Professional Documents
Culture Documents
FORD Focus
E223796
P346 R010 01
CGAPA/S en
To the best of our knowledge, the illustrations, technical information, data and descriptions in this issue were correct at the time
of going to print. The right to change prices, specifications, equipment and maintenance instructions at any time without notice
is reserved as part of FORD policy of continuous development and improvement for the benefit of our customers.
No part of this publication may be reproduced, stored in a data processing system or transmitted in any form, electronic,
mechanical, photocopy, recording, translation or by any other means without prior permission of Ford-Werke GmbH. No liability
can be accepted for any inaccuracies in this publication, although every possible care has been taken to make it as complete and
accurate as possible.
Please remember that our training literature has been prepared for FORD TRAINING PURPOSES only. Repairs and adjustments
MUST always be carried out according to the instructions and specifications in the workshop literature. Please make full use
of the training offered by Ford Technical Training Courses to gain extensive knowledge of both theory and practice.
Copyright 2015
Ford-Werke GmbH
Service training programs D-F/GT1 (GB)
Preface
The 2016 Focus RS is the latest in a line of iconic cars developed by Ford. Experts in small-car engineering, the
Ford Performance Team has consistently pioneered innovative performance technologies.
Featuring the new Ford performance All-Wheel Drive with Dynamic Torque Vectoring, the RS offers the next level
in handling capability.
The RS has taken the 2.3L engine to another level with its unique turbo charger, cooling and exhaust. With well in
excess of 257 kW and 440 Nm of torque, with the ability to over boost to an output of 470 Nm of torque.
Configuration of the RS drive options will enable street or on track performance:
Select Normal, Sport, Track, or the special Drift mode control that lets you achieve controlled oversteer drifts under
track conditions
With enhanced aerodynamic redesigns of the front grille and the rear diffuser and the unique spoiler addition, Focus
RS creates zero lift overall for optimum high-speed handling
The high-performance character also comes through with its sleek interior design.
The details are simply impressive with a new flat-bottomed steering wheel that has a soft-feel leather covered rim,
RECARO sport seats, alloy pedals and unique instrument graphics.
Course Objectives
At the conclusion of the course, the technician will be able to identify the unique vehicle features and systems on
the 2016 Focus RS.
Course Outcomes
At the conclusion of this course the Technician will be able to:
Course Materials
In order to participate in this New Model Training course you will require the following material:
Preface
This ISG contains information for the training course and for future reference, however, some of the information
contained in this publication may not be covered in the training. In time, the information contained in this ISG may
also become superseded and therefore inaccurate and/or obsolete. Always refer to the current Workshop Manual
(WSM) and Owner Guide along with the latest Technical Service publications to obtain the most accurate and up
to date information.
Always read the ISG again soon after completing the training course
(G1821216)
Service Training
Table of Contents
PAGE
Preface...............................................................................................................................
Introduction......................................................................................................................
10
10
11
12
...........................................................................................................................................................................................
12
Service Points................................................................................................................................................
13
2.3L EcoBoost...................................................................................................................................................................
13
Transport Mode............................................................................................................................................
13
13
14
...........................................................................................................................................................................................
14
Lesson 2 Chassis
Front Suspension..........................................................................................................................................
16
...........................................................................................................................................................................................
16
Rear Suspension............................................................................................................................................
18
...........................................................................................................................................................................................
19
20
...........................................................................................................................................................................................
20
21
21
Brake System.................................................................................................................................................
22
...........................................................................................................................................................................................
22
Power Steering..............................................................................................................................................
24
Lesson 3 Powertrain
Engine............................................................................................................................................................
Service Training
25
Table of Contents
Powertrain..........................................................................................................................................................................
25
26
Lubrication System...................................................................................................................................................................................
30
Engine Cooling..............................................................................................................................................
34
Radiator.............................................................................................................................................................................
34
35
35
36
Operating Modes...............................................................................................................................................................
36
Throttle Body....................................................................................................................................................................
36
37
37
Fuel Injectors.....................................................................................................................................................................
38
Turbocharger................................................................................................................................................
39
...........................................................................................................................................................................................
39
Twin-Scroll Turbocharger.................................................................................................................................................
40
42
43
Accessory Drive.............................................................................................................................................
44
Engine Ignition..............................................................................................................................................
45
...........................................................................................................................................................................................
45
46
48
48
Clutch.............................................................................................................................................................
48
...........................................................................................................................................................................................
48
Manual Transmission...................................................................................................................................
51
51
52
52
54
55
57
Exhaust System.............................................................................................................................................
61
...........................................................................................................................................................................................
61
Fuel System...................................................................................................................................................
62
62
Service Training
Table of Contents
Lesson 4 Electrical
Instrument Panel Cluster (IPC)..................................................................................................................
67
...........................................................................................................................................................................................
67
Exterior Lighting..........................................................................................................................................
70
...........................................................................................................................................................................................
70
Communications Network...........................................................................................................................
75
...........................................................................................................................................................................................
75
78
...........................................................................................................................................................................................
78
Instrument Panel..........................................................................................................................................
79
...........................................................................................................................................................................................
79
80
...........................................................................................................................................................................................
80
List of Abbreviations........................................................................................................
81
Service Training
Introduction
Introduction
Exhaust System
Chassis
Electrical
Instrument panel
Dynamic Suspension
Body
Braking - Brembo
Powertrain
Engine
2.3L EcoBoost 257 Kw
Vehicle Exterior
E215866
Trapezoid grille
(G1821216)
Service Training
Introduction
E215868
Rear diffuser
E73698
E133239
Introduction
To close the hood and allow it to drop under its own
weight from the last 20 30 centimetres
E223798
E87786
E129925
(G1821216)
Service Training
Introduction
E224054
E224216
Introduction
Capless Fuel Filler
3
E105362
E119190
1
E125860
10
(G1821216)
Service Training
Introduction
Tire Repair Kit
E134613
11
Towing
E203788
12
(G1821201)
Service Training
Service Points
2.3L EcoBoost
E215066
Coolant reservoir
Oil dipstick
Battery
Transport Mode
Transport Mode Deactivation
After vehicle build, some vehicle modules are set in
Transport mode including the IPC and the BCM.
Transport mode reduces battery drain during longer
periods where the vehicle is not used.
While in transport mode, the IPC displays TRANSPORT
MODE CONTACT DEALER in the message center.
13
E223756
14
(G1822861)
Service Training
15
Front Suspension
Lesson 2 Chassis
Front Suspension
3
5
8
E224055
Front hub
Ball joint
16
(G1821294)
Service Training
Lesson 2 Chassis
Modified springs with firmer spring rate
Electronic front shock absorbers - Two-mode shock
absorbers with normal and a firmer setting for track
driving
Front Suspension
Front Suspension Alignment and Adjustment
Front Toe Adjustment
E67410
17
Rear Suspension
Lesson 2 Chassis
Rear Suspension
4
3
E224060
18
Upper arm
Reinforced areas
Wheel knuckle
Service Training
Lesson 2 Chassis
Rear Suspension
1
3
5
6
E224096
19
Lesson 2 Chassis
E215833
20
(G1821752)
Service Training
Lesson 2 Chassis
3
4
E224181
Service Training
21
Brake System
Lesson 2 Chassis
To select Normal or Sport damping, do the following:
Press the button on the end of the direction indicator
lever
The current setting appears in the information
display (Normal/Sport)
E219514
Brake System
6
7
E224097
Caliper pistons
Brake pad
22
(G1821495)
Service Training
Lesson 2 Chassis
Front Brake Cooling Air Ducts
Brake System
front bumper to the inner wheel well. The inlet to the
air duct is located in the front bumper fascia next to the
front fog lamp.
There is also an air deflector which is used to diverted
additional air to the brake system from under the vehicle.
E223894
E223891
Air duct
Air deflector
23
Power Steering
Lesson 2 Chassis
Power Steering
3
4
2
6
E224217
Torque shaft
EPS module
EPS motor
24
(G1823037)
Service Training
Lesson 3 Powertrain
Engine
Engine
Powertrain
3
E224295
MMT6 transmission
Engine:
AWD System:
Transmission:
25
Engine
Lesson 3 Powertrain
E178752
26
Service Training
Lesson 3 Powertrain
Engine
E221208
2
E224359
Cylinder Head
Turbocharger
Service Training
27
Engine
Lesson 3 Powertrain
5
9
7
E223818
28
Service Training
Lesson 3 Powertrain
Cylinder Head
Engine
Cylinder head made of cast aluminum with integrated
exhaust manifold with 16 valve 4 valves per cylinder.
N0152419
Service Training
29
Engine
Lesson 3 Powertrain
Lubrication System
15
12
11
13
10
14
16
9
8
17
7
18
19
20
21
4
3
22
2
24
23
1
25
26
N0152464
30
10
Oil pump
11
12
13
Exhaust camshaft
14
Intake camshaft
15
Turbocharger
16
Vacuum pump
17
Cylinder head
18
Head gasket
Service Training
Lesson 3 Powertrain
Engine
19
Cylinder block
23
Oil filter
20
24
Crankshaft assembly
21
25
22
26
Oil pan
Service Training
31
Engine
Lesson 3 Powertrain
3
2
E178753
Friction washers
Friction washers
32
Service Training
Lesson 3 Powertrain
NOTE: The camshaft adjustment units can only be
changed as a complete set during servicing. They cannot
be repaired.
This system uses electro-hydraulically regulated
camshaft adjustment. The timing of the intake and
exhaust valves can be controlled independently of one
another using a pressurized engine oil supply which is
controlled by solenoids.
Engine
303-507 Crankshaft locking tool
303-1565 Camshaft alignment tool
303-1521 CKP alignment tool
303-507
E182334
303-1565
E202225
Service Training
x2
1
303-1521
E137263
33
Engine Cooling
NOTE: For further information regarding camshaft
timing procedures and tightening torques refer to the
Lesson 3 Powertrain
Workshop Manual.
Engine Cooling
Radiator
E221408
34
(G1821518)
Service Training
Lesson 3 Powertrain
4
3
1
E179607
Fuel injector
Fuel rail
Service Training
35
Lesson 3 Powertrain
System Operation
E210638
Inlet valve
Spark Plug
Piston
Fuel Injector
Component Description
Throttle Body
Operating Modes
The direct fuel injection system fitted to 2.3L EcoBoost
engines has two different operating modes:
Homogeneous operating mode
Heat catalytic converter operating mode
36
E219730
(G1821522)
Service Training
Lesson 3 Powertrain
assembly.
2
4
1
E219399
FRP sensor
Fuel injector
Service Training
x2
E217867
37
Lesson 3 Powertrain
Fuel Injectors
1
4
3
E217869
38
E217868
Service Training
Lesson 3 Powertrain
NOTE: When replacing fuel injector(s) the fuel injector
O-ring, injector support ring and lower fuel injector
Teflon seal must be removed and discarded and new
components must be installed.
Turbocharger
NOTE: When replacing fuel injector(s) the following
special tools must be used, 310-205 Brush, 310-206
Remover, 310-207 Seal Installer, 303-1567 Teflon
Seal Sizer and 307-005 (T59L-100-B) or equivalent
Slide Hammer.
Turbocharger
2
4
3
1
E224442
1
Turbocharger assembly
Exhaust system
39
Turbocharger
Lesson 3 Powertrain
System Operation
Twin-Scroll Turbocharger
9
3
4
8
E187368
1
2
40
Compressor wheel
Turbine wheel
Exhaust cylinder 1
(G1821756)
Service Training
Lesson 3 Powertrain
Turbocharger
Exhaust cylinder 2
Exhaust cylinder 4
Exhaust cylinder 3
2
E203664
Compressor wheel
Turbine wheel
Twin scrolls
Housing
Component Description
Service Training
41
Turbocharger
Lesson 3 Powertrain
4
2
3
E203665
Exhaust passage
Coolant passage
Cylinder head
42
Service Training
Lesson 3 Powertrain
Turbocharger
1
E221230
43
Accessory Drive
Lesson 3 Powertrain
Accessory Drive
1
2
8
7
4
5
E155977
44
Generator pulley
(G1821760)
Service Training
Lesson 3 Powertrain
Engine Ignition
Engine Ignition
E176727
Ignition coil-on-plug(s)
Spark plug(s)
The ignition system fitted to this engine is referred to a
COP (coil on plug) type, where each spark plug has its
own ignition coil. COP ignition coils eliminate the need
for secondary spark plug wires which improves ignition
spark reliability.
The ignition system uses a 3 wire COP type ignition
coil. This means the coil driver is integrated in the COP
assembly. This configuration eliminates the need for
high current circuits from the PCM to the COP.
E220120
45
Lesson 3 Powertrain
The PCM uses the CKP sensor signal to calculate a
spark target and then fires the COP. The PCM uses the
CMP sensor signal to identify the compression stroke
of cylinder 1.
The PCM controls the ignition coils after it calculates
the spark target. The COP coils fire the spark plug after
receiving the fire signal from the PCM.
The current flow or dwell through the primary ignition
coil is controlled by the COP electronics.
x2
N0152495
3
4
E224363
46
Turbocharger
Inlet manifold
Throttle body
(G1821770)
Service Training
Lesson 3 Powertrain
x4
2
3
E224362
47
Lesson 3 Powertrain
E131654
48
Clutch
The Focus RS is equipped with a modified PW10F
clutch to handle the additional engine torque.
The clutch utilises a 'TAC' (Travel Adjusted Clutch)
technology enabling higher overboost torques and is
automatically adapted to the wear.
(G1822047)
Service Training
Lesson 3 Powertrain
Clutch
E224437
Clutch plate
Clutch wear
Ramp ring
Service Training
49
Clutch
Lesson 3 Powertrain
1
E224435
Drive pawl
The drive pawl engages in the next tooth and drives the
pinion, which compensates for wear. A mechanical
freewheel locks the position of the pinion.
50
(G1821783)
Service Training
Lesson 3 Powertrain
Manual Transmission
Manual Transmission
MMT6 Manual Transmission with AWD (all-wheel drive)
E217553
Transmission Ratio
3,231
1,952
1,321
1,029
1,129
0,943
1,423
Final Drive
Ratio
4,063
4,063
4,063
4,063
2,955
2,955
2,955
Overall
Ratio
13,128
7,931
5,367
4,181
3,336
2,787
13,586
51
Lesson 3 Powertrain
3
4
5
E215177
52
(G1821787)
Service Training
Lesson 3 Powertrain
Mixture control
Messages
AWD OFF
Check AWD
Steering input
Wheel speed
Temperature
Service Training
53
Lesson 3 Powertrain
using 3 worn tires and 1 new tire.
System Operation
Dynamic Torque Vectoring
E220850
The vehicle tires may loose grip with the road surface
when cornering in the conditions listed below:
High speed
Wet road surface
Uneven road surface
Narrow curve radius
54
(G1822050)
Service Training
Lesson 3 Powertrain
Component Description
Transfer Case
E217955
Service Training
55
Lesson 3 Powertrain
2
5
E220840
Input shaft
Temperature sensors
Pinion
Ring gear
Output flange
56
Service Training
Lesson 3 Powertrain
E217956
Service Training
57
Lesson 3 Powertrain
E220578
58
Service Training
Lesson 3 Powertrain
1
3
E220579
Control valves
Service Training
59
Lesson 3 Powertrain
E221058
60
(G1821790)
Service Training
Lesson 3 Powertrain
Exhaust System
Exhaust System
E215856
61
Fuel System
Lesson 3 Powertrain
Fuel System
E223271
62
(G1821780)
Service Training
Lesson 3 Powertrain
Fuel System
1
E224103
Suction line
Service Training
63
Fuel System
Lesson 3 Powertrain
E224105
4
5
11
10
6
7
9
E222031
64
Service Training
Lesson 3 Powertrain
Fuel System
Fuel tank
Electric pump 1
Reservoir
Electric pump 2
10
Screen
Filter
11
Valve
One-way valve
The other suction jet pump draws in the fuel from the
fuel level sender unit via a suction pipe. Electric pump
1 (secondary pump) has a cooling flow opening for a
low fuel requirement.
1
3
E224104
PCM
Service Training
65
Fuel System
8
66
Lesson 3 Powertrain
9
(G1821780)
Service Training
Lesson 4 Electrical
E224148
Auxiliary Gauges
E224149
67
Lesson 4 Electrical
Oil temperature gauge - Displays engine
temperature
Turbo boost gauge - Displays the added intake
system pressure provided by the turbocharger
Oil pressure gauge - Displays engine oil pressure
If the needle enters the red section a warning lamp
illuminates and a message appears in the
information display
Drive Modes
1
E224150
68
Service Training
Lesson 4 Electrical
Normal
Sport
Normal Sport
Track
Sport
Drift
Sport
Normal
Sport
Sport
Sport
Normal
Sport
Sport
Drift
Normal
Sport
Sport
Normal
Normal
Normal
Sport
Sport
Normal
Sport
Sport
Normal
Launch Control
E224336
69
Exterior Lighting
Lesson 4 Electrical
Exterior Lighting
E224156
E224158
The rear lamps have been carried over from the Focus
MCA.
70
Service Training
Lesson 4 Electrical
Exterior Lighting
The vehicle is fitted with a unique rear fog lamp which
contains 6 LEDs (light emitting diodes). The LED fog
lamp has an approximate current consumption of 0.2
amps/2.4 watts.
E224157
2
3
4
E197692
Lens
Reflector
Service Training
71
Exterior Lighting
The Bi-Xenon HID headlamp also contains LEDs that
are signature lights when used as DRL (daytime running
lamps) and are illuminated at their highest intensity or
parking lamps and are illuminated at a reduced intensity
when the parking lamps or headlamps are activated.
Lesson 4 Electrical
Depending on the inputs received (steering wheel angle
and vehicle speed for example), the HCM can command
the angle at which the headlamps are aimed (left or
right) to improve nighttime visibility around curves.
Additional functions have been added to the existing
adaptive front lighting system enabling it to adapt the
light beam to the respective driving situation.
Different light distributions e.g. for city or country
roads, adverse weather or freeway light, can be
generated using the free-form drum based on internal
vehicle data. A projection module with a rotating
free-form drum between the light source and lens is
required for this.
E197679
E197661
72
Service Training
Lesson 4 Electrical
Exterior Lighting
E197662
E197678
Service Training
73
Exterior Lighting
Lesson 4 Electrical
E197663
E197664
74
Service Training
Lesson 4 Electrical
Adverse Weather Light Mode
Communications Network
This light mode is used at speeds from 0 to 50 km/h if
the wipers have been on for more than two minutes and
the front fog lamps are not switched on.
E197954
E197663
Communications Network
There are a total of Six data bus systems used on the
communication network:
HS-CAN (controller area network) bus
HS-CAN multimedia bus
Private HS-CAN bus
MS-CAN bus
LIN (local interconnect network) bus
ISO bus
75
Communications Network
The terminating resistors of the HS-CAN multimedia
system are located in the IPC (instrument panel cluster)
and in the ACM (audio front control module).
The HS-CAN multimedia bus signals can be picked off
via pins 1 and 8
Lesson 4 Electrical
The RCM (restraints control module) is connected to
the CAN module via a private HS-ABS (anti-lock brake
system) bus. Two separate termination resistors are
installed here.
The MS CAN bus terminating resistors are located in
the IPC and the BCM. The total resistance can be
measured at the DLC between pins 3 and 11 and should
be 60 ohms.
E224838
Module acronyms:
76
Service Training
Lesson 4 Electrical
Communications Network
77
Front Seats
Front Seats
1
E224221
78
(G1821514)
Service Training
Instrument Panel
Instrument Panel
E215834
79
E218404
Structural foam
80
(G1821799)
Service Training
List of Abbreviations
ABS
ACM
APIM
SYNC module
AWD
all-wheel drive
BCM
CAC
DDM
DRL
DSP
FDSM
FRP
GPSM
HCM
HVAC
ICM
IPC
LIN
PAM
PCM
PCV
PDM
PSCM
RCM
RFA
SASM
TC
turbocharger
VCT
Service Training
81