring
Checking the air conditioning system
Checking the oil level in a manual transmission
Checking the steering, suspension and wheels
Checking the rubber boots of the drive shafts and CV joints
Checking the exhaust system
Checking the bottom and pipeline of the brake and fuel systems
Checking the brake system
Checking the tightening of wheel nuts
Road test
Replacing the dust filter of the ventilation system
Replacing the air filter
Forced crankcase ventilation system
Automatic Transmission Fluid Replacement
Replacement of brake and coolant fluid
Replacing spark plugs on a 4-cylinder engine
Checking the expansion tank cap
Replacing the fuel filter
Replacing spark plugs on a 6-cylinder engine
Troubleshooting
Troubleshooting Tips
Engine malfunctions
Cooling system malfunctions
Malfunctions of the fuel and exhaust system
Clutch faults
Manual transmission faults
Automatic transmission faults
Drive shaft faults
Brake system malfunctions
Suspension and steering faults
Electrical system faults
Engine
4 cylinder engines
Technical requirements and tightening torques
General information about the engine
Repair operations performed without removing the engine
Compression check
Top dead center of cylinder #1
Removing and installing the cylinder head cover
Removing and installing the intake manifold
Removal, inspection and installation of the exhaust manifold
Removing and installing the crankshaft pulley
Timing belt covers of the timing mechanism
Timing belt of the timing mechanism
Timing Belt Tensioner and Toothed Pulleys
Replacing the camshaft seal
Camshafts and hydraulic valve lifters
Checking and adjusting valve clearances
Removing and installing the cylinder head
Removing and installing the pallet
Removal, inspection and installation of the oil pump
Removing and installing an oil radiator
Removing and installing the oil level sensor
Oil pressure indicator sensor
Replacing the crankshaft seal
Removing and installing the flywheel/faceplate
Inspection and replacement of engine and transmission mounts
6 cylinder engines
Technical requirements and tightening torques
General information about the engine
Repair operations performed without removing the engine
Compression check
Upper dead center of cylinder No. 1
Removing and installing the cylinder head cover
Removing and installing the intake manifold
Removing and installing the exhaust manifold
Removing and installing the crankshaft pulley
Timing mechanism cover (TMC)
Removing and installing the timing chain
Replacing the camshaft seal
Camshafts, hydraulic valve lifters and rocker arms
Removing and installing the cylinder head
Removing and installing the pallet
Removal, inspection and installation of the oil pump
Removing and installing an oil radiator
Oil pressure indicator sensor
Replacing the crankshaft seal
Removal, inspection and installation of flywheel/faceplate
Inspection and replacement of engine and transmission mounts
Removal and repair
Technical requirements of 4-cylinder engine
Technical requirements of 6-cylinder engine
Using the information in this chapter
General information about engine repair
Methods of removing the power unit and precautions
Removal and installation of the power unit (4-cylinder)
Removal and installation of the power unit (6-cylinder)
Engine disassembly sequence
Disassembling the cylinder head
Cylinder head inspection and valve mechanism
Cylinder head assembly
Removing connecting rod and piston groups
Removing the crankshaft
Cleaning and inspection of the cylinder block/crankcase
Inspection of connecting rod and piston groups
Inspection of the crankshaft
Inspection of main and connecting rod bearings
Engine assembly sequence
Installing piston rings
Installation and control of crankshaft main bearing clearance
Installation and control of connecting rod bearing clearance
First launch after repair
Cooling system
Technical requirements and tightening torques
General information about cooling, heating and air conditioning
General information about antifreeze
Disconnecting and replacing cooling system hoses
Removing, checking and installing the thermostat
Removing and installing an electric radiator fan
Removing and installing cooling system sensors
Removing and installing the radiator and expansion tank
Removing and installing the cooling system pump
Removal and installation of heating/ventilation system components
Heater/Air Conditioning Control Units
Air conditioning system
Removal and installation of air conditioning system components
Fuel/exhaust systems
Technical requirements and tightening torques
General information and precautions
Relieving 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 the tilt valves
Removing and installing the fuel cut-off switch
Fuel injection system information
Checking and diagnosing the fuel injection system
Removal and installation of fuel injection system components
General information and replacement of exhaust system components
Emission management
Technical requirements and tightening torques
General information about the emission control system
Description of emission control systems
Checking and replacing emission control system components
Catalytic Converter — Precautions
Starting and charging systems
Technical requirements and tightening torques
General information and precautions
Removing and installing the battery
General information and precautions for the loading system
Checking the loading system
Removing and installing the generator
Generator brushes and voltage regulator
Starting System — General Information and Precautions
Checking the launch system
Removing and installing the starter
Replacing the brushes and starter solenoid
Ignition system
Technical requirements and tightening torques
General information and precautions
Checking the ignition system
Checking, removing and installing the ignition coil
Removing and installing the ignition module
Checking the ignition timing
Transmission
Clutch
Technical requirements and tightening torques
Description and testing of the clutch
Clutch adjustment
Removing and installing the clutch cable
Removing and installing the master cylinder
Removing and installing the clutch pedal
Removal, inspection and installation of clutch components
Removing and installing the clutch release bearing
Removing and installing the clutch release shaft and sleeve
Removing air from the clutch hydraulic system
Mechanical gearbox
Technical requirements and tightening torques
General information about manual transmission
Adjusting the gear shift mechanism
Gear shift mechanism and lever
Removing and installing the speedometer drive gear
Replacing the cuff
Removing and installing the reverse light switch
Removing and installing manual transmission
Manual Transmission Repair
Automatic gearbox
Technical requirements and tightening torques
General information about automatic transmission
Troubleshooting
Removing, installing and adjusting the selector cable
Removing and installing the selector unit
Removing and installing the speedometer drive gear
Selector lever position sensor
Removal and installation of automatic transmission
Transmission repair
Drive shafts
Technical requirements and tightening torques
General information about drive shafts
Removing and installing drive shafts
Inner CV joint cover of the drive shaft
Outer CV joint cover of the drive shaft
Inspection and replacement of drive shaft joints
Chassis
Brake system
Technical requirements and tightening torques
General information about the braking system
Replacing the front brake pads
Removal, repair and installation of the front brake caliper
Inspection, removal and replacement of the front brake disc
Removal, inspection and installation of the rear brake drum
Replacing the rear drum brake shoes
Removal, repair and installation of the rear brake wheel cylinder
Replacing rear disc brake pads
Removal, repair and installation of the rear brake caliper
Removing and installing the master cylinder
Removing and installing the brake pedal
Brake pedal servo amplifier connection
Inspection, removal and installation of pipelines and hoses
Removing air from the hydraulic system
Checking, removing and installing the vacuum servo booster unit
Vacuum hose and check valve of vacuum servo booster
Removing and installing the pressure limiting valve (without ABS)
Removing and installing the pressure limiting valve (with ABS)
Removal and installation of the ABS hydraulic modulator
Checking, removing and installing the ABS wheel sensor
Removing and installing the ABS relay box
Throttle actuator of the traction control system
Removing and installing the brake light switch
Removing and installing the handbrake lever
Removing and installing handbrake cables
Suspension
Technical requirements and tightening torques
General information about the suspension
Removing and installing the steering knuckle and hub assembly
Inspection and replacement of the front hub and bearings
Removing and installing the front suspension strut
Front suspension strut repair
Front cross 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)
Removing and installing the rear suspension axle support (Sedan and Hatchback)
Removing and installing the rear suspension strut (Sedan and Hatchback)
Rear Suspension Strut Repair (Sedan and Hatchback)
Rear Anti-Roll Bar (Sedan and Hatchback)
Lower Rear Suspension Arms (Sedan and Hatchback)
Removing and installing the torque arm (Sedan and Hatchback)
Removing and installing the rear suspension beam (Sedan and Hatchback)
Inspection and replacement of rear hub and bearings (Station wagon)
Removing and installing the rear suspension axle support (Station wagon)
Removing and installing the rear shock absorber (Station wagon)
Rear anti-roll bar (Universal)
Rear Suspension Coil Spring (Wagon)
Rear Lower Control Arm (Wagon)
Front Lower Arm Rear Suspension (Wagon)
Upper control arm rear suspension (station wagon)
Rear Suspension Reactive Arm (Wagon)
Removing and installing the rear suspension beam (station wagon)
Steering
Removing and installing the steering wheel
Removal, inspection and installation of the steering column
Removing and installing the steering column elastic coupling
Power steering (4-cylinder)
Power steering (6 cylinder)
Replacing the rubber boots of the steering gear
Bleeding the hydraulic steering system
Removing and installing the hydraulic power steering pump
Radiator of working fluid of the hydraulic system of steering
Replacing the tie rod end
Wheel alignment and steering angles
Steering tightening torques
Body
Exterior
Tightening torques for body elements
General information about the body
Body and underbody maintenance
Repair of minor body damage
Repair of serious body damage
Removing and installing bumpers
Removing and installing the radiator grille
Removal, installation and adjustment of the hood
Hood release cable and lever
Removing, installing and adjusting the hood lock
Removing and installing rear door glass
Removing and installing the door
Removing and installing the outside mirror
Removing and installing the trunk lid
Removing and installing trunk lid lock components
Removing and installing the tailgate
Removing and installing the tailgate support pillars
Removing and installing tailgate lock components
Windshield and fixed glass
Removal and installation of moldings and stickers
General information and adjustment of the sunroof
Interior
Carpet and Upholstery Care
Removing and installing the interior door trim panel
Removing and installing the door window lifter
Removing and installing door handle and lock components
Removing and installing the interior mirror
Components of the central locking system
Removing and installing seats
Removing and installing seat belts
Removal and installation of interior trim panels
Removing and installing the central console
Removing and installing the ceiling remote control
Removing and installing the glove box
Removing and installing the front panel
Removing and installing the wheel arch liner
Fuel tank filler flap and its opening cable
Electrical equipment
Fuses, relays and bulbs
General information about electrical equipment
Troubleshooting Electrical Circuits
Checking and replacing fuses, relays and timers
Removing and installing switches
Replacing light bulbs (exterior lighting fixtures)
Replacing light bulbs (interior lighting fixtures)
Removal and installation of external lamp units
Headlight beam adjustment
Removing and installing the headlight tilt motor
Removing and installing the instrument panel
Removing and installing instrument panel components
Removing and installing the speedometer drive cable
Removing and installing the watch
Removing and installing the horn
Removing and installing windshield wiper arms
Windshield wiper motor and drive mechanism
Rear Door 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 Glass Washer Components
Radio receiver/audio cassette player
Radio/CD Player Amplifier
CD Player
Removing and installing speakers
Removing and installing the radio antenna
Removal and installation of airbag units
Removing and installing the airbag control unit
Airbag Power Supply Wiring Drum
Parking system by sensors
GPS navigation system
Removing and installing electrical components of seats
Electrical diagrams
Ford Mondeo 2
General information
User guide
Description of cars
Vehicle identification
General repair instructions
Working conditions and tools
Lifting a car
Technical specifications
Tightening torque specifications
Maintenance and care
Car maintenance and care
Spare parts
Checking the engine oil level
Checking the brake fluid level
Checking the brake lights
Checking the lighting system
Checking tire pressure
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
Adjusting the parking brake
Lubricants, sealants
Recommendations for working with threaded connections
The rechargeable battery
Airbag system
Seat belt pretensioning system
Wheels and rims
General description
Types of wheel rims
Wheel rims
Tires
Wheel replacement
Winter tires
Checking tire pressure
Extending the life of your tires
Checking the condition of the tires
Causes of tire wear
Tire storage
Power unit
V16 engine
Removing the engine
Engine installation
Disassembling the engine
Engine assembly
Removing and installing the cylinder head (on the engine in the car)
Disassembling the cylinder head
Repair of cylinder head and valves
Cylinder head assembly
Removing the pistons
Disassembling pistons and connecting rods
Checking the technical condition of pistons and connecting rods
Assembly of pistons and connecting rods
Installing pistons and connecting rods
Cylinder block
Checking the crankshaft
Rear oil seal ring and crankshaft flange
Camshafts and valve timing
Removing and installing a toothed drive belt
Measuring the axial clearance (play) of the camshaft
Checking the compression in the cylinders
Engine malfunctions
Replacing the front crankshaft oil seal (manufactured before May 1998)
Removal and installation of camshafts (produced before May 1998)
Camshaft seals (manufactured before May 1998)
Duratec VE
2.5-liter Duratec VE engine
Removing and installing the left cylinder head cover
Removing and installing the right cylinder head cover
Removing and installing the upper intake manifold
Replacing camshaft sealing rings
Removing and installing the left exhaust manifold
Removing and installing the right exhaust manifold
Removing and installing the oil pan
Replacing the rear crankshaft seal ring
Disassembling the engine
Engine assembly
Lubrication system
General information about the lubrication system
Selecting engine oil
Checking the engine oil level
Oil consumption
Oil change
Replacing the oil pump
Replacing the oil filter
Checking oil pressure
Replacing the oil pan
Oil leaks
Lubrication system malfunctions
Cooling system
General information about the cooling system
Replacing the coolant
Replacing the radiator cooling fan
Replacing the radiator
Checking the radiator cap and radiator
Replacing the liquid pump
Replacing the thermostat
Checking the Thermostat
Thermostat malfunctions
Checking the cooling system
Cooling system 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
Replacing the air filter
Replacing the fuel filter
Checking the operation of the fuel pump
Replacing the fuel pump
Adjusting the throttle cable
General information about the injection system
Precautions when working with the injection system
Neutralization of exhaust gases
Neutralization of exhaust gases of gasoline engines
Exhaust Gas Recirculation (EGR) System
Ignition system
General information about the ignition system
Precautions when working with the ignition system
Replacing the engine control unit
Spark plugs
Ignition system diagnostics
Exhaust system
Exhaust gas exhaust system
Removal and installation of the exhaust system
Precautions when handling a catalytic converter
Removing and installing the catalytic converter
Lambda probe
Transmission
Clutch
General information about the clutch
Checking the clutch
Removing the clutch
Clutch installation
Removing and installing the clutch master cylinder
Removing and installing the clutch hydraulic drive slave cylinder
Bleeding the Clutch Hydraulic Drive
Adjusting the free travel of the clutch pedal
Mechanical gearbox
Manual transmission
Removal and installation of a manual gearbox
Checking the oil level in a manual transmission
Gearbox malfunctions
Automatic gearbox
Automatic transmission
Removal and installation of 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
Precautions when working with wheel drive shafts
Removing and installing the drive shaft on the right side of the vehicle
Removing and installing the intermediate shaft
Removing and installing the drive shaft on the left side of the vehicle
Wheel drive repair
Replacing thrust bearings
Inner radial sealing rings
Chassis
Front suspension
General information about the front suspension
Removing the wheel bearing
Removing the steering knuckle
Installing the steering knuckle
Removing and installing the left wishbone
Removing and installing the right wishbone
Removing and installing the anti-roll bar
Removing and installing the shock absorber strut
Removing and installing front springs
Wheel alignment
Rear suspension (sedan)
Rear suspension (sedan body)
Removing and installing the rear suspension assembly
Removing and installing the front trailing arm
Removing and installing the rear trailing arm
Removing and installing the anti-roll bar
Rear suspension
Rear suspension
Removing and installing the rear suspension assembly
Removing and installing the wishbone and coil springs
Removing and installing front and rear side arms
Removing and installing the upper suspension arm
Removing and installing shock absorbers
Removal and installation of jet rods
Removing and installing the wheel hub
Removing and installing the anti-roll bar
Removing and installing rear wheel hubs
Adjusting the rear wheel alignment angles
Steering
General information about steering
Removing and installing the steering gear
Checking the technical condition of the toothed rack cuffs
Checking the technical condition of the cuffs and ends of the transverse steering rods
Replacing the steering gear coupling
Bleeding the power steering drive
Replacing the power steering pump
Removing and installing the steering wheel
Brake system
General information about the brake system
Brake design
General description of the braking system
Replacing the front brake pads
Removing and installing the front brake caliper
Disassembling the front brake caliper
Removing and installing the front brake disc
Removing the rear drum brake shoes
Installing rear drum brake shoes
Removing and installing the brake cylinder of drum brakes
Replacing rear disc brake pads
Removing and installing the rear disc brake caliper
Removing and installing the rear brake disc
Removing and installing the master brake cylinder
Repair of the main brake cylinder
Brake booster
Anti-lock braking system (ABS)
Removing and installing the ABS hydraulic unit
Replacing the ABS sensor (front wheels)
Replacing the ABS sensor (rear wheels)
Replacing the front parking brake cables
Replacing the rear parking brake cables
Traction control system
Removing and installing the adjusting electric motor
Brake service
Checking the brake fluid level
Replacing brake fluid
Checking the brake system
Checking the brake system for leaks and damage
Checking brake pads
Bleeding the brake system
Electrical equipment
Battery and alternator
The rechargeable battery
Checking the battery
Battery characteristics
Determination of a faulty consumer
Precautions when handling the generator
Checking the installed generator
Removing and installing the generator
Generator repair
Replacing generator brushes
Typical generator faults
Starter
Checking the starter (on the car)
Removing and installing the starter
Starter repair
Generator drive belt
Light and appliances
Checking the windshield wiper and alarm system
Removing and installing the windshield wiper motor (front)
Removing and installing the windshield wiper (front)
Replacing the wiper bearing
Removing and installing the windshield wiper motor (rear)
Outdoor lighting
Replacing headlight bulbs
Replacing parking light bulbs
Removing and installing headlights
Headlight adjustment
Control and measuring instruments
Electrical diagrams
Ford Mondeo 3
General information
Introduction to the guide
Introduction to the service repair manual
Presentation of the help system
First look at the Mondeo model range
Family of car engines
Dimensions of cars
Development of models
Technical specifications
Workplace equipment
Workplace equipment
Take care of spare parts in a timely manner
Tools — Basic Equipment
Special tools and accessories
A Matter of Experience – Advice from a Professional for Amateurs
Tips for those attending the workshop
Safety first
A practical lifting tool is a jack
Car care
Car care products
Internal cleaning — dirt doesn't stand a chance
External wash
Engine wash
To keep everything moving, call in a lubrication service
If you want to preserve your material assets, take care of the paintwork
Care of varnish
Decreasing the value of the product — ugly paint defects
Elimination of defects from stone impacts
Polishing of small scratches
Removing large scratches
Glass washing machine
Checking the windshield wiper and washer
Filling the windshield washer with water
Replacing the wiper blade rubber
Installing a Windshield Washer Nozzle
Installation and removal of the windshield washer nozzle
Removing and installing the windshield wiper arm
Removing and installing the front windshield wiper motor
Removing and installing the rear wiper motor
Help with malfunctions
Starter malfunctions
Battery and generator faults
Malfunctions of the petrol injection system
Brake malfunctions
Diesel injection system faults
Electric window lift malfunctions
Heating system malfunctions
Cooling system malfunctions
Clutch faults
Engine and system faults
Brake light malfunctions
Windscreen wiper malfunctions
Lubrication system malfunctions
Thermostat malfunctions
Malfunctions of the sound and light signaling system
Windscreen wiper blade malfunctions
Central locking system malfunctions
Spark plug faults
Cylinder head gasket faults
Power unit
Engine repair
Design and characteristics of engines
Make it in a workshop or do it yourself
Cranking the engine
Compression ratio
Measuring the compression ratio
Checking drive belts
Installation of drive belts
Determining the location of the fault by listening — noises in the engine compartment
Lubrication system
Engine lubrication system device
The Role of Motor 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
Replacing the coolant
Adding freeze protection
Removing and checking the thermostat — only when the engine is cold
First aid — short-circuit the thermal switch
Removing the cooling system fan
Dismantling and installation of the radiator
Replacing coolant hoses
Air filter (intake noise muffler)
Cleaning and replacing the filter cartridge
Fuel injection system
Fuel injection system device
Sometimes it makes sense to conduct a visual inspection of the injection system
Checking the intake system for leaks
Checking the idle speed
Idle oscillations are a systematic phenomenon
Checking the idle speed control valve
Checking the injector
Replacing the gas pedal rod (using Duratec-HE as an example)
Diesel Engine Fuel Supply — Basic Design
Visual inspection of the diesel engine injection system
Ignition system
Ignition system device
Ignition coil
High Temperature Resistant — Spark Plugs
Replace spark plugs — after 60,000 kilometers
Checking with a universal device — rotation 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 resistance on the ignition coil
Dismantling the ignition unit
Diesel engine preheating device
Checking the preheating device
Checking the preheating relay
Checking glow plugs
Fuel system
Fuel system device
Fuel types and handling
Checking the ventilation and airing of the tank
Replacing the fuel filter (petrol engine)
Replacing the fuel filter (diesel engine)
Emptying the tank without a fuel pump
Dismantling pipelines and hoses (general instructions)
Fuel Pump Troubleshooting
Removing and installing the fuel pump (petrol engine)
Exhaust gas exhaust system
Tips for working with the exhaust system
The question of cost — complete repair or partial replacement
Low exhaust gas — ASU
Neutralization of exhaust gases
Transmission
Gearbox device
Clutch device
Checking the clutch
Does the clutch disengage completely?
Five-speed manual transmission
Gear shift adjustment
Checking the transmission oil level (manual transmission)
Automatic transmission in combination with the 2.0-liter Duratec-HE engine
Checking the transmission oil level (automatic transmission)
Main gear
Checking the drive shaft seals
Removing and installing the drive shaft/transverse control arm
Replacing the universal joint seals
Chassis
Chassis
Chassis design
Front axle Mondeo
Front axle geometry
Checking shock absorbers after wearing two sets of tires
Regularly check the steering wheel free play
Checking the toothed rack protective cuffs
Checking the tie rod ends and seals
Checking the wishbone bearing
Checking the wheel bearing clearance
Replacing the front wishbone
Dismantling and installation of shock absorber struts
Replacing the tie rod ends
Replacing the steering gear cuffs
Replacing the steering gear pivot bearing
Removal and installation of the rear shock absorber strut
Replacing the shock absorber (station wagon)
Power steering gear
Tires and wheels
It is better to check the air pressure on cold tires
Wheel replacement
Checking the condition of the tires
Brake system
The structure of the braking system
Checking the brake fluid level
Checking the brake system
Checking the brake booster
Checking the brakes for functionality
Measuring the wear of disc brake pads
Checking the wear of the disc brake mechanism
Bleeding the brake system
Replacing brake fluid
Removing the master brake cylinder expansion tank
Removal and installation of the master brake cylinder
Dismantling and installation of the brake booster
Removing and installing brake hoses
Replacing disc brake pads
Replacing brake discs
Replacing the protective cuffs of the caliper and piston of the brake mechanism
Parking brake
Replacing the parking brake cable
Body
Interior
Car interior design
Ventilation and heating
Check heating and ventilation systems from time to time
Dismantling the heating and ventilation control unit
Fan
Troubleshooting a Fan
Replacing the fan motor
Replacing interior lamps
Switch
Ignition Key Coding
Checking the door contact switch
Dismantling the radio receiver
Removing the speaker
Dismantling the outdoor antenna
It is not recommended to remove the front seats yourself
Removing the backrest of the rear seats
Removing the front door trim
Removing side windows/window lifter
Window lifter
Adjusting the window lift motor
Removing the door handle
Removing the steering lock
Exterior
Description of the car body
Dismantling and installation of the door
Door adjustment
Removing and installing the outside rearview mirror
Removal and installation of the fairing
Dismantling and installation of the hood
Adjusting the engine hood
Removing and installing the bumper cover (front)
Dismantling and installation of wings
Removing and installing the bumper cover (rear)
Removing and installing the trunk lid
Adjusting the trunk lid
Removing and installing the rear door lock
Electrical equipment
Light and appliances
Description of electrical equipment
Contact care
Starting the engine «from the side» with a wire
Pushing a car
Towing a car
Identifying secret electricity consumers
Replacing drive belts
Replacing the belt pressure roller
Outdoor lighting
Replacing incandescent lamps
Adjusting headlights «in front of the wall»
Signaling devices
Checking the brake light switch
Checking the sound signal
Tools and control devices
Checking the operation of the switch
Dismantling and installation of the combined instrument
It's not always easy to follow the «winding» paths of wires
Fuses in the passenger compartment and engine compartment
Replacing fuses
Distributes high operating currents — changeover relay
Layout of fuses and relays
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
Structure of electrical circuits
Electrical diagrams of engine cooling
Electrical diagrams of the fuel system
Electrical diagrams of the diesel starting system
Electrical diagrams of engine control
Electrical diagrams of heating and air conditioning
Electrical diagrams of the generator and regulator
Electrical circuits for exterior lighting, headlights
Electrical circuits of the sound signal
Electrical diagrams of the clock mechanism
Electrical diagrams of the windshield wiper and washer system
Ford Mondeo 4
General information
User guide
General information about the car
Vehicle Passport Data
Cruise control system
On-board computer
Power unit
Engine repair
Features of the design and repair of the 2.5 l duratec-v15 engine
Checking the compression in the cylinders of the 2.5L duratec-v15 engine
Replacing the timing belt of the 2.5L duratec-v15 engine
Replacing crankshaft seals on a 2.5L duratec-v15 engine
Replacing the cylinder head gasket of the 2.5L duratec-v15 engine
Replacing camshafts and cylinder head cover seals for a 2.5L duratec-v15 engine
Replacing the oil pan seal of the 2.5L duratec-v15 engine
Features of the design and repair of the 2.2 l duratorq-tdci engine
Checking the compression in the cylinders of the 2.2L duratorq-tdci engine
Replacing the timing belt of the 2.2L duratorq-tdci engine
Replacing the crankshaft seals of the 2.2L duratorq-tdci engine
Replacing the cylinder head cover seals on a 2.2L duratorq-tdci engine
Replacing the cylinder head gasket of the 2.2L duratorq-tdci engine
Replacing camshafts on a 2.2L duratorq-tdci engine
Replacing the oil pan seal on a 2.2L duratorq-tdci engine
Removing and installing the decorative engine cover
Checking the compression in the cylinders
Removing and installing mudguard and engine crankcase protection
Replacing the right powertrain suspension support
Replacing the left support of the powertrain suspension
Replacing the rear support of the powertrain suspension
Cleaning the crankcase ventilation system
Setting the piston of the first cylinder to the TDC position of the compression stroke
Adjusting valve clearances
Checking and replacing the accessory drive belt
Checking and replacing the timing belt of the 1.6L Duratec Ti-VCT engine
Replacing the timing chain of the 2.0 and 2.3 L duratec-he engines
Removal, defect detection and installation of the flywheel
Replacing the cylinder head cover gasket
Replacing the cylinder head gasket
Replacing valve stem seals
Replacing camshaft seals
Replacing crankshaft seals
Replacing the oil pan seal
Replacing the intake manifold gasket
Replacing the catalytic converter gasket
Replacing camshafts
Removing and installing the engine
Lubrication system
Lubrication system
Changing engine oil and oil filter
Removing and installing the oil pump
Oil pump repair
Checking the level and adding oil to the lubrication system
Cooling system
Cooling system
Replacing the coolant
Replacing the cooling system radiator
Replacing the water pump
Removing and installing the thermostat
Removing and installing the expansion tank
Checking the level and adding coolant
Exhaust system
Exhaust gas exhaust system
Replacing the exhaust system suspension cushions
Removing and installing the catalytic converter and replacing its gasket
Removal and installation of main and additional mufflers
Removal and installation of thermal screens
Supply system
Power supply system
Checking the pressure in the engine fuel system
Decreased pressure in the engine fuel system
Replacing the air filter element
Removing and installing the air filter and intake noise muffler
Removal, repair and installation of the fuel module
Replacing the fuel tank
Removing and installing the fuel rail
Removal, inspection and installation of injectors
Removing and installing the throttle assembly
Removing and installing the throttle pedal
Checking the engine fuel system
Fuel injection system faults
Fuel vapor recovery
Fuel vapor recovery system
Removing and installing the fuel vapor recovery system canister
Transmission
Clutch
Clutch
Checking the Clutch Release Pedal Travel
Removing and installing the clutch
Replacing the clutch release drive slave cylinder with the clutch release bearing
Replacing the clutch release master cylinder
Replacing the clutch release hydraulic line
Removing and installing the clutch pedal
Bleeding the clutch release hydraulic drive
Car gearbox
Transmission
Changing the oil in a manual transmission or the working fluid in an automatic transmission
Replacing gearbox seals
Removing and installing the gearbox
Replacing gearbox control cables
Removing and installing the gearbox control lever linkage
Adjusting the gearbox control drive
Checking the level of working fluid in the automatic transmission
Wheel drives
Front wheel drives
Removing and installing 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
Removing and installing the shock absorber strut
Shock absorber strut repair
Replacing the upper shock absorber strut support
Replacing the ball joint
Replacing the front suspension arm
Replacing the front suspension stabilizer bar components
Removing and installing the steering knuckle
Replacing the front hub bearing
Removing and installing the front suspension subframe
Checking and adjusting wheel alignment angles
Rear suspension
Rear suspension
Checking the technical condition of the rear suspension parts on the car
Replacing the rear shock absorber
Replacing the rear suspension spring
Replacing the upper arm of the rear suspension
Replacing the front lower control arm of the rear suspension
Replacing the rear lower control arm of the rear suspension
Replacing the rear suspension trailing arm
Replacing the rear suspension stabilizer bar components
Replacing the rear wheel hub
Removing and installing the rear suspension crossmember
Steering
Steering control
Inspection and testing of the steering system on the vehicle
Checking the free play (play) of the steering wheel
Removing and installing the steering column cover
Removing and installing the steering wheel
Removing and installing the steering column
Replacing the outer tie rod end
Replacing the steering rod
Bleeding the power steering system
Replacing the power steering fluid reservoir
Replacing the steering gear
Replacing the power steering pump
Checking the level and adding working fluid to the power steering reservoir
Brake system
Brake system
Checking the brake pedal position
Checking the operation of the brake booster
Checking the degree of wear of brake pads and discs
Bleeding the hydraulic brake system
Replacing brake fluid
Replacing the brake master cylinder reservoir
Replacing the master brake cylinder
Replacing the vacuum booster
Replacing brake hoses
Replacing brake pipes
Removing and installing the brake pedal
Replacing the brake pads of the front wheel brake mechanism
Replacing the front wheel brake caliper
Replacing the brake disc of the front wheel brake mechanism
Replacing the brake pads of the rear wheel brake mechanism
Replacing the rear wheel brake caliper
Replacing the brake disc of the rear wheel brake mechanism
Adjusting the parking brake drive
Replacing the front parking brake cable
Replacing the rear parking brake cables
Removing and installing the parking brake lever
Checking the level and adding brake fluid to the reservoir of the hydraulic drives of the brake system and clutch release
Body
Exterior
General information about the body
Removing and installing the front bumper
Removing and installing wheel mudguards and fender liners
Removing and installing the rear bumper
Removing and installing the front wing
Removing and installing the hood
Removal, installation and adjustment of the hood lock and its drive
Removing and installing the air intake box lining
Removing and installing the trunk lid
Replacement of the trunk lid lock
Removing the trunk lid trims
Removing and installing the fuel tank filler pipe hatch cover
Removing and installing the outside mirror
Interior
Removing and installing the front seat
Removing and installing the rear seat
Removing and installing the floor tunnel lining
Removing and installing the interior mirror
Instrument panel
Removing and installing the instrument panel
Removal and installation of interior trim
Removing and installing trunk trims
Removing and installing the battery mounting shelf
Doors, locks and windows
Removing and installing the front door trim
Front door glass replacement
Replacing the front door window regulator
Replacing the outside handle and front door lock switch
Replacing the inner handle of the front door lock drive
Replacing the front door lock
Replacing the front door opening limiter
Removing and installing the front door
Removing and installing the rear door trim
Rear door glass replacement
Replacing the rear door window regulator
Replacing the outer rear door handle
Replacing the inner handle of the rear door lock actuator
Replacing the rear door lock
Replacing the rear door opening limiter
Removing and installing the rear door
Heating and ventilation
Ventilation, heating and air conditioning system
Features of the ventilation system
Features of the heating system
Features of the air conditioning system
Removing refrigerant from the air conditioning system
Replacing the sealing rings
Air conditioning compressor
Removing and installing the compressor
Replacing the drive pulley bearing
Replacing the compressor clutch solenoid
Removing and installing the condenser
Replacing the filter element of the receiver-dryer
Replacing the cabin air filter
Removal and installation of the ventilation, heating and air conditioning system control unit
Replacing the pressure sensor
Removing and installing the solar light sensor
Replacing the outside air temperature sensor
Activation of the on-board diagnostic system
Reading recorded fault codes
Reading the software version number
Security systems
Passive safety system (srs)
Removing and installing the driver's airbag
Removing and installing the front passenger airbag
Removing and installing the front seat belt
Removing and installing the rear seat belt
Removal and installation of the electronic control unit of the additional passive safety system
Removing and installing the side impact sensor
Active safety system (electronic braking control systems)
Removal and installation of the hydroelectronic control unit of the anti-lock braking system
Removing and installing front wheel speed sensors
Removing and installing rear wheel speed sensors
Electrical equipment
Electrical appliances
Electrical equipment
Location of fuses, fuse links and relays and their replacement
Removal and installation of mounting blocks
Replacing the ignition switch (lock) contact group
Replacing the ignition switch cylinder
Removing and installing the ignition switch (lock)
Replacement and maintenance of spark plugs
Engine management system
Checking the ignition coil
Removing and installing ignition coil for 1.6L duratec ti-vct engine
Removing and installing ignition coils for duratec-he and duratec-v15 engines
Replacing the electronic engine control unit
Checking and replacing engine management system sensors
Replacing steering column switches
Removing and installing the horn
Removing and installing the windshield wiper linkage and gear motor
Removing and installing the windshield washer
Replacing the electric window control unit and switches
Replacement of electric window lifter motors
Replacing window lifter control modules
Removal and installation of the electric motor of the radiator fan of the engine cooling system
Replacing the radiator fan control unit of the engine cooling system
Removing and installing the heater fan motor
Replacement of additional resistance of the heater electric fan and electric motors of the damper drives
Removing and installing the instrument cluster
Replacing the control unit for external lighting and instrument cluster illumination
Removing and installing switches for the electronic stability program (ESP), hazard warning lights and heated windshields and rear windows
Removing and installing front seat heating switches
Removing and installing a car radio
Removing and installing speakers of the acoustic system
Replacing the oil pressure warning light sensor
Checking and replacing the fuel level indicator sensor
Checking and replacing the reverse light switch
Replacing the brake light switch
Replacing the Parking Brake Indicator Light Switch
Headlights and lighting
Lighting, light and sound signaling
Replacing lamps
Removing and installing the multifunctional electronic unit (gem)
Headlight replacement
Replacing the fog light
Replacing the rear light
Replacing an additional brake light
Replacing the side turn signal light
Replacing license plate lights
Replacement of interior light
Battery and alternator
Removing and installing the battery
Generator
Removing and installing the generator
Checking the ignition system
Generator repair
Starter
Removing and installing the starter
Starter repair
Ford Escort 3
General information
Maintenance
Opening the hood
Ignition switch with anti-theft device
Features of engine starting
Lubrication system
Cooling system
Power supply system
Ignition system and spark plugs
Clutch adjustment and maintenance
Transmission
Steering control
Car suspension
Brake system
Electrical equipment of the car
Replacement of headlights, parking lights and alarms
Wheels and tires
Car body and layout
Lifting and towing a car
General requirements for car repair
Reference dimensions for checking the body floor
Tightening torques for threaded connections
Characteristics
Vehicle details
Operational data
Basic data for adjustments and control
Passport details
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 model engine
The device and inspection of the cylinder block
Connecting rod and piston group
Crankshaft
Cylinder head (except GLA model)
Cylinder head of the GLA engine
Cooling system
Features of the cooling system
Replacing the coolant
Removing and installing the radiator
Replacing the electric fan
Removing and installing the water pump
Removing and installing the thermostat
Lubrication system
Features of the lubrication system
Engine lubrication system for all models except GLA
Engine lubrication system of the GLA model
Oil pressure control check
Replacing the oil filter
Supply system
Fuel system of carburetor engines
Fuel tank
Fuel pump
Air filter
Ford Carburetor
Ford Carburetor Maintenance
Removing and installing a Ford carburetor
Disassembly and technical condition check
Ford Carburetor Adjustments
Replacing the dosing needle
Replacing the needle valve
Removing and installing the pneumatic drive of the air valve
Weber carburetor
Weber Carburetor Adjustments
Exhaust system
Fuel injection «K-Jetronic»
Operating principle and features of the device
Fuel pump and filter
Pressure accumulator
Air flow meter
Fuel dispenser and regulator
Valves and injectors
Forced idling device
Checking and adjusting the fuel injection system components
Removal and installation of injection system components
Possible malfunctions of the fuel injection system
Transmission
Clutch
Features of the device
Removing and installing the clutch slave disc
Replacing the clutch release bearing
Replacing the clutch cable
Adjusting the free travel of the pedal «Escort RS 1600 I»
Mechanical gearbox
Features of the device
Removal and installation of a manual transmission
Disassembling a four-speed gearbox
Assembly of a four-speed gearbox
Removing and installing the gear shift drive
Features of assembly of a five-speed gearbox
Hydromechanical box
General information about the hydromechanical gearbox
Features of the device
Removing the hydromechanical gearbox
Installation of a hydromechanical gearbox
Checking the hydromechanical transmission assembly
Adjusting the starter interlock switch
Testing of hydromechanical transmission
Test in motion
Possible malfunctions, their causes and methods of elimination
Drive shafts
Features of the wheel drive device
Front Wheel Drive Replacement
Disassembling the wheel drive shaft
Chassis
Front suspension
Features of the device
Features of the front suspension of the «Escort RS 1600 i»
Checking and adjusting the front wheel alignment angles
Replacing hub bearings
Removing and installing the front suspension strut
Disassembly and assembly of suspension strut
Removing and installing the lower suspension arm
Removing and installing the anti-roll bar
Rear suspension
Features of the device
Rear wheel alignment angles
Removing and installing the rear suspension assembly
Removing and installing the suspension spring
Replacing the shock absorber
Removing and installing the suspension arm
Removing and installing the stretch
Removing and installing the hub
Replacing hub bearings
Removing and installing the trunnion
Steering
Features of the device
Removing the steering gear
Installing the steering gear
Disassembly of the steering mechanism of cars produced before May 1983
Assembly of steering gear for cars manufactured before May 1983
Disassembling the steering gear on cars produced since May 1983
Assembly of steering gear for cars produced since May 1983
Checking the drive gear rotation torque
Removing and installing the steering shaft
Brake system
Features of the device
Replacing the front brake pads
Removing and installing the front wheel brake mechanism
Replacing the rear wheel brake pads
Removing and installing the rear wheel brake mechanism
Removing air from the hydraulic drive
Removing and installing the master cylinder
Disassembly and assembly of the master cylinder
Removing and installing the vacuum booster
Adjusting the parking brake
Electrical equipment
Starting and charging system
Electrical equipment diagram
Battery
Generator device
Generator repair
Disassembly and assembly of the generator
Starter device
Starter repair
Ignition system
General information about ignition
Ignition of engines of GLA, GMA and GPA models
Vacuum ignition advance regulator control
Removing and installing the distributor
Replacing contacts
Adjusting the gap between contacts
Setting the ignition timing
Contactless ignition system
Checks and repairs of contactless ignition system
Ignition «Escort RS 1600»
Features of the device
Removing and installing the crankshaft position sensor
Checking the electrical connections of the ignition system
Checking the initial ignition timing setting
Light and appliances
Features of lighting and signaling devices
Headlight adjustment
Windscreen wiper and washer
Windshield wiper operation
Removing and installing the windshield wiper
Rear window wiper and headlight washer
Fan motors
Electric windows and central locking
Control devices
Schematic diagrams
Electrical equipment of Escort cars 1980-1982
Wiring diagram for Escort 1980-1982 devices
Charging, starting and control devices «Escort» 1980-1982
Escort 1980-1982 Power Windows, Door Locks and Lighting
Exterior lighting for Escort cars manufactured in 1980-1982
Side lights and direction indicators «Escort» 1980-1982
Interior lighting for Escort cars 1980-1982
Ventilation, wipers and washers for Escort 1980-1982
Escort 1980-1982 Control Lights
Charging, starting and engine operation systems «Escort» 1983-1985
Power windows, door locks and lighting «Escort» 1983-1985
Exterior lighting for Escort cars manufactured in 1983-1985
Direction indicators for Escort cars 1983-1985
Interior lighting for Escort cars 1983-1985
Ventilation, wipers and washers of glass «Escort» 1983-1985
Control lamps of cars «Escort» 1983-1985
Fuel injection system of Escort cars 1983-1985
Schematic diagram of the electrical equipment of the Orion cars
Charging, starting and engine operation system of the Orion car
Wiring diagram for exterior lighting of the Orion car
Wiring diagram of the direction indicators of the Orion car
Ventilation, glass cleaners and washers «Orion»
Wiring diagram for interior lighting of the Orion car
Wiring diagram for control lamps of the Orion car
Orion power windows and heated rear window
Central locking of car doors «Orion»
Fuel injection system of the Orion car
Ford Escort 4
General information
User manual
Design Features of Ford Escort 4
Fuel consumption, l/100 km
Speed of movement in gears
Curb and gross vehicle weight
Overall dimensions of cars
Periodic inspections and maintenance of the car
Vehicle identification
Warning signs in text
Electrically adjustable exterior rear view mirrors
Front seats — adjustment
Steering column lock / ignition switch
Instrument panel
Instrument cluster
Steering column control levers
Manual gearbox
Heating and ventilation
Analog and digital clocks
Fuel computer
Door locks — opening and blocking
Mechanically operated hatch
Power lowering windows
Increased luggage compartment volume
Windscreen wipers and washers
Lifting a car
Starting the engine
Features of vehicle operation
Body repair dimensions
Maintenance
Location of units in the engine compartment
Operating materials and fluids
Maintenance intervals
Primary and secondary maintenance activities
Oil and oil filter change (10,000 km/12 months)
Checking the tightness of hoses and fluid leakage (10,000 km/12 months)
Checking idle speed and fuel mixture quality (10,000 km/12 months)
Checking ignition system components (10,000 km/12 months)
Lubrication of ignition distributor breaker contacts (10,000 km/12 months)
Adjusting the gap of the breaker contacts (10,000 km/12 months)
Ignition timing with contact breaker (10,000 km/12 months)
Replacing spark plugs on RS Turbo engine (10,000 km/12 months)
Checking the front brake pads (10,000 km/12 months)
Checking 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 gearbox oil level (20,000 km/12 months)
Replacement of breaker contacts (20,000 km/12 months)
Checking the oil level in a manual transmission (20,000 km/12 months)
Checking the transmission fluid level in the automatic transmission (20,000 km/12 months)
Checking the drive shaft protective cover (20,000 km/12 months)
Coolant replacement (40,000 km/24 months)
Replacing the air filter element (40,000 km/24 months)
Replacement of the crankcase ventilation filter (40,000 km/24 months)
Replacing the fuel filter on engines with a fuel injection system (40,000 km/24 months)
Replacing the timing belt on CVH engines (60,000 km/36 months)
Checking the components of the CVH brake system (60,000 km/36 months)
Brake fluid replacement (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
Valve timing 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
Adjusting valve clearances
Removing the cylinder head
Disassembling the cylinder head
Checking and repairing the cylinder head
Cylinder head assembly
Installing the cylinder head
Replacing the front crankshaft seal ring
Pistons and connecting rods — removal
Pistons and connecting rods — inspection and repair
Pistons and connecting rods — installation
Removing the engine
Disassembling the engine
Engine repair
Engine assembly
Engine installation
Checking the compression in the cylinders
CVH engine repair
General data of the CVH engine
Main parameters of CVH engines
Cylinder Head — Specifications
Engine Block — Specifications
Crank mechanism — specifications
Valve timing system — specifications
Fuel System — Specifications
Contact ignition system — specifications
Contactless Ignition System — Specifications
Lubrication system — specifications
Cooling system — specifications
Tightening torques for threaded connections
General view of the CVH engine and engine compartment
Replacing the timing belt
Removing the cylinder head
Disassembling the cylinder head
Checking and repairing the cylinder head
Hydraulic valve lifters
Cylinder head assembly
Installing the cylinder head
Replacing the camshaft sealing ring
Replacing the front crankshaft seal ring
Replacing the oil pan
Pistons and connecting rods — removal, inspection and installation
Removing the engine
Disassembling the engine
Engine repair
Engine assembly
Engine installation
Checking the compression in the cylinders
Fuel system
Fuel system — general information
FORD VV carburetor with variable diffuser section
Main dosing system
Idle system
Removing and installing the carburetor
Idle speed and CO content
Idle control valve
Starter — removal and installation
Speed increaser device
Jet Needle — Removal and Installation
Float chamber needle valve
Accelerator cable — removal, installation and adjustment
Starter cable — removal, installation and adjustment
Fuel pump — removal, inspection and installation
Fuel tank — removal and installation
Air supply system thermostat
Air filter — removal and installation
Weber 2V carburetor
Weber 2V Carburetor — Design Description
Removing and installing the carburetor
Carburetor Cover — Removal
Idle speed and CO content
Automatic starting device — removal and installation
Adjusting the air damper clearance
Speed increaser device
Float chamber needle valve
KE-Jetronic injection system
Location of fuel injection system components on a vehicle
K-Jetronic fuel injection system — operating principle
KE-Jetronic fuel injection system — design description
Starting injector — check
Thermal time switch
Idle speed
Adjusting CO content
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 testing
CFI injection system
CFI fuel injection system — design description
Throttle valve — general information
Injectors — General Information
Pressure regulator — general information
Fuel injection system sensors — general information
Functioning of the central injection system
Removing and installing the injector
Safety precautions when working with the injection system
Diagnostics of injection system faults
Ignition system
Ignition system — general information
Contact ignition system — general information
Ignition distributor — removal and installation
Vacuum ignition timing regulator
Capacitor — removal and installation
Adjusting the gap between the breaker contacts
Replacing breaker contacts
Checking the ignition timing angle
Diagnostics of faults of contact ignition system
Contactless ignition system — general information
Contactless ignition system distributor
Contactless ignition system switch
Electronic ignition system without distributor
Diesel engines
Engine repair
View of the engine compartment and technical specifications
Cylinder Head — Specifications
Engine Block — Specifications
Crank mechanism — specifications
Valve timing system — specifications
Fuel System — Specifications
Lubrication system — specifications
Cooling system — specifications
Tightening torques for threaded connections
How a diesel engine works
Engine adjustment
Removing and installing the timing belt (1.6L engine)
Removing and installing the timing belt (1.8L engine)
Removing the cylinder head
Cylinder head repair
Installing the cylinder head and adjusting the valve timing
Disassembling a 1.6 liter engine
Checking 1.6 liter engine parts
Assembly of 1.6 liter engine
Differences in the assembly of an engine with a working volume of 1.8 liters
Fuel system
General information about the fuel system
Injectors — removal, inspection and installation
Checking the tightness of the nozzle sprayer
Adjusting the initial injection pressure
Glow Plugs — Checking
Checking the compression in the cylinders
Removing air and water from the fuel system
Engine stop device
Replacing the fuel filter
Accelerator cable — removal and installation
High pressure pump
High pressure fuel pump — design description
Rotary pump — general information
Distributor piston — general information
Solenoid valve — general information
Centrifugal regulator and injection regulator
Setting the injection timing of the fuel pump
Checking the maximum number of revolutions and delay time
Adjusting the idle speed
Replacing the air filter
Cooling and lubrication system
Technical characteristics of the cooling system
Cooling system tightening torques
Replacing the coolant
Radiator Fan Motor — Removal and Installation
Thermostat — Removal, Checking and Installation
Temperature sensor for fan activation
Removing and installing the water pump
Removing and installing the radiator
Technical characteristics of the lubrication system
Tightening torques of the lubrication system
Engine lubrication system — design description
Checking oil pressure
Removing and installing the oil pan
Removing and installing the oil pump
Engine oil change
Replacing the oil filter
Engine crankcase ventilation system
Lubrication system malfunctions
Exhaust system — design description
Removal and installation of the exhaust system
Replacing the rear muffler
Vehicles with a catalytic converter — general information
Transmission
Clutch
Clutch specifications
Removing the clutch
Checking the clutch
Clutch installation
Removing and installing the release bearing
Removing and installing the clutch cable
Adjusting the free play
Main clutch faults
Mechanical gearbox
Gearbox — General Information
Gearbox specifications
Maintenance of a four-speed manual transmission
Removing a four-speed manual transmission
Installation of a four-speed manual transmission
Disassembling a four-speed manual transmission
Assembly of a four-speed manual transmission
Gear shift mechanism of a four-speed manual transmission
Removing a five-speed manual transmission
Disassembling a five-speed manual transmission
Gear shift mechanism of a five-speed manual transmission
Automatic gearbox
Technical characteristics of the automatic transmission FORD ATX
Removal and installation of gearbox FORD ATX
FORD ATX Gearbox Control Mechanisms
Checking the parking brake of the FORD ATX gearbox
Checking the oil level in the FORD ATX gearbox
Towing a car with an automatic transmission
Main faults of FORD ATX gearbox
Technical characteristics of the automatic transmission FORD CTX
Removal and installation of gearbox FORD CTX
Gear shift rod FORD CTX box
Drive shafts
Description of the design of drive shafts
Tightening torques for threaded connections
Removing drive shafts
Installation of drive shafts
Disassembling drive shafts
Assembly of drive shafts
Replacing the inner hinge protective cover
Replacing the outer hinge protective cover
Hinge housing seal
Drive shaft faults
Chassis
Suspension and wheels
Front suspension — design description
Front suspension specifications
Front suspension tightening torques
Removing and installing the front shock absorber strut
Removing and installing the front shock absorber and spring
Removing and installing the front ball joint
Removing and installing the front stabilizer
Removing and installing the front strut
Removing and installing front hub bearings
Rear suspension — design description
Rear suspension specifications
Removing and installing the rear shock absorber strut
Removing and installing the rear suspension arm and spring
Removing and installing the rear jet rod
Removing and installing rear hub bearings
Tyre designation
Wheel rim designation
Steering
Description of the steering design
Technical characteristics of the steering system
Tightening torques for threaded connections
Removing and installing the steering gear
Removing and installing the steering column
Removing and installing the steering wheel
Removing and installing the steering rod end
Brake system
General information about the braking system
Technical characteristics of the brake system
Tightening torques for threaded connections
Removing and installing front brake pads
Removing and installing the front brake caliper and brake disc
Removing and installing rear brake pads
Removing and installing rear wheel brake cylinders
Master Brake Cylinder — Removal and Installation
Vacuum brake booster — removal and installation
Bleeding the brake system
Adjusting the parking brake
Replacing the parking brake cables
Anti-lock braking system — design description
Maintenance of the brake system
Main faults of the brake system
Body
Body elements
General information about the car body
Radiator grille — removal
Hood release cable — removal and installation
Front bumper — removal and installation
Rear bumper — removal and installation
Trunk lid (Orion) — removal and installation
Headlining — Removal and Installation
Front seats — removal and installation
Rear seats — removal and installation
Outside mirror — removal and installation
Interior mirror — removal and installation
Air supply control panel
Adjusting the heating control cables
Heater Fan — Removal
Doors, locks and windows
Description of door construction
Removing and installing the side door
Removing and installing door trim
Removing and installing the door lock
Removing and installing the door lock cylinder
Adjusting the door installation
Removing and installing door glass
Removing and installing the rear door
Removing and installing the interior door opening handle
Electrical equipment
Equipment and devices
Technical characteristics of electrical equipment
Fuses and relays
Removing and installing the generator
Adjusting the V-belt tension
Replacing the generator brushes and voltage regulator Bosch
Replacing the Generator Brushes and Voltage Regulator Lucas
Motorola Generator and Voltage Regulator Brush Replacement
Main generator faults
Features of the starter design
Removing and installing the starter
Main faults of the starter
Removing and installing the instrument cluster
Removal and installation of measuring instruments
Removing and installing switches
Removing and installing the brake light switch
Lighting system
Replacing headlight bulbs
Headlight adjustment
Removing and installing headlights
Replacing the parking light and turn signal bulbs
Removing and installing the front turn signal
Replacing the rear light bulbs
Removing and installing the rear light
Replacing the license plate light bulb
Replacing the interior light bulb
Electrical circuits
General description and symbols on electrical diagrams
Starting system, battery, fan, sensors
Ignition systems (carburetor engines before 1995)
Ignition system (1.6 CVH engines and automatic transmissions before 1995)
Ignition and fuel injection systems (1.3 CFI engines before 1995)
Ignition and fuel injection systems (1.4 CFI engines before 1995)
Engine management system 1.6 EF
Zetec Engine Management System (16V)
External lighting, side lights, brake lights and reversing lights
External lighting, direction indicators, fog light
Interior lighting system
Horn, heated glass, electric mirrors
Central locking, power windows, windscreen and headlight washers
Starting system, battery, fan, horn
Control lamps and sensors, side lights
Headlamps, rear fog lamps
Direction indicators, brake lights and reversing lights
Interior lighting system, cigarette lighter, windshield washer
Windscreen and rear window defrosters, interior heater fan
Windscreen and rear window wipers, windscreen washer
CFI engine management system
SEFI engine management system
Ford Escort 5
General information
User manual
Vehicle identification
Opening the hood of the car
Car dashboard
Car instrument cluster
Steering column lock / ignition switch
Front and rear fog light switch
Windscreen heating switch
Rear window defroster switch
Analog and digital watches
Headlight leveling corrector
Multifunctional light and turn signal switch
Windscreen wiper/washer switch
Car keys and locks
Door locking system
Position of the car door
Central locking with double locking system
Anti-theft system of the car
Electrically adjustable exterior mirrors
Rear side windows (three-door version)
Electric side windows
Car interior lighting
Front seats of the car
Manual gearbox
Automatic transmission
Starting the car engine
Driving a car of various configurations
Heating and ventilation of the car
Car air conditioning
Maintenance
Filling capacities and specification of liquids
Consumables specifications and technical characteristics
Frequency of car maintenance
Checks every 400 km or weekly
Liquid leaks from the car
Weekly Check Points
Checking the coolant level
Checking the engine oil level
Checking the brake fluid level
Power steering fluid level
Incandescent lamps and fuses
Checking the windshield wipers
Engine compartment of the engine
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
Adjusting the Clutch Pedal Stroke (Models After 1996)
Checking the oil level in a manual transmission
Checking and adjusting idle speed and mixture quality
Checking the front suspension
Checking the rear suspension
Protective rubber covers for the drive shaft
Checking the brake system
Checking the oil level in an automatic transmission
Replacing spark plugs
Replacing the coolant
Replacing the air filter element
Exhaust emission control systems
Replacing transmission fluid in an automatic transmission
Adjusting the handbrake
Replacing the fuel filter
Engine
HCS and Endura-E engines
Technical specifications
General information
Compression check
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover
Valve clearances
Cylinder head valve mechanism
Cylinder head
Crankshaft pulley
Camshaft timing chain cover
Camshaft drive chain
Oil pan
Oil pump
Oil pump repair
Replacing the crankshaft sealing rings
Powertrain 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
Timing Belt Tensioner and Pulleys
Replacing the camshaft sealing ring
Camshaft, levers and tappets
Cylinder head
Oil pan
Oil pump
Disassembling the oil pump
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
Timing Belt Tensioner and Pulleys
Replacing camshaft sealing rings
Camshafts and hydraulic tappets
Cylinder head
Oil pan
Oil pump
Replacing the crankshaft oil seal rings
Flywheel or drive plate
Powertrain suspension
Gasoline engines
Technical specifications
Removing the engine together with the gearbox
Engine Removal and Installation (HCS and Endura-E Engines)
Removal and installation of CVH and RTE 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 cylinder block
Main and connecting rod bearings
Engine assembly sequence
Piston rings
Crankshaft main bearings
Installing pistons and connecting rods
Starting the engine after major repairs
Diesel engines
Technical specifications
Checking and adjusting valve clearance
Replacing the fuel filter
Nozzles
Fuel pump adjustment
Fuel pump BOSCH
Fuel pump CAV Roto diesel
Removing and installing the fuel pump
Cylinder head
Disassembling the engine
Checking engine parts
Checking the crankshaft and connecting rod clearances
Checking piston rings and piston clearance in the cylinder
Engine assembly
Removing and installing the oil pump
Checking oil pressure
Removing and installing the coolant pump
Replacing the coolant
Diesel engines (since 1992)
Fuel pump adjustment
Adjusting the idle speed
Fuel pump
Turbocharger
FORD EDC Electronic Engine Control Unit
Exhaust system
Fuel heater
Fuel filter
Removing air from the fuel system
Adjusting the fuel pump cable
Design and operation of electronic engine control FORD EDC
Electrical power supply of electronic engine control FORD EDC
Sensors
Executive devices
Turbocharger — removal and installation
Air radiator
Exhaust gas recirculation system
Exhaust gas recirculation valve
Bosch fuel pump vacuum control valve for 1.8 D engine
Cooling and heating
Technical specifications
General information
Antifreeze
Cooling system 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 RTE 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)
Eccentric control cable on models with automatic transmission STX
Accelerator pedal
Air damper control cable
Fuel pump
Fuel tank
Fuel level sensor
Check valve
Fuel tank filler pipe
Weber TLDM Carburetor
Weber TLDM Carburetor Fast Idle Speed Adjustment
Weber TLDM Carburetor Needle Valve and Float
Weber TLDM Carburetor Choke Damper
Removing and installing the Weber TLDM carburetor
Weber TLDM carburetor repair
Weber TLD Carburetor
Adjusting the Fast Idle Speed on a Weber TLD Carburetor
Weber TLD Carburetor Needle Valve and Float
Adjusting the automatic choke of the Weber TLD carburetor
Removing and installing the automatic air damper of the Weber TLD carburetor
Removing and installing the Weber TLD carburetor
Disassembly and assembly of the Weber TLD carburetor
Removing and installing the intake manifold
CFI fuel injection
Technical specifications
General information
Relieving pressure in the fuel system
Fuel lines
Air filter
Accelerator cable
Fuel pump
Fuel tank
Fuel level sensor, fuel pump
Automatic fuel pump switch
Checking the fuel injection system
Fuel injection system components
Intake manifold
EFI fuel injection
Technical specifications
General information
Air filter
Accelerator cable
Fuel pump
Fuel tank
Fuel injection system components
Intake manifold
SEFI fuel injection
Technical specifications
General information
Air filter
Accelerator cable
Fuel pump
Fuel tank
Fuel injection system components
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
Removing and installing the generator
Cleaning the generator and replacing the voltage regulator
Checking the engine starting system
Removing and installing the starter
Ignition system
Technical specifications
General information
Checking the ignition system
Ignition coil
Ignition unit for engines with carburetor
Ignition unit on the fuel injection system
Crankshaft angle sensor
Transmission
Clutch
Technical specifications
General information
Clutch cable
Clutch pedal
Removing the clutch
Clutch release bearing
Clutch release shaft and sleeve
Mechanical gearbox
Technical specifications
General information
Adjusting the gear shift rod
Removing and installing the gear shift lever and rod
Speedometer drive gear
Replacing the sealing rings
Reverse light switch
Removing and installing a B5 or iB5 gearbox
Mechanical gearbox MTX-75
Automatic gearbox
Technical specifications
General information
Gear shift rod
Gear shift mechanism
Speedometer drive gear
Removal and installation of automatic transmission
Drive shafts
Technical specifications
General information
Removing and installing drive shafts
Replacing the inner hinge protective cover
Replacing the outer hinge protective cover
Drive shaft faults
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 rear brake pads
Replacing the rear wheel brake cylinder
Rear brake shield
Replacing rear brake pads on disc brakes
Rear brake caliper
Rear brake disc
Master brake cylinder
Brake pedal
Brake pedal rod
Brake lines and hoses
Bleeding the brake system
Vacuum brake booster
Brake booster vacuum line
Handbrake operating mechanism (disc brakes)
Handbrake lever
Front handbrake cable
Rear handbrake cable
Brake pressure regulating valve
Pressure regulator (VAN models)
Adjusting the pressure regulator position (VAN models)
Anti-lock braking system (ABS)
Removal and installation of ABS system components
Car suspension
Technical specifications
General information
Steering knuckle
Replacing the front hub bearings (23 spline hub)
Replacing the front hub bearings (25 spline hub)
Front suspension strut
Front suspension shock absorber
Front suspension anti-roll bar
Front suspension lower cross member
Front cross beam
Replacing rear hub bearings
Rear shock absorbers
Repair of rear shock absorber strut
Rear axle
Replacing rear axle bushings
Rear shock absorbers (Combi and Van models)
Rear coil springs on estate models
Rear leaf spring on Van models
Rear axle (Van models)
Steering
Technical specifications
Steering wheel
Steering column
Steering column repair
Replacing the rubber protective covers of the steering gear
Steering gear
Power steering
Power steering pump
Bleeding the power steering system
Steering link rod end
Wheel alignment angles
Body
Technical specifications
General information
Car body care
Caring for upholstery and carpets
Repair of minor body damage
Repair of severe body damage
Bumpers
Hood
Hood lock cable
Hood lock
Door trim
Door glass
Window lifter
Door lock, lock cylinder and handles
Doors
Outside rear view mirror
Interior rear view mirror
Trunk lid
Trunk lid lock
Back door
Rear door lock
Central door locking system unit
Windshield
Overlays and emblems
Checking and adjusting the hatch
Seats
Seat belts
Interior trim
Instrument panel
Central 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
Indoor lighting lamps
External lighting devices
Headlight adjustment
Instrument cluster
Elements of the instrument cluster
Speedometer drive cable
Cigarette lighter
Watch
Sound signal
Windscreen wiper arms
Windscreen wiper motor and rods
Windscreen wiper arm drive
Rear door wiper
Windscreen washer
Radio receiver
Loudspeakers
Radio receiver antenna
Anti-theft system
Schematic diagrams
Information on diagrams of cars manufactured before 1996
Diagram 1. Starting, charging, cooling systems, alarms and indicators (before 1995)
Diagram 2. Ignition system (all carburetor models) (before 1995)
Diagram 3. Ignition system (CVH 1.6L engines with automatic transmission) (before 1995)
Diagram 4. Ignition and engine management system 1.3L CFI (before 1995)
Diagram 5. Ignition and engine management system 1.4L CFI (before 1995)
Diagram 6. Ignition and engine management system 1.6L EFi (before 1995)
Diagram 7. Zetec ignition and engine management system (16V) (before 1995)
Diagram 8. External lighting — side lights, brake lights, reverse lights (before 1995)
Diagram 9. External lighting — fog and main lights (before 1995)
Diagram 10. Interior lighting (before 1995)
Diagram 11. Alarm system, heating, heated glass and mirrors (before 1995)
Diagram 12. Windscreen wiper and washer system, central locking and power windows (before 1995)
Information on diagrams of cars manufactured since 1996
Diagram 2. Starting, charging, cooling systems, alarms and indicators (since 1996)
Diagram 3. Hazard warning lights, indicators, rear light and number plate light (since 1996)
Diagram 4. External 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. Glass 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 specifications
Engine Power System Specification
Fuel injection device specification
Ignition system specification
Starter and Generator Specification
Gearbox and Clutch Specification
Suspension and brake specifications
Light bulbs, fuses and relays
Engine tightening torques 1.1
Engine tightening torques 1.4i/1.6i
Tightening torques for diesel engine 1.8
Gearbox tightening torques
Suspension and brake tightening torques
Maintenance
General instructions for carrying out repairs
Correct lifting of the car
Engine
Disassembly and assembly
Description and location of engines
Removing the engine from the car
Installing the engine on a car
Disassembling the engine 1.1
Dismantling 1.4i/1.6i engines (with petrol injection)
Disassembling a 1.8 diesel engine
Engine assembly — general information
Engine assembly 1.1
Assembly of 1.4i/1.6i engines (with petrol injection)
Assembly of diesel engine 1.8
Block head
Inspection of the camshaft of the cylinder head
Removing and installing the engine cylinder head 1.1
Removal and installation of cylinder heads of 1.4i/1.6i engines
Removal and installation of the cylinder head of a 1.8 diesel engine
Disassembling the cylinder head of a gasoline engine
Checking and repairing the cylinder head and its parts
Checking and repairing the cylinder head of a 1.8 diesel engine
Checking the camshaft
Connecting rod and piston group
Checking the crankshaft
Checking the connecting rods
Checking the pistons
Installation of pistons with connecting rods in 1.1/1.4i engines
Checking the engine body
Checking the flywheel
Lubrication system
Description of the lubrication system
Checking the oil pump
Replacing the oil filter
Gas distribution system
Checking the engine timing 1.1
Checking the valve timing of 1.4i/1.6i engines
Checking the camshaft of a 1.8 diesel engine
Cooling system
Description of the cooling system
Removing the water pump in the 1.1 engine
Installing a water pump in a 1.1 engine
Removing the water pump in the 1.4i/1.6i engine
Installing a water pump in 1.4i/1.6i engines
Removing the water pump in a 1.8 diesel engine
Installing a water pump in a 1.8 diesel engine
Replacing the thermostat
Replacing the radiator and coolant
Supply system
Description of the power supply system
Carburetor repair and adjustment
Removing and installing the carburetor
Disassembling the carburetor
Carburetor cleaning
Petrol injection system in engines 1.1i/1.4i/1.6i
Removing and installing the coolant temperature sensor
Removing the electric throttle control motor
Installing a new electric motor
Removing and installing the pressure regulator
Removing and installing the throttle potentiometer
Removing and installing the injector
Removing and installing the CFJ device
Removing and installing the fuel pump
Replacing the fuel filter
Replacing the control device
Replacing the lambda probe
Removal and installation of other sensors
Exhaust gas discharge system
Diesel power system
Description of the diesel fuel supply system
Replacing the injector
Replacement of fuel injection pump
Installation of fuel injection pump
Replacing the fuel filter
Replacing spark plugs
Adjusting the engine idle speed
Ignition system
Description of ignition control
Replacing the coolant temperature sensor
Removing and installing the ignition coil
Removing and installing the engine speed sensor
Ignition and injection control system in 1.4i/1.6i engines
Removing and installing the ignition distributor
Removing and installing the ignition control module
Spark plugs and starting plugs
Transmission
Clutch
Description and testing of clutch operation
Removing and installing the clutch
Replacing the clutch control cable
Mechanical gearbox
Description of the five-speed manual transmission
Removing and installing the gearbox
Disassembling the gearbox
Disassembling the secondary shaft of the box
Assembly of the secondary shaft of the box
Disassembling the differential
Gearbox assembly
Automatic gearbox
Automatic transmission device
Removing the automatic transmission
Installation of automatic transmission
Checking the oil level
Replacing the manual control cable
Replacing the cam starter cable
Replacing the automatic transmission lock switch
Drive shafts
Description of drive axles
Replacing the axle shaft
Installing the axle shaft
Suspension and chassis
Front suspension
Description of front wheel suspension
Replacing the front wheel bearing
Replacing the front control arm
Replacing the ball joint
Removing and installing the suspension column
Disassembly and assembly of the suspension column
Rear suspension
Description of rear wheel suspension
Removing and installing the rear axle
Replacement and adjustment of rear wheel bearing clearance
Replacing the rear shock absorber
Replacing rubber bushings of the rear suspension
Steering
Description of the gear steering mechanism
Removing and installing the steering gear
Replacing the rubber boots of the steering gear
Removing and installing the steering column
Removing and installing the steering shaft
Wheel installation
Brake system
Description of the brake system
Adjusting the handbrake
Replacing disc brake pads
Replacing drum brake shoes
Removing and installing the front brake caliper
Removing and installing the brake disc
Replacing the rear brake cylinder
Replacing the handbrake cable
Replacing the master brake cylinder
Replacing the brake pressure regulator
Removal and installation of the brake booster
Bleeding the brake system and replacing brake fluid
Removing and installing the pressure regulating valve
Removing and installing the adjustment unit
Electrical equipment
Equipment and devices
General information about the battery
Checking the generator operation
Checking the regulated voltage
Removing and installing the generator
Checking the starter operation
Starter replacement
Headlights and windshield wipers
Removing and installing the windshield wiper motor
Heating and ventilation
Removing and installing the heater
Removing and installing the heater fan
Replacing fuses and relays
Electrical equipment diagrams
Brief description
List of conditional elements
List of grounding nodes
List of soldered units
Electrical diagram of the power supply system
Electrical diagram of the engine starting and battery charging system
Schematic diagram of the engine 1.1 (HSS-Valencia)
Schematic diagram of the engine 1.4 (CVH)
Schematic diagram of the 1.4 Fiesta XR2i engine
Schematic diagram of the engine 1.6 (CVH)
Schematic diagram of 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
Car engine lineup
Appendix 1. Technical data and characteristics
Volumes of operating fluids
Working conditions and tools
Purchase of spare parts
Workplace
Main working tool
Special tools and accessories
Professional tips for mechanics
Submitting a car for repair
Lifting a car
Car care
Interior cleaning
Car wash
Car wash outside
Engine wash
Lubrication of joints and assemblies
Care of the paintwork
Repairing damage from rock strikes
Polishing of small scratches
Removing deep scratches
Windscreen wiper and washer
Checking the windshield wiper and washer
Filling the windshield washer reservoir with fluid
Replacing brushes
Adjusting the windshield washer jets
Removing the jets
Removing the windshield wiper arm
Removing the windshield wiper gear motor
Removing the rear window gear motor
Possible malfunctions of the windshield wiper drive mechanism, their causes and methods of elimination
Power unit
Engine repair
General information about the engine
Nominal crankshaft speed and engine service life
Engine compression
Checking the poly V-belt
Engine diagnostics based on knocking sounds from the engine compartment
Determining bearing or liner 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
Motor 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 adding coolant
Replacing the coolant
Protecting the Fiesta engine from frost down to -30°C
Removing and checking the thermostat
Radiator fan
Troubleshooting the Radiator Fan
Removing the radiator fan
Removing the radiator
Replacing cooling system hoses
Possible malfunctions of the cooling system
Possible thermostat malfunctions and their causes
Air filter
Air filter and sound-absorbing pipe
Preheating of intake air
Symptoms of intake air preheating malfunctions
Fuel injection system
General information about the fuel injection system
Main systems and components of the EEC-V fuel injection
Checking the fuel injection system
Elimination of unstable engine crankshaft speed at idle
Checking the idle speed actuator
Checking the injectors
Accelerator cable
Replacing the accelerator cable on vehicles with Endura-E engines
Replacing the accelerator cable on cars with Zetec engines
Adjusting the accelerator cable
Diesel engine injection system 1.8D
Visual inspection of the diesel engine injection system
Adjusting the air-fuel mixture supply
Replacing the accelerator cable
Replacing the air filter
Possible malfunctions of the fuel injection system
Possible malfunctions of the fuel injection system of a diesel engine
Ignition system
General information about the ignition system
Electronic control unit
Adjusting the ignition timing angle
Ignition coil
Spark plugs
Every 45,000 km – removal, inspection and replacement of spark plugs
Temporary change of ignition timing to adjust fuel octane number
Turning off the ignition, checking the ignition unit and high-voltage wires
Checking the engine crankshaft 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
Measuring the resistance of the ignition coil
Removing the ignition unit
Possible engine and ignition system malfunctions
Supply system
General information about the fuel supply system
The most important elements of the power supply system
Fuel types and handling
Checking the fuel tank ventilation valve
Replacing the fuel filter on cars with gasoline engines
Replacing the fuel filter on cars with diesel engines
Removing water from the fuel filter of cars with diesel engines
Draining fuel from the tank without a hand pump
Removing fuel lines and hoses
Electric Fuel Pump Malfunctions
Removing the fuel pump on cars with gasoline engines
Exhaust system
General information about the exhaust system
Recommendations for replacing the exhaust system
Checking the technical condition of suspension elements and exhaust system
Replacement of the exhaust system, including the catalytic converter
Reducing toxicity of exhaust gases
Transmission
General information about transmission
General information about the clutch
Checking the clutch
Incomplete clutch disengagement
Five-speed gearbox
Adjusting the gear shift mechanism
Checking the transmission oil level
Topping up transmission oil
Continuously variable automatic transmission STX
Checking the level of working fluid in the automatic transmission STX
Replacement of working fluid and filter in automatic transmission STX
Main gear
Checking the protective covers of the constant velocity joints of the drive shafts
Removing the wheel drive shaft
Replacement of constant velocity joint protective boots
Possible clutch malfunctions
Possible malfunctions of the automatic transmission STX
Chassis
Car suspension
General information about suspension and steering
Front suspension
Rear suspension
Front suspension geometry
Checking shock absorbers
Checking the bushings of the transverse arm of the independent front suspension
Checking the play of wheel hub bearings
Removing the front suspension wishbone
Installing the front suspension wishbone
Removing the shock absorber strut
Replacing the wheel hub bearing
Removing the rear shock absorber
Replacing the rear wheel hub bearings
Steering
Checking the steering play
Checking the steering gear protective covers
Checking ball joints and dust covers of tie rod ends
Replacing ball joints of steering rod ends
Replacing the steering rod mudguards
Replacing the steering knuckle
Installing the steering knuckle
Removing the steering wheel
Replacing the coil spring
Power steering
Wheels and tires
Wheel and tire sizes
Construction and marking of tires
Wheel replacement
Checking the condition of the tires
Brake system
General information about the braking system
Checking the hydraulic drive of the brake system
Checking the brake booster
Anti-lock braking system (ABS), BTCS and EBD
Fiesta car 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 thickness of the brake shoe linings of the rear drum brakes
Removing air from the brake system (bleeding)
Replacing brake fluid
Removing the brake fluid reservoir from the brake master cylinder
Removing the master brake cylinder
Removing the 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 protective ring
Removing the brake drum
Replacing brake pads on rear drum brakes
Removing the wheel brake cylinder
Parking brake
Replacing the parking brake cables
Adjusting the parking brake
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 lighting bulbs
Checking the door contact switch
Replacement of the trunk light bulb
Removing the radio
Removing the speakers
Removing the external antenna
Front seats
Back seat
Backrest of the rear seat
Removing the door trim
Removing the door glass window regulator
Central lock
Removing the door handle
Removing the door lock cylinder
Possible heating malfunctions
Possible malfunctions of electric 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
Replacing the rear view mirror
Removing the hood
Removing the front bumper
Removing the wing
Installing the wing
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
Replacing the poly V-belt
Outdoor lighting
Replacing headlight bulbs
Replacing the turn signal lamp
Replacing the parking light bulb
Replacing the side turn signal repeater bulb
Replacing the fog light bulb
Rear combination lights
Rear combination lights for Courier cars
Replacing headlight lenses
Replacing the license plate light bulb
Temporary headlight adjustment
Signaling devices
Checking the brake light switch
Checking the sound signal
Control and measuring instruments and controls
Checking switches
Removing the instrument cluster
Replacing indicator lamps
Removing measuring instruments
Electrical circuits
Fuses in the passenger compartment and engine compartment
Replacing fuses
Relays and control circuits
Possible malfunctions of hazard warning lights 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 battery charge level
Starting an engine with a discharged battery
Charging the battery
Removing the battery
Checking the voltage regulator
Removing the generator
Removing the starter
Possible faults of the battery and generator
Possible starter malfunctions
Ford Taurus 1 and 2
General information
Characteristics
Vehicle identification number
Conventional designations
Unit Conversion Table
Adjustment parameters of vehicle systems
Maintenance
Jacking and towing
General specifications of the car
Introduction to Maintenance
Maintenance schedule
Checking fluid levels
Tires and tire pressure monitoring
Checking the power steering fluid level
Checking the fluid level in the automatic transmission
Changing engine oil and filter
Adjusting the clutch pedal
Checking and replacing under-hood pipes
Checking, adjusting and replacing the drive belt
Replacing the air filter
Checking the PCV valve and crankcase ventilation filter
Checking the fuel system
Replacing the fuel filter
Checking the cooling system
Checking the exhaust system
Changing tires
Checking shock absorbers
Checking the steering and suspension
Checking the brakes
Automatic transmission control rod lubrication
Checking the oil level in a manual transmission
Checking and disassembling the rear wheel bearing (up to 1989)
Replacing spark plugs
Checking and replacing spark plug wires
Maintenance of the cooling system (draining, flushing, filling)
Automatic transmission fluid and filter replacement
Troubleshooting
Engine diagnostics
Diagnostics of engine electrical equipment
Fuel system diagnostics
Cooling system diagnostics
Clutch diagnostics
Diagnostics of a manual transmission
Automatic transmission diagnostics
Axle drives and CV joints
Brake diagnostics
Suspension and steering diagnostics
Engine
Four-cylinder engine
Engine Specifications and Tightening Torques
General information
Repair operations permitted with the engine still in place
Removal and installation the valve cover
Removal, checking and installation valve levers and push rods
Location of top dead center (TDC) of piston No. 1
Replacing valve springs, gaskets and retainers
Measuring Camshaft Cam Wear
Removal and installation the intake manifold
Removal and installation the exhaust manifold
Removal and installation cylinder heads
Valve lifters — removal, inspection and installation
Removal and installation the oil pan
Oil pump — removal and installation
Checking and replacing the engine suspension and shock absorbers
Six-cylinder engine
Engine Specifications and Tightening Torques
Repair operations available with the engine still in place
Removal and installation valve covers
Removal, installation and adjustment of valve levers and push rods
Replacement of springs, retainers, valve seals
Removal and installation the intake manifold
Exhaust manifolds — removal and installation
Removal and installation cylinder heads
Replacing the front crankshaft oil seal
Removal and installation the camshaft drive chain cover
TDC location for piston #1
Removal and installation the camshaft drive chain and sprockets
Valve tappets — removal, inspection, installation
Removal and installation the oil pan
Oil pump and oil receiver — removal and installation
Checking and replacing the engine shock absorber suspension
Overhaul
Four-cylinder engine specifications
3.0LV6 Engine Specifications
3.8LV6 Engine Specifications
General information
Checking cylinder compression
General information about major repairs
Engine — removal and installation
Engine overhaul — disassembly sequence
Disassembling the cylinder head
Cylinder heads — cleaning and inspection
Cylinder head overhaul
Removal and installation the flywheel or drive plate
Replacing crankshaft seals
Front cover, camshaft drive chain and sprockets
Camshaft, balance shaft and bearings
Removal pistons and connecting rods
Removal 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
Installing piston rings
Installing the crankshaft and checking the oil clearance of the main bearings
Installing pistons and connecting rods, checking the oil clearance in the connecting rod bearing
Starting and running in the engine after major repairs
Cooling system
Tightening torque specifications
Cooling, heating, air conditioning systems
General information about antifreeze
Replacing the thermostat
Electric fan — description, checking and replacement of elements
Removal and installation the radiator
Checking and replacing the cooling system fan thermostat
Removal and installation the coolant reservoir
Checking the water pump
Water pump — removal and installation
Air conditioning and heating systems maintenance
Removal and installation 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 the air conditioning compressor
Removal and installation the air conditioner condenser
Air conditioner accumulator and pressure switch
Fuel/exhaust systems
Specifications
General information about the fuel and exhaust system
Relieving fuel system pressure
Replacement of fuel lines and pipeline connections
Checking the fuel pump
Gas tank — removal and installation
General information on cleaning and repairing the gas tank
Removal and installation the fuel pump
Removal and installation the air cleaner housing
Removal and installation throttle connection elements
Fuel injection system — general information
Measuring pressure in the fuel injection system
Replacing components of the central fuel injection (CFI) system
Replacing components (EFI) of the electronic fuel injection system
Replacing EFI system components (for 3.8LV6 engines)
Replacement of exhaust system components
Engine electrics
Specifications and General Information
Removal and installation the battery
Checking and replacing battery cables
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 angle
Electronic ignition unit check and replacement
Checking and replacing the Hall sensor stator distributor block
Power supply system — general information and safety precautions
Checking the power supply system
Generator — removal and installation
Replacing the generator brushes (type EVR)
Replacing the External Voltage Regulator (EVR)
Replacing the generator brushes (type IAR) / voltage regulator
Starting system — general information
Checking the engine and starter electrical circuit
Removal and installation the starter motor
Removal and installation the starter relay
Emission control
General information
Electronic Engine Control System (EEC — IV)
Exhaust Gas Recirculation (EGR) System
Manifold Air Intake Control System
Fuel 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 oil in manual transmission
Removal and installation the gear shift handle
Removal and installation of manual transmission
General information on gearbox overhaul
Replacing the speedometer drive mechanism sealing ring
Automatic gearbox
Tightening 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 automatic transmission
Adjusting the automatic transmission drive mechanism
Adjusting the Throttle Valve (TV) Control Mechanism
Checking and replacing the gearbox suspension
Replacing and adjusting the neutral start sensor
Clutch and drives
Specifications
General information
Checking the clutch operation
Clutch — removal, inspection and installation
Thrust bearing and its fork — removal, inspection and installation
Removal and installation the clutch cable
Internal starter/clutch switch
Checking axle drives, CV joints and covers
Removal and installation of axial drives
Replacement of the axle drive housing and CV joint overhaul
Replacing differential seals
Chassis
Brake system
Specifications
General information and safety precautions
Front brake pads — replacement
Front Disc Brake Caliper — Removal and Installation
Front brake disc — inspection, removal and installation
Brake drum — removal, inspection and installation
Replacing rear brake shoes
Wheel cylinder — removal, overhaul and installation
Master cylinder — removal, overhaul and installation
Brake pressure control valves
Brake system hoses and lines — inspection and replacement
Bleeding the brake hydraulic system
Adjusting the parking brake
Replacing the parking brake cables
Parking brake pedal — removal and installation
Removal and installation the 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 rear brake pads
Rear Disc Brake Caliper — Removal and Installation
Rear brake disc — inspection, removal and installation
Car suspension
Tightening torque specification
General information
Front anti-roll bar, control arm and bushings
Ball joints — inspection and replacement
Front Torque Rod and Elastic Joint — Removal and Installation
Front arm — removal, inspection and installation
Front shock absorber and coil spring assembly — removal and installation
Front shock absorber unit — replacement
Steering knuckle 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 unit (sedan) — replacement
Rear wishbones (sedan) — removal and installation
Jet thrust and ball joint cushions (sedan) — removal and installation
Wheel knuckle — removal and installation
Rear shock absorbers (station wagon) — removal and installation
Upper Rear Suspension Arms (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 knuckle (station wagon) — removal and installation
Replacing 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 the steering gear covers
Wheels and tires — general information
Front Wheel Alignment — General Information
Body
Repair and maintenance
Tightening torque specification
General information and care
Hood — removal, installation, adjustment
Front fender liner — removal and installation
Removal and installation the hood lock and cable
Door — removal, installation, adjustment
Trunk lid — removal, installation, adjustment
Tailgate of bodies (station wagon) — removal, installation, adjustment
Bumpers — removal and installation
Removal and installation 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 electrical equipment faults
Connectors — General Information
Fuses — General Information
Fusible Links — General Information
Circuit Breakers — General Information
Replacing the multifunction switch
Replacing the ignition key lock cylinder
Replacing the wiper switch and motor
Replacing the turn signal and hazard warning flasher
Headlight Switch and Dimmer/Rheostat Replacement
Headlights — removal and installation
Replacing lamps
Radio and speakers — removal and installation
Checking and replacing the radio antenna
Instrument panel — removal and installation
Instrument cluster — removal and installation
Repair and replacement of rear window heater and switch
Sound signal — check and replacement
Checking the cruise control system
Electrical diagrams
Ford Fusion
General information
Vehicle device
General information about the Ford Fusion
Vehicle Passport Data
Car keys
Instruments and controls
Instrument cluster
Trip computer
Heating (air conditioning) and ventilation of the passenger compartment
Door locks — opening and blocking
Window lift control
Seat belts on the front seats
Seat belts in the rear seats
Adjusting the position of the front seats
Rear seats
Using child seats
Adjusting the position of the steering wheel
Rear view mirrors
Interior lighting
Sun visors
Hood — opening and closing
Gearbox control
User manual
Safety regulations
Operating recommendations
Traffic safety recommendations
Running in a car
Operation of the vehicle during the warranty period
Preparing the car for departure
Filling up a car with petrol
Using a jack
Towing a car
Faults on the way
General techniques for starting an engine
Malfunctions in the starting system
Checking the ignition system
Checking the engine fuel system
Fuel injection system faults
Idle speed is gone
Engine misfires
Diagnosis of engine condition by the appearance of spark plugs
The car moves in jerks
The car accelerates poorly
The engine stalled while driving
Oil pressure dropped
Engine overheating
Checking the cooling system
The battery is not recharging
Checking electrical equipment
Starting the engine from external power sources
Electrical equipment faults
There was a knocking noise in the engine
Knocking noises appeared in the suspension and transmission
Possible causes of knocking in the suspension and ways to eliminate them
Possible transmission knocks (noises), their causes and methods of elimination
Vibration and shock on the steering wheel
Brake system malfunctions
Bleeding the brake system
Checking the brake system
Puncture and replacement of a wheel
Maintenance
Maintenance schedule
Safety regulations
Checking the wheels
Checking the level and adding oil to the engine
Checking the level and adding coolant
Checking the level and adding fluid to the brake and clutch reservoir
Checking the level and adding fluid to the power 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 cooling system hoses and connections
Checking the exhaust system
Checking the tightness of fuel lines
Checking and replacing the air filter element
Replacing the fuel filter
Checking the level and adding oil to the gearbox
Checking the front wheel drive protective covers
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 angles
Inspection and testing of the steering system on the vehicle
Checking the free play (play) of the steering wheel
Checking the tightness of the hydraulic brake drive
Checking the degree of wear of brake pads, discs and drums
Checking the operation of the brake booster
Checking the efficiency of the braking system
Checking the parking brake
Battery Maintenance
Checking and adjusting headlights
Lubrication of body fittings
Cleaning drainage holes
Replacement and maintenance of spark plugs
Replacement of auxiliary drive belt
Replacing the power steering pump drive belt
Replacing the timing belt and its tension roller
Replacing brake fluid in hydraulic brake and clutch release systems
Replacing the coolant
Tightening torques for threaded connections
Lamps used in the car
Fuels and lubricants and operating fluids
Tips for the car owner
Purchase of spare parts
Trip to the service station (STO)
How to prepare your car for winter
Recommendations for starting the engine in severe frost
What is useful to buy for winter
Useful winter tips
Recommendations for preparation for technical inspection
List of faults and conditions under which operation of vehicles is prohibited
Changes to state standards
Safety precautions during repair work
Tools for car repair and maintenance
Before you start working
Restoration of threaded connections
Auto Body Repair Tips
Power unit
Engine repair
Features of engine design
Possible engine malfunctions, their causes and solutions
Useful tips for engine repair
Checking the compression in the cylinders
Removal and installation the engine mudguard
Replacing the right powertrain suspension support
Replacing the left support of the powertrain suspension
Replacing the rear support of the powertrain suspension
Setting the piston of the first cylinder to the TDC position of the compression stroke
Removal, installation and inspection of the flywheel
Replacing the cylinder head cover gasket
Replacing the cylinder head gasket
Replacing valve stem seals
Replacing camshaft seals
Replacing crankshaft seals
Replacing the oil pan seal
Replacing the intake manifold gasket
Replacing the catalytic converter gasket
Adjusting valve clearances
Cylinder head — general information
Replacing camshafts
Lapping valves
Removal and installation the engine
Lubrication and cooling system
Design features of the engine lubrication system
Removal and installation the oil pump
Oil pump repair
Features of the design of the engine cooling system
Removal and installation the electric fan of the radiator of the cooling system
Replacing the cooling system radiator
Removal and installation the water pump
Removal and installation the thermostat
Removal and installation the expansion tank
Supply system
Features of the design of the engine power supply system
Checking the pressure in the fuel system
Reducing pressure in the fuel system
Removal and installation the air filter
Replacing the fuel tank
Replacing the fuel pump
Checking and replacing the fuel pressure regulator
Removal, inspection and installation of fuel injectors
Removal and installation the fuel rail
Removal and installation the throttle assembly
Removal and installation the accelerator pedal
Exhaust and vapor recovery
Design features of the exhaust system
Replacing the exhaust system suspension cushions
Removal and installation the catalytic converter
Replacing the main and additional mufflers
Removal and installation of thermal screens
Features of the fuel vapor recovery system
Replacing the fuel vapor recovery system canister
Transmission
Clutch
Clutch design features
Possible clutch malfunctions, their causes and solutions
Checking the Clutch Release Pedal Travel
Removal and installation the clutch
Replacing the clutch release drive slave cylinder with bearing
Replacing the clutch release master cylinder
Replacing the clutch release hydraulic lines
Removal and installation the clutch pedal
Bleeding the clutch release hydraulic drive
Car gearbox
Gearbox design features
Gearbox oil change
Replacing gearbox seals
Removal and installation the gearbox
Replacing gearbox control cables
Removal and installation the gearbox control lever linkage
Adjusting the gearbox control drive
Front wheel drives
Design features of drive shafts
Possible faults of front wheel drives
Removal and installation front wheel drives
Replacing constant velocity ball joints
Replacing the intermediate support bearing
Chassis
Front suspension
Features of the front suspension design
Possible faults of the front suspension
Removal and installation the shock absorber strut
Shock absorber strut repair
Replacing the upper shock absorber strut support
Replacing the shock absorber strut ball joint
Replacing the front suspension arm
Replacing the front suspension stabilizer bar
Removal and installation the steering knuckle
Replacing the front hub bearing
Removal and installation the front suspension crossmember
Rear suspension
Features of the rear suspension design
Possible faults of the rear suspension
Replacing the rear shock absorber
Replacing the rear suspension spring
Replacing the silent blocks of the rear suspension arms
Replacing the rear hub bearing
Replacing the rear suspension beam
Steering
Features of the steering design
Possible malfunctions of the power steering
Removal and installation the steering wheel
Removal and installation the steering column
Replacing the outer tie rod end
Replacing the steering rod
Bleeding the power steering system
Replacing the power steering fluid reservoir
Replacing the steering gear
Replacing the power steering pump
Brake system
Features of the brake system
Possible malfunctions of the brake system
Bleeding the hydraulic brake system
Checking the brake pedal position
Master Brake Cylinder — General Information
Replacing the brake master cylinder reservoir
Replacing the master brake cylinder
Brake booster — general information
Replacing the brake booster
Replacement of hydraulic brake hoses and tubes
Replacing brake hoses
Replacing brake pipes
Replacing the brake pads of the front wheel brake mechanism
Replacing the caliper assembly with the pad guide
Replacing the brake disc
Rear wheel brakes — general information
Removal and installation the brake drum
Replacing the brake pads of the rear wheel brake mechanism
Replacing the rear wheel brake slave cylinder
Adjusting the parking brake drive
Replacing the rear parking brake cables
Wheels and tires
Wheel rim markings
Tire markings
Wheel replacement
Wheel nuts
Tire running-in
Tire storage
Wheel balancing
Anti-skid chains
Spare wheel
Checking tire pressure
Checking the tire tread
Checking the valve
Checking the radial and lateral runout of the discs
Body
Exterior
Features of the body design
Possible bodywork faults
Removal and installation the radiator grille
Removal and installation wheel mudguards and fender liners
Removal and installation the front bumper and its bar
Removal and installation the rear bumper
Removal and installation the front wing
Removal and installation the air intake box grille
Removal and installation the hood
Removal, installing and adjusting the hood lock
Removal and installation the outside mirror
Removal and installation the battery shelf bracket
Interior
Removal and installation the front seat
Removal and installation the rear seat
Removal and installation the floor tunnel lining
Design features of the passive safety system
Removal and installation the driver's airbag
Replacing the front seat belt
Replacing the rear seat belt
Electronic control unit of additional passive safety system
Removal and installation the interior mirror
Features of the instrument panel design
Removal and installation the instrument panel
Design features of the heater and air conditioner
Control unit for heating, air conditioning and ventilation of the passenger compartment
Removal and installation the incoming air filter
Replacing handrails in the cabin
Replacing the glasses compartment
Replacing sun visors
Removal and installation of interior trim
Removal and installation steering column covers
Removal and installation trunk trims
Doors, locks and windows
Removal and installation the front door trim
Front door glass replacement
Replacing the front door window regulator
Replacing the outside handle and lock of the front door
Replacing the inner handle of the front door lock drive
Replacing the front door opening limiter
Removal and installation the front door
Removal and installation the rear door trim
Rear door glass replacement
Replacing the rear door window regulator
Replacing the outside handle and rear door lock
Replacing the inner handle of the rear door lock actuator
Replacing the rear door opening limiter
Removal and installation the rear door
Replacing the tailgate stops
Removal and installation the rear door trim
Removal and installation the decorative trim on the tailgate
Replacing the tailgate lock
Removal and installation the tailgate
Removal and installation the fuel tank filler pipe hatch cover
Removal and installation the fuel tank filler pipe hatch lock
Windscreen wiper — general information
Replacing windshield wiper blades
Replacing windshield wiper arms and rods
Windscreen wiper trapezoid assembly with gear motor
Rear Window Wiper — General Information
Replacing the rear window wiper blade
Replacing the rear window wiper arm
Replacement of fixed body glazing
Body сare
Car body wash
Polishing of the body paintwork
Anti-corrosion protection of the body
Preparation and anti-corrosion treatment of hidden cavities
Body sealing
Caring for upholstery and carpets
Car engine wash
Electrical equipment
Equipment and devices
Features of the design of electrical equipment
Diagnostics of faults of on-board electrical equipment
Location and replacement of fuses, fuse links and relays
Windscreen wiper motor gearbox replacement
Replacement of the rear window wiper motor
Removal and installation the windshield washer
Replacing the front door window lift motor
Electric motor of the radiator fan of the cooling system
Removal and installation the heater electric fan
Heater recirculation flap motor
Replacing the additional resistance of the heater electric fan
Electric heating of the rear door glass
Features of the instrument cluster design
Removal and installation the instrument cluster
Removal and installation speakers of the acoustic system
Removal and installation a car radio
Removal and installation the antenna
Removal and installation the audio system remote control
Removal and installation the cigarette lighter socket
Electronic anti-theft system remote control
Electronic anti-theft system control
Replacing the battery in the remote control
Removal and installation the electronic anti-theft system control unit
Features of the immobilizer design
Additional functions of the immobilizer
Engine electrics
Features of the battery design
Possible faults of the battery
Removal and installation the battery
Charging the battery
Design Features of the Generator
Possible generator faults
Removal and installation the generator
Generator repair
Features of the starter design
Possible starter malfunctions
Removal and installation the starter
Starter repair
Checking the ignition switch (lock)
Replacing the ignition switch (lock) contact group
Replacing the ignition switch cylinder
Removal and installation the ignition switch (lock)
Design features of the engine management system
Possible malfunctions of the engine management system
Checking the ignition coil
Removal and installation the ignition coil
Replacing the electronic engine control unit
Checking and replacing engine management system sensors
Lighting and signaling
Features of the lighting and signaling design
Replacing lamps in lighting fixtures
Headlight replacement
Replacing the side turn signal light
Front Fog Light Replacement
Replacing the rear light
Replacing an additional brake light
Replacing license plate lights
Replacing the front interior light
Replacing the rear interior light
Replacement of the trunk light
Replacing steering column switches
Removal and installation the horn
Switches and sensors
Replacing the external lighting control unit
Replacing the instrument panel switches
Replacing the hazard warning switch
Replacing the control unit for exterior mirrors
Replacing the electric trunk lock switch
Checking and replacing the fuel level indicator sensor
Replacing the pressure sensor in the power steering system
Checking and replacing the reverse light switch
Replacing the brake light switch
Replacing the clutch pedal position sensor
Replacing the brake pedal position sensor
Replacing the Parking Brake Indicator Light Switch
Replacing the fuel switch
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 supply system
Scheme 4. Engine starting system for cars with manual transmission
Diagram 5. Charging system
Scheme 6. Ignition system
Scheme 7. Car audio system
Scheme 8. Cooling system
Diagram 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
Scheme 15. Sound signal
Scheme 16. Clock in the car interior
Scheme 17. Heating and ventilation system
Scheme 18. Air conditioning system
Scheme 19. Interior lighting of the salon
Scheme 20. Daytime driving lights (DRL system)
Scheme 21. Fog lights
Scheme 22. Car headlights
Scheme 23. Side lights and number plate illumination
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 windshield washer
Scheme 30. Heating of the rear door glass and mirrors
Scheme 31. Lock drive
Scheme 32. Central lock
Scheme 33. Seat heating
Ford Scorpio 1
General information
User manual
Vehicle identification
Instrument panel and instrument cluster
Steering column control levers
Car keys
Doors — opening and locking
Steering column lock / ignition switch
Manual gearbox
Automatic transmission
Electric power windows
Adjusting the position of the steering wheel
Front seats
Interior lighting
Electrically adjustable exterior rear view mirrors
Increased luggage compartment volume
Windscreen wipers and washers
Lifting a car
Towing a car
Starting the engine
Starting a gasoline engine
Starting a diesel engine
Features of vehicle operation
Maintenance
Frequency of vehicle maintenance
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 plugs
Replacing the air filter
Replacing the fuel filter
Replacing the engine crankcase ventilation valve
Checking the fluid in the air conditioning system
Checking the gearbox oil level
Checking the oil level in the rear axle
Checking the condition of the drive shaft protective cover
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
Checking the condition of the suspension
Checking the Power Steering Fluid Level
Cleaning the air conditioner condensate drain
Recommendations for motor oils
Filling tanks and operating fluids
Power unit
Petrol engines OHC
Technical characteristics of OHC engines
Engine adjustment
Repairs that do not require engine removal
Removal and installation the timing belt
Removal the cylinder head
Disassembly and assembly of the cylinder head
Installing the cylinder head
Removal and installation the oil pan
Replacing the front crankshaft seal ring
Replacing the rear crankshaft seal ring
Replacing engine mounts
Removal and installation the engine
Disassembling the engine
Identification of interacting parts
Engine assembly
Replacing pistons
Removal and installation the intermediate shaft
Gas distribution system
Starting the engine after major repairs
OHC engine lubrication system
Crankcase ventilation system
Petrol engines DOHC
DOHC Engine Specifications
Repairs that do not require engine removal
Timing chain and sprockets
Cylinder head — design description
Removal the cylinder head
Disassembly and assembly of the cylinder head
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 the rear crankshaft seal ring
Removal the engine
Additional operations for engine removal on vehicles with automatic transmission
Additional operations for removing the engine with gearbox
Engine installation
Disassembling the engine
Cylinders — Checking for wear
Checking and restoring pistons and piston rings
Piston pins and connecting rods
Crankshaft — Checking and Installing
Main and connecting rod bearings
Flywheel — Checking and Installing
Engine assembly
Starting the engine after major repairs
Crankcase ventilation system
Removal and installation the oil pan
Removal and installation the oil pump
Disassembling the oil pump
Petrol engines V6
View of the engine bay of a V6 engine
Technical characteristics of V6 engines
Repairs that do not require engine removal
Removal the engine
Disassembling the engine
Checking the degree of wear of engine parts
Rocker arm axle assembly
Valve tappets and tappet rods
Camshaft — Checking for Wear
Cylinder heads
Cylinders — Checking for wear
Checking and restoring pistons and piston rings
Piston pins and connecting rods — inspection
Crankshaft — Check
Main and connecting rod bearings
Timing gears — check
Flywheel — Checking and Installing
Lubrication system — general information
Oil pump — removal and installation
Crankcase ventilation system
Engine assembly — general information
Installing the crankshaft
Installing the camshaft
Installing pistons and connecting rods
Installing an oil pump
Installing the flywheel
Installing the timing gear and cover
Installing the oil pan, water pump and crankshaft pulley
Removal and installation the oil heat exchanger
Cylinder heads, rocker shafts and intake manifold
Adjusting valve clearances
Engine Auxiliary Parts
Engine installation
Removal the 2.4 and 2.9 liter engine
Cylinder heads for 2.4 and 2.9 liter engines
Replacing the timing chain 2.4 and 2.9 liters
Adjusting the valve clearance of the 2.4 and 2.9 liter engine
Oil pump for 2.4 and 2.9 liter engines
Ignition and control
Ignition and engine management systems — general information
Technical characteristics of the ignition system
Ignition system ESC II — design description
Ignition system EEC IV — design description
Ignition distributor
Checking the ignition timing angle
Ignition unit (models with fuel injection system)
Ignition coil
Fuel trap on engines with carburetor
Engine control unit
Carburetor stepper motor
Device for heating the intake manifold of engines with a carburetor
Engine Management System Relay
Setting the ignition timing and idle speed
Crankshaft speed and position sensor
Air temperature sensor
Fuel temperature sensor
Vehicle speed sensor
Manifold Absolute Pressure (MAP) Sensor
Diesel engines
Diesel engines — general information
Technical characteristics of diesel engines
Repairs that do not require engine removal
Checking and adjusting valve clearances
Fuel system — design description
Injectors — removal, inspection and installation
Glow Plugs — Checking
Checking the compression in the cylinders
Removal air from the fuel system
Removal and installation the fuel pump
Checking and adjusting idle speed
Idle Speed Increase Cable — Removal and Installation
Removal the cylinder head
Installing the cylinder head
Checking and repairing the cylinder head
Removal and installation the engine
Disassembling the engine
Engine assembly — general information
Installing the rear main bearing
Installing side seals
Assembling the piston-connecting rod unit
Selection of pistons by cylinder diameter
Assembly of the timing drive
Further steps for engine assembly
Turbocharger — removal and installation
Oil pump — removal and installation
Checking oil pressure
Draining the cooling system
Filling the system and removing air
Cooling system fan
Removal and installation the fan clutch
Removal and installation the thermostat
Typical engine faults
Cooling system
Technical characteristics of the cooling system
Draining the coolant
Flushing the cooling system
Filling the cooling system
Removal and installation the radiator
Removal and installation the thermostat
Removal and installation a fan with a hydraulic clutch
Removal and installation an electric fan
Coolant pump — removal and installation
Coolant temperature sensor
DOHC Engine Drive Belt
Drive belt tensioning mechanism
Supply system
General information about the fuel system
Fuel system specifications
Fuel used for the car
Unleaded petrol for V6 engines, 2.4 and 2.9 litres
Removal and installation 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 the fuel tank
Removal and installation the fuel level sensor
Removal and installation the inertial fuel supply switch
Removal and installation the accelerator pedal
Removal and installation the accelerator cable
Fuel steam separator
Removal and installation the intake manifold
Carburetors
Pierburg carburetor — design description
Adjusting the idle speed and mixture quality (Pierburg)
Adjusting the throttle damper of the first chamber (Pierburg)
Adjusting the starting clearance of the air damper (Pierburg)
Removal and installation a Pierburg carburetor
Disassembling the Pierburg carburetor
Assembling a Pierburg carburetor
Fast Idle Adjustment (Pierburg)
Changes to the Pierburg 2V carburetor from September 1986
Weber 2V Carburetor — Design Description
Adjusting idle speed and mixture quality (Weber 2V)
Removal and installation the Weber 2V carburetor
Assembly and adjustment of the Weber 2V carburetor
Adjusting the air damper clearance (Weber 2V)
Adjusting the intermediate stage clearance (Weber 2V)
WEBER 2V TLD Carburetor — Design Description
Removal and installation the Weber 2V TLD carburetor
Adjusting idle speed and mixture quality (Weber 2V TLD)
Float chamber needle valve (Weber 2V TLD)
Secondary Throttle Valve Vacuum Drive (Weber 2V TLD)
Replacing the economizer valve diaphragm (Weber 2V TLD)
Automatic starting device (Weber 2V TLD)
Fast Idle Speed Adjustment (Weber 2V TLD)
Removal and installation the throttle damper (Weber 2V TLD)
Weber 2V TLD Carburetor Adjustment
Fuel injection
Fuel injection system — design description
Adjusting idle speed and mixture quality
Removal and installation the throttle position sensor
Removal and installation the idle speed control valve
Removal and installation air flow meters
Removal and installation fuel injectors
Removal and installation the fuel line temperature sensor
Removal and installation the fuel pressure regulator
Removal and installation the throttle body on a DOHC engine
Removal and installation the oxygen sensor (HEGO)
Removal and installation the carbon adsorber
Removal and installation the carbon adsorber electromagnetic valve
Transmission
Clutch
Clutch specifications
Removal the clutch
Checking the clutch
Clutch installation
Replacing the clutch shaft needle bearing
Replacing the clutch cable
Clutch pedal mechanism
Replacing the clutch pedal
Removal and installation the release bearing
Adjusting the free play
Manual gearbox «N»
Technical characteristics of the mechanical gearbox type «N»
Description of the design of the mechanical transmission type «N»
Removal and installation the gearbox
Gearbox gears and shafts — design description
Disassembling a manual gearbox
Assembly of a manual gearbox
Gear shift mechanism — design description
Disassembling the secondary shaft of the gearbox
Assembly of the secondary shaft of the gearbox
Disassembly and assembly of the intermediate shaft gear block
Manual gearbox «MT 75»
Technical characteristics of the mechanical gearbox type «MT 75»
Description of the design of the mechanical transmission type «MT 75»
Removal the gearbox
Gearbox installation
Gearbox housing — design description
Gear shift mechanism — design description
Disassembling the gearbox
Gearbox gears and shafts — design description
Replacing bearings in the gearbox
Checking the reverse gear pinion shaft
Primary and secondary shafts — disassembly and assembly
Gearbox assembly
Automatic gearbox «A4LD»
Automatic transmission specifications
Description of the operation of an automatic transmission
Checking the gearbox oil level
Checking and flushing the hydrokinetic gearbox
Checking oil pressure while the gearbox is running
Hydrokinetic transmission engine overload test
Adjusting the front planetary gear brake band
Removal and installation the vacuum regulator
Rear planetary gear hydraulic booster
Centrifugal oil pressure regulator
Replacing the rear sealing ring
Removal and installation the gear selection mechanism
Removal and installation the gear selector rod
Adjusting the Kick-down Mechanism Cable
Kick-down cable adjustment (with electromagnetic valve)
Removal and installation the gearbox
Automatic transmission faults
Rear axle and drive shafts
Technical characteristics of the cardan and drive shafts
Removal and installation the propeller shaft
Repair of intermediate bearing of cardan shaft
Removal and installation the rear axle
Disassembly and assembly of the rear axle
Disassembling the rear axle differential
Rear axle differential assembly
Adjusting the main gear bearings
Adjusting the main gear
Assembly and adjustment of the main gear
Replacing the final drive gear seal ring
Removal and installation drive shafts
Disassembly and assembly of drive shafts
Chassis
Steering
Technical characteristics of the steering system
Removal and installation the steering gear
Disassembly and assembly of the steering gear
Removal and installation the steering wheel
Steering wheel centering
Removal and installation the steering column lock
Removal and installation the steering column
Disassembly and assembly of the steering shaft
Power steering
Technical characteristics of the power steering
Removal and installation the steering gear
Disassembly and assembly of the CAM GEAR steering gear
Disassembly and assembly of the ZF steering gear
Removal and installation the steering column
Disassembly and assembly of the steering column
Removal and installation the power steering pump
Disassembly and assembly of the power steering pump
Replacing and adjusting the tension of the drive belt
Replacing the steering gear protective covers
Bleeding the Power Steering System
Front suspension
Front suspension specifications
Description of the front suspension design
Front suspension beam — removal and installation
Removal and installation the front suspension strut
Disassembly and assembly of suspension strut
Removal and installation the stabilizer
Replacing the metal-rubber bushing of the lever
Removal and installation the steering knuckle
Checking the installation of the front wheels
Replacing wheel hub bearings
Designation of tires and wheel rims
Rear suspension
Rear suspension specifications
Description of the rear suspension design
Replacing the rear shock absorber
Replacing the suspension spring
Removal and installation the suspension arm
Replacing the metal-rubber bushing of the rear axle beam
Removal and installation the stabilizer
Replacing wheel hub bearings
Ground clearance adjustment system
Removal and installation the compressor
Replacing the height sensor
Brake system
Technical characteristics of the brake system
Replacing the front brake pads
Replacing the front caliper
Replacing the front brake disc
Description of the rear brake design
Replacing rear brake pads
Removal and installation the rear caliper
Replacing the rear brake disc
Adjusting the handbrake
Bleeding the brake system
Description of the design of the anti-lock braking system
Checking the operation of ABS
Removal and installation of the ABS hydraulic control unit
Removal and installation the brake pedal
Removal and installation the ABS hydraulic unit accumulator
Removal and installation of the pump and motor of the ABS hydraulic unit
Replacing the front wheel speed sensor
Replacing the rear wheel speed sensor
Body
Exterior
Car body wash and care
Removal and installation the hood
Removal and installation the hood cable
Removal and installation the hood insulation panel
Removal and installation the radiator grille
Removal and installation the fuel filler neck lock cylinder
Removal and installation the hatch cover
Removal and installation of windshield and fixed glass
Removal and installation decorative windshield trims
Removal and installation decorative trims on the rear door glass
Removal and installation of emblems
Adjusting the front bumper installation height
Removal and installation bumpers
Removal and installation bumper pads
Removal and installation the front spoiler
Interior
Removal and installation the headlining
Removal and installation the interior rearview mirror
Removal and installation the instrument panel
Removal and installation the center console
Removal and installation the upper console
Removal and installation the rear shelf (Salon models)
Removal and installation the front seat
Removal and installation front seat belts
Removal and installation rear seat belts
Removal and installation the rear seat
Doors, locks and windows
Removal and installation doors
Adjusting the door position
Removal and installation the interior door trim panel
Removal and installation exterior door handles
Removal and installation the door lock cylinder
Removal and installation the door lock
Removal and installation the door seal
Removal and installation door glass
Removal and installation the window lift mechanism
Removal and installation decorative side door trims
Removal and installation decorative trims on door glass frames
Removal and installation exterior rearview mirrors
Removal and installation the rear door
Removal and installation the trunk door lock cylinder
Removal and installation the rear door lock
Removal and installation the gas-filled tailgate strut
Removal, installing and adjusting the trunk lid (Salon models)
Removal and installation the trunk lid lock (Salon models)
Heating and ventilation
Heating and ventilation system — general information
Removal and installation the heater control unit
Removal and installation heater control cables
Removal and installation the heater
Disassembly and assembly of the heater
Removal and installation of heater air ducts
Air Conditioner — General Information
Air Conditioner Maintenance
Compressor drive belt
Condenser Fan — Removal and Installation
Thermostat — removal and installation
Heater water valve
Electrical equipment
Equipment and devices
Technical characteristics of on-board electrical equipment
Fuses and relays
Electronic control units
Central locking system
Direction indicator system
Fuel computer
Additional control system — general information
Main faults of the starter
Rear window wiper
Replacement and adjustment of windshield washer nozzles
Removal and installation the instrument cluster
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 the radio
Removal and installation speakers
Anti-theft alarm system
Power devices
Generator — Safety precautions and testing
Removal and installation the generator
Disassembly and assembly of the generator
Replacing the generator brushes and voltage regulator
Main generator faults
Adjusting the V-belt tension
Removal and installation the starter
Disassembling and assembling the starter
Electrical circuits
Electrical power supply circuit diagram
Electrical circuit diagram for charging and starting the engine
Electrical circuit diagram for charging and starting the engine (all engines)
Electrical circuit diagram of the engine management system 1.8L
2.0L OHC Carb Engine Management System Circuit Diagram
2.0L OHC Fuel Injected Engine Management System Circuit Diagram
2.8L Engine Management System Electrical Circuit Diagram
Outdoor lighting electrical circuit diagram
Circuit diagram of signaling, turning and control systems
Interior lighting electrical circuit diagram
Windscreen wiper and washer drive circuit diagram
Central door locking system circuit diagram
Electrical circuit diagram of the window lift drive
Anti-lock braking system (ABS) circuit diagram
AWS Additional Control System Circuit Diagram
Electrical circuit diagram of the radio receiver connection
Electrical circuit diagram of a diesel engine
Electrical circuit diagram of the sunroof drive
Electrical circuit diagram for switching on the heater fan
Ford Scorpio 2
General information
Car care
Car wash
Care of the paintwork
Anti-corrosion protection of the underbody and hidden internal cavities
Seat Cushion Upholstery Care
Making engine starting easier
Towing a car
Starting the engine by pushing the car (emergency start)
Lifting a car
List of tools for maintenance and repair
Maintenance
Maintenance card
General information about maintenance
Engine and exhaust system
Engine oil change
Visual inspection of oil leaks
Checking the engine oil level
Checking the coolant level
Replacing the coolant
Visual inspection of the cooling system for leaks
Checking the concentration of antifreeze
Checking and adjusting valve clearances
Tightening the intake manifold mounting bolts
Spark plugs, checking connections and distributor cap
Replacing the air filter element
Replacing the fuel filter
Checking and replacing the poly V-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 inspection of gearbox tightness
Manual transmission — checking the oil level
Automatic transmission — checking the oil level
Checking the oil in the main gear of the bridges and in the transfer case
Checking the rubber boots of the cardan shafts
Automatic Transmission — Band Brake Adjustment
Brakes, tires and wheels
Checking the brake fluid level
Checking the thickness of brake pads
Visual inspection of brake lines
Replacing brake fluid
Checking the tire tread pattern
Checking tire inflation pressure
Checking the chamber valve
Steering and front axle
Checking the tie rod end dust caps
Checking ball joints for clearances
Checking the rubber boots of the steering gear
Checking the steering for play
Checking the oil level in the power steering reservoir
Electrical equipment system
Checking the battery
Body and interior equipment
Cleaning of drains for moisture condensate
Lubrication of locks
Visual inspection 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 the lower engine compartment casing
Removal and installation the engine
Removal, installing and adjusting the timing belt
Removal and installation the cylinder head (OHC petrol engine)
Removal and installation the cylinder head (DOHC engine)
Removal and installation cylinder heads (V6 OHV engine)
Removal and installation the camshaft (OHC engine)
Removal and installation valves (OHC engine)
Removal and installation valves (DOHC engine)
Removal and installation valves (V6 OHV engine)
Replacing valve stem seals (petrol engine)
Replacing valve stem seals (diesel engine)
Checking the valve guides
Lapping valves
Checking and adjusting valve clearances
Checking the compression in the cylinders
Removal, installation and tensioning of V-belts and poly V-belts
Engine fault diagnostics
Lubrication system
General information about motor oil
Recommended viscosity grades of motor oils
Engine oil consumption
Circulation of engine oil
Checking oil pressure
Checking the hydraulic switch
Removal and installation the oil pan
Diagnosing oil circulation problems
Cooling system
Coolant circulation
Coolant — Basic Information
Replacing the coolant
Checking the cooling system for leaks
Removal and installation thermostat (OHC engine)
Removal and installation the thermostat (DOHC engine)
Removal and installation the thermostat (V6 engine)
Removal and installation the thermostat (diesel engine)
Checking the Thermostat
Removal and installation the cooling system fan
Removal and installation the coolant pump
Removal and installation the radiator
Diagnostics of cooling system faults
Ignition system
General information about the ignition system
Operation of the ignition system
Safety precautions when working with the ignition system
Checking the distributor cap/high voltage wires
Checking the ignition coil
Removal and installation the ignition distributor
Removal and installation of the ignition system control unit
Checking and adjusting the ignition timing angle
Removal and installation spark plugs
Spark Plug Technique
Ignition system fault diagnostics
Supply system
General information about the power supply system
Safety and cleanliness when working with fuel supply systems
Removal, installing and checking the fuel level sensor
Removal and installation the fuel tank
Removal and installation an electric fuel pump
Removal, installation and testing of mechanical fuel pump
Removal and installation the air filter (cars up to 8/94)
Removal and installation the air filter (cars from 9/94)
Removal and installation the gas rod (cars from 9/94)
Adjusting the gas thrust
Checking, removing and installing the fuel pump relay
Carburetors
General information about the carburetor
Carburetor adjustment
Malfunctions in fuel supply
Carburetor Pierburg 2V — design description
Weber 2V-ISC Carburetor — Design Description
Checking and adjusting idle speed and CO content
Checking and adjusting CO content
Removal and installation the carburetor
Technical characteristics of carburetors
Carburetor fault diagnostics
Injection system (gasoline)
Schematic diagram of the electronic engine control system EEC V
General information about the fuel injection system
Safety rules when working with the injection system
Operation of the gasoline injection system
Injection system sensors
SEFI injection system (engines from 9/94)
Checking the valve injectors
Removal and installation of fuel manifold and valve injectors
Diagnostics of faults of the petrol injection system
Injection system (diesel)
General information about the fuel injection system
How a diesel engine works
General information about turbocharger
Removal air from the fuel system
Checking and adjusting the idle speed
Removal and installation the idle speed increase rod
Removal and installation injectors
Preheating system
Checking the heating system, removing and installing glow plugs
Characteristics of the diesel engine injection system
Diagnostics of faults of the injection system of a diesel engine
Exhaust system
Exhaust system (petrol up to 8/94) — design description
Exhaust system (petrol from 9/94) — design description
Exhaust system (diesel) — design description
Removal and installation of the exhaust system
Checking the exhaust system for leaks
Removal and installation the subsequent muffler
Operation of the catalytic converter
Handling of catalytic converters in vehicles
Transmission
Clutch
Description of the clutch design
Removal, installation and testing of the clutch
Removal and installation the clutch cable
Removal, installing and checking the clutch release bearing
Bleeding the Clutch Hydraulic Drive
Diagnosing Clutch Faults
Car gearbox
General information about the gearbox
Removal the N manual transmission (models before 1988)
Removal the MT-75 manual gearbox
Installation of a manual gearbox
All-wheel drive — design description
Automatic transmission
Chassis
Front suspension
Description of the front suspension design
Removal and installation the shock absorber strut
Removal and installation the swivel support
Shock absorber strut device
Disassembling the shock absorber, removing and installing the shock absorber
Checking the shock absorber
Removal and installation the transverse arm
Removal and installation the stabilizer (models up to 8/94)
Removal and installation the stabilizer (models from 9/94)
Definition of chassis parameters
Rear suspension
General information about the rear suspension
Removal and installation the propeller shaft
Removal and installation the rear shock absorber
Removal and installation the stabilizer
Removal and installation the rear wheel hub
Removal and installation the wheel hub bearing
Removal and installation the rear axle propeller shaft
Disassembling the cardan shaft, replacing the corrugated covers
Steering
Description of the steering design
Safety precautions when handling an airbag
Removal and installation the steering wheel
Adjusting the position of the steering wheel
Removal and installation the tie rod end
Removal and installation the steering gear bellows
Power steering pump (petrol, up to 8/94)
Power steering pump (petrol, since 9/94)
Power steering pump (diesel)
Bleeding the power steering hydraulic system
Brake system
General information about the braking system
Anti-lock braking system (ABS)
Front Disc Brake Caliper
Removal and installation front disc brake pads
Rear Disc Brake Caliper
Removal and installation rear disc brake pads
Checking the thickness and lateral runout of brake discs
Brake shoe guide with front brake caliper
Brake shoe guide with rear brake caliper
Removal and installation the brake disc
Checking the brake booster
Replacing the brake line and hose
Brake fluid — safety precautions
Bleeding air from the hydraulic brake system
Adjusting the handbrake
Removal and installation the handbrake cable
Removal and installation the brake light switch
Technical characteristics of the brake system
Brake fault diagnostics
Wheels and tires
General information about wheels and tires
Tyre and wheel designations
Wheel replacement and balancing
Rules for tire care
Anti-skid chains
Incorrect tire wear
Elimination of vibrations of the steering wheel / front of the car
Diagnosis of tire faults
Body
Exterior
General information about the body of the Scorpio I car
Removal and installation the front bumper (Scorpio I)
Front bumper adjustment (Scorpio I)
Removal and installation the rear bumper (Scorpio I)
Removal and installation the radiator grille (Scorpio I)
Removal and installation the fairing grille (Scorpio I)
Removal and installation decorative trim (Scorpio I)
Removal and installation the bonnet lock rod (Scorpio I)
Removal, installation and adjustment of the hood (Scorpio I)
Removal and installation the outside mirror (Scorpio I)
General information about the Scorpio II car body
Removal and installation the front bumper (Scorpio II)
Removal and installation the rear bumper (Scorpio II)
Removal and installation the radiator grille (Scorpio II)
Removal and installation the fairing grille (Scorpio II)
Removal and installation front wheel arch trim (Scorpio II)
Removal and installation the hood lock rod (Scorpio II)
Removal and installation the outside mirror (Scorpio II)
Interior
Removal and installation the glove box (Scorpio I)
Removal and installation the center console (Scorpio I, up to 1/92)
Removal and installation the center console (Scorpio I, after 1/92)
Removal and installation the front seat (Scorpio I)
Removal and installation the rear seat (Scorpio I)
Seat Belt Tensioner (Scorpio II)
Safety precautions when working with the seat belt tensioner
Removal and installation the front seat (Scorpio II)
Doors, locks and windows
Removal and installation the trunk lid (Scorpio I)
Removal and installation the rear door (Scorpio I)
Removal and installation the rear door lock (Scorpio I)
Removal and installation the door (Scorpio I)
Door adjustment (Scorpio I)
Removal and installation door trim (Scorpio I)
Removal and installation the door lock cylinder (Scorpio I)
Removal and installation the door lock (Scorpio I)
Windscreen (Scorpio I)
Removal and installation window glass (Scorpio I)
Removal and installation the window lift crank mechanism (Scorpio I)
Removal and installation the trunk lid (Scorpio II)
Lock cylinder, trunk lid lock (Scorpio II)
Removal and installation door trim (Scorpio II)
Removal and installation the lock and outer door handle (Scorpio II)
Removal and installation the door lock cylinder (Scorpio II)
Removal and installation window glass (Scorpio II)
Removal and installation the side trim of the luggage compartment (Scorpio II)
Removal and installation the fuel tank filler cap (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 the heater fan switch
Removal and installation the heater fan
Diagnostics of heating system faults
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
Measuring instruments
Measurement technique
Installation of additional components of the electrical equipment system
Troubleshooting electrical equipment
Electronic anti-theft system
Ignition key coding for anti-theft system
Checking the rear window and windshield heating
Replacing fuses
Location of relays and fuses
Instrument cluster — design description
Removal and installation the instrument panel
Removal and installation of devices
Removal and installation the speed sensor
Steering column and hazard warning light switches
Removal and installation a light switch and incandescent lamp
Removal and installation control panel switches
Removal and installation the radio
Entering the radio code
Removal and installation the loudspeaker
Headlights and lighting
General information about the lighting system
Table of lamps
Replacement of incandescent lamps for outdoor lighting (up to 8/94)
Replacing exterior light bulbs (after 8/94)
Replacing interior lighting bulbs
Removal and installation headlights (up to 8/94)
Removal and installation headlights (after 8/94)
Removal and installation the headlight diffuser
Electric motor for headlight beam angle adjustment system
Headlight adjustment
Removal and installation the rear light
Windshield wipers and washers
Replacing the rubber band of the windshield wiper blade
Adjustment, removal and installation of window washer nozzles
Checking the windshield washer pump and headlight lenses
Replacing the windshield washer pump and headlight lenses
Front windshield wiper system
Removal and installation the front wiper linkage system
Removal and installation the front windshield wiper motor
Rear window cleaning system
Removal and installation the rear window wiper motor
Checking and adjusting the angle of the windshield wiper blade
Diagnosing Windscreen Wiper Blade Rubber Band Faults
Power devices
Removal and installation the battery
Instructions for maintenance-free battery
Charging the battery
Checking the battery
Storage of the battery
Spontaneous discharge of the battery
Diagnosis of battery malfunctions
Generator from BOSCH — design description
Safety precautions when working with an alternator
Checking the generator voltage
Removal and installation the generator
Replacing and checking the generator brushes and voltage regulator
Generator fault diagnostics
BOSCH starter — design description
Removal and installation the starter
Starter fault diagnostics
Electrical circuits
Introduction to electrical circuits and letter symbols
Scheme 1. Power supply system of electrical circuits
Scheme 2. Charging and starting system I — all engines
Scheme 3. Charging and starting system II — DOHC engine (injection)
Scheme 4. Engine management system, gasoline injection system
Scheme 5. Outdoor lighting
Scheme 6. Control lamps and signaling devices
Scheme 7. Instrument panel, glove compartment, luggage compartment lighting
Scheme 8. Window glass cleaning and washing system
Ford Sierra
General information
User manual
Introduction to the Operation and Repair Manual
Vehicle identification data
Lifting a car
Towing a car
Instrument cluster and controls
Hood — opening and closing
Starting the engine
Lighting and signaling
Replacing light bulbs
Ventilation and heating of the passenger compartment
Doors — opening and locking
Sunroof and roof rack
Seats and headrests
Rear view mirrors
Seat belt fastening indicator light
Wheel replacement
Maintenance
Engine compartment of a car
Adjusting valve clearances
Checking and replacing oil and oil filter
Coolant — Checking and Replacing
Gasoline Engine Maintenance
Fuel system of diesel engines
Manual transmission
Automatic transmission
Checking the condition of the hinge covers
Checking the power steering pump drive belt
Checking the brake fluid level
Handbrake lever
Electrical equipment
Tires — checking condition and pressure control
Operating fluids
Tires, body size and fuel consumption
Vehicle weights and transmission ratios
Filling volumes and liquids used
Gasoline engines
Engine repair
Technical characteristics of gasoline engines
Tightening torques for threaded connections
Adjusting valve clearances
Description of the design of the gasoline engine ONS
Removal and installation the timing belt
Removal the cylinder head
Disassembly and assembly of the cylinder head
Installing the cylinder head
Removal and installation the engine
Disassembling the engine
Identification of interacting parts
Engine assembly
Replacing pistons
Removal and installation the intermediate shaft — removal and installation
Gas distribution system
Ignition system
Technical characteristics of the ignition system
Ignition system — general information
Hall Effect Pulse Sensor
Ignition Distribution — Design Description
Ignition system switch
Notes on the operation of the ignition system
Setting the ignition timing
Ignition System Fault Identification
Removal and installation the ignition distributor
Fuel system
Fuel system specifications
Ford variable diffuser carburetor
Removal and installation a Ford carburetor
Disassembly, inspection and assembly of the Ford carburetor
Adjusting idle speed and CO content (Ford carburetor)
Adjusting the starting device (Ford carburetor)
Adjusting the throttle cable (Ford carburetor)
Removal and installation the needle shaft (Ford carburetor)
Vacuum Regulator Diaphragm (Ford Carburetor)
Weber 32/36 DGAV Carburetor — Design Description
Removal and installation a Weber carburetor
Adjusting the float position (Weber carburetor)
Adjusting the starting choke (Weber carburetor)
Checking and adjusting the automatic starting device (Weber carburetor)
Adjusting idle speed and CO content (Weber carburetor)
Cooling and lubrication system
Technical characteristics of the lubrication system
Technical characteristics of the cooling system
Engine lubrication system — design description
Checking oil pressure
Replacing the oil filter
Oil pump repair
Draining and filling the cooling system
Removal and installation the radiator
Removal and installation the fan
Coolant pump — removal and installation
Replacing the cooling system thermostat
Powertrain suspension
Exhaust gas exhaust system
Changes 1984-1986
Changes in the design of the car from 1984 to 1986
Main engine parameters
Cylinder Head — Specifications
Engine Block — Specifications
Crank mechanism — specifications
Crankshaft — Specifications
Valve timing system — specifications
Engine mount — removal and installation
Draining and filling the cooling system
Ford carburetor with variable diffuser cross-section
Weber carburetors — design and adjustment
Pierburg carburetor — design and adjustment
Fuel injection system
Ignition system — specifications
Clutch — Description of changes
Four-speed manual transmission
Five-speed manual transmission
Technical characteristics of the automatic transmission Ford A 4 LD
Maintenance and repair of automatic transmission Ford A 4 LD
Changes in the design of the automatic transmission
Drive shaft and rear axle
Power steering system
Front suspension
Rear suspension
Front brake system
Turning on the dim headlights
Generator bracket mounting bolt
Fuses and relays
Changes 1987-1989
Changes in the design of the car from 1987 to 1989.
OHC Engine — Description of Changes
CVH 1.8 liter engine — technical characteristics
CVH 1.8 liter engine adjustment
Ignition system of the CVH 1.8 liter engine
Valve timing system of the CVH 1.8 liter engine
Assembly of the CVH 1.8 liter engine
DOHC Engine Specifications
DOHC engine ignition system
DOHC engine fuel injection system
2.0L DOHC Engine EEC IV System Diagram
Checking and adjusting the EEC IV system of the DOHC engine
DOHC Engine Troubleshooting
Checking the elements of the EEC IV system
DOHC Engine Timing System
DOHC Engine Cylinder Head
Disassembling a DOHC engine
DOHC Engine Assembly
DOHC engine lubrication system
Clutch specifications
N-type five-speed manual transmission
Technical characteristics of the gearbox type MT 75
Removal and installation of gearbox type MT 75
Disassembling the gearbox type MT 75
Checking and repairing parts of the MT 75 type gearbox
Assembly of gearbox type MT 75
Automatic transmission
Front suspension
Technical characteristics of the brake system
Maintenance and repair of the brake system
Adjusting the handbrake
Bleeding the brake system
Anti-lock braking system
Checking the operation of ABS
Hydraulic brake control unit — removal and installation
Wheel speed sensor
Generator and starter — technical characteristics
General data and characteristics of the car
Changes 1990-1993
Changes in the design of the car from 1990 to February 1993.
DOHC Engine Specifications
DOHC Engine Cylinder Head
DOHC Engine Timing System
Engine injection system type N9C
Clutch — Description of changes
Drive shaft and rear axle
Power steering system
Connecting fuses and relays
General data and characteristics of the car
Diesel engines
Engine repair
Technical characteristics of diesel engines
Tightening torques for threaded connections
Checking and adjusting valve clearances
Checking the compression in the cylinders
Cylinder head — design description
Removal and installation the cylinder head
Checking and repairing the cylinder head
Removal and installation the engine
Disassembly, repair and assembly of the engine
Installing the rear main bearing
Assembling the piston-connecting rod unit
Assembly of the timing drive
Further assembly of the engine
Fuel system
Fuel system specifications
Fuel system — general information
Rotary high pressure fuel pump
Injectors — removal, inspection and installation
Checking the tightness of the nozzle sprayer
Adjusting the initial injection pressure
Glow plugs
Removal air from the fuel system
Fuel Filter — Description and Water Removal
Fuel pump, fuel injection start setting
Adjusting the idle speed
Cooling and lubrication system
Technical characteristics of the lubrication system
Oil pump — removal and installation
Checking oil pressure
Engine cooling system — design description
Draining the cooling system
Filling the cooling system and removing air
Removal and installation the fan clutch
Thermostat — removal and installation
Changes 1988-1993
Changes in the design of the car from 1988 to 1993.
Repair of 2.3 liter diesel engine
Technical characteristics of the 1.8 liter engine
Cylinder head of the 1.8 liter engine
1.8 liter engine cylinder block
Crank mechanism of the 1.8 liter engine
1.8 liter engine valve timing system
1.8 liter engine lubrication system
Engine cooling system 1.8 liter
Fuel system of the 1.8 liter engine
Tightening torques for 1.8 liter engine
Engine tuning 1.8 liter
Fuel filter — removal and installation
Removal and installation injectors
Fuel pump — removal and installation
Removal and installation a turbocharger
Removal the cylinder head
Cylinder head repair
Cylinder head, valve timing adjustment
Removal and installation the engine
Disassembling a diesel engine
Checking engine parts
Checking the crankshaft and connecting rod clearances
Assembly of a diesel engine
Diesel engine lubrication system
Diesel engine cooling system
Clutch — Description of changes
Mechanical five-speed gearbox type MT 75
Drive shaft and rear axle
Steering system
Front suspension — checking and adjustment
Brake system — description of changes
Electrical Equipment — Description of Changes
General data and characteristics of the car
Transmission
Clutch
Description of the clutch design
Clutch specifications
Removal and installation the clutch
Replacing the needle bearing
Replacing the clutch cable
Clutch pedal mechanism
Replacing the clutch pedal — removal and installation
Clutch release bearing
Mechanical gearbox
Technical characteristics of the gearbox (4-speed)
Removal and installation of gearbox (4-speed)
Disassembly and assembly of gearbox (4-speed)
Disassembly and assembly of gearbox type A and B (4-speed)
Disassembly and assembly of gearbox type C (4-speed)
Technical characteristics of the gearbox (5-speed)
Removal and installation of gearbox (5-speed)
Disassembly and assembly of gearbox (5-speed)
Disassembly and assembly of gear block (5-speed)
Automatic gearbox
Automatic transmission Ford C 3 — design description
Automatic transmission specifications
Automatic transmission maintenance and repair
Checking the gearbox oil level
Checking and cleaning the hydrokinetic transmission
Checking oil pressure while the gearbox is running
Hydrokinetic transmission engine overload test
Checking the box while driving
Adjusting the front planetary gear brake band
Removal and installation the gearbox
Removal and installation the kick-down cable
Removal and installation the engine safety start relay
Box malfunctions and methods of their elimination
Cardan and rear axle
Propeller shaft and rear axle — general information
Technical characteristics of the cardan shaft and rear axle
Removal and installation the propeller shaft
Repair of intermediate bearing
Removal and installation the rear axle
Disassembly and assembly of the rear axle
Disassembling and assembling the differential
Adjusting the main gear bearings
Adjusting the main gear
Assembly and adjustment of the main gear
Replacing the final drive gear seal ring
Removal and installation of drive axle shafts
Disassembly and assembly of drive axle shafts
Chassis
Steering
Description of the steering design
Technical characteristics of the power steering
Removal and installation the steering gear
Disassembly and assembly of the steering gear
Removal and installation the steering column
Disassembling and assembling the steering wheel
Steering with power steering
Power steering — design description
Technical characteristics of the power steering
Removal and installation the steering gear
Removal and installation the hydraulic pump
Disassembly and assembly of the CAM GEAR steering gear
Disassembly and assembly of the ZF steering gear
Removal and installation the steering column
Disassembling and assembling the steering wheel
Bleeding the steering system
Front suspension
Front suspension specifications
Removal and installation the front suspension strut
Disassembly and assembly of suspension strut
Removal and installation the stabilizer
Replacing the metal-rubber bushing of the lever
Removal and installation the steering knuckle
Checking the installation of the front wheels
Replacing the front wheel hub bearings
Rear suspension
Rear suspension specifications
Replacing the rear shock absorber
Replacing the suspension spring — removal and installation
Removal and installation the suspension arm
Replacing the metal-rubber bushing of the suspension beam
Replacing the rear wheel hub bearings
Brake system
Technical characteristics of the brake system
Replacing the front brake pads
Replacing the front caliper
Replacing the front brake disc
Front Caliper Repair
Removal and installation the brake drum
Replacing rear brake pads
Replacing the rear brake cylinder
Removal and installation the master brake cylinder
Bleeding the brake system
Adjusting the handbrake
Body and electrical
Body elements and doors
Car body wash and treatment
Elements of the bonnet and front part of the body
Hood cable — removal and installation
Hood adjustments
Interior door trim — removal and installation
Adjusting the door lock closing
Interior Door Handle — Removal and Installation
Door Lock Cylinder — Removal and Installation
Door lock — removal and installation
Front seat — removal and installation
Electrical equipment
Technical characteristics of on-board electrical equipment
Relays and fuses
Removal and installation the generator
Disassembly and assembly of the generator
Adjusting the V-belt tension
Starter — design description
Windscreen wiper, indicator assembly and headlights
Removal and installation the instrument cluster
Headlight adjustment
Heating and ventilation system — removal and installation
Fan Motor — Removal and Installation
Electrical circuits
Electrical power supply circuit diagram
Electrical circuit diagram of the charging and starter
Electrical circuit diagram of a diesel engine
Outdoor lighting electrical circuit diagram
Fog Light Electrical Circuit Diagram
Instrument cluster electrical circuit diagram
Interior Lighting Electrical Circuit Diagram
Electrical circuit diagram of heating, ventilation, windshield wipers
Central door locking electrical circuit diagram
Electrical circuit diagram for side door glass control
Ford Transit 2
General information
User manual
About this guide
About the Ford Transit (diesel)
Introduction to the Car Manual
Breaking in a new car
Low dashboard
High dashboard
Instrument panel (option 1)
Instrument panel (option 2)
High instrument panel (option 1)
Instrument panel (option 3)
Instrument panel (option 4)
Control levers
Heating and ventilation
Interior equipment
Starting the engine
Brakes — abs
Automatic transmission
Towing a trailer
Care and maintenance
Opening the hood
Car windshield washer
What to do in an emergency — towing
Fuel filter water settling sensor (diesel only)
Fuel system (diesel)
Fuel injection system fuse switch
Reconnecting the fuse
Engines with a control unit (2.0 l, 2.5 l turbodiesel)
Batteries — general information
Jump starting using another car's battery
Changing a wheel
Spare wheel
Installing the jack
Removal the wheel
Wheel installation
Storing a spare tire
Replacing lamps
Fuses and relays
Fuel consumption
Dimensions of the car
Fuel, oils, liquids
Jacking, towing and wheel changing
Radio blocking system in case of theft
Maintenance
Maintenance and care — specifications
Lubricants, liquids and containers
Purchasing spare parts and identification numbers
Ford Transit Diesel Service Schedule
Maintenance and Care — introduction
Checking fluid levels (daily/monthly)
Check tire treads and pressure (daily)
Checking the power steering fluid level (monthly)
Inspection of windshield and rear window wipers/washers (daily/monthly)
Electrical system check (every 10,000 km or 6 months)
Checking, servicing and charging the battery (every 10,000 km or 6 months)
Seat belt inspection (every 10,000 km or 6 months)
Inspection and replacement of drive belts (every 10,000 km or 6 months)
Inspection and replacement of hoses in the engine compartment (every 10,000 km or 6 months)
Changing engine oil and oil filter (every 10,000 km or 6 months)
Checking and cleaning the oil filler cap (every 10,000 km or 6 months)
Draining sediment from the fuel filter (every 10,000 km or 6 months)
Check steering, suspension and wheels (every 10,000 km or 6 months)
Brake check (every 10,000 km or 6 months)
Checking the engine compartment wiring (every 20,000 km or 12 months)
Checking the air conditioning system (monthly/every 20,000 km or 12 months)
Check and lubricate the hood and doors (every 20,000 km or 12 months)
Kingpin and steering bush lubrication — models with independent front suspension (every 20,000 km or 12 months)
Checking the oil level in a manual transmission (every 20,000 km or 12 months)
Clutch cable lubrication (every 20,000 km or 12 months)
Lubrication of the sliding joint of the overdrive transmission and the propeller shaft (every 20,000 km or 12 months)
Lubrication of automatic transmission rods and levers (every 20,000 km or 12 months)
Lubrication and adjustment of parking brake rods and levers (every 20,000 km or 12 months)
Checking the universal joint and intermediate bearing of the propeller shaft (every 20,000 km or 12 months)
Inspection of the condition of the underbody and fuel and brake system pipelines (every 20,000 km or 12 months)
Exhaust system inspection (every 20,000 km or 12 months)
Checking the rear axle oil level (every 20,000 km or 12 months)
Checking and adjusting the rear brake pressure regulator (every 20,000 km or 12 months)
Checking the tightening torque of wheel nuts (every 20,000 km or 12 months)
Trial tests after service or repair (every 20,000 km or 12 months)
Checking the automatic transmission fluid level (every 20,000 km or 12 months)
Checking and adjusting normal idle speed and idle reduction mode (every 20,000 km or 12 months)
Replacing the air filter element (every 40,000 km or 2 years)
Fuel filter replacement (every 40,000 km or 2 years)
Technical data
Special tools and devices
Troubleshooting
Troubleshooting — general information
Engine fault diagnostics
Cooling system
Fuel system and exhaust system
Diagnosing clutch faults
Manual transmission
Automatic transmission
Cardan shaft
Rear axle
Brake system
Suspension and steering
Electrical system
Power unit
Engine in the car
Engine Repair Specifications
General information about engine repair
Repair operations that can be performed without removing the engine from the vehicle
Compression test and leak test
Setting piston No. 1 to top dead center (TDC)
Cylinder head valve cover — removal and installation
Timing Belt Cover — removal and installation
Timing Belt — removal, inspection, installation and tensioning
Timing Belt Pulleys and Timing Belt Tensioner — removal and installation
Valve clearances — checking and adjusting
Valve train drive — removal, inspection, installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Oil pump — disassembly, inspection and assembly
Crankshaft seals — replacement with new ones
Flywheel — removal, inspection and installation
Engine Mounts — inspection and replacement
Engine overhaul
Removal and overhaul — specifications
Removal and overhaul — general information
Engine overhaul — general information
Engine Removal — methods and precautions
Engine (non-turbocharged) — removal and installation
Engine (turbocharged) — removal and installation
Engine (non-turbocharged) with gearbox — removal and installation
Engine (turbocharged) and gearbox — removal and installation
Engine overhaul — disassembly procedure
Cylinder head — disassembly
Cylinder head and valve train components — cleaning and inspection
Cylinder head assembly
Cylinder head — inspection, installation
Connecting rod and piston group — removal
Crankshaft — removal
Cylinder block and crankcase — cleaning and inspection
Connecting rod and piston group — inspection
Crankshaft — inspection
Main and connecting rod bearings — inspection
Engine Overhaul — assembly sequence
Piston rings — installation
Crankshaft — shaft installation and main bearing clearance check
Connecting rod and piston group — installation and checking of the working clearance in the connecting rod lower head bearings
Engine — test run after major overhaul
Cooling and heating
Ventilation, Heating and Cooling Systems — technical data
General information and precautions
Coolant system hoses — disconnecting and replacing
Cooling system expansion tank — removal and installation
Radiator — removal, inspection and installation
Cooling fan clutch — removal and installation
Coolant Temperature Sensor — removal, inspection, and installation
Thermostat — removal, checking, and installation
Water pump — removal and installation
Heating and ventilation systems — general information
Heating and Ventilation Components — removal and installation
Heating and ventilation system deflectors — removal and installation
Air Conditioning System — general information and precautions
Fuel and exhaust system
Emission Control System — technical data
General information and precautions
Fuel system — filling with fuel and bleeding air
Air filter — removal and installation
Maximum engine speed — checking and adjustment
Thermostatic idle speed sensor — removal, installation and adjustment
Solenoid valve — description, removal and installation
High-pressure fuel pump — removal and installation
Fuel injection advance — testing methods and adjustment methods
Fuel injection advance — checking and adjustment
Fuel injectors — inspection, removal and installation
Fuel injector delivery pipes — removal and installation
Fuel filter — removal and installation
Accelerator cable — removal, installation and adjustment
Accelerator pedal — removal and installation
Fuel level sensor — removal and installation
Fuel tank — removal, maintenance and installation
Fuel pump — removal and installation
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Turbocharging — description and precautions
Turbocharging — removal and installation
Turbocharging — inspection and repair
Exhaust system — basic information and replacement of components
Exhaust emission control systems — general information
Emission Control Systems — checking and replacing parts
Lucas Epic Electronic Fuel Injection System — description and precautions
Lucas Epic System Sensors — general information, inspection, removal, and installation
Intercooling — basic information, removal and installation
Engine electrical equipment
Engine electrical equipment — technical requirements
Engine Electrical Systems — general information and precautions
Battery — removal and installation
Charging system — testing
Alternator — removal and installation
Alternator Brushes and Regulator — inspection and replacement
Launch system — testing
Starter — removal and installation
Starter — replacing brushes
Low oil pressure sensor — removal and installation
Engine preheating system — description and testing
Glow Plug — removal and installation
Transmission
Clutch
Clutch — technical data
Clutch — general information
Clutch cable — removal and installation
Clutch pedal — removal and installation
Clutch — removal, inspection and installation
Clutch release mechanism — removal, inspection and installation
Clutch cable — adjustment
Automatic clutch system components — removal and installation
Manual gearbox
Manual transmission — technical data
Manual transmission — general information
Gearbox control lever — removal and installation
Oil seals — replacement
Reverse Light Switch — removal and installation
Speedometer Drive Gear — removal and installation
Manual transmission mounts — inspection and replacement
Manual transmission — removal and installation
Manual Transmission Overhaul — general information
Overdrive — general information
Overdrive Switch — removal and installation
Overdrive Lock Switch — removal and installation
Overdrive Solenoid Valve — removal and installation
Overdrive gear — removal and installation
Automatic gearbox
Automatic transmission — technical data
Automatic transmission — general information
Brake bands — adjustment
Downshift cable (kick-down) — regulation
Downshift Cable — removal and installation
Gear Shift Lever Cable — removal, installation and adjustment
Gear shift mechanism — removal and installation
Locking switch — removal, installation and adjustment
Oil seals — replacement
Vacuum diaphragm — removal and installation
Servomechanism — removal and installation
Vacuum regulator — testing and adjustment
Vacuum regulator — removal and installation
Speedometer Drive Pinion — removal and installation
Automatic transmission — removal and installation
Automatic transmission overhaul — general information
Cardan and rear axle
Cardan shaft and rear axle — technical data
Driveshaft and rear axle — general information
Cardan shaft — description
Cardan shaft (two links) — removal and installation
Cardan shaft (three-section type) — removal and installation
Replacement of the center support bearing of the propeller shaft
Elastic quibo type hinge — removal and installation
Rear Axle — description
Rear axle — removal and installation
Rear axle half shafts — removal and installation
Rear Hub and Bearing (H-Type Axle) — removal, disassembly and installation
Rear Hub and Bearing (G-Type Axle) — removal, disassembly and installation
Pinion Oil Seals (All Axle Types) — renewal
Differential housing (type «H») — removal and installation
Differential (G-type axle) — overhaul
Chassis
Brake system
Brake system — basic information
Technical data — general information
Hydraulic system — air removal
Hydraulic tubes and hoses — inspection, removal and installation
Front disc brakes — replacement
Front Brake Caliper — removal and installation
Front brake caliper — disassembly
Front Brake Disc — inspection, removal and installation
Drum brake shoes — replacement
Rear wheel brake cylinder — removal, disassembly and installation
Master cylinder — removal and installation
Master cylinder — disassembly
Vacuum booster — inspection, removal and installation
Vacuum pump — removal and installation
Parking brake adjustment
Parking brake lever and drive rod — removal and installation
Parking brake cable — removal and installation
Brake pressure regulating valve — description, removal and installation
Rear Axle Load-Sensing Valve (LAV) — general information
Brake pedal — removal and installation
Anti-lock Braking System (ABS) — basic information
Anti-lock braking system components — removal and installation
Steering system
Front Steering and Suspension Specifications
Front Wheel Steering and Suspension — general information
Steering wheel — removal and installation
Steering column — removal and installation
Steering column — removal, inspection and assembly
Rack and Pinion Steering Gear — removal, disassembly and installation
Tie Rod End Ball Joint — removal and installation
Replacement of protective rubber steering gear boots
Screw-and-nut steering gear — removal, disassembly and installation
Steering gear of the screw-and-nut type — adjustment of the steering arm shaft preload
Steering knuckle of the steering gear of the «screw-nut» type — removal and installation
Steering gear longitudinal tie rod of the «screw-nut» type — removal and installation
Power steering pump — removal and installation
Power steering — removal and installation
Power Steering Tubes and Hoses — removal and installation
Power Steering — bleeding
Wheel installation — general information
Front suspension
Front Wheel Hub (IFS Models) — removal, installation and adjustment
Front Hub Bearings (IFS Models) — replacement
Front steering knuckle (IFS models) — removal and installation
Independent front suspension coil spring — removal and installation
Lower (transverse) arm of independent front suspension — removal and installation
Front Lower Control Arm Bushing (IFS Models) — replacement
Front Lower Control Arm Bracket Bushing (IFS Models) — replacement
Front Lower Arm Ball Joint (IFS Models) — removal and installation
Front Anti-Roll Bar (IFS Models) — removal and installation
Front Shock Absorber (IFS) — removal and installation
Front wheel hub (dependent front suspension) — removal, installation and adjustment
Steering knuckle (dependent front suspension) — removal and installation
Front axle beam (dependent front suspension) — removal and installation
Front dependent suspension leaf spring — removal and installation
Front suspension travel limiting buffer (front dependent suspension) — removal and installation
Front anti-roll bar (front dependent suspension) — removal and installation
Front shock absorber (front dependent suspension) — removal and installation
Rear axle leaf spring — removal and installation
Rear shock absorber — removal and installation
Body
Exterior
Body — technical data
Body — general information
Body and subframe
Carpet and Upholstery Care
Minor body damage — repair
Serious body damage — repair
Hood — removal, installation and adjustment
Hood Lock and Cable Replacement
Hood safety latch — removal and installation
Exterior mirrors and related parts — removal and installation
Front bumper — removal and installation
Rear bumper — removal and installation
Radiator grille — removal and installation
Windshield Grille — removal and installation
Interior
Instrument panel — removal and installation
Interior body trim — removal and installation
Headlining — removal and installation
Seats — removal and installation
Seat belts — removal and installation
Doors, locks and windows
Interior door trim — removal and installation
Front Door Parts — removal and installation
Front door — removal, installation, adjustment
Sliding Side Door Parts — removal and installation
Sliding side door — removal, installation and adjustment
Rear Door Parts — removal and installation
Rear doors — removal, installation and adjustment
Tailgate Parts — removal and installation
Tailgate — removal and installation
Front door window regulator and glass — removal and installation
Front door fixed glass — removal and installation
Sliding glass and frame — removal and installation
Sliding glass and frame — disassembly and assembly
Rear opening window — removal and installation
Windshield and fixed glass — removal and installation
Electrical equipment
Equipment and devices
Vehicle electrical equipment — technical data
General information and precautions
Electrical Circuit Troubleshooting — general information
Fuses and relays — general information
Switches — removal and installation
Instrument cluster (models without tachograph) — removal and installation
Instrument cluster instruments and bulbs (models without a tachograph) — removal and installation
Tachograph — removal and installation
Fuel and temperature gauge (models with tachograph) — removal and installation
Control lamp unit (models with tachograph) — removal and installation
Speedometer Cable — removal and installation
Cigarette lighter — removal and installation
Watch — removal and installation
Checking and adjusting low beam headlights
Exterior Light Bulbs and Parking Lights — replacement
Light bulbs (interior lighting) — replacement
External lighting fixtures — removal, installation
Horn — removal and installation
Windshield wiper arms — removal and installation
Windshield wiper motor and drive mechanism — removal and installation
Windshield wiper arm pivot shaft housing — removal and installation
Headlight and windshield washer reservoir — removal and installation
Rear Door Wiper Elements — removal and installation
Radio and car stereo — removal and installation
CD player — removal and installation
Radio antenna — removal and installation
Power amplifier — removal and installation
Speakers — removal and installation
Airbags — removal and installation
Airbag control unit — removal and installation
Passive anti-theft system — general information and replacement of components
Possible malfunctions of automotive electronics
Electrical circuits
Schematic 1. Information on the use of electrical diagrams for models before 1992
Scheme 2. Starting, charging, cold start, overdrive and headlight systems — models before 1992
Scheme 3. Tachograph and instrument cluster — models manufactured before 1992
Scheme 4. External lighting devices — models manufactured before 1992
Scheme 5. Interior lighting, windshield wipers and washers — models before 1992
Scheme 6. Horn, heater fan, cigarette lighter, radio, and rear window defroster — pre-1992 models
Schematic 7. Information on the use of electrical diagrams for 1992-1995 models
Scheme 8. Starting, charging, cold start and manifold heating systems for 1992-1995 models
Heated manifold, downshift mechanism, tachograph and instrument cluster (1992-1995 models)
Engine Management System and Anti-Lock Braking System (ABS) (1992-1995 models)
Exterior Lighting (1992-1995 Models)
Scheme 15. Washers and wipers — models manufactured in 1992-1995
Scheme 16. Rear window defroster, headlight washers, windshield defroster, cigarette lighter — 1992-1995 models
Scheme 17. Downshift control («kick-down»), heater fan and radio receiver-models 1992-1995
Scheme 18. Information on the use of electrical circuits for models manufactured since 1995
Scheme 19. Starting and charging system — models since 1995
Scheme 20. Cold start, fuel shut-off valve and manifold heater — models from 1995.
Scheme 21. Turbocharged diesel engine control system — models from 1995.
Scheme 22. Diagnostic connector, anti-lock braking system (ABS) and traction control system (TCS) (models from 1995).
Scheme 23. Automatic clutch and automatic transmission — models from 1995
Scheme 24. Side and tail lights, brake lights, reversing lights and license plate lights — models from 1995
Scheme 25. Headlights — models manufactured since 1995
Scheme 26. Indicator lamps for fog lights and headlights, direction indicators and hazard warning lights — models from 1995
Scheme 27. Indicator lamps and direction indicators — models from 1995
Scheme 28. Windscreen wipers, washers and horn — models from 1995
Scheme 29. Cigarette lighter, clock and interior lighting — models from 1995
Scheme 30. Windshield defrosters and heater fan — models from 1995
Scheme 31. Central locking system and electric windows — models from 1995
Scheme 32. Power mirrors, audio system and airbags — models from 1995
Focus 2 (2004-2010)
Focus Turnier 1 (1998-2004)
Focus 1 (1998-2004)
Mondeo 4 (2007-2014)
Mondeo 3 (2000-2007)
Mondeo 2 (1997-2000)
Mondeo 1 and 2 (1993-2000)
Mondeo 1 (1993-1996)
Escort 5 (1990-1997)
Escort 4 (1986-1990)
Escort 3 (1980-1985)
Fiesta 4 (1996-1999)
Fiesta 2 (1983-1989)
Taurus 1 and 2 (1986-1994)
Sierra (1982-1993)
Scorpio 2 (1994-1998)
Scorpio 1 (1985-1994)
Fusion (2002-2012)
Transit 2 (1986-2000)
Focus Turnier 1 (1998-2004)
Focus 1 (1998-2004)
Mondeo 4 (2007-2014)
Mondeo 3 (2000-2007)
Mondeo 2 (1997-2000)
Mondeo 1 and 2 (1993-2000)
Mondeo 1 (1993-1996)
Escort 5 (1990-1997)
Escort 4 (1986-1990)
Escort 3 (1980-1985)
Fiesta 4 (1996-1999)
Fiesta 2 (1983-1989)
Taurus 1 and 2 (1986-1994)
Sierra (1982-1993)
Scorpio 2 (1994-1998)
Scorpio 1 (1985-1994)
Fusion (2002-2012)
Transit 2 (1986-2000)