Ford Focus c307 2004.75 WSM - Not For 1.6tdci

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2004.75 Focus C307 South Africa

Workshop Manual
The illustrations, technical information, data and No part of this publication may be produced, stored in a
descriptive text in this issue, to the best of our retrieval system or transmitted in any form, electonic,
knowledge, were correct at the time of going to print. The mechanical, photocopying, recording, translating or by
right to make changes at any time, without notice, is any means without prior wirtten permission of Ford Motor
reserved as part of Ford's policy of continuous Company of Southern Africa/Ford Werke AG.
development and improvement. (c) Ford Motor Company of Southern Africa / Ford Werke AG
No liability can be accepted for any inaccuracies or 1998
omissions in this publication, although every possible Produced by:
care has been taken to make it as complete and accute Reiner Winters GmbH
as possible. D-57537 Wissen/Sieg
Published by Ford Motor Company of Southern Africa/
. Germany
Ford Werke AG Order code: CGen (Please quote when re-ordering)
This publication is printed on totally chlorine-free (TCF)
paper i.e. material that has been bleached without the
use of chlorine gas or chlorine-based chemicals.
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MAIN INDEX: 2004.75 Ford Focus

C307 Workshop Manual
Group 1 – General Information GI
Group 2 – Chassis CH
Group 3 – Powertrain PT
Group 4 – Electrical EL
Group 5 – Body and Paint BP
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Group
General Information 1
SECTION TITLE PAGE
Service Information
General Information .............................................................................................................. 100-00-1
Identification Codes............................................................................................................... 100-01-1
Jacking and Lifting ................................................................................................................ 100-02-1
Noise, Vibration and Harshness ............................................................................................ 100-04-1
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100-00-1 General Information 100-00-1
PAGE 1 OF 2
SECTION 100-00 General Information

VEHICLE APPLICATION: 2004.75 Focus
CONTENTS PAGE
DESCRIPTION AND OPERATION
About This Manual ............................................................................................................ 100-00-3

Introduction ...................................................................................................................... 100-00-3
Special Tools ................................................................................................................... 100-00-3
Important Safety Instructions............................................................................................ 100-00-3
Warnings, Cautions and Notes in This Manual ................................................................. 100-00-3
How to Use This Manual .................................................................................................. 100-00-3/4
Special Tools and Torque Figures.................................................................................... 100-00-5
Health and Safety Precautions.......................................................................................... 100-00-6
Introduction ...................................................................................................................... 100-00-6
Acids and Alkalis .............................................................................................................. 100-00-6
Air Bags ........................................................................................................................... 100-00-6
Air Conditioning Refrigerant ............................................................................................. 100-00-7
Adhesives and Sealers..................................................................................................... 100-00-7
Antifreeze......................................................................................................................... 100-00-8
Asbestos .......................................................................................................................... 100-00-8
Battery Acids.................................................................................................................... 100-00-8
Brake and Clutch Linings and Pads.................................................................................. 100-00-8
Brake Fluids (BASF Hydraulan 417-1(DOT4++)............................................................... 100-00-8
Brazing............................................................................................................................. 100-00-8
Chemical Materials........................................................................................................... 100-00-8/9
Chlorofluorocarbons (CFC) .............................................................................................. 100-00-10
Clutch Fluids .................................................................................................................... 100-00-10
Clutch Linings and Pads................................................................................................... 100-00-10
Corrosion Protection Materials ......................................................................................... 100-00-10
Cutting ............................................................................................................................. 100-00-10
Dewaxing ......................................................................................................................... 100-00-10
Dusts................................................................................................................................ 100-00-10
Electric Shock .................................................................................................................. 100-00-10
Engine Oils....................................................................................................................... 100-00-10
Exhaust Fumes ................................................................................................................ 100-00-11
Fibre Insulation................................................................................................................. 100-00-11
Fire................................................................................................................................... 100-00-11
First Aid............................................................................................................................ 100-00-11
Fluoroelastomer ............................................................................................................... 100-00-11
Foams - Polyurethane ...................................................................................................... 100-00-11
Freon ............................................................................................................................... 100-00-12
Fuels ................................................................................................................................ 100-00-12
Gas Cylinders .................................................................................................................. 100-00-13
Gases .............................................................................................................................. 100-00-13
Gaskets (Fluoroelastomer) ............................................................................................... 100-00-13
General Workshop Tools and Equipment ......................................................................... 100-00-13
High Pressure Air, Lubrication and Oil Test Equipment .................................................... 100-00-13
Halon ............................................................................................................................... 100-00-13
Legal Aspects .................................................................................................................. 100-00-13
Lubricants and Greases ................................................................................................... 100-00-13
Transmission Fluids ......................................................................................................... 100-00-13/14
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PAGE 2 OF 2
Noise ................................................................................................................................ 100-00-15
Noise Insulation Materials................................................................................................. 100-00-15
O-Rings (Fluoroelastomer) ............................................................................................... 100-00-15
Paints ............................................................................................................................... 100-00-15
Pressurized Equipment..................................................................................................... 100-00-15
Solder ............................................................................................................................... 100-00-15
Solvents............................................................................................................................ 100-00-15
Sound Insulation ............................................................................................................... 100-00-16
Suspended Loads............................................................................................................. 100-00-16
Transmission Brake Bands ............................................................................................... 100-00-16
Underseal ......................................................................................................................... 100-00-16
Viton ................................................................................................................................. 100-00-16
Welding ............................................................................................................................ 100-00-16
Warning Symbols on Vehicles .......................................................................................... 100-00-17
White Spirit ....................................................................................................................... 100-00-18
Standard Workshop Practices ........................................................................................... 100-00-19
Vehicle in Workshop ......................................................................................................... 100-00-19
Alternative Fuel................................................................................................................. 100-00-19
Alternative Fuel — Do's .................................................................................................... 100-00-19
Alternative Fuel — Do Nots............................................................................................... 100-00-19
Towing the Vehicle ........................................................................................................... 100-00-20
Connecting a Slave Battery Using Jumper Cables............................................................ 100-00-20
Component Cleaning ........................................................................................................ 100-00-21
Calibration of Essential Measuring Equipment.................................................................. 100-00-21
Solvents, Sealants and Adhesives..................................................................................... 100-00-22
Introduction....................................................................................................................... 100-00-22
Road/Roller Testing........................................................................................................... 100-00-23
Pre-Test Checks ............................................................................................................... 100-00-23
Starting the Engine ........................................................................................................... 100-00-23
Road or Roller Testing ...................................................................................................... 100-00-24
Brake Testing ................................................................................................................... 100-00-24
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About This Manual

DESCRIPTION AND OPERAT ION
Introduction
This manual has been written in a format that is A warning, caution or note is placed at the
designed to meet the needs of technicians beginning of a series of steps if it applies to
worldwide. The objective is to use common multiple steps. If the warning, caution or note only
formats and include similar content in each applies to one step, it is placed at the beginning of
manual. the specific step (after the step number).
This manual provides general descriptions for
accomplishing diagnosis and testing, service and How to Use This Manual
repair work with tested, effective techniques.
Following them will help assure reliability. This manual covers diagnosis and testing, service
and repair procedures.
This manual is structured into groups and sections,
Special Tools with specific system sections collected together
The special tool(s) table provided at the beginning under their relevant group.
of each procedure shows all special tools required A group covers a specific portion of the vehicle.
to carry out a repair. Where possible, illustrations The manual is divided into five groups, General
are provided to assist in identifying the special tool Information, Chassis, Powertrain, Electrical and
required. Body and Paint. The number of the group is the
first number of a section number.
Important Safety Instructions Pages at the start of the manual list all sections
available. Each section has a contents list
Appropriate service methods and correct repair detailing Specifications, Description and
procedures are essential for the safe, reliable Operation, Diagnosis and Testing, In Vehicle
operation of all motor vehicles as well as the Repairs, Disassembly and Assembly, Removal
personal safety of the individual carrying out the and Installation.
work.
If components need to be removed or
This manual cannot possibly anticipate all such disassembled in sequence, the sequence will be
variations and provide advice or cautions as to identified numerically in a graphic and the
each. Anyone who departs from the instructions corresponding text will be numbered accordingly.
provided in this manual must first establish that he
compromises neither his personal safety nor the All left and right-hand references to the vehicle are
vehicle integrity by his choice of methods, tools or taken from a position sitting in the driver seat
components. looking forward.
All left and right-hand references to the engine are
taken from a position at the flywheel looking
Warnings, Cautions and Notes in This Manual towards the front camshaft pulley.
WARNING: Warnings are used to indicate Where appropriate, instructions will be given for
that failure to follow a procedure the use of the diagnostic tool.
correctly may result in personal injury. Overview Procedures
CAUTION: Cautions are used to indicate Overview procedures contain an exploded view
that failure to follow a procedure illustration(s). The numbered sequence within the
correctly may result in damage to the illustration(s) indicate the order to be followed
vehicle or equipment being used. when removing/disassembling or when
NOTE: Notes are used to provide additional installing/assembling a component. Additional
essential information required to carry out a information, symbol(s) or a torque figure, may also
complete and satisfactory repair. be shown alongside the component.
As you read through this manual, you will come
across WARNINGS, CAUTIONS and NOTES.
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DESCRIPTION AND OPERATION (Continued)
There are ten symbols used to give additional

information when removing/disassembling or
when installing/assembling a component.
Item Designation Description

1 Special tool A special tool is required for this component. There will also
be a removal or installation symbol alongside the special tool
symbol.
2 Install new component Discard the old component and install a new component.
3 Inspect Check the component for damage.
4 Apply sealant Apply sealant to the component as specified in the mate-rials
table.
5 Apply petroleum jelly Apply petroleum jelly to the component as specified in the
materials table.
6 Apply oil Apply oil to the component as specified in the materials ta-
ble.
7 Apply fluid Apply fluid to the component as specified in the materials
table.
8 Apply grease Apply grease to the component as specified in the mate-rials
table.
9 Removal or Disassembly Go to the removal or disassembly detail for additional in-
detail formation to remove or disassemble a component
10 Installation or Assembly Go to the installation or assembly detail for additional in-
detail formation to install or assemble a component
Inspection and Verification
The boxed numbers indicate the order in which
Visual Inspection Charts, Symptom Charts and the described action is to be performed.
other information charts (such as diagnostic
Component Tests
routines) or supplement test procedures with
technical specifications will navigate the user to a A component test is used when a component is
specific test procedure. tested in multiple pinpoint tests, or if a procedure
is too complicated to be formatted within a single
Symptom Chart
page of the pinpoint test.
The symptom chart indicates symptoms, sources
Graphics
and actions to address a condition.
Test graphics show the measurement or test to be
Pinpoint Tests
performed in a test step.
For electrical systems, pinpoint test steps are A representative tester graphic is used for
used to identify the source of a concern in a logical, voltmeters and ohmmeters.
step-by-step manner. pinpoint tests have two
columns: CONDITIONS and If multiple measurements are made in a single
DETAILS/RESULTS/ACTIONS. graphic, the test leads are drawn with a solid line
until the test lead splits to indicate the multiple
The CONDITIONS column is used exclusively for measurements, at which point dashed lines are
graphics and icons (with or without captions) and used.
the DETAILS/RESULTS/ACTIONS column
provides direction to another test step or specific
corrective actions.
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Breakout box-type testers are represented by a

double circle test pin. Test pins are labeled with
the pin number.
Special Tools and Torque Figures

Any requirement for special tools will picture the
tool, showing it in use and with its tool number
shown. Torque settings will be given at the
relevant point in the procedure.
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Health and Safety Precautions
Introduction
Many of the procedures associated with vehicle an air bag inflator as this will lead to the risk of
maintenance and repair involve physical hazards exposure to Sodium Azide. If a gas generator is
or other risks to health. This subsection lists, ruptured, full protective clothing should be worn
alphabetically, some of these hazardous when dealing with the spillage.
operations and the materials and equipment After normal deployment, gloves and safety
associated with them. Precautions necessary to goggles must be worn during the handling
avoid these hazards are identified. process.
The list is not exhaustive and all operations and Deployed air bags should be disposed of in a
procedures, and the handling of materials, should plastic bag in accordance with local regulations at
be carried out with health and safety in mind. an approved chemical waste site.
Before using any product the Materials Safety Following any direct contact with gas generant.
Data Sheet supplied by the manufacturer or
supplier should be consulted. – wash affected areas thoroughly with water.
– seek medical assistance if necessary.
Air Bags - Do's
Acids and Alkalis
– Do store modules in an upright position.
See also Battery Acids.
– Do keep modules dry.
For example caustic soda, sulphuric acid. – Do carry modules with the cover side pointing
Used in batteries and cleaning materials. away from the body.
Irritant and corrosive to the skin, eyes, nose and – Do place modules with their cover side
throat. Cause burns. Can destroy ordinary upwards.
protective clothing. – Do carefully inspect modules for damage.
Avoid splashes to the skin, eyes and clothing. – Do stand to one side when connecting
Wear suitable protective impervious apron, gloves modules.
and goggles. Do not breath mists. – Do make sure all test equipment is properly
calibrated and maintained.
Make sure access to eye wash bottles, shower
and soap are readily available for splashing – Do wash hands after handling deployed air
accidents. bags.
Display Eye Hazard sign. Air Bags - Do Nots
Air Bags
See also Fire, Chemical Materials.
Highly flammable, explosive – observe No
Smoking policy.
Used as a safety restraint system mounted in the
steering wheel and passenger side of the
instrument panel.
The inflator contains a high-energetic propellant
which, when ignited, produces a VERY HOT GAS
(2500°C).
The gas generant used in air bags is Sodium
Azide. This material is hermetically sealed in the
module and is completely consumed during
deployment. No attempt should be made to open
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– Do not store highly flammable material Highly flammable, flammable, combustible –

together with modules or gas generators. observe No Smoking policy.
– Do not store gas generators at temperatures Generally should be stored in No Smoking areas.
exceeding 80°C. Cleanliness and tidiness in use should be
– Do not store modules upside down. observed, for example disposable paper covering
– Do not attempt to open a gas generator benches; should be dispensed from applicators
housing. where possible; containers, including secondary
containers, should be labeled appropriately.
– Do not expose gas generators to open flame
or sources of heat.
– Do not place anything on top of a module Solvent-based Adhesives/Sealers - See Solvents
cover. Follow manufacturers instructions.
– Do not use damaged modules.
– Do not touch a fired module or gas generator
Water-based Adhesives/Sealers
for at least 10 minutes.
– Do not use any electrical probes on the wiring Those based on polymer emulsions and rubber
circuit. latexes may contain small amounts of volatile
toxic and harmful chemicals. Skin and eye contact
should be avoided and adequate ventilation
Air Conditioning Refrigerant provided during use.
See also Chlorofluorocarbon, Chemical Materials
Hot Melt Adhesives
Highly flammable, combustible – observe No
Smoking policy. In the solid state, they are safe. In the molten state
they may cause burns and health hazards may
Skin contact may result in frostbite. arise from the inhalation of toxic fumes.
Instructions given by the manufacturer must be Use appropriate protective clothing and a
followed. Avoid naked lights, wear suitable thermostatically controlled heater with a thermal
protective gloves and goggles. cut-out and adequate extraction.
If refrigerant comes into contact with the skin or
eyes, immediately rinse the affected areas with
Resin-based Adhesives/Sealers, for example
water. Eyes should also be rinsed with an
appropriate irrigation solution and should not be Epoxide and Formaldehyde Resin-based
rubbed. SEEK MEDICAL ASSISTANCE IF Mixing should be carried out in well ventilated
NECESSARY. areas, as harmful or toxic volatile chemicals may
be released.
Air Conditioning Refrigerant - Do Nots Skin contact with uncured resins and hardeners
can result in irritation, dermatitis, and absorption
– Do not expose refrigerant bottles to sunlight or
of toxic or harmful chemicals through the skin.
heat.
Splashes can damage the eyes.
– Do not stand refrigerant bottles upright; when
filling, hold them with the valve downwards. Provide adequate ventilation and avoid skin and
eye contact.
– Do not expose refrigerant bottles to frost.
– Do not drop refrigerant bottles.
– Do not vent refrigerant to atmosphere under Anaerobic, Cyanoacrylate (super-glues) and other
any circumstance. Acrylic Adhesives
– Do not mix refrigerants, for example R12 Many are irritant, sensitizing or harmful to the skin
(Freon) and R134a. and respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the
manufacturers instructions followed.
Adhesives and Sealers
Cyanoacrylate adhesives (super-glues) MUST
See also Fire, Chemical Materials. NOT contact the skin or eyes. If skin or eye tissue
is bonded, cover with a clean moist pad and SEEK
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IMMEDIATE MEDICAL ATTENTION. Do not to general, food preparation or drinking water

attempt to pull tissue apart. Use in well ventilated supplies.
areas as vapors can cause irritation to the nose
and eyes.
For two-pack systems see Resin-based and Asbestos
Isocyanate Adhesives/Sealers. See also Warning Symbols on Vehicles at the end
of this subsection.
Isocyanate (Polyurethane) Adhesives/Sealers Breathing asbestos dust may cause lung damage
or, in some cases, cancer.
See also Resin-based Adhesives.
Used in brake and clutch linings, transmission
Individuals suffering from asthma or respiratory
brake bands and gaskets.
allergies should not work with or near these
materials as sensitivity reactions can occur. The use of drum cleaning units, vacuum cleaning
or damp wiping is preferred.
Over exposure is irritating to the eyes and
respiratory system. Excessive concentrations may Asbestos dust waste should be dampened, placed
produce effects on the nervous system including in a sealed container and marked for safe disposal.
drowsiness. In extreme cases, loss of If any cutting or drilling is attempted on materials
consciousness may result. Long term exposure to containing asbestos the item should be dampened
vapor concentrations may result in adverse health and only hand tools or low speed power tools
effects. used.
Prolonged contact with the skin may have a
defatting effect which may lead to skin irritation
Battery Acids
and in some cases, dermatitis.
See also Acids and Alkalis.
Splashes entering the eye will cause discomfort
and possible damage. Gases released during charging are explosive.
Never use naked flames or allow sparks near
Any spraying should preferably be carried out in
charging or recently charged batteries.
exhaust ventilated booths, removing vapors and
spray droplets from the breathing zone. Make sure there is adequate ventilation.
Wear appropriate gloves, eye and respiratory
protection.
Brake and Clutch Linings and Pads
See Asbestos.
Antifreeze
See also Fire, Solvents.
Brake Fluids (BASF Hydraulan 417-1(DOT4++)
For example isopropanol, ethylene glycol,
methanol. See also Fire.
Highly flammable, flammable, combustible. Splashes to the skin and eyes are slightly irritating.
Avoid skin and eye contact as far as possible.
Used in vehicle coolant systems, brake air Inhalation vapor hazards do not arise at ambient
pressure systems, screenwash solutions. temperatures because of the very low vapor
Vapors may be given off from coolant antifreeze pressure.
(glycol) when heated. Avoid breathing these
vapors.
Brazing
Antifreeze may be absorbed through the skin in
toxic or harmful quantities. Antifreeze, if See Welding.
swallowed, can be fatal and MEDICAL
ATTENTION SHOULD BE SOUGHT
IMMEDIATELY. Chemical Materials
These products must not be used in any cooling or See also Legal Aspects.
industrial water system that is connected or linked
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Chemical materials such as solvents, sealers, Chemical Materials - Do's

adhesives, paints, resin foams, battery acids,
– Do carefully read and observe hazard and
antifreeze, brake fluids, fuels, oils and grease
precaution warnings given on material
should always be used with caution and stored
containers (labels) and in any accompanying
and handled with care. They may be toxic, harmful,
leaflets, posters or other instructions. Material
corrosive, irritant or highly flammable and give rise
health and safety data sheets can be obtained
to hazardous fumes and dusts.
from manufacturers.
The effects of excessive exposure to chemicals – Do remove chemical materials from the skin
may be immediate or delayed; briefly experienced and clothing as soon as practicable after
or permanent; cumulative; superficial; life soiling. Change heavily soiled clothing and
threatening; or may reduce life expectancy. have it cleaned.
– Do organize work practices and protective
clothing to avoid soiling of the skin and eyes;
breathing vapors, aerosols, dusts or fumes;
inadequate container labeling; fire and
explosion hazards.
– Do wash before job breaks, before eating,
smoking, drinking or using toilet facilities when
handling chemical materials.
– Do keep work areas clean, uncluttered and
free of spills.
– Do store chemical materials according to
national and local regulations.
– Do keep chemical materials out of the reach of
children.
Chemical Materials - Do Nots

– Do not mix chemical materials except under
the manufacturers instructions; some
chemicals can form other toxic or harmful
chemicals, give off toxic or harmful fumes or
become explosive when mixed together.
– Do not spray chemical materials, particularly
those based on solvents, in confined spaces,
for example when people are inside a vehicle.
– Do not apply heat or flame to chemical
materials except under the manufacturers
instructions. Some are highly flammable and
some may release toxic or harmful fumes.
– Do not leave containers open. Fumes given off
can build up to toxic, harmful or explosive
concentrations. Some fumes are heavier than
air and will accumulate in confined areas such
as pits.
– Do not transfer chemical materials to
unlabelled containers.
– Do not clean hands or clothing with chemicals.
Chemicals, particularly solvents and fuels, will
dry the skin and may cause irritation leading to
dermatitis or be absorbed through the skin in
toxic or harmful quantities.
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– Do not use emptied containers for other Dusts

materials except when they have been
Powder, dusts or clouds may be irritant, harmful or
cleaned under supervised conditions.
toxic. Avoid breathing dusts from powdery
– Do not sniff or smell chemical materials. Brief chemical materials or those arising from dry
exposure to high concentrations of fumes can abrasion operations. Wear respiratory protection if
be toxic or harmful. ventilation is inadequate.
Fine dusts of combustible material can present an
Chlorofluorocarbons (CFC) explosion hazard. Avoid explosive limits and
sources of ignition.
There is concern in the scientific community that
CFCs and Halons are depleting the upper ozone
layer which filters out harmful ultraviolet radiation. Electric Shock
Decreased filtration of ultraviolet radiation may
result in increases in skin cancer, cataracts and Electric shock can result from the use of faulty
immune system suppression in humans, as well electrical equipment or from the misuse of
as decreased productivity of crops and aquatic equipment in good condition.
systems. Make sure that electrical equipment is maintained
CFCs are used primarily as refrigerants in vehicle in good condition and frequently tested. Faulty
air conditioning systems and as aerosol equipment should be labeled and preferably
propellants. Halons are used as fire removed from the workstation.
extinguishants. Make sure that flexes, cables, plugs and sockets
are not frayed, kinked, cut, cracked or otherwise
damaged.
Clutch Fluids
Make sure that electrical equipment and flexes do
See Brake fluids. not come into contact with water.
Make sure that electrical equipment is protected
by the correct rated fuse.
Clutch Linings and Pads
Never misuse electrical equipment and never use
See Asbestos.
equipment that is in any way faulty. The results
could be fatal.
Corrosion Protection Materials Make sure that the cables of mobile electrical
equipment cannot get trapped and damaged,
See also Solvents, Fire. such as in a vehicle hoist.
Highly flammable, flammable – observe No Make sure that the designated electrical workers
Smoking policy. are trained in basic First Aid.
These materials are varied and the manufacturers In cases of electrocution:
instructions must be followed. They may contain
solvents, resins or petroleum products. Skin and – switch off the power supply before
eye contact should be avoided. They should only approaching the victim.
be sprayed in conditions of adequate ventilation – if this is not possible push or drag the victim
and not in confined spaces. from the source of electricity using dry
non-conductive material.
– commence resuscitation if trained to do so.
Cutting – SUMMON MEDICAL ASSISTANCE.
See Welding.
Engine Oils
Dewaxing
See Lubricants and Grease.
See Solvents and Fuels (Kerosene).
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Exhaust Fumes Splashes in the eye should be flushed carefully

with clean water for at least ten minutes.
These contain asphyxiating, harmful and toxic
chemicals and particles such as carbon oxides, Soiled skin should be washed with soap and
nitrogen oxides, aldehydes, lead and aromatic water.
hydrocarbons. Engines should be run only under In case of cold burns, from alternative fuels, place
conditions of adequate exhaust extraction or affected area in cool to cold water.
general ventilation and not in confined spaces.
Individuals affected by inhalation of gases and
fumes should be removed to fresh air immediately.
Gasoline (petrol) engine If effects persist, consult a doctor.
There may not be adequate warning of odor or of If liquids are swallowed inadvertently, consult a
irritation before toxic or harmful effects arise. doctor giving him the information on the container
These may be immediate or delayed. or label. Do not induce vomiting unless this action
is indicated on the label.
Diesel engine
Soot, discomfort and irritation usually give Fluoroelastomer
adequate warning of hazardous fume
concentrations. See Viton.
Fibre Insulation Foams - Polyurethane
See also Dusts. See also Fire.
Used in noise and sound insulation. Used in sound and noise insulation. Cured foams
used in seat and trim cushioning.
The fibrous nature of surfaces and cut edges can
cause skin irritation. This is usually a physical and Follow manufacturers instructions.
not a chemical effect. Unreacted components are irritating and may be
Precautions should be taken to avoid excessive harmful to the skin and eyes. Wear gloves and
skin contact through careful organization of work goggles.
practices and the use of gloves. Individuals with chronic respiratory diseases,
asthma, bronchial medical problems, or histories
of allergic diseases should not work in or near
Fire uncured materials.
See also Welding, Foams, Legal Aspects. The components, vapors or spray mists can cause
Many of the materials found on or associated with direct irritation, sensitivity reactions and may be
the repair of vehicles are highly flammable. Some toxic or harmful.
give off toxic or harmful fumes if burnt. Vapors and spray mists must not be inhaled.
Observe strict fire safety when storing and These materials must be applied with adequate
handling flammable materials or solvents, ventilation and respiratory protection. Do not
particularly near electrical equipment or welding remove the respirator immediately after spraying;
processes. wait until the vapors/mists have cleared.
Make sure, before using electrical or welding Burning of the uncured components and the cured
equipment, that there is no fire hazard present. foams can generate toxic and harmful fumes.
Smoking, naked flames or the use of electrical
Have a suitable fire extinguisher available when equipment during foaming operations and until
using welding or heating equipment. vapors/mists have cleared should not be allowed.
Any heat cutting of cured foams or partially cured
foams should be conducted with extraction
First Aid ventilation. See also the vehicle Body Repair
Apart from meeting any legal requirements it is Manual.
desirable for someone in the workshop to be
trained in First Aid procedures.
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Freon Kerosene (Paraffin)

See Air Conditioning Refrigerant. Used also as heating fuel, solvent and cleaning
agent.
Flammable - observe No Smoking policy.
Fuels
Irritation of the mouth and throat may result from
See also, Fire, Legal Aspects swallowing. The main hazard from swallowing
, Chemicals and Solvents. arises if liquid aspiration into the lungs occurs.
Avoid skin contact with fuel where possible. Liquid contact dries the skin and can cause
Should contact occur, wash the affected skin with irritation or dermatitis. Splashes in the eye may be
soap and water. slightly irritating.
In normal circumstances the low volatility does not
Gasoline (Petrol) give rise to harmful vapors. Exposure to mists and
Highly flammable - observe No Smoking policy. vapors from kerosene at elevated temperature
should be avoided (mists may arise in dewaxing).
Swallowing can result in mouth and throat irritation Avoid skin and eye contact and make sure there is
and absorption from the stomach can result in adequate ventilation.
drowsiness and unconsciousness. Small amounts
can be fatal to children. Aspiration of liquid into the
lungs, through vomiting, is a very serious hazard. Alternative Fuel
Gasoline dries the skin and can cause irritation Highly flammable. Observe ``NO SMOKING"
and dermatitis on prolonged or repeated contact. signs.
Liquid in the eye causes severe smarting. Make sure there is adequate ventilation when
Motor gasoline may contain appreciable quantities working on alternative fuelled vehicles. Great care
of benzene, which is toxic upon inhalation, and the must be taken to avoid the serious consequences
concentration of gasoline vapors must be kept of inhalation in the event of vapor build up in
very low. High concentrations will cause eye, nose confined spaces.
and throat irritation, nausea, headache, Inhalation in high concentrations may cause
depression and symptoms of drunkenness. Very dizziness, headache, nausea and loss of
high concentrations will result in rapid loss of co-ordination. Very high concentrations may result
consciousness. in loss of consciousness.
Make sure there is adequate ventilation when Contact with liquefied petroleum gas (LPG) or
handling and using gasoline. Great care must be compressed natural gas (CNG) to the skin may
taken to avoid the serious consequences of cause cold burns and frost bite.
inhalation in the event of vapor build up arising
from spillages in confined spaces. Long sleeved cotton overalls, steel toe capped
safety boots and rubber neoprene gloves should
Special precautions apply to cleaning and be worn during removal and installation of
maintenance operations on gasoline storage LPG/CNG fuel system components.
tanks.
LPG/CNG fuel leaks could cause a fire and be a
Gasoline should not be used as a cleaning agent. hazard to health that can lead to personal injury,
It must not be siphoned by mouth. See First Aid. illness or even death.
If a leak is detected, under no circumstances
Gas-oil (Diesel Fuel) attempt to seal the leak by tightening the
Combustible. union/connection until the fuel in the system or
component is depressurized. Once tightened the
Gross or prolonged skin contact with high boiling system should be checked for integrity following
point gas oils may also cause serious skin the specified procedures.
disorders including skin cancer.
If the fuel tank is to be removed for service or
repair the fuel must be evacuated using dedicated
equipment and following the specified procedures.
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Gas Cylinders asbestos-based materials or using spraying

equipment.
See also Fire.
Make sure there is adequate ventilation to control
Gases such as oxygen, acetylene, argon and
dusts, mists and fumes.
propane are normally stored in cylinders at
pressures of up to 138 bar (2000 psi) and great
care should be taken in handling these cylinders
to avoid mechanical damage to them or to the High Pressure Air, Lubrication and Oil Test
valve gear attached. The contents of each cylinder Equipment
should be clearly identified by appropriate See also Lubricants and Greases.
markings.
Always keep high-pressure equipment in good
Cylinders should be stored in well-ventilated condition, and regularly maintained, particularly at
enclosures, and protected from ice and snow, or joints and unions.
direct sunlight. Fuel gases, for example acetylene
Never direct a high-pressure nozzle, for example
and propane, should not be stored in close
diesel injector, at the skin as the fluid may
proximity to oxygen cylinders.
penetrate to the underlying tissue, and cause
Care should be exercised to prevent leaks from serious injury.
gas cylinders and lines, and to avoid sources of
ignition.
Only trained personnel should undertake work Halon
involving gas cylinders. See CFCs.
Gases Legal Aspects

See Gas Cylinders. There are many laws and regulations relating to
health and safety in the use and disposal of
materials and equipment in a workshop.
Gaskets (Fluoroelastomer)
For a safe working environment and to avoid
See Viton. environmental pollution, workshops should be
familiar, in detail, with the many health and safety
laws and regulations within their country,
General Workshop Tools and Equipment published by both national and local authorities.
It is essential that all tools and equipment are
maintained in good condition and that the correct
safety equipment is used where required. Lubricants and Greases
Never use tools or equipment for any purpose Avoid all prolonged and repeated contact with
other than that for which they were designed. mineral oils. All lubricants and greases may be
Never overload equipment such as hoists, jacks, irritating to the eyes and skin.
axle and chassis stands or lifting slings. Damage
caused by overloading is not always immediately
apparent and may result in a fatal failure the next Transmission Fluids
time that the equipment is used.
Do not use damaged or defective tools or Safety instructions
equipment, particularly high-speed equipment Certain Transmission and Power Steering fluids
such as grinding wheels. A damaged grinding supplied to Ford may contain additives which have
wheel can disintegrate without warning and cause the potential to cause skin disease (dermatitis) to
serious injury. exposed persons. The dermatitis may be irritant or
Wear suitable eye protection when using grinding, allergic in nature. Risks are higher where
chiseling or sand blasting equipment. prolonged or repeated skin contact with a fluid
may occur. These fluids are used for vehicle initial
Wear a suitable breathing mask when using fill and service purposes. This sub-section is to:
abrasive blasting equipment, working with
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• Inform Service personnel who may come into If accidental skin contact occurs with the fluids,
contact with these vehicle fluids (hazard wash the area thoroughly with soap or skin
communication). cleanser and water.
• Summarise appropriate workplace control Accidental eye contact should be dealt with as per
measures and personal protective equipment normal first aid practices, by flushing the eyes with
requirements. an eye wash or clean cool water for 10 minutes,
• Draw attention to the existence of Material after which medical attention should be obtained.
Safety Datasheets (MSDS's) for the fluids
Remove and launder clothing which becomes
(available from Ford Customer Service contaminated with the fluids. Do not place rags
Division). These MSDS's contain detailed contaminated with fluid in clothing pockets.
information on hazards and appropriate
controls. Wash thoroughly after completing operations
where skin exposure may have occurred.
Control measures It is important that personnel do not smoke, eat or
drink whilst handling the fluids or affected
Workplace risk assessments made under national transmissions. These measures are designed to
chemical control regulations should identify limit the risk from accidental ingestion.
operations involving the fluids as potentially
hazardous and specify workplace control and Label any decanted fluid properly/use an
worker awareness measures. In such equivalent label to that on original product
circumstances, the relevant Material Safety containers.
Datasheet (see the details specified below) which Clean up any spills promptly using an inert
specifies hazards and control measures in detail absorbent and wash down contaminated surfaces
should be made available for guidance. with detergent and water.
Avoid unprotected skin contact with the fluids, and Dispose of any waste fluids safely as hazardous
in particular, avoid prolonged or repeated skin waste.
contact. Work practices should be organised so as
to minimise the potential for skin contact. This may
include the use of drip trays, absorbents, correct Safety Data Sheets
fluid handling equipment (funnels etc), and Safety Data Sheets, which detail specific material
workplace housekeeping measures such as the handling instructions and precautions are
cleaning of contaminated surfaces. available from the respective national sales
Personnel engaged in operations where skin company, and via internet www.msds.ford.com.
contact could occur (such as fluid draining or
filling) should wear impervious gloves made from Used Engine Oil
nitrile rubber, certified to a chemical protection
standard, e.g. Europe Standard EN374. This Prolonged and repeated contact with mineral oil
glove type is widely available from reputable will result in the removal of natural fats from the
suppliers of gloves for chemical protection skin, leading to dryness, irritation and dermatitis.
[including the manufacturers Ansell-Admont In addition, used engine oil contains potentially
(Solvex Range), North Safety products (North harmful contaminants, which may cause skin
Nitrile Latex Gloves range), and Marigold cancer. Adequate means of skin protection and
Industrial (Blue Nitrile range)]. If gloves become washing facilities must be provided.
torn or contaminated on the inside they should be Do not employ used engine oils as lubricants or for
replaced. Eye protection with safety glasses is any application where appreciable skin contact is
appropriate. Use of an impervious apron and arm likely to occur.
protectors may be necessary if more extensive
exposure is possible. Use of skin barrier creams
suitable for work with mineral oil products may Environmental Precautions
offer some supplementary protection, but such Burning used engine oil in small space heaters or
barrier creams should not be used in place of boilers can be recommended only for units of
protective clothing. approved design. If in doubt check with the
appropriate local authority and manufacturer of
approved appliances.
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Dispose of used oil and used oil filters through Pressurized Equipment
authorized waste disposal contractors or licensed
See High Pressure Air, Lubrication and Oil Test
waste disposal sites, or to the waste oil
Equipment.
reclamation trade. If in doubt, contact the relevant
local authority for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down Solder
sewers or drains, or into watercourses.
Solders are mixtures of metals such that the
melting point of the mixture is below that of the
constituent metals (normally lead and tin). Solder
Noise
application does not normally give rise to toxic
Some operations may produce high noise levels, lead fumes, provided a gas/air flame is used.
which could, in time, damage hearing. In these Oxy-acetylene flames should not be used, as they
cases, suitable ear protection must be worn. are much hotter and will cause lead fumes to be
produced.
Some fumes may be produced by the application
Noise Insulation Materials of any flame to surfaces coated with grease, and
See Foams, Fibre Insulation. inhalation of these should be avoided.
Removal of excess solder should be undertaken
with care, to make sure that fine lead dust is not
O-Rings (Fluoroelastomer) produced, which can give toxic effects if inhaled.
See Viton. Respiratory protection may be necessary.
Solder spillage and filings should be collected and
removed promptly to prevent general air
Paints contamination by lead.
See also Solvents, Chemical Materials. High standards of personal hygiene are necessary
Highly flammable, flammable - observe No in order to avoid ingestion of lead or inhalation of
Smoking policy solder dust from clothing.
One Pack Solvents

Can contain harmful or toxic pigments, driers and See also Chemical Materials, Fuels (Kerosene),
other components as well as solvents. Spraying Fire.
should be carried out only with adequate
ventilation. For example acetone, white spirit, toluene, xylene,
trichloroethane.
Used in cleaning and dewaxing materials, paints,
Two Pack
plastics, resins and thinners.
Can also contain harmful and toxic unreacted
Some may be highly flammable or flammable.
resins and resin hardening agents. The
manufacturers instructions should be followed. Skin contact will degrease the skin and may result
See also Resin-based Adhesives and Isocyanate in irritation and dermatitis following repeated or
Adhesives and Sealers under Adhesives and prolonged contact. Some can be absorbed
Sealers. through the skin in toxic or harmful quantities.
Spraying should preferably be carried out in Splashes in the eye may cause severe irritation
exhausted ventilated booths removing vapor and and could lead to loss of vision.
spray mists from the breathing zone. Individuals Brief exposure of high concentrations of vapors or
working in booths should wear appropriate mists will cause eye and throat irritation,
respiratory protection. Those doing small-scale drowsiness, dizziness, headaches and, in the
repair work in the open workshop should wear worst circumstances, unconsciousness.
air-fed respirators.
Repeated or prolonged exposure to excessive but
lower concentrations of vapors or mists, for which
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there might not be adequate warning indications, Viton is a fluoroelastomer, that is a synthetic
can cause more serious toxic or harmful effects. rubber type material, which contains Fluorine. It is
commonly used for O-rings, gaskets and seals of
Aspiration into the lungs, for example through
all types. Although Viton is the most well known
vomiting, is the most serious consequence of
fluoroelastomer, there are others, including
swallowing.
Fluorel and Tecmoflon.
Avoid splashes to the skin, eyes and clothing.
When used under design conditions
Wear protective gloves, goggles and clothing if
fluoroelastomers are perfectly safe. If, however,
necessary.
they are exposed to temperatures in excess of
Make sure there is good ventilation when in use, 400°C, the material will not burn, but will
avoid breathing fumes, vapors and spray mists decompose, and one of the products formed is
and keep containers tightly sealed. Do not use in hydrofluoric acid.
confined spaces.
This acid is extremely corrosive and may be
When spraying materials containing solvents, for absorbed directly, through contact, into the
example paints, adhesive, coatings, use general body system.
extraction ventilation or personal respiratory
O-rings, seals or gaskets which have been
protection in the absence of adequate general
exposed to very high temperatures will appear
ventilation.
charred or as a black sticky substance.
Do not apply heat or flame except under specific
DO NOT; under any circumstances touch them or
and detailed manufacturers instructions.
the attached components.
Enquiries should be made to determine whether
Sound Insulation Viton or any other fluoroelastomer has been used
in the affected O-ring, seal or gasket. If they are of
See Fibre Insulation, Foams.
natural rubber or nitrile there is no hazard. If in
doubt, be cautious, as the material may be Viton
or any fluoroelastomer.
Suspended Loads
If Viton or any other fluoroelastomers have been
CAUTION: Never improvise lifting tackle. used, the affected area should be decontaminated
There is always a danger when loads are lifted or before the commencement of work.
suspended. Never work under an unsupported, Disposable heavy duty plastic gloves should be
suspended or raised load, for example a worn at all times, and the affected area washed
suspended engine. down using wire wool and a limewater (calcium
Always make sure that lifting equipment such as hydroxide) solution to neutralize the acid before
jacks, hoists, axle stands and slings are adequate disposing of the decomposed Viton residue and
and suitable for the job, in good condition and final cleaning of the area. After use, the plastic
regularly maintained. gloves should be discarded carefully and safely.
Transmission Brake Bands Welding
See Asbestos. See also Fire, Electric Shock, Gas Cylinders.

Welding processes include Resistance Welding
(Spot Welding), Arc Welding and Gas Welding.
Underseal
See Corrosion Protection. Resistance Welding
This process may cause particles of molten metal
Viton to be emitted at a high velocity, and the eyes and
skin must be protected.
In common with many other manufacturers
vehicles, some components have O-rings, seals
or gaskets, which contain a material known as
`Viton'.
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Arc Welding avoid inhalation of fumes and expert advice may

be required.
This process emits a high level of ultra-violet
radiation, which may cause arc-eye, and skin SPECIAL PRECAUTIONS MUST BE TAKEN
burns to the operator and to other persons nearby. BEFORE ANY WELDING OR CUTTING TAKES
Gas-shielded welding processes are particularly PLACE ON VESSELS, WHICH HAVE
hazardous in this respect. Personal protection CONTAINED COMBUSTIBLE MATERIALS, FOR
must be worn, and screens used to shield other EXAMPLE BOILING OR STEAMING OUT OF
people. FUEL TANKS.
CONTACT LENS WEARERS ARE ADVISED TO
REVERT TO ORDINARY SPECTACLES WHEN
ARC WELDING as the arc spectrum is believed to Warning Symbols on Vehicles
emit microwaves which dry out the fluid between Decals showing warning symbols will be found on
the lens and the eye. This may result in blindness various vehicle components.
when the lens is removed from the eye.
These decals must not be removed. The warnings
Metal spatter will also occur, and appropriate eye are for the attention of owners/operators and
and skin protection is necessary. persons carrying out service or repair operations
The heat of the welding arc will produce fumes on the vehicle.
and gases from the metals being welded, the rods The most commonly found decals are reproduced
and from any applied coatings or contamination below together with an explanation of the
on the surfaces being worked on. These gases warnings.
and fumes may be toxic and inhalation of these
should be avoided. The use of extraction
ventilation to remove the fumes from the working
area may be necessary particularly in cases
where the general ventilation is poor, or where
considerable welding work is anticipated. In
extreme cases or confined spaces where
adequate ventilation cannot be provided, air-fed
respirators may be necessary.
Gas Welding (and Cutting)

Oxy-acetylene torches may be used for welding
and cutting, and special care must be taken to
prevent leakage of these gases, with consequent 1. Components or assemblies displaying the
risk of fire and explosion. caution triangle and open book symbol advise
The process will produce metal spatter and eye consultation of the relevant section of the
and skin protection is necessary. owner literature before touching or attempting
adjustments of any kind.
The flame is bright, and eye protection should be
used, but the ultra-violet emission is much less
than that from arc welding, and lighter filters may
be used.
The process itself produces few toxic fumes, but
such fumes and gases may be produced from
coatings on the work, particularly during cutting
away of damaged body parts, and inhalation of the
fumes should be avoided.
In brazing, toxic fumes may be produced from the
metals in the brazing rod, and a severe hazard
may arise if brazing rods containing cadmium are
used. In this event particular care must be taken to
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2. Components or assemblies displaying the of naked lights or flames within the immediate
warning triangle with the èlectrified' arrow vicinity due to the presence of highly
and open book symbol give warning of flammable or explosive liquids or vapors.
inherent high voltages. Never touch these with See Fire in this subsection.
the engine running or the ignition switched on.
See Electric Shock in this subsection.
6. Displaying this symbol (normally in

conjunction with 5 above) warn of the
3. Vehicles and replacement components which presence of potentially explosive matter within
contain asbestos are identified by this symbol. the immediate vicinity.
See Asbestos in this subsection.
7. Displaying this symbol warn that children

4. Components or assemblies displaying this should not be allowed in the immediate vicinity
symbol give warning that the component unsupervised.
contains a corrosive substance.
See Acids and Alkalis in this subsection.
White Spirit
See Solvents.
5. Displaying the caution circle with a deleted

lighted match symbol, caution against the use
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Standard Workshop Practices
Vehicle in Workshop – extinguish all flames and lighted tobacco.

When working on a vehicle in the workshop – shut off electrical and air powered equipment.
always make sure that: – evacuate the area.
– the parking brake is applied or the wheels are – ventilate the area.
securely chocked to prevent the vehicle – contact the fire control authorities.
moving forwards or backwards. – remove the vehicle to a dedicated, ventilated
– the key is removed from key operated hood area.
locks before any work is carried out around the
front of the vehicle.
– if the engine is to be run, there is adequate Alternative Fuel — Do's
ventilation, or an extraction hose to remove – Do work on the vehicle in a designated area
exhaust fumes. that is well ventilated and with access
– there is adequate room to raise the vehicle restricted to qualified personnel only.
and remove the wheels, if necessary. – Install new warning labels to their original
– fender covers are always fitted if any work is to locations.
be carried out in the engine compartment. – If possible always isolate the alternative fuel
– the battery is disconnected if working on the tank, and run the vehicle on the alternative fuel
engine, underneath the vehicle, or if the until it automatically switches to its normal fuel
vehicle is raised. prior to taking the vehicle into the
workshop/service area.
CAUTION: When electric arc welding on a – Only use tested and approved components
vehicle, always disconnect the generator and pipes when repairing or servicing LPG
wiring to prevent the possibility of a and CNG systems.
surge of current causing damage to the
internal components of the generator.
– If using welding equipment on the vehicle, a Alternative Fuel — Do Nots
suitable fire extinguisher is readily available.
– Do not vent off LPG fuel.
– Do not use shop air pressure to force LPG fuel
Alternative Fuel from the fuel tank.
– Do not use paint drying ovens above 40°C for
WARNING: When servicing the fuel any alternative fuel vehicles. LPG and CNG
system always follow the recommended fuel tanks must be removed from the vehicles
procedures. Failure to follow these prior to being put into paint drying ovens above
instructions may result in personal injury. 40°C.
If the odor of liquefied petroleum gas (LPG) or – Do not modify the system or install new
compressed natural gas (CNG) is present in the components that are not designed for gas
air in the workshop, warn all persons in the area vehicles.
to: – Do not evacuate fuel tanks unless there is
repair that requires the removal of the fuel
tank.
– Do not work on the fuel lines or system
components unless the alternative fuel has
been evacuated and the pressure in the
system reduced to atmospheric or less.
– Do not use anything other than the specified
leak detector fluid to trace fuel leaks.
Be aware of situations that may cause the LPG or
CNG fuel system to vent off fuel, such as:
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– extremely hot days. CAUTION: A discharged battery condition

– parking by a space heater. may have been caused by an electrical
– hoisting a vehicle up near a ceiling heater. short circuit. If this condition exists there
will be an apparently live circuit on the
Only fully trained personnel, who are conversant vehicle even when all normal circuits are
with local standards, are to work on alternative switched off. This can cause arcing when
fuel vehicles. the jumper cables are connected.
CAUTION: While it is not recommended
Towing the Vehicle that the vehicle is jump started, it is
recognized that this may occasionally be
WARNING: When the vehicle is being the only practical way to mobilize a
towed the ignition switch must be in vehicle. In such an instance, the
position II (steering lock released and discharged battery must be recharged
warning lamps illuminated). Only then immediately after jump starting to avoid
will the steering, turn signal lamps, horn permanent damage.
and stop lamps be operational. Failure to
– Always make sure that the jumper cables are
follow these instructions may result in
adequate for the task. Heavy duty cables must
personal injury.
be used.
NOTE: The removable towing eye (if equipped),
– Always make sure that the slave battery is of
has a left-hand thread and must be fully tightened
the same voltage as the vehicle battery. The
before towing can commence.
batteries must be connected in parallel.
When towing is necessary, the vehicle towing – Always make sure that switched electric
eyes should be used. The rope must be securely circuits are switched off before connecting
fastened to the towing eyes and must also be jumper cables. This reduces the risk of arcing
attached to the other vehicle such that the rope occurring when the final connection is made.
will not foul the bodywork.
When a vehicle with automatic transmission is
towed, the gear selector must be in position N
(Neutral). Never tow a vehicle with automatic
transmission at a speed greater than 30 mph (50
km/h) or for a distance greater than 30 miles (50
km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off
the ground.
Alternatively the vehicle can be transported on a
low loader or a trailer.
Connecting a Slave Battery Using Jumper WARNING: Make sure that the ends of the
Cables jumper cables do not touch each other or
ground against the vehicle body at any
WARNING: If the slave battery has time while the cables are attached to the
recently been charged and is gassing, battery. A fully charged battery, if shorted
cover the vent plugs or covers with a through jumper cables, can discharge at
damp cloth to reduce the risk of a rate well above 1000 amps causing
explosion should arcing occur when violent arcing and very rapid heating of
connecting the jumper cables. Failure to the jumper cables and terminals, and can
follow these instructions may result in even cause the battery to explode. Failure
personal injury. to follow these instructions may result in
personal injury.
Always connect the jumper cables in the following
sequence:
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– Slave battery positive first and then vehicle – Blowing dirt off with compressed air. Eye
battery positive. protection must be worn when using this
– Slave battery negative next and then vehicle method.
ground at least 12 inches (300 mm) from the – Removal of dry dust using vacuum equipment.
battery terminal, for example engine lifting This method should always be used to remove
eye. friction lining material dust (asbestos
particles).
Always reduce the engine speed to idle before
disconnecting the jumper cables. – Steam cleaning.
Before removing the jumper cables from the WARNING: Most solvents require careful
vehicle that had the discharged battery, switch on handling and some are harmful. Refer to
the heater blower (high) or the heated rear window, Health and Safety Precautions and to the
to reduce the voltage peak when the cables are manufacturers literature for safety
removed. precautions. Failure to follow these
Always disconnect the jumper cables in the instructions may result in personal injury.
reverse order to the connecting sequence and do Various solvents are available which are suitable
not short the ends of the cables. for component cleaning. Some components such
Do not rely on the generator to restore a as brake hydraulic parts and electrical assemblies
discharged battery. For a generator to recharge a should be cleaned only with recommended
battery, it would take in excess of eight hours solvents — refer to Solvents, Sealers and
continuous driving with no additional loads placed Adhesives or to the section of the manual relevant
on the battery. to the component.
Component Cleaning Calibration of Essential Measuring Equipment
To prevent ingress of dirt, accumulations of loose WARNING: Failure to follow these

dirt and greasy deposits should be removed instructions may result in personal injury
before disconnecting or dismantling components or damage to components.
or assemblies. It is of fundamental importance that certain
Components should be thoroughly cleaned before essential equipment, for example torque
inspection prior to reassembly. wrenches, multimeters, exhaust gas analyzers or
rolling roads, are regularly calibrated in
accordance with the manufacturers instructions.
Cleaning Methods:
– Dry cleaning.
– Removal of loose dirt with soft or cable
brushes.
– Scraping dirt off with a piece of metal or wood.
– Wiping off with a rag.
CAUTION: Compressed air is sometimes
'wet' so use with caution, especially on
hydraulic systems.
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Solvents, Sealants and Adhesives
Introduction
WARNING: Always handle all solvents,
sealers and adhesives with extreme care.
Some contain chemicals or give off
fumes which can be dangerous to health.
Always follow the manufacturers
instructions. If in doubt about any
substance, particularly a solvent, DO
NOT use it.
CAUTION: If in doubt about the suitability
of any proprietary solvent or sealer for a
particular application, contact the
manufacturer of the product for
information regarding storage, handling
and application.
The Health and Safety Precautions subsection
refers to some commonly used chemicals and
materials, hazards associated with their use, and
safety measures to be taken.
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Road/Roller Testing
Road or roller testing may be carried out for – the engine oil level.
various reasons and a procedure detailing pre-test – the engine coolant level.
checks, engine starting and stopping, pre-driving – the tires, for correct pressure, compatible
checks, on-test checks and final checks to be
types and tread patterns, and wear within
completed on completion of the test is given
limits.
below.
– that there is sufficient fuel in the tank to
Unless complete vehicle performance is being complete the test.
checked, the full road test procedure need not be
– all around the engine, transmission and under
carried out. Instead, those items particularly
the vehicle for oil, coolant, hydraulic and fuel
relevant to the system(s) being checked can be
leaks. Make a note of any apparent leaks and
extracted.
wipe off the surrounding areas to make it
easier to identify the extent of the leak on
completion of the test.
Pre-Test Checks
WARNING: If the brake system hydraulic
fluid level is low, pedal travel is excessive Starting the Engine
or a hydraulic leak is found, do not NOTE: On initial drive away from cold and within
attempt to road test the vehicle until the the first 1.5 km (1 mile), do not depress the
reason for the low fluid level, excessive accelerator pedal beyond half travel until the
pedal travel or hydraulic leak is found vehicle has attained a minimum speed of 25 km/h
and rectified. (15 miles/h). Never operate at high engine speed
It is suggested that pre-test checks and functional or with the accelerator pedal at full travel whilst the
tests of those systems and circuits which affect engine is cold.
the safe and legal operations of the vehicle, such With the ignition switched off, check:
as brakes, lights and steering, should always be
carried out before the road or roller test. – that the parking brake is applied.
– that the gear lever is in the neutral position.
With the ignition switched off, check:
– that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
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– that the ignition controlled warning lamps are steering is returned to the straight ahead
illuminated. position.
– that the engine temperature gauge registers a – that the heating and ventilation systems
reading compatible with the engine operate correctly and effectively.
temperature. – the brake operation and efficiency.
– that the fuel gauge registers a reading
appropriate to the fuel level in the tank.
– the operation of the parking brake warning Brake Testing
lamp and fluid level warning indicator.
WARNING: When brake testing, avoid
breathing the fumes from hot brakes, this
may contain asbestos dust which is
Road or Roller Testing
hazardous to health. Failure to follow this
CAUTION: If road testing, check the brake instruction may result in personal injury.
operation while still traveling at low For additional information, refer to Health
speed before continuing with the test. If and Safety Precautions in this section.
the brakes pull to one side, or appear to
CAUTION: Avoid brake testing on busy
be otherwise faulty, do not continue with
roads where it may cause inconvenience
the road test until the fault has been
or danger to other road users.
found and rectified.
During the road or roller test, check: CAUTION: Brake testing which includes
heavy brake applications should not be
– that the clutch pedal operation is not stiff or carried out with new brake pads/discs or
heavy. linings/drums until the components have
– that the initial gear engagement is smooth and bedded-in. New brake friction
there is no evidence of clutch drag. components will not reach full efficiency
– that the parking brake control operates until the bedding-in process is complete.
smoothly and releases quickly and completely. Test the brakes at several speeds within the
– that the clutch takes up the drive smoothly, normal operating range using both light and heavy
without slip or judder. pedal pressure. Note any tendency to snatch, pull
– that gear changing is smooth with no abnormal or drag, and any undue delay in application or
noises or vibrations from the transmission. release.
– the engine power output is satisfactory, full Allow the vehicle to coast and note any tendency
power is achieved, acceleration is smooth and to pull to one side, or evidence that the brakes are
pedal operation is not stiff or heavy, and binding.
engine speed returns to idle correctly.
After stopping the vehicle (not immediately after a
– there is no excessive or abnormally colored period of heavy braking), carefully check the brake
smoke from the engine under normal driving, temperature. A brake disc or brake drum that feels
heavy load or overrun conditions. hot or is appreciably hotter than the others,
– that steering operation, including power indicates that the brake is binding.
steering (if equipped), is smooth, accurate, not
After completion of the test, check for:
excessively heavy or with excessive free play
or vibration. – oil, coolant, hydraulic, air and fuel leaks.
– that the steering does not pull to one side and – abnormal temperature of any moving
self centers smoothly after cornering. components or assemblies, for example wheel
– that the speedometer, coolant temperature hubs, transmission and axle, which might
gauge and tachometer (if equipped) register indicate over tightness or lack of lubrication.
the correct readings and operate correctly.
– that the switches and controls operate
smoothly and positively, warning and indicator
lamps operate correctly and the direction
indicator control self cancels when the
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100-01-1 Identification Codes 100-01-1
SECTION 100-01 Identification Codes

CONTENTS PAGE
Identification Codes .......................................................................................................... 100-01-2

Identification Codes.......................................................................................................... 100-01-2
VIN (an example of VIN shown) ....................................................................................... 100-01-3/5
Vehicle Certification Label (Typical) or VIN Plate ............................................................. 100-01-6
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Identification Codes
Identification Codes
The vehicle identification plate (VIN plate) is vehicle build specification to be established. The
located on the right-hand B-pillar. The codes vehicle identification number (VIN) may also be
stamped or printed on the VIN plate during viewed through the windshield or in the drivers
production enable the precise details of the compartment where it is stamped into the floor
panel.
Item Part Description

Number
1 - Visible VIN
2 - VIN on the floor panel
3 - Vehicle identification plate
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VIN (an example of VIN shown)

Item Part Description Number
Number
5 - VIN Position 11 - Year of
1 - VIN Position 1, 2 and 3 - manufacture
World manufacturer identifier
6 - VIN Position 12 - Month of
2 - VIN Position 5 and 6 - Con- manufacture
stant X
7 - VIN Positions 13 to 17 - Ve-
3 - VIN Position 7 and 8 - hicle serial number
Product source company and
assembly plant 8 - VIN Position 4 and 10 - Body
type
4 - VIN Position 9 - Model
VIN Position 1, 2 and 3 - World Manufacturer Identifier

Codes World Manufacturer
WF0 Ford-Werke AG Germany (European vehicles)
VIN Position 4 and 10 - Body Type

Code Body Type
W Wagon
3 3-door
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Code Body Type

4 4-door
5 5-door
VIN Position 5 and 6 - Constant X
VIN Position 7 and 8 - Product Source Company and Assembly Plant

Code Product Source Company and Assembly Plant
WP Valencia/Spain
GC Saarlouis/Germany
VIN Position 9 - Model

Code Model
D Focus
VIN Position 11 - Year of Manufacture

Code Year of Manufacture
4 2004
5 2005
6 2006
7 2007
8 2008
9 2009
VIN Position 12 - Month of Manufacture

Month 2004 2005 2006 2007 2008 2009
January B J L C B J
February R U Y K R U
March A M S D A M
April G P T E G P
May C B J L C B
June K R U Y K R
July D A M S D A
August E G P T E G
September L C B J L C
October Y K R U Y K
November S D A M S D
December T E G P T E
VIN Positions 13 to 17 - Vehicle Serial Number
Five Digit Number
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Vehicle Certification Label (Typical) or VIN

Plate

Number
10 - Door combination
1 - National or whole vehicle
type approval 11 - Exhaust emission level
codes
2 - VIN
12 - Body color codes
3 - Gross vehicle mass (GVM)
13 - Interior trim codes
4 - Gross train mass (GTM)
14 - Voice control module lan-
5 - Maximum permissible front guage codes
axle mass
15 - Transaxle codes and trans-
6 - Maximum permissible rear axle final drive ratio
axle mass
16 - Engine codes
7 - Smoke value (Diesel only)
17 - Hand of drive
8 - Model body or type
18 - Axle mounting (Transit only)
9 - Model type
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Items 1 to 6: Vehicle Certification Label

Item Details
Item 1: National or whole vehicle type approval A unique code required by legislation in certain
territories.
Item 2: VIN Vehicle identification number.
Item 3: GVM Indicates maximum legal laden mass, in territories
where this is required.
Item 4: GTM Indicates the maximum combined mass of vehicle
and trailer or caravan.
Item 5: Maximum permissible front axle mass Maximum permissible loading on the front wheels
of the vehicle.
Item 6: Maximum permissible rear axle mass Maximum permissible loading on the rear wheels of
the vehicle.
Item 7: Smoke Value (Diesel only)

Number Smoke Value
Per meter
Item 8: Model Body or Type

Code Model Body or Type
DA3 3-door
DB3 4-door
DA3 5-door
DA3 Wagon
Item 9: Model Type

Code Model Type
- -
Item 10: Door Combination

Code Door Combination
- -
Item 11: Exhaust Emission Level Codes

Code Exhaust Emissions
K Stage V
S 2000 EEC (Stage III)
V Stage IV + Diesel Particulate Filter (DPF)
7 Stage IV
Item 12: Body Color Codes

Code Body Color
C Colorado Red
D Machine Silver
F Panther Black
G Aquarius
I Ink Blue
K Magnum Grey
L Flare
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Code Body Color

N Diamond White
O Moondust Silver
U Vitro
V Deep Navy
W Honor Green
X Neptune Green
Z Tonic
1 Sublime
2 Jeans
3 Stirling Silver
9 Deep Rosso Red
For vehicles built in continental plants, the second digit of the paint code, on the VIN label, denotes the original
model year of the color’s introduction, (‘0’=color introduction in 2000 model year).
Item 13: Interior Trim Codes

Code Interior Trim
AD Element - Dark Flint
AE Humy - Dark Flint
AF Louis Leather - Dark Flint
AG Linea - Dark Flint
AH Blue Element - Dark Flint
AM Chess - Dark Flint
AN Rack - Dark Flint
AP Cubical - Dark Flint
AR Span - Dark Flint
AU Stripy/Gene - Dark Flint
AV Stripy - Dark Flint
A9 Culture - Dark Flint
BF Louis Leather - Ebony
BG Linea - Ebony
BJ Light Flint - Ebony
BL Medium light Flint - Ebony
CF Louis Leather - Camel
CG Linea - Camel
CK Camel Verona - Camel
DE Humy - Medium Light Flint
DF Leather - Medium Light Flint
FD Element - Blue
LF Leather - Medium Light Stone Blue
LN Rack - Medium Light Stone Blue
LR Span - Medium Light Stone Blue
VE Humy - Medium Light Stone Blue
VM Louis Leather - Medium Light Stone Blue
VN Rack - Medium Light Stone Blue
VP Cubical - Medium Light Stone
VR Span - Medium Light Stone
Item 14: Voice Control Module Language Codes
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Code Voice Control Module Language

1 English
2 French
3 Spanish
4 German
5 Italian
Item 15: Transaxle Codes and Final Drive Ratio Codes

Code Transaxle Final Drive Ratio
Q 5-Speed Manual Transaxle (MTX-75) 4.07
R Automatic Transaxle (CFT23) 5.19
W 5-Speed Manual Transaxle (iB5) 4.06
2 4-Speed Automatic Transaxle (4F27 E) 4.203
6 6-Speed Manual Transaxle (MMT6) 4.07/2.85 (a)
a) The 6-speed manual transaxle (MMT6) has two output shafts. First, second, third and fourth gears have the
higher final drove ratio. Fifth, sixth and reverse gears have the lower final drive ratio.
Item 16: Engine Codes

Code Engine
A 1.4L Duratec-16V (Sigma) (75 PS)
B 1.6L Duratec-16V (Sigma) (100 PS)
C 1.6L Duratec-16V Ti-VCT (Sigma) (115 PS)
D 1.8L Duratec-HE (MI4) (120 PS)
E 2.0L Duratec-HE (MI4) (145 PS)
G 1.8L Duratec-16V (LPG)
H 1.8L Duratec-HE (MI4) (125 PS)
3 2.0L Duratorq-TDCi (DW) Diesel (136 PS)
Item 17: Hand of Drive

Code Drive
E Left-hand drive
F Right-hand drive
U Left-hand drive
V Right-hand drive
1 Left-hand drive
2 Right-hand drive
5 Left-hand drive
6 Right-hand drive
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100-02-1 Jacking and Lifting 100-02-1
SECTION 100-02 Jacking and Lifting

CONTENTS PAGE
Jacking ............................................................................................................................. 100-02-2

Lifting ................................................................................................................................ 100-02-3
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Jacking
WARNING: Always position the vehicle on CAUTION: It is important that only the
a hard level surface. If the vehicle must correct jacking and support locations are
be jacked up on a soft surface use load used at all times.
spreading blocks under the jack. Always NOTE: When using the vehicle jack, refer to the
chock the wheel diagonally opposite the owner guide for correct operating instructions.
jacking point. Failure to follow these
instructions may result in personal injury.
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Lifting
CAUTION: When lifting the vehicle with a CAUTION: It is important that only the
two post lift, vehicle lift arm adapters correct lifting and support locations are
must be used under the lifting points. used at all times.
CAUTION: When lifting the vehicle with a
two post lift, the maximum curb weight
must not be exceeded.
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100-04-1 Noise, Vibration and Harshness 100-04-1
SECTION 100-04 Noise, Vibration and Harshness

CONTENTS PAGE
Noise, Vibration and Harshness (NVH) ............................................................................. 100-04-2

Diagnostic Theory ............................................................................................................ 100-04-2
Know the System ............................................................................................................. 100-04-2
Know the History of the System ....................................................................................... 100-04-2
Know the History of the Condition .................................................................................... 100-04-2
Know the Probability of Certain Conditions Developing .................................................... 100-04-2
Do Not Cure the Symptom and Leave the Cause............................................................. 100-04-2
Be Positive the Cause is Found ....................................................................................... 100-04-3
Diagnostic Charts............................................................................................................. 100-04-3
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH) ............................................................................. 100-04-4

Inspection and Verification ............................................................................................... 100-04-4
Noise Diagnostic Procedure ............................................................................................. 100-04-4
Road Test ........................................................................................................................ 100-04-5
Road Test Quick Checks.................................................................................................. 100-04-6
Road Conditions............................................................................................................... 100-04-6
Vehicle Preparation.......................................................................................................... 100-04-7
Power Steering Conditions ............................................................................................... 100-04-7
Power Steering Operation Noise Check ........................................................................... 100-04-7/8
Symptom Chart ................................................................................................................ 100-04-9/13
Pinpoint Tests .................................................................................................................. 100-04-14/18
GENERAL PROCEDURES
Powertrain/Drivetrain Mount Neutralizing ...................................................... (14 001 0) 100-04-19
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Noise, Vibration and Harshness (NVH)

Noise, vibration and harshness (NVH) is – How old or new is the system?
becoming more important as vehicles become – What kind of treatment has it had?
more sophisticated and passenger comfort levels
– Has it been serviced in the past in such a
increase. This section is designed to aid in the
manner that might relate to the present
diagnosis and testing and repair of NVH concerns.
condition?
– Noise is defined as sounds not associated with – What is the service history?
the operation of passenger compartment
equipment that interface with customer
satisfaction. Know the History of the Condition
– Vibration is defined as impulses felt by the
– Did it start suddenly or appear gradually?
customer that are not caused by road surface
changes. – Was it related to some other occurrence such
as a collision or previous part replacement?
– Harshness is a ride quality issue where the
customer feels that the vehicle response to the – Know how the condition made itself known; it
road surface is sharply transmitted to the may be an important clue to the cause.
customer.
Know the Probability of Certain Conditions

Diagnostic Theory Developing
Diagnosis is more than just following a series of – Look for the simple rather than the complex.
interrelated steps in order to find the solution to – For example:
the specific condition. It is a way of looking at - Electrical conditions usually occur at
systems that are not functioning the way they connections rather than components.
should and finding out why. Also it is knowing how
- An engine no-start is more likely to be
the system should work and whether it is working
caused by a loose wire or small adjustment
correctly.
rather than a sheared-off camshaft.
There are basic rules for diagnosis. If these rules – Know the difference between impossible and
are followed, the cause of the condition is usually improbable. Certain failures in a system can
found the first time through the system. be improbable but still happen.
– New parts are just that, new. It does not mean
they are always good functioning parts.
Know the System
– Know how the parts go together.
– Know how the system operates as well as its Do Not Cure the Symptom and Leave the
limits and what happens when the system Cause
goes wrong. Lowering the pressure in a front tire may correct
– Sometimes this means checking the system the condition of a vehicle leaning to one side, but it
against one that is known to be working does not correct the original condition.
correctly.
Know the History of the System

A clue in any one of these areas may save time:
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Be Positive the Cause is Found

– Double check findings.
– What caused a worn component?
– A loose transmission or engine mount could
indicate that other mounts are also loose.
Diagnostic Charts
Charts are a simple way of expressing the
relationship between basic logic and a physical
system of components. They help discover the
cause of a condition in the least time. Diagnostic
charts combine many areas of diagnosis into one
visual display:
– Probability of certain things occurring in a
system.
– Speed of checking certain components or
functions before others.
– Simplicity of performing certain tests before
others.
– Elimination of checking huge portions of a
system by performing simple tests.
– Certainty of narrowing down the search to a
small portion before performing in-depth
testing.
The fastest way to find a condition is to work with
the tools that are available. This means working
with proven diagnostic charts and the correct
special equipment for the system.
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Noise, Vibration and Harshness (NVH)

DIAGN OSIS AND TESTIN G
Inspection and Verification – tires

1. Verify the customer concern. – engine accessories
2. Visually inspect for obvious signs of – suspension
mechanical or electrical damage. – driveline
3. If an obvious cause for an observed or It is important, therefore, that an NVH concern be
reported concern is found, correct the cause isolated into its specific area(s) as soon as
(if possible) before proceeding to the next possible. The easiest and quickest way to do this
step. is to carry out the Road Test as outlined. To assist
4. If the concern is not visibly evident, verify the in the diagnosis and testing procedure(s), use a
symptom and REFER to the Symptom Chart. suitable approved NVH diagnosis tester.
How To Use This Diagnostic Procedure Section Noise Diagnostic Procedure

– Noise, vibration and harshness (NVH)
concerns have become more important as
Non-Axle Noise
vehicles have become more sensitive to these
vibrations. This section is designed to aid in The five most common sources of non-axle noise
identifying these concerns. are exhaust, tires, roof racks, trim panels and
– The section provides diagnostic procedures transmission.
based on symptom. If the condition occurs at Therefore, make sure that none of the following
high speed, for instance, the most likely place conditions are the cause of the noise before
to start is under Shake and Vibration While proceeding with a driveline teardown and
Driving. diagnosis.
– The road test procedure will tell how to sort the
conditions into categories and how to tell a
vibration from a shake.
– A series of Road Test Quick Checks is
provided to make sure that a cause is either
pinpointed or eliminated.
– Name the condition, proceed to the
appropriate section and locate the correct
diagnosis. When the condition is identified, the
job is partly done.
– Follow the diagnostic procedure as outlined.
– Quick Checks are described within the step,
while more involved tests and adjustments are
outlined in General Procedures.
– Always follow each step exactly and make
notes to recall important findings later.
Customer Interview
The road test and customer interview (if available)
provide information that will help identify the
concern and will provide direction to the correct
starting point for diagnosis.
Identify the Condition

NVH usually occur in four areas:
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DIAGNOSIS AND TESTING (Continued)
– In certain conditions, the pitch of the exhaust Vibration Conditions

may sound very much like gear noise. At other
Vibration at highway speeds may be caused by
times, it can be mistaken for a wheel bearing
the following:
rumble.
– Tires, especially snow tires, can have a high – out-of-balance front or rear wheels
pitched tread whine or roar, similar to gear – out-of-round tires
noise. Radial tires, may have this Shudder or vibration during acceleration may be
characteristic. Also, any non-standard tire with caused by the following:
an unusual tread construction may emit a roar
or whine noise. – damaged powertrain/drivetrain mounts
– Trim panels can also cause whistling or – excessively high constant velocity (CV) joint
whining noise. operating angles caused by incorrect ride
– Clunk may be a metallic noise heard when the height. Check ride height, verify correct spring
automatic transaxle is engaged in REVERSE rate and check items under Inoperative
or DRIVE, or it may occur when the throttle is Conditions
applied or released. It is caused by backlash
somewhere in the driveline.
Road Test
– Bearing rumble sounds like marbles being
tumbled. This condition is usually caused by a A gear-driven unit will produce a certain amount of
damaged wheel bearing. noise. Some noise is acceptable and may be
audible at certain speeds or under various driving
conditions, as on a newly paved asphalt road. The
Noise Conditions slight noise is in no way detrimental and must be
– Gear noise is typically a howling or whining considered normal.
due to gear damage or incorrect bearing The road test and customer interview (if available)
preload. It can occur at various speeds and provide information needed to identify the
driving conditions, or it can be continuous. condition and give direction to the correct starting
– Chuckle is a particular rattling noise that point for diagnosis.
sounds like a stick against the spokes of a
spinning bicycle wheel. It occurs while
decelerating from 64 km/h (40 mph) and can
usually be heard all the way to a stop. The
frequency varies with vehicle speed.
– Knock is very similar to chuckle, though it may
be louder and occurs on acceleration or
deceleration. The teardown will disclose what
has to be corrected.
Clicking, popping or grinding noises may be
caused by the following:
• worn, damaged or incorrectly installed wheel
bearing, suspension or brake component.
Check and rule out tires, exhaust and trim items
before disassembling the transaxle to diagnose
and correct gear noise.
The noises described under Road Test usually
have specific causes that can be diagnosed by
observation as the unit is disassembled. The initial
clues are the type of noise heard on the road test
and the driving conditions.
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1. Make notes throughout the diagnosis routine. by applying the brakes lightly. REFER to Idle
Make sure to write down even the smallest bit Boom/Shake/Vibration in the Symptom Chart.
of information, because it may turn out to be 3. High Speed: A vibration is felt in the front floor
the most important. pan or seats with no visible shake, but with an
2. Do not touch anything until a road test and a accompanying sound or rumble, buzz, hum,
thorough visual inspection of the vehicle have drone or booming noise. Coast with the clutch
been carried out. Leave the tire pressures and pedal depressed (manual transmission) or
vehicle load just where they were when the shift control selector lever in neutral
condition was first observed. Adjusting tire (automatic transmission) and engine idling. If
pressures, vehicle load or making other vibration is still evident, it may be related to
adjustments may reduce the condition(s) wheels, tires, front brake discs, wheel hubs or
intensity to a point where it cannot be front wheel bearings. REFER to Shake and
identified clearly. It may also inject something Vibration While Driving in the Symptom Chart.
new into the system, preventing correct 4. Engine rpm Sensitive: A vibration is felt
diagnosis. whenever the engine reaches a particular rpm.
3. Make a visual inspection as part of the It will disappear in neutral coasts. The
preliminary diagnosis routine, writing down vibration can be duplicated by operating the
anything that does not look right. NOTE tire engine at the problem rpm while the vehicle is
pressures but do not adjust them yet. NOTE stationary. It can be caused by any
leaking fluids, loose nuts and bolts or bright component, from the accessory drive belt to
spots where components may be rubbing the clutch or torque converter which turns at
against each other. Check the load space for engine speed when the vehicle is stopped.
unusual loads. REFER to Shake and Vibration While Driving
4. Road test the vehicle and define the condition in the Symptom Chart.
by reproducing it several times during the road 5. Noise and Vibration While Turning: Clicking,
test. popping, or grinding noises may be due to the
5. Carry out the Road Test Quick Checks as following:
soon as the condition is reproduced. This will – worn, damaged, or incorrectly installed front
identify the correct diagnostic procedure. wheel bearing
Carry out the Road Test Quick Checks more – damaged powertrain/drivetrain mounts
than once to verify they are providing a valid
result. Remember, the Road Test Quick
Checks may not tell where the concern is, but Road Conditions
they will tell where it is not.
An experienced technician will always establish a
route that will be used for all NVH diagnosis road
Road Test Quick Checks tests. The road selected should be reasonably
smooth, level and free of undulations (unless a
1. At a speed of 24-80 km/h (15-50 mph): With particular condition needs to be identified). A
light acceleration, a moaning noise is heard smooth asphalt road that allows driving over a
and possibly a vibration is felt in the front floor range of speeds is best. Gravel or bumpy roads
pan. It is usually worse at a particular engine are unsuitable because of the additional road
speed and at a particular throttle setting noise produced. Once the route is established and
during acceleration at that speed. It may also consistently used, the road noise variable is
produce a moaning sound, depending on eliminated from the test results.
what component is causing it. REFER to
Tip-In Moan in the Symptom Chart. NOTE: Some concerns may be apparent only on
smooth asphalt roads.
2. Acceleration/Deceleration: With slow
acceleration and deceleration, a shake is If a customer complains of a noise or vibration on
sometimes noticed in the steering a particular road and only on a particular road, the
wheel/column, seats, front floor pan, front source of the concern may be the road surface. If
door trim panel or front end sheet metal. It is a possible, try to test the vehicle on the same type of
low frequency vibration (around 9-15 cycles road.
per second). It may or may not be increased
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Vehicle Preparation • Check for the noise in several temperature

conditions.
Carry out a thorough visual inspection of the
vehicle before carrying out the road test. Note • Is the noise from when the vehicle was new?
anything which is unusual. Do not repair or adjust • Can the noise be repeated constantly or is it
any condition until the road test is carried out, random?
unless the vehicle is inoperative or the condition • Check the condition of the vehicle age,
could pose a hazard to the technician. mileage and service record.
After verifying that the condition has been • Interview the customer to find the operating
corrected, make sure all components removed condition in which the noise will occur. Test the
have been installed. vehicle based on the detail(s) from the
customer interview.
• Follow the power steering operation noise
Power Steering Conditions condition tables below, to find which condition
Check for the noise in the following conditions to the noise will occur.
verify the customer concern.
Power Steering Operation Noise Check
Step 1: Check for NVH concerns from
non-steering components, which may sound like
noises coming from the steering system.
Power assisted steering operating condition
Parking Driving
Steering central/slightly Steering at a steering Driving straight ahead Cornering condition
off center lock stop
REFER to NVH con- REFER to NVH con- REFER to NVH con- REFER to NVH con-
cerns from other com- cerns from other com- cerns from other com- cerns from other com-
ponents column A ponents column B ponents column C ponents column D
NVH concerns from other components

NVH concerns from other condition (column A to D)
Noise Driving Condition A B C D
Pedal box knocking Drive off, stop driving and slow cornering X X O X
over uneven roads
Stabilizer bar link Drive off, driving and cornering X O O X
knocking
Engine support insu- Drive off, driving, acceleration and de- X X
lator knocking celeration
Air conditioning Engine on, activate switch for air condi- X X O O
knocking tioning
Suspension knocking Drive off, driving, cornering, acceleration X O X
(Subframe, Springs) and deceleration
Constant velocity joint Drive off, driving, cornering, acceleration X O X
knocking and deceleration
Washer bottle Deceleration, acceleration and single O X
impact
Loose suspension All driving conditions O O X
bolts
Instrument panel rat- All driving conditions. Engine RPM de- X X X X
tle/squeak pendant
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NVH concerns from other condition (column A to D)

Noise Driving Condition A B C D
• X = Noise will most likely occur in this operating condition.
• O = Noise can possibly occur in this operating condition.
• Blank = Noise is unlikely to occur in this operating condition.
Step 2: Check for steering system NVH concerns
according to operation condition described at the
customer interview.
Power assisted steering operating condition
Parking Driving Vehicle stationary with engine off
Steering Steering at a Steering cen- Steering at a Steering cen- Steering at a
cen- steering lock tral/slightly off steering lock tral/slightly off cen- steering lock stop
tral/slightly stop center stop tre
off center
REFER to REFER to REFER to REFER to REFER to steering REFER to steering
steering steering sys- steering sys- steering system system NVH con- system NVH con-
system NVH tem NVH tem NVH NVH concerns cerns column E cerns column F
concerns concerns concerns column D
column A column B column C
Steering system NVH concerns

Steering System operation condition (column A to F)
Noise Driving condition A B C D E F
Moan Parking between lock stops, at engine idle and X O
also increased engine speed
Whine Driving, high engine RPM. Must be present from O O X X
new
Hiss a) Parking between lock stops. Must be present X X O O
from new
b) Holding steering wheel against lock stops. Must X
be present from new
Lock Stop Impact a) Parking at lock stop. Must be present from new X X
Knock
Mechanical Knock b) Parking between lock stops, engine off. Must be X
(PAS off) present from new
Mechanical Knock c) Parking between lock stops, engine on (ball joint X
(PAS on) knock)
Hammer Knock d) Parking into lock stop and release (vehicle with X
hydraulic power assisted steering (HPAS) only,
not for vehicles with electro-hydraulic power as-
sisted steering (EHPAS))
Hydraulic Knock e) Driving, cobble stones, rough road (clonk). Must O X
(clonk) be present from new
Column Knock f) Parking, driving. cobble stones and rough roads X X O X X X
Column rattle Mainly driving on rough roads O X X O
Toc-toc Steering left and right at high frequency. Must be X
present from new
Grinding When turning steering wheel X O X
Zip At engine start, low temperatures below -10 °C X O
only
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Steering System operation condition (column A to F)

Noise Driving condition A B C D E F
• X = Noise will most likely occur in this operating condition.
• O = Noise can possibly occur in this operating condition.
• Blank = Noise is unlikely to occur in this operating condition.
Step 3: According to each identified operating 1. Engine speed at idle with no steering action.
condition (Column A, B, C, D, E, F), check each 2. Engine speed at idle with slow 90 degrees/sec
possible Steering System NVH concern with the turning of the steering wheel.
detail symptom charts below.
3. Engine speed at 1250 +/- 50 RPM with no
Before conducting vehicle a test to identify a NVH steering action.
concern inspect the vehicle. 4. Engine speed at 1250 +/- 50 RPM with slow
1. Check the tire pressures and adjust to 90 degrees/sec turning of the steering wheel.
specification, as necessary.
2. Make sure the steering system fluid is correct,
the system is free of leaks and is operating
correctly.
3. Make sure the vehicle steering system
temperature is the same as described at the
customer interview.
4. All evaluations must take place in a relatively
quiet location.
5. The heating - A/C fan and radio must be
turned off during evaluations and the windows
closed.
Symptom Chart
Power Steering Moan Noise

Test Condition
Listen for steering moan noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions.
Symptom Possible Sources Action
• CHECK the routing of the
power steering lines.
• CHECK the power steering
Power steering system moan line clamps are secure.
Power steering lines. • CHECK the power steering
noise – A continuous low pitched
humming noise occurs when the lines for clearance from the
steering wheel is turned and the vehicle body, front axle
steering system is loaded. Noise crossmember and steering
frequency changes with engine gear.
RPM changes. Particularly an- FLUSH the power steering sys-
Incorrect power steering fluid.
noying at lower engine speed. tem.
Pressure pulses from the power
steering pump. Certain amount of
Power steering pump.
noise level acceptable, not a
safety critical item.
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1. Engine speed at 1800 +/- 50 RPM with no

steering action.
Power Steering Whine Noise
2. Engine speed at 1800 +/- 50 RPM with slow
Test Condition 90 degrees turning of the steering wheel.
Listen for steering whine noise with the vehicle 3. Engine speed at 3000 +/- 50 RPM with no
parked, transmission in neutral and all windows steering action.
closed in the following test conditions. 4. Engine speed at 3000 +/- 50 RPM with slow
90 degrees turning of the steering wheel.
Power steering system whine Power steering fluid aeration. Bleed the power steering system.
noise – a high pitched buzzing FLUSH the power steering sys-
Incorrect power steering fluid.
sound like an electric motor or tem.
drill. Whine occurs at the higher FLUSH the power steering sys-
engine RPM, 1500-5000 RPM, Overheated power steering fluid.
tem.
frequency does not change if Hydraulic operating condition of Certain amount of noise level ac-
system is loaded or not loaded. the power steering pump. ceptable, not a safety critical item.
Power Steering Hiss Noise

Test Condition
Listen for steering hiss noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions.
NOTE: Engine speed at idle CHECK the installation and po-
Floor seal.
turning the steering wheel slowly tential damage of the floor seal.
lock to lock. Certain amount of noise level
Power steering system hiss noise Power steering gear valve design. acceptable, not a safety critical
– a high frequency, continuous item.
rush or swish noise like escaping
air from a balloon. Hiss occurs
while turning between the steer- Certain amount of noise level
Power steering system hydraulic
ing lock stops, all steering angles. acceptable, not a safety critical
design.
Noise does not change with en- item.
gine RPM and is worse at high
operating temperatures.
NOTE: Engine speed at idle
holding the steering wheel against
a steering lock for three seconds.
Do not hold for more than five Certain amount of noise level
seconds. Power steering pump pressure
acceptable, not a safety critical
Power steering system hiss noise relief valve. item.
– a continuous noise like escap-
ing air occurs while holding the
steering against a steering lock
stop.
1. Turn the steering wheel to the left-hand and
Power Steering Lock Stop Impact Knock Noise right-hand steering locks and listen for the
impact noise.
Test Condition
Listen for steering knock noise with the engine
speed at idle in the following test conditions (noise
also apparent with engine off).
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Power steering system knock
noise – a heavy loud sound like a Power steering gear mechanical Certain amount of noise level
knock on a door that occurs in noise, metal to metal at end of acceptable, not a safety critical
parking condition when hitting the steering travel. item.
lock stop.
1. Turn the steering wheel 90 degrees to the
Power Steering Mechanical Knock Noise (PAS off) right, hold and then quickly release.
Test Condition
2. Turn the steering wheel 90 degrees to the left,
hold and then quickly release.
Listen for steering knock noise with the engine off
in the following test conditions (no power assist).
noise – a damped, metallic knock Certain amount of noise level
noise which only occurs at steer- acceptable, not a safety critical
noise – a heavy loud repeating
ing condition with engine off (very item.
sound like a knock on a door that
high efforts).
occurs in several driving and
steering conditions. Certain amount of noise level
Tolerances in the steering gear
components.
item.
1. Turn the steering wheel to a steering lock and
Power Steering Mechanical Knock Noise (PAS on) return to center quickly.
2. Turn the steering wheel 90 degrees to the left
Test Condition
and then 90 degrees to the right quickly.
Listen for steering knock noise with the engine
speed at idle in the following test conditions
(Power assist).
Worn tie-rod ball joints (inner and
noise – clear knock noise from REFER to Steering System.
outer ball joints).
steering gear linkage area.
vehicles with hydraulic power assisted steering
(HPAS) only, not electro hydraulic power assisted
Power Steering Hammer Knock (Hydraulic) Noise steering (EHPAS)).
Test Condition 1. Turn the steering wheel into steering lock
Listen for steering knock noise with the engine position and return quickly.
speed at idle in the following test conditions (for
noise – loud, metallic sound if hit-
ting the suspension crossmember Certain amount of noise level
Hydraulic noise created by pres-
with a hammer (sounds like me- acceptable, not a safety critical
sure impulses.
tallic noise but is created by item.
pressure impulse in gear and re-
turn line).
1. Drive over cobbled roads at low speed
Power Steering Hydraulic Knock/Clonk Noise (6-20mph / 10-30km/h) with and without
turning.
Test Condition
2. Drive over straight tar strips, road rails, or
Listen for steering knock/clonk noise in the 25mm tall harshness strips at low speed
following test conditions with the windows closed.
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(6-20mph / 10-30km/h) both driving straight

and with moderate turning.
Power steering system Certain amount of noise level
knock/clonk noise – sounds al- Power steering return lines. acceptable, not a safety critical
most identical to column knock item.
that occurs when driving and High power assist gain of power Certain amount of noise level
cornering over cobbled stones or steering gear valve (steering gear acceptable, not a safety critical
rough roads. Noise may appear to design - no quality issue). item.
emanate from a location closer to
the floor than that for column
knock (Sounds like metallic noise Certain amount of noise level
but is created by pressure im- High power steering pump flow
pulse in gear and return line – rate (by design).
item.
similar to a sound like quickly
turning off a water tap).
1. Drive over cobbled stones at low speed
Power Steering Column Knock Noise (10-25 mph) with and without steering input
carefully listening for knock sounds.
Test Condition
2. Drive over straight tar strips, road rails, or 25
Listen for steering knock noise in the following test mm tall harshness strips at low speed (10-25
conditions with windows closed. mph) both driving straight and with moderate
cornering.
CHECK the steering column re-
Power steering system column taining bolts and attachments to
knock noise – a loose sounding the steering column and secure if
Steering column or steering
rattle or vibration coming from the necessary.
column shaft.
column. Noticeable by hearing Check steering column and in-
and touch. termediate shaft for lash, free play
or loose components.
1. Turn the steering wheel from left to right
Power Steering Toc-Toc Noise abruptly changing direction.
Test Condition
2. Drive the vehicle for low speed parking
manoeuvres constantly changing steering
Listen for steering toc-toc noise the engine speed direction.
at idle and the vehicle parked, transmission in
park or neutral and the windows closed.
Power steering system toc-toc
noise – a metallic noise created
Certain amount of noise level
when changing direction of Steering gear (design tolerance in
steering wheel rotation during steering rack).
item.
parking manoeuvre or at stand-
still.
1. Slowly turn the steering wheel from lock to
Power Steering Grinding Noise lock.
Test Condition
2. Tilt and extend the steering column in various
positions and slowly turn the steering wheel
Listen for steering grinding noise the engine from lock to lock.
speed at idle and the vehicle parked, transmission
in park or neutral and the windows closed.
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Steering wheel to shroud inter-
ference.
item.
Power steering system grinding
noise – an abrasive noise (like
Steering column bearing. acceptable, not a safety critical
sand paper rubbing against
item.
wood) occurs between moving
components such as steering CHECK if floor covering is ob-
wheel and the steering column Foreign material in contact with structing the steering gear pin-
shroud. the steering column shaft. ion.CHECK the installation of the
floor seal.
CHECK the clockspring and se-
Clockspring.
cure if necessary.
Power Steering Zip Noise

Power steering system zip noise Certain amount of noise level
High viscosity of power steering
– occurs when hydraulic fluid acceptable, not a safety critical
fluid at low temperature.
does not flow freely through the item.
power steering pump supply hose
from steering fluid reservoir to
power steering pump causing Aeration of the power steering
Bleed the power steering system.
cavitation at the pump. Zip is fluid.
primarily a cold weather start-up
phenomenon (below -10°C).
Driveline Noise and Vibration

• Wheel end vibration.
Shake and vibration while driving GO to Pinpoint Test A
• Engine/transmission.
• Air cleaner.
• Power assisted steering
(PAS).
Tip-in moan GO to Pinpoint Test B
• Powertrain.
• Powertrain/drivetrain mounts.
• Exhaust system.
• Cable(s)/hose(s).
Idle boom/shake/vibration, or • Powertrain/drivetrain mounts.
GO to Pinpoint Test C
shudder • Exhaust system.
• Belt/pulleys.
Suspension Noise and Vibration

• Suspension.
Wheel end vibration analysis GO to Pinpoint Test D
• Wheel bearings.
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• Trim panels.
Non-axle noise • Air conditioning (A/C) system. GO to Pinpoint Test D
• Accessories.
After verifying that the condition has been cor-
rected, make sure all components removed have
Pinpoint Tests been installed.
NOTE: These pinpoint tests are designed to take
the technician through a step-by-step diagnosis
procedure to determine the cause of a condition. It
may not always be necessary to follow the chart to
its conclusion. Carry out only the pinpoint test
steps necessary to correct the condition. Then
check the operation of the system to make sure
the condition has been corrected.
PINPOINT TEST A: SHAKE AND VIBRATION WHILE DRIVING
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: NEUTRAL COAST
1 Carry out the neutral coast test.
• Does the vibration disappear during the neutral
coast test?
→ Yes
GO to A2
→ No
GO to Pinpoint Test D
A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Visually check the hydraulic power-
train/drivetrain mounts for leaks and condition.
• Are the powertrain/drivetrain mounts OK?
→ Yes
GO to A3
→ No
A3: CHECK THE POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZATION
1 Carry out the powertrain/drivetrain mount neu-
tralizing procedure in this section.
• Is the shake and vibration OK?
→ Yes
Vehicle condition corrected. CARRY OUT a
road test.
→ No
VERIFY the customer concern.
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PINPOINT TEST B: TIP-IN MOAN

B1: CHECK THE AIR CLEANER
1 Check the condition of the air cleaner mounts,
inlet tube, outlet tube, resonators and all other
components associated with the air induction
system for correct installation and tightness of
all connections.
• Are the air cleaner and associated components
OK?
→ Yes
GO to B2
→ No
CORRECT the condition. REPEAT the Road
Test as outlined.
B2: CHECK THE EXHAUST SYSTEM
1 Check the exhaust system mounts.
• Are the exhaust system mounts OK?
→ Yes
GO to B3
→ No
INSTALL new mounts as necessary.
REPEAT the Road Test as outlined.
B3: CHECK THE POWER STEERING
1 Remove the auxiliary drive belt and test for
tip-in moan.
• Is the tip-in moan OK?
→ Yes
REPAIR the power steering as necessary.
→ No
GO to B4
B4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
→ Yes
GO to B5
→ No
B5: CHECK THE POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZATION
• Is the tip-in moan OK?
→ Yes
Vehicle condition corrected. REPEAT the
Road Test as outlined.
→ No
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PINPOINT TEST C: IDLE BOOM/SHAKE/VIBRATION/SHUDDER
C1: CHECK CABLE/HOSES
1 Check the engine compartment for any com-
ponent that may have a touch condition be-
tween the engine and body or chassis. For
example: control cable, air conditioning (A/C)
hoses, and acceleration cable.
• Are the engine compartment components OK?
→ Yes
GO to C2
→ No
CORRECT the condition. REPEAT the Road
Test as outlined.
C2: CHECK THE ENGINE COOLING RADIATOR
1 Check the engine cooling radiator mountings
and bushings for security and condition. Check
the radiator installation for any component that
may have a touch condition.
• Is the engine cooling radiator installation and
bushings OK?
→ Yes
GO to C3
→ No
REPAIR or INSTALL new components as
necessary. REPEAT the Road Test as out-
lined.
C3: CHECK THE EXHAUST SYSTEM
1 Check the exhaust system mounts.
• Are the exhaust system mounts OK?
→ Yes
GO to C4
→ No
C4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
→ Yes
GO to C5
→ No
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C5: CHECK THE POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZATION
• Is the boom/shake/vibration/shudder OK?
→ Yes
Vehicle condition corrected. REPEAT the
Road Test as outlined.
→ No
PINPOINT TEST D: WHEEL END VIBRATION ANALYSIS
D1: INSPECT THE TIRES
1 Inspect the wheels and tires.
• Are the wheels and tires OK?
→ Yes
GO to D2
→ No
INSTALL new wheels and tires as neces-
sary. REPEAT the Road Test as outlined.
D2: INSPECT WHEEL AND TIRE RUNOUT
1 Inspect the wheel and tire runout.
• Is the wheel and tire runout OK?
→ Yes
GO to D3
→ No
REPAIR as necessary. REPEAT the Road
Test as outlined.
D3: INSPECT THE WHEEL BEARINGS
1 Inspect the wheel bearings.
• Are the wheel bearings OK?
→ Yes
→ No
INSTALL new wheel bearings/wheel hub as
necessary. REPEAT the Road Test as out-
lined
PINPOINT TEST E: NON-AXLE NOISE
E1: INSPECT THE VEHICLE TRIM
1 Check the radiator grille and trim panels to see
if they are the source of the noise.
• Are the vehicle trim components causing the
noise?
→ Yes
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INSTALL new trim components or REPAIR
as necessary.
→ No
GO to E2
E2: CHECK THE HEATING AND VENTILATION SYSTEM FOR NOISE
1 Ignition switch in position III.
2 Ignition switch in position II.
3 Check the heating and ventilation system
components for noise by turning the heating and
ventilation system ON and OFF.
• Is the heating and ventilation system causing
the noise?
→ Yes
DIAGNOSE the heating and ventilation sys-
tem.
→ No
GO to E3
E3: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
1 Check the A/C system components for noise by
turning the A/C system ON and OFF.
• Is the A/C system causing the noise?
→ Yes
DIAGNOSE the A/C system.
→ No
GO to E4
E4: CHECK NON-FACTORY ACCESSORIES
1 Check any accessories for being the source of
the noise. Example: grounding body-to-frame,
antennas, visors, deflectors and fog lights.
• Are the accessories the cause of the noise?
→ Yes
ADJUST, REPAIR or INSTALL new acces-
sories or fasteners as required.
→ No
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GENERAL PROCEDURES
Powertrain/Drivetrain Mount Neutralizing (14 001 0)

GEN ERAL PROC EDURES
NOTE: There is no procedure for neutralizing the

powertrain/drivetrain mounts. To check the
alignment of the powertrain mounts visually,
proceed as follows.
1. Loosen the rear support insulator retaining
bolts (if equipped).
2. Loosen the powertrain/drivetrain mount
retaining bolts.
3. NOTE: Support the powertrain/drivetrain in an
approximate position and height.
NOTE: Make sure that the right-hand mount and
left-hand insulator align over the studs on the
powertrain and drivetrain to allow the fixings to be
assembled through the large holes in the support
insulator bracket without overstraining.
Check the powertrain/drivetrain mount
alignment.
4. Tighten the powertrain/drivetrain mount to
powertrain/drivetrain mount bracket
retaining bolts.
5. Tighten the powertrain/drivetrain mount to
body retaining bolts.
6. Tighten the rear support insulator retaining
bolts (if equipped).
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Group
Chassis 2
PAGE
SECTION TITLE
Suspension
Suspension System - General Information ............................................................................ 204-00-1
Front Suspension .................................................................................................................. 204-01-1
Rear Suspension................................................................................................................... 204-02-1
Wheels and Tires .................................................................................................................. 204-04-1
Driveline
Front Drive Halfshafts............................................................................................................ 205-04-1
Brake System
Brake System - General Information ..................................................................................... 206-00-1
Drum Brake........................................................................................................................... 206-02-1
Front Disc Brake ................................................................................................................... 206-03-1
Rear Disc Brake .................................................................................................................... 206-04-1
Parking Brake and Actuation ................................................................................................. 206-05-1
Hydraulic Brake Actuation ..................................................................................................... 206-06-1
Power Brake Actuation.......................................................................................................... 206-07-1
Anti-Lock Control................................................................................................................... 206-09A-1
Anti-Lock Control - Traction Control ...................................................................................... 206-09B-1
Anti-Lock Control - Stability Assist......................................................................................... 206-09C-1
Steering System
Steering System - General Information ................................................................................. 211-00-1
Power Steering...................................................................................................................... 211-02-1
Steering Linkage ................................................................................................................... 211-03-1
Steering Column ................................................................................................................... 211-04-1
Steering Column Switches .................................................................................................... 211-05-1
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204-00-1 Suspension System - General Information 204-00-1
SECTION 204-00 Suspension System - General

Information
CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 204-00-2
Suspension System .......................................................................................................... 204-00-3

Symptom Chart ................................................................................................................ 204-00-3/4
Pinpoint Tests .................................................................................................................. 204-00-5/6
Component Tests............................................................................................................. 204-00-7
GENERAL PROCEDURES
Front Toe Adjustment.................................................................................... (14 117 0) 204-00-8

Rear Toe Adjustment .................................................................................... (15 211 0) 204-00-9
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SPECIFICATIONS
Information not available at this time
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Suspension System
Mechanical
• Tire pressure(s)
Special Tool(s) • Wheels and tires
• Wheel knuckles
Alignment Pins, Subframe
• Tie-rod ends
205-316 (15-097A)
• Front suspension lower arm ball joints
• Front suspension lower arm bushings
• Front strut and spring assemblies
• Front and rear stabilizer bar and links
• Rear springs
Inspection and Verification • Rear shock absorbers
• Rear suspension arms
1. Verify the customer concern.
3. If an obvious cause for an observed or
2. Visually inspect for obvious signs of
reported concern is found, correct the cause
mechanical damage.
(if possible) before proceeding to the next
step.
Visual Inspection Chart
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart
• Drift left or right • Vehicle attitude incorrect (front • CHECK for abnormal loading,
or rear is high or low). coil spring sag or non-standard
springs.
• Steering gear or linkage worn or • CHECK the steering system.
damaged. REFER to Section 211-00.
• Brake system. • CHECK the brake system.
REFER to Section 206-00.
• Incorrect wheel alignment. • CHECK the wheel alignment.
• Incorrect front crossmember • Using the special tool, CHECK
alignment. the front crossmember align-
ment.
• Worn front wheel bearings. • CHECK and INSTALL new
wheel hubs as necessary.
• Wheels and tires. • GO to Pinpoint Test A
• Steering wheel off center • Vehicle attitude incorrect (front • CHECK for abnormal loading,
springs.
• Suspension lower arm ball joint. • CARRY OUT the Ball Joint
Component Test in this section.
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• Tracks incorrectly • Incorrect front suspension toe • CHECK the wheel alignment.
castor or camber angles. INSTALL new suspension
components as necessary.
• Incorrect rear suspension toe or • CHECK the wheel alignment.
camber angles. INSTALL new suspension
• Front or rear suspension dam- • CHECK and INSTALL new
age. suspension components as
necessary. REFER to Section
204-01 / 204-02.
• Rough ride • Front strut and spring assem- • CHECK and INSTALL new
blies. suspension components as
necessary.
• Front or rear stabilizer bar links • CHECK and INSTALL new
or bushings. suspension components as
204-01/ 204-02.
• Front suspension lower arm • CHECK and INSTALL new
bushings. suspension components as
204-01.
• Rear suspension arm bushings. • CHECK and INSTALL new
suspension components as
necessary.
• Rear shock absorbers. • CHECK and INSTALL new
suspension components as
necessary.
• Excessive noise • Front strut and spring assembly • CHECK and INSTALL new
upper mounting bolts loose or suspension components as
broken. necessary.
• Front strut and spring assem- • CHECK and INSTALL new
necessary.
• Front suspension lower arm • CHECK and INSTALL new
bushings. suspension components as
necessary.
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• Suspension lower arm ball joint. • CARRY OUT the Ball Joint
• Wheels and tires. • CHECK the wheels and tires.
BALANCE or INSTALL new
wheels and tires as necessary.
• Incorrect tire wear • Front or rear suspension dam- • CHECK and INSTALL new
age. suspension components as
204-01 / 204-02.
• Vibration • Damaged or worn front wheel • CHECK and INSTALL new
bearings. wheel hubs as necessary.
necessary.
• Damaged front suspension lower • CHECK and INSTALL new
arm(s). suspension components as
necessary.
Pinpoint Tests
PINPOINT TEST A: DRIFT LEFT OR RIGHT
WARNING: To avoid personal injury due to the loss of vehicle control, the inspection should
be carried out by two people to maintain safe driving conditions. Adequate grip should al-
ways be maintained on the steering wheel. Failure to follow these instructions may result in
personal injury.
NOTE: The following conditions must be met when evaluating the vehicle.
NOTE: The tire swapping procedures are for bi-directional rotating tires only.
A1: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle.
• Swap the front left-hand wheel and tire
assembly with the front right-hand wheel and
tire assembly.
• Road test the vehicle.
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• Does the vehicle drift?

→ Yes
Go to A2
→ No
The concern has been corrected.
A2: SWAP THE REAR WHEEL AND TIRE ASSEMBLIES
• Swap the rear left-hand wheel and tire assembly
with the rear right-hand wheel and tire
assembly.
→ Yes
Go to A3
→ No
A3: SWAP THE LEFT-HAND WHEEL AND TIRE ASSEMBLIES
assembly with the rear left-hand wheel and tire
assembly.
→ Yes
Go to A4
→ No
A4: SWAP THE RIGHT-HAND WHEEL AND TIRE ASSEMBLIES
• Swap the front right-hand wheel and tire
assembly with the rear right-hand wheel and tire
assembly.
→ Yes
Go to A5
→ No
A5: SWAP THE FRONT LEFT-HAND WHEEL AND TIRE ASSEMBLY
assembly with the rear right-hand wheel and tire
assembly.
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→ Yes
Go to A6
→ No
A6: SWAP THE FRONT RIGHT-HAND WHEEL AND TIRE ASSEMBLY
• Swap the front right-hand wheel and tire
assembly with the rear left-hand wheel and tire
assembly.
→ Yes
Go to A7
→ No
A7: INSTALL NEW TIRES
NOTE: Install new tires only once.
1 Install new tires to the four road wheels.
→ Yes
Verify possible sources,
refer to the Symptom Chart.
→ No
Component Tests
Ball Joint Inspection

1. Raise and support the vehicle.
2. Firmly grasp the outer end of the suspension
lower arm and try to move it up and down,
watching and feeling for any movement. Free
movement will usually be accompanied by an
audible "click''. There should be no free
movement.
3. If there is any free movement install a new
lower arm ball joint.
4. If a new lower arm ball joint is installed it will
be necessary to check and adjust the front
wheel alignment.
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GENERAL PROCEDURES
Front Toe Adjustment (14 117 0)

NOTE: The checking and subsequent adjustment

of the front toe setting should be carried out on a
4. Rotate the tie-rods an equal amount in ei-
flat surface and in accordance with the
ther a clockwise or a counterclockwise di-
manufacturers instructions for the wheel
rection to adjust the toe setting.
alignment equipment used.
1. Centralize the steering and lock it in posi-
tion.
5. Tighten the tie-rod end locknuts. For addi-

tional information, refer to Section 211-03.
2. Loosen the tie-rod end locknuts.
6. Install the steering gear boot outer clamps.

3. Remove the steering gear boot outer
clamps.
7. Check the toe setting.
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GENERAL PROCEDURES
Rear Toe Adjustment (15 211 0)
6. NOTE: Do not fully tighten the rear lower arm

General Equipment adjustment cam nut at this stage.
Four wheel alignment equipment Tighten the rear lower arm adjustment cam
nut.
NOTE: The checking and subsequent adjustment
of the rear toe setting should be carried out on a
flat surface and in accordance with the
manufacturers instructions for the particular wheel
alignment equipment being used.
1. NOTE: Final tightening of the rear suspension
components should be carried out when the
vehicle weight is on the road wheels.
Using suitable four wheel alignment
equipment, check the toe setting.
2. Check the tire pressures and adjust as
necessary.
3. Make sure the vehicle is at curb weight and
that the spare wheel, jack and vehicle tools
are stowed in their designated positions. 7. Adjust the toe setting.
Additional items should be removed from
the vehicle.
4. Bounce the vehicle to make sure that the
suspension is in its normal resting
position.
5. Loosen the rear lower arm adjustment cam
nut.
8. Tighten the rear lower arm adjustment cam

nut.
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204-01-1 Front Suspension 204-01-1
SECTION 204-01 Front Suspension

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 204-01-2
Front Suspension.............................................................................................................. 204-01-3

Overview .......................................................................................................................... 204-01-3
Front Suspension.............................................................................................................. 204-01-4
REMOVAL AND INSTALLATION
Wheel Hub ........................................................................................................................ 204-01-5

Lower Arm ........................................................................................................................ 204-01-6/10
Stabilizer Bar .................................................................................................................... 204-01-11/20
Lower Arm Ball Joint ......................................................................................................... 204-01-21/23
Wheel Knuckle .................................................................................................................. 204-01-24/29
Strut and Spring Assembly................................................................................................ 204-01-30/33
DISASSEMBLY AND ASSEMBLY
Strut and Spring Assembly................................................................................................ 204-01-34
09/2004 2004.75 Focus

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SPECIFICATIONS
Torque Specifications
Description Nm lb-ft lb-in
Top mount retaining bolts 32 24 -
Top mount brace to bulkhead retaining nuts 25 18 -
Thrust bearing retaining nut 50 37 -
Stabilizer bar link retaining nuts 48 35 -
Wheel knuckle to strut and spring assembly pinch 90 66 -
bolt
Lower arm ball joint heat shield retaining nut 9 - 80
Brake caliper anchor plate retaining bolts 115 85 -
Lower arm ball joint retaining nut 70 52 -
Tie-rod end retaining nut 48 35 -
Stabilizer bar to stabilizer bar link retaining nut 48 35 -
Stabilizer bar clamp retaining bolts 48 35 -
Lower arm front retaining bolt 175 129 -
Lower arm rear clamp retaining bolts 115 85 -
Lower arm ball joint to lower arm retaining bolts 70 52 -
Front axle crossmember front retaining bolts 115 85 -
Front axle crossmember rear retaining bolt 275 203 -
Front axle crossmember bracket retaining bolts 70 52 -
Wheel hub retaining bolt a) - -
Catalytic converter to rear muffler flange retaining 51 38 -
nuts - Vehicles with diesel engine
nuts - All except vehicles with diesel engine
Engine support insulator front retaining bolt 80 59 -
Wheel speed sensor retaining bolt 9 - 80
Steering column to steering gear pinion retaining 28 21 -
bolt
a) Refer to the procedure in this section.
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Front Suspension
Overview
NOTE: The Anti-lock Brake System (ABS) sensor

ring is incorporated into the wheel hub. Incorrect
installation of the wheel hub would result in an
ABS malfunction.
The front suspension features McPherson struts
and 'L' shaped lower arms which are attached to
the front axle crossmember by means of two
maintenance-free bushings.
The ball joint is attached to the lower arm by
means of three rivets. Bolt-on replacement ball
joints are available for service operations.
The correct installation position must be observed
when installing the strut and spring assembly
turret support bearings. To make sure that the
strut and spring assembly turret support bearings,
springs and piston rods are all aligned correctly,
the spring retainers and strut and spring assembly
turret support bearings have alignment marks.
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Front Suspension
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Wheel Hub
REMOVAL AND IN ST ALLAT ION
3. To install, reverse the removal procedure.
Special Tool(s) Removal Details

Remover/Installer, Wheel
Hub/Wheel Bearing Item 1 : Wheel hub
1. Using the special tools, remove the wheel
204-348
hub.
Protector, Axle Shaft

205-332
1. Remove the wheel knuckle.

2. Remove the components in the order
indicated in the following illustration(s) and
table(s).
Installation Details
Item 1 : Wheel hub

1. Using the special tool, install the wheel
hub.

Number
1 - Wheel hub
See Removal Detail
See Installation Detail
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Lower Arm
Special Tool(s) 3. Remove the components in the order

Protector, Ball Joint Gaiter indicated in the following illustration(s) and
table(s).
204-349
General Equipment
Ball joint separator
1. Remove the wheel and tire. For additional
information, refer to Section 204-04.
[Wheels and Tires, REMOVAL AND
INSTALLATION, Wheel and Tire]
2. Remove the engine undershield.
• Rotate the locking tangs counterclockwise.
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Item Part Description [Suspension System - General
Number Information, GENERAL PROCEDURES,
Front Toe Adjustment]
1 - Lower arm ball joint
See Removal Detail
2 - Lower arm
See Removal Detail

5. Check the front toe setting and adjust as
necessary. For additional
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REMOVAL AND INSTALLATION (Continued)
Removal Details 3. Using a suitable ball joint separator, detach

the lower arm from the wheel knuckle.
Item 1 : Lower arm ball joint
1. Using the special tool to prevent the ball
joint from rotating, remove the lower arm
ball joint retaining nut.
• Discard the lower arm ball joint retaining
nut.
Item 2 : Lower arm

1. Remove the lower arm front retaining bolt.
2. CAUTION: Make sure the special tool is

installed with the curved surface
facing upwards to prevent damage to
the ball joint seal.
Install the special tool.
2. Remove the lower arm rear clamp retaining

bolts.
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Installation Details 3. CAUTION: While tightening the rear

clamp retaining bolts, make sure the
lower arm does not move.
Item 2 : Lower arm
NOTE: Make sure the lower arm rear clamp and
1. NOTE: Do not fully tighten the lower arm rear
the crossmember are correctly aligned.
clamp retaining bolts at this stage.
Tighten the lower arm rear clamp retaining
Install the lower arm rear clamp retaining
bolts.
bolts.
4. Tighten the lower arm front retaining bolt.

2. NOTE: Do not fully tighten the lower arm front
retaining bolt at this stage.
Install the lower arm front retaining bolt.
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1. WARNING: Install a new lower arm ball
joint retaining nut. Failure to follow
this instruction may result in personal
injury.
Using the special tool to prevent the ball
joint from rotating, install the lower arm
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Stabilizer Bar
1. NOTE: Make sure the road wheels are in the

straight ahead position.
Special Tool(s)
Centralize the steering wheel and lock it in
Protector, Ball Joint Gaiter position.
204-349

205-316 (15-097A)
Separator, Ball Joint

211-020
2. Detach the steering column from the

General Equipment
steering gear pinion.
Ball joint separator • Discard the bolt.
Securing strap
Transmission jack
All vehicles
CAUTION: Make sure the strut and spring
assembly does not move in a forwards or
rearwards direction, to prevent damage
to the top mount center cup.
3. Remove the front wheels and tires. For

additional information, refer to Section 204-04.
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All except vehicles with diesel engine
7. CAUTION: Using suitable cable ties,
support the rear muffler and exhaust
tailpipe assembly to prevent damage
to the exhaust hanger insulators.
Detach the exhaust flexible pipe from the
rear muffler flange.
• Discard the gasket and nuts.
5. CAUTION: Over bending of the exhaust

flexible pipe may cause damage
resulting in failure.
Support the exhaust flexible pipe with a
suitable support wrap or a suitable splint.
Vehicles with diesel engine

6. CAUTION: Take care when removing

the exhaust hanger insulators to
prevent damage.
front axle crossmember exhaust hanger
insulators.

table(s).
G410656 en 09/2004 2004.75 Focus

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Number
3 - Lower arm ball joint retaining
1 - Tie-rod end retaining nut nut
See Removal Detail See Removal Detail
See Installation Detail See Installation Detail
2 - Stabilizer bar link retaining
nut
See Removal Detail
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Number
5 - Front axle crossmember
4 - Engine support insulator See Removal Detail
front retaining bolt See Installation Detail
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Number
6 - Stabilizer bar clamp retaining
bolts
7 - Stabilizer bar clamps
8 - Stabilizer bar
See Removal Detail
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10. To install, reverse the removal procedure. Removal Details

11. WARNING: Install a new steering Item 1 : Tie-rod end retaining nut
column to steering gear pinion bolt.
Failure to follow this instruction may 1. CAUTION: Leave the tie-rod end
result in personal injury. retaining nut in place to protect the
NOTE: Make sure the road wheels are in the ball joint stud.
straight ahead position. NOTE: Use a 5 mm Allen key to prevent the ball
Attach the steering column to the steering joint stud from rotating.
gear pinion. Loosen the the tie-rod end retaining nut on
both sides.
1. Remove the cotter pin.
2. Loosen the retaining nut.
• Discard the cotter pin.

necessary. For additional
[Suspension System - General
Information, GENERAL PROCEDURES,
Front Toe Adjustment] 2. CAUTION: Protect the ball joint seal
using a soft cloth to prevent damage.
Using the special tool, detach the tie-rod
end from the wheel knuckle on both sides.
Item 2 : Stabilizer bar link retaining nut

1. NOTE: Use a 5 mm Allen key to prevent the ball
joint stud from rotating.
Detach the stabilizer bar link from the
stabilizer bar on both sides.
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Item 3 : Lower arm ball joint retaining nut 3. Using a suitable ball joint separator, detach
1. Using the special tool to prevent the ball the lower arm from the wheel knuckle on
joint stud from rotating, remove the lower both sides.
arm ball joint retaining nut on both sides.
nut.
Item 5 : Front axle crossmember

1. Using a transmission jack and a wooden
block, support the front axle crossmember,
2. CAUTION: Make sure that the special stabilizer bar and lower arm assembly.
tool is installed with the curved 2. WARNING: Make sure the front axle
surface facing upwards to prevent crossmember is secured to the
damage to the ball joint seal. transmission jack. Failure to follow
Install the special tool. this instruction may result in personal
injury.
Using a suitable securing strap, secure the
front axle crossmember, stabilizer bar and
lower arm assembly to the transmission
jack.
3. Remove the front axle crossmember
bracket retaining bolts on both sides.
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4. Remove the front axle crossmember re- Installation Details

taining bolts (transmission jack shown
removed for clarity). Item 8 : Stabilizer bar
1. CAUTION: The stabilizer bar bushings
must be located correctly on the flats
of the stabilizer bar with no lubricant.
Install the stabilizer bar bushings.
5. CAUTION: To prevent damage to the

power steering lines, only lower the
crossmember sufficiently to allow the
stabilizer bar to be removed.
Lower the front axle crossmember.
2. Position the stabilizer bar on the front axle
Item 8 : Stabilizer bar
1. Remove the stabilizer bar bushings. crossmember.
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Item 5 : Front axle crossmember 3. Install the front axle crossmember bracket
retaining bolts on both sides.
1. WARNING: Make sure the front axle
crossmember is secured to the
transmission jack. Failure to follow
injury.
Using a transmission jack and the special
tool, position and align the front axle
crossmember.
1. Insert the alignment pins through the front
axle crossmember alignment holes.
2. Slide the locking plates into the groove of
the special tool and tighten the alignment
pin sleeve.
3. Raise the front axle crossmember engaging
the alignment pins into the front axle 4. Remove the special tool.
crossmember alignment holes. 5. Remove the securing strap.
6. Lower and remove the transmission jack
and the wooden block.
Item 3 : Lower arm ball joint retaining nut
injury.
joint stud from rotating, install the lower
arm ball joint retaining nut on both sides.
2. CAUTION: Make sure the front axle

crossmember does not move while
tightening the front axle crossmember
retaining bolts.
Install the front axle crossmember retain-
ing bolts (transmission jack removed for
clarity).

Attach the stabilizer bar link to the
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Item 1 : Tie-rod end retaining nut

1. NOTE: Install a new tie-rod end retaining nut
cotter pin.
NOTE: Use a 5 mm Allen key to prevent the ball
Attach the tie-rod end to the wheel knuckle
on both sides.
1. Tighten the retaining nut.
2. Install the cotter pin.
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Lower Arm Ball Joint

Special Tool(s)
Protector, Ball Joint Gaiter rearwards direction, to prevent damage
204-349 to the top mount center cup.
General Equipment indicated in the following illustration(s) and
Ball joint separator table(s).
Electric hand drill
to Section 204-00.[Suspension System -

Item Part Description General Information, GENERAL
Number PROCEDURES, Front Toe Adjustment]
1 - Lower arm ball joint
See Removal Detail

necessary. For additional information, refer
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Removal Details 3. Using a suitable ball joint separator, detach

the lower arm from the wheel knuckle.
joint stud from rotating, remove the lower
arm ball joint retaining nut.
nut.
4. Remove the lower arm ball joint.

• Using a suitable electric hand drill remove
the rivets.
2. CAUTION: Make sure that the special

tool is installed with the curved
surface facing upwards to prevent
damage to the ball joint seal.

1. Using suitable M10 nuts and M10 x 30 mm
bolts, install a new lower arm ball joint.
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injury.
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Wheel Knuckle

Lever, Wheel Knuckle table(s).
204-159 (14-039)
Protector, Ball Joint Gaiter

204-349

211-020
General Equipment

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Number
4 - Wheel hub retaining bolt
1 - Brake caliper and anchor
plate assembly 5 - Tie-rod end retaining nut
2 - Brake disc 6 - Lower arm ball joint heat

See Removal Detail shield
3 - Wheel speed sensor retain-

ing bolt
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Item Part Description Item 2 : Brake disc

Number 1. Remove the brake disc.
• Remove and discard the retaining washer (if
7 - Lower arm ball joint retaining equipped).
nut
See Removal Detail
8 - Wheel knuckle to strut and
spring assembly pinch bolt
9 - Strut and spring assembly
See Removal Detail
10 - Wheel knuckle
Removal Details
Item 1 : Brake caliper and anchor plate
assembly 1. CAUTION: Leave the tie-rod end
retaining nut in place to protect the
1. CAUTION: Suspend the brake caliper ball joint stud.
and anchor plate assembly to prevent NOTE: Use a 5 mm Allen key to prevent the ball
load being placed on the brake hose. joint stud from rotating.
Detach the brake caliper and anchor plate Loosen the tie-rod end retaining nut on
assembly from the wheel knuckle. both sides.
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2. CAUTION: Protect the ball joint seal 2. CAUTION: Make sure the special tool is
using a soft cloth to prevent damage. installed with the curved surface
end from the wheel knuckle.

1. Using the special tool to prevent the ball 3. Using a suitable ball joint separator, detach
joint stud from rotating, remove the lower the lower arm from the wheel knuckle.
nut.
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4. CAUTION: Support the halfshaft. The Installation Details

inner constant velocity (CV) joint must
not be bent more than 23 degrees. The
Item 8 : Wheel knuckle to strut and spring
outer CV joint must not be bent more
assembly pinch bolt
than 45 degrees.
1. WARNING: Install a new wheel knuckle
CAUTION: Do not apply excessive force to
to strut and spring assembly pinch
the strut and spring assembly. Do not
bolt.
pull the strut and spring assembly
outwards by more than 28 mm. CAUTION: The wheel knuckle to strut and
NOTE: Make sure the halfshaft is still fully spring assembly pinch bolt must be
engaged in the CV joint housing. installed from the front of the vehicle.
Detach the wheel hub from the halfshaft. Attach the wheel knuckle to the strut and
• Pull the strut and spring assembly spring assembly.
outwards.
Item 9 : Strut and spring assembly
1. Using the special tool, detach the wheel
knuckle from the strut and spring assem-
bly.
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Item 7 : Lower arm ball joint retaining nut Item 5 : Tie-rod end retaining nut
1. NOTE: Install a new tie-rod end retaining nut
1. CAUTION: Support the halfshaft. The
cotter pin.
inner constant velocity (CV) joint must
not be bent more than 23 degrees. The NOTE: Use a 5 mm Allen key to prevent the ball
outer CV joint must not be bent more joint stud from rotating.
than 45 degrees. Attach the tie-rod end to the wheel knuckle
on both sides.
the strut and spring assembly. Do not 1. Tighten the retaining nut.
pull the strut and spring assembly 2. Install the cotter pin.
outwards by more than 28 mm.
Attach the wheel hub to the halfshaft.
• Pull the strut and spring assembly
outwards.
injury.
Item 1 : Brake caliper and anchor plate

assembly
1. Attach the brake caliper and anchor plate
assembly to the wheel knuckle.
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Strut and Spring Assembly
4. Detach the strut and spring assembly top

Special Tool(s) mount brace from the bulkhead (left-hand
Lever, Wheel Knuckle side shown).
204-159

1. Remove the engine upper cover.
2. Remove the cowl panel grille. For
additional information, refer to Section 5. Remove the strut and spring assembly top
501-02.[Front End Body Panels, REMOVAL mount brace (left-hand side shown).
AND INSTALLATION, Cowl Panel Grille] • Loosely install the strut and spring assem-
3. Remove the bulkhead extension panel. bly top mount bolts.
1. Remove the retaining screws and washers.
2. Detach the panel from the retaining clips.

table(s).
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Item Part Description 8. To install, reverse the removal procedure.

Number
Removal Details
1 - Stabilizer bar link to strut and
spring assembly retaining nut
Item 1 : Stabilizer bar link to strut and spring
See Removal Detail
assembly retaining nut
2 - Brake hose joint from rotating.
3 - Wheel knuckle to strut and Item 3 : Wheel knuckle to strut and spring
spring assembly pinch bolt assembly pinch bolt
See Removal Detail 1. Using the special tool, detach the strut and
See Installation Detail spring assembly from the wheel knuckle.
top mount retaining bolts
See Removal Detail
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Item 4 : Strut and spring assembly top mount Item 3 : Wheel knuckle to strut and spring
retaining bolts assembly pinch bolt
CAUTION: With the aid of another 1. WARNING: Install a new wheel knuckle
technician, support the strut and spring to strut and spring assembly pinch
assembly. bolt. Failure to follow this instruction
may result in personal injury.
CAUTION: The wheel knuckle to strut and
spring assembly pinch bolt must be
Item 4 : Strut and spring assembly top mount
installed from the front of the wheel
retaining bolts
knuckle.
1. CAUTION: With the aid of another Attach the strut and spring assembly to the
technician, support the strut and wheel knuckle.
spring assembly.
Install the strut and spring assembly top
mount bolts.
Item 1 : Stabilizer bar link to strut and spring

assembly retaining nut
joint from rotating.
Install the stabilizer bar link to strut and
spring assembly retaining nut.
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2. Remove the strut and spring assembly top

mount bolts.
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Strut and Spring Assembly

DISASSEM BLY AND ASSEM BLY
WARNING: The spring is under extreme

Special Tool(s)
tension; care must be taken at all times.
Compressor, Coil Spring Failure to follow this instruction may
204-167 (14-042) result in personal injury.
1. Disassemble the components in the order
table(s).
Adapters for 204-167

204-167-01 (14-042-01)

Number
1 - Thrust bearing retaining nut
See Disassembly Detail
See Assembly Detail
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DISASSEMBLY AND ASSEMBLY (Continued)
Item Part Description Assembly Details

Number
Item 6 : Spring
2 - Top mount
CAUTION: The ends of the spring must
3 - Thrust bearing and spring
locate correctly in the spring seats.
seat assembly
See Assembly Detail Item 3 : Thrust bearing and spring seat
assembly
4 - Boot
5 - Bump stop CAUTION: Make sure the thrust bearing
and spring seat assembly is correctly
6 - Spring seated onto the boot before assembly.
See Assembly Detail
Item 1 : Thrust bearing retaining nut
2. To assemble, reverse the disassembly CAUTION: Make sure the alignment
procedure. markings on the top mount and the top
mount bearing are aligned with the spring
Disassembly Details seat cut out and the alignment marking
on the strut.
Item 1 : Thrust bearing retaining nut
1. WARNING: The spring is under extreme
tension; care must be taken at all times.
Failure to follow this instruction may
result in personal injury.
NOTE: Make a note of the position of the top
mount, the top mount bearing alignment marking,
the strut alignment marking and the spring seat
cut out, to aid assembly.
Using the special tools, compress the
spring.
2. CAUTION: Use an Allen key to prevent

the piston rod from rotating.
Remove the thrust bearing retaining nut.
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204-02-1 Rear Suspension 204-02-1
SECTION 204-02 Rear Suspension

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 204-02-2
Rear Suspension .............................................................................................................. 204-02-3

Vehicles with ball joint stabilizer bar link 3-door and 5-door............................................. 204-02-3/4
Vehicles with solid stabilizer bar link 3-door and 5-door ................................................... 204-02-5/6
Wagon ............................................................................................................................. 204-02-7/8
Rear Suspension .............................................................................................................. 204-02-9
Wheel Hub — Vehicles With: Rear Drum Brakes .............................................................. 204-02-10/11

Wheel Hub — Vehicles With: Rear Disc Brakes................................................................ 204-02-12/13
Upper Arm .................................................................................................... (15 701 0) 204-02-14/15
Front Lower Arm ........................................................................................... (15 690 0) 204-02-16/17
Rear Lower Arm — Vehicles With: Solid Stabilizer Bar Link.............................................. 204-02-18/20
Wheel Knuckle .................................................................................................................. 204-02-21/26
Spring ........................................................................................................... (15 621 0) 204-02-27
09/2004 2004.75 Focus

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SPECIFICATIONS
Stabilizer bar link to rear lower arm retaining nut – 25 18 -
Vehicles with solid stabilizer bar link
Stabilizer bar link to rear lower arm retaining nut – 48 35 -
Vehicles with ball joint stabilizer bar link
Stabilizer bar to stabilizer link retaining nut – Vehi- 70 52 -
cles with ball joint stabilizer bar link
Rear axle crossmember retaining bolts 125 92 -
Upper arm retaining bolts 115 85 -
Front lower arm retaining bolts 115 85 -
Rear lower arm to wheel knuckle retaining bolt 115 85 -
Rear lower arm adjustment cam nut 90 66 -
Wheel hub retaining bolts 55 41 -
Wheel knuckle front retaining bolts 125 92 -
Shock absorber upper mount retaining bolt 25 18 -
Shock absorber lower mount retaining bolt 115 85 -
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Rear Suspension

3-door and 5-door

Number
4 - Wheel knuckle
1 - Crossmember
5 - Wheel hub
2 - Stabilizer bar
6 - Upper arm
3 - Ball joint stabilizer bar link
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Item Part Description Item 2 : Stabilizer Bar

Number The stabilizer bar is uniquely shaped with modified
7 - Front lower arm locating holes to accomodate the ball joint
stabilizer bar link.
8 - Rear lower arm
9 - Bump stop
10 - Shock absorber
11 - Spring
12 - Rear lower arm adjustment
cam nut Item 3 : Ball Joint Stabilizer Bar Link
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The ball joint stabilizer bar link has been

introduced to provide a quicker response to
suspension movement. This enables the stabilizer
bar to respond more directly to wheelstation
movement. The ball joint stabilizer bar link is
assembled between the rear lower arm and
stabilizer bar with retaining nuts.
Item 4: Wheel Knuckle

The wheel knuckle provides a wider track width
and attachment surface for the unique wheel hub
assembly.
Item 5: Wheel Hub

The wheel hub assembly incorporates the wheel
bearing, wheel speed sensor ring, wheel hub and
wheel spindle as one assembly.
Item 8: Rear Lower Arm

The rear lower arm has a unique shape to
incorporate the ball joint stabilizer bar link.
Item 10: Shock Absorber

The shock absorber includes a unique upper
mount damper to provide additional noise
reduction.
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Vehicles with solid stabilizer bar link 3-door

and 5-door

Number
5 - Wheel hub
1 - Crossmember
6 - Upper arm
2 - Stabilizer bar
7 - Front lower arm
3 - Solid stabilizer bar link
8 - Rear lower arm
4 - Wheel knuckle
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Item Part Description Item 5: Wheel Hub

Number The wheel hub assembly incorporates the wheel
9 - Bump stop bearing, wheel speed sensor ring, wheel hub and
10 - Shock absorber
11 - Spring Item 10: Shock Absorber
12 - Rear lower arm adjustment The shock absorber includes a unique upper
cam mount damper to provide additional noise
reduction.
The wheel knuckle provides a wider track width Wagon
and attachment surface for the unique wheel hub The wagon is only available with a solid stabilizer
assembly. bar link.

Number
6 - Upper arm
1 - Crossmember
7 - Front lower arm
2 - Stabilizer bar
8 - Rear lower arm
3 - Solid stabilizer bar link
9 - Shock absorber
4 - Wheel knuckle
10 - Spring
5 - Wheel hub
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Number
11 - Rear lower arm adjustment
cam

The wheel knuckle provides a wider track width
and attachment surface for the unique wheel hub
assembly.
Item 5: Wheel Hub

The wheel hub assembly incorporates the wheel
bearing, wheel speed sensor ring, wheel hub and
Item 9: Shock Absorber

Nivomat shock absorbers are available as an
option to provide load leveling rear suspension.
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Rear Suspension
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Wheel Hub — Vehicles With: Rear Drum Brakes

1. Remove the brake drum. For additional refer to Section 206-09A.[Anti-Lock

information, refer to Section 206-02.[Drum Control, REMOVAL AND INSTALLATION,
Brake, REMOVAL AND INSTALLATION, Rear Wheel Speed Sensor]
Brake Drum] 3. Remove the components in the order
2. Remove the rear wheel speed sensor. For indicated in the following illustration(s) and
additional information, table(s).

Number
1 - Wheel hub
See Removal Detail
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Removal Details
Item 1 : Wheel hub

1. CAUTION: Suspend the brake backing
plate, wheel cylinder and brake shoes
assembly to prevent load being placed
on the brake hose.
Remove the wheel hub.
Item 1 : Wheel hub

1. Install the wheel hub.
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Wheel Hub — Vehicles With: Rear Disc Brakes
1. Remove the brake disc. For additional 3. Remove the components in the order
information, refer to Section 206-04. indicated in the following illustration(s) and
2. Remove the rear wheel speed sensor. For table(s).
additional information, refer to Section
206-09A / 206-09B / 206-09C.

Number
1 - Wheel hub
See Removal Detail
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Removal Details
Item 1 : Wheel hub

1. Remove the wheel hub.
Item 1 : Wheel hub

1. Install the wheel hub.
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Upper Arm (15 701 0)

4. NOTE: The spacer must be positioned exactly

General Equipment as shown.
Transmission jack Install the spacer.
1. Remove the bump stop.
2. Install the spacer between the rear lower
Removal arm and the rear axle crossmember making
sure that the spacer is in a vertical plane.
1. Remove the spring.
2. Fabricate a 20 mm wide by 113 mm long
spacer.
5. Detach the upper arm from the wheel

knuckle.
3. CAUTION: The suspension must be set

to the design height setting.
Using a transmission jack and a wooden
block, raise the suspension to the design
height setting.
• Position the transmission jack and the
wooden block as shown.
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6. NOTE: Make a note of the position of the upper 3. Lower the suspension from the design
arm to aid installation. height setting.
Remove the upper arm. 1. Remove the spacer.
2. Install the bump stop.
Installation 4. Install the spring. For additional

information, refer to Spring in this section.
1. Install the upper arm to the rear axle
crossmember.
2. Attach the upper arm to the wheel knuckle.
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Front Lower Arm (15 690 0)

General Equipment as shown.
Transmission jack Install the spacer.
Removal arm and the rear axle crossmember making
1. Remove the spring. For additional
spacer.
5. CAUTION: The front lower arm is

marked FRONT. Make a note of the
position of the front lower arm to aid
installation.
3. CAUTION: The suspension must be set Remove the front lower arm.
Using a transmission jack and a wooden
height setting.
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Installation
1. Install the front lower arm.
2. Lower the suspension from the design

height setting.
1. Remove the spacer.
3. Install the spring. For additional

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Rear Lower Arm — Vehicles With: Solid Stabilizer Bar Link
1. Remove the spring. For additional

General Equipment information, refer to Spring in this section.
Transmission jack 2. Remove the components in the order
table(s).
5. NOTE: Final tightening of the rear lower arm

Item Part Description adjustment cam nut should be carried out when
Number the vehicle weight is on the road wheels.
1 - Rear lower arm adjustment Tighten the rear lower arm adjustment cam
cam nut nut.
See Removal Detail
2 - Rear lower arm to wheel
knuckle retaining bolt

4. Check the toe setting and adjust as
necessary. For additional information,
refer to Section 204-00.[Suspension
System - General Information, GENERAL
PROCEDURES, Rear Toe Adjustment]
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Removal Details as shown.
Install the spacer.
Item 1 : Rear lower arm adjustment cam nut 1. Remove the bump stop.
spacer.
arm and the rear axle crossmember making

to the design height setting. 4. Using paint or typing correction fluid, mark
Using a transmission jack and the wooden the position of the rear lower arm adjust-
block, raise the suspension to the design ment cam to the rear axle crossmember.
height setting.
5. Remove the rear lower arm adjustment cam

nut.
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Item 1 : Rear lower arm adjustment cam nut

adjustment cam nut at this stage.
NOTE: Align the mark on the rear lower arm
adjustment cam to the mark on the rear axle
crossmember.
Install the rear lower arm adjustment cam
nut.
2. Lower the suspension from the design

height setting.
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Wheel Knuckle
5. Detach the wheel speed sensor wiring

General Equipment harness from the wheel knuckle.
Transmission jack
Removal
Vehicles with rear disc brakes
1. Remove the brake disc shield. For
206-04.[Rear Disc Brake, REMOVAL AND
INSTALLATION, Brake Disc Shield]
Vehicles with rear drum brakes
2. Remove the wheel hub. For additional
information, refer to Wheel Hub - Vehicles
With: Rear Drum Brakes in this section.
6. Remove the spring.
All vehicles
3. Detach the rear brake hose from the wheel 7. Fabricate a 20 mm wide by 113 mm long
knuckle. spacer.
4. Detach the parking brake cable from the

wheel knuckle.
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8. CAUTION: The suspension must be set 10. Detach the front lower arm from the wheel
to the design height setting. knuckle.
Using a transmission jack and wooden
height setting.
• Position the transmission jack and wooden
block as shown.
11. Detach the upper arm from the wheel

knuckle.

as shown.
Install the spacer.
sure the spacer is in a vertical plane.
12. Using paint or typing correction fluid,

mark the position of the rear lower arm
adjustment cam to the rear axle cross-
member.
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13. Remove the rear lower arm. 2. NOTE: Do not fully tighten the wheel knuckle
retaining bolts at this stage.
Install the wheel knuckle.
14. Remove the air deflector.
3. NOTE: Do not fully tighten the upper arm to

wheel knuckle retaining bolt at this stage.
Attach the upper arm to the wheel knuckle.
15. Remove the wheel knuckle.

• Lower and remove the transmission jack.
4. NOTE: Do not fully tighten the front lower arm to

wheel knuckle retaining bolt at this stage.
Attach the front lower arm to the wheel
knuckle.
Installation
All vehicles
1. Using a transmission jack, support the
wheel knuckle.
5. Lower and remove the transmission jack.
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6. NOTE: Do not fully tighten the rear lower arm 8. NOTE: The spacer must be positioned exactly
retaining bolts at this stage. as shown.
Install the rear lower arm retaining bolts. Install the spacer.
• Install the spacer between the rear lower
sure the spacer is in a vertical plane.

Using a transmission jack and wooden
height setting. 9. Tighten the wheel knuckle retaining bolts.
• Position the transmission jack and wooden
block as shown.
10. Tighten the upper arm to wheel knuckle

retaining bolt.
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11. Tighten the front lower arm to wheel 14. Lower the suspension from the design
knuckle retaining bolt. height setting.
12. Tighten the rear lower arm to wheel

knuckle retaining bolt.
15. Install the air deflector.

adjustment cam nut at this stage.
NOTE: Align the mark on the rear lower arm 16. Install the spring.
adjustment cam to the mark on the rear axle 17. Attach the wheel speed sensor wiring
crossmember. harness to the wheel knuckle.
Install the rear lower arm adjustment cam
nut.
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18. Attach the parking brake cable to the System - General Information, GENERAL
wheel knuckle. PROCEDURES, Rear Toe Adjustment]
24. NOTE: Final tightening of the rear lower arm
adjustment cam nut must be carried out when
the vehicle weight is on the road wheels.
Tighten the rear lower arm adjustment
cam nut.
19. Attach the rear brake hose to the wheel

knuckle.

20. Install the brake disc shield. For
[Rear Disc Brake, REMOVAL AND
INSTALLATION, Brake Disc Shield]
21. Install the wheel hub. For additional
information, refer to Wheel Hub - Vehicles
With: Rear Drum Brakes in this section.
All vehicles
22. Bleed the brake system. For additional
[Brake System - General
Brake System Bleeding] For additional
Brake System Pressure Bleeding]
refer to Section 204-00.[Suspension
G388087 en 09/2004 2004.75 Focus

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Spring (15 621 0)

Special Tool(s) 3. Detach the stabilizer bar link from the rear
lower arm on both sides.
Compressor, Coil Spring
204-167 (14-042)
Adapters for 204-167

204-215 (15-111)
General Equipment
Trolley jack All vehicles
4. Using a suitable trolley jack, support the
wheel knuckle.
Removal 5. Detach the shock absorber from the wheel
knuckle.
All vehicles
1. Remove the rear wheel and tire. For
2. Detach the stabilizer bar link from the rear
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6. WARNING: As the spring is under 2. WARNING: As the spring is under

extreme tension care must be taken at extreme tension care must be taken at
all times. Failure to follow this all times. Failure to follow this
instruction may result in personal instruction may result in personal
injury. injury.
Using the special tools, compress the Using the special tools, compress the
spring. spring.
7. Remove the trolley jack. 3. WARNING: As the spring is under

extreme tension care must be taken at
8. WARNING: As the spring is under
all times. Failure to follow this
extreme tension care must be taken at
instruction may result in personal
injury.
injury. CAUTION: Make sure the top seat mount
With the aid of another technician, pull the is installed, and the spring ends butt
rear lower arm downwards to release the correctly against the upper and lower
spring from the spring seats and remove spring seats.
the spring. Install the spring.
4. Remove the special tools.
Installation 5. Using a suitable trolley jack, position and
align the wheel knuckle with the shock
All vehicles absorber.
1. Using a suitable trolley jack, support the
wheel knuckle.
G424865 en 09/2004 2004.75 Focus
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6. NOTE: Do not fully tighten the shock absorber All vehicles

to wheel knuckle retaining bolt at this stage. 10. Install the rear wheel and tire.
For additional information,
Attach the shock absorber to the wheel
knuckle. refer to Section 204-04.
11. NOTE: The final tightening of the shock
absorber to wheel knuckle retaining bolt should
be carried out when the vehicle weight is on the
road wheels.
Tighten the shock absorber to wheel
knuckle retaining bolt.
7. Remove the trolley jack.

8. Attach the stabilizer bar link to the rear

9. Attach the stabilizer bar link to the rear
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204-04-1 Wheels and Tires 204-04-1
SECTION 204-04 Wheels and Tires

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 204-04-2
Wheels and Tires .............................................................................................................. 204-04-3

Symptom Chart ................................................................................................................ 204-04-4/6
Wheel and Tire.................................................................................................................. 204-04-7
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SPECIFICATIONS
Wheel nuts 85 63 -
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Wheels and Tires

- engine torque
- vehicle speed
- engine speed
To maximize tire performance, inspect the tires for – type of vibration - sensitivity: torque sensitive,
signs of incorrect inflation and uneven wear which vehicle speed sensitive or engine speed
may indicate a need for balancing, rotation or sensitive.
suspension alignment. Tires should also be
checked frequently for cuts, stone bruises, The following explanations help isolate the source
abrasions, blisters, and for objects that may have of the vibration.
become embedded in the tread. More frequent
inspections are recommended when rapid or
Torque Sensitive
extreme temperature changes occur or when road
surfaces are rough or occasionally littered with This means that the condition can be improved or
foreign material. made worse by accelerating, decelerating,
coasting, maintaining a steady vehicle speed or
As a further visible check of tire condition, tread
applying engine torque.
wear indicators are molded into the bottom of the
tread grooves. When these indicator bands
become visible, new tires must be installed. Vehicle Speed Sensitive
This means that the vibration always occurs at the
Tire Wear Diagnosis same vehicle speed and is not affected by engine
torque, engine speed or the transmission gear
Uneven wear is usually caused by either
selected.
excessive camber or excessive toe on tires.
Sometimes incorrect toe settings or worn struts
will cause severe `cupping' or `scalloped' tire wear Engine Speed Sensitive
on non-driven wheels. This means that the vibration occurs at varying
Severely incorrect toe settings will also cause vehicle speeds when a different transmission gear
other unusual wear patterns. is selected. It can sometimes be isolated by
increasing or decreasing engine speed with the
transmission in NEUTRAL or by stall testing with
Tire Vibration Diagnosis the transmission in gear. If the condition is engine
speed sensitive, the cause is probably not related
A tire vibration diagnostic procedure always
to the tires.
begins with a road test. The road test and
customer interview (if available) will provide much If the road test indicates that there is tire whine,
of the information needed to find the source of a but no shake or vibration, the noise originates with
vibration. the contact between the tire and the road surface.
During the road test, drive the vehicle on a road A thumping noise usually means that the tire is flat
that is smooth and free of undulations. If vibration or has soft spots making a noise as they slap the
is apparent, note and record the following: roadway. Tire whine can be distinguished from
axle noise. Tire whine remains the same over a
– the speed at which the vibration occurs.
range of speeds.
– what type of vibration occurs in each speed
range. A complete road test procedure is described in
Section 100-04.REFER to Section 100-04.
- mechanical or audible
– how the vibration is affected by changes in the
following:
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Symptom Chart
• Tires show excess wear on edge • Tires under-inflated. • ADJUST the tire pressure.
of tread
• Vehicle overloaded. • CORRECT as necessary.
• Incorrect wheel alignment. • ADJUST the wheel alignment.
• Tires show excess wear in cen- • Tires over-inflated. • ADJUST the tire pressure.
ter of tread
• Other excessive tire wear con- • Incorrect tire pressure. • ADJUST the tire pressure.
cerns
• Tires need rotating. • ROTATE the tires.
• Incorrect wheel alignment. • ADJUST the wheel alignment.
• Vehicle overloaded. • CORRECT as necessary.
• Loose or leaking front strut and • TIGHTEN or INSTALL new
spring assembly. suspension components as
necessary.
• Wheel bearings worn. • INSTALL new wheel bearings as
necessary.
REFER to Section 204-01/ 204-02.
• Suspension components, bush- • CHECK or INSTALL new sus-
ings and ball joints. pension components as neces-
sary.
• Excessive lateral or radial runout • CHECK the wheel and tire radial
of wheel or tire. runout.
• Wheel mounting is difficult • Incorrect application or mis- • FOLLOW manufacturers speci-
matched parts, including wheel fications.
studs and nuts.
• Wheel rust or corrosion • Poor maintenance. • CLEAN and PROTECT with
paint.
• Wobble or shimmy affecting • Damaged wheel. • INSPECT wheel rims for dam-
wheel runout age. INSTALL new parts as
necessary.
• Front wheel bearing. • CHECK or INSTALL new wheel
bearings as necessary.
• Excessive vehicle vibration, • Suspension components. • CHECK or INSTALL new parts.
rough steering REFER to Section 204-00.
• Vehicle vibrations from wheels • Incorrect tire pressure. • ADJUST the tire pressure.
and tires
• Wheel or tire imbalance. • BALANCE the tire and wheel
assembly.
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• Uneven tire wear. • INSTALL a new tire(s) as nec-
essary.
• Brake disc imbalance. • CHECK the brake disc for for-
eign material.
• Water in tires. • REMOVE the water.
• Bent wheel. • INSTALL a new wheel. Attempts
to straighten a wheel can cause
fractures in the wheel and
weaken the wheels strength.
• Incorrectly seated tire bead. • SPIN the wheel on the vehicle.
EXAMINE the area where the
tire and the wheel meet. If that
section of the tire appears to
waver while being rotated, the
tire bead may not be correctly
seated on the wheel. REMOVE
the tire and CLEAN the bead
seat areas on both wheel and
tire.
• Radial runout of wheel or tire. • Using a suitable dial indicator
gauge and holding fixture,
CHECK the radial runout of both
the wheel and the tire.
• Wheel stud, wheel nut or • CHECK or INSTALL new parts
enlarged stud holes. as necessary.
• Foreign material between wheel • CLEAN mounting surfaces.
mounting face and hub mounting
surface.
• Lateral runout of wheel or tire. • Using a suitable dial indicator
gauge and holding fixture,
CHECK the radial runout of both
the wheel and the tire.
• Front wheel bearing. • CHECK or INSTALL a new
wheel bearing as necessary.
• Cracks develop in rim base back • Overloading or abusive use. • INSTALL a new wheel. CHECK
(rim bead seat) loading and operating condi-
tions. AVOID over inflation of
tires. CHECK the specifications
for the rim load capacity, working
load, tire size, ply rating and tire
construction.
• Incorrect use of tools. • CHECK mounting, demounting,
and maintenance procedures.
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• Damaged wheel studs • Sliding wheel across wheel studs • INSTALL new wheel studs as
during assembly. necessary. INSTALL a new
wheel as necessary.
• Loose brake drum • Wheel studs too long. • INSTALL new wheel studs of the
correct length as necessary.
• Broken wheel studs • Loose wheel nuts. • INSTALL new wheel studs and
nuts. TIGHTEN to specification.
• Overloading. • INSTALL new wheel studs.
TIGHTEN to specification.
Compare actual load against
vehicle load ratings.
• Stripped wheel stud threads • Excessive tightening. • INSTALL new wheel studs and
nuts. TIGHTEN to specification.
• Rust streaks from the wheel stud • Wheel nuts. • CHECK complete assembly. If
holes in the wheel parts are damaged INSTALL
new parts. TIGHTEN to specifi-
cation.
• Damaged wheel nuts • Wheel assembly. • INSTALL new wheel nuts.
TIGHTEN to specification.
• Over tightened wheel nuts. • FOLLOW correct tightening
procedure.
• Seized wheel nuts • Corrosion. • CAUTION: Do not permit lubri-
cant to get on cone sets of stud
holes or on cone angle of wheel
nuts. If corrosion is slight, wire
brush away. If corrosion is ex-
cessive, INSTALL new wheel
studs and nuts. If the condition
persists, LUBRICATE the first
three threads of each wheel stud
with a graphite-based lubricant.
• Overloading • REDUCE weight.
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Wheel and Tire

Removal
CAUTION: Do not use heat to loosen a
seized wheel nut. Heat may damage the
wheel and wheel hub.
1. Loosen the wheel nuts.
2. Raise and support the vehicle. For
additional information,
refer to Section 100-02.
3. Remove the wheel and tire.
Installation
1. WARNING: Remove any corrosion or
dirt from the mounting surfaces of the
wheel, wheel hub or brake disc.
Corrosion or dirt on the mounting
surfaces may cause the wheel nuts to
loosen and the wheel to come off while
the vehicle is in motion. Failure to
follow this instruction may result in
personal injury.
Clean the wheel hub and mounting
surfaces.
2. Install the wheel and tire.
3. Lower the vehicle.
4. Tighten the wheel nuts in the sequence
shown.
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205-04-1 Front Drive Halfshafts 205-04-1
SECTION 205-04 Front Drive Halfshafts

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 205-04-2
Front Drive Halfshafts ....................................................................................................... 205-04-3
Front Drive Halfshafts ....................................................................................................... 205-04-4

Inspection and Verification ............................................................................................... 205-04-4/5
Halfshaft LH .................................................................................................. (14 320 0) 205-04-6/11

Halfshaft RH ................................................................................................. (14 321 0) 205-04-12/16
Intermediate Shaft............................................................................................................. 205-04-17
Inner Constant Velocity (CV) Joint Boot ........................................................ (14 336 0) 205-04-18/20
Outer Constant Velocity (CV) Joint Boot ....................................................... (14 338 0) 205-04-21/22
Halfshaft LH .................................................................................................. (14 320 8) 205-04-23/26

Halfshaft RH ................................................................................................. (14 321 8) 205-04-27
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SPECIFICATIONS
Information not available at this time
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Front Drive Halfshafts

Overview
The front axle halfshafts both have the same

length as each other.
The vehicle uses improved constant velocity joints
which are designed for the larger bending radii
occurring in conjunction with the new transmission
and the increased travel of the suspension
springs.
The constant velocity joints satisfy durability
requirements of 240,000 km.
A support mounting is located on the right-hand
drive halfshaft. A new bearing cap and new nuts
should be used when installing this support
mounting.
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Front Drive Halfshafts

front wheel driveshaft CV joint boot clamp

damage.
Inspection and Verification 3. Inspect for inboard CV joint stub shaft pilot
NOTE: New front wheel drive halfshafts should bearing housing seal leakage at the front
not be installed unless disassembly and wheel driveshaft CV joint.
inspection reveals unusual wear. 4. Make sure front axle wheel hub retainer is the
1. Inspect front wheel driveshaft joint boots for correct prevailing torque type.
evidence of cracks, tears or splits. 5. The silicone front wheel driveshaft CV joint
NOTE: While inspecting the front wheel driveshaft boot will sweat during operation, causing a
CV joint boots, watch for indentations (dimples) in light film of grease to show on the outside of
the boot convolutions. If an indentation is the front wheel driveshaft CV joint boot. This
observed, it must be removed. condition is normal.
NOTE: Halfshafts are not balanced and do not
contribute to rotational vibration.
2. Inspect the underbody for any indication of
grease splatter in the vicinity of the front wheel 6. If the concerns remain after the inspection,
driveshaft CV joint boots outboard and determine the symptoms and go to the
inboard locations, which is an indication of Symptom Chart. For additional Noise, Vibra-
front wheel driveshaft CV joint boot and/or tion and Harshness (NVH).
Symptom Chart
• Clicking, Popping or Grinding • Inadequate or contaminated lube • INSPECT, CLEAN and
Noises While Turning in outboard/inboard front wheel LUBRICATE as necessary.
driveshaft CV joint.
• Another component contacting • INSPECT and REPAIR as nec-
driveshaft assembly. essary.
• Wheel bearings, brakes, sus- • INSPECT and REPAIR as nec-
pension or steering components. essary. REFER to Section
204-00 / 206-00 / 211-00.
• Vibration at Highway Speeds • Out of balance front wheels or • REPAIR or INSTALL new as
tires. necessary.
• Out-of-round tires. • REPAIR or INSTALL new as
necessary.
• Incorrectly seated outboard front • REPAIR or INSTALL new as
wheel driveshaft CV joint in front necessary. REFER to Halfshaft
wheel hub. Disassemblv and Assembly in
this section.
• Shudder Vibration During Ac- • Excessively high CV joint oper- • CHECK ride height, VERIFY
celeration. ating angles caused by incorrect correct spring rate and CHECK
ride height. items under Halfshaft Joint
Pullout. REPAIR or INSTALL
new as necessary.
• Excessively worn or damaged • INSPECT and INSTALL new as
inboard front wheel driveshaft necessary.
joint or outboard front wheel
driveshaft joint.
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• Halfshaft Joint Pullout • Inboard driveshaft bearing re- • INSPECT and REPAIR or
tainer circlip missing or not cor- INSTALL new as necessary.
rectly seated in differential side
gear.
• Engine/transaxle assembly • CHECK engine mounts for
mispositioned. damage or wear. REPAIR or
INSTALL new as necessary.
• Frame rail or strut tower out of • CHECK underbody dimensions.
position or damaged. REFER to Section 501-00.
• Front suspension components • CHECK for worn bushings or

worn or damaged. bent components (front stabilizer
bar, front suspension lower arm).
REPAIR or INSTALL new as
necessary.
G17442 en 09/2004 2004.75 Focus

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Halfshaft LH (14 320 0)

Special Tool(s)
Remover, Halfshaft Removal
204-226 (16-092)
All vehicles
Adapter for 204-226 [Wheels and Tires, REMOVAL AND
204-226-01 (16-092-01) INSTALLATION, Wheel and Tire]
2. Remove the wheel hub retaining bolt.
• Discard the wheel hub retaining bolt.
204-349
Slide Hammer
205-047 (15-011)
Protector, Halfshaft Seal

205-775
3. NOTE: Use a suitable brass drift if necessary.
Push the halfshaft into the tripode housing
as far as the stop (approximately 20 mm).
Remover, Halfshaft 4. Using the special tool to prevent the ball
308-256 (16-089) joint stud from rotating, remove and dis-
card the lower arm ball joint retaining nut.
General Equipment
Tire lever
Name Specification
Silicone Grease ESE-M1C171-A
Transmission Fluid WSD-M2C200-C
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5. CAUTION: Make sure the special tool is 7. CAUTION: The inner constant velocity
installed with the curved surface (CV) joint must not be bent more than
facing upwards to prevent damage to 23 degrees. The outer CV joint must
the ball joint seal. not be bent more than 45 degrees.
Install the special tool. CAUTION: Do not apply excessive force to
NOTE: Make sure the halfshaft is still fully
engaged in the tripode housing.
Detach the halfshaft from the wheel hub.
• Pull the strut and spring assembly outwards
approximately 28 mm.
Vehicles with 5-speed manual transaxle (iB5)
6. CAUTION: Make sure the strut and
spring assembly does not move in a 8. CAUTION: The inner CV joint must not
forwards or rearwards direction, to be bent more than 23 degrees. The
prevent damage to the top mount outer CV joint must not be bent more
center cup. than 45 degrees.
Using a suitable ball joint separator, detach CAUTION: Make sure the halfshaft seal is
the lower arm from the wheel knuckle. not damaged.
• Remove the special tool. NOTE: Plug the transaxle to prevent oil loss or dirt
ingress.
Using the special tool, remove the
halfshaft.
• Discard the snap ring.
• Allow the oil to drain into a suitable con-
tainer.
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Vehicles with 4-speed automatic transaxle Vehicles with 5-speed manual transaxle (MTX75)
or 6-speed manual transaxle (MMT6)
9. CAUTION: The inner CV joint must not
be bent more than 23 degrees. The 10. CAUTION: The inner CV joint must not
outer CV joint must not be bent more be bent more than 23 degrees. The
than 45 degrees. outer CV joint must not be bent more
than 45 degrees.
CAUTION: Make sure that the halfshaft
seal is not damaged. CAUTION: Make sure that the halfshaft
seal is not damaged.
CAUTION: Plug the transaxle to prevent
oil loss or dirt ingress. CAUTION: Plug the transaxle to prevent
oil loss or dirt ingress.
Using the special tools, remove the
halfshaft. Using the special tools, remove the
• Discard the snap ring. halfshaft.
• Allow the oil to drain into a suitable con- • Discard the snap ring.
tainer. • Allow the oil to drain into a suitable con-
tainer.
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Vehicles with automatic transaxle (CFT23) All vehicles

11. CAUTION: The inner CV joint must not 2. CAUTION: The inner CV joint must not
be bent more than 23 degrees. The be bent more than 23 degrees. The
outer CV joint must not be bent more outer CV joint must not be bent more
than 45 degrees. than 45 degrees.
CAUTION: Make sure that the halfshaft CAUTION: Make sure that the halfshaft
seal is not damaged. seal is not damaged.
CAUTION: Plug the transaxle to prevent CAUTION: Make sure the snap ring is
dirt ingress. correctly seated.
Using a suitable tire lever, remove the NOTE: Install a new snap ring.
halfshaft. Attach the left-hand halfshaft to the
• Discard the snap ring. transaxle.
• Remove the special tool before fully in-
stalling the halfshaft.
Installation
3. Push the halfshaft into the tripode housing
Vehicles with automatic transaxle (CFT23) as far as the stop (approximately 20 mm).
1. Coat the halfshaft seal with grease.
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4. CAUTION: The inner CV joint must not 7. CAUTION: Install a new wheel hub
be bent more than 23 degrees. The retaining bolt.
outer CV joint must not be bent more NOTE: Do not tighten the wheel hub retaining bolt
than 45 degrees. at this stage.
CAUTION: Do not apply excessive force to Install the wheel hub retaining bolt.
Attach the halfshaft to the wheel hub.
spring assembly does not move in a
forwards or rearwards direction, to
8. Install the wheel and tire. For additional
prevent damage to the top mount
center cup.
Attach the lower arm ball joint to the wheel INSTALLATION, Wheel and Tire]
knuckle. 9. Tighten the wheel hub retaining bolt (wheel
and tire shown removed for clarity).
joint retaining nut. Failure to follow • Tighten the wheel hub retaining bolt in two
this instruction may result in personal stages.
injury. • Stage 1: 35 Nm.
Using the special tool to prevent the ball • Stage 2: 90 degrees.
Vehicles with 4-speed automatic transaxle

10. With the vehicle on a level surface, check
the transmission fluid level.
Vehicles with manual transaxle
the transmission fluid level and top up
with clean transmission fluid until the
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fluid level is 5 - 10 mm below the fluid

filler plug.
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Halfshaft RH (14 321 0)
4. Remove the crashbox.

Special Tool(s)
204-349
Protector, Halfshaft Seal

205-775

General Equipment joint stud from rotating, remove and dis-
Ball joint separator card the lower arm ball joint retaining nut.
Name Specification
Removal
2. Remove the wheel hub retaining bolt.
• Discard the wheel hub retaining bolt. 6. CAUTION: Make sure the special tool is
installed with the curved surface
3. NOTE: Use a suitable brass drift if necessary.

Push the halfshaft into the tripode housing
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7. CAUTION: Make sure the strut and 8. CAUTION: The inner constant velocity
spring assembly does not move in a (CV) joint must not be bent more than
forwards or rearwards direction, to 23 degrees. The outer CV joint must
prevent damage to the top mount not be bent more than 45 degrees.
center cup.
Using a suitable ball joint separator, detach the strut and spring assembly. Do not
the lower arm from the wheel knuckle. pull the strut and spring assembly
• Remove the special tool. outwards by more than 28 mm.
NOTE: Make sure that the halfshaft is still fully
engaged in the tripode housing.
Detach the halfshaft from the wheel hub.
9. Remove the intermediate shaft center
bearing cap.
• Discard the bearing cap and retaining nuts.
• Remove the intermediate shaft center
bearing heat shield (if equipped).
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All vehicles
10. CAUTION: The inner CV joint must not
be bent more than 23 degrees. The 2. CAUTION: The inner CV joint must not
outer CV joint must not be bent more be bent more than 23 degrees. The
than 45 degrees. outer CV joint must not be bent more
than 45 degrees.
CAUTION: Make sure the halfshaft seal is
not damaged. CAUTION: Make sure the halfshaft seal is
not damaged.
CAUTION: Plug the transaxle to prevent
oil loss or dirt ingress. Attach the right-hand halfshaft and
intermediate shaft assembly to the
Remove the halfshaft and intermediate
transaxle.
shaft assembly.
• Remove the special tool before fully in-
• Allow the oil to drain into a suitable con-
stalling the halfshaft.
tainer (all except vehicles with CFT23).
Installation
Vehicles with automatic transaxle (CFT23)
1. Coat the halfshaft seal with grease.
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3. NOTE: Install a new intermediate shaft center 5. CAUTION: The inner CV joint must not
bearing cap and retaining nuts. be bent more than 23 degrees. The
NOTE: Make sure that the intermediate shaft outer CV joint must not be bent more
center bearing is correctly positioned in the than 45 degrees.
intermediate shaft center bearing retaining
bracket. CAUTION: Do not apply excessive force to
Install the intermediate shaft center pull the strut and spring assembly
bearing cap. outwards by more than 28 mm.
• Position the center bearing cap.
• Position the intermediate shaft center CAUTION: Make sure the strut and spring
bearing heat shield (if equipped). assembly does not move in a forwards or
• Tighten the center bearing cap retaining to the top mount center cup.
nuts.
Attach the halfshaft to the wheel hub.
spring assembly does not move in a
forwards or rearwards direction, to
prevent damage to the top mount
center cup.
Attach the lower arm ball joint to the wheel
knuckle.
4. Push the halfshaft into the tripode housing injury.
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11. Tighten the wheel hub retaining bolt

8. CAUTION: Install a new wheel hub
(wheel and tire shown removed for
retaining bolt.
clarity).
NOTE: Do not tighten the wheel hub retaining bolt
• Tighten the wheel hub retaining bolt in two
at this stage.
stages.
Install the wheel hub retaining bolt. • Stage 1: 35 Nm.
• Stage 2: 90 degrees.
9. Install the crashbox.

1. Tighten the bolt M10 x 16. Vehicles with automatic transaxle
2. Tighten the bolts M10 x 25. 12. With the vehicle on a level surface, check
the transmission fluid level.
the transmission fluid level and top up
with clean transmission fluid until the
fluid level is 5 - 10 mm below the fluid
filler plug.

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Intermediate Shaft
2. Pack the tripode joint with grease.

Special Tool(s) 1. Insert a small screwdriver under the boot
seat to allow the air to escape.
Clamping Tool, Boot 2. Slide the tripode joint in as far as the stop,
Retaining Clamp then pull it out 20 mm.
204-169 (14-044) • Remove the screwdriver.
Name Specification
Constant Velocity Joint ESP-M1C207-A
Grease
Removal
1. Remove the right-hand halfshaft.
2. CAUTION: Use vise jaw protectors.
NOTE: Make sure the boot is not damaged.
3. NOTE: Install new constant velocity (CV) joint
Detach the intermediate shaft from the boot retaining clamps.
right-hand halfshaft.
Locate the retaining clamp in the boot ring
• Remove and discard the constant velocity
groove and using the special tool, tighten
(CV) joint boot retaining clamps and slide the CV joint boot retaining clamps.
back the boot.
• Detach the intermediate shaft from the
halfshaft.
• Remove the grease.
4. Install the right-hand halfshaft.
Installation
1. CAUTION: Use vise jaw protectors.
Attach the intermediate shaft to the
right-hand halfshaft.
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Inner Constant Velocity (CV) Joint Boot (14 336 0)
2. CAUTION: Use vice with soft jaw

Special Tool(s)
protectors.
Clamping Tool, Boot Detach the inner constant velocity joint
Retaining Clamp from the front halfshaft.
204-169 (14-044) • Hold the front halfshaft in a vice.
1. Cut and discard the boot clamps. Slide the
boot back.
2. Remove the tripode housing.
Remover, Bearing/Gear
205-310 (15-091)
205-311 (15-092)
Installer, Extension Housing

Bushing/Oil Seal
308-046 (16-016)
3. Remove the snap ring.
Name Specification
Constant velocity joint ESP-M1C207-A
high-temperature
grease
Removal
1. Remove the halfshaft. For additional
information,
refer to Halfshaft LH in this section.
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4. Using the special tools detach the tripode 2. Insert the clamping strap in the boot ring
star. groove and tighten with the special tool.
• Remove and discard the rubber boot.
3. CAUTION: Do not damage the

universal joint rollers.
Installation NOTE: Chamfer points towards front halfshaft.
Attach the tripode star using the special
1. NOTE: Install a new clamping strap. tool.
NOTE: Install a new rubber boot. • Drive the tripode star onto the front drive
Place the clamping strap and inner CV joint halfshaft as far as it will go.
rubber boot in position on the front half-
shaft.
4. NOTE: Install a new snap ring.

Install the snap ring.
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5. Fill the constant velocity joint with grease.

1. Insert a small screwdriver under the boot
2. Push on the tripode housing to stop, then
pull it back 20 mm.
• Remove the screwdriver.
6. NOTE: Install a new clamping strap.

Insert the clamping strap in the boot ring
groove and tighten with the special tool.
7. Install the halfshaft. For additional

information,
refer to Halfshaft LH in this section.
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Outer Constant Velocity (CV) Joint Boot (14 338 0)
Installation
Special Tool(s)
1. NOTE: Install a new rubber boot.
Clamping Tool, Boot
Retaining Clamp Install the outer CV joint boot.
204-169 (14-044) • Pack the CV joint with grease.
• Press the rubber boot into the groove of the
CV joint.
General Equipment 2. Position the rubber boot.
Expanding pliers, snap-ring • Remove the screwdriver.
Name Specification
high-temperature
grease
Removal
1. Remove the inner CV joint boot. For
refer to Inner Constant Velocity (CV)
Joint Boot in this section.
2. CAUTION: Use a vice with protective 2. NOTE: Install a new clamping strap.
jaw covers.
Insert the inner clamping strap into the ring
Remove the outer CV joint boot. groove of the rubber boot and tighten with
• Cut and discard the boot clamps. the special tool.
• Remove the grease packing.
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Insert the outer clamping strap into the ring
groove of the rubber boot and tighten with
the special tool.
4. Install the inner CV joint boot. For

refer to Inner Constant Velocity (CV)
Joint Boot in this section.
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Halfshaft LH (14 320 8)

Disassembly
Special Tool(s)
1. CAUTION: Use a vice with protective
Gaiter clamp tightening tool jaw covers.
204-169 (14-044)
Detach the inner constant velocity joint
from the front halfshaft.
• Clamp the front halfshaft in a vice.
1. Separate and discard the clamping straps.
Separating tool, Slide the boot back.
Bearing/Gear 2. Remove the tripode housing.
205-310 (15-091) • Remove the grease from inside the joint.
205-311 (15-092)

Bushing/Oil Seal
308-046 (16-016)
2. Detach the circlip.

Name Specification • Discard the snap ring.
high-temperature
grease
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3. Using the special tools detach the tripode Assembly

star.
• Remove and discard the rubber boot. 1. NOTE: Install a new rubber boot.
Install the outer CV joint boot.
• Pack the CV joint with grease.
CV joint.
2. Position the rubber boot.
4. Detach the outer CV joint boot.

• Separate and discard the clamping straps.
2. Insert the small and large clamping straps

in the boot ring grooves and tighten them
with the special tool.
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3. NOTE: Install a new clamping strap. 5. CAUTION: Do not damage the

NOTE: Install a new rubber boot. universal joint rollers.
Place the clamping strap and inner CV joint NOTE: Chamfer points towards the front halfshaft.
rubber boot in position on the front half- Install the tripode star.
shaft.
• Using the special tool, push the tripode star
onto the front halfshaft to the stop.
4. Attach the inner CV joint boot.

• Insert the clamping strap in the boot ring 6. NOTE: Install a new snap ring.
Install the snap-ring.
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2. Push on the CV joint to stop, then pull it
back 20 mm.

Insert the clamping strap in the boot ring
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Halfshaft RH (14 321 8)
Disassembly
Special Tool(s)
1. CAUTION: Use a vice with protective
Gaiter clamp tightening tool jaw covers.
204-169 (14-044)
Detach the intermediate shaft from the
front halfshaft.
• Hold the front halfshaft in a vice.
Separating tool, Bearing/Gear Slide the boot back.
205-310 (15-091) • Remove the intermediate shaft.
205-311 (15-092)

Bushing/Oil Seal
308-046 (16-016)
2. Remove circlip.
Name Specification • Discard the snap ring.
high-temperature
grease
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3. Using the special tools detach the tripode Assembly

star.
• Remove and discard the rubber boot. 1. NOTE: Install a new rubber boot.
Install the outer CV joint boot.
• Pack the CV joint with grease.
CV joint.
2. Position the rubber boot.
4. Detach the outer CV joint boot.

2. NOTE: Install new clamping straps.

Insert the small and large clamping straps
in the boot ring grooves and tighten them
with the special tool.
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3. NOTE: Install a new clamping strap. 5. CAUTION: Do not damage the

NOTE: Install a new rubber boot. universal joint rollers.
Place the clamping strap and inner CV joint NOTE: Chamfer points towards the front halfshaft.
rubber boot in position on the front half- Install the tripode star.
shaft.
• Using the special tool, push the tripode star
onto the front halfshaft to the stop.
4. Attach the inner CV joint boot.

• Insert the clamping strap in the boot ring 6. NOTE: Install a new snap ring.
Install the snap ring.
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2. Push on the CV joint to stop, then pull it
back 20 mm.
8. Insert the clamping strap in the boot ring

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206-00-1 Brake System - General Information 206-00-1
SECTION 206-00 Brake System - General Information

CONTENTS PAGE
Brake System ................................................................................................................... 206-00-2

Road Test ........................................................................................................................ 206-00-2/4
Pinpoint Tests .................................................................................................................. 206-00-5/9
Component Tests............................................................................................................. 206-00-10
Brake System Check........................................................................................................ 206-00-10
Brake Booster Functional Test ......................................................................................... 206-00-11/12
GENERAL PROCEDURES
Brake System Bleeding................................................................................. (12 141 0) 206-00-13

Brake System Pressure Bleeding.................................................................. (12 141 0) 206-00-14
Brake System Leak Check ................................................................................................ 206-00-15
Brake Disc Runout Check ............................................................................. (12 221 0) 206-00-16
Check............................................................................................................................... 206-00-16
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Brake System
performance guidelines to make good

comparisons and detect performance concerns.
An experienced technician will always establish a
General Equipment
route that will be used for all brake diagnosis road
Pressure/vacuum gauge set tests. The road selected will be reasonably
smooth and level. Gravel or bumpy roads are not
Worldwide diagnostic system (WDS) suitable because the surface does not allow the
tires to grip the road equally. Crowned roads
should be avoided because of the large amount of
The brake system operates by transferring effort weight shifted to the low set of wheels on this type
applied to the brake pedal by the driver to the of road. Once the route is established and
brakes at each wheel. consistently used, the road surface variable can
be eliminated from the test results.
The braking effort is distributed to each wheel,
using a hydraulic system. The system is assisted Before a road test, get a complete description of
using a vacuum brake booster that reduces pedal the customer concerns or suspected condition.
effort and increases hydraulic pressure. From the description, the technician will be able to
match possible causes with symptoms. Certain
The parking brake operates on the rear wheels
components will be identified as possible sources
and is applied using a hand operated control.
while others will be eliminated by the evidence.
More importantly, the customer description can
reveal unsafe conditions which should be checked
or corrected before a road test. The description
NOTE: Before carrying out any diagnosis, make will also help form the basic approach to the road
sure that the brake system warning indicator is test by narrowing the concern to specific
functional. components, vehicle speed or conditions.
1. Verify the customer concern. Begin the road test with a general brake
2. Visually inspect for obvious signs of performance check. Using the description of the
mechanical or electrical damage. concern, test the brakes at different vehicle
speeds using both light and heavy pedal pressure.
Visual Inspection Chart Determine if the concern is in the front or rear
Mechanical Electrical braking system. First use the foot brake and then
the parking brake. If the condition (i.e. pull,
• Tire pressure(s) • Electrical vibration, pulsation) occurs only on operation of
• Wheels and tires connector(s) the parking brake, the concern is in the rear brake
• Fluid leak(s) • Wiring harness(s) system. If the condition occurs when the foot
• Switch(es) brake is depressed, the concern is in the front
brake system.
reported concern is found, correct the case (if Avoid locking the brakes and sliding the tires. This
possible) before proceeding to the next step. condition will not indicate brake efficiency. A
4. If the cause if not visually evident, verify the heavily braked but turning wheel will stop the
symptom and refer to the Symptom Chart. vehicle in a shorter distance than locked wheels.
If the concern becomes evident during this check,
make sure it fits the description given before the
Road Test road test. If the concern is not evident, attempt to
Carry out a road test to compare actual vehicle duplicate the condition using the information from
braking performance with the performance the description.
standards expected by the driver. The ability of the If a concern exists, use the Brake System Symp-
test driver to make valid comparisons and detect tom Chart in order to isolate it to a specific
performance deficiencies will depend on sub-system and condition description. From this
experience. description, a list of possible sources can be used
The driver should have a thorough knowledge of to further narrow the cause to a specific compo-
the brake system operation and accepted general nent or condition.
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Symptom Chart
• Brakes pull or drift • Worn or damaged brake shoes • INSTALL new brake shoes or
or brake pads and linings. brake pads. REFER to Section
206-02 / 206-03 / 206-04.
• Abnormal wear or distortion of • INSTALL a new front brake disc.
front brake disc. REFER to Section 206-03.
• Incorrect rear brake adjustment. • ADJUST the parking brake ca-
ble. REFER to Section 206-05.
• Incorrect wheel alignment ad- • ADJUST the wheel alignment.
justment. REFER to Section 204-00.
• Incorrect wheel bearing preload • ADJUST or INSTALL a new
adjustment. wheel bearing.
• Grease or fluid on the brake • INSTALL new brake shoes or
shoes or brake pads; glazed brake pads. REFER to Section
linings. 206-02 / 206-03/ 206-04.
• Stuck or seized wheel cylinders • INSTALL a new wheel cylinder
or brake calipers. or brake caliper. REFER to Sec-
tion 206-02 / 206-03 / 206-04.
• The red brake warning indicator • Low brake fluid level. • FILL the reservoir. CHECK the
is always on brake and clutch system for
leaks including brake fluid in the
brake booster.
• Leaking brake master cylinder • INSTALL a new brake master
primary piston cup. cylinder.
• Parking brake control not fully • FREE UP and ADJUST the
released. parking brake cable. REFER to
Section 206-05. INSTALL new
• Malfunctioning anti-lock braking • REFER to Section 206-09A /
system (ABS). 206-09B / 206-09C.
• Shorted indicator circuit. • REFER to Section 413-01.
• Vibration when the brakes are • Grease or fluid on the brake • INSTALL new brake shoes or
applied shoes or brake pads; glazed brake pads. REFER to Section
linings. 206-02 / 206-03 / 206-04.
• Worn or damaged brake shoes • INSTALL new brake shoes or
or brake pads. brake pads. REFER to Section
206-02 / 206-03 / 206-04.
• Loose caliper mounting bolt(s). • TIGHTEN the caliper mounting
bolt(s).
• Damaged brake drum contact • INSTALL a new brake drum.
surface. REFER to Section 206-02.
• Excessive brake disc thickness • REFER to Brake Disc Runout
variation or brake disc runout. Check in this section.
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• Wheels and tires. • CHECK the tires. BALANCE or
INSTALL new tires as neces-
sary. REFER to Section 204-04.
• Loose or missing wheel hub • TIGHTEN or INSTALL new
bolts. wheel hub bolts as necessary.
• Worn or damaged brake drums • INSTALL new brake drums or
or brake discs. brake discs. REFER to Section
206-02 / 206-03 / 206-04.
• Pedal goes down fast • Low brake fluid level. • FILL the reservoir. CHECK the
brake and clutch system for
leaks including brake fluid in the
brake booster.
• Leak in the hydraulic system. • REPAIR the leak. CHECK the
entire hydraulic system. FILL
and BLEED the brake system.
• Air in the system. • CHECK for leaks. BLEED the
brake system.
• Brake disc “brake knock back” • CARRY OUT a brake disc runout
(Brake pads push the brake check. REFER to Brake Disc
caliper piston back into the brake Runout Check in this section.
caliper. Caused by excessive
brake disc lateral runout or loose
wheel bearings.)
• Worn brake shoes or brake • INSTALL new brake shoes or
pads. brake pads. REFER to Section
206-02 / 206-03 / 206-04.
• Worn brake master cylinder • GO to Pinpoint Test A
piston cups or scored cylinder
bore.
• Pedal eases down slowly • Air in the system. • BLEED the brake system.
• Malfunctioning brake master • GO to Pinpoint Test B
cylinder.
• Low engine vacuum (stationary).
• Pedal is low or feels spongy • Worn brake shoes or brake • INSTALL new brake shoes or
206-02/ 206-03/ 206-04.
• Air in the system. • CHECK for leaks. BLEED the
brake system.
• Brake lockup during light brake • Glazed or worn brake shoes or • INSTALL new brake shoes or
pedal force brake pads. brake pads. REFER to Section
206-02 / 206-03 / 206-04.
• Brake booster. • GO to Pinpoint Test C
• Low engine vacuum.
• Excessive or erratic pedal travel • Worn brake shoes or brake • INSTALL new brake shoes or
206-02 / 206-03 / 206-04.
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• Wheel bearings • CARRY OUT a brake disc runout
check. REFER to Brake Disc
Runout Check in this section.
• Brake drag • Incorrectly adjusted parking • ADJUST the parking brake ca-
brake. ble. REFER to Section 206-05.
• Brake booster. • REFER to brake booster opera-
tion check in this procedure.
• Seized wheel cylinder or brake • INSTALL a new wheel cylinder
caliper. or brake caliper. REFER to Sec-
tion 206-02 / 206-03 / 206-04.
• Seized brake caliper slide pins. • INSTALL a new brake caliper.
REFER to Section 206-03
/ 206-04.
• Seized parking brake cables. • INSTALL new parking brake ca-
bles. REFER to Section 206-05.
• Excessive brake pedal effort • Worn or contaminated brake • INSTALL new brake shoes or
shoes or brake pads. brake pads. REFER to Section
206-02 / 206-03 / 206-04.
• Malfunctioning vacuum pump • INSTALL a new brake vacuum
(diesel). pump.
• Disconnected or damaged brake • CONNECT or INSTALL a new
booster vacuum pipe. brake booster vacuum pipe as
necessary.
• Brake booster. • GO to Pinpoint Test D
• Brake noise • Worn or damaged brake shoes • INSTALL new brake shoes or
or brake pads. brake pads. REFER to Section
206-02/ 206-03 / 206-04.
• Brake booster. • GO to Pinpoint Test E
• Slow or incomplete brake pedal • Brake booster. • GO to Pinpoint Test F
return • Seized brake pedal pivot.
Pinpoint Tests
PINPOINT TEST A: PEDAL GOES DOWN FAST
A1: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
• Does the brake pedal height build up and then
hold?
→ Yes
CHECK parking brake adjustment and
ADJUST as necessary. REFER to Section
206-05. If the condition still exists. BLEED
the brake system. TEST the system for
normal operation.
→ No
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GO to A2
A2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake and clutch system
leaks. Refer to Brake Master Cylinder Compo-
nent Test in this procedure.
• Are any leaks present?
→ Yes
REPAIR as necessary. ADD fluid and
BLEED the brake system.
TEST the system for normal operation.
→ No
GO to A3
A3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass Con-
dition Test. Refer to the Brake Master Cylinder
Component Test in this procedure.
• Was a concern found?
→ Yes
INSTALL a new brake master cylinder.
REFER to Section 206-06. TEST the system
for normal operation.
→ No
PINPOINT TEST B: PEDAL EASES DOWN SLOWLY
B1: CHECK THE BRAKE PEDAL OPERATION
1 Depress the brake pedal.
• Does the pedal ease down slowly?
→ Yes
GO to B2
→ No
Refer to the Brake Master Cylinder Com-
ponent Test in this procedure.
B2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks.
• Are any leaks present?
→ Yes
REPAIR as necessary. ADD fluid and
→ No
GO to B3
B3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass Con-
dition Test. Refer to the Brake Master Cylinder
Component Test in this procedure.
• Was a concern found?
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→ Yes
INSTALL a new brake master cylinder.
REFER to Section 206-06. TEST the system
→ No
GO to B4
B4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2 Blow into the hose attached to the brake
booster check valve.
• Does air pass through the valve?
→ Yes
INSTALL a new brake booster check valve.
→ No
Go to B5
B5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
2 Using a suitable vacuum gauge, check the
vacuum pressure.
• Is the vacuum pressure above 40.5 kPa (0.4
bar) with the brake booster non-operational?
→ Yes
→ No
INSTALL a new brake booster check valve
vacuum hose. TEST the system for normal
operation.
PINPOINT TEST C: BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE
C1: CHECK THE BRAKE BOOSTER
1 Check the brake booster push rod alignment
and pedal travel.
• Is the push rod and pedal travel OK?
→ Yes
TEST the brake pedal application.
→ No
INSTALL a new brake booster. REFER to
Section 206-07.TEST the system for normal
operation.
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PINPOINT TEST D: EXCESSIVE BRAKE PEDAL EFFORT

D1: CHECK BRAKE APPLICATION
1 With the engine off, apply and release the brake
pedal five times to deplete all vacuum from the
brake booster. Apply the brake pedal, hold with
light pressure. Start the engine.
• Does the brake pedal hold?
→ Yes
GO to D2
→ No
GO to D3
D2: CHECK THE BRAKE BOOSTER FOR LEAKS
1 Run the engine at approximately 1000 rpm,
release the accelerator pedal and turn the en-
gine off. Wait 90 seconds and apply the brakes.
Two or more brake applications should be
power assisted.
• Does the brake booster work?
→ Yes
→ No
GO to D4
D3: CHECK THE BRAKE PEDAL LINKAGE
1 Disconnect the actuator rod from the pedal pin
and fully depress the brake pedal.
• Did the pedal move freely?
→ Yes
→ No
INSTALL new brake pedal bushings. TEST
the system for normal operation.
D4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2 Blow into the hose attached to the brake
booster check valve.
• Does air pass through the valve?
→ Yes
INSTALL a new brake booster check valve.
→ No
GO to D5
D5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
2 Using a suitable vacuum gauge, check the
vacuum pressure.
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• Is the vacuum pressure above 40.5 kPa (0.4

bar) with the brake booster non-operational?
→ Yes
GO to D6
→ No
INSTALL a new vacuum hose and fittings.
D6: CHECK THE BRAKE BOOSTER
1 Check the brake booster. REFER to the Brake
Booster Operation Check in this procedure.
• Is the brake booster OK?
→ Yes
→ No
operation.
PINPOINT TEST E: BRAKE NOISE
E1: CHECK FOR PEDAL NOISE
1 Run the engine at idle for 10 seconds or longer.
2 Apply the brake pedal and listen for noise.
3 Compare results with a known good system.
• Was a noise present?
→ Yes
GO to E2
→ No
E2: CHECK THE BRAKE BOOSTER
1 Check the brake booster push rod alignment
and travel.
• Is the push rod and pedal travel OK?
→ Yes
→ No
Section 206-07. TEST the system for normal
operation.
PINPOINT TEST F: SLOW OR INCOMPLETE BRAKE PEDAL RETURN
F1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at approximately 1200 rpm
whilst making several brake applications.
2 Pull the brake pedal upwards with approxi-
mately 44.5 N (10 lbs) force.
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3 Release the brake pedal and measure the dis-
tance to the floor panel and note the reading.
4 Make a hard brake application.
5 Release the brake pedal and measure the dis-
tance to the floor panel and note the reading.
6 Compare the measurements.
• Did the brake pedal return to its original posi-
tion?
→ Yes
→ No
GO to F2
F2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal for free operation.
• Did the brake pedal operate freely?
→ Yes
operation.
→ No
INSTALL new brake pedal bushings. TEST
1. Operate the engine at idle with the transaxle in
the NEUTRAL position.
Component Tests
2. Apply the brake pedal lightly three or four
times.
Hydraulic Leak Check 3. Allow 15 seconds for the vacuum to replenish
NOTE: There is a common clutch and brake fluid the brake booster.
reservoir, therefore it is possible that a clutch leak NOTE: This increased resistance may feel like
can lead to reduction in the reservoir level. something has bottomed out.
It is possible that all evidence of fluid leakage may 4. Apply the brake pedal until it stops moving
have washed off if the vehicle has been operated downward or an increased resistance to the
in rain or snow, as brake fluid is water-soluble. pedal travel occurs.
Refill the system, bleed then apply the brakes 5. Hold the brake pedal in the applied position
several times. Examine the system to verify that and raise the engine speed to approximately
the reservoir fluid level is actually dropping. 2000 rpm.
Locate and repair the external leak. If the fluid NOTE: The additional movement of the brake
level drops and no external leak can be found, pedal is the result of the increased engine
check for a brake master cylinder bore end seal manifold vacuum which exerts more force on the
leak. brake booster during engine rundown. This means
that additional stroke is available in the brake
master cylinder and the brake system is not
Brake System Check bottoming out.
Brake Pedal Reserve Check

Where a low brake pedal or the feel of a
bottomed-out condition exists, check for brake
pedal reserve.
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6. Release the accelerator pedal and observe Section 206-07. If the brake pedal movement
that the brake pedal moves downward as the feels spongy, bleed the brake system.
engine returns to idle speed.
Brake Master Cylinder
Brake Booster Functional Test Usually, the first and strongest indicator of
anything wrong with the braking system is a
Inspect all hoses and connections. All unused
feeling through the brake pedal. In diagnosing the
vacuum connectors should be capped. Hoses and
condition of the brake master cylinder, check
their connections should be correctly secured and
pedal feel as evidence of a brake concern. Check
in good condition with no holes and no collapsed
for the red brake warning indicator illumination
areas. Inspect the check valve on the brake
and the fluid level in the master cylinder reservoir.
booster for damage.
Normal Conditions
Brake Booster Operation Check
The following conditions are considered normal
1. Check the hydraulic brake system for leaks or
and are not indications that the brake master
low fluid.
cylinder is in need of service.
2. With the transaxle in the NEUTRAL position,
stop the engine and apply the parking brake. – Modern brake systems are not designed to
Apply the brake pedal several times to produce as hard a pedal effort as in the past.
exhaust all the vacuum in the system. Complaints of light pedal efforts should be
compared to pedal efforts of another vehicle,
3. With the engine turned off and the vacuum in
of the same model and year.
the system exhausted, apply the brake pedal
and hold it down. Start the engine. If the – During normal operation of the brake pedal,
vacuum system is operating, the brake pedal the fluid level in the reservoir will rise during
will tend to move downward under constant brake pedal application and fall during release.
foot pressure. If no motion is felt, the vacuum The net fluid level (i.e., after brake pedal
booster system is not functioning. application and release) will remain
unchanged.
4. Remove the vacuum hose from the brake
booster. Manifold vacuum should be available – A trace of brake fluid will exists on the brake
at the brake booster end of the hose with the booster shell below the master cylinder
engine at idle speed and the transaxle in the mounting flange. This results from the normal
NEUTRAL position. Make sure that all unused lubricating action of the master cylinder bore
vacuum outlets are correctly capped, hose end seal.
connectors are correctly secured and vacuum – The fluid level will fall with brake shoe and
hoses are in good condition. When it is lining wear.
established that manifold vacuum is available
to the brake booster, connect the vacuum
hose to the brake booster and repeat Step 3. If Abnormal Conditions
no downward movement of the brake pedal is NOTE: Prior to performing any diagnosis, make
felt, install a new brake booster. sure the brake system warning indicator is
REFER to Section 206-07. functional.
5. Operate the the engine a minimum of 10 Changes in brake pedal feel or travel are
seconds at approximately 1200 rpm. Stop the indicators that something could be wrong with the
engine and let the vehicle stand for 10 braking system. The diagnostic procedure and
minutes. Then, apply the brake pedal with techniques use brake pedal feel, warning indicator
approximately 89 N (20 lb) force. The pedal illumination and low brake fluid level as indicators
feel (brake application) should be the same as in diagnosing braking system concerns. The
that noted with the engine operating. If the following conditions are considered abnormal and
brake pedal feels hard (no power assist), indicate that the brake master cylinder is in need
install a new vacuum check valve and then of service.
repeat the test. If the brake pedal still feels
hard, install a new brake booster. REFER to
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– The brake pedal goes down fast. This could be Non-Pressure Leaks
caused by an external or internal leak.
Any empty brake master cylinder reservoir
– The brake pedal eases down slowly. This condition may be caused by two types of
could be caused by an external or internal non-pressure external leaks.
leak.
Type 1: An external leak may occur at the brake
– The brake pedal is low and or feels spongy.
master cylinder reservoir cap because of incorrect
This condition may be caused by no fluid in the
positioning of the gasket and cap. Reposition the
brake master cylinder reservoir, reservoir cap
cap and gasket.
vent holes clogged or air in the hydraulic
system. Type 2: An external leak may occur at the brake
– The brake pedal effort is excessive. This may master cylinder reservoir mounting seals. Service
be caused by a bind or obstruction in the pedal such a leak by installing new seals.
or linkage, clogged fluid control valve or
insufficient booster vacuum.
– The rear brakes lock up during light pedal
force. This may be caused by incorrect tire
pressures, grease or fluid on the brake shoes
and linings, damaged brake shoes and linings,
incorrectly adjusted parking brake, or
damaged or contaminated brake pressure
control valves.
– The brake pedal effort is erratic. This condition
could be caused by a brake booster
malfunction, extreme caliper piston knock
back or incorrectly installed brake shoes and
linings.
– The red brake warning indicator is ON. This
may be caused by low fluid level, ignition wire
routing too close to the fluid level indicator
assembly, or float assembly damage.
Bypass Condition Test

1. Check the fluid in the brake master cylinder
reservoir. Fill the brake master cylinder
reservoir if low or empty.
2. Observe the fluid level in the brake master
cylinder reservoir. If after several brake
applications, the fluid level remains the same,
measure the wheel turning torque required to
rotate the wheels with the brakes applied as
follows:
Place the transaxle in the NEUTRAL position.
Raise and support the vehicle.
Apply the brakes with a minimum of 445 N (100 lb)
and hold for approximately 15 seconds. With the
brakes still applied, exert a torque on the front
wheels of 10.1 Nm (75 lb ft). If either wheel rotates,
install a new brake master cylinder.
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GENERAL PROCEDURES
Brake System Bleeding (12 141 0)

Bleeding
9. With the brake pedal fully depressed
Vehicles with anti-lock brakes tighten the bleed nipple.
1. Disconnect the battery ground cable. For
additional information, 10. CAUTION: Make sure the bleed nipple
refer to Section 414-01. cap is installed after bleeding the
All Vehicles brake line(s). This will prevent
corrosion to the bleed nipple. Failure
WARNING: Brake fluid contains to follow this instruction may result in
polyglycol ethers and polyglycols. Avoid the bleed nipple becoming seized.
contact with the eyes. Wash hands Repeat the procedure for the remaining
thoroughly after handling. If brake fluid brake lines.
contacts the eyes, flush the eyes for 15
minutes with cold running water. Get Vehicles with anti-lock brakes
medical attention if irritation persists. If 11. Connect the battery ground cable. For
taken internally, drink water and induce additional information,
vomiting. Get medical attention refer to Section 414-01.
immediately. Failure to follow these Vehicles with front and rear power windows
instructions may result in personal injury. 12. Initialize the door window motors. For
CAUTION: If brake fluid is spilt on the refer to Section 501-11.
paintwork, the affected area must be
immediately washed down with cold
water.
NOTE: Make sure that the vehicle is standing on a
level surface.
NOTE: The system consists of separate circuits
for each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
2. CAUTION: The brake fluid reservoir
must remain full with new, clean brake
fluid at all times during bleeding.
Install the bleed tube to the bleed nipple.
3. Immerse the end of the bleed tube in a
bleed jar containing a small quantity of
approved brake fluid.
4. Position the bleed jar base at least 300 mm
above the bleed nipple to maintain fluid
pressure and prevent air leaking past the
threads of the bleed nipple.
5. Loosen the bleed nipple by one-half turn.
6. Operate the brake pedal fully (pumping
brake fluid and air into the bleed jar) and
allow the brake pedal to return to the rest
position.
7. Fill the brake fluid reservoir to the MAX
mark.
8. Continue operating the brake pedal until
air-free fluid is being pumped into the bleed
jar.
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GENERAL PROCEDURES
Brake System Pressure Bleeding (12 141 0)
Bleeding
Vehicles with anti-lock brakes
Vehicles with anti-lock brakes 5. Connect the battery ground cable. For
1. Disconnect the battery ground cable. For additional information,
refer to Section 414-01. Vehicles with front and rear power windows
All vehicles 6. Initialize the door window motors. For
WARNING: Brake fluid contains refer to Section 501-11.
polyglycol ethers and polyglycols. Avoid
contact with the eyes. Wash hands
thoroughly after handling. If brake fluid
minutes with cold running water. Get
medical attention if irritation persists. If
taken internally, drink water and induce
vomiting. Get medical attention
immediately. Failure to follow these
CAUTION: If brake fluid is spilt on the
water.
NOTE: Make sure that the vehicle is standing on a
level surface.
NOTE: The system consists of separate circuits
for each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
2. Fill the brake fluid reservoir to the MAX
mark.
3. CAUTION: Make sure that the pressure
within the brake system does not
exceed 1 bar.
CAUTION: Make sure that the pressure
bleeding equipment is filled with new
brake fluid to the correct specification.
Using suitable pressure bleeding
equipment, pressure bleed the system in
accordance with the manufacturer's
instructions.
4. CAUTION: Make sure the bleed nipple
cap is installed after bleeding the
brake line(s). This will prevent
corrosion to the bleed nipple. Failure
to follow this instruction may result in
the bleed nipple becoming seized.
Fill the brake fluid reservoir to the MAX
mark as necessary.
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GENERAL PROCEDURES
Brake System Leak Check
Check
1. NOTE: Brake fluid is water soluble and it is
possible that all evidence of fluid leakage has
been washed off if the vehicle has been
operated in rain or snow.
Check the brake fluid level. Add brake fluid
as necessary.
2. Apply the brakes several times and make
sure the pedal feel is not spongy. If
necessary, bleed the brake system. For
additional information, refer to Brake
System Bleeding in this section.
3. Check the brake fluid level and verify that
the fluid level is actually dropping.
4. NOTE: If the brake fluid level drops and no
external leak is evident, check for a brake
master cylinder bore end seal leak.
Locate and correct the external leak.
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GENERAL PROCEDURES
Brake Disc Runout Check (12 221 0)
2. NOTE: Using paint or typing correction fluid,

Special Tool(s) mark the position of the wheel in relation to the
wheel hub.
Dial Indicator Gauge (Metric)
205-069 (15-046) Remove the wheel and tire. For additional
3. Remove the brake pads. For additional
information,
Holding Fixture, Dial Indicator refer to Section 206-03/ 206-04.
Gauge 4. Install the wheel nuts and tighten the wheel
205-070 (15-022A) nuts to 10 Nm, to hold the brake disc in
place.
5. NOTE: The total dial indicator gauge reading
should not exceed 0.05 mm.
Holding Fixture, Dial Indicator Using the special tools, measure the brake
Gauge (Disc Brake) disc runout on the inner and outer faces of
206-003 (12-003) the brake disc (outer face measurement
shown).
1. Position the dial indicator gauge so that it
contacts the brake disc approximately 10
General Equipment mm from the outer edge.
Micrometer 0-125 mm 2. Slowly rotate the brake disc and note the
readings.
Check
1. NOTE: The total dial indicator gauge reading
should not exceed 0.05 mm.
Using the special tools, measure the brake
disc runout on the inner face of the brake
disc (wheel and tire shown removed for
clarity).
1. Position the dial indicator gauge so that it
contacts the brake disc approximately 10
mm from the outer edge.
2. Slowly rotate the wheel and tire and note
the readings.
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GENERAL PROCEDURES (Continued)
6. NOTE: If any of the readings vary by more than 11. NOTE: Make sure that the wheel hub face is
0.015 mm or the brake disc thickness is less clean and free of rust and foreign material.
than the specified minimum, a new brake disc NOTE: Re-position the dial indicator gauge so that
must be installed and the brake disc runout it contacts the wheel hub approximately 10 mm
re-checked. from the outer edge of the wheel hub.
Check the brake disc thickness variation. Check the wheel hub face runout.
• Using a suitable micrometer, measure the • Slowly rotate the wheel hub and note the
brake disc thickness at eight positions, 45 readings.
degrees apart and approximately 15 mm
from the outer edge of the brake disc.
12. If the wheel hub runout exceeds 0.03 mm,

install a new wheel hub. For additional
7. If all the brake disc runout measurements information,
and the thickness variation are within the refer to Section 204-01/ 204-02.
specifications, check the wheel balance. 13. If the wheel hub face runout is within
8. If just the brake disc runout measurement specification, install a new brake disc. For
with the wheel and tire fitted exceeds the additional information,
specification, the wheel and tire must be refer to Section206-03/ 206-04.
rotated through 90 degrees in relation to
the brake disc and the brake disc runout
re-checked.
• If the brake disc runout measurement still
exceeds the specification, repeat the wheel
and tire rotation and checking process until
the measurement is within specification.
9. If the brake disc runout measurement
without the wheel and tire fitted is outside
the specification, check the wheel hub face
runout.
10. NOTE: Using paint or typing correction fluid,
mark the position of the brake disc in relation to
the wheel hub.
Remove the brake disc. For additional
information,
refer to Section 206-03/ 206-04.
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206-02-1 Drum Brake 206-02-1
SECTION 206-02 Drum Brake

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 206-02-2
Drum Brake....................................................................................................................... 206-02-3
Brake Drum....................................................................................................................... 206-02-4

Brake Shoes ..................................................................................................................... 206-02-5/6
Wheel Cylinder.................................................................................................................. 206-02-7/8
Brake Backing Plate.......................................................................................................... 206-02-9
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206-02-2 Drum Brake 206-02-2
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives

Specification
Silicon grease ESA-M1C171-A
BASF Hydraulan 417-1(DOT4++) -
Drum Brake Dimensions

Description mm
New brake drum nominal diameter 228.3
Worn brake drum discard diameter* 230.2
Brake shoe width 38
Worn brake shoe lining discard thickness** 1
Brake shoe adjuster pre-set diameter 228
* When the discard thickness has been reached, install a new brake drum/brake shoes.
** When the discard thickness has been reached, install new brake shoes.
Brake hose to wheel cylinder union 18 13 -
Wheel cylinder retaining bolts 10 - 89
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206-02-3 Drum Brake 206-02-3
Drum Brake
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206-02-4 Drum Brake 206-02-4
Brake Drum
1. Release the parking brake. 3. Remove the components in the order

2. Remove the wheel and tire. For additional indicated in the following illustration(s) and
information, refer to Section 204-04. table(s).

Number
1 - Brake Drum
See Removal Detail
Removal Details
Item 1 : Brake Drum

CAUTION: Do not use a screwdriver or
any other similar tool to remove the brake
drum from the wheel hub.
NOTE: Remove and discard the brake drum
retaining clip (if equipped).
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206-02-5 Drum Brake 206-02-5
Brake Shoes
Name Specification 1. Remove the brake drum. For additional

information, refer to Brake Drum in this
section.
table(s).

Number
1 - Brake shoe hold down
springs
2 - Brake shoe release springs
See Removal Detail
3 - Brake shoe adjuster
4 - Brake shoes
See Removal Detail
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206-02-6 Drum Brake 206-02-6
3. To install, reverse the removal procedure. Item 2 : Brake shoe release springs
NOTE: Install a new brake shoe upper return
Removal Details spring.
1. Adjust the brake shoes to obtain a brake
Item 2 : Brake shoe release springs shoe diameter of 228 mm.
1. CAUTION: Do not damage the wheel
cylinder boots.
NOTE: Hold the wheel cylinder pistons in place
with a rubber band.
Detach the brake shoes from the wheel
cylinder (wheel hub shown removed for
clarity).
2. NOTE: Fully release the brake shoe adjuster.

NOTE: Discard the upper return spring.
Remove the brake shoe return springs.
Item 4 : Brake shoes
1. Disconnect the parking brake cable from
the brake shoe.
Item 4 : Brake shoes

1. Clean the backing plate and apply grease
to the brake shoe contact points.
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206-02-7 Drum Brake 206-02-7
Wheel Cylinder

General Equipment
Brake hose clamp immediately washed down with cold
water.
1. Remove the brake shoes. For additional
information, refer to Brake Shoes in this
section.
table(s).

Number 4. Bleed the brake system. For additional
information, refer to Section 206-00.[Brake
1 - Brake hose to wheel cylinder
union
PROCEDURES, Brake System Bleeding]
See Removal Detail
For additional information, refer to Section
2 - Wheel cylinder retaining 206-00.[Brake System - General
bolts Information, GENERAL PROCEDURES,
3 - Wheel cylinder
See Removal Detail
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206-02-8 Drum Brake 206-02-8
Removal Details
Item 1 : Brake hose to wheel cylinder union

1. Loosen the brake hose to wheel cylinder
union.
1. Using a suitable brake hose clamp, clamp
the brake hose.
2. Loosen the union.
Item 3 : Wheel cylinder

1. CAUTION: Cap the brake hose to
prevent fluid loss or dirt ingress.
Disconnect the brake hose from the wheel
cylinder.
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206-02-9 Drum Brake 206-02-9
Brake Backing Plate
1. Remove the wheel cylinder. For additional

3. Disconnect the wheel speed sensor elec-
information, refer to Wheel Cylinder in this
trical connector.
section.
brake backing plate (wheel hub shown
removed for clarity).
1. Depress the retaining clip.
2. Detach the cable.

table(s).
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206-02-10 Drum Brake 206-02-10

Number
1 - Wheel hub retaining bolts
2 - Wheel hub
3 - Brake backing plate
Item 3 : Brake backing plate

CAUTION: Make sure that the mating
faces are clean and free from rust and
foreign material.
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TO MODEL INDEX
206-03-1 Front Disc Brake 206-03-1
SECTION 206-03 Front Disc Brake

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 206-03-2
Front Brake Disc Specification ......................................................................................... 206-03-2
Front Disc Brake ............................................................................................................... 206-03-3
Brake Pads ....................................................................................................................... 206-03-4/6

Brake Caliper .................................................................................................................... 206-03-7/8
Brake Disc ........................................................................................................................ 206-03-9
Brake Caliper .................................................................................................................... 206-03-10
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SPECIFICATIONS

Specification
Front Brake Disc Specification

mm
Brake disc diameter – vehicles with 2.0L engine, 2.0L diesel 300
Brake disc diameter – vehicles with 1.6L or 1.8L engine 278
New brake disc nominal thickness 25
Worn brake disc discard thickness * 23
Maximum brake disc thickness variation 0.025
Worn brake pad discard thickness** 1.5
* When the discard thickness has been reached, install a new brake disc and brake pads.
** When the discard thickness has been reached, install new brake pads.
Brake caliper retaining bolts 28 21 -
Brake hose to brake caliper union 18 13 -
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Front Disc Brake

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Brake Pads
Special Tool(s) 1. Remove the wheel and tire. For additional

Retractor, Brake Caliper
Piston 2. Remove the components in the order
206-005 (12-014)
table(s).
Name Specification
BASF Hydraulan 417-1 -
(DOT4++)

water.
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Number
4 - Outer brake pad
1 - Brake caliper retaining clip See Installation Detail
2 - Brake caliper retaining bolt 5 - Inner brake pad
covers See Removal Detail
3 - Brake caliper retaining bolts See Installation Detail
See Removal Detail
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3. To install, reverse the removal procedure. Installation Details

4. Depress the brake pedal, check the fluid
level in the brake fluid reservoir and top up Item 5 : Inner brake pad
if necessary with brake fluid.
1. CAUTION: When the brake caliper
piston is retracted into the piston
Removal Details housing, brake fluid will be displaced
into the brake fluid reservoir.
Item 3 : Brake caliper retaining bolts
NOTE: Make sure the brake pad contact points
CAUTION: Suspend the brake caliper to are clean and free from contamination.
prevent load being placed on the brake Using the special tool, retract the brake
hose. caliper piston.
Item 5 : Inner brake pad
1. NOTE: The inner brake pad is secured to the
brake caliper piston by a spring clip.
Remove the inner brake pad.
Item 4 : Outer brake pad

NOTE: Remove the adhesive foil from the rear of
the brake pad.
are clean and free from contamination.
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Brake Caliper

General Equipment
Brake hose clamp immediately washed down with cold
water.
Name Specification
BASF Hydraulan 417-1 - 2. Remove the components in the order
(DOT4++) indicated in the following illustration(s) and
table(s).
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Item Part Description Item 6 : Inner brake pad
Number 1. NOTE: The inner brake pad is secured to the
1 - Brake caliper retaining clip
Remove the inner brake pad.
2 - Brake hose to brake caliper
union
See Removal Detail
3 - Brake caliper retaining bolt
covers
4 - Brake caliper retaining bolts
5 - Outer brake pad
6 - Inner brake pad
See Removal Detail
7 - Brake caliper
See Removal Detail Item 7 : Brake caliper
3. To install, reverse the removal procedure. 1. CAUTION: Cap the brake hose to
4. Bleed the brake system. For additional prevent fluid loss or dirt ingress.
information, refer to Section 206-00. Disconnect the brake hose from the
caliper.
Removal Details • Rotate the caliper counterclockwise.
Item 2 : Brake hose to brake caliper union

1. Loosen the brake hose to brake caliper
union.
the brake hose.

NOTE: Remove the adhesive foil from the rear of
the brake pad.
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Brake Disc
1. Remove the wheel and tire. For additional 2. Remove the components in the order
table(s).
Item Part Description Removal Details

Number
1 - Brake caliper anchor plate Item 2 : Brake caliper and anchor plate
retaining bolts CAUTION: Suspend the brake caliper and
2 - Brake caliper and anchor anchor plate to prevent load being placed
plate on the brake hose.
See Removal Detail 1. Detach the brake caliper and anchor plate
from the wheel knuckle.
3 - Brake disc
See Removal Detail Item 3 : Brake disc
NOTE: Remove and discard the retaining washer
3. To install, reverse the removal procedure. (if equipped).
NOTE: Make sure the wheel hub face is clean and
free of rust and foreign material.
4. If a new brake disc has been installed,
install new brake pads. For additional
information, refer to Brake Pads in this
section.
G296171 en 09/2004 2004.75 Focus

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206-03-10 Front Disc Brake 206-03-10
Brake Caliper

Name Specification indicated in the following illustration(s) and
table(s).
BASF Hydraulan 417-1
-
(DOT4++)

Number 2. WARNING: Use only as much
1 - Brake caliper dust seal compressed air as is necessary to
remove the brake caliper piston.
2 - Brake caliper piston Excessive pressure may force the
See Disassembly Detail piston out of the caliper bore with
3 - Brake caliper piston seal sufficient force to cause personal
See Disassembly Detail injury. Never attempt to catch the
See Assembly Detail piston as it comes out of the bore.
Failure to follow these instructions
2. To assemble, reverse the disassembly
procedure. CAUTION: Do not use a screwdriver or
any other similar tool to pry the brake
Disassembly Details caliper piston out of the brake caliper
bore.
Item 2 : Brake caliper piston Apply compressed air through the brake
1. Place a suitable block of wood between the hose union housing to remove the brake
body of the brake caliper and the brake caliper piston.
caliper piston.
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206-03-11 Front Disc Brake 206-03-11
Item 3 : Brake caliper piston seal

CAUTION: Do not use a screwdriver or
any other similar tool to pry the brake
caliper seal out of the brake caliper bore.
Assembly Details
Item 3 : Brake caliper piston seal

WARNING: Install a new brake caliper if
rust, pitting or scores are evident in the
brake caliper bore or on the brake caliper
piston.
NOTE: Lubricate the piston, piston bore and
piston seal with BASF Hydraulan 417-1(DOT4++) prior to
installation.
G296172 en 09/2004 2004.75 Focus

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206-04-1 Rear Disc Brake 206-04-1
SECTION 206-04 Rear Disc Brake

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 206-04-2
Rear Disc Brake Specification .......................................................................................... 206-04-2
Rear Disc Brake................................................................................................................ 206-04-3
Brake Caliper .................................................................................................................... 206-04-4/6

Brake Pads ....................................................................................................................... 206-04-7/9
Brake Disc ........................................................................................................................ 206-04-10
Brake Disc Shield.............................................................................................................. 206-04-11
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206-04-2 Rear Disc Brake 206-04-2
SPECIFICATIONS

Specification
Rear Disc Brake Specification

Description mm
Brake disc diameter – vehicles with 1.8L diesel or 2.0L engine 280
Brake disc diameter – vehicles with 1.6L or 1.8L engine 260
New brake disc nominal thickness 11
Worn brake disc discard thickness * 9
Maximum brake disc thickness variation 0.025
Worn brake pad discard thickness ** 1.5
* When the discard thickness has been reached, install a new brake disc and brake pads.
** When the discard thickness has been reached, install new brake pads.
Brake caliper retaining bolts 35 26 -
Brake hose to brake caliper union 18 13 -
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206-04-3 Rear Disc Brake 206-04-3
Rear Disc Brake

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206-04-4 Rear Disc Brake 206-04-4
Brake Caliper

Special Tool(s) indicated in the following illustration(s) and
table(s).
Retractor, Rear Brake Caliper
Piston
206-085 (12-025)
General Equipment
Brake hose clamp
Name Specification
(DOT4++)

water.
1. Release the parking brake.
3. Loosen the brake hose to brake caliper
union.
the brake hose.
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206-04-5 Rear Disc Brake 206-04-5

Item Part Description For additional information,
Number refer to Section 206-00.[Brake System - General
1 - Parking brake cable Brake System Pressure Bleeding]
See Removal Detail
2 - Brake caliper retaining clip Removal Details
Item 1 : Parking brake cable
covers
4 - Brake caliper retaining bolts brake caliper lever.
See Removal Detail
5 - Outer brake pad
6 - Inner brake pad
See Removal Detail
7 - Brake caliper
See Removal Detail

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206-04-6 Rear Disc Brake 206-04-6
Item 4 : Brake caliper retaining bolts Installation Details

CAUTION: Suspend the brake caliper to Item 6 : Inner brake pad
prevent load being placed on the brake
hose. 1. CAUTION: When the brake caliper
Item 6 : Inner brake pad piston is retracted into the piston
housing, brake fluid will be displaced
1. NOTE: The inner brake pad is secured to the
Remove the inner brake pad. CAUTION: Support the brake caliper
during brake caliper retraction.
• Slide the brake pad out.
Using the special tool, retract the brake
caliper piston.
Item 7 : Brake caliper

1. CAUTION: Cap the brake hose to
NOTE: The brake hose union has a right-handed Item 5 : Outer brake pad
thread.
NOTE: If new brake pads are installed, remove
Disconnect the brake hose from the brake the adhesive foil from the rear of the brake pad.
caliper. NOTE: Make sure the brake pad contact points
• Rotate the caliper clockwise when viewed are clean and free from contamination.
as shown.
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206-04-7 Rear Disc Brake 206-04-7
Brake Pads

Special Tool(s)
Retractor, Rear Brake Caliper immediately washed down with cold
206-085 (12-025) water.
Name Specification
BASF Hydraulan 417-1 - table(s).
(DOT4++)

Number
1 - Parking brake cable covers
See Removal Detail
4 - Brake caliper retaining bolts
2 - Brake caliper retaining clip See Removal Detail
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206-04-8 Rear Disc Brake 206-04-8
Item Part Description Item 6 : Inner brake pad

Number 1. NOTE: The inner brake pad is secured to the
5 - Outer brake pad
See Installation Detail Remove the inner brake pad.
6 - Inner brake pad • Slide the brake pad out.
See Removal Detail

5. Fully depress and release the brake pedal.
6. Check the fluid level in the brake fluid
reservoir and top up if necessary with
brake fluid.
Removal Details
Item 1 : Parking brake cable

brake caliper lever.

1. CAUTION: When the brake caliper
pistons are retracted into the piston
housing, brake fluid will be displaced
CAUTION: Support the brake caliper
during brake caliper retraction.
Using the special tool, retract the brake
caliper piston.
Item 4 : Brake caliper retaining bolts

CAUTION: Suspend the brake caliper to
prevent load being placed on the brake
hose.
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206-04-9 Rear Disc Brake 206-04-9
2. CAUTION: Do not apply grease or

lubricant to the brake pad spring clip
or the brake caliper piston.
CAUTION: Make sure that the brake pad
spring clip is fully located in the brake
caliper piston end groove.
NOTE: The inner brake pad is secured to the
Install the inner brake pad.
• Slide the brake pad on to the brake caliper
piston until the brake pad spring clip is fully
engaged.

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206-04-10 Rear Disc Brake 206-04-10
Brake Disc
1. Remove the brake pads. For additional 2. Remove the components in the order
information, refer to Brake Pads in this indicated in the following illustration(s) and
section. table(s).

Number
1 - Brake caliper anchor plate Item 3 : Brake disc
retaining bolts NOTE: Remove and discard the retaining clip (if
equipped).
2 - Brake caliper and anchor
plate Installation Details
3 - Brake disc
See Removal Detail Item 3 : Brake disc
See Installation Detail 1. If a new brake disc has been installed,
install new brake pads. For additional
3. To install, reverse the removal procedure. information, refer to Brake Pads in this
NOTE: Make sure the wheel hub face is clean and section.
free of rust and foreign material.
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206-04-11 Rear Disc Brake 206-04-11
Brake Disc Shield
1. Remove the brake disc. For additional

information, refer to Brake Disc in this
section. 3. Remove the components in the order
2. Disconnect the wheel speed sensor elec-
table(s).
trical connector.

Number
2 - Wheel hub
1 - Wheel hub retaining bolts
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206-04-12 Rear Disc Brake 206-04-12

Number
3 - Brake disc shield
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206-05-1 Parking Brake and Actuation 206-05-1
SECTION 206-05 Parking Brake and Actuation

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 206-05-2
Parking Brake ................................................................................................................... 206-05-3

Conventional parking brake.............................................................................................. 206-05-3
Electronic parking brake................................................................................................... 206-05-3/6
Parking Brake ................................................................................................................... 206-05-7

Symptom Chart ................................................................................................................ 206-05-7
Pinpoint Tests .................................................................................................................. 206-05-7/9
GENERAL PROCEDURES
Parking Brake Cable Adjustment................................................................... (12 662 0) 206-05-10/12
Parking Brake Control ....................................................................................................... 206-05-13/14

Parking Brake Cable ......................................................................................................... 206-05-15
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SPECIFICATIONS
Parking brake control retaining bolts 35 26 -
Exhaust flexible pipe to exhaust muffler and tailpipe 51 38 -
nuts
Electronic parking brake release actuator retaining 23 17 -
bolts
Electronic parking brake module support bracket 23 17 -
retaining nut
Electronic parking brake module support bracket 9 - 80
retaining bolts
Electronic parking brake module retaining nuts 5 - 44
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Parking Brake
The layout and operation of the mechanical

parking brake are similar to the current Focus.
Conventional parking brake
A conventional parking brake is used.
Electronic parking brake
hydraulics of the brake system fail while

Item Part Description driving. The system is automatically
Number coordinated with the ABS system to prevent
the braked wheels from locking up.
1 - Electronic parking brake ac- The system comprises the following components:
tuator
• Pushbutton for operation of the electronic
2 - Handbrake cable parking brake
3 - Emergency release • Emergency release mechanism
• Clutch pedal switch
The electronic parking brake actuator can only be • Electronic parking brake actuator
replaced as a complete unit.
• Brake pedal switch
An electronic parking brake is available as an
option for the vehicle. In comparison to a
conventional handbrake, the electronic parking Pushbutton for operation of the electronic parking
brake offers the following advantages: brake
• Ease of operation, as the electronic parking The pushbutton for operation of the electronic
brake is always applied firmly, regardless of parking brake is located in the centre console. To
the strength of the driver. release the electronic parking brake press the
• Safety, as the vehicle can be slowed down pushbutton, to engage it pull the button.
with the electronic parking brake if the
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Neutral position • 1 and 5

• 4 and 3
• 2 and 6
Emergency release
When the pushbutton is in the neutral position, the

following pins are connected to each other:
• 1 and 6
• 4 and 2
• 5 and 3
If the electronic parking brake has been released
For safety reasons six change-over contacts by means of the emergency release mechanism
which switch the three circuits are integrated in the then it is necessary to release the electronic
pushbutton. The system will still function if one of parking brake via the pushbutton after the service
the circuits fails. An error message then appears repairs have been carried out.
on the display of the instrument cluster.
It is also possible to release the electronic parking
brake manually if required. There is a rubber mat
Engaged position underneath the storage compartment in the centre
When the pushbutton is in the engaged position, console which needs to be removed in order to
the following pins are connected to each other: access and operate the emergency release
mechanism. The electronic parking brake is then
• 1 and 4
released by firmly pulling the T-shaped handle
• 2 and 5 upwards until a loud noise is heard.
• 3 and 6 • The electronic parking brake reinitialises itself
during its first electrical operation after an
Released position emergency release.
When the pushbutton is in the released position,

the following pins are connected to each other: Electronic parking brake actuator
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Item Part Description value matches the reference value then the DC
Number motor is no longer actuated.
1 - Handbrake cable
Engaging the parking brake
2 - Connections
When the electronic parking brake is engaged, a
3 - DC motor distinction is made between static and dynamic
4 - Electronic parking brake braking. If the foot brake fails the vehicle can be
control module braked dynamically by means of the electronic
parking brake.
5 - Emergency release cable
6 - Splined shaft Dynamic braking
7 - Transmission At speeds above 4 km/h the vehicle is gradually
8 - Hollow shaft braked if the pushbutton is lifted up. If one of the
braked wheels locks up then the force under
9 - Force sensor which the parking brake cables are applied is
The electronic parking brake actuator is reduced. The vehicle continues to brake while the
positioned underneath the spare wheel well. The button is pulled up.
following components are integrated in the
parking brake actuator:
Static braking
• Electronic parking brake control module
At speeds below 4 km/h or if the vehicle is
• DC motor
stationary the pushbutton is lifted up briefly to
• Transmission engage the electronic parking brake.
• Force sensor
If the ignition key is removed within 10 minutes of
• Hollow shaft turning the ignition off, then the electronic parking
• Splined shaft brake is automatically engaged. The electronic
• Handbrake cable parking brake control module switches to "sleep"
mode 10 minutes after the ignition is switched off.
• Emergency release cable
It is then no longer possible to engage the
electronic parking brake.
Mechanical layout The automatic engagement of the electronic
The motor/gearing unit is a floating fit in the parking brake is configured separately for each
electronic parking brake actuator. different country at the factory. The automatic
engagement of the electronic parking brake is
A hollow shaft is driven via the gearing. A splined
disabled in countries where the handbrake cables
shaft engages in turn in the hollow shaft. The
are prone to freezing up. The automatic
hollow shaft is connected to a force sensor via a
engagement of the electronic parking brake is
link which can be released mechanically
enabled in all other countries. The automatic
(emergency release). The parking brake cables
engagement of the electronic parking brake can
are hooked into the force sensor and the splined
be activated or deactivated with WDS according to
shaft.
the customer's wishes.
After renewing the rear brake pads, always press
the brake pedal several times before operating the
electronic parking brake. Releasing the parking brake
In order to release the parking brake, it is
necessary for the ignition to be switched on, the
Operation
pushbutton to be pressed and the brake pedal or
When the electronic parking brake is operated the clutch pedal to be depressed.
DC motor is actuated using a map stored in the
In order to prevent automatic engagement of the
electronic parking brake control module. The
electronic parking brake when the ignition key is
values stored in the map are used as reference
removed from the switch, press and hold the
values. The voltage signal supplied from the force
sensor is compared to the reference values. If the
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button while switching off the ignition and

removing the key.
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Parking Brake

1. Verify the customer concern by operating the 3. If an obvious cause for an observed or
parking brake system. reported concern is found, correct the cause
2. Visually inspect for obvious signs of (if possible) before proceeding to the next
mechanical or electrical damage. step.
4. If the concern is not visually evident, verify the
Visual Inspection Chart symptom and refer to the Symptom Chart.
Mechanical Electrical
– Parking brake – Parking brake
control warning circuit.
REFER to Parking REFER to Section
Brake Control 413-01.[Instrument
in this section. Cluster,
– Cable and conduit DIAGNOSIS AND
TESTING, Instru-
ment Cluster]
Symptom Chart
• The parking brake will not apply • Parking brake control. • GO to Pinpoint Test A
• Cable and conduit.
• The parking brake will not re- • Parking brake control. • GO to Pinpoint Test B
lease • Cable and conduit.
Pinpoint Tests
PINPOINT TEST A: THE PARKING BRAKE WILL NOT APPLY
A1: CHECK FOR MISADJUSTED REAR PARKING BRAKE CABLE
1 Operate the parking brake control several times
to adjust the cable.
• Does the parking brake now engage correctly?
→ Yes
Vehicle OK
→ No
GO to A2
A2: CHECK FOR WORN BRAKE SHOES OR PADS
1 Inspect the brake shoes or pads for excessive
wear. REFER to Section 206-04.[Rear Disc
Brake, REMOVAL AND INSTALLATION, Brake
Pads]
• Are the brake shoe linings or brake pads OK?
→ Yes
GO to A3
→ No
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INSTALL new brake shoes or pads.
REFER to Section 206-04.[Rear Disc Brake,
REMOVAL AND INSTALLATION, Brake
Pads] TEST the system for normal operation.
A3: CHECK FOR DAMAGED PARKING BRAKE CABLES
1 Inspect the parking brake cables and conduits
for damage, rust or fraying.
• Are the parking brake cables and conduits OK?
→ Yes
CHECK for other causes such as loose
parking brake control or conventional brake
system components.
→ No
REPAIR or INSTALL cables and conduit as
necessary. TEST the system for normal op-
eration.
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE
B1: CHECK PARKING BRAKE CONTROL
1 Raise and support the vehicle on a lift with the
parking brake fully applied.
- With the aid of another technician, release the
parking brake and check the operation of the
brake cables and levers.
• Did the parking brake release?
→ Yes
CHECK the other causes such as conven-
tional brake system components. REPAIR or
INSTALL new components as necessary.
→ No
GO to B2
B2: CHECK PARKING BRAKE CABLES
1 Loosen the parking brake cable tension.
- Rotate the rear wheels by hand.
• Did the rear wheels turn freely?
→ Yes
INSTALL a new parking brake control.
REFER to Parking Brake Control in this sec-
tion. TEST the system for normal operation.
→ No
GO to B3
B3: CHECK FRONT PARKING BRAKE CABLE
1 Disconnect the parking brake front cable and
conduit from the rear brake cable and conduit at
the equalizer.
- Rotate the rear wheels by hand.
• Did the rear wheels turn freely?
→ Yes
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INSTALL a new front parking brake cable
and conduit. TEST the system for normal
operation.
→ No
GO to B4
B4: CHECK REAR PARKING BRAKE CABLES
1 Disconnect the parking brake at the rear
brakes, one at a time.
- Rotate the wheel affected by the disconnected
parking brake.
• Did the wheel turn freely?
→ Yes
INSTALL a new parking brake control lever
on the rear drum brakes or caliper assembly
on rear disc brakes. REFER to Section
206-04.[Rear Disc Brake, REMOVAL AND
INSTALLATION, Brake Caliper] TEST the
system for normal operation.
→ No
REFER to Section 206-00.[Brake System -
General Information, DIAGNOSIS AND
TESTING, Brake System]
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GENERAL PROCEDURES
Parking Brake Cable Adjustment (12 662 0)

All vehicles
1. Remove the parking brake control boot. 5. CAUTION: The torque applied to the
adjustment nut must not exceed 10 Nm.
Failure to follow this instruction will
cause damage to the parking brake
cable thread.
NOTE: Make sure the parking brake control is fully
released.
NOTE: Before carrying out the adjustment to a
new or relocated parking brake cable, settle the
parking brake system.
Settle the parking brake system in four
stages.
• Stage 1: Tighten the parking brake cable
adjustment nut to 2 Nm.
• Stage 2: Raise the parking brake control
2. Release the parking brake. twelve notches.
3. Loosen the parking brake cable adjustment • Stage 3: Fully release the parking brake
nut to the end of the parking brake cable control.
thread.
• Stage 4: Loosen the parking brake cable
• Remove the parking brake cable adjust-
adjustment nut to the end of the thread.
ment nut lock nut.
[Jacking and Lifting, DESCRIPTION
AND OPERATION, Jacking] For additional
AND OPERATION, Lifting]
4. Make sure the parking brake cable is

correctly located.
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7. NOTE: Make sure the parking brake control is 9. Remove the brake drum.
fully released. • Remove and discard the retaining washer (if
Adjust the parking brake cable in five equipped).
stages.
• Stage 1: Insert a 0.7 mm feeler gauge
between the parking brake lever and the
brake caliper abutment on both sides.
• Stage 2: With the aid of another technician,
tighten the parking brake cable adjustment
nut until movement is observed on one of
parking brake levers.
• Stage 3: Remove the feeler gauges.
• Stage 4: Rotate the rear wheels and tires
and check for brake drag. If brake drag is
felt, loosen the parking brake cable
adjustment nut to the end of the parking
brake cable thread, clean the parking brake
10. NOTE: Make sure the parking brake control is
cables and repeat the parking brake cable
fully released.
adjustment procedure.
• Stage 5: Install the parking brake cable Adjust the parking brake cable in four
adjustment nut lock nut. stages.
• Stage 1: Insert a 2.0 mm feeler gauge
between the parking brake lever end stop
and the rear brake shoe on both sides.
• Stage 2: With the aid of another technician,
tighten the parking brake cable adjustment
nut until movement is observed on one of
parking brake levers.
• Stage 3: Remove the feeler gauges.
• Stage 4: Install the parking brake cable
adjustment nut lock nut.

8. Remove the rear wheels and tires. For
11. Install the brake drum.

12. Install the rear wheels and tires. For
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13. Check the parking brake cable adjustment

in two stages.
• Stage 1: Raise and release the parking
brake control and check that it returns to the
fully released position. If the parking brake
control does not fully release, repeat the
parking brake cable adjustment procedure.
• Stage 2: Rotate the rear wheels and tires
and check for brake drag. If brake drag is
felt, loosen the parking brake cable
adjustment nut two full turns and repeat the
parking brake cable adjustment procedure.
All vehicles
14. Install the parking brake control boot.
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Parking Brake Control

1. Remove the floor console. For additional

3. Disconnect the parking brake control table(s).
switch electrical connector.

Number
3 - Parking brake control
1 - Parking brake cable adjust- See Removal Detail
ment nut See Installation Detail
2 - Parking brake control re-
taining bolts
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6. Adjust the parking brake cable.
Item 3 : Parking brake control
Removal Details 1. CAUTION: When repositioning the
parking brake cable retaining tab,
Item 3 : Parking brake control make sure that the parking brake cable
1. NOTE: Make a note of the position of the retaining tab does not clamp the
parking brake cable retaining tab, to aid parking brake cable.
installation. NOTE: Make sure that the parking brake cable is
NOTE: The parking brake cable retaining tab must correctly located in the parking brake control.
be positioned away from the parking brake cable,
to aid removal. Reposition the parking brake cable retain-
ing tab.
Position the parking brake cable retaining
tab away from the parking brake cable.
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Parking Brake Cable
Name Specification 4. Raise and support the vehicle.

Lubricant ESE-M99B144-B 5. Remove the air deflector on both sides.
1. Remove the parking brake control boot.

2. Release the parking brake. table(s).
3. Loosen the parking brake cable adjustment
nut to the end of the thread.
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Number
1 - Exhaust muffler and tailpipe
assembly
See Removal Detail
2 - Exhaust hanger insulators
See Removal Detail
3 - Exhaust system heat shield
center section
4 - Exhaust system heat shield
front section
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Number
8 - Parking brake cable floor
5 - Parking brake cable end panel clips
connectors See Removal Detail
See Removal Detail See Installation Detail
6 - Parking brake cable support 9 - Parking brake cables
hangers
See Removal Detail 7. To install, reverse the removal procedure.
8. Adjust the parking brake cable. For
7 - Parking brake equalizer additional information, refer to Parking
See Removal Detail Brake Cable Adjustment in this section.
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Removal Details Item 5 : Parking brake cable end connectors

1. Detach the parking brake cable guide from
Item 1 : Exhaust muffler and tailpipe assembly the tie bar on both sides.

suitable support wrap or suitable splint.
2. NOTE: The left-hand parking brake cable has a

black sleeve and the right-hand parking brake
cable has a white sleeve. Note the color of the
sleeves to aid installation.
Disconnect the parking brake cables.
2. Detach the exhaust muffler and tailpipe

assembly from the exhaust flexible pipe.
3. Pull the parking brake cable and guide

through the tie bar on both sides.
Item 2 : Exhaust hanger insulators

NOTE: Support the exhaust muffler and tailpipe
assembly.
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Item 6 : Parking brake cable support hangers 2. NOTE: The left-hand parking brake cable has a
1. NOTE: There are marks on the cable outer to black sleeve and the right-hand parking brake
indicate the clip positions. Note the position of cable has a white sleeve. Note the color of the
the clips on the outer cable to aid installation. sleeves to aid installation.
Detach the parking brake cable from the Detach the parking brake cables from the
parking brake cable support hanger. bracket.
Item 7 : Parking brake equalizer Item 8 : Parking brake cable floor panel clips
1. Detach the parking brake cables from the 1. Detach the parking brake cables from the
parking brake equalizer. floor panel on both sides.
• Turn the cable through 90 degrees. • Release the cables from the clips.
Item 8 : Parking brake cable floor panel clips

NOTE: Check the parking brake cable floor panel
clips for damage and fatigue. Install new parking
brake cable floor panel clips as required.
Item 6 : Parking brake cable support hangers
NOTE: Check the parking brake cable support
hangers for damage and fatigue. Install new
parking brake cable support hangers as required.
NOTE: Check the exhaust hanger insulators for
damage and fatigue. Install new exhaust hanger
insulators as required, using a suitable lubricant.
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Item 1 : Exhaust muffler and tailpipe assembly

NOTE: Install a new exhaust flexible pipe gasket
and nuts.
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206-06-1 Hydraulic Brake Actuation 206-06-1
SECTION 206-06 Hydraulic Brake Actuation

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 206-06-2
Hydraulic Brake Actuation................................................................................................. 206-06-3
Brake Pedal and Bracket — RHD ..................................................................................... 206-06-4/7

Brake Master Cylinder — RHD ......................................................................................... 206-06-8/10
Brake Fluid Reservoir........................................................................................................ 206-06-11
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SPECIFICATIONS

Specification
BASF Hydraulan 417-1(DOT 4++) -
Brake master cylinder retaining nuts 25 18 -
Brake tube to brake master cylinder unions 15 11 -
Brake pedal bracket retaining bolts 23 17 -
Strut and spring assembly top mount brace retain- 32 24 -
ing bolts
ing nuts
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Hydraulic Brake Actuation

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Brake Pedal and Bracket — RHD

1. Remove the accelerator pedal. For 2. Remove the components in the order
additional information, refer to Section indicated in the following illustration(s) and
310-02.[Acceleration Control, REMOVAL table(s).
AND INSTALLATION, Accelerator Pedal]

Number
1 - Instrument panel lower outer
trim panel
See Removal Detail
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Number
4 - Brake pedal and bracket re-
2 - Brake pedal switches taining nut
See Removal Detail
See Installation Detail 5 - Brake booster retaining nuts
3 - Brake booster actuating rod 6 - Brake pedal and bracket

pin
See Removal Detail
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3. To install, reverse the removal procedure. 3. CAUTION: Make sure that the brake
pedal is kept in the rest position and is
Removal Details not depressed or moved during the
removal of the brake pedal switches.
Item 1 : Instrument panel lower outer trim
result in damage to the switches.
panel
1. Detach the diagnostic link connector (DLC) Remove the brake pedal switches.
from the instrument panel lower trim panel. 1. Speed control deactivation switch (colored
blue and white) (if equipped).
2. Stop lamp switch (colored black).
Item 2 : Brake pedal switches

1. Disconnect the electrical connectors.
1. Speed control deactivation switch (if Item 3 : Brake booster actuating rod pin
equipped). 1. NOTE: The brake pedal actuating rod pin will be
2. Stop lamp switch. damaged during removal.
Detach the brake booster actuating rod
from the brake pedal.
• Using a suitable lever, remove the brake
booster actuating rod pin.
2. Detach the brake pedal switches wiring

harness from the brake pedal bracket.
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Installation Details 3. Connect the electrical connectors.

1. Speed control deactivation switch (if
Item 2 : Brake pedal switches equipped).
1. CAUTION: Make sure that the brake 2. Stop lamp switch.
not depressed or moved during
installation of the brake pedal switches.
CAUTION: When installing the brake
pedal switches, the stop lamp switch is
rotated counterclockwise and the speed
control deactivation switch is rotated
clockwise. Failure to follow this
instruction will result in the switch
plunger binding inside the switches.
CAUTION: Make sure the brake pedal
switches are correctly installed.
NOTE: The speed control deactivation switch (if
equipped) and the stop lamp switch are
automatically adjusted during installation.
Install the brake pedal switches.
2. Speed control deactivation switch (colored
2. Attach the brake pedal switches wiring

harness to the pedal bracket.
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Brake Master Cylinder — RHD
2. NOTE: It will be necessary to carry out this step

Name Specification on both sides in order to completely drain the
brake reservoir.
(DOT4++) Drain the brake fluid reservoir.
1. Connect one end of a suitable piece of clear
plastic pipe to the bleed nipple and place
CAUTION: If brake fluid is spilt on the the other end into a suitable container.
paintwork, the affected area must be 2. Loosen the bleed nipple.
immediately washed down with cold 3. Depress the brake pedal until all the brake
water. fluid is drained from the brake fluid
reservoir.
4. Tighten the bleed nipple.
extension cap must not become
contaminated.
Remove the brake fluid reservoir extension
cap.
3. Install the brake fluid reservoir extension

cap.
4. Detach the brake fluid reservoir extension
from the bulkhead extension panel.

table(s).
G401822 en 09/2004 2004.75 Focus

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Item Part Description 206-00.[Brake System - General
Number Information, GENERAL PROCEDURES,
1 - Brake fluid reservoir
extension
Removal Details
See Removal Detail
2 - Clutch master cylinder Item 1 : Brake fluid reservoir extension
supply line
See Removal Detail CAUTION: Cap the brake fluid reservoir
connections to prevent fluid loss or dirt
3 - Low brake fluid warning in- ingress.
dicator switch electrical
connector Item 2 : Clutch master cylinder supply line
4 - Brake tubes 1. CAUTION: Cap the clutch master

See Removal Detail cylinder supply line to prevent fluid
loss or dirt ingress.
5 - Brake master cylinder re-
taining nuts Disconnect the clutch master cylinder
supply line from the brake fluid main
6 - Brake master cylinder reservoir.
Item 4 : Brake tubes
6. To install, reverse the removal procedure. 1. CAUTION: Cap the brake tubes to
7. Bleed the brake system. For additional prevent fluid loss or dirt ingress.
Disconnect the brake tubes from the brake
master cylinder.
G401822 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 6 : Brake master cylinder

CAUTION: Make sure the brake master
cylinder vacuum seal is correctly
positioned before installation.
G401822 en 09/2004 2004.75 Focus

TO MODEL INDEX
Brake Fluid Reservoir

brake fluid reservoir.
the other end into a suitable container.
reservoir.
extension cap must not become
contaminated.
Remove the brake fluid reservoir extension
cap.
3. Install the brake fluid reservoir extension

cap.
4. Remove the brake fluid reservoir
extension.
• Disconnect the feed hose coupling from the
master cylinder.

table(s).
G401823 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
1 - Clutch master cylinder Item 1 : Clutch master cylinder supply line
supply line 1. CAUTION: Cap the clutch master
See Removal Detail cylinder supply line to prevent fluid
2 - Low brake fluid warning in- loss or dirt ingress.
dicator switch electrical Disconnect the clutch master cylinder
connector supply line from the brake fluid main
3 - Brake fluid main reservoir reservoir.
retaining pin Item 4 : Brake fluid main reservoir
4 - Brake fluid main reservoir CAUTION: Cap the brake fluid reservoir
See Removal Detail hose connections to prevent fluid loss or
dirt ingress.
refer to Section 206-00.[Brake System - General
G401823 en 09/2004 2004.75 Focus

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206-07-1 Power Brake Actuation 206-07-1
SECTION 206-07 Power Brake Actuation

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 206-07-2
Power Brake System......................................................................................................... 206-07-3
Brake Booster — RHD ...................................................................................................... 206-07-4/10

Brake Vacuum Pump — 2.0L Duratorq-TDCi (DW) Diesel................................................ 206-07-11
09/2004 2004.75 Focus

TO MODEL INDEX
SPECIFICATIONS

Specification
Brake master cylinder to brake booster retaining 25 18 -
nuts
Brake booster retaining nuts 23 17 -
Brake tubes to hydraulic control unit (HCU) unions 18 13 -
Brake vacuum pump retaining bolts - Vehicles with 22 16 -
2.0L diesel engine
Brake vacuum pump retaining nut - Vehicles with 22 16 -
2.0L diesel engine
ing bolts
ing nuts
Exhaust gas recirculation (EGR) valve tube support 10 7 -
bracket retaining bolt
Fuel filter line bracket retaining nut 10 7 -
Fuel filter shield retaining bolts 6 - 53
Refrigerant line connectors 9 - 80
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Power Brake System

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Brake Booster — RHD

5. Disconnect the high-pressure cut-off

Name Specification switch and low-pressure cut-off switch
Refrigerant Oil WSH-M1C231-B electrical connectors.

water.
All vehicles
1. Remove the brake master cylinder.
[Hydraulic Brake Actuation,
REMOVAL AND INSTALLATION, Brake
Master Cylinder - RHD]
Vehicles with air conditioning
6. CAUTION: Cap the refrigerant line
2. Evacuate the air conditioning system. For connections to prevent fluid loss or
additional information, refer to Section dirt ingress.
412-00.[Climate Control System - General
Information, GENERAL PROCEDURES, Air Disconnect the refrigerant lines at the
Conditioning (A/C) System Recovery, evaporator.
Evacuation and Charging] • Discard the O-rings.
3. Remove the right-hand headlamp assembly.
417-01.[Exterior Lighting, REMOVAL AND
INSTALLATION, Headlamp Assembly]
4. Detach the coolant expansion tank from
the wheelhouse assembly and position it to
one side.
G401825 en 09/2004 2004.75 Focus

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7. CAUTION: Cap the refrigerant line 9. Remove the refrigerant lines.

connections to prevent fluid loss or • Detach the lines from the wheelhouse as-
dirt ingress. sembly.
Disconnect the refrigerant line at the
condenser.
• Discard the O-ring.
All vehicles
10. Disconnect the brake vacuum pipe from
the brake booster.
8. CAUTION: Cap the refrigerant line

connections to prevent fluid loss or
dirt ingress.
Disconnect the refrigerant line at the
accumulator.
• Discard the O-ring.

indicated in the following illustration(s)
and table(s).
G401825 en 09/2004 2004.75 Focus

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Number
1 - Instrument panel lower outer
trim panel
See Removal Detail
G401825 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
4 - Brake booster retaining nuts
2 - Brake pedal switches
See Removal Detail 5 - Brake booster
See Installation Detail See Removal Detail
3 - Brake booster actuating rod
pin All vehicles
G401825 en 09/2004 2004.75 Focus

TO MODEL INDEX
Vehicles with air conditioning 2. Detach the brake pedal switches wiring
3. NOTE: Coat the O-rings for the refrigerant lines harness from the brake pedal bracket.
with refrigerant oil prior to installation.
3. CAUTION: Make sure that the brake
Install new O-rings on the refrigerant lines. pedal is kept in the rest position and is
All vehicles not depressed or moved during the
4. Bleed the brake system. For additional removal of the brake pedal switches.
information, refer to Section 206-00.[Brake Failure to follow this instruction may
System - General Information, GENERAL result in damage to the switches.
PROCEDURES, Brake System Bleeding] Remove the brake pedal switches.
206-00.[Brake System - General
Brake System Pressure Bleeding] 2. Stop lamp switch (colored black).
Removal Details
Item 1 : Instrument panel lower outer trim

panel
1. Detach the diagnostic link connector (DLC)
from the instrument panel lower trim panel.
Item 3 : Brake booster actuating rod pin

1. Detach the brake booster actuating rod
from the brake pedal.
• Using a suitable lever, remove and discard
the brake booster actuating rod pin.
Item 2 : Brake pedal switches

1. Disconnect the electrical connectors.
equipped).
2. Stop lamp switch.
Item 5 : Brake booster

1. Detach the brake master cylinder to
hydraulic control unit (HCU) tubes from the
bulkhead to aid removal.
2. Rotate the brake booster through 180
degrees to aid removal.
G401825 en 09/2004 2004.75 Focus

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3. Remove the brake booster. Item 2 : Brake pedal switches

• Discard the gasket.
Installation Details not depressed or moved during
installation of the brake pedal switches.
Item 5 : Brake booster Failure to follow this instruction may
booster actuating rod is correctly CAUTION: When installing the switches,
positioned through the bulkhead the stop lamp switch is rotated
rubber boot. counterclockwise and the speed control
deactivation switch is rotated clockwise.
CAUTION: Make sure that the brake
booster gasket is correctly positioned on
result in the switch plunger binding
the brake booster before installation.
inside the switches.
NOTE: Install a new brake booster gasket.
CAUTION: Make sure the switches are
Compress the brake booster actuating rod
to aid installation. correctly installed.
NOTE: The speed control deactivation switch (if
equipped) and the stop lamp switch are
automatically adjusted during installation.
Install the brake pedal switches.
Item 3 : Brake booster actuating rod pin

CAUTION: Install a new brake booster
actuating rod pin. Failure to follow this
instruction may result in damage to the
brake pedal.
2. Attach the brake pedal switches wiring

harness to the brake pedal bracket.
G401825 en 09/2004 2004.75 Focus

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3. Connect the electrical connectors.

equipped).
2. Stop lamp switch.
G401825 en 09/2004 2004.75 Focus

TO MODEL INDEX
Brake Vacuum Pump — 2.0L Duratorq-TDCi (DW) Diesel
All vehicles
All vehicles
3. Detach the fuel filter line from the exhaust
gas recirculation (EGR) valve tube support
bracket.
Left-hand drive vehicles

2. Detach the brake fluid reservoir from the
bulkhead extension panel and position it to
4. Detach the EGR valve tube from the brake
one side.
vacuum pump.

table(s).
G354588 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 4 : Brake vacuum pump

Item Part Description 1. Remove and discard the brake vacuum
Number pump seals.
1 - Vacuum hose
2 - Brake vacuum pump retain-
ing bolts
3 - Brake vacuum pump
retaining nut
See Removal Detail
See Removal Detail
Removal Details
Item 3 : Brake vacuum pump retaining nut

NOTE: Remove the brake vacuum pump retaining
nut stud, to aid removal of the brake vacuum
pump.
G354588 en 09/2004 2004.75 Focus

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Item 4 : Brake vacuum pump

1. CAUTION: Make sure the drive coupling
is aligned with the camshaft coupling.
Install new brake vacuum pump seals.
G354588 en 09/2004 2004.75 Focus

TO MODEL INDEX
206-09A-1 Anti-Lock Control 206-09A-1
SECTION 206-09A Anti-Lock Control

CONTENTS PAGE
SPECIFICATIONS
Specifications................................................................................................................... 206-09A-2
Anti-Lock Control ............................................................................................................. 206-09A-3

Inspection and Verification .............................................................................................. 206-09A-3
Hydraulic Control Unit (HCU) ........................................................................................... 206-09A-4/9

Rear Wheel Speed Sensor............................................................................................... 206-09A-10/11
Anti-Lock Brake System (ABS) Module ............................................................................ 206-09A-12
09/2004 2004.75 Focus

TO MODEL INDEX
SPECIFICATIONS

Specifications
Hydraulic control unit (HCU) and anti-lock brake 9 - 80
system (ABS) module assembly to support bracket
retaining bolts
HCU and ABS module assembly support bracket 9 - 80
retaining bolt
ABS module to HCU retaining bolts 2 - 18
Brake tube to HCU unions 18 13 -
Brake tube in-line connector unions 18 13 -
Wheel speed sensor retaining bolts 5 - 44
ing bolts
ing nuts
Windshield wiper arms retaining nuts 15 11 -
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Anti-Lock Control
Refer to Wiring Diagrams Section 206-09A for

schematic and connector information.
General Equipment
Worldwide diagnostic system (WDS)

mechanical or electrical damage.

• Wheel speed • Fuse(s)
sensor(s) • Electrical
• Wheel speed sensor connector(s)
ring(s) • Wiring harness(s).
step.
4. If the cause is not visually evident, connect the
diagnostic tool to the data link connector and
select the vehicle to be tested from the
diagnostic tool menu.
G325340 en 09/2004 2004.75 Focus

TO MODEL INDEX
Hydraulic Control Unit (HCU)

Name Specification 2. NOTE: It will be necessary to carry out this step

BASF Hydraulan 417-1 on both sides in order to completely drain the
(DOT4++) brake fluid reservoir.
Drain the brake fluid reservoir.
CAUTION: If brake fluid is spilt on the plastic pipe to the bleed nipple and place
paintwork, the affected area must be the other end into a suitable container.
immediately washed down with cold 2. Loosen the bleed nipple.
water.
3. Depress the brake pedal until all the brake
1. CAUTION: The brake fluid reservoir cap fluid is drained from the brake fluid
must not become contaminated. reservoir.
Remove the brake fluid reservoir cap.
3. Install the brake fluid reservoir cap.

4. Remove the battery tray. For additional
[Battery, Mounting and Cables,
REMOVAL AND INSTALLATION, Battery
Tray - 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma)/1.8L Duratec-HE
(MI4)/2.0L Duratec-HE (MI4)]
G401826 en 09/2004 2004.75 Focus

TO MODEL INDEX
5. CAUTION: Cap the anti-lock brake 6. Remove the components in the order
system (ABS) module electrical indicated in the following illustration(s) and
connector and socket to prevent dirt table(s).
and fluid ingress.
Disconnect the ABS module electrical
connector.
1. Depress the locking tangs.
2. Release the retainer.
G401826 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
3 - HCU to rear brake tubes
1 - Hydraulic control unit (HCU) See Removal Detail
to brake master cylinder See Installation Detail
brake tubes
See Removal Detail 4 - HCU and ABS module as-
See Installation Detail sembly support bracket re-
taining bolt
2 - HCU to front brake tubes
See Removal Detail
G401826 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
5 - HCU and ABS module
assembly

Number
6 - HCU and ABS module as-
sembly to support bracket
retaining bolts
G401826 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item Part Description Item 2 : HCU to front brake tubes

Number
1. CAUTION: Cap the brake tubes to
7 - ABS module to HCU retain- prevent fluid loss or dirt ingress.
ing bolts
CAUTION: Plug the HCU ports to prevent
8 - HCU fluid loss or dirt ingress.
See Removal Detail NOTE: Make a note of the position of the brake
See Installation Detail tubes, to aid installation.
7. To install, reverse the removal procedure. Disconnect the brake tubes from the HCU.
8. Bleed the brake system. For additional 2. CAUTION: Cap the brake tubes to
information, refer to Section 206-00.[Brake prevent fluid loss or dirt ingress.
Remove the HCU to right-hand front caliper
brake tube.
Removal Details
Item 1 : Hydraulic control unit (HCU) to brake

master cylinder brake tubes
fluid loss or dirt ingress.
NOTE: Make a note of the position of the brake
tubes, to aid installation.
Disconnect the brake tubes from the HCU.
• Detach the tubes from the securing clips.
2. Remove the HCU to master cylinder brake
tubes.
G401826 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 3 : HCU to rear brake tubes CAUTION: Do not drop or knock the HCU.
cause damage to the hydraulic
components.
CAUTION: Do not remove the ABS module
port blanking plugs until the HCU is ready
NOTE: Make a note of the position of the brake to be installed.
Item 5 : HCU and ABS module assembly
• Detach the tubes from the securing clips. WARNING: Do not install a damaged HCU
and ABS module assembly. Failure to
2. CAUTION: Cap the brake tubes to follow this instruction may result in
prevent fluid loss or dirt ingress. personal injury.
Remove the HCU to rear brake tubes. CAUTION: Do not drop or knock the HCU
follow this instruction will cause damage
to the electronic and hydraulic
components.
Item 3 : HCU to rear brake tubes
CAUTION: Do not remove the brake tube
blanking caps or HCU port blanking
plugs until the brake tubes are ready to
be installed.
Item 2 : HCU to front brake tubes
Item 8 : HCU plugs until the brake tubes are ready to
be installed.
WARNING: Do not touch the HCU or ABS
module contact points as this may affect Item 1 : Hydraulic control unit (HCU) to brake
the brake system operation. Failure to master cylinder brake tubes
personal injury. CAUTION: Do not remove the brake tube
CAUTION: Plug the ABS module ports to plugs until the brake tubes are ready to
prevent dirt ingress. be installed.
Item 8 : HCU
WARNING: Do not install a damaged HCU.
WARNING: Make sure that the HCU is
correctly located on the ABS module.
G401826 en 09/2004 2004.75 Focus

TO MODEL INDEX
Rear Wheel Speed Sensor
1. Remove the wheel and tire. For additional 3. Remove the components in the order
table(s).
2. CAUTION: Make sure that the wheel
speed sensor, wheel speed sensor
electrical connector and the area
around the wheel speed sensor are
free from contamination and moisture.
Clean the wheel speed sensor, wheel
speed sensor electrical connector and the
area around the wheel speed sensor.

Number
4 - Wheel speed sensor O-ring
1 - Wheel speed sensor See Removal Detail
electrical connector See Installation Detail
See Removal Detail
2 - Wheel speed sensor retain-
ing bolt
3 - Wheel speed sensor
G296210 en 09/2004 2004.75 Focus

TO MODEL INDEX
4. To install, reverse the removal procedure. CAUTION: Do not rotate the wheel speed
sensor during installation.
Removal Details 1. CAUTION: Make sure that the wheel
speed sensor is correctly aligned with
Item 1 : Wheel speed sensor electrical the wheel speed sensor housing.
connector
1. Disconnect the wheel speed sensor Position the wheel speed sensor.
electrical connector.
Item 4 : Wheel speed sensor O-ring
1. Using a suitable lint-free cloth, clean the
wheel speed sensor O-ring sealing groove.
2. Using a suitable lint-free cloth, clean the
wheel speed sensor retaining bolt housing.
3. CAUTION: Plug the wheel speed sensor
housing to prevent dirt ingress.
Plug the wheel speed sensor housing.
Item 4 : Wheel speed sensor O-ring

1. CAUTION: Make sure that the wheel
speed sensor housing is free from 2. NOTE: A resistance should only be detected
contamination and moisture. during the final 2 mm of installation of the wheel
speed sensor.
CAUTION: Make sure that the wheel speed Install the wheel speed sensor.
sensor O-ring is correctly seated.
CAUTION: Do not install the wheel speed
sensor O-ring onto the wheel speed
sensor.
Install the wheel speed sensor O-ring.
Item 3 : Wheel speed sensor

CAUTION: Make sure that the wheel speed
sensor is correctly seated.
G296210 en 09/2004 2004.75 Focus

TO MODEL INDEX
Anti-Lock Brake System (ABS) Module

reservoir.
1. CAUTION: The brake fluid reservoir cap
must not become contaminated.

G401827 en 09/2004 2004.75 Focus

TO MODEL INDEX
5. CAUTION: Cap the anti-lock brake 6. Remove the components in the order
system (ABS) module electrical indicated in the following illustration(s) and
connector and socket to prevent dirt table(s).
and fluid ingress.
Disconnect the ABS module electrical
connector.
1. Depress the locking tangs.
G401827 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
brake tubes
taining bolt
See Removal Detail
G401827 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
assembly

Number
6 - HCU and ABS module as-
retaining bolts
G401827 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
7 - ABS module to HCU retain- prevent fluid loss or dirt ingress.
ing bolts
8 - ABS module fluid loss or dirt ingress.
7. To install, reverse the removal procedure. Disconnect the brake tubes from the HCU.
8. Bleed the brake system. For additional 2. CAUTION: Cap the brake tubes to
information, refer to Section 206-00.[Brake prevent fluid loss or dirt ingress.
Remove the HCU to right-hand front caliper
brake tube.
Removal Details

tubes.
G401827 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 3 : HCU to rear brake tubes CAUTION: Do not drop or knock the ABS
module. Failure to follow this instruction
will cause damage to the electronic
components.
port blanking plugs until the ABS module
NOTE: Make a note of the position of the brake is ready to be installed.
components.
be installed.
Item 8 : ABS module plugs until the brake tubes are ready to
be installed.
the brake system operation. Failure to master cylinder brake tubes
personal injury. CAUTION: Do not remove the brake tube
prevent dirt ingress. be installed.
Item 8 : ABS module

WARNING: Do not install a damaged ABS
WARNING: Make sure that the ABS
module is correctly located on the HCU.
G401827 en 09/2004 2004.75 Focus

TO MODEL INDEX
206-09B-1 Anti-Lock Control - Traction Control 206-09B-1
SECTION 206-09B Anti-Lock Control - Traction

Control
CONTENTS PAGE
SPECIFICATIONS
Specifications................................................................................................................... 206-09B-2
Anti-Lock Control - Traction Control ................................................................................. 206-09B-3
Hydraulic Control Unit (HCU) ........................................................................................... 206-09B-4/8

Rear Wheel Speed Sensor............................................................................ (12 785 0) 206-09B-9
Anti-Lock Brake System (ABS) Module ............................................................................ 206-09B-10
09/2004 2004.75 Focus

TO MODEL INDEX
SPECIFICATIONS

Specifications
Hydraulic control unit (HCU) and anti-lock brake 9 - 80
system (ABS) module assembly to support bracket
retaining bolts
HCU and ABS module assembly support bracket 9 - 80
retaining bolt
ABS module to HCU retaining bolts 5.5 - 49
G307386 en 09/2004 2004.75 Focus

TO MODEL INDEX
Anti-Lock Control - Traction Control

REFER to Section 206-09A / 206-09B / 206-09C.
G17539 en 09/2004 2004.75 Focus

TO MODEL INDEX


water.
1. CAUTION: The brake fluid reservoir cap Duratec-16V (Sigma)/1.8L Duratec-HE
must not become contaminated. (MI4)/2.0L Duratec-HE (MI4)]
Remove the brake fluid reservoir cap. refer to Section 414-01.
2. NOTE: It will be necessary to carry out this step [Battery, Mounting and Cables,
on both sides in order to completely drain the REMOVAL AND INSTALLATION, Battery
brake fluid reservoir. Tray - 1.6L (Z6)]
Drain the brake fluid reservoir. 5. CAUTION: Cap the anti-lock brake
1. Connect one end of a suitable piece of clear system (ABS) module electrical
plastic pipe to the bleed nipple and place connector and socket to prevent dirt
the other end into a suitable container. and fluid ingress.
2. Loosen the bleed nipple. Disconnect the anti-lock brake system
3. Depress the brake pedal until all the brake (ABS) module electrical connector.
fluid is drained from the brake fluid 1. Depress the locking tangs.
reservoir.

3. Install the brake fluid reservoir cap. indicated in the following illustration(s) and
table(s).
G384572 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
brake tubes
taining bolt
See Removal Detail
G384572 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
assembly
G384572 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
6 - HCU and ABS module as- prevent fluid loss or dirt ingress.
retaining bolts CAUTION: Plug the HCU ports to prevent
7 - ABS module to HCU retain- NOTE: Make a note of the position of the brake
ing bolts tubes, to aid installation.
8 - HCU Disconnect the brake tubes from the HCU.
See Removal Detail
See Installation Detail 2. CAUTION: Cap the brake tubes to
7. To install, reverse the removal procedure. Remove the HCU to right-hand front caliper
8. Bleed the brake system. For additional brake tube.
PROCEDURES, Brake System Pressure
Bleeding] For additional
Bleeding]
Removal Details

tubes.
G384572 en 09/2004 2004.75 Focus

TO MODEL INDEX
components.
port blanking plugs until the HCU is ready
NOTE: Make a note of the position of the brake to be installed.
components.
be installed.
Item 8 : HCU plugs until the brake tubes are ready to
be installed.
the electronic program. Failure to follow master cylinder brake tubes
injury. CAUTION: Do not remove the brake tube
prevent fluid loss or dirt ingress. be installed.
Item 8 : HCU
correctly located on the ABS module.
G384572 en 09/2004 2004.75 Focus

TO MODEL INDEX
Rear Wheel Speed Sensor (12 785 0)

Removal
1. For additional information, refer to Section
206-09A / 206-09B / 206-09C.
G17542 en 09/2004 2004.75 Focus

TO MODEL INDEX
Anti-Lock Brake System (ABS) Module

water.
1. CAUTION: The brake fluid reservoir cap Duratec-16V (Sigma)/1.8L Duratec-HE
must not become contaminated. (MI4)/2.0L Duratec-HE (MI4)]
on both sides in order to completely drain the [Battery, Mounting and Cables,
brake fluid reservoir. REMOVAL AND INSTALLATION, Battery
Tray - 1.6L (Z6)]
1. Connect one end of a suitable piece of clear 5. CAUTION: Cap the anti-lock brake
plastic pipe to the bleed nipple and place system (ABS) module electrical
the other end into a suitable container. connector and socket to prevent dirt
and fluid ingress.
2. Loosen the bleed nipple.
3. Depress the brake pedal until all the brake Disconnect the anti-lock brake system
fluid is drained from the brake fluid (ABS) module electrical connector.
reservoir. 1. Depress the locking tangs.
4. Tighten the bleed nipple. 2. Release the retainer.
3. Install the brake fluid reservoir cap. 6. Remove the components in the order
table(s).
G384577 en 09/2004 2004.75 Focus

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Number
brake tubes
taining bolt
See Removal Detail
G384577 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
assembly
G384577 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
6 - HCU and ABS module as- prevent fluid loss or dirt ingress.
retaining bolts CAUTION: Plug the HCU ports to prevent
7 - ABS module to HCU retain- NOTE: Make a note of the position of the brake
ing bolts tubes, to aid installation.
8 - ABS module Disconnect the brake tubes from the HCU.
See Removal Detail
See Installation Detail 2. CAUTION: Cap the brake tubes to
7. To install, reverse the removal procedure. Remove the HCU to right-hand front caliper
8. Bleed the brake system. For additional brake tube.
Bleeding] For additional
Bleeding]
Removal Details

tubes.
G384577 en 09/2004 2004.75 Focus

TO MODEL INDEX
components.
CAUTION: Do not remove the HCU port
blanking plugs until the ABS module is
NOTE: Make a note of the position of the brake ready to be installed.
components.
be installed.
Item 8 : ABS module plugs until the brake tubes are ready to
be installed.
the electronic program. Failure to follow master cylinder brake tubes
injury. CAUTION: Do not remove the brake tube
prevent fluid loss or dirt ingress. be installed.
Item 8 : ABS module

WARNING: Do not install a damaged ABS
WARNING: Make sure that the ABS
module is correctly located on the HCU.
G384577 en 09/2004 2004.75 Focus

TO MODEL INDEX
206-09C-1 Anti-Lock Control - Stability Assist 206-09C-1
SECTION 206-09C Anti-Lock Control - Stability Assist

CONTENTS PAGE
SPECIFICATIONS
Specifications................................................................................................................... 206-09C-2
Anti-Lock Control - Stability Assist.................................................................................... 206-09C-3

Anti-lock Brake System (ABS) and Emergency Brake Assist (EBA) ................... 206-09C-3
ABS module................................................................................................. 206-09C-3/5
Anti-Lock Control - Stability Assist.................................................................................... 206-09C-6
Hydraulic Control Unit (HCU) ........................................................................................... 206-09C-7/12

Stability Assist Module ..................................................................................................... 206-09C-13/18
Rear Wheel Speed Sensor............................................................................ (12 785 0) 206-09C-19
Steering Wheel Rotation Sensor ...................................................................................... 206-09C-20/25
Yaw Rate Sensor and Accelerometer .............................................................................. 206-09C-26
09/2004 2004.75 Focus

TO MODEL INDEX
SPECIFICATIONS

Specifications
Hydraulic control unit (HCU) and stability assist 9 - 80
module assembly to support bracket retaining bolts
HCU and stability assist module assembly support 9 - 80
Stability assist module to HCU retaining bolts 5.5 - 49
Yaw rate sensor bracket retaining bolts 9 - 80
Yaw rate sensor retaining nuts 4 - 35
Wheel speed sensor retaining bolts 5 - 44
Steering wheel retaining bolt 48 35 -
ing bolts
ing nuts
Windshield wiper arms retaining nuts 15 11 -
G307387 en 09/2004 2004.75 Focus

TO MODEL INDEX
Anti-Lock Control - Stability Assist

Anti-lock Brake System (ABS) and Emergency

Brake Assist (EBA)
ABS module
The ABS module is attached to the bulkhead on

the left-hand side for all vehicle markets.
Modules pre-filled with brake fluid are available for
service operations.
Diagnosis is done using WDS.
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Communication with other control units is done on Front wheel sensors

the high-speed CAN bus. The exception to this are
the yaw rate and lateral acceleration sensor
modules which communicate with the electronic
stability programme module via a special CAN
bus.
Combined yaw rate sensor and lateral acceleration

sensor
Active sensors are used to determine the

rotational speeds of the wheels at the hub. After
the ignition is switched on, the ABS module
supplies the sensors with power. The sensors
work in accordance with the Hall effect principle
and generate a square wave output signal. The
signal acts in proportion to the rotational speed of
the sensor ring.
The ABS sensor rings are built into the seals in the
Item Part Description front wheel bearings.
Number The wheel sensors are joined to the main wiring
harness using a separate connecting cable.
1 - Combined yaw rate sensor
and lateral acceleration
sensor Rear wheel sensors
The combined yaw rate sensor and lateral

acceleration sensor is similar to that on vehicles
with the electronic stability programme. The
sensor is attached to the floor crossmember. Its
operating principle is the same.
The combined yaw rate sensor and lateral
acceleration sensor has its own CAN bus. As a
result, the signals can be transmitted to the
electronic stability programme module in a
specific way.
The ABS Anti-lock Brake System sensor rings are

built into the hubs of the rear axle.
When installing a replacement bearing, ensure
that the new part is aligned correctly.
The sensors are joined to the main wiring harness
using a separate connecting cable.
The ABS module evaluates the signals from all
four sensors to calculate road speed based on all
wheel rotational speeds. The road speed is
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transmitted on the CAN bus. The powertrain

control module (PCM) uses this signal and the
programmed tyre size to calculate road speed.
The calculated vehicle speed is forwarded on the
CAN bus and is requested by other control units
that need this input information.
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Anti-Lock Control - Stability Assist

REFER to Section 206-09A / 206-09B / 206-09C.
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General Equipment 5. Remove the battery tray. For additional
Worldwide diagnostic system (WDS) [Battery, Mounting and Cables,
CAUTION: If brake fluid is spilt on the Duratec-16V (Sigma)/1.8L Duratec-HE
paintwork, the affected area must be (MI4)/2.0L Duratec-HE (MI4)]
immediately washed down with cold 6. CAUTION: Cap the stability assist
water. module electrical connector and
1. Obtain and record the stability assist socket to prevent dirt and fluid
program code using WDS. ingress.
2. CAUTION: The brake fluid reservoir cap Disconnect the stability assist module
must not become contaminated. electrical connector.
Remove the brake fluid reservoir cap. 1. Depress the locking tangs.
3. NOTE: It will be necessary to carry out this step 2. Release the retainer.
on both sides in order to completely drain the
fluid is drained from the brake fluid
reservoir.

table(s).
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Number
brake tubes
See Removal Detail 4 - HCU and stability assist
See Installation Detail module assembly support
See Removal Detail
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Number
5 - HCU and stability assist
module assembly
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Number
6 - HCU and stability assist master cylinder brake tubes
module assembly to support
bracket retaining bolts 1. CAUTION: Cap the brake tubes to
7 - Stability assist module to
HCU retaining bolts CAUTION: Plug the HCU ports to prevent
8 - HCU fluid loss or dirt ingress.
8. To install, reverse the removal procedure. • Detach the tubes from the securing clips.
9. Bleed the brake system. For additional 2. Remove the HCU to master cylinder brake
information, refer to Section 206-00.[Brake tubes.
10. WARNING: The stability assist
program must be re-configured.
Configure the stability assist program
using WDS.

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2. CAUTION: Cap the brake tubes to Item 8 : HCU

WARNING: Do not touch the HCU or
Remove the HCU to right-hand front caliper stability assist module contact points as
brake tube. this may affect the electronic program.
CAUTION: Plug the stability assist module
ports to prevent fluid loss or dirt ingress.
Item 8 : HCU
Item 3 : HCU to rear brake tubes correctly located on the stability assist
1. CAUTION: Cap the brake tubes to may result in personal injury.
CAUTION: Do not drop or knock the HCU.
CAUTION: Plug the HCU ports to prevent Failure to follow this instruction will
fluid loss or dirt ingress. cause damage to the hydraulic
NOTE: Make a note of the position of the brake components.
CAUTION: Do not remove the stability
Disconnect the brake tubes from the HCU. assist module port blanking plugs until
• Detach the tubes from the securing clips. the HCU is ready to be installed.
2. CAUTION: Cap the brake tubes to Item 5 : HCU and stability assist module
prevent fluid loss or dirt ingress. assembly
Remove the HCU to rear brake tubes. WARNING: Do not install a damaged HCU
and stability assist module assembly.
CAUTION: Do not drop or knock the HCU
cause damage to the electronic and
hydraulic components.
be installed.
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be installed.
be installed.
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Stability Assist Module
General Equipment 4. Install the brake fluid reservoir cap.

Worldwide diagnostic system (WDS) 5. Remove the battery tray. For additional
CAUTION: If brake fluid is spilt on the Tray - 1.4L Duratec-16V (Sigma)/1.6L
paintwork, the affected area must be Duratec-16V (Sigma)/1.8L Duratec-HE
immediately washed down with cold (MI4)/2.0L Duratec-HE (MI4)]
water.
1. Obtain and record the stability assist 6. CAUTION: Cap the stability assist
program code using WDS. module electrical connector and
socket to prevent dirt and fluid
2. CAUTION: The brake fluid reservoir cap ingress.
must not become contaminated.
Disconnect the stability assist module
Remove the brake fluid reservoir cap. electrical connector.
3. NOTE: It will be necessary to carry out this step 1. Depress the locking tangs.
on both sides in order to completely drain the 2. Release the retainer.
fluid is drained from the brake fluid
reservoir.

table(s).
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Number
brake tubes
See Removal Detail 4 - HCU and stability assist
See Installation Detail module assembly support
See Removal Detail
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Number
5 - HCU and stability assist
module assembly
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Number
6 - HCU and stability assist master cylinder brake tubes
module assembly to support
bracket retaining bolts 1. CAUTION: Cap the brake tubes to
7 - Stability assist module to
HCU retaining bolts CAUTION: Plug the HCU ports to prevent
8 - Stability assist module fluid loss or dirt ingress.
8. To install, reverse the removal procedure. • Detach the tubes from the securing clips.
9. Bleed the brake system. For additional 2. Remove the HCU to master cylinder brake
information, refer to Section 206-00.[Brake tubes.
refer to Section 206-00.[Brake System - General
10. WARNING: The stability assist
program must be re-configured.
Configure the stability assist program
using WDS.

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2. CAUTION: Cap the brake tubes to Item 8 : Stability assist module

WARNING: Do not touch the HCU or
Remove the HCU to right-hand front caliper stability assist module contact points as
brake tube. this may affect the electronic program.
CAUTION: Plug the stability assist module
ports to prevent fluid loss or dirt ingress.
Item 8 : Stability assist module

WARNING: Do not install a damaged
stability assist module. Failure to follow
injury.
Item 3 : HCU to rear brake tubes WARNING: Make sure that the stability
assist module is correctly located on the
1. CAUTION: Cap the brake tubes to HCU. Failure to follow this instruction
prevent fluid loss or dirt ingress. may result in personal injury.
CAUTION: Plug the HCU ports to prevent CAUTION: Do not drop or knock the
fluid loss or dirt ingress. stability assist module. Failure to follow
NOTE: Make a note of the position of the brake this instruction will cause damage to the
tubes, to aid installation. electronic components.
Disconnect the brake tubes from the HCU. CAUTION: Do not remove the HCU port
• Detach the tubes from the securing clips. blanking plugs until the stability assist
module is ready to be installed.
prevent fluid loss or dirt ingress. Item 5 : HCU and stability assist module
assembly
Remove the HCU to rear brake tubes.
WARNING: Do not install a damaged HCU
CAUTION: Do not drop or knock the HCU
cause damage to the electronic and
hydraulic components.
be installed.
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be installed.
be installed.
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Rear Wheel Speed Sensor (12 785 0)

Removal
1. For additional information,
refer to Section 206-09A / 206-09B / 206-09C.
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Steering Wheel Rotation Sensor
General Equipment 3. NOTE: Make sure the road wheels are in the
Worldwide diagnostic system (WDS)
Centralize the steering and lock it in posi-
tion.
WARNING: To avoid accidental

deployment, the air bag control module
backup power supply must be depleted.
Wait at least one minute after
disconnecting the battery ground
cable(s) before commencing any repair or
adjustment to the supplemental restraint
system (SRS), or any component(s)
adjacent to the SRS sensors. Failure to
personal injury.
WARNING: To minimize the possibility of
premature deployment, do not use radio
key code savers when working on the
supplemental restraint system. Failure to
personal injury. 4. Remove the components in the order
WARNING: Never probe the electrical
table(s).
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
GENERAL PROCEDURES, Battery
Disconnect]
2. Remove the driver air bag module.
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Number
5 - Steering wheel rotation
1 - Audio control switch (if sensor electrical connector
equipped)
See Removal Detail 6 - Clockspring electrical con-
nector
2 - Steering column lower
shroud 7 - Clockspring and steering
See Removal Detail wheel rotation sensor
assembly
3 - Steering wheel retaining bolt See Removal Detail
4 - Steering wheel See Installation Detail
See Removal Detail
See Installation Detail All vehicles
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3. WARNING: The electronic stability Item 2 : Steering column lower shroud

program must be re-configured. 1. Release the steering column locking lever
Failure to follow this instruction may to aid the removal of the steering column
result in personal injury. shroud.
Configure the electronic stability program Item 4 : Steering wheel
using WDS.
1. CAUTION: Make sure the clockspring
Vehicles with global closing rotor is not allowed to rotate.
4. Initialize the door window motors. For
additional information, refer to Section 501-11. Using a suitable piece of tape, secure the
[Glass, Frames and Mechanisms, clockspring rotor to the clockspring outer
GENERAL PROCEDURES, Door Window case.
Motor Initialization]
Removal Details
Item 1 : Audio control switch (if equipped)

1. Detach the audio control switch from the
steering column lower shroud.
• Using a thin bladed screwdriver, release the
locking tang.
2. Disconnect the steering wheel switches

electrical connector (if equipped).
3. CAUTION: Care must be taken not to
damage the clockspring pins.
Remove the steering wheel.
• Feed the driver air bag module wiring har-
nesses through the steering wheel.
2. Remove the audio control switch.

• Disconnect the electrical connector.
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Item 7 : Clockspring and steering wheel

rotation sensor assembly 2. CAUTION: Make sure the road wheels
are in the straight ahead position.
1. CAUTION: Make sure the clockspring to
steering wheel rotation sensor NOTE: Make sure the turn signal lamp switch is in
retaining clips do not get damaged. the off position.
Remove the steering wheel rotation Install the clockspring and steering wheel
sensor. rotation sensor assembly.
• Release the locking tangs.
Item 7 : Clockspring and steering wheel

rotation sensor assembly
1. CAUTION: Do not remove the tape
securing the clockspring at this stage.
CAUTION: Make sure the clockspring to
steering wheel rotation sensor retaining
clips do not get damaged.
Install the steering wheel rotation sensor.
1. Align the steering wheel rotation sensor
locating tangs to the clockspring.
2. Make sure the retaining clips lock into posi-
tion on the steering wheel rotation sensor.
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3. WARNING: If there is a break between

installing the clockspring and steering
wheel rotation sensor assembly and
installing the steering wheel, or the
vehicle is left unattended by the
technician, the centralizing procedure
MUST be carried out. Failure to follow
injury.
WARNING: Incorrect centralization may
result in premature component failure. If
in doubt when centralizing the
clockspring, repeat the procedure.
Failure to follow this instruction may 4. NOTE: When the clockspring is centralized, the
result in personal injury. U-shaped part of the flat flexible cable will be
visible.
CAUTION: Do not turn the clockspring
and steering wheel rotation sensor Check to see if the U-shaped part of the flat
assembly in a clockwise direction more flexible cable is visible.
than three turns. • Secure the clockspring rotor to the clock-
spring outer.
CAUTION: Make sure the road wheels are
in the straight ahead position.
CAUTION: When carrying out the
clockspring centralizing procedure, the
first turns must be in the
counterclockwise direction.
Centralize the clockspring.
1. Turn the clockspring and steering wheel
rotation sensor assembly in a
counterclockwise direction until a resistance
is felt.
rotation sensor assembly in a clockwise
direction, until the arrow marked on the rotor
of the clockspring aligns with the raised 'V'
section on the outer cover of the clockspring
at the 195 degrees position.
rotation sensor assembly in a clockwise
direction three turns.
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Item 4 : Steering wheel

1. CAUTION: Make sure the road wheels
are in the straight ahead position.
Install the steering wheel.
1. Remove the tape securing the clockspring.
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Yaw Rate Sensor and Accelerometer
NOTE: The yaw rate sensor and accelerometer

cannot be separated.
5. Disconnect the yaw rate sensor and accel-
1. Remove the right-hand front seat. For
erometer electrical connector and position
additional information, refer to Section 501-10. it to one side.
[Seating, REMOVAL AND
INSTALLATION, Front Seat]
2. Remove the front scuff plate trim panel. For
[Interior Trim and Ornamentation,
REMOVAL AND INSTALLATION, Front
Scuff Plate Trim Panel]
3. Remove the B-pillar trim panel.
4. Locally detach the carpet from the floor
panel and crossmember.

table(s).
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Number
1 - Yaw rate sensor and accel-
erometer assembly bracket
bolts
erometer assembly bracket
erometer assembly nuts
4 - Yaw rate sensor and
accelerometer assembly
Item 4 : Yaw rate sensor and accelerometer

assembly
WARNING: Make sure the yaw rate sensor
and accelerometer assembly is correctly
positioned. Failure to follow this
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211-00-1 Steering System - General Information 211-00-1
SECTION 211-00 Steering System - General

Information
CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 211-00-2
Steering Wheel Alignment ................................................................................................ 211-00-2
Steering System — 1.6L (Z6)............................................................................................ 211-00-3

Symptom Chart ................................................................................................................ 211-00-3/9
Components Tests ........................................................................................................... 211-00-10/12
Steering System................................................................................................................ 211-00-13
Symptom Chart ................................................................................................................ 211-00-13/26
Components Tests ........................................................................................................... 211-00-27/29
GENERAL PROCEDURES
Power Steering System Flushing — Vehicles With: Electro-Hydraulic Power (13 001 0)
Steering (EHPS)........................................................................................... 211-00-30/31
Power Steering System Bleeding — 1.6L (Z6) .............................................. (13 416 1) 211-00-32
Power Steering System Bleeding — Vehicles With: Electro-Hydraulic Power (13 416 1)
Steering (EHPS)........................................................................................... 211-00-33
Bleeding ........................................................................................................................... 211-00-33
Power Steering System Filling — 1.6L (Z6)................................................... (13 002 0) 211-00-34
Power Steering System Filling — Vehicles With: Electro-Hydraulic Power (13 002 0)
Steering (EHPS)........................................................................................... 211-00-35
Refill................................................................................................................................. 211-00-35
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SPECIFICATIONS

Specifications
Hydraulic Fluid - vehicles with electrical hydraulic power steering WSS-M2C204-A
Power Steering Fluid - vehicles with hydraulic power steering 5M51-3F823-AA
Grease SA-M1C9107-A
Steering Wheel Alignment

Description Degrees
Maximum allowable steering wheel misalignment +/- 3.00
Turning Effort
Description Nm lb-in
Turning effort 8 71
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Steering System — 1.6L (Z6)

• Tire pressure(s) • Power steering
• Accessory drive belt pressure (PSP)
Special Tool(s)
switch
• Tie-rod ends
• Tie-rod(s)
205-316 (15-097A)
• Steering gear
housing
• Front strut and
spring assemblies
Simulator, Driver and • Front suspension
Passenger Air Bags and Side lower arm ball joints
Air Curtains • Front suspension
501-073 (40-016) lower arm bushings
• Pinch bolt on
steering column
shaft flexible
Inspection and Verification coupling
1. Verify the customer concern. • Wheels and tires
2. Visually inspect for obvious signs of • Power steering line
mechanical or electrical damage. fluid leaks
• Steering gear bel-
Visual Inspection Chart lows
step.
Symptom Chart
springs.
• Incorrect wheel alignment. • CHECK the wheel alignment and
adjust if necessary.
[Suspension System -
General Information, GENERAL
PROCEDURES, Front Toe Ad-
justment] REFER to Section
204-00.[Suspension
System - General Information,
GENERAL PROCEDURES,
Rear Toe Adjustment]
• Incorrect front axle crossmember • Using the special tool, CHECK
alignment. the front axle crossmember
alignment.
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• Damaged or worn front wheel • CHECK and INSTALL new front
REFER to Section 204-01.[Front
Suspension, REMOVAL AND
INSTALLATION, Wheel Hub]
Information, DIAGNOSIS AND
• Steering linkage. • CARRY OUT the steering link-
age component test.
REFER to Steering Linkage
Component Test.
• Steering gear. • CARRY OUT the steering link-
age component test.
Component Test.
[Wheels and Tires,
DIAGNOSIS AND TESTING,
Wheels and Tires]
springs.
justment]
• Front suspension lower arm ball • REFER to Section 204-00.
joint. [Suspension System -
General Information,
Suspension System]
age component test.
Component Test.
age component test.
Component Test.
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• Vibration • Incorrect wheel alignment. • CHECK the wheel alignment and
adjust if necessary.
justment]
[Wheels and Tires,
REMOVAL AND
INSTALLATION, Wheel and
Tire]
• Damaged or worn front wheel • CHECK and INSTALL new front
necessary. REFER
to Section 204-00.[Suspension
System General Information,
Suspension System]
necessary. REFER
to Section 204-00.[Suspension
System General Information,
Suspension System]
age component test. REFER to
Steering Linkage Component
Test.
• Steering effort is high/low • Loose or worn accessory drive • CHECK the accessory drive belt.
belt. REFER to Section 303-05
.[Accessory Drive,
REMOVAL AND
INSTALLATION, Accessory
Drive Belt - 1.6L (Z6)]
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• Power steering lines restriction. • CHECK the power steering lines
for damage, kinks or restrictions.
INSTALL new components as
necessary. REFER
to Section 211-02.[Power
Steering, REMOVAL AND
INSTALLATION, Power Steering
Pump to Steering Gear Pressure
Line - 1.6L (Z6)]
[Power Steering,
REMOVAL AND
INSTALLATION, Steering Gear
to Power Steering Fluid Reser-
voir Return Line - 1.6L (Z6)]
• Power steering fluid aeration. • BLEED the power steering sys-
tem. REFER to Power Steering
System Bleeding - 1.6L (Z6) in
this section.
• Steering column. • CHECK if the floor covering is
obstructing the steering gear
pinion.
• CHECK the installation of the
floor seal.
• CARRY OUT the steering col-
umn universal joint component
test. REFER to Steering Column
Universal Joint Component Test.
age component test.
Component Test.
age component test.
Component Test.
• Worn power steering pump. • INSTALL a new power steering
pump. REFER to Section 211-02
.[Power Steering, REMOVAL
AND INSTALLATION, Power
Steering
Pump - 1.6L (Z6)]
• Excessive noise • Power steering fluid aeration. • BLEED the power steering sys-
tem. REFER to Power Steering
System Bleeding - 1.6L (Z6) in
this section.
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• Power steering lines. • CHECK the power steering line
clamps are secure. REFER to
Section 211-02.[Power Steering,
REMOVAL AND
Line - 1.6L (Z6)]
[Power Steering,
REMOVAL AND
to Power Steering Fluid
Reservoir Return Line - 1.6L
(Z6)]
• CHECK the power steering lines
for clearance from the vehicle
body, front axle crossmember
and steering gear.
• CHECK the steering gear
transfer lines for clearance from
the steering gear.
• Steering gear bushings worn or • CHECK and INSTALL new
perished. components as necessary.
[Power Steering,
REMOVAL AND
INSTALLATION, Steering Gear -
1.6L (Z6)]
• Loose steering gear retaining • CHECK and INSTALL new
bolts. steering gear retaining bolts as
211-02.[Power Steering,
SPECIFICATIONS, Specifica-
tions]
• Worn power steering pump. • INSTALL a new power steering
.[Power Steering,
REMOVAL AND
Pump - 1.6L (Z6)]
• Worn tie-rod. • CARRY OUT the Tie-Rod com-
ponent test. REFER to Tie-Rod
Component Test.
• Steering does not vary with in- • Worn tie-rod ends. • INSTALL new components as
creased wheel rotation necessary. REFER to Section
211-03.[Steering Linkage,
REMOVAL AND
INSTALLATION, Tie-Rod End -
1.6L (Z6)]
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• Worn front suspension bushings. • CHECK and INSTALL new
.[Suspension System -
Suspension System]
• Worn front suspension lower arm • CARRY OUT the suspension
ball joints. ball joint inspection component
test. REFER to Section 204-00
Suspension System]
[Power Steering,
REMOVAL AND
INSTALLATION, Steering Gear -
1.6L (Z6)]
• Loose steering gear retaining • CHECK and INSTALL new
bolts. steering gear retaining bolts as
211-02.[Power Steering,
tions]
• Loose steering column retaining • CHECK and INSTALL new
bolts. steering column retaining bolts
as necessary. REFER to Section
211-04.[Steering Column,
tions]
• Loose steering column to steer- • CHECK and INSTALL a new
ing gear pinion retaining bolt. steering column to steering gear
pinion retaining bolt as neces-
sary. REFER to Section 211-02
.[Power Steering,
tions]
• Excessive steering gear back- • CARRY OUT the steering link-
lash. age component test.
Component Test.
• Engine stalls when parking with • PSP switch or circuit. • GO to Pinpoint Test A
engine speed at idle
PINPOINT TEST A: ENGINE STALLS WHEN PARKING WITH ENGINE SPEED AT IDLE
NOTE: Use a digital multimeter for all electrical measurements.
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A1: CHECK THE VOLTAGE TO THE PSP SWITCH
1 Disconnect PSP Switch C170.
3 Measure the voltage between the PSP switch
C170, circuit 7-CE6 (YE), harness side and
ground.
• Is the voltage greater than 10 volts?

→ Yes
INSTALL a new PSP switch.
→ No
GO to A2
A2: CHECK THE PSP SWITCH CIRCUIT FOR OPEN CIRCUIT OR HIGH RESISTANCE
1 Ignition switch in position 0.
2 Disconnect Powertrain Control Module (PCM)
C680.
3 Measure the resistance between the PCM
C680 pin AC, circuit 7-CE6 (YE), harness side
and the PSP switch C170, circuit 7-CE6 (YE),
harness side.
• Is the resistances less than 5 ohms?

→ Yes
INSTALL a new PCM. REFER to Section
418-01.[Module Configuration, GENERAL
PROCEDURES, Programmable Module In-
stallation]
→ No
REPAIR circuit 7-CE6 (YE).
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1. Raise and support the vehicle. REFER to

Section 100-02.[Jacking and Lifting,
Components Tests DESCRIPTION AND OPERATION, Jacking]
REFER to Section 100-02.[Jacking and Lifting,
DESCRIPTION AND OPERATION, Lifting]
Steering Linkage
1. Grasp the steering wheel firmly and move it up
and down and to the left and right without
turning the steering wheel, to check for
steering column bearing wear, steering
column universal joint free play, steering
wheel or steering column looseness. The
steering column cannot be repaired. Install a
new steering column. REFER to Section 211-04
.[Steering Column, REMOVAL AND
INSTALLATION, Steering Column]
2. With the road wheels in the straight ahead
position, gently turn the steering wheel to the
left and the right to check free play in the 2. Firmly grasp the road wheel and apply a
steering linkage. rocking motion to check for any free play in the
3. There should be no excessive free play at the wheel bearing or suspension components.
steering wheel rim. If there is excessive free
play, CHECK the tie-rod inner and outer ball
joints, REFER to Tie-Rod Component Test.
CHECK steering column universal joint,
REFER to Steering Column Universal Joint
Component Test. If there is no free play in the
tie-rod and the steering column, install a new
steering gear. REFER to Section 211-02
.[Power Steering, REMOVAL AND
INSTALLATION, Steering Gear - 1.6L (Z6)]
Tie-Rod
CAUTION: The steering gear boots must

be handled carefully to avoid damage. NOTE: To isolate the steering gear design
Use new steering gear boot clamps when clearance, check the right-hand tie-rod with the
installing the steering gear boots. steering held against the right-hand steering lock
stop.
NOTE: Noises such as knocks, which may appear
to originate from the steering linkage, may also be
generated by front suspension components.
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3. With the aid of another technician holding the 8. Detach the steering gear boot from the
steering against the right-hand steering lock steering gear body and check for free play at
stop, firmly grasp the right-hand road wheel the tie-rod inner ball joint.
and apply a rocking motion to check for any 9. If there is free play at the tie-rod inner ball joint,
free play in the tie-rod. install a new tie-rod. REFER to Section 211-03.
[Steering Linkage, REMOVAL AND
INSTALLATION, Tie-Rod - 1.6L (Z6)]
10. If there is free play at the tie-rod end, install a
new tie-rod end. REFER to Section 211-03.
INSTALLATION, Tie-Rod End - 1.6L (Z6)]
Turning Effort Test

NOTE: Before carrying out this test, make sure
that the suspension components are serviceable.
that the steering column is serviceable.
4. Detach the steering gear boot from the NOTE: Before carrying out this test, make sure
steering gear body and check for free play at that the front toe adjustment and tire pressures
the tie-rod inner ball joint. are correct.
5. If there is free play at the tie-rod inner ball joint,
install a new tie-rod. REFER to Section 211-03.
INSTALLATION, Tie-Rod - 1.6L (Z6)]
6. If there is free play at the tie-rod end, install a
new tie-rod end. REFER to Section 211-03.
INSTALLATION, Tie-Rod End - 1.6L (Z6)]
NOTE: To isolate the steering gear design
clearance, check the left-hand tie-rod with the
steering held against the left-hand steering lock
stop.
7. With the aid of another technician holding the
steering against the left-hand steering lock
stop, firmly grasp the left-hand road wheel and
apply a rocking motion to check for any free
play in the tie-rod.
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1. Park the vehicle on a dry, even surface and 1. Detach the steering column shaft from the
apply the parking brake. steering gear pinion.
2. Remove the driver air bag module. REFER to • Discard the steering column shaft to
Section 501-20B.[Supplemental Restraint steering gear pinion retaining bolt.
System, REMOVAL AND INSTALLATION,
Driver Air Bag Module]
3. Connect the air bag simulators to the
sub-harnesses in place of the driver air bag
module at the top of the steering column.
4. Start the engine and turn the steering wheel
from lock to lock several times until the power
steering fluid has reached normal operating
temperature.
5. Using a suitable torque wrench and socket,
check the steering wheel turning effort.
6. If the steering wheel turning effort is greater
than the specification, install a new steering
gear. REFER to Section 211-02
.[Power Steering, REMOVAL AND 2. Check for smooth movement of the steering
INSTALLATION, Steering Gear - 1.6L (Z6)] column shaft universal joint.
1. Hold the steering column shaft universal
joint yoke.
Steering Column Shaft Universal Joint
2. Articulate the free yoke in a figure of eight
movement.
• If the movement is not smooth or resistance
is felt, renew the steering column.
REFER to Section 211-04.[Steering Column,
REMOVAL AND INSTALLATION, Steering
Column]
3. Hold both of the steering column shaft
universal joint yokes and then twist them
clockwise and counterclockwise.
• If any movement is felt, install a new
steering column. REFER to Section 211-04
.[Steering Column, REMOVAL AND
WARNING: Install a new steering column
shaft to steering gear pinion retaining
bolt. Failure to follow this instruction may
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Steering System
• Tire pressure(s) • Steering angle
• Loose tie-rod end(s) sensor electrical
Special Tool(s)
• Loose strut and connector
Alignment Pins, Subframe spring assemblies or • Power steering
205-316 (15-097A) ball joints pump control
module electrical
• Loose pinch bolts on
connectors
steering column
shaft flexible • Steering angle
coupling sensor warning
Simulator, Driver and indicator
Passenger Air Bags and Side • Wheels and tires
• Fuse(s)
Air Curtains • Power steering line
501-073 (40-016) fluid leaks
• Steering gear bel-
lows
General Equipment 3. If an obvious cause for an observed or
Worldwide diagnostic system (WDS) reported concern is found, correct the cause
step.
Symptom Chart
or rear is high or low) coil spring sag or non-standard
springs.
ADJUST if necessary.
justment]
• Incorrect front axle crossmember • Using the special tool, CHECK
alignment. the front axle crossmember
alignment.
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• Steering linkage. • CARRY OUT the Steering
Linkage Component Test.
Component Test.
• Steering gear. • CARRY OUT the Steering
Component Test.
• Wheel and tires. • REFER to Section 204-04
.[Wheels and Tires,
Wheels and Tires]
or rear is high or low) coil spring sag or non-standard
springs.
justment]
• Suspension lower arm ball joint. • REFER to Section 204-00.
Suspension System]
Component Test.
Component Test.
• Vibration • Incorrect wheel alignment. • CHECK the wheel alignment and
justment]
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[Wheels and Tires,
REMOVAL AND
INSTALLATION, Wheel and
Tire]
• Damaged or worn front wheel • CHECK and INSTALL new
204-00.[Suspension System -
Suspension System]
204-00.[Suspension System -
Suspension System]
Component Test.
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• Steering effort is high/low • Power steering hose restriction. • CHECK the power steering
hoses for damage, kinks or re-
strictions. INSTALL new com-
ponents as necessary. REFER
to Section 211-02.[Power
Steering, REMOVAL AND
Line - 1.8L Duratec-HE
(MI4)/2.0L Duratec-HE
(MI4)/ 2.0L Duratorq-TDCi (DW)
Diesel]
[Power Steering, REMOVAL AND
to Power Steering Fluid Reser-
voir Return Line - 1.8L Du-
ratec-HE (MI4)/2.0L Duratec-HE
Diesel]
• Power steering fluid. • Check the power steering fluid

level.
• Power steering pump. • REFER to WDS.
• Steering column. • CHECK if the floor covering is
obstructing the steering gear
pinion.
• CHECK the installation of the
floor seal.
• CARRY OUT the Steering Col-
umn Universal Joint Component
Test. REFER to Steering Col-
umn Universal Joint Component
Test.
Component Test.
Component Test.
• Excessive noise • Aeration of the power steering • Bleed the power steering sys-
fluid. tem. REFER to Power Steering
System Bleeding - Vehicles
With: Electro-Hydraulic Power
Steering (EHPS) in this section.
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• Power steering lines. • CHECK the power steering line
clamps are secure. REFER to
Section 211-02.[Power Steering,
REMOVAL AND
Line - 1.8L Duratec-HE
Diesel]
[Power Steering, REMOVAL AND
to Power Steering Fluid
Reservoir Return Line - 1.8L
Duratec-HE (MI4)/2.0L
Duratec-HE (MI4)/2.0L
Duratorq-TDCi (DW) Diesel]
• CHECK the power steering lines
for clearance from the vehicle
body, crossmember and steering
gear.
• CHECK the steering gear
transfer lines for clearance from
the steering gear.

• Loose steering gear retaining • CHECK and INSTALL new bolts
bolts. as necessary.
• Power steering pump rubber • CHECK and INSTALL new
mountings. power steering pump rubber
mountings as necessary.
• Power steering pump. • INSTALL a new power steering
pump. REFER to Section 211-02.
[Power Steering,
REMOVAL AND
Pump - 1.8L Duratec-HE
(MI4)/2.0L Duratorq-TDCi (DW)
Diesel]
• Tie-rod. • CARRY OUT the Tie-Rod

Component Test. REFER to
Tie-Rod Component Test.
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• Steering does not vary with in- • Worn tie-rod ends. • INSTALL new components as
creased wheel rotation necessary. REFER to Section
211-03.[Steering Linkage,
REMOVAL AND
INSTALLATION, Tie-Rod End]
• Worn front suspension bushings. • CHECK and INSTALL new
Suspension System]
• Worn suspension ball joints. • CARRY OUT the suspension
ball joint inspection component
test. REFER to Section 204-00
Suspension System]
• Steering gear insulator bushings • CHECK and INSTALL new
worn or perished. components as necessary.
• Loose steering gear retaining • CHECK and INSTALL new bolts
• Loose steering column retaining • CHECK and INSTALL new bolts
• Loose steering column to steer- • CHECK and INSTALL a new bolt
ing gear pinion retaining bolt. as necessary.
• Excessive steering gear back- • INSTALL a new steering gear.
lash.
• Steering assist does not vary • Powertrain control module. • REFER to WDS.
with vehicle speed
• Electrical hydraulic power assist • REFER to WDS.
steering (EHPAS) control mod-
ule.
NOTE: The warning light is • Ignition circuit. • GO to Pinpoint Test B
illuminated when the ignition is • EHPAS module ground circuit.
switched ON for approximately
three seconds then extinguishes.
• Steering system warning light
stays on
• CAN circuit. • REFER to WDS.
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• DTC B1238: Over temperature • Electrical hydraulic power assist • CLEAR the DTCs. Drive the ve-
fault steering (EHPAS) control mod- hicle 30km (20 miles) or until the
ule. vehicle reaches normal operat-
ing temperature. REFER to
WDS. If the DTC is present,
INSTALL a new power steering
.[Power Steering,
REMOVAL AND
Diesel] REPEAT the self-test
CLEAR the DTCs.
• DTC B1317: Battery voltage high • Charging system. • CHECK the charging system.
[Charging System -
Charging System]
• DTC B1318: Battery voltage low • Battery. • GO to Pinpoint Test C
• Charging system.
• Circuit.
• DTC B1342: Electrical hydraulic • Electrical hydraulic power as- • INSTALL a new power steering
power assisted steering sisted steering (EHPAS) control pump. REFER to Section 211-02.
(EHPAS) control module is faulty module. [Power Steering,
REMOVAL AND
Diesel] REPEAT the self-test,
CLEAR the DTCs.
• DTC B2477: Module configura- • Electrical hydraulic power assist • CONFIGURE the electrical hy-
tion failure steering (EHPAS) control mod- draulic power assist steering
ule. (EHPAS) control module.
.[Module Configuration,
GENERAL PROCEDURES,
Module Configuration] REPEAT
the self-test, CLEAR the DTCs.
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• DTC C1099: Electronic power • Electrical hydraulic power assist • CLEAR the DTCs. Drive the ve-
steering motor malfunction steering (EHPAS) control mod- hicle 30km (20 miles) or until the
ule. vehicle reaches normal operat-
ing temperature. REFER to
WDS. If the DTC is present,
INSTALL a new power steering
.[Power Steering,
REMOVAL AND
CLEAR the DTCs.
• DTC C1955: Steering angle • Circuit(s). • GO to Pinpoint Test D

sensor circuit open
• DTC C1956: Steering angle • Circuit(s). • GO to Pinpoint Test E
sensor circuit failure
• DTC P1796: CAN controller cir- • Circuit(s). • GO to Pinpoint Test F
cuit (Bus off)
• DTC U1900: CAN communica- • Powertrain control module • Check the electronic engine
tion bus fault controls. REFER to Section
303-14.[Electronic Engine Con-
trols, DIAGNOSIS AND
TESTING, Electronic Engine
Controls]
• Circuit(s). • CHECK the CAN bus,
• DTC U2011: Module transmitted • Electrical hydraulic power assist • INSTALL a new power steering
invalid data steering (EHPAS) control mod- pump. REFER to Section 211-02.
ule. [Power Steering,
REMOVAL AND
CLEAR the DTCs.
PINPOINT TEST B: STEERING SYSTEM WARNING LIGHT STAYS ON

NOTE: Use a digital multimeter for all electrical measurements.
B1: CHECK THE ELECTRICAL HYDRAULIC POWER ASSIST STEERING (EHPAS) CONTROL
MODULE GROUND CIRCUIT
1 Disconnect EHPAS Control Module C793.
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2 Measure the resistance between the EHPAS
control module C793 pin 2, circuit 31-CE7 (BK),
harness side and ground.
• Is the resistance less than 5 ohms?

→ Yes
GO to B2
→ No
REPAIR circuit 31-CE7 (BK). TEST the
B2: CHECK FOR IGNITION VOLTAGE TO THE EHPAS CONTROL MODULE
4 With the engine at 2000 rpm, measure the
voltage between the EHPAS control module
C794 pin 1, circuit 15-CE7 (GN/BU), harness
side and ground.

→ Yes
CHECK the CAN bus,
→ No
GO to B3
B3: CHECK FOR CONTINUITY BETWEEN THE FRONT JUNCTION BOX (FJB) AND THE EHPAS
CONTROL MODULE
1 Disconnect Fuse 22 (10A).
2 Measure the resistance between the front junc-
tion box fuse 22 (10A), harness side and the
EHPAS control module C794 pin 1, circuit
15-CE7 (GN/BU), harness side and ground.
→ Yes
REPAIR circuit 15-DC22 (GN/BU). TEST the
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→ No
REPAIR circuit 15-CE7 (GN/BU). TEST the
PINPOINT TEST C: DTC B1318: BATTERY VOLTAGE LOW
C1: CHECK THE BATTERY VOLTAGE
3 Check the battery voltage with the ignition in the
ON position.
• Is the battery voltage greater than 10 volts?
→ Yes
GO to C2
→ No
CHECK the battery and charging system.
REFER to Section 414-00.[Charging System
- General Information, DIAGNOSIS AND
TESTING, Charging System] REPEAT the
self-test, CLEAR the DTCs.
C2: CHECK FOR VOLTAGE TO THE ELECTRICAL HYDRAULIC POWER ASSISTED STEERING
(EHPAS) CONTROL MODULE
3 Measure the voltage between the EHPAS con-
trol module C793 pin 1, circuit 30-CE7 (RD),

→ Yes
GO to C3
→ No
REPAIR circuit 30-CE7 (RD). TEST the
C3: CHECK FOR CONTINUITY BETWEEN THE BATTERY JUNCTION BOX (BJB) AND THE
EHPAS CONTROL MODULE
2 Measure the resistance between the BJB fuse 2
(80A), harness side and the EHPAS control
module C793 pin 1, circuit 30-CE7 (RD), har-
ness side and ground.
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→ Yes
INSTALL a new power steering pump.
REFER to Section 211-02.[Power Steering,
REMOVAL AND INSTALLATION, Power
Steering Pump - 1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4)/ 2.0L Duratorq-TDCi
(DW) Diesel]
REPEAT the self-test, CLEAR the DTCs.
→ No
REPAIR circuit 30-CE7 (RD). TEST the
PINPOINT TEST D: DTC C1955: STEERING ANGLE SENSOR CIRCUIT OPEN
D1: CHECK THE STEERING ANGLE SENSOR CIRCUIT FOR A SHORT TO BATTERY OR
IGNITION
2 Disconnect Steering Angle Sensor C788.
3 Measure the voltage between the steering an-
gle sensor C788 pin 1, circuit 8-CE10 (WH/VT),
• Is any voltage present?

→ Yes
REPAIR circuit 8-CE10 (WH/VT). TEST the
→ No
Go to D2
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D2: CHECK THE STEERING ANGLE SENSOR CIRCUIT FOR A SHORT TO GROUND
1 Measure the resistance between the steering
angle sensor C788 pin 1, circuit 8-CE10
(WH/VT), harness side and ground.
• Is the resistance greater than 10,000 ohms?

→ Yes
Go to D3
→ No
D3: CHECK FOR CONTINUITY BETWEEN THE STEERING ANGLE SENSOR AND THE EHPAS
CONTROL MODULE
(WH/VT), harness side and the EHPAS control
module C792 pin 3, circuit 8-CE10 (WH/VT),
harness side.

→ Yes
INSTALL a new steering angle sensor.
Angle Sensor] TEST the system for normal
operation.
→ No
PINPOINT TEST E: DTC C1956: STEERING ANGLE SENSOR CIRCUIT FAILURE
E1: CHECK THE STEERING ANGLE SENSOR CIRCUIT FOR A SHORT TO GROUND
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(YE/VT), harness side and ground.

→ Yes
Go to E2
→ No
REPAIR circuit 7-CE10 (YE/VT). TEST the
E2: CHECK FOR CONTINUITY BETWEEN THE STEERING ANGLE SENSOR AND THE EHPAS
CONTROL MODULE
(YE/VT), harness side and the EHPAS control
module C792 pin 1, circuit 7-CE10 (YE/VT),
harness side.

→ Yes
Go to E3
→ No
REPAIR circuit 7-CE10 (YE/VT). TEST the
E3: CHECK THE STEERING ANGLE SENSOR CIRCUIT FOR A SHORT TO IGNITION
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2 Measure the voltage between the steering an-
gle sensor C788 pin 2, circuit 9-CE10 (BN/WH),

→ Yes
REPAIR circuit 9-CE10 (BN/WH). TEST the
→ No
GO to E4
CONTROL MODULE
(BN/WH), harness side and the EHPAS control
module C792 pin 2, circuit 9-CE10 (BN/WH),
harness side.

→ Yes
GO to E5
→ No
REPAIR circuit 9-CE10 (BN/WH). TEST the
CONTROL MODULE
2 Clear the DTCs.
5 REFER to WDS.
• Is DTC C1956 present?
→ Yes
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INSTALL a new power steering pump.
REMOVAL AND INSTALLATION, Power
Steering Pump - 1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4)/ 2.0L Duratorq-TDCi
(DW) Diesel]
REPEAT the self-test, CLEAR the DTCs.
→ No
INSTALL a new steering angle sensor.
Angle Sensor] REPEAT the self-test, CLEAR
the DTCs.
PINPOINT TEST F: DTC P1796: CAN CONTROLLER CIRCUIT (BUS OFF)
F1: CHECK THE CAN BUS CIRCUIT
• Is WDS able to communicate with the instru-
ment cluster?
→ Yes
REPAIR circuit 4-EC7W (GY/RD) or circuit
5-EC7W (BU/RD). TEST the system for
normal operation.
→ No
CHECK the CAN bus,
tie-rod and the steering column, install a new
steering gear.
Components Tests
Tie-Rod
Steering Linkage
CAUTION: Steering gear boots must be
1. Grasp the steering wheel firmly and move it up handled carefully to avoid damage. Use
and down and to the left and right without new steering boot clamps when installing
turning the wheel, to check the steering boots.
column bearing wear, steering column shaft NOTE: Noises such as knocks, which may appear
joint play, steering wheel or steering column to originate from the steering linkage, may also be
looseness. generated by front suspension components.
2. The steering column cannot be repaired. 1. Raise and support the vehicle.
Install a new steering column. REFER to
Section 211-04.[Steering Column, REMOVAL
AND INSTALLATION, Steering Column]
3. With the wheels in the straight ahead position,
gently turn the steering wheel to the left and
the right to check for free play.
4. There should be no excessive free play at the
steering wheel rim. If there is excessive free
play, CHECK the Tie-Rod inner and outer ball
joints, REFER to Tie-Rod Component Test.
CHECK the steering column universal joint,
REFER to Steering Column Universal Joint
Component Test. If there is no free play in the
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2. Firmly grasp the road wheel and apply a 4. Detach the steering gear boot from the
rocking motion checking for any free play in steering gear body and check for free play at
the wheel bearing or suspension components. the inner ball joint.
5. If there is free play at the inner ball joint, install
a new tie-rod. REFER to Section 211-03.
INSTALLATION, Tie-Rod]
6. Check the tie-rod end for free play. Install a
new tie-rod end if necessary.
[Steering Linkage, REMOVAL
AND INSTALLATION, Tie-Rod End]
Turning Effort Test

NOTE: To isolate the steering gear design the suspension components are serviceable.
clearance, check the right-hand linkage with the NOTE: Before carrying out this test, make sure
steering held against the right lock stop and the the steering column is serviceable.
left-hand linkage with the steering held against the
left lock stop. NOTE: Before carrying out this test, make sure
the toe adjustment and tire pressures are correct.
3. With the aid of another technician holding the
steering against the lock stop, firmly grasp the
road wheel and apply a rocking motion
checking for any free play in the steering
linkage.
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1. Park the vehicle on a dry, even surface and 2. Check for smooth movement of the yokes and
apply the parking brake. spider.
2. Remove the driver air bag module. REFER to 1. Hold the steering column yoke.
Section 501-20B.[Supplemental Restraint 2. Articulate the free yoke in a figure of eight
System, REMOVAL AND INSTALLATION, movement.
Driver Air Bag Module] 3. If the movement is not smooth or resistance is
3. Connect the air bag simulators to the felt, install a new steering column. REFER to
sub-harnesses in place of the driver air bag Section 211-04.[Steering Column, REMOVAL
module at the top of the steering column. AND INSTALLATION, Steering Column]
4. Start the engine and turn the steering wheel
from lock to lock several times until the power
steering fluid has reached normal operating
temperature.
5. Using a suitable torque wrench and socket,
check the steering wheel turning effort.
6. If the steering wheel turning effort is greater
than the specification, install a new steering
gear.
Steering Column Universal Joint

1. Detach the steering column from the steering
gear pinion.
4. Hold both yokes and twist clockwise and

counterclockwise. If movement is felt, install a
new steering column. REFER to Section 211-04.
[Steering Column, REMOVAL AND
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GENERAL PROCEDURES
Power Steering System Flushing — Vehicles With: Electro-Hydraulic Power

Steering (EHPS) (13 001 0)
1. Remove the headlight assembly. For

5. NOTE: Using a suitable blanking cap, cap the
power steering fluid reservoir.
INSTALLATION, Headlamp Assembly] Disconnect the steering gear return line
2. Raise and support the vehicle. from the power steering fluid reservoir.
3. Remove the engine undershield (if • Allow the fluid to drain into a suitable con-
equipped). tainer.
6. Place the end of the steering gear return

4. Remove the radiator splash shield. line into a suitable container.
7. Lower the vehicle until the wheels are clear
of the floor to allow the steering wheel to
be rotated from lock to lock.
8. NOTE: When filling the power steering fluid
reservoir, make sure the fluid is clean and not
agitated prior to use. The fluid should be
poured slowly into the reservoir to minimize the
possibility of aeration. The fluid level should be
checked with the fluid cold.
Fill the power steering reservoir to the MAX
mark with the appropriate fluid.
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9. CAUTION: When flushing the power 13. Install the engine undershield.
steering system, make sure that the
power steering fluid in the reservoir
does not fall below the MIN mark.
NOTE: When filling the power steering fluid
agitated prior to use. The fluid should be poured
slowly into the reservoir to minimize the possibility
of aeration. The fluid level should be checked with
the fluid cold.
Start the engine and slowly turn the
steering wheel from lock to lock.
• With the aid of another technician, add the
appropriate fluid until the system is free of
contaminated fluid.
15. Fill the reservoir to the MAX mark with the
11. Remove the blanking cap from the power appropriate fluid as necessary.
steering fluid reservoir and connect the
16. Install the headlight assembly. For
power steering gear return line.
12. Install the radiator splash shield.
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GENERAL PROCEDURES
Power Steering System Bleeding — 1.6L (Z6) (13 416 1)
6. NOTE: When bleeding the power steering

system the vacuum will decrease. Maintain a
Special Tool(s)
sufficient vacuum of 38cm-Hg, using the
Adaptor, Power Steering special tools. If the vacuum decreases by more
Bleeding than 5cm-Hg in 5 minutes, the system should
211-189 (13-016) be checked for leaks.
Using the special tools, bleed the power
steering system.
Hand Vacuum • Start the engine and slowly turn the steering
Pump/Pressure Pump wheel from lock to lock once; then turn the
416-D001 (23-036A) steering wheel to the right, just off the stop.
• Switch OFF the engine and using the
special tools apply a vacuum of 38cm-Hg.
Maintain the vacuum until the air is
evacuated from the system (minimum of
five minutes).
Bleeding
• Release the vacuum at the special tools.
1. NOTE: When filling the power steering fluid • Repeat the power steering bleeding pro-
reservoir, make sure the fluid is clean and not cedure, turning the steering wheel to the left,
agitated prior to use. The fluid should be just off the stop.
mark with the appropriate fluid. For
refer to Specifications in this section.
2. Raise the vehicle until the road wheels are
clear of the floor. Support the vehicle. For
100-02.[Jacking and Lifting, DESCRIPTION
AND OPERATION, Jacking]
3. NOTE: Make sure that the fluid in the reservoir
does not fall below the MIN mark, as air could
enter the system. 7. Remove the special tools. Fill the power
steering reservoir to the MAX mark with the
appropriate fluid if necessary. For
steering wheel from lock to lock.
additional information, refer to Specifications
4. Switch OFF the engine and examine the in this section.
hose connections, steering gear boots,
8. Start the engine, turn the steering wheel
valve body and pump for external leaks.
from lock to lock. If excessive noise is
5. Check the fluid level. Fill the power apparent, repeat the power steering
steering fluid reservoir to the MAX mark bleeding procedure.
with the appropriate fluid. For additional
information, refer to Specifications in this
section. 10. If the noise level is still unacceptable,
leave the vehicle standing overnight then
repeat the power steering system
bleeding procedure.
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GENERAL PROCEDURES
Power Steering System Bleeding — Vehicles With: Electro-Hydraulic Power

Steering (EHPS) (13 416 1)
(MI4)/2.0LDuratorq-TDCi (DW) Diesel]
Bleeding
11. Install the headlamp assembly. For
1. Remove the headlamp assembly. For additional information, refer to Section
additional information, refer to Section 417-01.[Exterior Lighting, REMOVAL AND
417-01.[Exterior Lighting, REMOVAL AND INSTALLATION, Headlamp Assembly]
3. Raise the vehicle until the road wheels are
clear of the floor. Support the vehicle.
4. NOTE: Make sure the fluid in the reservoir does
not fall below the MIN mark, as air could enter
the system.
steering wheel from lock to lock until the
air is expelled.
• With the aid of another technician, add the
appropriate fluid until the system is free of
contaminated fluid.
5. Switch OFF the engine and examine the
hose connections, steering gear boots,
valve body and pump for external leaks.
6. Check the fluid level. Fill the power
steering fluid reservoir to the MAX mark
with appropriate fluid as necessary.
7. Start the engine, turn the steering wheel
from lock to lock. If excessive noise is
apparent, refer to the steering system
diagnostic and testing. For additional
information, refer to Steering System in
this section.
8. If the noise level is still unacceptable, leave
the vehicle standing overnight then start
the engine and slowly turn the steering
wheel from lock to lock until the air is
expelled.
9. If the noise level is still unacceptable,
install a new power steering pump. For
211-02.[Power Steering, REMOVAL AND
INSTALLATION, Power Steering Pump -
1.8L Duratec-HE (MI4)/2.0L Duratec-HE
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GENERAL PROCEDURES
Power Steering System Filling — 1.6L (Z6) (13 002 0)

as necessary. For additional information,
Special Tool(s)
Adaptor, Power Steering
Bleeding
211-189 (13-016)
Hand Vacuum
Pump/Pressure Pump
416-D001 (23-036A)
Refill
Fill the power steering fluid reservoir to the
MAX mark with the appropriate fluid.
2. Using the special tools, apply a vacuum of
62cm-Hg - 75cm-Hg for 30 seconds.
3. Observe the vacuum gauge reading.

• If the vacuum decreases by more than
5cm-Hg in 5 minutes, the system should be
checked for leaks.
4. Remove the special tools. Fill the reservoir
to the MAX mark with the appropriate fluid
G418584 en 09/2004 2004.75 Focus

TO MODEL INDEX
GENERAL PROCEDURES
Power Steering System Filling — Vehicles With: Electro-Hydraulic Power Steering

(EHPS) (13 002 0)
Refill
1. Remove the headlamp assembly. For
3. NOTE: Make sure the fluid in the reservoir does
not fall below the MIN mark, as air could enter
the system.
Start the engine and fill the power steering
fluid reservoir to the MAX mark with the
appropriate fluid as necessary.
4. Slowly turn the steering wheel from lock to
lock five times.
5. Switch OFF the engine.
6. Fill the power steering fluid reservoir to the
MAX mark with the appropriate fluid as
necessary.
7. Start the engine and turn the steering
wheel from lock to lock. If excessive noise
is apparent, bleed the system. For
additional information, refer to Power
Steering System Bleeding - Vehicles With:
Electro-Hydraulic Power Steering (EHPS) in
this section.
9. Install the headlamp assembly. For
G163377 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-1 Power Steering 211-02-1
SECTION 211-02 Power Steering

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 211-02-2
Power Steering ................................................................................................................. 211-02-3

Electro-hydraulic power steering ...................................................................................... 211-02-3/4
Brushless direct current motor.......................................................................................... 211-02-5
Power steering pump ....................................................................................................... 211-02-6
Power Steering ................................................................................................................. 211-02-7
Power Steering Pump — 1.6L (Z6) ................................................................................... 211-02-8/10

Power Steering Pump — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)/ (13 434 0)
2.0L Duratorq-TDCi (DW) Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................... 211-02-11/12
Power Steering Pump to Steering Gear Pressure Line — 1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4)/2.0L Duratorq-TDCi (DW) Diesel.......................................................... 211-02-13/16
Power Steering Pump to Steering Gear Pressure Line — 1.6L (Z6).................................. 211-02-17/19
Steering Gear ................................................................................................................... 211-02-20/30
Steering Gear — 1.6L (Z6)................................................................................................ 211-02-31/42
Steering Angle Sensor ...................................................................................................... 211-02-43
Steering Gear to Power Steering Fluid Reservoir Return Line — 1.8L Duratec-HE
(MI4)/2.0L Duratec-HE (MI4)/2.0L Duratorq-TDCi (DW) Diesel......................................... 211-02-44/47
Steering Gear to Power Steering Fluid Reservoir Return Line — 1.6L (Z6)....................... 211-02-48
09/2004 2004.75 Focus

TO MODEL INDEX
SPECIFICATIONS
Item Nm lb-ft lb-in
Steering column shaft to steering gear pinion re- 28 21 -
taining bolt
Steering angle sensor retaining screws 6 - 53
Power steering lines to steering gear valve body 18 13 -
retaining screw
Power steering line to steering gear union - Vehi- 35 26 -
cles with 1.6L (Z6) engine
Steering gear mounting bolts 90 66 -
Power steering line bracket to vehicle body retain- 23 17 -
ing bolt
Power steering line bracket to steering gear re- 14 10 -
taining bolt - Vehicles with 1.6L (Z6) engine
Power steering line to power steering pump union - 33 24 -
Vehicles with 1.6L (Z6) engine
Power steering pump retaining bolts - Vehicles with 35 26 -
1.6L (Z6) engine
Power steering line to power steering pump union 30 22 -
Power steering pump retaining bolts 23 17 -
Steering gear heat shield retaining bolts 7 - 62
Steering gear heat shield retaining bolts - Vehicles 9 - 80
with 1.6L (Z6) engine
nuts - Vehicles with diesel engine
nuts - All except vehicles with diesel engine
Engine support insulator front retaining bolt 80 59 -
Front axle crossmember rear retaining bolts 275 203 -
G418586 en 09/2004 2004.75 Focus

TO MODEL INDEX
Power Steering
Electro-hydraulic power steering

Steering gear
Number
A - Pump speed (in rev/min)
B - Steer angle rate (in de-
grees/second)
C - Road speed (in km/h)
The electrohydraulic power steering system uses

an electrically-driven hydraulic pump and a
conventional rack and pinion steering system.
This ensures precise steering operation and
steering assistance with minimum energy
consumption.
Under continuous monitoring of the turning speed
of the steering wheel with the aid of the integrated
steering angle sensor, and under evaluation of the Item Part Description
vehicle speed input signal, the control module Number
uses a map to adjust the rate of the pump.
1 - Input shaft
G183842 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
2 - Steering angle sensor
3 - Valve body
4 - Cylinder
5 - Oil line
Conventional rack and pinion steering

Integrated steering angle sensor
Heat shield and cable grommet are part of the
steering gear
Integrated steering angle sensor

Number
1 - Steering angle sensor
2 - Sensor wheel
NOTE: The steering angle rotor is incorporated
into the valve body of the steering gear and cannot
be re-used.
Installed above the steering valve, the steering
angle sensor forms an integral part of the rack and
pinion steering system.
The steering angle sensor is a inductive sensor.
The steering angle sensor monitors the speed
with which the steering wheel is being turned. This
information is sent to the control module.
G183842 en 09/2004 2004.75 Focus

TO MODEL INDEX
Brushless direct current motor
consumption in the majority of phases in a drive

Item Part Description cycle.
Number Commutation in the motor is done electronically.
1 - Connector As a result, there are no brushes to wear away.
The entire system is designed for
2 - Control unit maintenance-free operation.
3 - Seal In more than 85% of all driving situations, the
4 - Bearing power steering pump operates at standby speed
and consumes less than 4A. However, pump
5 - Shaft speed can quickly increase to full rotational speed
6 - Cover if emergency steering manoeuvres require it.
The system has a continuously variable pump
7 - Rotor with magnets
rotational speed.
8 - Stator
9 - Distributor
10 - Bearing
In the electrohydraulic power steering system, a

brushless 12 volt direct current motor drives the
hydraulic pump. Higher pumping rates are only
provided when they are required for steering
manoeuvres. This avoids unnecessary energy
G183842 en 09/2004 2004.75 Focus

TO MODEL INDEX
Power steering pump
NOTE: The power steering pump must be filled

and vented as specified.
The power steering pump comprises an electric
motor, the hydraulic pump and the reservoir for
the power steering fluid.
Using a brushless motor increases reliability and
prolongs service life.
The hydraulic pump is a gear pump; a resonance
chamber incorporated into the pump body
reduces noise emissions.
A pressure limiting valve built into the pump
housing limits the hydraulic fluid pressure to a
maximum of approx. 120 bar.
There is no service interval specified for the power
steering fluid.
G183842 en 09/2004 2004.75 Focus

TO MODEL INDEX
Power Steering
REFER to: Steering System (211-00, DIAGNOSIS

AND TESTING).
G37425 en 09/2004 2004.75 Focus

TO MODEL INDEX
Power Steering Pump — 1.6L (Z6)

2. Remove the accessory drive belt. For

Special Tool(s) additional information, refer to Section 303-05.
[Accessory Drive, REMOVAL AND
Remover/Installer, Cooling INSTALLATION, Accessory Drive Belt -
Hose Clamp 1.6L (Z6)]
303-397 (24-003) 3. Remove the components in the order
table(s).
G418591 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
3 - Power steering pump to
1 - Power steering pressure steering gear pressure line
(PSP) switch electrical con- See Removal Detail
nector See Installation Detail
2 - Power steering fluid supply 4 - Power steering pump upper
hose retaining bolt
See Removal Detail
5 - Power steering pump
See Removal Detail
G418591 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-10 Power Steering 211-02-10
4. To install, reverse the removal procedure. Item 3 : Power steering pump to steering gear
5. Fill and bleed the power steering system. pressure line
1. CAUTION: Cap the power steering
211-00.[Steering System - General
pump to steering gear pressure line to
Power Steering System Filling - 1.6L (Z6)]
For additional information, refer to Section CAUTION: Cap the power steering pump
211-00.[Steering System - General connection to prevent fluid loss or dirt
Information, GENERAL PROCEDURES, ingress.
Power Steering System Bleeding - 1.6L
(Z6)] Discard the power steering pump pressure
line union washers.
Removal Details
Item 2 : Power steering fluid supply hose

1. CAUTION: Cap the power steering fluid
supply hose to prevent fluid loss or
dirt ingress.
CAUTION: Cap the power steering pump
connection to prevent fluid loss or dirt
ingress.
Using the special tool, disconnect the
power steering fluid supply hose from the
power steering pump.
• Allow the fluid to drain into a suitable con- Item 5 : Power steering pump
tainer. 1. Remove the power steering pump.
1. Loosen and detach the lower retaining bolt
from the engine block.
2. Rotate and remove the power steering
pump.
Item 3 : Power steering pump to steering gear

pressure line
NOTE: Install new washers to the power steering
pump pressure line union.
G418591 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-11 Power Steering 211-02-11
Power Steering Pump — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)/ 2.0L

Duratorq-TDCi (DW) Diesel (13 434 0)
Removal 5. Remove the radiator splash shield.

2. Disconnect the power steering pump elec-
trical connectors.
6. Remove the right-hand front fender splash

shield.
3. Remove the right-hand front wheel and tire.


pump outlet union to prevent fluid loss
or dirt ingress.
Disconnect the power steering pressure
line from the power steering pump.
• Allow the fluid to drain into a suitable con-
tainer.
G163382 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-12 Power Steering 211-02-12
8. CAUTION: Cap the power steering fluid

return line to prevent fluid loss or dirt
ingress.
Disconnect the power steering fluid return
tainer.
9. Remove the power steering pump.
Installation
2. Fill and bleed the power steering system.
G163382 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-13 Power Steering 211-02-13
Power Steering Pump to Steering Gear Pressure Line — 1.8L Duratec-HE

(MI4)/2.0L Duratec-HE (MI4)/2.0L Duratorq-TDCi(DW) Diesel

• Rotate the locking tangs counterclockwise. shield.
3. Remove the radiator splash shield. 5. Remove the components in the order
table(s).
G296227 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-14 Power Steering 211-02-14
Power Steering System Filling - Vehicles

Item Part Description With: Electro-Hydraulic Power Steering
Number (EHPS)] For additional information, refer to
Section 211-00.[Steering System - General
1 - Power steering pump union Information, GENERAL PROCEDURES,
See Removal Detail Power Steering System Bleeding - Vehicles
2 - Power steering pump to With: Electro-Hydraulic Power Steering
steering gear pressure line (EHPS)]
retaining bolt
See Removal Detail
3 - Power steering fluid lines
support bracket to vehicle
body
See Removal Detail
support bracket to steering
gear
See Removal Detail

G296227 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-15 Power Steering 211-02-15
Removal Details Item 3 : Power steering fluid lines support

bracket to vehicle body
Item 1 : Power steering pump union 1. NOTE: Note the position of the power steering
fluid lines support bracket to aid installation.
pump outlet union to prevent fluid loss Detach the power steering fluid lines
or dirt ingress. bracket from the vehicle body.
Disconnect the power steering pressure
tainer.
2. Detach the power steering line to steering

gear pressure line from the support
bracket.
1. Release the retaining clip.
2. Open the support bracket.
pressure line retaining bolt
1. Disconnect the power steering lines from
the steering gear valve body.
1. Remove the retaining bolt.
2. Rotate the clamp plate.
tainer.
G296227 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-16 Power Steering 211-02-16
Item 4 : Power steering fluid lines support Item 2 : Power steering pump to steering gear
bracket to steering gear pressure line retaining bolt
1. Detach the power steering fluid lines sup- 1. Connect the power steering lines to the
port bracket from the steering gear. steering gear valve body.
2. Install the retaining bolt.
2. Remove the power steering line to steering

gear pressure line.
Item 3 : Power steering fluid lines support

CAUTION: Make sure the power steering
fluid lines are a minimum of 15 mm from
the auxiliary drive belts.
G296227 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-17 Power Steering 211-02-17
Power Steering Pump to Steering Gear Pressure Line — 1.6L (Z6)
1. Raise and support the vehicle. For 2. Remove the engine undershield.
AND OPERATION, Jacking] For

table(s).

Number
1 - Power steering pressure and
return line support clamps
G418596 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-18 Power Steering 211-02-18

Number
Item 2 : Power steering pump pressure line
2 - Power steering pump union
pressure line union
See Removal Detail 1. CAUTION: Cap the power steering
See Installation Detail pump outlet to prevent fluid loss or dirt
ingress.
3 - Steering gear valve body
pressure line union NOTE: Note the position of the power steering
See Removal Detail pump to steering gear pressure line to aid
See Installation Detail installation.
4 - Power steering pump to Discard the steering gear pressure line

steering gear pressure line union washers.
bracket • Allow the fluid to drain into a suitable con-
See Removal Detail tainer.

(Z6)]
Item 3 : Steering gear valve body pressure line

union
1. CAUTION: Cap the steering gear inlet
to prevent fluid loss or dirt ingress.
NOTE: Note the position of the power steering
pump to steering gear pressure line to aid
installation.
Discard the steering gear pressure line
union washers.
tainer.
G418596 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-19 Power Steering 211-02-19
Item 2 : Power steering pump pressure line

union
pressure line bracket
1. Install new power steering pump pressure
1. Detach the power steering pump to steer-
line union washers.
ing gear pressure line bracket from the
steering gear.
Item 3 : Steering gear valve body pressure line

union
1. Install new steering gear pressure line un-
ion washers.
G418596 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-20 Power Steering 211-02-20
Steering Gear
Special Tool(s) Centralize the steering and lock it in posi-
tion.
204-349

205-316 (15-097A)

211-020 (13-006)
2. Detach the steering column shaft from the

General Equipment
• Discard the retaining bolt.
Securing strap
Transmission jack
All vehicles
3. Remove both front wheels and tires. For

204-04.[Wheels and Tires, REMOVAL AND
G418592 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-21 Power Steering 211-02-21
4. Remove the engine undershield (if

equipped).
• Rotate the locking tangs counterclockwise. prevent damage.
insulators.

Support the exhaust flexible pipe with a All except vehicles with diesel engine
G418592 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-22 Power Steering 211-02-22


table(s).
G418592 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-23 Power Steering 211-02-23

Number
nut
See Removal Detail
G418592 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-24 Power Steering 211-02-24

Number
4 - Engine support insulator
front retaining bolt
See Removal Detail
G418592 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-25 Power Steering 211-02-25
NOTE: Install new gaskets and nuts.

Item Part Description 11. Fill and bleed the power steering system.
Number For additional information, refer to
Section 211-00.[Steering System -
6 - Steering gear exhaust heat
shield retaining bolts
PROCEDURES, Power Steering System
7 - Steering gear exhaust heat Filling - Vehicles With: Electro-Hydraulic
shield Power Steering (EHPS)] For additional
information, refer to Section
8 - Bulkhead floor seal
9 - Steering gear retaining bolts Information, GENERAL PROCEDURES,
Power Steering System Bleeding -
10 - Steering gear Vehicles With: Electro-Hydraulic Power
Steering (EHPS)]
10. To install, reverse the removal procedure. 12. Check the toe setting and adjust as
WARNING: Install a new steering column necessary. For additional information,
shaft to steering gear pinion bolt. Failure refer to Section 204-00.[Suspension
to follow this instruction may result in System - General Information,
personal injury. SPECIFICATIONS, Specifications]
For additional information, refer to
CAUTION: Never use jointing compound Section 204-00.[Suspension System -
forward of the diesel particulate filter (if General Information, GENERAL
equipped). PROCEDURES, Front Toe Adjustment]
NOTE: Make sure the road wheels are in the
NOTE: Coat the catalytic converter studs with
anti-seize grease.
G418592 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-26 Power Steering 211-02-26
Removal Details Item 3 : Lower arm ball joint retaining nut

Item 1 : Tie-rod end retaining nut joint rotating, remove the lower arm ball
joint retaining nut on both sides.
1. CAUTION: Leave the tie-rod end • Discard the lower arm ball joint retaining
retaining nut in place to protect the nut.
ball joint stud.
Loosen the tie-rod end retaining nut on
both sides.

2. CAUTION: Protect the ball joint seal
• Discard the tie-rod end retaining nut.

G418592 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-27 Power Steering 211-02-27
3. Using a suitable ball joint separator, detach 2. NOTE: Cap the power steering lines to prevent
the lower arm from the wheel knuckle on fluid loss or dirt ingress.
both sides. NOTE: Cap the steering gear inlet and outlet to
Disconnect the pressure and return lines
from the steering gear valve body.
tainer.

1. Detach the pressure and return lines from
the steering gear.

stabilizer bar and lower arm assembly.
injury.
jack.
G418592 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-28 Power Steering 211-02-28
6. Remove the front axle crossmember re- Installation Details

taining bolts (transmission jack removed
for clarity). Item 5 : Front axle crossmember
1. Install the stabilizer bar.
• Install the stabilizer bar clamp retaining
bolts on both sides.
7. Remove the front axle crossmember.

injury.
Using the transmission jack and the
special tool, position and align the front
axle crossmember.
8. Remove the stabilizer bar. the special tool and tighten the alignment
• Remove the stabilizer bar clamp retaining pin sleeve.
bolts on both sides. 3. Raise the front axle crossmember engaging
the alignment pins into the chassis aligning
holes.
G418592 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-29 Power Steering 211-02-29
8. NOTE: Check the pressure and return lines to

steering gear valve body O-ring seals for
damage or fatigue. Install new O-ring seals if
necessary.
retaining bolts.
Connect the pressure and return lines to
clarity). 1. Rotate the clamp plate.
4. Install the front axle crossmember bracket

retaining bolts on both sides. 9. Attach the pressure and return lines to the
steering gear.
5. Remove the special tool.

6. Remove the securing strap.
G418592 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-30 Power Steering 211-02-30

injury.
ball joint retaining nut on both sides.

on both sides.
G418592 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-31 Power Steering 211-02-31
Steering Gear — 1.6L (Z6)

Special Tool(s)
Protector, Ball Joint Gaiter tion.
204-349

205-316 (15-097A)

211-020 (13-006)

General Equipment
Ball joint separator • Discard the retaining bolt.
Securing strap
Transmission jack
All vehicles

G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-32 Power Steering 211-02-32

equipped).
• Rotate the locking tangs counterclockwise. prevent damage.
insulators.

Support the exhaust flexible pipe with a All except vehicles with diesel engine
G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-33 Power Steering 211-02-33


table(s).
G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-34 Power Steering 211-02-34

Number
nut
See Removal Detail
G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-35 Power Steering 211-02-35

Number
4 - Engine support insulator See Removal Detail
front retaining bolt See Installation Detail
G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-36 Power Steering 211-02-36

Item Part Description For additional information,
Number refer to Section 211-00 .[Steering System -
6 - Steering gear exhaust heat PROCEDURES, Power Steering System
shield Filling - 1.6L (Z6)] For additional
7 - Bulkhead floor seal information, refer to Section 211-00.
[Steering System - General
8 - Steering gear retaining bolts Information, GENERAL PROCEDURES,
9 - Steering gear Power Steering System Bleeding - 1.6L
(Z6)]
10. To install, reverse the removal procedure. 12. Check the toe setting and adjust as
WARNING: Install a new steering column refer to Section 204-00.[Suspension
to steering gear pinion bolt. Failure to System - General Information,
follow this instruction may result in SPECIFICATIONS, Specifications]
personal injury. For additional information,
CAUTION: Never use jointing compound [Suspension System -
forward of the diesel particulate filter (if General Information, GENERAL
equipped). PROCEDURES, Front Toe Adjustment]
NOTE: Coat the catalytic converter studs with
anti-seize grease.
NOTE: Install new gaskets and nuts.
G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-37 Power Steering 211-02-37
Removal Details Item 3 : Lower arm ball joint retaining nut

Item 1 : Tie-rod end retaining nut joint rotating, remove the lower arm ball
joint retaining nut on both sides.
1. CAUTION: Leave the tie-rod end • Discard the lower arm ball joint retaining
retaining nut in place to protect the nut.
ball joint stud.
both sides.


G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-38 Power Steering 211-02-38
3. Using a suitable ball joint separator, detach 3. CAUTION: Cap the power steering line
the lower arm from the wheel knuckle on to prevent fluid loss or dirt ingress.
both sides.
CAUTION: Cap the power steering gear
inlet to prevent fluid loss or dirt ingress.
Disconnect the power steering pump to
steering gear pressure line from the steer-
ing gear.

1. Detach the steering gear to power steering
fluid reservoir return line from the steering
gear.
4. Discard the steering gear pressure line

union washers.
2. Detach the power steering pump to steer-

ing gear pressure line from the steering
gear.
G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-39 Power Steering 211-02-39
5. CAUTION: Cap the power steering line 9. Remove the front axle crossmember re-
to prevent fluid loss or dirt ingress. taining bolts (transmission jack removed
for clarity).
CAUTION: Cap the power steering gear
outlet to prevent fluid loss or dirt ingress.
Using the special tool, detach the steering
gear to power steering fluid reservoir re-
turn line from the steering gear.
10. Remove the front axle crossmember.

injury.
front axle crossmember, stabilizer bar and 11. Remove the stabilizer bar.
lower arm assembly to the transmission • Remove the stabilizer bar clamp retaining
jack. bolts on both sides.
G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-40 Power Steering 211-02-40
Installation Details 3. CAUTION: Make sure the front axle

retaining bolts.
1. Install the stabilizer bar.
• Install the stabilizer bar clamp retaining Install the front axle crossmember retain-
bolts on both sides. ing bolts (transmission jack removed for
clarity).
2. WARNING: Make sure the front axle 4. Install the front axle crossmember bracket
crossmember is secured to the retaining bolts on both sides.
injury.
Using the transmission jack and the
special tool, position and align the front
axle crossmember.
pin sleeve.
holes.
6. Remove the securing strap.
G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-41 Power Steering 211-02-41
8. Using the special tool, attach the steering 11. Attach the power steering pump to
gear to power steering fluid reservoir re- steering gear pressure line to the steering
turn line to the steering gear. gear.
9. Install new steering gear pressure line un- 12. Attach the steering gear to power steering
ion washers. fluid reservoir return line to the steering
gear.
10. Connect the power steering pump to

steering gear pressure line to the steering
gear valve body.
G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-42 Power Steering 211-02-42

injury.
ball joint retaining nut on both sides.

on both sides.
G418593 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-43 Power Steering 211-02-43
Steering Angle Sensor
1. NOTE: Make sure the road wheels are in the 4. Remove the components in the order
straight ahead position. indicated in the following illustration(s) and
Centralize the steering and lock it in posi- table(s).
tion.

Number
1 - Steering angle sensor elec-
trical connector
3. Remove the engine undershield (if 2 - Steering angle sensor re-
equipped). taining screws
• Rotate the locking tangs counterclockwise. 3 - Steering angle sensor
G296229 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-44 Power Steering 211-02-44
Steering Gear to Power Steering Fluid Reservoir Return Line — 1.8L Duratec-HE
(MI4)/2.0L Duratec-HE (MI4)/2.0L Duratorq-TDCi (DW) Diesel

• Rotate the locking tangs counterclockwise. shield.
3. Remove the radiator splash shield. 5. Remove the components in the order
table(s).
G296230 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-45 Power Steering 211-02-45

Item Part Description Information, GENERAL PROCEDURES,
Number Power Steering System Filling - Vehicles
With: Electro-Hydraulic Power Steering
1 - Steering gear to power (EHPS)] For additional information, refer to
steering fluid reservoir return Section 211-00.[Steering System - General
line Information, GENERAL PROCEDURES,
See Removal Detail Power Steering System Bleeding - Vehicles
2 - Steering gear to power With: Electro-Hydraulic Power Steering
steering fluid reservoir return (EHPS)]
line retaining bolt
See Removal Detail
support bracket to vehicle
body
See Removal Detail
support bracket to steering
gear
See Removal Detail

For additional information, refer to Section 211-00.
G296230 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-46 Power Steering 211-02-46
Removal Details Item 3 : Power steering fluid lines support

Item 1 : Steering gear to power steering fluid 1. NOTE: Note the position of the power steering
reservoir return line fluid lines support bracket to aid installation.
1. CAUTION: Cap the power steering fluid Detach the power steering fluid lines
return line to prevent fluid loss or dirt bracket from the vehicle body.
ingress.
Disconnect the power steering fluid return
tainer.
2. Detach the power steering fluid return line

from the support bracket.
Item 2 : Steering gear to power steering fluid

reservoir return line retaining bolt
1. Disconnect the power steering lines from
tainer.

bracket to steering gear
1. Detach the power steering fluid lines sup-
port bracket from the steering gear.
G296230 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-47 Power Steering 211-02-47
2. Remove the power steering fluid return

line.

CAUTION: Make sure the power steering
fluid lines are a minimum of 15 mm from
the auxiliary drive belts.
Item 2 : Steering gear to power steering fluid
reservoir return line retaining bolt
1. Connect the power steering lines to the
steering gear valve body.
G296230 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-48 Power Steering 211-02-48
Steering Gear to Power Steering Fluid Reservoir Return Line — 1.6L (Z6)

3. Remove the radiator splash shield.
AND OPERATION, Jacking] For additional

shield.

table(s).
G418594 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-49 Power Steering 211-02-49

Number
1 - Steering gear to power
steering fluid reservoir return
line retaining clips
See Removal Detail
2 - Steering gear to power
steering fluid reservoir return
line retaining clamps and
bolts
See Removal Detail

(Z6)]
G418594 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-02-50 Power Steering 211-02-50
Removal Details Item 2 : Steering gear to power steering fluid

reservoir return line retaining clamps and
Item 1 : Steering gear to power steering fluid bolts
reservoir return line retaining clips 1. Detach the steering gear to power steering
fluid reservoir return line from the vehicle
1. CAUTION: Cap the power steering fluid body.
reservoir outlet union to prevent fluid
NOTE: Note the position of the steering gear to
power steering fluid reservoir return line to aid
installation.
steering gear to power steering fluid res-
ervoir return line from the power steering
fluid reservoir.
2. Remove the steering gear to power

steering fluid reservoir return line.
• Detach the retaining clip from the vehicle
body.
2. CAUTION: Cap the steering gear outlet

union to prevent fluid loss or dirt
ingress.
NOTE: Note the position of the steering line to aid
installation.
steering gear to power steering fluid res-
ervoir return line from the steering gear.
G418594 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-03-1 Steering Linkage 211-03-1
SECTION 211-03 Steering Linkage

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 211-03-2
Steering Linkage ............................................................................................................... 211-03-3
Tie-Rod End.................................................................................................. (13 273 0) 211-03-4/5

Tie-Rod End — 1.6L (Z6).............................................................................. (13 273 0) 211-03-6/7
Steering Gear Boot ....................................................................................... (13 134 0) 211-03-8/9
Tie-Rod......................................................................................................... (13 263 0) 211-03-10/12
Tie-Rod — 1.6L (Z6) ..................................................................................... (13 263 0) 211-03-13
09/2004 2004.75 Focus

TO MODEL INDEX
SPECIFICATIONS
Tie-rod to steering gear 90 66 -
Tie-rod end locknut 62 46 -
G307389 en 09/2004 2004.75 Focus

TO MODEL INDEX
Steering Linkage
G17594 en 09/2004 2004.75 Focus

TO MODEL INDEX
Tie-Rod End (13 273 0)


Special Tool(s)
Separator, Ball Joint Using the special tool, detach the tie-rod
211-020 (13-006) end from the wheel knuckle.
1. Release the tie-rod end.
2. Remove and discard the tie-rod end re-
taining nut.
Removal
2. CAUTION: Leave the tie-rod end
ball joint stud.
Loosen the tie-rod end locknut and the
tie-rod end retaining nut.
1. Loosen the locknut. 4. NOTE: Make a note of the number of turns used
to remove the tie-rod end.
Remove the tie-rod end.
G307390 en 09/2004 2004.75 Focus

TO MODEL INDEX
Installation
1. NOTE: Install the tie-rod end using the same
number of turns used to remove it.
Install the tie-rod end.
2. WARNING: Install a new tie-rod end

retaining nut. Failure to follow this
injury.
Attach the tie-rod end to the wheel knuckle.
2. Tighten the locknut.

G307390 en 09/2004 2004.75 Focus

TO MODEL INDEX
Tie-Rod End — 1.6L (Z6) (13 273 0)

Special Tool(s)
Separator, Ball Joint Using the special tool, detach the tie-rod
211-020 (13-006) end from the wheel knuckle.
Removal
ball joint stud. 4. NOTE: Make a note of the number of turns used
NOTE: Use a 5 mm Allen key to prevent the ball to remove the tie-rod end.
joint stud from rotating. Remove the tie-rod end.
Loosen the tie-rod end locknut and the
tie-rod end retaining nut.
1. Loosen the locknut.
G418599 en 09/2004 2004.75 Focus

TO MODEL INDEX
Installation General Information, GENERAL

PROCEDURES, Front Toe Adjustment]
Install the tie-rod end.
2. WARNING: Install a new tie-rod end

retaining nut. Failure to follow this
injury.
NOTE: Install a new tie-rod end retaining nut
cotter pin.
Attach the tie-rod end to the wheel knuckle.
2. Install the cotter pin.
3. Tighten the locknut.

refer to Section 204-00.[Suspension System -
G418599 en 09/2004 2004.75 Focus

TO MODEL INDEX
Steering Gear Boot (13 134 0)
Installation
General Equipment
1. NOTE: Lubricate the steering gear boot.
Pincers
Install the steering gear boot.
Name Specification
Grease ESB-M1C119-B
Removal
1. Remove the tie-rod end.
2. Remove the tie-rod end locknut.
2. Using a suitable pair of pincers, install a

new steering gear boot inner clamp.
3. NOTE: Make sure the tie-rod is clean before

removing the steering gear boot.
Remove the steering gear boot.
• Discard the clamps.
3. NOTE: Make sure the steering gear boot outer

clamp is located over the recess in the tie-rod.
Using a suitable pair of pincers, install a
new steering gear boot outer clamp.
G105651 en 09/2004 2004.75 Focus

TO MODEL INDEX
4. Install the tie-rod end locknut.
5. Install the tie-rod end.
G105651 en 09/2004 2004.75 Focus

TO MODEL INDEX
Tie-Rod (13 263 0)
3. Remove and discard the steering gear boot

Special Tool(s) clamps.
Socket, Tie-Rod End,
Steering Gear
211-245 (13-025)
General Equipment
Pipe wrench
Vise jaw protectors
Pincers
Name Specification
Grease ESB-M1C119-B 4. Remove and discard the steering gear
boot.
Removal
1. Remove the steering gear. For additional
2. NOTE: Make a note of the number of turns used
to remove the tie-rod end.
Remove the tie-rod end and the tie-rod end
locknut.
1. Remove the tie-rod end.
2. Remove the tie-rod end locknut.
5. Rotate the steering gear pinion to expose

the rack.
G307391 en 09/2004 2004.75 Focus

TO MODEL INDEX
6. CAUTION: Do not clamp the steering 2. NOTE: Lubricate the steering gear boot.
rack on exposed hydraulic sealing Install a new steering gear boot.
surfaces.
CAUTION: Make sure vise jaw protectors
are used.
CAUTION: To counter the extensive
torque forces required to remove the
tie-rod, clamp the steering rack teeth in a
suitable vise. Do not clamp the steering
gear body.
Secure the steering rack in a vise and us-
ing a suitable pipe wrench remove the
tie-rod.
3. Using a suitable pair of pincers, install a

new steering gear boot inner clamp.
Installation
1. Using the special tool, install the tie-rod.
4. NOTE: Make sure the steering gear boot outer
Using a suitable pair of pincers, install a
new steering gear boot outer clamp.
G307391 en 09/2004 2004.75 Focus

TO MODEL INDEX

Install the tie-rod end and the tie tie-rod end
locknut.
6. Install the steering gear. For additional

G307391 en 09/2004 2004.75 Focus

TO MODEL INDEX
Tie-Rod — 1.6L (Z6) (13 263 0)
4. Remove the steering gear boot.

General Equipment • Discard the steering gear boot.
Vise jaw protectors
Pincers
Name Specification
Grease ESB-M1C119-B
Removal
1. Remove the steering gear. For additional
information, refer to Section 211-02.[Power
Steering, REMOVAL AND INSTALLATION,
Steering Gear - 1.6L (Z6)]
2. NOTE: Make a note of the number of turns used 5. Rotate the steering gear pinion to expose
to remove the tie-rod end. the steering gear rack.
Remove the tie-rod end and the tie-rod end

locknut.
3. Remove the steering gear boot clamps.

• Discard the steering gear boot clamps.
G418600 en 09/2004 2004.75 Focus

TO MODEL INDEX
6. CAUTION: Do not clamp the steering 2. NOTE: Lubricate the steering gear boot.
gear rack on exposed hydraulic NOTE: Install a new steering gear boot.
sealing surfaces. Install the steering gear boot.
CAUTION: Make sure vise jaw protectors
are used.
CAUTION: To counter the extensive
torque forces required to remove the
tie-rod, clamp the steering gear rack teeth
in a suitable vise. Do not clamp the
steering gear body.
Secure the steering gear rack in a vise and
remove the tie-rod.
3. NOTE: Install a new steering gear boot clamp.

Using a suitable pair of pincers, install the
steering gear boot inner clamp.
Installation
1. Install the tie-rod.
4. NOTE: Install a new steering gear boot clamp.

NOTE: Make sure the steering gear boot outer
Using a suitable pair of pincers, install the
steering gear boot outer clamp.
G418600 en 09/2004 2004.75 Focus

TO MODEL INDEX

Install the tie-rod end locknut and the
tie-rod end.
6. Install the steering gear. For additional

information, refer to Section 211-02.[Power
Steering, REMOVAL AND INSTALLATION,
Steering Gear - 1.6L (Z6)]
G418600 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-04-1 Steering Column 211-04-1
SECTION 211-04 Steering Column

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 211-04-2
Steering Column ............................................................................................................... 211-04-3
Steering Wheel ............................................................................................. (13 524 0) 211-04-4/5

Steering Column ............................................................................................................... 211-04-6/8
Steering Column ............................................................................................................... 211-04-9
09/2004 2004.75 Focus

TO MODEL INDEX
SPECIFICATIONS
Item Nm lb-ft lb-in
Steering wheel retaining bolt 48 35 -
Steering column shaft to steering gear pinion re- 28 21 -
taining bolt
Steering column retaining bolts 25 18 -
G164691 en 09/2004 2004.75 Focus

TO MODEL INDEX
Steering Column
G17604 en 09/2004 2004.75 Focus

TO MODEL INDEX
Steering Wheel (13 524 0)

Removal 4. Disconnect the steering wheel electrical

connector (vehicles with speed control
1. Remove the driver air bag module.
shown).
tion.
5. Remove the steering wheel retaining bolt.
3. CAUTION: Make sure the clockspring

rotor is not allowed to rotate. Secure in
the central position with a piece of
suitable tape.
Secure the clockspring rotor to the clock-
spring outer.
6. CAUTION: Care must be taken not to

damage the clockspring pins.
Remove the steering wheel.
• Feed the driver air bag wiring harness
through the steering wheel.
G415564 en 09/2004 2004.75 Focus

TO MODEL INDEX
Installation
1. NOTE: When the clockspring is centralized,
part of the flat flexible cable will be visible and is
U-shaped.
Look for the U-shaped part of the flat flexi-
ble cable to confirm the clockspring is
centralized.
G415564 en 09/2004 2004.75 Focus

TO MODEL INDEX
Steering Column
1. Remove the driver air bag module. For 2. Remove the components in the order
501-20B.[Supplemental Restraint System, table(s).
REMOVAL AND INSTALLATION, Driver Air
Bag Module]

Number
5 - Steering column wiring
1 - Instrument panel lower outer harness
trim panel See Removal Detail
See Removal Detail
6 - Steering column shaft to
2 - Audio control switch (if steering gear pinion retaining
equipped) bolt
3 - Steering column upper 7 - Steering column retaining
shroud bolts
shroud
See Removal Detail
G401832 en 09/2004 2004.75 Focus

TO MODEL INDEX
3. To install, reverse the removal procedure. Item 3 : Steering column upper shroud
1. NOTE: Turn the steering wheel to gain access
Removal Details to the steering column upper shroud retaining
clips.
Item 1 : Instrument panel lower outer trim Detach the steering column upper shroud
panel from the steering column lower shroud
1. Detach the diagnostic link connector (DLC) (steering wheel shown removed for clarity).
from the instrument panel lower trim panel.
retaining clips (one each side)
Item 2 : Audio control switch (if equipped)

1. Using a thin bladed screwdriver, release
the locking tang.
tion.
2. Disconnect the electrical connector.
Item 4 : Steering column lower shroud

1. Release the steering column locking lever
to aid the removal of the steering column
lower shroud.
G401832 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 5 : Steering column wiring harness

1. Detach the wiring harness from the steer-
ing column.
Item 7 : Steering column retaining bolts

WARNING: Install new steering column
retaining bolts. Failure to follow this
Item 6 : Steering column shaft to steering gear
pinion retaining bolt
1. Feed the audio control switch wiring
harness through the steering column lower
shroud.
G401832 en 09/2004 2004.75 Focus

TO MODEL INDEX
Steering Column

table(s).

Number
3 - Multifunction switch / clock-
1 - Steering wheel retaining bolt spring carrier
2 - Steering wheel 4 - Ignition switch
See Assembly Detail
G296236 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item Part Description 2. Disconnect the electrical connectors.

Number • Carefully feed the driver air bag module
wiring harness through the steering wheel.
5 - Passive anti-theft system
(PATS) transceiver Item 6 : Ignition lock cylinder
1. Remove the ignition lock cylinder.
6 - Ignition lock cylinder
See Disassembly Detail 1. Insert the ignition key and turn the ignition
switch to position 1.
2. To assemble, reverse the disassembly 2. Using a suitable tool, depress the locking
procedure. tang.
Disassembly Details

1. CAUTION: Make sure the clockspring is
not allowed to rotate. Secure in the
central position with a piece of suitable
tape.
Secure the clockspring rotor to the clock-
spring outer.
Assembly Details

1. Connect the electrical connectors.
• Carefully feed the driver air bag module
wiring harness through the steering wheel.
2. Remove the tape securing the clockspring.
G296236 en 09/2004 2004.75 Focus

TO MODEL INDEX
211-05-1 Steering Column Switches 211-05-1
SECTION 211-05 Steering Column Switches

CONTENTS PAGE
Ignition Switch................................................................................................................... 211-05-2
09/2004 2004.75 Focus

TO MODEL INDEX
Ignition Switch
1. Disconnect the battery ground cable. For 2. Turn the ignition key to position 1.
414-01.[Battery, Mounting and Cables,
table(s).
Disconnect]
G307409 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item Part Description 2. Disconnect the audio control electrical

Number connector.
1 - Remote audio control switch

(if equipped)
See Removal Detail
2 - Steering column upper
shroud
See Removal Detail
shroud
See Removal Detail
4 - Ignition switch electrical
connector
5 - Ignition switch
Item 2 : Steering column upper shroud
See Removal Detail
See Installation Detail 1. NOTE: Turn the steering wheel to access the
steering column upper shroud retaining clips.
All vehicles Detach the steering column upper shroud
2. To install, reverse the removal procedure. from the steering column lower shroud
Vehicles with global closing (steering wheel shown removed for clarity).
3. Initialize the door window motors. For • Using a thin bladed screwdriver, release the
additional information, refer to Section 501-11. retaining clips (one each side).
[Glass, Frames and Mechanisms,
GENERAL PROCEDURES, Door Window
Removal Details
Item 1 : Remote audio control switch (if

equipped)
1. Using a thin bladed screwdriver, release
the locking tang.

1. To aid the removal of the steering column
lower shroud, release the steering column
locking lever.
Item 5 : Ignition switch
CAUTION: Do not turn the ignition switch
lock cylinder from position 1 when the
ignition switch has been removed.
G307409 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 5 : Ignition switch

1. CAUTION: Do not turn the ignition
switch lock cylinder from position 1
when the ignition switch has been
removed.
Check and turn the ignition switch to
position 1.
G307409 en 09/2004 2004.75 Focus

TO MODEL INDEX
Group
Powertrain 3
PAGE 1 OF 2 PAGE
SECTION TITLE
Engine
Engine System - General Information.................................................................................... 303-00-1
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)........................................................ 303-01A-1
Engine - 2.0L Duratorq-TDCi (DW) Diesel............................................................................. 303-01B-1
Engine - 1.6L (Z6) ................................................................................................................. 303-01C-1
Engine Cooling - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)........................................... 303-03A-1
Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel................................................................ 303-03B-1
Engine Cooling - 1.6L (Z6) .................................................................................................... 303-03C-1
Fuel Charging and Controls - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) ....................... 303-04A-1
Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel............................................. 303-04B-1
Fuel Charging and Controls - Turbocharger .......................................................................... 303-04C-1
Fuel Charging and Controls - 1.6L (Z6) ................................................................................. 303-04D-1
Accessory Drive .................................................................................................................... 303-05-1
Starting System..................................................................................................................... 303-06-1
Engine Ignition - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) ........................................... 303-07A-1
Glow Plug System - 2.0L Duratorq-TDCi (DW) Diesel................................................... ........ 303-07B-1
Engine Ignition - 1.6L (Z6) ..................................................................................................... 303-07C-1
Engine Emission Control - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) ............................ 303-08A-1
Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel ................................................. 303-08B-1
Engine Emission Control - 1.6L (Z6)...................................................................................... 303-08C-1
Intake Air Distribution and Filtering........................................................................................ 303-12-1
Evaporative Emissions .......................................................................................................... 303-13-1
Electronic Engine Controls .................................................................................................... 303-14-1
Automatic Transmission/Transaxle
Automatic Transmission/Transaxle - Vehicles With: 4-Speed Automatic Transaxle (4F27E) . 307-01-1
Transmission/Transaxle Cooling - Vehicles With: 4-Speed Automatic Transaxle (4F27E)..... 307-02-1
Automatic Transmission/Transaxle External Controls - Vehicles With: 4-Speed Automatic 307-05-1
Transaxle (4F27E)..............................................................................................................
Manual Transmission/Transaxle, Clutch and Transfer Case
Manual Transmission/Transaxle and Clutch - General Information........................................ 308-00-1
Clutch - Vehicles With: 5-Speed Manual Transaxle (MTX-75) ............................................... 308-01A-1
09/2004 2004.75 Focus

TO MODEL INDEX
Group
Powertrain 3
PAGE 2 OF 2 PAGE
SECTION TITLE
Clutch - Vehicles With: 6-Speed Manual Transaxle (MMT6).................................................. 308-01B-1

Clutch - Vehicles With: 5-Speed Manual Transaxle (F35M-R)............................................... 308-01C-1
Clutch Controls - Vehicles With: 5-Speed Manual Transaxle (MTX-75)................................. 308-02A-1
Clutch Controls - Vehicles With: 6-Speed Manual Transaxle (MMT6) ................................... 308-02B-1
Clutch Controls - Vehicles With: 5-Speed Manual Transaxle (F35M-R)................................. 308-02C-1
Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transaxle (MTX-75) ....... 308-03A-1
Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transaxle (MMT6).......... 308-03B-1
Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transaxle (F35M-R) ....... 308-03C-1
Manual Transmission/Transaxle External Controls - Vehicles With: 5-Speed Manual 308-06A-1
Transaxle (MTX-75)............................................................................................................
Manual Transmission/Transaxle External Controls - Vehicles With: 6-Speed Manual 308-06B-1
Transaxle (MMT6) ..............................................................................................................
Exhaust System
Exhaust System .................................................................................................................... 309-00-1
Fuel System
Fuel System - General Information........................................................................................ 310-00-1
Fuel Tank and Lines.............................................................................................................. 310-01-1
Acceleration Control.............................................................................................................. 310-02-1
Speed Control ....................................................................................................................... 310-03-1
09/2004 2004.75 Focus

TO MODEL INDEX
303-00-1 Engine System - General Information 303-00-1
SECTION 303-00 Engine System - General

Information
CONTENTS PAGE
Engine .............................................................................................................................. 303-00-2/7

Engine - Oil Leaks............................................................................................................ 303-00-8
Ultraviolet (UV) Testing .................................................................................................... 303-00-8
Measure the compression pressure ................................................................................. 303-00-9
Measure the compression pressure (Engine - 1.6L Duratec-16V, Engine - 1.6L Du-
ratec-16V Ti-VCT) ......................................................................................................... 303-00-9/11
Measure the compression pressure (Engine - 1.8L/2.0L Duratec-HE).............................. 303-00-12/13
Measure the compression pressure (Engine - 1.6L Duratorq-TDCi (DV) Diesel) .............. 303-00-14/16
Measure the compression pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel) ............. 303-00-17/19
Measure the oil pressure (21 113 0)................................................................................. 303-00-20
Measure the oil pressure (Engine - 1.6L Duratec-16V, Engine - 1.6L Duratec-16V Ti-VCT)
...................................................................................................................................... 303-00-20
Measure the oil pressure (Engine - 1.8L/2.0L Duratec-HE) .............................................. 303-00-21/22
Measure the oil pressure (Engine - 1.6L Duratorq-TDCi (DV) Diesel)............................... 303-00-23
Measure the oil pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel).............................. 303-00-24
Valve train analysis - static (engine off) ............................................................................ 303-00-25
GENERAL PROCEDURES
Camshaft Bearing Journal Diameter ................................................................................. 303-00-26

Camshaft Bearing Journal Clearance................................................................................ 303-00-27
Camshaft End Play ........................................................................................................... 303-00-28
Camshaft Surface Inspection ............................................................................................ 303-00-29
Camshaft Lobe Lift............................................................................................................ 303-00-30
Crankshaft Main Bearing Journal Diameter....................................................................... 303-00-31
Crankshaft End Play ......................................................................................................... 303-00-32
Cylinder Bore Taper .......................................................................................................... 303-00-33
Piston Inspection............................................................................................................... 303-00-34
Piston Pin to Bore Diameter .............................................................................................. 303-00-35
Piston Diameter ................................................................................................................ 303-00-36
Piston Ring End Gap......................................................................................................... 303-00-37
Piston Ring-to-Groove Clearance...................................................................................... 303-00-38
Piston Pin Diameter .......................................................................................................... 303-00-39
Connecting Rod Large End Bore ...................................................................................... 303-00-40
Valve Stem Diameter ........................................................................................................ 303-00-41
Flywheel Inspection .......................................................................................................... 303-00-42
Cylinder Head Distortion ................................................................................................... 303-00-43
Cylinder Block Distortion ................................................................................................... 303-00-44
Exhaust Manifold Cleaning and Inspection........................................................................ 303-00-45
Bearing Inspection ............................................................................................................ 303-00-46
09/2004 2004.75 Focus

TO MODEL INDEX
Engine
1. Verify the customer concern by operating the

system
Special Tool(s)
Compression Test Adapter 3. If an obvious cause for an observed or
303-1052 reported concern is found, correct the cause
step.
Compression Test Adapter
303-1056
– Coolant leaks – Fuse(s)
– Oil leaks – Loose or corroded
Name Specification – Fuel system leaks connector(s)
– Visibly damaged or – Control module
Adhesive - Loctite 243 WSK-M2G349-A7
worn parts – Damaged or worn
– Loose or missing switch(es)
nuts or bolts
Symptom Chart
• Loss of oil • Oil leaks on components that are • CHECK for evidence of oil leaks
either coated in oil themselves or on components. Use an ultra-
on components local to them. violet (UV) leak tester if an oil
leak is not evident. INSTALL new
gaskets or components as re-
quired.
• Internal or external leak at the oil • CHECK the coolant expansion
cooler. tank for a film of oil on the cool-
ant surface. INSTALL a new oil
cooler or oil cooler gasket.
• Leak at the crankshaft seal. • INSTALL a new crankshaft seal.
• Leaks from oil carrying compo- • CHECK for cracks in oil-carrying
nents or basic engine. components of the basic engine
by means of a UV leak test.
INSTALL new components or
seals as necessary.
• Oil consumption • Use of the wrong type of engine • DETERMINE the last type of
oil. engine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
G296460 en 09/2004 2004.75 Focus

TO MODEL INDEX

• Faulty positive crankcase • CHECK if the PCV system is
ventilation (PCV) system. operating correctly and repair as
• Hoses or ventilation or breather necessary. Engine - 1.6L Du-
valves are blocked. This causes ratec-16V - Engine - 1.8L/2.0L
excessive pressure in the Duratec-HE - REFER to Section
crankcase which causes more oil 303-08A.[Engine Emission Con-
to enter the combustion trol - 1.8L Duratec-HE (MI4)/2.0L
chamber. Duratec-HE (MI4), DIAGNOSIS
• PCV oil separator is faulty and AND TESTING, Engine Emis-
engine oil can enter the com- sion Control] Engine - 1.6L Du-
bustion chamber through the ratorq-TDCi (DV) Diesel - En-
intake manifold. gine - 2.0L Duratorq-TDCi (DW)
Diesel -
• Turbocharger seals (only diesel • INSTALL a new turbocharger.
engine).
• Damaged gaskets or mating • CHECK the gaskets and mating
surfaces. surfaces for damage.
• Cylinder head gasket is • Remove the cylinder head.
damaged or mating face are CHECK the mating faces,
warped. cylinder head gasket and the
• Valve stem seals are worn and evenness of the cylinder head
engine oil can enter the com- and engine block mating faces.
bustion chamber between the • INSTALL new valve stem seals.
valve stem and the valve stem Engine - 1.6L Duratec-16V -
guide. Engine - 1.6L Duratec-16V
Ti-VCT Engine - 1.8L/2.0L Du-
ratec-HE - REFER to Section
303-01A.[Engine - 1.8L Du-
(MI4), IN-VEHICLE REPAIR,
Valve Seals] Engine - 1.6L Du-
ratorq-TDCi (DV) Diesel - En-
gine - 2.0L Duratorq-TDCi (DW)
Diesel -
• Piston ring or cylinder liner wear. • INSTALL new components as
necessary.
• Damaged cylinder liners or • CHECK the running surfaces
excessive clearance of engine and clearances of the individual
components. engine components. INSTALL
• Pistons new components as necessary.
• Piston rings (clearance in groove INSTALL a new cylinder block if
and end gap) necessary.
• Cylinder liners • Check the pistons and piston
rings. REFER to Piston Inspec-
tion in this section.
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• Coolant consumption • Cooling system components. • Check the cooling system com-
ponents. Engine - 1.6L Du-
ratec-16V - Engine - 1.6L Du-
ratec-16V Ti-VCT - Engine -
1.8L/2.0L Duratec-HE - REFER
to Section 303-03A.[Engine
Cooling - 1.8L Duratec-HE
(MI4)/2.0L Duratec-HE (MI4),
Engine Cooling] Engine - 1.6L
Duratorq-TDCi (DV) Diesel -
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Oil cooler. • INSTALL a new oil cooler.
• Damaged gaskets or warped • CHECK the cylinder head gasket
mating faces. for damage. CHECK the cylinder
head for distortion.
• Cracks or fractures in engine • DETERMINE the damaged en-
components surrounded by gine component(s) and install
coolant, such as cylinder liners new component(s) as neces-
and cylinder head combustion sary.
chamber.
• Engine will not crank • Battery or cables. • CHECK the battery, bracket and
cables.REFER to Section 414-01.
[Battery, Mounting and
Cables, DIAGNOSIS AND
TESTING, Battery]
• Starter motor or cables. • CHECK the starting system.
[Starting System,
Starting System]
• Engine cranks but will not start. • Fuel tank is empty. • CHECK the fuel level.
• Water in fuel (only diesel en- • Drain the water from the fuel
gine). system.
• Fuel filter blocked. • INSTALL a new fuel filter.
• Engine intake air system. • CHECK the intake air system.
[Intake Air Distribution
and Filtering, DIAGNOSIS AND
TESTING, Intake Air Distribution
and Filtering]
• Glow plug faulty (only diesel en- • CHECK the glow plugs.
gine). INSTALL new glow plugs as
necessary.
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• Engine management system. • CHECK the engine management
system. REFER to Section
Controls]
• Ignition system (only petrol en- • CHECK the ignition system. En-
gines). gine - 1.6L Duratec-16V - En-
gine - 1.8L/2.0L Duratec-HE -
REFER to Section 303-07A.
[Engine Ignition - 1.8L
Duratec-HE (MI4)/2.0L Du-
ratec-HE (MI4), DIAGNOSIS
AND TESTING, Engine Ignition]
• Incorrect valve timing. • CHECK and adjust the valve
timing. Engine - 1.6L Du-
to Section 303-01A.[Engine -
1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4), IN-VEHICLE
REPAIR, Timing Chain] Engine -
1.6L Duratorq-TDCi (DV) Diesel
- Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Broken or damaged timing • CHECK the timing belt/timing
belt/timing chain or pul- chain and sprockets/pulleys.
ley/sprocket. INSTALL new components as
necessary. Engine - 1.6L Du-
(DW) Diesel -
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• Very poor power output or fuel • Fuel system. • CHECK the fuel system. Engine
consumption too high or engine - 1.6L Duratec-16V - Engine -
running rough 1.6L Duratec-16V Ti-VCT - En-
[Fuel Charging and
Controls - 1.8L Duratec-HE
(MI4)/2.0L Duratec-HE (MI4),
Fuel Charging and Controls]
(DV) Diesel - Engine - 2.0L
Duratorq-TDCi (DW) Diesel -
• Engine intake air system. • CHECK the intake air system.
[Intake Air Distribution
and Filtering, DIAGNOSIS AND
TESTING, Intake Air Distribution
and Filtering]
• Exhaust system blocked. • CHECK the exhaust system.
• Engine management system. • CHECK the engine management
system. REFER to Sect o i n303-14.
[Electronic Engine Con-
Controls]
• Fault in ignition system (only • CHECK the ignition system. En-
petrol engines). gine - 1.6L Duratec-16V - En-
[Engine Ignition - 1.8L
ratec-HE (MI4), DIAGNOSIS
AND TESTING, Engine Ignition]
• Turbocharger (only diesel en- • CHECK the turbocharger.
gine).
• Incorrect valve timing. Timing • CHECK and adjust valve timing.
belt/timing sprocket or pul- INSTALL new components as
ley/sprocket damaged. necessary. Engine - 1.6L Du-
1.8L/2.0L Duratec-HE -REFER
(DW) Diesel -
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• Ignition timing incorrect (only • CHECK the electronic engine
petrol engines). controls. REFER to Section
Controls]
• Noisy running • Engine auxiliary components • CHECK engine auxiliary com-
loose or damaged. ponents for damage or loose-
ness. CHECK and adjust valve
timing. INSTALL new compo-
nents as necessary. Engine -
1.6L Duratec-16V - Engine -
1.6L Duratec-16V Ti-VCT - En-
[Engine - 1.8L Du-
Timing Chain] Engine - 1.6L
(DW) Diesel -
• Noisy running, misfiring, back- • Incorrect fuel • DETERMINE which type of fuel
firing or knocking was last put in the tank (note the
country specific fuel specifica-
tions).
• Water in fuel or fuel contami- • CHECK the fuel system for water
nated. or other contamination.
• Valve timing incorrect, timing • CHECK and adjust valve timing.
belt/chain or pulley/sprocket INSTALL new components as
damaged. necessary. Engine - 1.6L Du-
(DW) Diesel -
• Noisy running or valve train • Valve clearance too large due to • INSTALL new hydraulic lash
noise faulty valve tappets or worn adjusters or adjust the valve
valve train components. clearance. Engine - 1.6L Du-
1.8L/2.0L Duratec-HE - Engine -
(DW) Diesel -
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• Timing belt or timing chain • INSTALL a new timing belt or
damaged. timing chain. Engine - 1.6L Du-
(DW) Diesel -
• Timing belt or timing chain in- • CHECK the timing belt tension.
correctly tensioned. INSTALL a new timing belt or
timing chain as necessary. En-
gine - 1.6L Duratec-16V - En-
gine - 1.6L Duratec-16V Ti-VCT -
Engine - 1.8L/2.0L Duratec-HE -
[Engine - 1.8L Du-
Timing Chain] Engine - 1.6L
(DW) Diesel -
• Noisy running or engine noise • Engine components • CHECK the engine components
– Pistons for wear or damage. Make sure
– Piston rings all components are within speci-
– Connecting rod big end, main fication. INSTALL new compo-
bearing or thrust bearing nents as necessary. Engine -
journals 1.6L Duratec-16V - Engine -
– Connecting rods bent or 1.6L Duratec-16V Ti-VCT - En-
damaged. gine - 1.8L/2.0L Duratec-HE -
(DV) Diesel - Engine - 2.0L
Duratorq-TDCi (DW) Diesel -
through the oil filler neck into the engine and
install the oil filler cap.
Engine - Oil Leaks
WARNING: Vehicles with manual
NOTE: Before installing new gaskets or oil seals, transaxle, shift the transaxle into Neutral.
make sure that the fault is clearly established. Failure to follow this instruction may
If the oil leak cannot be identified clearly by a result in personal injury.
visual inspection, carry out an ultraviolet (UV) test: 3. Start the engine and let it run for about five
minutes.
4. Switch off the engine.
Ultraviolet (UV) Testing NOTE: If no leak can be found, road test the
1. Clean the engine and transmission with a vehicle under various loads and check the engine
suitable cleaning fluid. for leaks again.
2. Pour the UV-test fluid in accordance with the
quantity specified by the manufacturer
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5. Check the engine for oil leaks using a suitable Measure the compression pressure (Engine -
UV lamp. 1.6L Duratec-16V, Engine - 1.6L Duratec-16V
6. Rectify any leaks found and check the engine Ti-VCT)
for oil leaks.
Measure the compression pressure

NOTE: The powertrain control module (PCM)
receives an error message when the fuel pump
relay is removed or electrical components are
disconnected. This error message must be
deleted from the fault memory using worldwide
diagnostic system (WDS) after completing the
compression test.
NOTE: Valve clearance must be set correctly
before performing a compression test. Make sure
the engine is at the normal operating temperature.
NOTE: The varying design of compression
checking devices and fluctuating starter motor
speeds normally only allows for a comparison to
be made of the compression pressures in all
cylinders.
1. Remove the central junction box (CJB) cover.
2. Open the CJB and remove the fuel pump

relay.
NOTE: The engine will start, run for a few seconds
and then stop.
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3. Start the engine. 6. Remove the spark plugs.
NOTE: Operate the starter motor with wide open

4. Disconnect the electronic ignition (EI) coil throttle until the reading on the compression tester
connector from the EI coil. stops rising.
7. Carry out the measurement in accordance
with the instructions supplied with the
measuring device on every cylinder using a
suitable compression pressure recorder with a
suitable adapter.
NOTE: Twist the spark plug connectors slightly

before disconnecting them. Pull on the connector
and not on the cable.
5. Remove the spark plug connectors.
8. Install the spark plugs.
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9. Install the spark plug connectors. 11. Install the fuel pump relay and close the CJB .
10. Connect the EI coil connector to the EI coil.
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12. Install the CJB cover. 3. Start the engine.

13. Using worldwide diagnostic system (WDS), 4. Remove the cowl panel grille.
clear the fault codes from the powertrain REFER to Section 501-02.
control modul (PCM). [Front End Body Panels,
REMOVAL AND INSTALLATION, Cowl Panel
Grille]
Measure the compression pressure (Engine -
1.8L/2.0L Duratec-HE)
5. Remove the oil filler pipe.

• Release the securing clip and rotate the oil
filler pipe counterclockwise.
6. Remove the engine cover.

1. Remove the central junction box (CJB) cover.
2. Open the CJB and remove the fuel pump

relay.
NOTE: The engine will start, run for a few seconds
and then stop.
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7. Disconnect the ignition coil-on-plug electrical 10. Carry out the measurement in accordance
connectors. with the instructions supplied with the
measuring device on every cylinder using a
suitable compression pressure recorder with a
suitable adapter.
8. Remove the ignition coil-on-plug.
11. Using the special tool, install the spark plugs.
9. Using the special tool, remove the spark

plugs.
12. Install the ignition coil-on-plug.
NOTE: Operate the starter motor with wide open

throttle until the pointer on the measuring device
stops rising.
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13. Connect the ignition coil-on-plug electrical 17. Install the fuel pump relay and close the CJB.
connectors.
14. Install the engine cover.
15. Install the oil filler pipe. 18. Install the CJB cover.
• Rotate the oil filler pipe approximately 90 19. Reset the PCM fault memory.
degrees clockwise until the securing clip
snaps into position.
16. Install the cowl panel grille. REFER to Section Measure the compression pressure (Engine -
501-02.[Front End Body Panels, REMOVAL 1.6L Duratorq-TDCi (DV) Diesel)
AND INSTALLATION, Cowl Panel Grille]
WARNING: Do not smoke or carry lighted
tobacco or open flame of any type when
working on or near any fuel related
components. Highly flammable mixtures
are always present and can ignite. Failure
to follow these instructions may result in
personal injury.
WARNING: Do not carry out any repairs to
the fuel injection system without
checking that the fuel pressure has
dropped to zero and that the fuel
temperature has either reached ambient
temperature or is below 30° C, whichever
is the greater. Failure to follow these
1. Using datalogger in world wide diagnostic
system (WDS), check that the fuel pressure
has dropped to zero and that the fuel
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temperature or is below 30° C, whichever is 5. Remove the glow plug relay.

the greater. 6. Lower the vehicle.
2. Raise and support the vehicle. 7. Remove the cowl panel grille.
REFER to Section 501-02.[Front End Body
Panels, REMOVAL AND INSTALLATION,
Cowl Panel Grille]
4. Remove the radiator undershield.
CAUTION: Do not disconnect the fuel

injection pump electrical connectors and
crank the engine.
9. Disconnect the fuel injector electrical
connectors.
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10. Detach the exhaust gas recirculation (EGR) 14. Carry out the measurement on all cylinders,
cooler (if equipped) and position it to one side. following the measuring equipment
manufacturer's instructions.
15. Detach the compression tester and the special
tool.
11. Remove the glow plug power supply.
16. Install the glow plugs.
12. Remove the glow plugs.
17. Install the glow plug power supply.
13. Install the special tool and a suitable

compression tester into the glow plug bore.
NOTE: Crank the engine with the starter motor
until the reading on the compression tester stops
rising.
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18. Attach the EGR cooler (if equipped). 23. Install the glow plug relay.
19. Connect the fuel injector electrical connectors.

24. Install the radiator undershield.
20. Install the engine upper cover.

21. Install the cowl panel grille. REFER to Section
501-02.[Front End Body Panels, REMOVAL 25. Install the engine undershield.
AND INSTALLATION, Cowl Panel Grille] 26. Lower the vehicle.
22. Raise and support the vehicle. 27. Reset the PCM fault memory.
Measure the compression pressure (Engine -

2.0L Duratorq-TDCi (DW) Diesel)
components. Highly flammable vapors
personal injury.
the fuel injection system without
checking that the fuel pressure has
dropped to zero and that the fuel
temperature or is below 30° C, whichever
is the greater. Failure to follow these
1. Using datalogger in world wide diagnostic
system (WDS), check that the fuel pressure
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has dropped to zero and that the fuel 5. Remove the glow plug relay.
temperature has either reached ambient 6. Lower the vehicle.
temperature or is below 30° C, whichever is
7. Remove the cowl panel grille. REFER to
the greater.
Section 501-02.[Front End Body Panels,
2. Raise and support the vehicle. REMOVAL AND INSTALLATION, Cowl Panel
Grille]
3. Remove the engine undershield. 8. Remove the engine cover.

CAUTION: Do not disconnect the fuel
injection pump electrical connectors and
crank the engine.
9. Disconnect the fuel injector electrical
connectors.
10. Remove the exhaust gas recirculation (EGR)
cooler.
11. Remove the EGR valve.
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12. Remove the glow plug power supply. 17. Install the glow plugs.
13. Remove the glow plugs. 18. Install the glow plug power supply.
19. Install the EGR valve.
20. Install the EGR cooler.
14. Install the special tool and a suitable

compression tester into the glow plug bore.
NOTE: Crank the engine with the starter motor 21. Connect the fuel injector electrical connectors.
until the reading on the compression tester stops
rising.
15. Carry out the measurement on all cylinders,
following the measuring equipment
manufacturer's instructions.
16. Detach the compression tester and the special
tool.
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22. Install the engine cover. 27. Install the engine undershield.
23. Install the cowl panel grille. REFER to Section 28. Lower the vehicle.
501-02.[Front End Body Panels, REMOVAL 29. Reset the PCM fault memory.
Measure the oil pressure (21 113 0)
The oil pressure depends on various factors
(engine speed, oil temperature, oil viscosity,
amount of oil filter contamination etc.).
Measure the oil pressure (Engine - 1.6L

Duratec-16V, Engine - 1.6L Duratec-16V
Ti-VCT)
NOTE: The oil pressure depends on various
25. Install the glow plug relay. factors (engine speed, oil temperature, oil
viscosity, extent of oil filter contamination).
NOTE: Measure the oil pressure at the specified
engine speed.
26. Install the radiator undershield.
2. Disconnect the oil pressure switch electrical

connector from the oil pressure switch.
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3. Remove the oil pressure switch. 8. Detach the oil pressure gauge and connector
from the oil pressure switch bore.
9. Coat the oil pressure switch with .
4. Attach the oil pressure gauge with the oil

pressure gauge connector to the oil pressure 10. Install the oil pressure switch.
switch bore, and position it to allow reading
from above.
11. Connect the oil pressure switch electrical

connector to the oil pressure switch.
NOTE: Measure the oil pressure at an oil
temperature of 80°C.
NOTE: Oil pressure at 2000 rpm: 2.5 bar. Measure the oil pressure (Engine - 1.8L/2.0L
6. Measure the oil pressure. Duratec-HE)
7. Raise and support the vehicle. 1. Raise and support the vehicle.
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2. Remove the engine undershield. 5. Attach the oil pressure gauge with the oil
pressure gauge connector to the oil pressure
switch bore, and position it to allow reading
from above.


engine speed. Measure the oil pressure at an oil
temperature of 100° C.
NOTE: Oil pressure at 1500 rpm: 1.3 - 2.7 bar.
NOTE: Oil pressure at 3000 rpm: 2.3 - 5.2 bar.
7. Measure the oil pressure.
4. Remove the oil pressure switch.
9. Detach the oil pressure gauge and connector

from the oil pressure switch bore.
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11. Install the oil pressure switch. 1. Disconnect the oil pressure switch electrical
12. Connect the oil pressure switch electrical 2. Remove the oil pressure switch.

13. Install the engine undershield. pressure gauge connector.
14. Lower the vehicle. NOTE: Measure the oil pressure at the specified
Measure the oil pressure (Engine - 1.6L NOTE: Measure the oil pressure at idle speed and
Duratorq-TDCi (DV) Diesel) at 2000 rpm.
4. Check the oil pressure.
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5. Detach the oil pressure gauge and the oil 2. Remove the engine under shield.
pressure gauge connector.

7. Install the oil pressure switch.
4. Remove the oil pressure switch.

8. Connect the oil pressure switch electrical
Measure the oil pressure (Engine - 2.0L

Duratorq-TDCi (DW) Diesel)

NOTE: Measure the oil pressure at 2000 rpm and
at 4000 rpm.
NOTE: Oil pressure at 2000 rpm: 2.0 bar.
NOTE: Oil pressure at 4000 rpm: 4.0 bar.
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6. Check the oil pressure. 10. Connect the oil pressure switch electrical
7. Detach the oil pressure gauge and the oil

8. Coat the oil pressure switch with . 11. Install the engine under shield.
Valve train analysis - static (engine off)

Remove the valve cover.
Check all valve train components for damage and
wear. Ensure that only original components are
installed and that all bolts and nuts have been
tightened to the correct tightening torque.
9. Install the oil pressure switch.
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GENERAL PROCEDURES
Camshaft Bearing Journal Diameter

1. Determine the diameter of the camshaft

journals.
• Using a micrometer measure the diameter
at 90 degrees intervals to determine if the
journals are out-of-round.
• Measure at two different points on the
journal to determine if there is any tapering.
• If the measurements are out of the specified
range, install a new camshaft.
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GENERAL PROCEDURES
Camshaft Bearing Journal Clearance
1. NOTE: Make sure that the following stages are 4. Using the Plastigage, read off the
followed exactly. The tappets or followers must measurement.
be removed to carry out this measurement. • Compare the width of plastigage with the
NOTE: Make sure that the camshaft is to plastigage scale.
specification. • The value that is read off is the bearing
NOTE: The bearing caps and journals should be clearance.
free from engine oil and dirt.
Position on a width of plastigage on the
bearing cap.
• Insert the camshaft, without lubrication, into
the cylinder head.
• Position a plastigage strip, which should be
equal to the width of the bearing cap, on the
bearing journal.
2. Following the tightening specification,

install the camshaft bearing caps.
Refer to the corresponding Section 303-01.
3. NOTE: Do not strike the bearing caps.
Remove the camshaft bearing caps,
refer to the corresponding Section 303-01.
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TO MODEL INDEX
GENERAL PROCEDURES
Camshaft End Play
1. NOTE: Make sure that the camshaft is to

specification.
Using a Dial Indicator Gauge, measure the
end play.
• Slide the camshaft in both directions. Read
and note the maximum and minimum
values on the Dial Indicator Gauge.
• End play = maximum value minus
minimum value
• If the measurement is out of specification,
install new components.
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TO MODEL INDEX
GENERAL PROCEDURES
Camshaft Surface Inspection
1. Inspect the camshaft lobes for pitting or

damage in the active area. Minor pitting is
acceptable outside the active area.
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GENERAL PROCEDURES
Camshaft Lobe Lift
1. Determine the cam lift.

• Using a micrometer measure the cam in two
directions.
• The difference between the two measure-
ments is the cam lift.
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GENERAL PROCEDURES
Crankshaft Main Bearing Journal Diameter
General Equipment
Micrometer
1. Measure the diameter of the main bearing
journals and the big-end bearing journals.
• Repeat the measurement with the
micrometer offset by 90°, in order to
determine any eccentricity which may be
present.
• Measure the journal at two different posi-
tions to determine any conicity which may
be present.
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GENERAL PROCEDURES
Crankshaft End Play
General Equipment
Dial indicator
Dial indicator fixture
1. NOTE: Operation for vehicles with Zetec-E
engines only. Dismantling the crank gear is not
permitted on Zetec-SE engines.
Determine the end float
• Place on the dial indicator and bracket .
• Determine the end float by raising the
crankshaft with the aid of a screwdriver.
• If necessary, correct the end float by using
new thrust half washers.
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GENERAL PROCEDURES
Cylinder Bore Taper
1. NOTE: The main bearing caps or lower

crankcase must be in place and tightened to
the specified torque; however, the bearing
shells should not be installed.
Measure the cylinder bore with an internal
micrometer.
• Carry out the measurements in different
directions and at different heights to
determine if there is any out-of-roundness
or tapering.
• If the measurement is out of the specified
range, install a new block or hone out the
cylinder block (if aplicable/allowed).
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GENERAL PROCEDURES
Piston Inspection
1. CAUTION: Do not use any aggressive

cleaning fluid or a wire brush to clean
the piston.
Carry out a visual inspection.
• Clean the piston skirt, pin bush, ring
grooves and crown and check for wear or
cracks.
• If there are signs of wear on the piston skirt,
check whether the connecting rod is twisted
or bent.
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GENERAL PROCEDURES
Piston Pin to Bore Diameter
1. NOTE: The piston and piston pin form a

matched pair. Do not mix up the components.
Measure the diameter of the piston pin
bore.
• Measure the diameter in two directions.
• If the values are not to specification, install
both a new piston and a new piston pin.
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GENERAL PROCEDURES
Piston Diameter
General Equipment
Micrometer
1. NOTE: Mark the piston to make sure the piston
is installed correctly.
Using a Micrometer measure the piston
diameter.
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GENERAL PROCEDURES
Piston Ring End Gap
1. CAUTION: Do not mix up the piston

rings. Install the piston rings in the
same position and location.
Take the piston ring and use a piston
without rings to push the piston ring about
30 mm into the cylinder bore.
2. Using the Feeler Gauge, measure the pis-

ton ring gap.
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GENERAL PROCEDURES
Piston Ring-to-Groove Clearance
General Equipment
Feeler Gauge
1. NOTE: The piston ring must protrude from the
piston groove. To determine the piston ring
clearance, insert the Feeler Gauge right to the
back of the groove, behind the wear ridge.
Using the Feeler Gauge , measure the pis-
ton ring clearance.
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GENERAL PROCEDURES
Piston Pin Diameter
1. NOTE: The piston and piston pin are a matched

pair. Do not mix up the components.
Measure the piston pin diameter.
• Measure the diameter in two directions.
• If the values are not to specification, install a
new piston and a new piston pin.
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GENERAL PROCEDURES
Connecting Rod Large End Bore
1. Measure the bearing bore in two directions.

The difference is the connecting rod bore
out-of-round. Verify the out-of-round and
the bearing bore is within specification.
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GENERAL PROCEDURES
Valve Stem Diameter
1. Using a micrometer measure the diameter

of the valve stems.
• If the measurements are not to specification,
install a new valve.
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GENERAL PROCEDURES
Flywheel Inspection
CAUTION: Do not rework the flywheel if it 3. CAUTION: Make sure that the three
is distorted. locating dowels are installed.
CAUTION: Do not clean the dual mass Check if the locating dowels are touching
flywheel with any kind of fluid. Clean the the primary mass of the flywheel.
flywheel with a dry cloth only. • If the height of the locating dowels is less
than 11 mm, install a new flywheel.
CAUTION: Do not clean the gap between
the primary and secondary mass. Only
clean the bolt connection surface and the
clutch surface.
1. Inspect the flywheel, if there is evidence of
the following install a new flywheel:
• Cracks.
• Worn ring gear teeth.
• Chipped or cracked ring gear teeth.
2. Check the flywheel for lateral movement.
• Rotation movement in either one or both
directions, or rock on its axis up to x = ± 1.5
mm measured at a radius of y = 125 mm in
relation to the primary mass is acceptable.
4. Inspect for grease along the welding.
• A small amount of lateral movement is
• If more than 2 g or 2 cm³ grease is evident,
permissible.
install a new flywheel.
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GENERAL PROCEDURES
Cylinder Head Distortion
General Equipment
Feeler gauge
Straight edge
1. Using a straight edge and feeler gauge,
measure the cylinder head distortion.
• Measure the mating face distortion.
• Refer to Specifications in the appropriate
engine section.
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GENERAL PROCEDURES
Cylinder Block Distortion
1. Using a Straight Edge and a Feeler Gauge,

measure the cylinder block/cylinder head
distortion.
• Measure the mating face distortion.
• If the value is not to specification rework the
mating face (if allowed).
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GENERAL PROCEDURES
Exhaust Manifold Cleaning and Inspection
1. Inspect the cylinder head joining flanges of

the exhaust manifold for evidence of
exhaust gas leaks.
2. Inspect the exhaust manifold for cracks,
damaged gasket surfaces, or other damage
that would make it unfit for further use.
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GENERAL PROCEDURES
Bearing Inspection
1. Inspect bearings for the following defects.

1. Cratering - fatigue failure
2. Spot polishing - incorrect seating.
3. Imbedded dirt engine oil.
4. Scratching - dirty engine oil.
5. Base exposed - poor lubrication.
6. Both edges worn - journal damaged.
7. One edge worn - journal tapered or bearing
not seated.
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303-01A-1 Engine — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE 303-01A-1

(MI4)
PAGE 1 OF 2
SECTION 303-01A Engine — 1.8L Duratec-HE

(MI4)/2.0L Duratec-HE (MI4)
CONTENTS PAGE
SPECIFICATIONS
Engine Data 1.8L ............................................................................................................ 303-01A-3
Engine Data 2.0L ............................................................................................................ 303-01A-3
Engine Oil ....................................................................................................................... 303-01A-3
Oil system ....................................................................................................................... 303-01A-4
Engine Oil Capacity 1.8/2.0L Engine ............................................................................... 303-01A-4
Valve Dimensions, 1.8/2.0L Engine................................................................................. 303-01A-4
Camshaft Dimensions, 1.8L Engine ................................................................................ 303-01A-4
Camshaft Dimensions, 2.0L Engine ................................................................................ 303-01A-4
Crankshaft 1.8/2.0L Engine ............................................................................................. 303-01A-4
Cylinder Block, 1.8L/ 2.0L Engine ................................................................................... 303-01A-4/6
Engine ............................................................................................................................. 303-01A-7

1.8L Duratec HE (MI4) engine......................................................................................... 303-01A-7/9
GENERAL PROCEDURES
Valve Clearance Adjustment ............................................................................................ 303-01A-10/13
IN-VEHICLE REPAIR
Intake Manifold.............................................................................................. (21 183 0) 303-01A-14/17

Crankshaft Pulley.......................................................................................... (21 572 0) 303-01A-18/26
Crankshaft Front Seal ................................................................................... (21 467 0) 303-01A-27
Engine Front Cover ....................................................................................... (21 148 0) 303-01A-28/32
Valve Seals................................................................................................... (21 238 0) 303-01A-33/34
Valves ........................................................................................................... (21 215 4) 303-01A-35/36
Camshafts..................................................................................................... (21 284 0) 303-01A-37/45
Timing Chain................................................................................................. (21 314 0) 303-01A-46/47
Cylinder Head ............................................................................................... (21 163 0) 303-01A-48/60
Oil Pan.......................................................................................................... (21 154 0) 303-01A-61/68
Oil Pump ....................................................................................................... (21 714 0) 303-01A-70/71
Crankshaft Rear Seal.................................................................................... (21 468 4) 303-01A-72/77
Engine — Vehicles With: Manual Transaxle..................................................................... 303-01A-78/87

Engine — Vehicles With: 4-Speed Automatic Transaxle (4F27E) .................................... 303-01A-88/95
DISASSEMBLY
Engine .......................................................................................................... (21 134 8) 303-01A-96/103
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PAGE 2 OF 2
ASSEMBLY
Engine .......................................................................................................... (21 134 8) 303-01A-104/116
INSTALLATION
Engine — Vehicles With: Manual Transaxle .................................................................... 303-01A-117/125

Engine — Vehicles With: Automatic Transaxle ................................................................ 303-01A-126
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SPECIFICATIONS
Engine Data 1.8L

Description
Engine code QQDA QQDB
Firing order 1-3-4-2 1-3-4-2
Emission level Stage III Stage IV
Bore 83 mm 83 mm
Stroke 83.1 mm 83.1 mm
Cubic capacity 1798 cm³ 1798 cm³
Compression ratio 10.8 : 1 10.8 : 1
Power output at 6000 rpm 92 kW (125 PS) 92 kW (125 PS)
Maximum torque at 4000 rpm 165 Nm 165 Nm
Maximum engine speed (intermit- 6850 rpm 6850 rpm
tent)
Maximum engine speed (continous) 6500 rpm 6500 rpm
Idle speed 700±50 rpm 700±50 rpm
Number of main bearings 5 5
Camshaft drive Chain Chain
Maximum oil consumption 0.5 l/1000 Km 0.5 l/1000 Km
Engine Data 2.0L

Description
Engine code AODB
Firing order 1-3-4-2
Emission level Stage III
Bore 87.5 mm
Stroke 83.1 mm
Cubic capacity 1998 cm³
Compression ratio 10.8 : 1
Power output at 6000 rpm 107 kW (146 PS)
Maximum torque at 4500 rpm 185 Nm
Maximum engine speed (intermittent) 6850 rpm
Maximum engine speed (continous) 6500 rpm
Idle speed 700 ± 50 rpm
Number of main bearings 5
Camshaft drive Chain
Maximum oil consumption 0.5 l/1000 Km
Engine Oil
Viscosity / ambient
temperature Type Specification
Recommended engine oil
SAE 5W-30 / below -20°C to over Ford Formula E WSS-M2C913-B
+40°C
Alternative engine oils
SAE 10W-40 / -20°C to over Ford XR+ High-performance ACEA A3/B3
+40°C
SAE 5W-40 / below -20°C to over Ford Formula S ACEA A3/B3
+40°C
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SPECIFICATIONS (Continued)
Item Specification
Sealant, oil pan contact surface to crankshaft rear seal retainer, oil pan to WSE-M4G323-A4
cylinder block, oil pan to front cover, engine front cover to cylinder block/ oil
pan
Sealant, oil pressure switch and engine front cover blanking plug WSK-M2G349-A7
Anti-seize grease ESE-M1244-A
Silicone grease ESE-M1C171-AA
Oil system
Description bar
Pressure relief valve opening pressure 5
Engine Oil Capacity 1.8/2.0L Engine

Description Liters
Initial fill, including oil filter 4.6
Service fill including filter 4.3
Service fill excluding filter 3.9
Valve Dimensions, 1.8/2.0L Engine

Description mm
Valve clearance (engine cold), intake 0.220 - 0.280
Valve clearance (engine cold), exhaust 0.270 - 0.330
Valve stem diameter, intake 5.470 - 5.485
Valve stem diameter, exhaust 5.465 - 5.480
Camshaft Dimensions, 1.8L Engine

Description mm
Camshaft journal diameter 24.97 ± 0.01
Camshaft journal clearance 0.035 - 0.080
Camshaft end play 0.090 - 0.240
Camshaft lobe lift, intake, 120 PS engine 7.4
Camshaft lobe lift, intake, 125 PS engine 8.5
Camshaft lobe lift, exhaust 7.7
Camshaft Dimensions, 2.0L Engine

Description mm
Camshaft journal diameter 24.97 ± 0.01
Camshaft journal clearance 0.035 - 0.080
Camshaft lobe lift, intake 8.8
Camshaft lobe lift, exhaust 7.7
Crankshaft 1.8/2.0L Engine

Description mm
Crankshaft end play 0.335 ± 0.115
Cylinder Block, 1.8L/ 2.0L Engine

Description mm
Cylinder block distortion (maximum) 0.1
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Cylinder head bolts a) - -
Cylinder block lower blanking plug 20 15 -
Timing chain guide retaining bolts 10 - 89
Timing chain tensioner retaining bolts 10 - 89
Camshaft bearing caps retaining bolts a) - -
Camshaft sprocket retaining bolts 72 53 -
Camshaft position (CMP) sensor retaining bolt 6 - 53
Engine front cover retaining bolts a) - -
Engine front cover upper blanking plug 10 - 89
Engine front cover lower blanking plug 12 9 -
Crankshaft pulley retaining bolts a) - -
Crankshaft rear seal carrier retaining bolts 10 - 89
Crankshaft position (CKP) sensor retaining bolts 7 - 62
Coolant plug to cylinder block 55 41 -
Coolant plugs (4) to cylinder head 75 55 -
Coolant pump retaining bolts 10 - 89
Coolant pump pulley retaining bolts 25 18 -
Coolant outlet connector retaining bolts 10 - 89
Exhaust manifold retaining bracket retaining bolts 15 11 -
Exhaust manifold heat shield retaining bolts 10 - 89
Exhaust manifold to cylinder head retaining nuts 48 35 -
Exhaust manifold to exhaust manifold retaining 20 15 -
bracket
Exhaust manifold studs to cylinder head 17 13 -
Exhaust gas recirculation (EGR) tube to cylinder 55 41 -
head
Valve cover retaining bolts 10 - 89
Oil pressure switch 15 11 -
Oil pan retaining bolts 25 18 -
Oil filter adaptor retaining bolts 25 18 -
Oil level indicator tube retaining bolts 10 - 89
Oil drain plug 28 21 -
Oil pump retaining bolts a) - -
Oil pump sprocket retaining bolt 25 18 -
Oil pump screen and pickup tube retaining bolts 10 - 89
Oil pump chain guide retaining bolts 10 - 89
Oil pump chain tensioner retaining bolt 10 - 89
Flywheel retaining bolts a) - -
Positive crankcase ventilation housing retaining 10 - 89
bolts
Knock sensor (KS) retaining bolt 20 15 -
Thermostat housing retaining bolts 10 - 89
Accessory drive belt tensioner retaining bolt 18 13 -
Intake manifold retaining bolts 18 13 -
Transaxle retaining bolts 44 32 -
Halfshaft center bearing carrier retaining bolts 48 35 -
Intermediate shaft bearing cap retaining nuts 25 18 -
Starter motor retaining bolts 35 26 -
Ignition coil-on-plug retaining bolts 10 - 89
Spark plugs 12 9 -
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Generator retaining bolts 48 35 -
Electrical connector retaining bracket retaining 6 - 59
bolts
Ground cable retaining bolt to cylinder head 15 11 -
Air conditioning (A/C) compressor retaining bolts 24 18 -
Engine rear mount center nut 133 98 -
Engine front mount studs to front cover 10 - 89
Engine front mount retaining bolts 80 59 -
Engine support insulator retaining bolts 80 59 -
Engine lifting eye retaining bolt 45 33 -
Strut and spring assembly top mount nuts 32 24 -
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Engine
Cylinder block
1.8L Duratec HE (MI4) engine
Valve cover

Number
1 - Alternator mounting point
The cylinder block has additional bolt mounting

points for attaching the alternator.
The alternator is bolted onto the left-hand side of
the engine (viewed from the rear of the vehicle)
The cylinder block also has attachment points for
the bolts of the knock sensors.
Number
1 - Oil filler neck
2 - Attachment points for bolting
on the direct ignition coils
3 - Camshaft
Position (CMP) sensor
Due to space restrictions the oil filler neck has

been extended, and it is attached to the valve
cover via a bayonet fixing.
Additional attachment points are provided to
secure the bolts for the direct ignition coils.
The bolt attachment point for the CMP sensor has
been rotated by 90°.
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Positive crankcase ventilation

Number
1 - Positive Crankcase Ventila-
tion (PCV)
Due to the increased space requirements of the
intake manifold it was necessary to modify the oil
separator and the shape and installation location
of the PCV hose.
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Oil pan

Number
1 - Protective cover
The oil pan has been modified in accordance with
the space requirements of the Air Conditioning
(A/C) compressor.
A protective metal hood is installed underneath
the A/C compressor to provide protection against
damage.
The protective hood is bolted to the A/C
compressor.
The thickness of the walls of the oil pan has been
increased, and additional reinforcement ribs have
now also been introduced.
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GENERAL PROCEDURES
Valve Clearance Adjustment
4. Disconnect the positive crankcase ventila-

Special Tool(s) tion (PCV) hose from the valve cover.
Socket, Spark Plug

303-499
General Equipment
Feeler gauges
Name Specification
Silicone Sealant WSE-M4G323-A4
All vehicles 5. Remove the ignition coil-on-plug.

6. Using the special tool, remove the spark

2. Disconnect the battery ground cable. For plugs.
Disconnect]
3. Disconnect the camshaft position (CMP)
sensor electrical connector.
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7. Remove the engine cover retaining brack- 11. NOTE: Only rotate the crankshaft in the
ets. normal direction of rotation.
Rotate the crankshaft until each piston is
at TDC and measure the valve clearances.
12. NOTE: Only carry out the following steps
when the valve clearance(s) require
adjustment.
Remove the camshafts. For additional
information, refer to Camshafts in this
section.
13. NOTE: The number on the valve tappet is the
valve tappet thickness, however only the
decimal places are marked (for example .650 =
3.650).
Determine the valve tappet thickness
8. Remove the valve cover. required:
1. Remove the valve tappet and read the
thickness from the underside.
2. Calculate the valve tappet thickness
required (thickness of currently installed
valve tappet, + the measured valve
clearance, - the required valve clearance).
3. Install the correct valve tappet.
14. NOTE: Do not install the valve cover at this
stage.
Install the camshafts. For additional
section.
15. NOTE: Only rotate the crankshaft in the
9. NOTE: Only rotate the crankshaft in the normal normal direction of rotation.
direction of rotation.
Rotate the crankshaft until piston No. 1 is at TDC and measure the valve clearances.
at top dead center (TDC).
16. Repeat this procedure as necessary until
10. NOTE: Note down each cylinder number and all valve clearances are within the
the valve clearances measured. specified tolerance.
Using a suitable set of feeler gauges, 17. Apply a small bead of sealant to the areas
measure the valve clearances. as shown.
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18. NOTE: Install a new valve cover gasket if 21. Install the ignition coil-on-plug.
necessary.
Install the valve cover.
• Tighten the bolts in the sequence shown.
22. Connect the positive crankcase ventila-

tion (PCV) hose to the valve cover.
19. Install the engine cover retaining brack-

ets.
23. Connect the camshaft position (CMP)

20. Using the special tool, install the spark

plugs.
24. Connect the battery ground cable. For

Disconnect]
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Vehicles with global closing

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(MI4)
IN-VEHICLE REPAIR
Intake Manifold (21 183 0)
IN-VEH ICLE R EPAIR
Removal 5. Remove the oil level indicator tube lower

retaining bolt.
6. Remove the intake manifold lower retaining

2. Disconnect the battery. For additional bolt.
Disconnect]
3. Remove the air cleaner outlet pipe.
7. Detach the wiring harness from the intake

manifold.
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IN-VEHICLE REPAIR (Continued)

9. Disconnect the knock sensor (KS) 12. Detach the throttle body from the intake
electrical connector for cylinder 3 and 4 manifold.
from the intake manifold (if equipped). • Remove the retaining nuts in the sequence
• Detach the knock sensor (KS) electrical shown.
connector for cylinder 3 and 4 from the in-
take manifold.
13. Detach the hood latch from the radiator

grille opening panel reinforcement.
10. Disconnect the manifold absolute pres-
sure (MAP) sensor electrical connector.
14. Disconnect the brake booster vacuum

line from the intake manifold.
11. Disconnect the knock sensor (KS)
• Detach the KS electrical connector from the
intake manifold.
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15. Detach the engine wiring harness from 18. Disconnect the vacuum hose from the
the intake manifold. intake manifold.
16. Remove the oil level indicator and oil level 19. Remove the intake manifold retaining
indicator tube. bolts (engine shown removed for clarity).
• Detach the intake manifold from the cylinder
head.
17. Disconnect the vacuum hose from the

intake manifold.
20. Disconnect the positive crankshaft venti-
lation (PCV) hose from the intake mani-
fold.
21. Remove the intake manifold.
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Installation
All vehicles
1. NOTE: Install a new intake manifold gasket if
necessary.
To install, reverse the removal procedure.
2. Initialize the window regulator motor. For
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IN-VEHICLE REPAIR
Crankshaft Pulley (21 572 0)
Removal
Special Tool(s)
Universal Flange Holding
Wrench
205-072
Adapter for 205-072

205-072-02
Alignment Plate, Camshaft

303-376

Socket, Spark Plug [Battery, Mounting and Cables,
303-499 GENERAL PROCEDURES, Battery
Disconnect]
3. Disconnect the camshaft position sensor
(CMP sensor) connector.
Timing Peg, Crankshaft TDC
303-507
General Equipment
Bolt, M6 x 18 mm
Name Specification
Silicon sealer WSE-M4G323-A4
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4. Detach the positive crankcase ventilation 7. Remove the engine cover bracket.
(PCV) hose from the cylinder head cover.
8. Remove the cylinder head cover.

5. Remove the ignition coils.
• Lay the ignition coils to one side.
9. Remove the drive belt. For additional

6. Remove the spark plugs with the special [Accessory Drive, REMOVAL AND
tool. INSTALLATION, Accessory Drive Belt -
(MI4)]
10. Detach the right-hand front wheel.
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11. Detach the right-hand wheel arch cover 14. Remove the crankshaft front oil seal. For
(shown with wheel arch cover removed additional information, refer to Crankshaft
for clarity). Front Seal in this section.
15. Remove the front friction washer (engine
shown removed for clarity).
• Discard the friction washer.
12. NOTE: Only turn the crankshaft in the normal

Turn the crankshaft until piston no. 1 is
approx. 45 degrees before TDC.
Installation
All vehicles
1. NOTE:Install a new front friction washer.
Install the front friction washer (engine
13. NOTE: Do not discard the crankshaft pulley

bolt.
Counterhold the crankshaft pulley using
the special tools and remove the pulley.
2. Install the crankshaft front oil seal. For

additional information, refer to Crankshaft
Front Seal in this section.
4. NOTE: Only turn the camshafts in the normal
Carefully turn the camshafts using a
spanner until the cams, cylinder no. 4, are
positioned at the valve overlap.
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5. Attach the special tool. 9. Remove the crankshaft pulley bolt.
• Discard the bolt.
10. CAUTION: Tighten M6 x 18 mm bolt
hand-tight only.
Install the crankshaft pulley and fasten to
the timing cover with an M6 x 18 mm bolt.
6. Raise the vehicle.

7. Remove the cylinder block lower blanking
plug and attach the special tool.
11. NOTE: Install a new crankshaft pulley bolt.

Counterhold the crankshaft pulley using
the special tools and tighten the
crankshaft pulley bolt.
• Tighten the bolt in two stages.
• Stage 1: 100 Nm.

Turn the engine at the crankshaft pulley
bolt until the crankshaft contacts the spe-
cial tool.
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12. Remove bolt, M6 x 18 mm. 17. NOTE: Only turn the crankshaft in the normal
Turn the crankshaft one and three quar-
ters of a turn until piston no. 1 is approx.
45 degrees before TDC.

18. Attach the special tool.


Turn the crankshaft until no. 1 piston is at
TDC.
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20. CAUTION: Tighten M6 x 18 mm bolt 23. Remove the special tool.

hand-tight only.
NOTE: If the M6 x 18 mm bolt cannot be
installed, correct the valve timing.
Check the position of the crankshaft pul-
ley with an M6 x 18 mm bolt.

25. Remove the M6 x 18 mm bolt.

22. NOTE: If the special tool cannot be attached,
correct the valve timing.
Check the position of the camshafts using
the special tool.
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27. Screw in the cylinder block lower blank- 29. Install the CKP sensor (engine shown
ing plug. removed for clarity).
1. Install the CKP sensor bolts.
2. Remove the tool.
28. NOTE: When installing a new timing cover,

the crankshaft position sensor (CKP sensor)
must be aligned using the tool supplied.
30. Attach the right-hand wheel arch cover
Align the CKP sensor (engine shown (shown with wheel arch cover removed
removed for clarity). for clarity).
1. Loosen the CKP sensor bolts.
2. Insert the supplied tool so that it engages
with the teeth of the crankshaft pulley.
31. Attach the right-hand front wheel. For

32. Install the drive belt. For additional
INSTALLATION, Accessory Drive Belt -
(MI4)]
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33. Apply sealer thinly onto the indicated ar- 36. Install the spark plugs using the special
eas. tool.
34. NOTE: If necessary, install a new cylinder 37. Install the ignition coils.
head cover gasket.
Install the cylinder head cover.
38. Attach the positive crankcase ventilation

(PCV) hose to the cylinder head cover.
35. Install the engine cover bracket.
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sensor connector.

Disconnect]

42. Initialize the window winder motors. For
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(MI4)
IN-VEHICLE REPAIR
Crankshaft Front Seal (21 467 0)
Installation
Special Tool(s)
1. NOTE: Install a new crankshaft front seal.
Adapter for 205-071 (Thrust
Pad) Using the special tools, install the crank-
shaft front seal.
205-071-02 (15-026-51)
Remover, Crankshaft Seal

303-293 (21-143)
Installer, Crankshaft Seal

303-395 (21-171)
2. Install the crankshaft pulley.

Remover, Halfshaft Seal
308-208 (16-074)
Removal
1. Remove the crankshaft pulley.
2. Using the special tool, remove the
crankshaft front seal.
• Discard the seal.
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(MI4)
IN-VEHICLE REPAIR
Engine Front Cover (21 148 0)
5. Remove the engine front cover lower re-

General Equipment taining bolts.
Vehicle jack
Name Specification
Removal
1. Remove the crankshaft pulley.
3. Detach the air conditioning compressor
(A/C compressor) cover. 6. Disconnect the crankshaft position (CKP)
4. Detach the A/C compressor and secure it to

one side. 7. Lower the vehicle.
8. Remove the drive belt tensioner.
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9. Detach the coolant expansion tank and lay 13. Remove the engine front mount
it to one side. nuts/bolts.
• Discard the nuts.
10. Remove the coolant pump pulley.

14. Remove the engine front mount studs.
11. Support the engine with a vehicle jack.

12. Detach the A/C compressor line bracket 15. Remove the engine front mount.
from the engine front mount. 16. Remove the engine front cover upper
bolts.
• Remove the engine front cover.
Installation
1. Clean the engine front cover mating faces.
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2. NOTE: Install the engine front cover within 10 3. Install the engine front cover (engine
minutes of applying the silicon sealer. shown removed for clarity).
Apply sealer to the engine front cover • Tighten the bolts in the indicated sequence.
(bead diameter: 3 mm). • Tighten bolts 1 through 8 to 10 Nm.
• Tighten the bolt 9 to 48 Nm.
• Tighten bolts 10 through 19 to 10 Nm.
• Tighten bolts 20 through 22 to 48 Nm.
4. Install the engine front mount.

5. Install the engine front mount studs.
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6. NOTE: Install new engine front mount nuts. 10. Attach the A/C compressor.
Install the engine front mount nuts/bolts.
11. Connect the electrical connector for the

crankshaft position sensor (CKP sensor).
7. Attach the A/C line bracket to the engine
front mount.

8. Raise and support the vehicle. For 13. Install the coolant pump pulley.
9. Attach the air conditioning compressor
(A/C compressor) cover.
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14. Install the coolant expansion tank.
15. Install the drive belt tensioner.
16. Install the crankshaft pulley.
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IN-VEHICLE REPAIR
Valve Seals (21 238 0)
4. Using the special tools, remove the valve

springs.
Special Tool(s)
• Compress the valve spring.
Compressor, Valve Spring • Remove the valve collets.
303-361A (21-155A) • Release the valve spring.
• Remove the valve spring retainer and the
valve spring.
Adapter for 303-361A

303-361-02 (21-155-02A)
Installer, Valve Stem Collets

303-362 (21-156)
Adapter, Air Supply (Cylinder

Head) 5. Using the special tools, remove the valve
303-363 (21-157) seals.
• Discard the seals.
Pliers, Valve Stem Seal

303-508 (21-165)
Removal
1. Remove the camshafts.
2. Using the special tool, apply 7 to 10 bar of
compressed air into the cylinder.
3. Remove the valve tappets.
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Installation
1. NOTE: Install new valve seals.
NOTE: Cover the valve collet groove on the valve
stem with a protective sleeve.
Using the special tools, install the valve
seals.
• Remove the protective sleeve.
2. Using the special tools, install the valve

springs.
• Install the valve spring retainer and the
valve springs.
• Install the valve collets.
• Release the valve spring.

4. Install the valve tappets.
5. Install the camshafts.
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IN-VEHICLE REPAIR
Valves (21 215 4)
3. Using the special tool, remove the valve

Special Tool(s) seals.
Compressor, Valve Spring • Discard the seals.
303-361A (21-155A)

303-361-02 (21-155-02A)

303-362 (21-156)
4. Remove the valves.
Pliers, Valve Stem Seal Installation

303-508 (21-165) 1. Install the valves.
NOTE: Cover the valve collet groove on the valve
stem with a protective sleeve.
Removal Using the special tool, install the valve
seals.
1. Remove the cylinder head.
• Remove the protective sleeve.
springs.
• Remove the valve collets.
• Remove the valve spring retainer and the
valve spring.
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(MI4)

springs.
• Install the valve spring retainer and the
valve spring.
• Compress the valve spring
• Install the valve collets.

5. Install the cylinder head.
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IN-VEHICLE REPAIR
Camshafts (21 284 0)
Disconnect]
Special Tool(s) sensor electrical connector.
303-376
Socket, Spark Plug

303-499

303-507
tion (PCV) hose from the valve cover.
General Equipment
M6 x 18 mm bolt
M6 x 25 mm bolt
Name Specification
Hypoid Gear Oil SQM-2C9002-AA
Adhesive - Loctite 243 WSK-M2G349-A7
Removal
5. Remove the ignition coil-on-plug.

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6. Using the special tool, remove the spark 10. NOTE: Only rotate the crankshaft in the
plugs. normal direction of rotation.
Rotate the crankshaft until piston No. 1 is
approximately 45 degrees before top dead
center (BTDC).
7. Remove the engine cover retaining brack-

ets.
11. Remove the engine front cover lower

blanking plug.
8. Remove the valve cover.

plug and install the special tool.
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14. Remove the engine front cover upper 15. CAUTION: To detension the timing
blanking plug. chain, make sure the timing chain
tensioner ratchet is in the released
position.
Detension the timing chain.
1. Using a suitable screwdriver, unlock the
timing chain tensioner ratchet.
2. Carefully rotate the exhaust camshaft by the
hexagon in the normal direction of rotation,
to detension the timing chain tensioner.
3. Install a suitable M6 x 25 mm bolt through
the blanking plug to secure the timing chain
guide in the detensioned position.
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16. CAUTION: Hold the camshafts by the 18. NOTE: Using a suitable piece of wire, prevent
hexagon with an open-ended wrench the timing chain and the sprocket from
to prevent them from rotating. dropping into the cylinder block.
NOTE: Using a suitable piece of wire, prevent the Detach the intake camshaft sprocket from
timing chain and the sprocket from dropping into the intake camshaft.
the timing case.
Loosen the camshaft sprockets retaining Installation
bolts.
• Detach the exhaust camshaft sprocket to- All vehicles
gether with the timing chain from the ex- 1. NOTE: Do not tighten the camshaft sprocket
haust camshaft. retaining bolt at this stage.
Attach the intake camshaft sprocket
together with the timing chain to the intake
camshaft and insert the intake camshaft.
2. CAUTION: Install the camshafts
approximately at valve overlap
position cylinder No. 4.
CAUTION: Install the camshafts and
bearing caps in their original location.
Install the camshafts.
• Working in several stages, evenly tighten
the camshaft bearing cap bolts in the
sequence shown, one half turn at a time.
17. CAUTION: Keep the camshaft bearing • Coat the camshaft bearing caps with oil.
caps, the camshafts and the camshaft
• Tighten the bolts in two stages:
sprockets in order for installation.
• Stage 1: 7 Nm
NOTE: Working in several stages, release each
camshaft bearing cap retaining bolt two turns at a • Stage 2: 16 Nm
time.
Remove the camshaft bearing caps in the
sequence shown.
3. NOTE: Only carry out the following step when

new camshafts are installed.
Adjust the valve clearance. For additional
information, refer to Valve Clearance
Adjustment in this section.
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4. NOTE: Do not tighten the exhaust camshaft 8. NOTE: Only rotate the crankshaft in the normal
sprocket retaining bolt at this stage. direction of rotation.
Attach the exhaust camshaft sprocket to- Rotate the crankshaft until piston No. 1 is
gether with the timing chain to the exhaust at TDC.
camshaft. 9. NOTE: Hold the camshafts by the hexagon with
an open-ended wrench to prevent them from
rotating.
Tighten the camshaft sprocket retaining
bolts.
5. Install the special tool.
6. Coat the engine front cover upper blanking

plug with adhesive.
7. Remove the M6 x 25 mm bolt, tension the
timing chain.
• Install the engine front cover upper blanking 11. Raise and support the vehicle.
plug.
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13. NOTE: Only rotate the crankshaft in the 16. CAUTION: Only tighten the crankshaft
normal direction of rotation. pulley securing bolt finger tight.
Rotate the crankshaft approximately one NOTE: If it is not possible to install the crankshaft
and three quarter revolutions, until piston pulley securing bolt, correct the valve timing.
No. 1 is 45 degrees before TDC.
Using a M6 x 18 mm bolt, check the posi-
tion of the crankshaft pulley.

18. NOTE: If it is not possible to install the special
tool, correct the valve timing.
Using the special tool, check the position
of the camshafts.

normal direction of rotation.
at TDC.
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19. Remove the special tool. 23. Install the cylinder block lower blanking
plug.

21. Remove the crankshaft pulley securing 24. Coat the engine front cover lower
bolt. blanking plug with adhesive.
25. Install the engine front cover lower
blanking plug.
26. Apply a small bead of sealant to the areas

as shown.
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27. NOTE: Install a new valve cover gasket if 30. Install the ignition coil-on-plug.
necessary.

tion (PCV) hose to the valve cover.
28. Install the engine cover retaining brack-

ets.

29. Using the special tool, install the spark

plugs.
33. Connect the battery ground cable.

Disconnect]
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IN-VEHICLE REPAIR
Timing Chain (21 314 0)
Removal 4. Remove the timing chain guides.

1. Remove the engine front cover.
2. Detension the timing chain.
1. Unlock the timing chain tensioner ratchet.
2. Apply pressure to the timing chain guide.
3. Fix the timing chain tensioner with a suitable
pin punch.
5. Remove the timing chain tensioner.
3. NOTE: Hold the camshafts by the hexagon with

an open-ended wrench to stop them from
rotating.
Loosen the camshaft sprocket retaining
bolts.
Installation
1. Install the timing chain tensioner.
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2. Install the timing chain guides. 5. NOTE: Hold the camshafts by the hexagon with
an open ended wrench to stop them from
rotating.
Tighten the camshaft sprocket retaining
bolts.
3. CAUTION: Do not tighten the camshaft

sprocket retaining bolts at this stage.
Make sure the camshaft sprockets
rotate on the camshafts.
Install the camshaft sprockets. 6. Install the engine front cover.
• Install the timing chain.
4. Tension the timing chain.

• Apply pressure to the timing chain and re-
move the securing pin.
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IN-VEHICLE REPAIR
Cylinder Head (21 163 0)
AND INSTALLATION, Air Cleaner - 1.8L
Duratec-HE (MI4)/2.0L Duratec-HE (MI4)]
5. Remove the timing chain. For additional
Special Tool(s) information, refer to Timing Chain in this
Remover/Installer, Hose section.
Clamp 6. Raise and support the vehicle.
303-397 7. Remove the oil level indicator tube lower
retaining bolt.
Name Specification
Removal
are always present and may ignite.
Failure to follow these instructions may 8. Remove the intake manifold lower retaining
result in personal injury. bolt.
1. Drain the cooling system. For additional
information, refer to Section 303-03A.
[Engine Cooling - 1.8L Duratec-HE
(MI4)/2.0L Duratec-HE (MI4), GENERAL
PROCEDURES, Cooling System Draining,
Filling and Bleeding]
9. Detach the wiring harness from the intake

manifold.
3. Disconnect the battery. For additional

Disconnect]
4. Remove the air cleaner. For additional
information, refer to Section 303-12.[Intake
Air Distribution and Filtering, REMOVAL
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13. Disconnect the thermostat electrical
10. Disconnect the knock sensor (KS)
connector.
electrical connector for cylinder 3 and 4 (if
equipped).
• Detach the knock sensor (KS) electrical
connector for cylinder 3 and 4 from the in-
take manifold.
14. Disconnect the air conditioning (A/C)

compressor electrical connector.
11. Disconnect the manifold absolute pres-

sure (MAP) sensor electrical connector.
15. Disconnect the crankshaft position (CKP)

12. Disconnect the generator electrical con-

nector.
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16. Remove the exhaust manifold lower re- 20. Disconnect the brake booster vacuum
taining bolts. line from the intake manifold.
17. Remove the wiring harness retaining 21. Disconnect the heated oxygen (HO2S)
bracket. sensor electrical connector.
18. Remove the starter motor. 22. Disconnect the catalyst monitor sensor
• Position the starter motor to one side. electrical connector.
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23. Disconnect the evaporative emission 26. Disconnect the engine wiring harness
canister purge valve (EVAP) electrical interface connectors.
connector.
27. Remove the oil level indicator and oil level

24. Disconnect the engine coolant tempera- indicator tube.
ture (ECT) sensor electrical connector.
28. Disconnect the vacuum hose from the

25. Detach the engine wiring harness from intake manifold.
the intake manifold.
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29. Disconnect the knock sensor (KS) 32. Remove the exhaust manifold heat shield
electrical connector. (engine shown removed for clarity).
• Detach the knock sensor (KS) electrical
connector from the intake manifold.
30. Using the special tool, disconnect the

coolant hoses from the throttle body.
33. Remove the exhaust manifold retaining

nuts (engine shown removed for clarity).
• Detach the exhaust manifold from the
cylinder head and position it to one side.
31. Using the special tool, disconnect the • Discard the gaskets.
coolant hose from the coolant expansion
tank.
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34. Disconnect the exhaust gas recirculation 37. Disconnect the fuel supply line. For addi-
(EGR) valve electrical connector. tional information, refer to Section 310-00.
[Fuel System - General Information,
GENERAL PROCEDURES, Quick Release
Coupling]

coolant hoses from the coolant outlet
connector.
38. CAUTION: Keep the camshaft bearing
caps, valve tappets and the camshafts
in order for installation.
CAUTION: Remove the camshaft bearing
caps in the sequence shown.
camshaft bearing cap retaining bolt two turns at a
time.
Remove the camshaft.
• Remove the valve tappets.
36. Detach the ground lead from the cylinder

head.
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2. NOTE: Install new cylinder head bolts and

39. CAUTION: Remove the cylinder head
gasket.
bolts in the sequence shown.
Install the cylinder head.
Remove the cylinder head.
• Tighten the cylinder head bolts in the
sequence shown in five stages:
• Discard the bolts.
• Stage 1: 5 Nm.
• Stage 2: 15 Nm.
• Stage 3: 45 Nm.
Installation
All vehicles
1. Check the cylinder head for distortion. For
additional information, refer to Section 303-00. 3. Install the valve tappets.
[Engine System - General
Information, GENERAL PROCEDURES, 4. CAUTION: Working in several stages,
Cylinder Head Distortion] evenly tighten the camshaft bearing
cap bolts in the sequence shown, one
half turn at a time.
• Coat the camshaft bearing caps with hypoid
oil.
• Tighten the bolts in the sequence shown in
two stages:
• Stage 1: 7 Nm.
• Stage 2: 16 Nm.
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5. Connect the fuel supply line. For additional
9. Connect the exhaust gas recirculation
information, refer to Section 310-00.[Fuel
(EGR) valve electrical connector.
PROCEDURES, Quick Release Coupling]
10. NOTE: Install a new exhaust manifold gasket.

6. NOTE: Only carry out the following step when a NOTE: Do not tighten the exhaust manifold
new cylinder head or new valves are installed. retaining nuts at this stage.
Adjust the valve clearance. For additional Attach the exhaust manifold to the cylin-
information, refer to Valve Clearance der head (engine shown removed for
Adjustment in this section. clarity).
7. Attach the ground lead to the cylinder
head.

12. Install the exhaust manifold lower retain-
8. Using the special tool, connect the coolant ing bolts.
hoses to the coolant outlet connector.
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13. Lower the vehicle. 16. Using the special tool, connect the cool-
14. Tighten the exhaust manifold retaining ant hose to the coolant expansion tank.
17. Using the special tool, connect the cool-

15. Install the exhaust manifold heat shield ant hoses to the throttle body.
(engine shown removed for clarity).
18. Connect the knock sensor (KS) electrical

connector.
• Attach the knock sensor (KS) electrical
connector to the intake manifold.
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19. Connect the vacuum hose to the intake 22. Attach the engine wiring harness to the
manifold. intake manifold.
20. Install the oil level indicator and oil level 23. Connect the engine coolant temperature
indicator tube. (ECT) sensor electrical connector.
21. Connect the engine wiring harness inter- 24. Connect the evaporative emission canis-
face connectors. ter purge valve (EVAP) electrical con-
nector.
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25. Connect the catalyst monitor sensor 29. Install the starter motor.
30. Install the wiring harness retaining

26. Connect the heated oxygen (HO2S) sen- bracket.
sor electrical connector.
31. Connect the crankshaft position (CKP)

27. Connect the brake booster vacuum line to sensor electrical connector.
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32. Connect the air conditioning compressor 35. Connect the manifold absolute pressure
electrical connector. (MAP) sensor electrical connector.
33. Connect the thermostat electrical con- 36. Connect the knock sensor (KS) electrical
nector. connector for cylinder 3 and 4 (if
equipped).
• Attach the knock sensor (KS) electrical
connector for cylinder 3 and 4 to the intake
manifold.
34. Connect the generator electrical connec-

tor.
37. Attach the wiring harness to the intake

manifold.
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38. Install the intake manifold lower retaining 45. Install the engine cover.
bolt.

39. Install the oil level indicator tube lower 46. Initialize the door window motors.
retaining bolt. For additional information,

41. Install the timing chain.
refer to Timing Chain in this section.
42. Install the air cleaner. For additional
[Intake Air Distribution and
Filtering, REMOVAL AND INSTALLATION,
Air Cleaner - 1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4)]
43. Connect the battery. For additional
Disconnect]
44. Fill and bleed the cooling system. For
additional information, refer to Section 303-03A.
[Engine Cooling - 1.8L
Duratec-HE (MI4)/2.0L Duratec-HE (MI4),
GENERAL PROCEDURES, Cooling
System Draining, Filling and Bleeding]
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IN-VEHICLE REPAIR
Oil Pan (21 154 0)

General Equipment 4. Loosen the transaxle upper retaining bolts
Transmission jack
Name Specification
Removal
All vehicles
All vehicles
indicator tube upper retaining bolt.

3. Loosen the transaxle upper retaining bolts
approximately 10 mm. 6. Raise and support the vehicle.
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8. Drain the engine. 12. Disconnect the A/C compressor electrical
• Allow the oil to drain into a suitable connector.
container.
9. NOTE: Inspect the oil drain plug and seal for
damage. Install a new oil drain plug or seal if
necessary.
Install the oil drain plug.
13. Remove the A/C compressor cover.
10. Remove the engine support insulator.
14. Detach the A/C compressor from the oil

pan and position it to one side.
11. Remove the air conditioning (A/C)

compressor belt. For additional
INSTALLATION, Air Conditioning (A/C)
Compressor Belt - 1.8L Duratec-HE
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15. Detach the A/C line bracket from the oil 18. Remove the engine front cover lower re-
pan. taining bolts.
16. Remove the oil level indicator and oil level 19. Using a suitable transmission jack and a
indicator tube. suitable wooden block, support the en-
gine.
17. Detach the wiring harness from the en-

gine front cover studs. Vehicles with 4-speed automatic transaxle
20. Loosen the transaxle right-hand retaining
bolts approximately 10 mm.
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21. Loosen the transaxle lower retaining bolts 24. Loosen the transaxle left-hand retaining
approximately 10 mm. bolts approximately 10 mm.
22. Loosen the transaxle left-hand retaining 25. Remove the transaxle lower retaining
bolt approximately 10 mm. bolts.
Vehicles with manual transaxle All vehicles

23. Loosen the transaxle right-hand retaining 26. Slide the transaxle back approximately 8
bolts approximately 10 mm. mm, lower and remove the transmission
jack.
27. Remove the oil pan.
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Installation 4. NOTE: Do not tighten the oil pan retaining bolts
at this stage.
All vehicles
Install the oil pan.
1. Clean the mating faces of the cylinder
block and the oil pan.
2. NOTE: Install the oil pan within 10 minutes of
applying the silicone sealant and tighten the
retaining bolts within a further 5 minutes.
Apply a 3 mm bead of sealant to the mating
face of the oil pan to the cylinder block.
5. Install the engine front cover lower retain-

ing bolts.

face of the oil pan to the engine front cover.
6. Tighten the oil pan retaining bolts in the

sequence shown.
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7. Using a suitable transmission jack and a 11. Install the transaxle lower retaining bolts.
suitable wooden block, support the engine.

8. Slide the transaxle towards the engine. 12. Install the transaxle right-hand retaining
Vehicles with manual transaxle bolts.
9. Tighten the transaxle left-hand retaining
bolts.
13. Install the transaxle lower retaining bolts.
10. Tighten the transaxle right-hand retaining

bolts.
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14. Tighten the transaxle left-hand retaining 18. Attach the air conditioning (A/C) line
bolt. bracket to the oil pan.
All vehicles 19. Attach the A/C compressor to the oil pan.
15. Remove the transmission jack and
wooden block.
16. Attach the wiring harness to the engine
front cover studs.
20. Install the A/C compressor cover.
17. Install the oil level indicator and oil level

indicator tube.
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21. Connect the A/C compressor electrical 26. Install the oil level indicator and oil level
connector. indicator tube upper retaining bolt.
22. Install the air A/C compressor belt. For Vehicles with manual transaxle
additional information, refer to Section 27. Tighten the transaxle upper retaining
303-05.[Accessory Drive, REMOVAL AND bolts.
23. Install the engine support insulator.

28. Tighten the transaxle upper retaining
bolts.
24. Install the engine undershield.
All vehicles
25. Lower the vehicle. information, refer to Section 303-12.
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Duratec-HE (MI4)]
31. Fill the engine with engine oil.
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IN-VEHICLE REPAIR
Oil Pump (21 714 0)
5. Using the special tools, loosen the oil

Special Tool(s) pump sprocket retaining bolt.
Wrench
205-072 (15-030A)
Adapter for 205-072

205-072-01 (15-030A-01)
Removal
information, refer to Timing Chain in this 6. Remove the oil pump chain.
section. 1. Remove the oil pump sprocket retaining
2. Remove the oil pan. bolt.
3. Remove the oil pump chain guide. 2. Remove the oil pump chain and the oil
pump sprocket.
4. Remove the oil pump chain tensioner.

7. Remove the oil pump.
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Installation 3. Using the special tools, tighten the oil
pump sprocket retaining bolt.
1. NOTE: Install a new oil pump gasket.
Install the oil pump.
• Tighten the retaining bolts in the sequence
shown in two stages.
• Stage 1: 10 Nm.
• Stage 2: 23 Nm.
4. Install the oil pump chain tensioner.
2. Install the oil pump chain.

1. Install the oil pump chain and the oil pump
sprocket.
2. Install the oil pump sprocket retaining bolt.
5. Install the oil pump chain guide.
6. Install the oil pan.

7. Install the timing chain. For additional
information, refer to Timing Chain in this
section.
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IN-VEHICLE REPAIR
Crankshaft Rear Seal (21 468 4)
3. Remove the clutch disc and pressure plate.
Special Tool(s)
[Clutch - Vehicles With: 5-Speed
Locking Tool, Flywheel Manual Transaxle (MTX-75), REMOVAL
303-254 AND INSTALLATION, Clutch Disc and
Pressure Plate]
Vehicles with automatic transaxle
4. Remove the transaxle. For additional
[Automatic
Transmission/Transaxle - Vehicles With:
Name Specification 4-Speed Automatic Transaxle (4F27E),
Cleaner WSK-M5B401-A1 REMOVAL, Transaxle - 1.8L Duratec-HE
All vehicles
Engine Oil - 5W-30 WSS-M2C913-B 5. Drain the engine.
• Allow the oil to drain into a suitable
container.
Removal
6. NOTE: Inspect the oil drain plug seal for
All vehicles damage. Install a new drain plug and seal if
1. Remove the engine cover. necessary.

indicator tube upper retaining bolt. 7. Remove the oil level indicator and oil level
indicator tube.
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8. Remove the air conditioning (A/C) 12. Using the special tool, lock the flywheel
compressor belt. For additional or flexplate in position.
9. Disconnect the A/C compressor electrical
connector.
13. Remove the flywheel or flexplate.


15. Remove the engine front cover lower re-
taining bolts.

pan and secure it to one side.
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16. Remove the oil pan. Installation
All vehicles
1. CAUTION: Do not remove the
installation sleeve before installation.
NOTE: Install a new crankshaft rear seal carrier.
NOTE: A new crankshaft rear seal carrier is
supplied preassembled with an installation sleeve
that must be removed following installation.
NOTE: Make sure that the dowel pins are
correctly seated.
Install the crankshaft rear seal carrier.
• Tighten the retaining bolts in the sequence
shown.
17. Remove the crankshaft rear seal carrier.
• Discard the crankshaft rear seal carrier.
2. Clean the mating faces of the cylinder

block, the engine front cover and the oil
pan with cleaner.
face of the oil pan to the cylinder block.
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4. NOTE: Install the oil pan within 10 minutes of 7. Tighten the oil pan retaining bolts in the
applying the silicone sealant and tighten the sequence shown.
face of the oil pan to engine front cover.
8. NOTE: Install new flywheel or flexplate

retaining bolts.
Install the flywheel or flexplate.
5. NOTE: Do not tighten the oil pan retaining bolts
at this stage.
9. Using the special tool, lock the flywheel or

flexplate in position.
6. Install the engine front cover lower retain-

ing bolts.
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10. Tighten the flywheel or flexplate retaining 15. Install the A/C compressor cover.
bolts.
three stages.
• Stage 1: 50 Nm.
• Stage 2: 80 Nm.
• Stage 3: 112 Nm.
16. Connect the A/C compressor electrical

connector.

12. Install the clutch disc and pressure plate.
Section 308-01.[Clutch - Vehicles With:
5-Speed Manual Transaxle (MTX-75),
REMOVAL AND INSTALLATION, Clutch
Disc and Pressure Plate]
Vehicles with automatic transaxle
13. Install the transaxle. For additional 17. Install the A/C compressor belt. For
information, refer to Section 307-01A. additional information, refer to Section 303-05.
[Automatic [Accessory Drive, REMOVAL AND
Transmission/Transaxle - Vehicles With: INSTALLATION, Air Conditioning (A/C)
4-Speed Automatic Transaxle (4F27E), Compressor Belt - 1.8L Duratec-HE
INSTALLATION, Transaxle - 1.8L (MI4)/2.0L Duratec-HE (MI4)]
Duratec-HE (MI4)/2.0L Duratec-HE (MI4)] 18. Install the oil level indicator and oil level
All vehicles indicator tube.
14. Attach the A/C compressor to the oil pan.
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indicator tube upper retaining bolt.
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REMOVAL
Engine — Vehicles With: Manual Transaxle
REMOVAL

Special Tool(s)
Lifting Bracket, Engine
303-122
Remover/Installer, Hose
Clamp
303-397

Disconnect Tool, Fuel Line information, refer to Section 414-01.
(5/16”) [Battery, Mounting and Cables,
310-040
3. Disconnect the battery positive cable from
General Equipment the battery positive cable terminal clamp.
Workshop table
Engine hoist
Retaining straps
Removal
All vehicles
are always present and may ignite. 4. Drain the cooling system. For additional
Failure to follow these instructions may information, refer to Section 303-03A.
result in personal injury. [Engine Cooling - 1.8L Duratec-HE
Filling and Bleeding]
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REMOVAL (Continued)
5. Detach the ground cables from the wheel 8. Disconnect the heated oxygen sensor
housing. (HO2S) electrical connector.
6. Remove the central junction box (CJB) 9. Disconnect the catalyst monitor sensor
cover. electrical connector.
7. Disconnect the engine wiring harness 10. Remove the radiator. For additional
electrical connector. information, refer to Section 303-03A.
REMOVAL AND INSTALLATION, Radiator]
coolant hose from the coolant outlet
connector.
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REMOVAL (Continued)
12. Disconnect the coolant hose. 15. Disconnect the brake booster vacuum
line from the intake manifold.

coolant hose from the coolant expansion Vehicles with iB5 manual transaxle
tank. 16. Raise and support the vehicle. For
refer to Section 100-02.[Jacking and Lifting,
17. Remove the gearshift cables cover.
14. Remove the coolant expansion tank.
18. Detach the gearshift cables from the

transaxle.
1. Detach the gearshift cables and the selector
cable from the selector levers.
2. Turn the abutment sleeve clockwise and
detach the cables from the bracket.
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(MI4)
REMOVAL (Continued)
Vehicles with MTX-75 manual transaxle
19. Disconnect the reversing lamp switch
transaxle.
1. Press the locking tab and detach the
selector cable from the transaxle selector
lever.
2. Press the locking tab and detach the
gearshift cable from the transaxle selector
lever.
20. CAUTION: If brake fluid is spilt on the

water.
Disconnect the clutch slave cylinder
supply line.
• Remove the spring clip. 23. Detach the gearshift cables from the
abutment.
1. Rotate the abutment sleeves
counterclockwise and detach the selector
cable from the abutment.
2. Rotate the abutment sleeves counter-
clockwise and detach the gearshift cable
from the abutment.
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(MI4)
REMOVAL (Continued)
24. Disconnect the reversing lamp switch 26. CAUTION: If brake fluid is spilt on the
electrical connector. paintwork, the affected area must be
water.
CAUTION: Close off the clutch slave
cylinder supply line to prevent fluid loss
or dirt ingress.
Detach the clutch slave cylinder supply
line from the clutch slave cylinder.
• Remove the spring clip.
• Detach the clutch slave cylinder supply line
from the bracket.
25. Detach the ground cable from the trans-

axle.
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(MI4)
REMOVAL (Continued)
All vehicles 29. Disconnect the evaporative emission
27. Remove the exhaust manifold heat shield (EVAP) valve vacuum line.
30. Using the special tool, disconnect the fuel

supply line.

nuts (engine shown removed for clarity). 31. Raise and support the vehicle. For
• Discard the nuts. additional information,
• Discard the gasket. refer to Section 100-02.[Jacking and Lifting,
32. Remove the exhaust manifold lower
retaining nuts (engine shown removed for
clarity).
• Detach the exhaust manifold from the cyl-
inder head and position it to one side.
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(MI4)
REMOVAL (Continued)
33. Remove the air conditioning (A/C) 37. Detach the A/C compressor from the oil
compressor belt. For additional pan and position it to one side.
34. Remove the A/C line retaining bracket.
39. Remove the left-hand halfshaft. For

[Front Drive Halfshafts, REMOVAL
AND INSTALLATION, Halfshaft LH]
36. Disconnect the A/C compressor electrical

connector.
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(MI4)
REMOVAL (Continued)
41. NOTE: Using suitable retaining straps to
44. Remove the engine front mount retaining
secure the engine and the transaxle on the
studs.
workshop table.
Position the workshop table under the
vehicle and carefully lower the vehicle,
until the engine and transaxle assembly is
in the correct position to remove the en-
gine mounts.
45. Remove the engine front mount.

46. Remove the engine rear mount retaining
bolt.
42. Detach the A/C compressor line retaining

bracket from the engine front mount.
47. Raise and support the vehicle and remove

the engine and transaxle assembly. For
nuts and bolts.
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(MI4)
REMOVAL (Continued)
48. Using a suitable engine hoist support the 51. Remove the transaxle lower retaining
engine and transaxle assembly and re- bolts.
move the retaining straps.
52. Remove the transaxle right-hand retain-

ing bolts.
49. Remove the wiring harness retaining
bracket.
53. Remove the transaxle left-hand retaining

bolts.
50. Remove the starter motor.
• Detach the wiring harness from the retain-
ing bracket.
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TO MODEL INDEX

(MI4)
REMOVAL (Continued)
54. Remove the transaxle upper retaining
bolts.
55. Remove the transaxle.
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TO MODEL INDEX

(MI4)
REMOVAL
Engine — Vehicles With: 4-Speed Automatic Transaxle (4F27E)

Special Tool(s)
303-122
Clamp
303-397
3. Disconnect the battery positive cable from

Disconnect Tool, Fuel Line the battery positive cable terminal clamp.
(5/16”)
310-040
General Equipment
Workshop table
Engine hoist
Retaining straps
Removal
WARNING: Do not smoke or carry lighted information, refer to Section 303-03A.
tobacco or open flame of any type when [Engine Cooling - 1.8L Duratec-HE
working on or near any fuel related (MI4)/2.0L Duratec-HE (MI4), GENERAL
components. Highly flammable vapors PROCEDURES, Cooling System Draining,
are always present and may ignite. Filling and Bleeding]
Failure to follow these instructions may
result in personal injury. 5. Detach the ground cables from the wheel
1. Remove the battery tray. For additional housing.
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TO MODEL INDEX

(MI4)
REMOVAL (Continued)
9. Disconnect the catalyst monitor sensor
6. Remove the central junction box (CJB)
cover.
10. Disconnect the turbineshaft speed (TSS)

7. Disconnect the engine wiring harness sensor electrical connector.
11. Disconnect the automatic transaxle elec-

8. Disconnect the heated oxygen sensor trical connector.
(HO2S) electrical connector.
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(MI4)
REMOVAL (Continued)
12. WARNING: Beware, risk of scalding 15. Disconnect the coolant hose.
when draining transmission fluid.
Failure to observe this instruction can
lead to injury.
CAUTION: Close off the transmission fluid
cooler feed and return lines to prevent
NOTE: Mark the position of the feed and return
lines as an aid to installation.
Detach the transmission fluid cooler feed
and return lines from the automatic
transmission.
tainer.
coolant hose from the coolant expansion
tank.
13. Remove the radiator. For additional

Duratec-HE (MI4)/2.0L Duratec-HE (MI4), 17. Remove the coolant expansion tank.
REMOVAL AND INSTALLATION, Radiator]
coolant hose from the coolant outlet
connector.
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TO MODEL INDEX

(MI4)
REMOVAL (Continued)
18. Disconnect the brake booster vacuum 20. Remove the exhaust manifold retaining
line from the intake manifold. nuts (engine shown removed for clarity).
19. Remove the exhaust manifold heat shield

21. Disconnect the evaporative emission
(EVAP) valve vacuum line.
22. Using the special tool, disconnect the fuel

supply line.
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TO MODEL INDEX

(MI4)
REMOVAL (Continued)
24. Remove the exhaust manifold lower 27. Disconnect the transmission Range (TR)
retaining nuts (engine shown removed for sensor electrical connector.
clarity).
• Detach the exhaust manifold from the cyl-
inder head and position it to one side.
28. Detach the selector lever cable from the

transmission.
25. Remove the air conditioning (A/C) selector mechanism.
compressor belt. For additional 2. Press the locking pins together and detach
information, refer to Section 303-05. the selector lever cable from the abutment.
26. Remove the A/C line retaining bracket.
29. Disconnect the outputshaft speed (OSS)

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(MI4)
REMOVAL (Continued)
30. Remove the A/C compressor cover. 33. Remove the engine support insulator.
31. Disconnect the A/C compressor electrical 34. Remove the left-hand halfshaft.
connector. additional information,
For refer to Section 205-04.
36. NOTE: Using suitable retaining straps to
secure the engine and the transaxle on the
workshop table.
Position the workshop table under the
vehicle and carefully lower the vehicle,
until the engine and transaxle assembly is
in the correct position to remove the en-
gine mounts.

pan and position it to one side.
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TO MODEL INDEX

(MI4)
REMOVAL (Continued)
37. Detach the A/C compressor line retaining 41. Remove the engine rear mount retaining
bracket from the engine front mount. bolt.
38. Remove the engine front mount retaining 42. Raise and support the vehicle and remove
nuts and bolts. the engine and transaxle assembly.
• Discard the nuts. 43. Using a suitable engine hoist support the
engine and transaxle assembly and re-
move the retaining straps.

studs.
44. Remove the wiring harness retaining

bracket.
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TO MODEL INDEX

(MI4)
REMOVAL (Continued)
45. Remove the starter motor. 48. Remove the transaxle right-hand retain-
• Detach the wiring harness from the retaining bolts.
ing bracket.

46. Remove the torque converter nuts (four bolts.
nuts).
• Discard the torque converter nuts.

bolt.
47. Remove the transaxle lower retaining
bolts.
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(MI4)
DISASSEMBLY
Engine (21 134 8)
DISASSEM BLY
Special Tool(s)
Mounting Plate for
Special Tool(s) 303-435-06
303-435-11A
Wrench
205-072
1. Using the special tools, mount the engine
to the mounting stand.
Adapter for 205-072
205-072-01
Adapter for 205-072

205-072-02

303-122
Locking Tool, Flywheel

303-254
Clamp
303-397
Mounting Stand
303-435
Mounting Bracket for 303-435

303-435-06
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(MI4)
DISASSEMBLY (Continued)
3. Drain the engine. 7. Remove the oil level indicator and oil level
• Allow the oil to drain into a suitable indicator tube.
container.
4. NOTE: Inspect the oil pan drain plug seal for
damage. Install a new drain plug and seal if
required.
Install the drain plug.
8. Remove the intake manifold.

bracket.

coolant hose.
6. Detach electrical connector bracket from

the thermostat housing.
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(MI4)
10. Remove the ignition coil-on-plug. 13. Remove the generator.
11. Remove the valve cover. 14. Remove the coolant pump pulley.
12. Remove the accessory drive belt ten- 15. Using the special tools, prevent the
sioner. crankshaft pulley from rotating and re-
move the crankshaft pulley.
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TO MODEL INDEX

(MI4)
16. Remove the engine front cover. 18. NOTE: Hold the camshafts by the hexagon
with an open-ended wrench to stop them from
rotating.
Remove the camshaft sprockets and the
timing chain.
19. Remove the timing chain guides.
17. Detension the timing chain.

pin punch.
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(MI4)
21. Remove the oil pump chain guide. 24. Remove the oil pump chain.
1. Remove the oil pump sprocket retaining
bolt.
2. Remove the oil pump chain and the oil
pump sprocket.
22. Remove the oil pump chain tensioner.
25. Remove the front friction washer.

• Discard the friction washer.
23. Using the special tool, loosen the oil

26. Remove the crankshaft sprocket.
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(MI4)
27. Remove the rear friction washer. 29. CAUTION: Remove the cylinder head
• Discard the friction washer. bolts in the sequence shown.
Remove the cylinder head.
28. CAUTION: Keep the camshaft bearing

caps, valve tappets and the camshafts
in order for installation. 30. Remove the coolant pump.
CAUTION: Remove the camshaft bearing • Discard the O-ring.
caps in the sequence shown.
camshaft bearing cap retaining bolt two turns at a
time.
Remove the camshaft bearing caps.
• Remove the camshafts.
• Remove the valve tappets.
31. Remove the thermostat housing.

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(MI4)
32. Remove the knock sensor (KS) for cylin- 35. Remove the oil filter adapter.
der 1 and 2 and for cylinder 3 and 4. • Discard the gasket.
33. Remove the KS (if equipped). 36. Remove the clutch disc and pressure
plate. For additional information,
refer to Section 308-01.[Clutch - Vehicles
With: 5-Speed Manual Transaxle (MTX-75),
37. Using the special tool, lock the flywheel in
position.
34. Remove the crankcase ventilation oil

separator.
38. Remove the flywheel.

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(MI4)
40. NOTE: Remove the oil pan by pulling it
downwards to prevent oil deposits or abraded
particles from entering the engine.
Remove the oil pan.
41. Remove the crankshaft rear seal carrier.

• Discard the seal carrier.
42. Remove the oil pump.

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(MI4)
ASSEMBLY
Engine (21 134 8)
ASSEM BLY
General Equipment
Engine hoist
Special Tool(s)
M6 x 18 mm bolt
Universal Flange Holding Straight edge
Wrench
205-072
Name Specification
Cleaner WSK-M5B401-A1
Adapter for 205-072
205-072-01
Adapter for 205-072 Assembly

205-072-02
1. NOTE: Install a new oil pump gasket.
Install the oil pump.
Lifting Bracket, Engine two stages.
303-122 • Stage 1: 10 Nm.
• Stage 2: 23 Nm.

303-254

303-376
Clamp
303-397

303-507
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(MI4)
ASSEMBLY (Continued)
2. NOTE: Install a new crankshaft rear seal 5. NOTE: Do not tighten the oil pan retaining bolts
carrier. at this stage.
NOTE: Install a new crankshaft rear seal carrier Install the oil pan.
gasket.
Install the crankshaft rear seal carrier.
6. Using a suitable straight edge, align the oil

pan to the mating face of cylinder block on
the timing chain side.
3. Clean the mating faces of the cylinder 7. Tighten the oil pan retaining bolts.
block and the oil pan with cleaner. • Tighten the bolts in the sequence shown.
applying the sealer and tighten the retaining
bolts within a further 5 minutes.
Apply a 3 mm bead of sealant to the oil pan.
8. NOTE: Install new flywheel bolts.

Install the flywheel.
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(MI4)
9. Using the special tool, lock the flywheel in 5-Speed Manual Transaxle (MTX-75),
position. REMOVAL AND INSTALLATION, Clutch
13. NOTE: Install a new oil filter adapter gasket.
Install the oil filter adapter.
10. Tighten the flywheel bolts.

three stages.
• Stage 1: 50 Nm 14. Install the crankcase vent oil separator.
• Stage 2: 80 Nm
• Stage 3: 112 Nm
15. NOTE: Rotate the knock sensor (KS) as far

counter-clockwise as possible without touching
11. Remove the special tool. the PCV housing.
Install the KS (engine with one KS
shown).
12. Install the clutch disc and pressure plate.

For additional information, refer toSection 308-01.
[Clutch - Vehicles With:
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(MI4)
16. Install the KS for cylinder 1 and 2 and 19. NOTE: Only rotate the crankshaft in the
cylinder 3 and 4 (engine with two KS normal direction of rotation.
shown).
Using the crankshaft pulley retaining bolt,
rotate the crankshaft until piston No. 1 is
approximately 20 mm before top dead
center (TDC).
17. NOTE: Install a new thermostat housing

gasket.
Install the thermostat housing.
20. Remove the crankshaft pulley bolt.
21. NOTE: Install new cylinder head bolts and
cylinder head gasket.
Install the cylinder head.
• Tighten the cylinder head bolts in the
sequence shown in five stages.
• 1. Stage: 5 Nm.
• 2. Stage: 15 Nm.
• 3. Stage: 45 Nm.
• 4. Stage: 90 degrees.
• 5. Stage: 90 degrees.
18. NOTE: Install a new coolant pump O-ring seal.

Install the coolant pump.
22. Install the valve tappets.
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(MI4)
23. CAUTION: Install the camshafts 25. NOTE: Install a new rear friction washer.
approximately at valve overlap Install the rear friction washer.
position cylinder No. 4.
CAUTION: Working in several stages,
evenly tighten the camshaft bearing caps
in the sequence shown, tightening the
bolts one half turn at a time.
• Coat the camshaft bearing caps with hypoid
oil.
• Tighten the camshaft bearing caps in the
sequence shown, tighten the bolts in two
stages:
• Stage 1: 7 Nm.
• Stage 2: 16 Nm.
26. Install the crankshaft sprocket.

27. NOTE: Install a new front friction washer.
Install the front friction washer.
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(MI4)
28. Install the oil pump chain. 31. Install the oil pump chain guide.
1. Install the oil pump chain and the oil pump
sprocket.
2. Install the oil pump sprocket retaining bolt.
32. Install the timing chain tensioner.
29. Using the special tool, tighten the oil

33. Install the timing chain guides.
30. Install the oil pump chain tensioner.
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(MI4)
34. CAUTION: Do not fully tighten the 36. CAUTION: Hold the camshafts by the
camshaft sprocket retaining bolts at hexagon with an open-ended wrench
this stage. to stop them from rotating.
NOTE: Make sure the camshaft sprockets rotate Tighten the camshaft sprockets retaining
on the camshafts. bolts.
Install the camshaft sprockets.
• Install the timing chain.
37. Clean the mating faces of the engine front

cover with cleaner.
35. Tension the timing chain. 38. NOTE: Install the engine front cover within 10
minutes of applying the sealer.
• Apply pressure to the timing chain and re-
move the securing pin. Apply a 3 mm bead of sealant to the en-
gine front cover.
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(MI4)
39. Install the engine front cover. 41. NOTE: Only rotate the crankshaft in the
• Tighten the bolts in the sequence shown in normal direction of rotation.
four stages: Using the crankshaft pulley retaining bolt,
• Stage 1: Tighten bolts 1 through 8 to 10 Nm. rotate the crankshaft against the special
• Stage 2: Tighten bolt 9: 48 Nm. tool until piston No. 1 is at TDC.
• Stage 3: Tighten bolts 10 through 19 to 10
Nm.
• Stage 4: Tighten bolts 20 through 22 to 48
Nm.
42. Remove the crankshaft pulley retaining

bolt.
43. CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
NOTE: Install a new crankshaft pulley retaining
bolt.
Install the crankshaft pulley onto the
crankshaft and secure the crankshaft
pulley to the front cover using a M6 x 18
mm bolt.

plug from the cylinder block and install
the special tool.
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(MI4)
44. Using the special tools, tighten the 47. Remove the special tool.
crankshaft pulley retaining bolt.
• Tighten the bolt in two stages.
• Stage 1: 100 Nm.

Rotate the crankshaft two revolutions.
45. Remove the crankshaft pulley securing
bolt.

46. Remove the special tool. Rotate the crankshaft until piston No. 1 is
at TDC.
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(MI4)
51. CAUTION: Only tighten the crankshaft

54. Remove the crankshaft pulley securing
pulley securing bolt finger tight.
bolt.
NOTE: If it is not possible to install the crankshaft
pulley securing bolt, correct the engine timing.
Using a M6 x 18 mm bolt, check the posi-
tion of the crankshaft pulley.
52. NOTE: If it is not possible to install the special

tool, correct the engine timing.
Using the special tool, check the position
of the camshafts.
56. Install the cylinder block lower blanking

plug.
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(MI4)
57. NOTE: When installing a new crankshaft
60. Install the generator.
pulley or engine front cover, the crankshaft
position (CKP) sensor must be aligned using
the tool supplied with the new component.
NOTE: Do not tighten the bolts at this stage.
Align the CKP sensor.
1. Loosen the CKP sensor retaining bolts.
2. Insert the tool supplied, so that its hooked in
the crankshaft pulley teeth.
61. Install the accessory drive belt tensioner.
58. Install the CKP sensor.

1. Tighten the CKP sensor retaining bolts.
2. Remove the tool.

as shown.
59. Install the coolant pump pulley.
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(MI4)
63. NOTE: Install a new valve cover gasket if 66. Install the intake manifold.
necessary.
67. Attach the electrical connector bracket to

the thermostat housing.
64. Install the ignition coil-on-plug.

indicator tube.
65. Using the special tool, install the coolant
hoses.
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(MI4)
69. Install the exhaust manifold retaining
bracket.

71. Using the special tool and an engine hoist,
support the engine.
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(MI4)
INSTALLATION
INST ALLAT ION
4. Install the transaxle left-hand retaining

Special Tool(s) bolts.
Clamp
303-397
General Equipment
Workshop table
Retaining straps
Engine hoist
5. Install the transaxle right-hand retaining

Installation bolts.
All vehicles
1. NOTE: Using suitable retaining straps, secure
the engine on the workshop table.
Support the engine with wooden blocks.
2. Install the transaxle.
3. Install the transaxle upper retaining bolts. 6. Install the transaxle lower retaining bolts.
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(MI4)
INSTALLATION (Continued)
7. Install the starter motor. 10. NOTE: Do not tighten the engine rear mount
Install the engine rear mount retaining
bolt.
8. Install the wiring harness retaining bracket.

• Attach the wiring harness to the retaining
bracket.
12. Install the engine front mount retaining
studs.
9. Position the workshop table under the ve-

hicle and carefully lower the vehicle until
the engine and transaxle assembly is in the
correct position to install the engine
13. NOTE: Install new engine front mount
mounts.
retaining nuts.
NOTE: Do not tighten the engine front mount
retaining nuts and retaining bolts at this stage.
Install the engine front mount retaining
nuts and bolts.
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(MI4)
14. Attach the air conditioning compressor
(A/C) line retaining bracket to the engine 20. Install the left-hand halfshaft.
front mount. For additional information,
15. Remove the retaining straps from the

transaxle.
16. Connect the fuel supply line.
22. Attach the air conditioning (A/C) com-

pressor to the oil pan.
17. Connect the evaporative emission (EVAP)

valve vacuum line.

connector.

refer to Section 100-02.[Jacking and Lifting, 24. Install the A/C compressor belt. For
DESCRIPTION AND OPERATION, Lifting] additional information, refer to Section
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(MI4)
303-05.[Accessory Drive, REMOVAL AND 29. Tighten the engine rear mount retaining
INSTALLATION, Air Conditioning (A/C) bolt.
25. Install the A/C compressor cover.
30. Tighten the engine front mount retaining

nuts and retaining bolts.
26. Install the A/C line retaining bracket.

Tighten the exhaust manifold retaining
27. Install the exhaust manifold lower retain- nuts (engine shown removed for clarity).
ing nuts (engine shown removed for clar-
ity).
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(MI4)
32. Install the exhaust manifold heat shield 35. CAUTION: If brake fluid is spilt on the
(engine shown removed for clarity). paintwork, the affected area must be
water.
NOTE: Make sure the spring clip is correctly
seated.
Connect the clutch slave cylinder supply
line.
• Install the spring clip.
36. Attach the gearshift cables to the bracket

and turn the abutment sleeves counter-
clockwise.
Vehicles with iB5 manual transaxle

34. Connect the reversing lamp switch elec-
trical connector.
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(MI4)
37. Attach the gearshift cables to the selector Vehicles with MTX-75 manual transaxle
levers.
water.
line to the clutch slave cylinder.
• Attach the clutch slave cylinder supply line
to the bracket.
38. Install the gearshift cables cover.
41. Attach the ground cable to the transaxle.
42. Connect the reversing lamp switch elec-

trical connector.
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(MI4)
All vehicles
43. Attach the gearshift cables to the
45. Connect the brake booster vacuum line to
abutment.
1. Rotate the abutment sleeves clockwise and
attach the gearshift cable to the abutment.
2. Rotate the abutment sleeves clockwise and
attach the selector cable to the abutment.
46. Install the coolant expansion tank.

transaxle.
1. Press the locking tab and attach the
gearshift cable to the transaxle selector
lever.
2. Press the locking tab and attach the selec-
tor cable to the transaxle selector lever.

ant hose to the coolant expansion tank.
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(MI4)
48. Connect the coolant hose. 51. Connect the heated oxygen (HO2S) sen-
sor electrical connectors.

ant hose to the coolant outlet connector. 52. Connect the engine wiring harness elec-
trical connector.
50. Connect the catalyst monitor sensor

electrical connector. 53. Install the central junction box (CJB)
cover.
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(MI4)
54. Attach the ground cables to the wheel 303-03A.[Engine Cooling - 1.8L
housing. Duratec-HE (MI4)/2.0L Duratec-HE (MI4),
55. Adjust the gearshift cables.

refer to Section 308-00.[Manual
Transmission/Transaxle and Clutch - Vehicles with global closing
General Information, GENERAL 61. Initialize the door window motors.
PROCEDURES, Gearshift Cable For additional information,
Adjustment - Vehicles With: 5-Speed refer to Section 501-11.
Manual Transaxle (MTX-75)] [Glass, Frames and Mechanisms,
56. Bleed the hydraulic clutch system. GENERAL PROCEDURES, Door Window
For additional information, Motor Initialization]
[Manual Transmission/Transaxle
and Clutch - General Information,
GENERAL PROCEDURES, Clutch System
Bleeding]
57. Install the battery tray. For additional
58. Connect the battery positive lead to the
battery positive cable terminal clamp.

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(MI4)
INSTALLATION
Engine — Vehicles With: Automatic Transaxle
3. CAUTION: The torque converter hub

Special Tool(s)
must engage fully with the oil pump
Remover/Installer, Hose drive gear.
Clamp Check the installation depth of the torque
303-397 converter.
1. Position the steel straightedge on the
transmission flange.
2. Measure the correct installation depth be-
General Equipment tween the automatic transmission flange
and the torque converter guide collar.
Workshop table
Retaining straps
Engine hoist
Installation
All vehicles
1. NOTE: Using suitable retaining straps, secure
the engine on the workshop table.
Support the engine with wooden blocks.
2. CAUTION: The torque converter must
remain at the correct installation depth
during the entire installation.
NOTE: Before installing the bolts in the
transmission, the torque converter studs must be
aligned with the holes in the drive plate.
Install the torque converter.
4. Install the transaxle.
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5. Install the transaxle upper retaining bolts. 8. Install the transaxle lower retaining bolts.
6. Install the transaxle left-hand retaining 9. NOTE: Install new torque converter nuts.
bolt.
Install the torque converter nuts (4 nuts).
7. Install the transaxle right-hand retaining

bolts. 10. Install the starter motor.
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(MI4)
11. Install the wiring harness retaining
bracket.
15. Install the engine front mount retaining
• Attach the wiring harness to the retaining
studs.
bracket.
16. NOTE: Install new engine front mount

12. Position the workshop table under the
retaining nuts.
vehicle and carefully lower the vehicle
until the engine and transaxle assembly is NOTE: Do not tighten the engine front mount
in the correct position to install the en- retaining nuts and retaining bolts at this stage.
gine mounts. Install the engine front mount retaining
nuts and bolts.
13. NOTE: Do not tighten the engine rear mount

retaining bolt at this stage. 17. Attach the air conditioning compressor
Install the engine rear mount retaining (A/C) line retaining bracket to the engine
bolt. front mount.
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18. Remove the retaining straps from the 24. Install the engine support insulator.
transaxle.
19. Connect the fuel supply line.
25. Attach the air conditioning (A/C) com-

pressor to the oil pan.
20. Connect the evaporative emission (EVAP)
valve vacuum line.

connector.
AND INSTALLATION, Halfshaft RH]
23. Install the left-hand halfshaft.
27. Install the A/C compressor belt.

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28. Install the A/C compressor cover. 31. Attach the selector lever cable to the
transmission.
1. Press the locking pins together and attach
the selector lever cable to the abutment
2. Attach the selector lever cable to the se-
lector mechanism.
29. Install the A/C line retaining bracket.
32. Connect the transmission range (TR)

30. Connect the output shaft speed (OSS)

33. Install the exhaust manifold lower retain-

ing nuts (engine shown removed for clar-
ity).
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35. Tighten the engine rear mount retaining 38. Install the exhaust manifold heat shield
bolt. (engine shown removed for clarity).
36. Tighten the engine front mount retaining

nuts and retaining bolts.
39. Connect the brake booster vacuum line to

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40. Install the coolant expansion tank. 43. Using the special tool, connect the cool-
ant hose to the coolant outlet connector.

ant hose to the coolant expansion tank. 44. Connect the automatic transaxle electri-
cal connector.
42. Connect the coolant hose.

45. NOTE: The transmission fluid cooler feed and
return lines connectors are color coded.
Attach the transmission fluid cooler feed
and return lines to the automatic trans-
axle.
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(MI4)
46. Connect the turbine shaft speed (TSS) 49. Connect the engine wiring harness elec-
sensor electrical connector. trical connector.
47. Connect the catalyst monitor sensor 50. Install the central junction box (CJB)
electrical connector. cover.
48. Connect the heated oxygen (HO2S) sen- 51. Attach the ground cables to the wheel
sor electrical connectors. housing.
52. Adjust the gearshift cables.

refer to Section 308-00.[Manual
Transmission/Transaxle and Clutch -
PROCEDURES, Gearshift Cable
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Adjustment - Vehicles With: 5-Speed 59. Install the engine cover.
Manual Transaxle (MTX-75)]
53. Bleed the hydraulic clutch system. For
308-00.[Manual Transmission/Transaxle
Bleeding]
55. Connect the battery positive lead to the Vehicles with global closing
battery positive cable terminal clamp. 60. Initialize the door window motors.
56. Connect the battery. For additional

Disconnect]
Duratec-HE (MI4)]
additional information, refer to Section 303-03A.
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303-01B-1 Engine — 2.0L Duratorq-TDCi (DW) Diesel 303-01B-1
PAGE 1 OF 2
SECTION 303-01B Engine — 2.0L Duratorq-TDCi (DW)

Diesel
CONTENTS PAGE
SPECIFICATIONS
Engine Data .................................................................................................................... 303-01B-3
Engine Oil Capacity......................................................................................................... 303-01B-3
Cylinder Block ................................................................................................................. 303-01B-3
Pistons ............................................................................................................................ 303-01B-3
Crankshaft....................................................................................................................... 303-01B-4
Connecting Rod .............................................................................................................. 303-01B-4
Piston Pin........................................................................................................................ 303-01B-4
Camshaft......................................................................................................................... 303-01B-4
Valves ............................................................................................................................. 303-01B-4
Cylinder Head ................................................................................................................. 303-01B-4
Oil Pressure Specifications.............................................................................................. 303-01B-4/6
Engine ............................................................................................................................. 303-01B-7

Overview ......................................................................................................................... 303-01B-7
General ........................................................................................................................... 303-01B-8
Cylinder head ancillary components................................................................................ 303-01B-9
Valve cover ..................................................................................................................... 303-01B-10
Cylinder head.................................................................................................................. 303-01B-11/12
Valve train ....................................................................................................................... 303-01B-13
Camshafts....................................................................................................................... 303-01B-14
Camshaft drive ................................................................................................................ 303-01B-15
Timing chain tensioner .................................................................................................... 303-01B-15
Timing chain.................................................................................................................... 303-01B-16
Pistons and piston rings .................................................................................................. 303-01B-16
Cylinder block ................................................................................................................. 303-01B-17
Crankshaft main bearings ............................................................................................... 303-01B-18
Oil pump.......................................................................................................................... 303-01B-19
Oil filter/oil cooler unit ...................................................................................................... 303-01B-20
Oil spray tubes ................................................................................................................ 303-01B-21
Engine ............................................................................................................................. 303-01B-22
IN-VEHICLE REPAIR
Intake Manifold — VIN Plate Emission Level Code: K...................................................... 303-01B-23/30

Intake Manifold — VIN Plate Emission Level Code: S...................................................... 303-01B-31/39
Crankshaft Front Seal ...................................................................................................... 303-01B-40/41
Valve Seals...................................................................................................................... 303-01B-42/45
Camshafts........................................................................................................................ 303-01B-46/50
Camshaft Seal ................................................................................................................. 303-01B-51/52
Timing Belt....................................................................................................................... 303-01B-53/62
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PAGE 2 OF 2
Exhaust Manifold ............................................................................................................. 303-01B-63/64

Cylinder Head.................................................................................................................. 303-01B-65/73
Oil Pan ............................................................................................................................ 303-01B-74/77
Oil Pump.......................................................................................................................... 303-01B-78/81
Crankshaft Rear Seal ...................................................................................................... 303-01B-82/84
Engine ............................................................................................................................. 303-01B-85/99
DISASSEMBLY
Engine ............................................................................................................................. 303-01B-100/135
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Cylinder Head.................................................................................................................. 303-01B-136/139
ASSEMBLY
Engine ............................................................................................................................. 303-01B-140/185
INSTALLATION
Engine ............................................................................................................................. 303-01B-186
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SPECIFICATIONS
Engine Data
Description
Engine code G6DA G6DB G6DC
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Emission level Stage III Stage IV Stage III
Bore 85.0 mm 85.0 mm 85.0 mm
Stroke 88.0 mm 88.0 mm 88.0 mm
Cubic capacity 1998 cm³ 1998 cm³ 1998 cm³
Compression ratio 18:1 18:1 18:1
Power output at 4000 rpm 100 kW (136 PS) 100 kW (136 PS) 98 kW (133 PS)
Torque at 1750 rpm 320 Nm 320 Nm 320 Nm
Maximum engine speed 5000 rpm 5000 rpm 5000 rpm
(intermittent)
Maximum engine speed 4500 rpm 4500 rpm 4500 rpm
(continous)
Idle speed 750 rpm 750 rpm 750 rpm
Maximum oil consumption 0.1L / 1000 Km 0.1L / 1000 Km 0.1L / 1000 Km

Item Specification
Engine oil WSS-M2C913-B
Coolant WSS-M97B44-D
Sealant WSE-M4G323-A4
Engine Oil Capacity

Description Liters
Initial fill including oil filter 5.5
Service fill including oil filter 5.5
Service fill without oil filter 5.0
Cylinder Block
Description mm
Cylinder bore diameter 85.000 - 85.018
Main bearing parent bore diameter 63.731 - 63.750
Main bearing clearance - radial 0.022 - 0.072
Pistons
Description mm
Piston diameter 84.915 - 84.946
Piston clearance in cylinder 0.056 - 0.103
Piston ring end gaps
— upper compression ring 0.200 - 0.350
— lower compression ring 0.800 - 1.000
— oil control ring 0.250 - 0.500
Piston ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston.
This also applies to the oil control ring elements. Align the piston ring gaps at 120 degrees to each other.
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Crankshaft
Description mm
Main bearing journal diameter 59.975 - 60.000
Connecting rod bearing journal diameter 49.980 - 50.000
Crankshaft end play 0.07 - 032
Connecting Rod
Description mm
Big end bore diameter 53.708 - 53.695
Small end bore diameter 28.007 - 28.020
Connecting rod bearing clearance 0.023 - 0.072
Piston Pin
Description mm
Piston pin length 69.700 - 70.000
Piston pin diameter 27.995 - 28.000
Camshaft
Description mm
Camshaft end float 0.070 - 0.168
Camshaft bearing journal diameter 25.059 - 25.080
Valves
Description mm
Valve stem diameter 5.969 - 5.987
Valve guide 6.000 - 6.018
Valve stem to valve guide clearance — intake valve 0.013 - 0.049
Valve stem to valve guide clearance — exhaust valve 0.023 - 0.059
Cylinder Head
Description mm
Thickness of cylinder head gasket with piston protrusion of 0.55 - 0.60 1.210- 1.290 (one hole)
Thickness of cylinder head gasket with piston protrusion of 0.61 - 0.65 1.260 - 1.340 (two holes)
Thickness of cylinder head gasket with piston protrusion of 0.66 - 0.70 1.310 - 1.390 (three holes)
Thickness of cylinder head gasket with piston protrusion of 0.71 - 0.75 1.360 - 1.440 (four holes)
Maximum distortion — measured longitudinally and diagonally 0.030
Oil Pressure Specifications

Description bar
Oil pressure at 2000 rpm 2.0
Oil pressure at 4000 rpm 4.0
Engine rear mount retaining nuts 48 35 -
Engine rear mount center bolt 80 59 -
Engine front mount retaining nuts 80 59 -
Engine front mount bracket retaining bolts 56 41
Engine support insulator to transaxle bracket bolt 80 59 -
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Engine support insulator to front axle crossmember 80 59 -
bolts
Lower arm ball joint retaining nuts 70 52 -
Intermediate shaft centre bearing cap locknuts 25 18 -
Thermostat housing retaining nuts 18 13 -
Crankshaft front seal retainer bolt 14 10 -
Crankshaft pulley retaining bolt a) - -
Flywheel retaining bolts a) - -
Crankshaft main bearing cap retaining bolts a) - -
Piston cooling jets retaining bolts 10 - 89
Connecting rod bearing cap retaining bolts a) - -
Fuel pump retaining bolts 20 15 -
Fuel injection supply manifold retaining nuts 22 16 -
Fuel injector retaining bracket nuts a) - -
High pressure fuel supply line nuts to fuel injectors a) - -
High-pressure fuel supply line nuts to fuel injection a) - -
supply manifold
Clutch disc and pressure plate retaining bolts 29 21 -
Camshaft housing retaining bolts a) - -
Camshaft housing retaining studs 10 - 89
Camshaft position sensor (CMP) retaining bolt 2 - 18
Timing belt tensioner retaining bolt a) - -
Timing belt cover retaining bolts 7 - 62
Brake vacuum pump retaining bolts 9 - 80
Camshaft pulley retaining bolt a) - -
Oil pump pickup tube retaining bolts 12 9 -
Oil cooler retaining bolts 20 15 -
Oil pump retaining bolts 16 12 -
Oil pump guiding bolt 16 12 -
Oil pan drain plug 34 25 -
Oil pan retaining bolts 16 12 -
Oil pan to transaxle retaining bolts 48 35 -
Oil filter 25 18 -
Oil level indicator tube retaining bolt 12 9 -
Oil filler tube retaining bolts 9 - 80
Cylinder head bolts a) - -
Timing belt upper cover retaining bolt 7 - 62
Timing belt lower cover retaining bolt 7 - 62
Timing belt lower cover retaining nut 7 - 62
Exhaust manifold studs 10 - 89
Exhaust manifold retaining nuts 30 22 -
Exhaust gas recirculation (EGR) vacuum regulator 7 - 62
retaining bolts
EGR valve retaining bracket retaining bolts 6 - 53
Glow plugs 10 - 89
Glow plug wiring loom retaining nuts 3 - 27
Generator front retaining bolts 25 19 -
Generator rear retaining bolt 48 35 -
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Generator mounting bracket retaining bolts 12 9 -
A/C compressor retaining adapter 48 35 -
Intake manifold assembly retaining bolts a) - -
Throttle body retaining bolts 9 80
Turbocharger retaining nut 25 19 -
Turbocharger retaining bolt 25 19 -
Turbocharger stud 10 - 89
Turbocharger oil return tube flange bolts 10 - 89
Turbocharger oil supply line union bolt to turbo- 28 21 -
charger
Turbocharger oil supply line union bolt to cylinder 40 30 -
block
Turbocharger variable vain vacuum regulator re- 10 - 89
taining nuts
Crankshaft position (CKP) sensor retaining bolt 8 - 71
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Engine
Overview
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camshaft. The exhaust camshaft drives the inlet

camshaft via a short timing chain.
General The oil pump is located inside the oil pan and is
The 2.0L Duratorq TDCi (DW10) engine uses the driven by the crankshaft via an oil pump chain.
Siemens common rail direct fuel injection process. The vacuum pump is flange-mounted onto the
The cylinder head is made of two parts. The upper inlet camshaft and is driven directly.
and lower parts are made of aluminium and are
bolted to each other. The lower section houses
Engine identification
four valves per combustion chamber and the valve
gear and camshafts. NOTE: Cylinder 1 is located on the transmission
side.
The valves are actuated by means of two
overhead camshafts and roller followers with The serial number of the engine and the engine
hydraulic tappets. code are located on the intake side of the cylinder
block (in line with the second cylinder).
The exhaust camshaft and the coolant pump are
driven by a toothed belt. The fuel pump is
flange-mounted directly onto the exhaust

Number
1 - Engine code
2 - Engine serial number
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Cylinder head ancillary components

Number
3 - exhaust gas
1 - Valve cover recirculation (EGR) connec-
2 - positive crank- tion
case ventilation (PCV) con- 4 - Cylinder head (upper part)
nection
5 - Cylinder head (lower part)
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Item Part Description Valve cover

Number
6 - Cylinder head gasket
The valve cover and the inlet manifold form one

assembly and are made of plastic.
The PCV valve is also located on the valve cover.
It is sealed off from the cylinder head with a
separate seal.
The cylinder head's intake ports and injector ports
are each sealed off from the inlet manifold by four
sealing rings.
NOTE: Refer to the current service literature for
precise details of how to assemble the valve cover
and inlet manifold.
Before re-installing the valve cover and the inlet
manifold, carefully check the sealing rings for
damage and renew if necessary.
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Cylinder head
The aluminium cylinder head has four valves per

Item Part Description combustion chamber. The valve seats and guides
Number are made of sintered steel.
1 - Seal The inlet ports are located on the front of the
2 - Exhaust camshaft cylinder head, the exhaust ports at the back (with
respect to the direction of travel).
3 - Inlet camshaft
4 - Alignment sleeves
5 - Timing chain
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The upper halves of the camshaft mountings are

Item Part Description incorporated into the upper part of the cylinder
Number head. Here the camshafts run directly in
1 - Inlet ports aluminium, without additional bearing shells.
2 - Cylinder head upper part The upper part of the cylinder head features
top-entry intake ports.
3 - Cylinder head lower part
The two individual parts are sealed using a
4 - Oil supply hole one-component, silicone-based sealant when
they are joined together.
NOTE: The upper and lower parts of the cylinder
head are matched to each other and cannot be
renewed separately.
NOTE: It is important to ensure that the oil supply
holes are not blocked by sealant when the two
parts of the cylinder head are brought together.
The cylinder head is made of two separate parts.
This special design ensures that the overall
structure is stronger.
The upper and lower parts of the cylinder head are
milled in a single operation and are accurately
positioned with two alignment sleeves.
The lower part of the cylinder head is bolted to the
cylinder block.
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Valve train
The hydraulic tappets are connected with the

Item Part Description engine's oil circuit by oil ports cast into the cylinder
Number head.
1 - Exhaust camshaft
2 - Inlet camshaft
3 - Roller cam follower
4 - Hydraulic tappet
The inlet valves are made entirely of one material.

The heads and stems of the exhaust valves are
manufactured from different materials and are
joined to one another by means of friction welding.
By using roller followers, it has been possible to
keep valve actuation friction losses low.
Valve clearance adjustment is done automatically
by the hydraulic tappets. As a result, there is no
need to adjust the valve clearances.
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Camshafts

Number
2 - Drive - fuel pump
3 - Drive - vacuum pump
4 - Inlet camshaft
The inlet and exhaust camshafts are made from

steel tubes. The cams and ends of the camshaft
are shrunk on.
Each camshaft runs directly in aluminium in five
bearings, without additional bearing shells.
The vacuum pump is flange-mounted onto the
rear of the inlet camshaft and is driven directly.
The fuel pump is flange-mounted onto the rear of
the exhaust camshaft and is also driven directly.
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Camshaft drive A hole is located on the exhaust camshaft timing

pulley into which can be inserted the timing pin
(special tool) to adjust the timing.
Timing chain tensioner

Number
1 - Timing belt pulley - exhaust
camshaft
2 - Timing chain tensioner
3 - Exhaust camshaft sprocket
4 - Inlet camshaft sprocket
The timing chain tensioner is attached to the

Item Part Description upper part of the cylinder head, between the
Number camshaft sprockets.
1 - Bore for timing peg Two securing bolts are used to secure the chain
tensioner.
2 - Idler pulley
3 - Crankshaft timing pulley
4 - Coolant pump pulley
5 - Tensioning pulley
NOTE: A spacer shim is located between the
cylinder block and the idler pulley (2); this must be
re-fitted when carrying out installation work.
The exhaust camshaft is driven by a toothed belt.
The toothed belt also drives the coolant pump.
The toothed belt drive has an automatic
tensioning pulley. The tensioning pulley operates
by spring force.
A feather key specifies the installation position of
the exhaust camshaft timing pulley and the
crankshaft timing pulley.
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Item Part Description markings must align with the arrow marks (B) on
Number the sprockets.

housing Pistons and piston rings
2 - Spring
3 - Timing chain guide
4 - Oil bore
The timing chain guide is made of plastic.

Timing chain guide wear is compensated for by a
spring loaded timing chain tensioner.
Because the timing chain tensioner is connected
to the engine oil supply circuit, the components
are lubricated and chain noise is reliably
prevented.
A second timing chain guide is attached to the
cylinder head lower section.
Timing chain

Number
1 - Upper compression ring
2 - Lower compression ring
3 - Oil scraper ring
Item Part Description The light alloy pistons have a combustion
Number chamber incorporated into the centre of the piston
1 - Exhaust camshaft crown. This optimises swirling of the fuel/air
mixture.
2 - Inlet camshaft
Two recesses are incorporated into each piston
(A) - Bright chrome-finished chain crown.
links
In order to minimise friction, particularly during the
(B) - Markings on the sprockets running-in phase, the piston stem has a
graphite-based coating.
The inlet camshaft is driven via a timing chain.
The piston pin is a floating fit and is held in position
The timing chain is tensioned using an automatic by two snap rings.
chain tensioner.
The timing chain has two bright chrome-finished
chain links (A). When installed, these two
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Cylinder block
Number
1 - Big-end bearing shells
the exact procedure and the correct tightening
torques for installing the big end bearings.
The connecting rods are made of forged steel.
The big-end bearing caps are cut and machined at
the joins to the connecting rod.
The big end bearing shells have retaining lugs to
prevent radial movement.
The retaining nuts are tightened in three stages. In
the third stage the nuts are tightened to a specified
angle.
The connecting rods and big-end bearing caps are
paired and must not be mixed up.

the exact procedure and the correct
measurements for machining.
The cylinder block is made of cast iron and has no
cylinder liners.
The running surfaces of the cylinders are worked
directly into the cylinder block.
The mating face of the cylinder block with the
cylinder head can be re-worked.
Two holes are provided in the cylinder block, for
the guide sleeves used to secure the cylinder
head gasket.
Connecting rods
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Crankshaft main bearings

Number
1 - Marking
A - Colour marking
2 - Barcode
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Item Part Description Retaining lugs on the crankshaft bearing shells

Number prevent radial movement.
3 - Alphanumerical code NOTE: The crankshaft main bearing caps must be

installed in the correct position.
4 - Thrust washers NOTE: Cylinder 1 is located on the transmission
5 - Marking side.
Numbers on the crankshaft main bearing caps
specify where they should be installed. When
For accurate adjustment of the crankshaft bearing installing them, the crankshaft main bearing cap
clearance, the crankshaft bearing shells in the marked "1F" must be nearest the transmission.
crankshaft main bearing caps are available in five
different thicknesses. Axial play is restricted by means of two thrust
plates on the crankshaft main bearing of cylinder
The upper crankshaft main bearings (cylinder 1.
block side) are only available in one thickness.
The thrust plates have lubricating grooves which
Marks on the cylinder block (1) and on the must be pointing towards the main bearing when
crankshaft (timing side) (4) indicate the installing them.
thicknesses of the crankshaft bearing shells
installed.
The barcode (2) is for production and the Oil pump
alphanumeric code (3) for service operations.

Number
2 - Oil pump housing
1 - Oil pump sprocket
3 - Oil strainer
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Item Part Description Oil filter/oil cooler unit

Number
4 - Pressure relief valve
5 - Retaining bolts
6 - Blanking plug
The oil pump is located on the front face of the

engine and is housed inside the oil pan.
It is a rotor pump and is driven by the crankshaft
via a short oil pump chain.
An oil pressure control valve is incorporated in the
oil pump housing. It opens when the oil pressure
reaches about 8 bar. Item Part Description
Number
1 - Oil filter housing
2 - Oil cooler
The oil cooler is an oil/coolant heat exchanger.

The oil filter/oil cooler unit is located on the side of
the cylinder block in line with cylinder 2.
The oil filter element has a blanking plug which
seals off the drain hole in the oil filter housing.
When changing the oil filter cartridge, the plug is
removed with the oil filter cartridge. The oil can
return to the oil pan through the housing, so that
no pollution can be caused by leaking oil.
The oil filter/oil cooler unit is connected directly
with the engine's coolant circuit by means of an
adapter and connecting hose.
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Number
1 - Oil pressure switch
The oil pressure switch is on the right-hand side,

beside the oil/coolant heat exchanger.
The oil pressure switch monitors the minimum oil
pressure of 0.5 bar. If the system does not reach
this pressure, the oil filter remains closed, for
safety reasons.
Oil spray tubes
The banjo bolts are connected to the engine oil

Item Part Description circuit.
Number
Valves are built into the banjo bolts, and from a
1 - Banjo bolts minimum oil pressure of about 0.5 bar they supply
2 - Oil spray tubes the oil spray tubes.
The piston skirts are cooled from below using oil

from the oil spray tubes. The oil spray tubes are
secured in the cylinder block with banjo bolts.
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Engine
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IN-VEHICLE REPAIR
Intake Manifold — VIN Plate Emission Level Code: K

IN-VEH ICLE R EPAIR

WARNING: Do not smoke or carry lighted additional information,
components. Highly flammable vapors [Front End Body Panels, REMOVAL
are always present and may ignite. AND INSTALLATION, Cowl Panel Grille]
Failure to follow these instructions may 2. Disconnect the battery ground cable. For
result in personal injury. additional information,
the fuel injection system with the engine [Battery, Mounting and Cables,
running. The fuel pressure within the GENERAL PROCEDURES, Battery
system is approximately 1600 bar. Failure Disconnect]
to follow these instructions may result in 3. Remove the engine cover.
personal injury.
WARNING: Wait at least one minute after
the engine stops before commencing any
repair to the fuel injection system. Failure
personal injury.
CAUTION: Diesel fuel injection equipment
is manufactured to very precise
tolerances and fine clearances. It is
therefore essential that absolute
cleanliness is observed when working
with these components. Always install
blanking plugs to any open orifices or
lines. 4. Remove the components in the order
table(s).
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IN-VEHICLE REPAIR

Number
1 - Exhaust gas recirculation
(EGR) pipe clamp
2 - EGR pipe
3 - Positive crankcase ventila-
tion (PCV) upper hose
4 - Throttle body retaining bolts
5 - Throttle body retaining
bracket bolt
6 - Throttle body O-ring seal
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IN-VEHICLE REPAIR

Number
6 - PCV upper hose
7 - EGR pipe retaining bolts
8 - EGR pipe
9 - Fuel injector electrical
connectors
See Removal Detail
10 - PCV lower hose
11 - Camshaft position (CMP)
sensor electrical connector
12 - CMP sensor
13 - Timing belt upper cover
See Removal Detail
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IN-VEHICLE REPAIR
Item Part Description All vehicles

Number
2. CAUTION: When installing the engine
14 - Intake manifold assembly cover, care must be taken to avoid
See Removal Detail damaging the fuel filter crash
See Installation Detail protection shield.
15 - Intake manifold assembly To install, reverse the removal procedure.
seals Vehicles with front and rear power windows
3. Initialize the door window motors.
G388108 en 09/2004 2004.75 Focus
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2. Remove the timing belt upper cover.
Removal Details
Item 9 : Fuel injector electrical connectors

1. Clean the area around the fuel injectors.
303-04B.[Fuel Charging and Controls - 2.0L
Duratorq-TDCi (DW) Diesel, DIAGNOSIS
AND TESTING, Fuel Charging and
Controls]
Item 13 : Timing belt upper cover
1. Detach the engine wiring harness from the
timing belt upper cover.
Item 14 : Intake manifold assembly
1. Remove the intake manifold assembly re-
taining bolts in the sequence shown.
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IN-VEHICLE REPAIR
2. Detach the fuel temperature sensor from Installation Details

the intake manifold assembly.
1. Attach the fuel temperature sensor to the
intake manifold assembly.
2. NOTE: Do not tighten the intake manifold

assembly retaining bolts at this stage.
Install the intake manifold assembly.
• Bolt with length 55 mm on position 14.
• Bolts with length 70 mm on position 16 and
17.
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IN-VEHICLE REPAIR
3. Tighten the intake manifold assembly bolts • Stage 1: 5 Nm.

in the sequence shown in two stages. • Stage 2: 9 Nm.
Item 12 : CMP sensor

1. NOTE: Only rotate the crankshaft in the normal
Position one of the camshaft pulley spokes
in an upright position.
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TO MODEL INDEX
2. Install the CMP sensor. 2. Attach the engine wiring harness to the
• Installing a new CMP sensor, position the timing belt upper cover.
CMP sensor so that the tip of the sensor is
in contact with the camshaft pulley and
tighten the retaining bolt.
• Reinstalling the original CMP sensor,
position the CMP sensor so that the tip of
the sensor is in contact with the camshaft
pulley.
• Measure the distance between the CMP
sensor and the intake manifold (YY).
• Pull back the CMP sensor until the dis-
tance between the CMP sensor and the
intake manifold = YY + 1.2 mm, and

1. Install the timing belt upper cover.
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IN-VEHICLE REPAIR
Intake Manifold — VIN Plate Emission Level Code: S

the fuel injection system with the engine
running. The fuel pressure within the
system is approximately 1600 bar. Failure
personal injury.
table(s).
personal injury.
lines.
[Front End Body Panels, REMOVAL
Disconnect]
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IN-VEHICLE REPAIR

Number
(EGR) pipe clamp
2 - EGR pipe
tion (PCV) upper hose
4 - Throttle housing retaining
bolts
5 - Throttle housing O-ring seal
G296584 en 09/2004 2004.75 Focus

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IN-VEHICLE REPAIR

Number
6 - PCV upper hose
8 - EGR pipe
9 - Fuel injector electrical
connectors
See Removal Detail
10 - PCV lower hose
12 - CMP sensor
See Removal Detail
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TO MODEL INDEX
IN-VEHICLE REPAIR
Item Part Description All vehicles

Number
2. CAUTION: When installing the engine
14 - Intake manifold assembly cover, care must be taken to avoid
See Removal Detail damaging the fuel filter crash
See Installation Detail protection shield.
15 - Intake manifold assembly To install, reverse the removal procedure.
seals Vehicles with front and rear power windows
G296584 en 09/2004 2004.75 Focus

TO MODEL INDEX
GENERAL PROCEDURES, Door Window 2. Remove the timing belt upper cover.
Removal Details
Item 9 : Fuel injector electrical connectors

1. Clean the area around the fuel injectors.
AND TESTING, Fuel Charging and
Controls]
1. Remove the intake manifold assembly re-
taining bolts in the sequence shown.
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IN-VEHICLE REPAIR
2. Detach the fuel temperature sensor from

the intake manifold assembly. Installation Details

1. Attach the fuel temperature sensor to the
intake manifold assembly.
2. NOTE: Do not tighten the intake manifold

assembly retaining bolts at this stage.
Install the intake manifold assembly.
• Bolt with length 55 mm on position 14.
• Bolts with length 70 mm on position 16 and
17.
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TO MODEL INDEX
3. Tighten the intake manifold assembly bolts

in the sequence shown in two stages.
• Stage 1: 5 Nm.
• Stage 2: 9 Nm.
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TO MODEL INDEX
the sensor is in contact with the camshaft

Item 12 : CMP sensor
pulley.
• Measure the distance between the CMP
sensor and the intake manifold (YY).
Position one of the camshaft pulley spokes • Pull back the CMP sensor until the dis-
in an upright position. tance between the CMP sensor and the
intake manifold = YY + 1.2 mm, and
2. Install the CMP sensor.

• Installing a new CMP sensor, position the
CMP sensor so that the tip of the sensor is
in contact with the camshaft pulley and
• Reinstalling the original CMP sensor,
position the CMP sensor so that the tip of
G296584 en 09/2004 2004.75 Focus

TO MODEL INDEX

2. Attach the engine wiring harness to the

G296584 en 09/2004 2004.75 Focus

TO MODEL INDEX
IN-VEHICLE REPAIR
Crankshaft Front Seal

1. Remove the timing belt. For additional
information, refer to Timing Belt in this
Special Tool(s) section.
Installer, Timing Cover Seal 2. Remove the components in the order
303-255
table(s).

303-293
Installer, Crankshaft Seal

303-395
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Item Part Description Installation Details

Number
Item 3 : Crankshaft front seal
1 - Timing belt pulley
1. NOTE: New crankshaft front seals are supplied
2 - Crankshaft pulley Woodruff with an alignment sleeve which will be pushed
key out during installation.
3 - Crankshaft front seal Using the special tool and the old
See Removal Detail crankshaft pulley bolt, install the
See Installation Detail crankshaft front seal.
• Remove and discard the alignment sleeve.
Removal Details

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IN-VEHICLE REPAIR
Valve Seals
Special Tool(s) working on or near any fuel related
Slide Hammer are always present and may ignite.
205-047 Failure to follow these instructions may
1. Remove the camshafts. For additional
Installer, Valve Stem Seal section.
303-037 2. Position the appropriate piston at top dead
center (TDC).
Compressor, Valve Spring
table(s).
303-060
Adapter for 303-060

303-060-07
Adapter for 303-060

303-060-09
Remover, Valve Stem Seal

303-292
G296586 en 09/2004 2004.75 Focus

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IN-VEHICLE REPAIR

Number
4 - Valve spring
1 - Camshaft followers See Removal Detail
See Removal Detail
5 - Valve stem seal
2 - Valve collets See Removal Detail
6 - Valve
3 - Valve spring retainer See Installation Detail
See Removal Detail
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4. To install, reverse the removal procedure. Item 5 : Valve stem seal

Removal Details stem seals.
• Discard the seals.
Item 1 : Camshaft followers
1. CAUTION: Keep the camshaft followers
Remove the camshaft followers.
Item 2 : Valve collets
collets.
Item 6 : Valve
1. NOTE: Clean the valve with clean hypoid oil.
Cover the valve collet grooves on the valve
stem with a protective sleeve (valve shown
Item 3 : Valve spring retainer
1. CAUTION: Keep the valve spring
retainers and the valve springs in
order for installation.
Remove the valve spring retainers.
Item 4 : Valve spring
1. CAUTION: Keep the valve springs in
Remove the valve springs.
G296586 en 09/2004 2004.75 Focus

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Item 5 : Valve stem seal

Using the special tool, install the valve
seals.
2. Remove the valve stem protective sleeve

after the valve seals have been installed.
collets.
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IN-VEHICLE REPAIR
Camshafts
Special Tool(s) 4. Remove the brake vacuum pump. For

Remover, O-Ring Seal [Power Brake Actuation, REMOVAL
100-010 AND INSTALLATION, Brake Vacuum Pump
- 2.0L Duratorq-TDCi (DW) Diesel]
Name Specification table(s).
Engine Oil - 5W-30 WSS-M2C913-B

Metal surface cleaner

1. Remove the fuel injectors. For additional
information, refer to Section 303-04B. [Fuel
Charging and Controls - 2.0L
Duratorq-TDCi (DW) Diesel, REMOVAL
AND INSTALLATION, Fuel Injectors - VIN
Plate Emission Level Code: S]
2. Remove the camshaft seal. For additional
information, refer to Camshaft Seal in this
section.
3. Remove the fuel pump. For additional
information, refer to Section 303-04B. [Fuel
AND INSTALLATION, Fuel Pump]
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IN-VEHICLE REPAIR

Number
3 - Camshaft housing
1 - Timing chain tensioner See Removal Detail
4 - Timing chain
2 - Fuel injector retaining studs See Removal Detail
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TO MODEL INDEX
6. To install, reverse the removal procedure. 2. Remove the timing chain tensioner.
Item 2 : Fuel injector retaining studs
Removal Details 1. Remove the fuel injector retaining studs in
the sequence shown.
Item 1 : Timing chain tensioner
1. Using the special tool, lock the timing
chain tensioner.
Item 3 : Camshaft housing

1. Remove the camshaft housing retaining
Item 4 : Timing chain

1. Remove both camshafts together with the Installation Details
timing chain from the cylinder head and
remove the timing chain. Item 4 : Timing chain
1. Lubricate the camshaft bearings with clean
engine oil
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2. CAUTION: The copper links of the 2. CAUTION: Make sure that the timing
timing chain must align with the timing chain tensioner oil supply hole is free
marks on the camshaft sprockets. from sealant.
Position the camshafts together with the Apply a 4 mm diameter bead of sealant to
timing chain on to the cylinder head. the cylinder head.
Item 3 : Camshaft housing 3. Tighten the camshaft housing retaining

1. Clean the upper mating face of the cylinder bolts in the sequence shown in two stages.
head and the camshaft housing with metal • Stage 1: 5 Nm.
surface cleaner.
• Stage 2: 10 Nm.
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IN-VEHICLE REPAIR
Item 2 : Fuel injector retaining studs Item 1 : Timing chain tensioner

1. Install the fuel injector retaining studs in 1. Using the special tool, install the timing
the sequence shown. chain tensioner.
2. Remove the special tool, unlock the timing

chain tensioner.
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TO MODEL INDEX
IN-VEHICLE REPAIR
Camshaft Seal
Special Tool(s)
Installer, Crankshaft Front
Special Tool(s) Seal
303-684/1
Wrench
205-072
1. Remove the timing belt. For additional
information, refer to Timing Belt in this
Gauge, Bolt Angle section.
303-174 2. Remove the components in the order
table(s).
303-293

Number
1 - Camshaft pulley bolt
See Removal Detail
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Number
Item 3 : Camshaft seal
2 - Camshaft pulley
1. NOTE: New camshaft seals are supplied with
3 - Camshaft seal an alignment sleeve which will be pushed out
See Removal Detail during installation.
Using the special tool, install the camshaft
seal.
• Remove and discard the alignment sleeve.
Removal Details
Item 1 : Camshaft pulley bolt

1. Using the special tool, remove the cam-
shaft pulley bolt.
Item 1 : Camshaft pulley bolt

1. Using the special tool, install the camshaft
pulley bolt.
• Tighten the camshaft pulley bolt in two
stages.
Item 3 : Camshaft seal • Stage 1: 20 Nm.
1. Using the special tool, remove the • Stage 2: 60 degrees.
camshaft seal.
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IN-VEHICLE REPAIR
Timing Belt
CAUTION: Do not install the timing belt

Special Tool(s)
until the engine has cooled to workshop
Locking Tool, Flywheel temperature.
303-393 1. Remove the cowl panel grille. For
Adapter for 303-393 2. Disconnect the battery ground cable.
303-393-01 For additional information,
Disconnect]
Clamp
303-397
Alignment Peg, Camshaft

303-735
Alignment Peg, Crankshaft

303-1059

information, refer to Section 303-03B.
Universal Flange Holding [Engine Cooling - 2.0L
Wrench Duratorq-TDCi (DW) Diesel, GENERAL
205-072 PROCEDURES, Cooling System Draining,
Filling and Bleeding - 2.0L]
5. Remove the accessory drive belt.
General Equipment refer to Section 303-05.
Trolley jack [Accessory Drive, REMOVAL AND
2.0L Duratorq-TDCi (DW) Diesel]
6. Remove the starter motor. For additional
CAUTION: Never install a used timing belt. information, refer to Section 303-06.
[Starting System, REMOVAL AND
INSTALLATION, Starter Motor - 2.0L
table(s).
G296593 en 09/2004 2004.75 Focus
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IN-VEHICLE REPAIR

Number
1 - Coolant expansion tank
coolant hoses
See Removal Detail
3 - Engine wiring harness
See Removal Detail
See Removal Detail
G296593 en 09/2004 2004.75 Focus

TO MODEL INDEX
IN-VEHICLE REPAIR

Number
5 - Crankshaft pulley retaining
bolt
See Removal Detail
6 - Crankshaft pulley
7 - Crankshaft position (CKP)
8 - CKP sensor retaining bolt
9 - CKP sensor
10 - Timing belt lower cover re-
taining bolt
11 - Timing belt lower cover re-
taining nut
12 - Timing belt lower cover
See Removal Detail
G296593 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
14 - Timing belt tensioner retain-
ing bolt
15 - Timing belt tensioner
16 - Timing belt
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TO MODEL INDEX
IN-VEHICLE REPAIR

Number
20 - Engine front mount bracket
17 - Engine front mount retaining retaining bolts
nuts
See Removal Detail 21 - Engine front mount bracket
18 - Engine front mount retaining 22 - Timing belt idler pulley

bolts
All vehicles
19 - Engine front mount 2. To install, reverse the removal procedure.
G296593 en 09/2004 2004.75 Focus

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Vehicles with global closing Item 4 : Timing belt upper cover

3. Initialize the door window motors. 1. Remove the timing belt upper cover.
Removal Details
Item 1 : Coolant expansion tank coolant hoses

1. CAUTION: Protect the generator with
lint free cloth to prevent dirt ingress.
Using the special tool, remove the coolant
expansion tank coolant hoses. Item 5 : Crankshaft pulley retaining bolt
Using the special tool, align the camshaft.
• Turn the crankshaft until the alignment hole
in the camshaft pulley is at the 4 o'clock
position.
Item 3 : Engine wiring harness

2. Insert the special tool into the flywheel.
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3. CAUTION: Make sure that the special Installation Details

tool engages correctly.
Using the special tools, lock the flywheel. Item 16 : Timing belt
1. CAUTION: Install the timing belt with
the direction arrows in the direction of
crankshaft rotation.
CAUTION: Do not install the timing belt
until the engine has cooled to workshop
temperature.
NOTE: Install a new timing belt.
Install the timing belt.
2. NOTE: Do not fully tighten the timing belt
tensioner retaining bolt at this stage.
NOTE: A new timing belt tensioner is supplied
locked to aid installation.
4. NOTE: Do not discard the crankshaft pulley bolt
at this stage. Install the timing belt tensioner.
3. NOTE: Install a new timing belt tensioner.
Remove the crankshaft pulley retaining
bolt. NOTE: Use an Allen key to maintain tension on
the timing belt tensioner until the retaining bolt is
Item 13 : Crankshaft timing pulley tightened.
1. NOTE: Do not touch the outer sensor ring.
Unlock the timing belt tensioner and
Remove the crankshaft timing pulley. tension the timing belt.
Item 17 : Engine front mount retaining nuts 1. Using an Allen key, turn the timing belt
1. Using a trolley jack and a suitable wooden tensioner counterclockwise to increase the
block under the oil pan raise the engine so tension on the timing belt.
that the engine front mount is free from 2. Check that the pointer is positioned on the
load. left-hand side of the window, if necessary
increase the tension of the timing belt by
turning the Allen key.
3. Tighten the timing belt tensioner retaining
bolt.
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4. CAUTION: Do not touch the outer 7. Remove the special tools.

sensor ring.
Using the old crankshaft pulley retaining
bolt, install the timing pulley and the
crankshaft pulley.

Rotate the crankshaft four times.
9. Insert the special tool into the flywheel.

6. Remove the special tool. tool engages correctly.
Using the special tools, lock the flywheel.
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11. NOTE: Only rotate the crankshaft in the 13. NOTE: Use an Allen key to maintain tension
normal direction of rotation. until the timing belt tensioner retaining bolt is
tightened.
Using the special tool, align the camshaft.
• If its not possible to install the special tool, Using an Allen key, adjust the correct
repeat the previous steps. timing belt tension.
1. Using an Allen key, keep the timing belt
tensioner adjustment arm in position.
2. Loosen the timing belt tensioner retaining
bolt.
bolt when the pointer is positioned centrally
in the window.
12. CAUTION: Do not touch the outer

sensor ring.
Remove the crankshaft pulley and the
timing pulley.
Item 13 : Crankshaft timing pulley

sensor ring.
Install the timing pulley.
Item 5 : Crankshaft pulley retaining bolt
1. NOTE: Install a new crankshaft pulley retaining
bolt.
Install the crankshaft pulley retaining bolt.
• Tighten the crankshaft pulley retaining bolt
in two stages.
• Stage 1: 70 Nm.
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Item 3 : Engine wiring harness
1. Attach the engine wiring harness to the
Item 1 : Coolant expansion tank coolant hoses

expansion tank hoses.
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IN-VEHICLE REPAIR
Exhaust Manifold
1. Remove the EGR cooler. For additional 3. Remove the components in the order
information, refer to Section 303-08A / indicated in the following illustration(s) and
303-08B / 303-08C. table(s).
2. Remove the turbocharger. For additional
information, refer to Section 303-04A /
303-04B / 303-04C / 303-04D.

Number
2 - Exhaust manifold heat shield
1 - Exhaust manifold retaining
nuts
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Number
nut spacers
4 - Exhaust manifold
5 - Exhaust manifold gasket
Item 4 : Exhaust manifold

1. Install new turbocharger and EGR cooler
retaining studs into the exhaust manifold.
G296594 en 09/2004 2004.75 Focus

TO MODEL INDEX
IN-VEHICLE REPAIR
Cylinder Head
Special Tool(s) 2. Remove the fuel filter. For additional

Gauge, Bolt Angle Tank and Lines, REMOVAL AND
303-174 INSTALLATION, Fuel Filter - 2.0L
Duratorq-TDCi (DW) Diesel, Vehicles With:
Water-in-Fuel Sensor] For additional
General Equipment [Fuel Tank and Lines, REMOVAL
AND INSTALLATION, Fuel Filter - 2.0L
Trolley jack Duratorq-TDCi (DW) Diesel, Vehicles
Without: Water-in-Fuel Sensor]
Name Specification 3. Remove the camshafts. For additional
Metal surface cleaner section.
4. Install the engine front mount bracket.

system is approximately 1600 bar. Failure
personal injury.
5. Loosely install the engine front mount
WARNING: Wait at least one minute after using the engine front mount retaining nuts
the engine stops before commencing any only.
repair to the fuel injection system. Failure • Do not install new engine front mount re-
to follow this instruction may result in taining nuts at this stage.
personal injury.
cleanliness be observed when working
lines.
CAUTION: Always carry out the cleaning
process before carrying out any repairs
to the fuel injection system components
to prevent foreign material entering the
components.
1. Remove the battery.
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6. Remove the trolley jack and the wooden refer to Section 303-03B.[Engine Cooling -
block. 2.0L Duratorq-TDCi (DW) Diesel, REMOVAL
AND INSTALLATION, Thermostat Housing]
8. Remove the exhaust gas recirculation
(EGR) cooler. For additional information,
refer to Section 303-08B.[Engine Emission
Control - 2.0L Duratorq-TDCi (DW) Diesel,
REMOVAL AND INSTALLATION, Exhaust
Gas Recirculation (EGR) Cooler]
9. Remove the EGR valve. For additional
[Engine Emission Control - 2.0L
AND INSTALLATION, Exhaust Gas
Recirculation (EGR) Valve]
7. Remove the thermostat housing. For indicated in the following illustration(s)
additional information, and table(s).

Number
3 - Fuel filter bracket lower re-
1 - Timing belt rear cover retaining bolt
taining bolt
4 - Fuel filter bracket
2 - Fuel filter bracket upper re-
taining bolt
G296595 en 09/2004 2004.75 Focus

TO MODEL INDEX
IN-VEHICLE REPAIR

Number
9 - Turbocharger intake pipe
5 - Glow plug wiring harness gasket
See Removal Detail
See Installation Detail 10 - Turbocharger vacuum hose
6 - Turbocharger intake pipe 11 - Turbocharger outlet pipe re-

retaining bolt taining nut
7 - Turbocharger intake pipe 12 - Turbocharger outlet pipe

flange bolts 13 - Catalytic converter bracket
8 - Turbocharger intake pipe retaining nuts
G296595 en 09/2004 2004.75 Focus

TO MODEL INDEX
IN-VEHICLE REPAIR

Number
19 - Turbocharger retaining nut
14 - Turbocharger oil supply line
See Removal Detail 20 - Engine support insulator re-
See Installation Detail taining bolt
15 - Turbocharger oil return line 21 - Exhaust manifold retaining

flange bolts nuts
16 - Turbocharger oil return line 22 - Exhaust manifold spacers
17 - Turbocharger oil return line 23 - Exhaust manifold heat shield

gasket
18 - Turbocharger retaining bolt
G296595 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item Part Description Item Part Description

Number Number
24 - Exhaust manifold 25 - Exhaust manifold gasket
See Removal Detail

Number
27 - Cylinder head bolts
26 - Engine front mount See Removal Detail
G296595 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item Part Description Item 24 : Exhaust manifold

Number 1. Move the engine 50 mm forwards until the
exhaust manifold is clear of the exhaust
28 - Cylinder head manifold studs.
Removal Details
Item 5 : Glow plug wiring harness

1. Detach the glow plug wiring harness from
the glow plugs.
Item 26 : Engine front mount

1. Using a trolley jack and a suitable wooden
block under the oil pan raise the engine so
that the engine front mount is free from
load.
Item 14 : Turbocharger oil supply line

1. Remove the turbocharger oil supply line
banjo bolt.
1. Discard the turbocharger banjo bolt seal.
G296595 en 09/2004 2004.75 Focus

TO MODEL INDEX
3. Remove the engine front mount bracket. Installation Details
Item 29 : Cylinder head gasket

1. Clean the mating faces of the cylinder head
and the cylinder block with metal surface
cleaner.
Item 27 : Cylinder head bolts

1. Remove the engine rear lifting eye.
2. Remove the cylinder head bolts in the se- 2. Check the cylinder head for distortion. For
quence shown. additional information, refer to Section 303-00.
Cylinder Head Distortion]
3. CAUTION: The thickness of the new
cylinder head gasket must be the same
as that of the old one (hole marked).
Install a new cylinder head gasket.
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Item 27 : Cylinder head bolts 2. Install the engine front mount with the
1. Using the special tool, install the cylinder engine front mount nuts only.
head bolts. • Do not install new engine front mount re-
• Tighten the bolts in the sequence shown in taining nuts at this stage.
two stages.
• Stage 1: 60 Nm.
3. Remove the trolley jack and the wooden

block.
2. Install the engine rear lifting eye.

1. Move the engine 50 mm rearwards until the
Item 26 : Engine front mount exhaust manifold is located on the exhaust
1. Install the engine front mount bracket. manifold studs.
G296595 en 09/2004 2004.75 Focus

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Item 14 : Turbocharger oil supply line

1. NOTE: Install a new turbocharger oil supply line
banjo bolt seal.
Install the turbocharger oil supply line
banjo bolt.
Item 5 : Glow plug wiring harness

1. Attach the glow plug wiring harness to the
glow plugs.
G296595 en 09/2004 2004.75 Focus

TO MODEL INDEX
IN-VEHICLE REPAIR
Oil Pan
Name Specification
Silicone Sealant WSE-M4G323-A4 4. CAUTION: Support the air conditioning
Vehicles without air conditioning (A/C) compressor before removing the
1. Raise and support the vehicle. For retaining bolts and secure it to one
additional information, side to prevent load being placed on
refer to Section 100-02. the refrigerant lines.
2. Remove the engine undershield. Detach the A/C compressor from the re-
taining adapter and the cylinder block and
secure it to one side.

additional information, 5. Remove the A/C compressor retaining
refer to Section 303-05. adapter.

table(s).
G296596 en 09/2004 2004.75 Focus

TO MODEL INDEX
IN-VEHICLE REPAIR

Number
5 - Charge air cooler intake pipe
1 - Oil drain plug
See Removal Detail 6 - Oil pan retaining bolt - long
2 - Oil drain plug seal 7 - Oil pan retaining bolt - short
3 - Charge air cooler intake pipe 8 - Oil pan to transaxle retaining

rear retaining bolt bolt

G296596 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item Part Description Item 9 : Oil pan

Number 1. Using a suitable spatula, remove the oil
pan.
9 - Oil pan • Slide the spatula around the profile of the oil
See Removal Detail pan.
8. Fill the engine with engine oil. Item 9 : Oil pan
1. Clean the mating faces of the oil pan and
Removal Details the cylinder block with suitable metal sur-
face cleaner.
Item 1 : Oil drain plug
1. Drain the engine.
2. NOTE: Do not install the new oil drain plug seal
at this stage.
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2. CAUTION: Install the oil pan within four

minutes of applying the sealer.
face of the oil pan.
3. NOTE: Do not fully tighten the oil pan retaining

bolts at this stage.
4. Tighten the oil pan to transaxle retaining
bolts.
5. Tighten the oil pan retaining bolts.
G296596 en 09/2004 2004.75 Focus

TO MODEL INDEX
IN-VEHICLE REPAIR
Oil Pump
1. Remove the oil pan. For additional

Name Specification information, refer to Oil Pan in this section.
Metal Surface Cleaner 2. Remove the crankshaft front seal. For
Silicone Sealant WSE-M4G323-A4 Front Seal in this section.
table(s).

Number
3 - Crankshaft front seal retainer
1 - Crankshaft front seal retainer See Removal Detail
bolts - long See Installation Detail
bolts - short
G296597 en 09/2004 2004.75 Focus

TO MODEL INDEX
IN-VEHICLE REPAIR

Number
8 - Oil pump drive sprocket
4 - Oil pump retaining bolts O-ring seal
5 - Oil pump guiding bolt
6 - Oil pump
See Removal Detail
Woodruff key
G296597 en 09/2004 2004.75 Focus

TO MODEL INDEX
4. To install, reverse the removal procedure. 2. Install the oil pump together with the oil
pump chain and the oil pump drive
Removal Details sprocket.
Item 3 : Crankshaft front seal retainer

1. Using a suitable spatula, remove the
crankshaft front seal retainer.
• Slide the spatula around the profile of the
Item 6 : Oil pump
1. Remove the oil level indicator tube retain-
ing bolt.
3. Install the oil level indicator tube retaining

bolt.
2. Remove the oil pump together with the oil

sprocket.
3. Detach the oil pump chain and the oil pump

drive sprocket from the oil pump.
Item 6 : Oil pump

1. Attach the oil pump chain and the oil pump
drive sprocket to the oil pump.
G296597 en 09/2004 2004.75 Focus

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1. Clean the crankshaft front seal retainer
mating face and the cylinder block mating
face with metal surface cleaner.
2. CAUTION: Install the crankshaft front

seal retainer within four minutes of
applying the sealer.
Apply a 3 mm bead of sealant to the
crankshaft front seal retainer mating face.
G296597 en 09/2004 2004.75 Focus

TO MODEL INDEX
IN-VEHICLE REPAIR
Crankshaft Rear Seal

Special Tool(s)
Special Tool(s) 303-293
Adapter for 205-044
205-044-01

Installer, Wheel Speed refer to Section 308-01B.
Sensor Ring [Clutch - Vehicles With: 6-Speed
205-307 Manual Transaxle (MMT6), REMOVAL AND
INSTALLATION, Clutch Disc and Pressure
Plate]
Locking Tool, Flywheel 2. Remove the components in the order
303-254 indicated in the following illustration(s) and
table(s).
G296598 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number Installation Details
1 - Flywheel retaining bolts
See Removal Detail Item 3 : Crankshaft rear seal
See Installation Detail 1. NOTE: A new crankshaft rear seal is supplied
with an alignment and protection sleeve that
2 - Flywheel must be removed following installation.
Using the special tool, install the
3 - Crankshaft rear seal crankshaft rear seal.
See Removal Detail • Remove and discard the alignment and
See Installation Detail protection sleeve.
Removal Details
Item 1 : Flywheel retaining bolts

NOTE: Only rotate the crankshaft in the normal
Using the special tool, lock the flywheel.
Item 2 : Flywheel
1. Inspect the flywheel. For additional
Flywheel Inspection]
Item 3 : Crankshaft rear seal

crankshaft rear seal.
G296598 en 09/2004 2004.75 Focus

TO MODEL INDEX

1. NOTE: Do not fully tighten the flywheel
• Tighten the flywheel retaining bolts finger
tight.
3. Tighten the flywheel retaining bolts in the

sequence shown.
G296598 en 09/2004 2004.75 Focus

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REMOVAL
Engine
REMOVAL
Special Tool(s)
303-122
Clamp
303-397

General Equipment REMOVAL AND INSTALLATION, Battery
Tray - 2.0LDuratorq-TDCi (DW) Diesel]
Retaining strap 5. Remove the intake air cleaner. For additi-
Workshop table onal information, refer to Section 303-12.
[Intake Air Distribution and Filtering,
Engine hoist REMOVAL AND INSTALLATION, Air
Cleaner - 2.0L Duratorq-TDCi (DW) Diesel]
6. Remove the front drive halfshafts. For additi-
WARNING: Do not smoke or carry lighted onal information, refer to Section 205-04.
tobacco or open flame of any type when [Front Drive Halfshafts, REMOVAL
working on or near any fuel related AND INSTALLATION, Halfshaft LH]
components. Highly flammable vapors 7. Remove the fender splash shield.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
all times and always observe fuel
handling precautions. Failure to follow
these instructions may result in personal
injury.
1. Using Datalogger in WDS, check that the
fuel pressure has dropped to zero and that
the fuel temperature is below 30°C.
2. Remove the cowl panel grille. For additi
onal information, refer to Section 501-02.
AND INSTALLATION, Cowl Panel Grille] 8. Remove the charge air cooler. For additi-
REMOVAL AND INSTALLATION, Charge
Air Cooler - 2.0L Duratorq-TDCi (DW) Diesel]
9. Remove the radiator. For additional
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL (Continued)
[Engine Cooling - 2.0L INSTALLATION, Catalytic Converter - 2.0L

Duratorq-TDCi (DW) Diesel, REMOVAL Duratorq-TDCi (DW) Diesel]
AND INSTALLATION, Radiator] 11. Remove the components in the order
10. Remove the catalytic converter. For indicated in the following illustration(s)
additional information, refer to Section 309-00. and table(s).
[Exhaust System, REMOVAL AND

Number
hoses
See Removal Detail
G296608 en 09/2004 2004.75 Focus

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REMOVAL (Continued)

Number
3 - Fuel supply line and fuel
return line
See Removal Detail
4 - Air intake pipe

Number
5 - Battery junction box (BJB)
cover
6 - Engine wiring harness elec-
trical connector
7 - Coolant regulator valve elec-
trical connector
8 - Engine ground cable
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL

Number
11 - PCM electrical connectors
9 - Powertrain control module See Removal Detail
(PCM) cover
12 - PCM
10 - PCM security bracket (if
equipped)
See Removal Detail
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL

Number
13 - Brake booster vacuum hose
14 - Coolant degas hose
15 - Thermostat housing upper
coolant hose
See Removal Detail
16 - Thermostat housing lower
coolant hose
See Removal Detail
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL

Number
17 - Clutch slave cylinder supply
line
See Removal Detail
18 - Gearshift cables
See Removal Detail
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL

Number
20 - Air conditioning (A/C) com-
19 - Accessory drive belt pressor electrical connector
See Removal Detail
21 - A/C compressor
See Removal Detail
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL

Number
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL

Number
24 - Heater core hose
25 - Engine front mount
See Removal Detail
26 - Engine rear mount
See Removal Detail
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL

Number
27 - Starter motor power supply
28 - Starter motor
29 - Transaxle ground cable
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL

Number
30 - Transaxle
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL
Item 3 : Fuel supply line and fuel return line

Item Part Description 1. Disconnect the fuel supply line and fuel
Number return line quick release coupling. For additi-
31 - Transaxle retaining bolts onal information, refer to Section 310-00.
Removal Details Coupling]
Item 1 : Coolant expansion tank hoses Item 10 : PCM security bracket (if equipped)
1. Using the special tool, remove the coolant 1. File a flat across the PCM security bracket
expansion tank hoses. welded nut.
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL (Continued)
2. Remove the PCM security bracket sheer Item 15 : Thermostat housing upper coolant
bolt. hose
• Drill a 2mm pilot hole 3mm from the outer 1. Using the special tool, detach the thermo-
edge of the security bracket welded nut at stat housing upper coolant hose from the
an angle of approximately 2°. thermostat housing.
• Drill a 5mm hole in the security bracket
welded nut and remove the security bracket
sheer bolt.
2. Using the special tool, remove the thermo-

stat housing upper coolant hose.
3. Slide the security bracket off of the PCM.

Item 11 : PCM electrical connectors
1. Detach the PCM electrical connectors in
the sequence shown.
Item 16 : Thermostat housing lower coolant

hose
1. Using the special tool, detach the thermo-
stat housing lower coolant hose from the
thermostat housing.
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL (Continued)
2. Using the special tool, remove the thermo- Item 18 : Gearshift cables
stat housing lower coolant hose. 1. Detach the gearshift cables from the
transaxle.
1. Detach the gearshift cable and the selector
cable from the selector levers.
2. Press the tabs together and detach the ca-
bles from the bracket.
Item 17 : Clutch slave cylinder supply line

water.
Item 19 : Accessory drive belt
Detach the clutch slave cylinder supply line 1. Remove the accessory drive belt. For
from the clutch slave cylinder. additional information, refer to Section 303-05.
• Detach the clutch slave cylinder supply line [Accessory Drive, REMOVAL AND
from the bracket. INSTALLATION, Accessory Drive Belt -
• Remove the spring clip. 2.0L Duratorq-TDCi (DW) Diesel]
Item 21 : A/C compressor
1. CAUTION: Support the A/C compressor
before removing the retaining bolts
and secure it to one side to prevent
load being placed on the refrigerant
lines.
Detach the A/C compressor from the
mounting bracket and secure it to one side.
G296608 en 09/2004 2004.75 Focus

TO MODEL INDEX
REMOVAL (Continued)
Item 25 : Engine front mount Item 26 : Engine rear mount

1. Remove the engine rear mount.
1. WARNING: Support the engine and
transaxle assembly on wooden blocks
and secure it with a retaining strap.
Position the workshop table under the ve-
hicle and carefully lower the vehicle, until
the engine and transaxle assembly is in the
correct position to remove the engine
mounts.
2. Raise the vehicle and remove the engine

and transaxle assembly.
3. Using the special tool, attach the engine
and transaxle assembly to the engine hoist.
• Remove the retaining strap.

G296608 en 09/2004 2004.75 Focus

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DISASSEMBLY
Engine
DISASSEM BLY
Special Tool(s)
Adapter for 205-044
205-044-01
Mounting Plate for

303-435-04
Universal Flange Holding 303-435-12A
Wrench
205-072

303-122
General Equipment
Pneumatic vacuum gun
1. Drain the engine oil.
Locking Tool, Flywheel • Allow the oil to drain into a suitable
303-254 container.
table(s).

303-293
Clamp
303-397
Mounting Stand
303-435
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
2 - Glow plug wiring harness
electrical connector
3 - Fuel injector electrical con-
nectors
4 - Intake air temperature (IAT)
5 - Manifold absolute pressure
(MAP)
6 - Fuel temperature sensor
7 - Fuel filter heater electrical
connector
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
9 - Generator electrical con-
nector
10 - Water in fuel sensor electri-
cal connector
11 - Fuel pressure sensor elec-
trical connector
12 - Wiring harness retaining clip
13 - Engine coolant shutoff valve
14 - Turbocharger variable vain
vacuum regulator electrical
connector
15 - Oil pressure switch electrical
connector
(EGR) vacuum regulator
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
17 - Fuel pump fuel pressure
regulator electrical connector
(EGR) valve electrical con-
nector
solenoid electrical connector
20 - Engine coolant temperature
(ECT) sensor electrical
connector
21 - Fuel pump fuel temperature
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
tion (PCV) breather hose 26 - Turbocharger intake pipe
O-ring seal
support bracket retaining bolt
retaining bolt
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
30 - Turbocharger oil supply tube
27 - Turbocharger oil supply tube to cylinder block banjo bolt
to turbocharger banjo bolt seal
28 - Turbocharger oil supply tube 31 - Turbocharger oil supply tube
banjo bolt seal
32 - Vacuum hose
to cylinder block banjo bolt 33 - Turbocharger retaining bolts
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
34 - Turbocharger retaining nut

Number
35 - Turbocharger oil return hose
retaining bolts
gasket
38 - Turbocharger support
bracket retaining bolts
39 - Turbocharger

Number
40 - Intermediate shaft retaining
bracket
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
42 - EGR coolant hose
43 - EGR cooler cover
bracket
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
48 - EGR pipe retaining stud
bracket retaining nut 49 - EGR pipe retaining bolts
47 - Engine wiring harness 50 - EGR pipe retaining clamp

bracket 51 - EGR pipe
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
55 - EGR valve lower retaining
52 - EGR cooler lower retaining bolt
nut
56 - EGR cooler
53 - EGR cooler retaining nuts
57 - EGR cooler gasket
54 - EGR valve upper retaining
bolt
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
58 - EGR valve bracket retaining
bolts
G296609 en 09/2004 2004.75 Focus

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Number Number
59 - EGR valve bracket 62 - Exhaust manifold bushers
60 - Exhaust manifold heat shield 63 - Exhaust manifold
nuts 64 - Exhaust manifold gasket

Number
66 - Coolant bypass to thermostat
65 - Thermostat housing coolant housing coolant hose re-
hose retaining clamp taining bolt
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number Number
67 - Coolant bypass to thermostat 70 - High pressure fuel line
housing coolant hose
71 - Fuel pump retaining bolts
68 - Fuel return line
72 - Fuel pump
69 - Fuel supply line
73 - Fuel pump gasket

Number
74 - Turbocharger variable vain bracket
vacuum regulator hose
79 - Thermostat housing retaining
75 - Turbocharger variable vain nuts
vacuum regulator retaining
nuts 80 - Thermostat housing
76 - Turbocharger variable vain 81 - Thermostat housing O-ring

vacuum regulator seal

bracket retaining nut
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
tion upper hose
83 - Brake vacuum pump vacuum
hose
84 - Brake vacuum pump retain-
ing bolts
86 - Brake vacuum pump O-ring
seals
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
87 - Fuel filter crash protection
shield
88 - Fuel filter
89 - Fuel filter bracket
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
90 - Crankshaft pulley bolt
92 - Engine coolant bypass pipe See Disassembly Detail
93 - Engine coolant bypass pipe 97 - Timing belt tensioner
O-ring seal
98 - Timing belt
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
102 - Camshaft pulley
103 - Timing belt rear cover
100 - Timing belt idler pulley
101 - Camshaft pulley retaining
bolt
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
105 - EGR vacuum regulator
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
108 - Generator
106 - Generator retaining bolts
109 - Generator retaining bracket
107 - Generator retaining clamp
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number Number
110 - Oil cooler supply hose clamp 111 - Oil cooler

Number
113 - Intake manifold assembly
112 - Intake manifold assembly seals
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
114 - Oil level indicator and tube
115 - Oil filler tube
116 - Vacuum reservoir
117 - Block heater
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
120 - Fuel injector fuel return pipe
118 - Fuel injector high-pressure connections
supply lines See Disassembly Detail
121 - Fuel injector retaining
119 - Fuel injector high-pressure bracket nuts
supply line support grom-
mets 122 - Fuel injectors
123 - Fuel injectors to cylinder
head sealing washer
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
124 - Fuel injector seals

Number
125 - Pressure plate retaining bolts
126 - Pressure plate
127 - Clutch disc
129 - Flywheel
130 - Crankshaft rear seal
131 - Clutch cover clip
132 - Left-hand clutch cover
133 - Right-hand clutch cover
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
138 - Oil pan
134 - Crankshaft position (CKP) See Disassembly Detail
sensor
135 - Coolant pump bolts - long
136 - Coolant pump gasket 140 - Crankshaft front seal retainer
137 - Crankshaft front seal bolts - short
See Disassembly Detail 141 - Crankshaft front seal retainer
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
142 - Camshaft seal
144 - Fuel injector retaining studs
146 - Timing chain
147 - Cylinder head
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY

Number
149 - Oil pump O-ring seal
woodruff key
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item Part Description Item 65 : Thermostat housing coolant hose

Number retaining clamp
152 - Crankshaft bearing caps coolant bypass to thermostat housing
See Disassembly Detail coolant hose.
153 - Connecting rod bearing caps
Disassembly Details

1. Using the special tools, mount the engine
to the mounting stand.

CAUTION: Do not touch the outer sensor
ring.
Item 101 : Camshaft pulley retaining bolt
1. Using the special tool, remove the cam-
shaft pulley retaining bolt.
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 105 : EGR vacuum regulator 2. Detach the high-pressure fuel supply line
1. Remove the EGR vacuum regulator vac- unions from the fuel injector and the fuel
uum lines. injection supply manifold.
3. Using the pneumatic vacuum gun, vacuum
foreign material from the high-pressure
fuel supply line, the fuel injector and the
fuel injection supply manifold.
4. Remove and discard the high-pressure fuel
supply line.
5. Install new blanking plugs to the open
threaded ports on the fuel injector and the
Item 120 : Fuel injector fuel return pipe
connections
1. Disconnect the fuel injector fuel return
pipes.
Item 112 : Intake manifold assembly 1. Pull down the release clip.
1. Remove the intake manifold assembly re- 2. Remove the fuel injector fuel return pipe
taining bolts in the sequence shown. with a twisting motion.
Item 118 : Fuel injector high-pressure supply 2. Install blanking plugs to the open ends of
lines the fuel return pipes and the fuel injectors.
CAUTION: Make sure that the
high-pressure fuel supply line remains in
contact with both the fuel injector and the
fuel injection supply manifold until both
unions have been detached and cleaned.
result in foreign matter ingress to the fuel
injection system.
1. Clean the fuel injectors, fuel injection
supply manifold, high-pressure fuel supply
lines and surrounding areas. For additional
information, refer to Section 303-04B.[Fuel
Duratorq-TDCi (DW) Diesel, GENERAL
PROCEDURES, Fuel Injection Component
Cleaning]
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 125 : Pressure plate retaining bolts Item 130 : Crankshaft rear seal
1. CAUTION: Make sure that the special crankshaft rear seal.

Item 128 : Flywheel retaining bolts • Discard the seal.
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 138 : Oil pan Item 143 : Timing chain tensioner

1. Using a suitable spatula, remove the oil 1. Using the special tool, lock the timing
pan. chain tensioner.
• Slide the spatula around the profile of the oil
pan.
1. Using a suitable spatula, remove the
• Slide the spatula around the profile of the
Item 142 : Camshaft seal
camshaft seal.

Item 144 : Fuel injector retaining studs
1. Remove the fuel injector retaining studs in
the sequence shown.

1. Remove the camshaft housing retaining
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 146 : Timing chain Item 149 : Oil pump

1. Remove both camshafts together with the 1. Remove the oil pan baffle.
timing chain from the cylinder head and
remove the timing chain.
Item 147 : Cylinder head
1. Remove the cylinder head bolts in the
sequence shown.
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
2. Remove the oil level indicator tube retain-

ing bolt. 2. CAUTION: Keep the main bearing lower
shells in order for installation.
Remove the main bearing lower shells.
3. Remove the oil pump together with the oil

sprocket. 3. Remove the crankshaft half thrust wash-
ers.
4. Detach the oil pump chain and the oil pump

drive sprocket from the oil pump.
Item 153 : Connecting rod bearing caps
Item 152 : Crankshaft bearing caps
1. CAUTION: Keep the connecting rod
1. CAUTION: Keep the crankshaft bearing bearing caps in order for installation.
caps in order for installation.
Remove the connecting rod bearing caps.
Remove the crankshaft bearing caps.
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
2. CAUTION: Keep the connecting rod 6. Remove the piston cooling jets.
bearing shells and connecting rod
bearing cap shells in order for
installation.
Remove the connecting rod bearing shells
and connecting rod bearing cap shells.
3. Remove the crankshaft.

4. CAUTION: Keep the main bearing upper
shells in order for installation.
Remove the main bearing upper shells.
5. CAUTION: Keep the the pistons in order

for installation.
Remove the pistons.
G296609 en 09/2004 2004.75 Focus

TO MODEL INDEX
Cylinder Head
DISASSEM BLY AND ASSEM BLY OF SUBASSEMBLIES

Special Tool(s)
Slide Hammer working on or near any fuel related
205-047 components. Highly flammable vapors
Installer, Valve Stem Seal 1. Remove the camshafts. For additional
303-037 information, refer to Camshafts in this
section.
2. Position the appropriate piston at top dead
center (TDC).
Compressor, Valve Spring 3. Disassemble the components in the order
table(s).
Adapter for 303-060

303-060-07
Adapter for 303-060

303-060-09A
Remover, Valve Stem Seal

303-292
Name Specification
G296610 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
5 - Valve stem seal
1 - Camshaft followers See Disassembly Detail
See Disassembly Detail See Assembly Detail
2 - Valve collets 6 - Valve
See Disassembly Detail See Assembly Detail
See Assembly Detail
3 - Valve spring retainer
4 - Valve spring
G296610 en 09/2004 2004.75 Focus

TO MODEL INDEX
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
4. To assemble, reverse the disassembly Item 5 : Valve stem seal

procedure. 1. Using the special tools, remove the valve
stem seals.
Disassembly Details • Discard the seals.
Item 1 : Camshaft followers

1. CAUTION: Keep the camshaft followers
Remove the camshaft followers.
collets.
Assembly Details
Item 6 : Valve
1. Cover the valve collet grooves on the valve
• Coat the valve with clean engine oil

1. CAUTION: Keep the valve spring
retainers and the valve springs in
Remove the valve spring retainers.
1. CAUTION: Keep the valve springs in
Remove the valve springs.
G296610 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 5 : Valve stem seal

seals.
2. Remove the valve stem protective sleeve

after the valve seals have been installed.
collets.
G296610 en 09/2004 2004.75 Focus

TO MODEL INDEX
ASSEMBLY
Engine
ASSEM BLY
Special Tool(s)
Installer Crankshaft Seal
Remover, O-Ring Seal
100-010
Clamp
Adapter for 205-044 303-397
205-044-01
Mounting Stand
303-435
Wrench
205-072
Installer, Wheel Speed

Sensor Ring Mounting Bracket for 303-435
205-307 303-435-04

303-122 Mounting Plate for
303-435-04
303-435-12A
Gauge, Bolt Angle

303-174
Installer, Crankshaft Front

Locking Tool, Flywheel Seal
303-254 303-684
Alignment Peg, Camshaft

303-735
Installer, Timing Cover Seal
303-255
Installer, Main Bearing Cup
303-1057
G296611 en 09/2004 2004.75 Focus

TO MODEL INDEX
Special Tool(s)
Alignment Peg, Crankshaft CAUTION: Always carry out the cleaning
303-1059 process before carrying out any repairs
to prevent foreign material entering the
components.
Aligner, Clutch Disc
308-204
General Equipment
Pneumatic Vacuum Gun
Name Specification

injury.
tolerances. It is therefore essential that
absolute cleanliness is observed when
working with these components. Always
install blanking plugs to any open
orifices or lines.
G296611 en 09/2004 2004.75 Focus

TO MODEL INDEX
ASSEMBLY
G296611 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
2 - Connecting rod bearing caps
1 - Crankshaft bearing caps See Assembly Detail
See Assembly Detail
G296611 en 09/2004 2004.75 Focus

TO MODEL INDEX
ASSEMBLY

Number
O-ring seal
woodruff key
5 - Oil pump
See Assembly Detail
G296611 en 09/2004 2004.75 Focus

TO MODEL INDEX
ASSEMBLY
G296611 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number Number
6 - Cylinder head gasket 10 - Fuel injector retaining studs
See Assembly Detail See Assembly Detail
7 - Cylinder head 11 - Timing chain tensioner
8 - Timing chain 12 - Camshaft seal
See Assembly Detail
G296611 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number Number
13 - Crankshaft front seal retainer 16 - Crankshaft position (CKP)
See Assembly Detail sensor
14 - Coolant pump gasket 17 - Crankshaft front seal
See Assembly Detail
15 - Coolant pump
See Assembly Detail 18 - Oil pan
See Assembly Detail

Number
19 - Left-hand clutch cover See Assembly Detail
20 - Left-hand clutch cover clip 25 - Clutch disc
21 - Right-hand clutch cover 26 - Pressure plate
22 - Crankshaft rear seal 27 - Pressure plate retaining bolt
23 - Flywheel
See Assembly Detail
G296611 en 09/2004 2004.75 Focus

TO MODEL INDEX
ASSEMBLY

Number
31 - Fuel injectors retaining
28 - Fuel injector to cylinder head bracket nuts
sealing washer See Assembly Detail
29 - Fuel injector seals 32 - Fuel injector fuel return line
See Assembly Detail connections
30 - Fuel injectors See Assembly Detail
See Assembly Detail 33 - Fuel injector high-pressure
fuel supply line support
grommets
G296611 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
34 - Fuel injector high-pressure
fuel supply line
See Assembly Detail

Number
37 - Oil filler tube
35 - Block heater
38 - Oil level indicator and tube
36 - Vacuum reservoir
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ASSEMBLY

Number
seals
See Assembly Detail
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ASSEMBLY
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Number Number
41 - Oil cooler 42 - Oil cooler supply hose clamp

Number
44 - Generator
43 - Generator retaining bracket
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ASSEMBLY

Number
(EGR) vacuum regulator
See Assembly Detail
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ASSEMBLY

Number
50 - Camshaft pulley retaining
48 - Timing belt rear cover bolt
49 - Camshaft pulley See Assembly Detail
See Assembly Detail 51 - Timing belt idler pulley
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ASSEMBLY

Number
58 - Crankshaft pulley bolt
53 - Timing belt tensioner
See Assembly Detail 59 - Timing belt upper cover
54 - Timing belt 60 - Engine coolant bypass pipe

See Assembly Detail O-ring seal
55 - Crankshaft timing pulley 61 - Engine coolant bypass pipe

See Assembly Detail
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ASSEMBLY

Number
62 - Fuel filter bracket shield
63 - Fuel filter
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ASSEMBLY

Number
65 - Brake vacuum pump O-ring
seals
See Assembly Detail
67 - Brake vacuum pump vacuum
hose
tion (PCV) hose
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ASSEMBLY

Number
69 - Thermostat housing O-ring
seal
70 - Thermostat housing
nuts
vacuum regulator
vacuum regulator retaining
nuts
vacuum regulator hose
bracket
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ASSEMBLY

Number
80 - High pressure fuel line
78 - Fuel pump
82 - Thermostat housing coolant
79 - Fuel supply line hose retaining clamp
See Assembly Detail
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ASSEMBLY

Number
84 - Exhaust manifold
83 - Exhaust manifold gasket See Assembly Detail
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Number Number
85 - Exhaust manifold heat shield 87 - Exhaust manifold retaining
nuts
86 - Exhaust manifold bushers
88 - EGR valve bracket

Number
90 - EGR cooler
89 - EGR cooler gasket
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ASSEMBLY

Number
93 - EGR pipe retaining stud
91 - EGR pipe
92 - EGR pipe retaining clamp bracket
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ASSEMBLY

Number
retaining bolt
96 - EGR cooler cover
97 - EGR coolant hose

Number
bracket
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ASSEMBLY

Number
99 - Turbocharger
gasket
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ASSEMBLY

Number
102 - Turbocharger retaining bolts to turbocharger banjo bolt
103 - Turbocharger retaining nut 106 - Turbocharger oil supply tube
104 - Turbocharger oil supply tube to cylinder block banjo bolt
to turbocharger banjo bolt seal
seal
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Number Number
107 - Turbocharger oil supply tube 108 - Turbocharger variable vain
to cylinder block banjo bolt solenoid vacuum supply tube
See Assembly Detail

Number
111 - PCV breather hose
O-ring seal
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ASSEMBLY

Number
connect
115 - EGR valve electrical con-
nector
116 - Fuel pump fuel pressure
regulator electrical connector
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ASSEMBLY

Number
121 - Wiring harness retaining clip
117 - EGR vacuum regulator elec-
trical connector 122 - Fuel pressure sensor elec-
trical connector
connector 123 - Water in fuel sensor electri-
cal connector
vacuum regulator electrical 124 - Generator electrical con-
connector nector

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ASSEMBLY
Item Part Description Assembly Details

Number
125 - Crankshaft position (CKP) Item 1 : Camshaft pulley bolt
sensor electrical connector 1. Install the piston cooling jets.
126 - Fuel filter heater electrical

connector
(MAP) sensor electrical
connector
nectors
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2. CAUTION: Install the crankshaft main 5. Using the special tool, install the crank-
bearing upper shells in the correct shaft rear main bearing cap.
order.
Install the crankshaft main bearing upper
shells.
6. Install the crankshaft half thrust washers

into the fourth crankshaft main bearing
with the oil grooves facing outwards.
3. Install the crankshaft.
4. CAUTION: Install the crankshaft main
bearing lower shells in the correct
order.
Install the crankshaft main bearing lower
shells.
7. CAUTION: Install the crankshaft main

bearing caps in the correct order.
Install the crankshaft main bearing caps
and tighten the bolts in two stages.
• Stage 1: 25 Nm
• Stage 2: 60 degrees
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Item 2 : Connecting rod bearing caps 3. CAUTION: Install the connecting rods
bearing caps in the correct order.
1. CAUTION: Install the connecting rods
Install the connecting rods and tighten the
bearing caps shells in the correct
nuts in two stages.
order.
• Stage 1: 20 Nm
Install the connecting rod bearing shells. • Stage 2: 70 degrees
2. NOTE: Install the pistons with the arrows

Item 5 : Oil pump
pointing to the front of the engine.
1. Install the oil pump together with the oil
NOTE: The piston ring gaps and oil supply ring pump chain and the oil pump drive
elements must be distributed evenly around the sprocket.
circumference.
Using a suitable piston ring compressor,
install the pistons and connecting rods.
2. Install the oil level indicator tube retaining

bolt.
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2. CAUTION: The thickness of the new

3. Install the oil pan baffle.
cylinder head gasket must be the same
as that of the old one (hole marked).
Install a new cylinder head gasket.
Item 6 : Cylinder head gasket Item 7 : Cylinder head

1. Clean the mating faces of the cylinder head 1. NOTE: Only rotate the crankshaft in the normal
and the cylinder block with cleaner. direction of rotation.
approximately 90 degrees before top dead
center (TDC).
2. Using the special tool, install the cylinder
head bolts.
two stages.
• Stage 1: 60 Nm

1. Lubricate the camshaft bearings with clean
engine oil
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2. Apply a 4 mm diameter bead of sealant to

2. CAUTION: The copper links of the the cylinder head.
timing chain must align with the timing
marks on the camshaft sprockets.
Position the camshafts together with the
timing chain on to the cylinder head.
3. Tighten the camshaft housing retaining

bolts in the sequence shown in two stages.
• Stage 1: 5 Nm
• Stage 2: 10 Nm
1. Clean the upper mating face of the cylinder
head and the camshaft housing with
cleaner.
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Item 10 : Fuel injector retaining studs Item 11 : Timing chain tensioner

1. Install the fuel injector retaining stud in the 1. Using the special tool, install the chain
sequence shown. tensioner.
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Item 12 : Camshaft seal 2. CAUTION: Install the crankshaft front

1. NOTE: Install a new camshaft seal. seal retainer within four minutes of
Using the special tool, install the camshaft applying the sealer.
seal. Apply a 3 mm bead of sealant to the mating
face of the crankshaft front seal retainer.
Item 13 : Crankshaft front seal retainer Item 15 : Coolant pump

1. Clean the mating faces of the crankshaft 1. Tighten the coolant pump retaining bolts in
front seal retainer and the cylinder block the sequence shown.
with cleaner.

1. Using the special tool, install the crank-
shaft front seal.
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Item 18 : Oil pan 3. Install the oil pan.

1. Clean the mating face of the oil pan and the
cylinder block with cleaner.

1. NOTE: A new crankshaft rear seal is supplied
with an alignment and protection sleeve that
must be removed following installation.
Using the special tool, install the
• Remove and discard the alignment and
protection sleeve.
2. CAUTION: Install the oil pan within four

minutes of applying the sealant.
Apply a 3mm bead of sealant to the mating
Item 23 : Flywheel
1. Inspect the flywheel. For additional
Flywheel Inspection]
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2. NOTE: Do not fully tighten the flywheel Item 27 : Pressure plate retaining bolt
retaining bolts at this stage. 1. Using the special tool, centralize the clutch
disc on the pressure plate.
• Tighten the flywheel retaining bolts finger
tight.
2. Using the special tool, install the clutch

disc and pressure plate.
2. Tighten the flywheel retaining bolts in the

sequence shown.

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4. NOTE: Install new clutch pressure plate

2. Remove and discard the blanking cap from
retaining bolts.
the injector nozzle.
Tighten the clutch pressure plate retaining
Item 31 : Fuel injectors retaining bracket nuts
bolts finger tight and then by two turns at a
1. Install the fuel injector retaining bracket
time in the sequence shown to the speci-
nuts finger tight.
fied torque.
Item 32 : Fuel injector fuel return line
connections
1. Remove and discard the blanking plugs
from the fuel injectors and the fuel injector
return pipe connections.
Item 34 : Fuel injector high-pressure fuel
supply line
CAUTION: Remove the blanking plugs
from the high-pressure fuel supply line,
the fuel injector and the fuel injection
supply manifold at the last possible
moment. Failure to follow this instruction
may result in foreign matter ingress to
5. Remove the special tools. the fuel injection system.
Item 29 : Fuel injector seals CAUTION: Do not allow the unions to hit
1. Press the new fuel injector seal into the the ends of the high-pressure fuel supply
cylinder head. line. Failure to follow this instruction may
result in damage to the ends of the line
and allow foreign material to enter the
fuel injection system.
CAUTION: Make sure the tool used to
tighten the high-pressure fuel supply line
unions is used at the top of the unions as
this is where there is most material.
result in damage to the unions.
NOTE: Maintain pressure on the high-pressure
fuel supply line to keep the line in contact with the
fuel injector cone and fuel injection supply
manifold while installing the unions.
Item 30 : Fuel injectors NOTE: If it is not possible to correctly install the
1. Make sure the fuel injector retaining new high-pressure fuel supply line, it will be
bracket retaining clip is correctly installed. necessary to remove the remaining high-pressure
fuel supply lines and to loosen the fuel injection
supply manifold to allow correct alignment.
foreign material from the area around the
fuel injectors and the fuel injection supply
manifold.
from the high-pressure fuel supply lines,
the fuel injection supply manifold and the
fuel injectors.
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3. Install the fuel injector high-pressure fuel

supply lines. 5. CAUTION: Individual high-pressure fuel
• Finger tighten the high-pressure fuel supply supply lines must have both unions
line unions. tightened before continuing on to the
next high-pressure fuel supply line.
4. NOTE: Tighten the fuel injector retaining Failure to follow this instruction may
bracket nuts so that the fuel injector retaining result in damage to the high-pressure
bracket remains level. fuel supply lines.
Using the special tool, tighten the fuel Tighten the high-pressure fuel supply line
injector retaining bracket nuts in two unions.
stages.
1. Stage 1: 4 Nm Item 40 : Intake manifold assembly
1. Tighten the intake manifold retaining bolts
2. Stage 2: 45 degrees in two stages in the sequence shown.
• Stage 1: 5 Nm
• Stage 2: 9Nm
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Item 46 : Exhaust gas recirculation (EGR)

vacuum regulator
1. Install the EGR vacuum regulator vacuum
lines.
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Item 49 : Camshaft pulley Item 54 : Timing belt

1. NOTE: Only rotate the camshaft in the normal 1. NOTE: Only rotate the camshaft in the normal
direction of rotation. direction of rotation.
Using the special tool, align the camshaft. Install the special tool.
• Turn the camshaft until the alignment hole • Turn the camshaft until the alignment hole
of the camshaft pulley is at the 4 oćlock of the camshaft pulley is at the 4 oćlock
position. position.
2. Remove the special tool. 2. NOTE: Only rotate the crankshaft in the normal
Item 50 : Camshaft pulley retaining bolt
1. Using the special tool, tighten the camshaft Rotate the crankshaft until piston No. one
pulley bolt in two stages. is at TDC.
• Stage 1: 20 Nm 3. Install the special tool.
Item 53 : Timing belt tensioner

NOTE: A new timing belt tensioner is supplied
locked to aid installation.
NOTE: Do not tighten the timing belt tensioner
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4. CAUTION: Make sure that the special sensor ring.
Using the old crankshaft pulley retaining
NOTE: Only rotate the crankshaft in the normal bolt, install the timing pulley and the
direction of rotation. crankshaft pulley.
5. CAUTION: Install the timing belt with

the direction arrows in the direction of
crankshaft rotation.
NOTE: Install a new timing belt.
Install the timing belt.
6. NOTE: Use an Allen key to maintain tension on
the timing belt tensioner until the retaining bolt
is tightened.
Unlock the timing belt tensioner and
tension the timing belt.
1. Using an Allen key, turn the timing belt
tensioner counterclockwise to increase the
tension on the timing belt.
2. Check that the pointer is positioned on the
left-hand side of the window, if necessary
increase the tension of the timing belt by 9. Remove the special tool.
turning the Allen key.
bolt.
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10. Remove the special tool. 14. NOTE: Use an Allen key, maintain tension
until the timing belt tensioner bolt is tightened.
Use an Allen key, adjust the correct
timing belt tension.
1. Use an Allen key, keep the timing belt
tensioner adjustment arm in position.
2. Loosen the timing belt tensioner retaining
bolt.
bolt when the pointer is positioned centrally
in the window.

Rotate the crankshaft four times.
13. Using the special tool, check the valve

timing.
• If its not possible to install the special tool,
repeat the previous steps.
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16. Remove the special tool. Item 58 : Crankshaft pulley bolt


sensor ring. 2. NOTE: Install a new crankshaft pulley retaining
bolt.
Remove the crankshaft pulley and the
crankshaft timing pulley. Install the crankshaft timing pulley and the
• Discard the bolt. crankshaft pulley.
• Tighten the crankshaft pulley retaining bolt
in two stages.
• Stage 1: 70 Nm

CAUTION: Do not touch the outer sensor
ring.
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Item 65 : Brake vacuum pump O-ring seals Item 84 : Exhaust manifold

1. CAUTION: Make sure the drive coupling
is aligned with the camshaft coupling.
Install new brake vacuum pump seals.

Item 82 : Thermostat housing coolant hose
retaining clamp
1. Using the special tool, connect the coolant
bypass to thermostat housing coolant
house.
Item 107 : Turbocharger oil supply tube to

cylinder block banjo bolt
1. Install the turbocharger oil supply tube in
line filter into the turbocharger oil supply
tube to cylinder block banjo bolt.
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INSTALLATION
Engine
INST ALLAT ION
General Equipment
Retaining strap
Special Tool(s)
Workshop table
Lifting Bracket, Engine Engine hoist
303-122
Name Specification
Clamp WARNING: Do not smoke or carry lighted
303-397 tobacco or open flame of any type when

Number
1 - Transaxle
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Number Number
2 - Transaxle right-hand retain- 3 - Transaxle lower retaining
ing bolts bolts

Number
4 - Transaxle left-hand retaining
bolts
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INSTALLATION

Number
9 - Transaxle ground cable
5 - Starter motor
10 - Transaxle ground cable re-
6 - Starter motor retaining bolts taining bolt
7 - Starter motor power supply
8 - Starter motor electrical con-
nector retaining nuts
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INSTALLATION

Number
11 - Engine rear mount
12 - Engine front mount
13 - Heater core hose
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INSTALLATION

Number
14 - Engine roll restrictor
15 - Engine roll restrictor retaining retaining bolts
bolts
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INSTALLATION

Number
20 - A/C compressor electrical
18 - Air conditioning (A/C) com- connector
pressor
21 - Accessory drive belt
19 - A/C compressor retaining See Installation Detail
bolt
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INSTALLATION

Number
22 - Gearshift cables line
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INSTALLATION

Number
24 - Thermostat housing lower
coolant hose
25 - Thermostat housing upper
coolant hose
26 - Coolant degas hose
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INSTALLATION

Number
30 - PCM security bracket (if
28 - Powertrain control module equipped)
(PCM) cover See Installation Detail
29 - PCM electrical connectors 31 - PCM cover
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INSTALLATION

Number
32 - Engine ground cable
33 - Engine ground cable retain-
ing bolts
34 - Coolant regulator valve elec-
trical connector
35 - Engine wiring harness elec-
trical connector
36 - Battery junction box (BJB)
cover
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INSTALLATION

Number
37 - Air intake pipe hoses
38 - Fuel supply line and fuel See Installation Detail
return line All vehicles
See Installation Detail 1. Install the catalytic converter. For
39 - Coolant expansion tank [Exhaust System, REMOVAL AND
INSTALLATION, Catalytic Converter - 2.0L
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2. Install the radiator. For additional 10. Fill and bleed the clutch system.
information, refer to Section 303-03B. 11. Install the engine cover.
AND INSTALLATION, Radiator]
3. Install the charge air cooler. For additional
information, refer to Section 303-12. [Intake
AND INSTALLATION, Charge Air Cooler -
4. Install the intake air cleaner. For additional
information, refer to Section 414-01. 12. Install the cowl panel grille. For additional
[Battery, Mounting and Cables, information, refer to Section 501-02.[Front
REMOVAL AND INSTALLATION, Battery End Body Panels, REMOVAL AND
Tray - Duratorq-TDCi (DW) Diesel]2.0L INSTALLATION, Cowl Panel Grille]
13. With the vehicle on a level surface fill the
6. Install the fender splash shield.
transaxle with transmission oil until the
level is just below the filler hole.
14. Initialize the door window motors. For additi-
Item 1 : Transaxle
1. WARNING: Make sure that the two
locating dowels are installed.
Install the transaxle.
7. Install the front drive halfshafts. For additi-
onal information, refer to Section 205-04. Item 11 : Engine rear mount
[Front Drive Halfshafts, REMOVAL 1. WARNING: Support the engine and
AND INSTALLATION, Halfshaft LH] transaxle assembly on wooden blocks
8. Fill and bleed the cooling system. For and secure it with a suitable retaining
additional information, refer to Section 303-03B. strap.
Duratorq-TDCi (DW) Diesel, GENERAL Position the engine and transaxle
PROCEDURES, Cooling System Draining, assembly on the workshop table.
9. Adjust the gearshift cables. For additional
GENERAL PROCEDURES, Gearshift Cable
Adjustment - Vehicles With: 6-Speed
Manual Transaxle (MMT6)]
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2. Detach the special tool from the engine Item 12 : Engine front mount
hoist and the engine and transaxle assem- 1. NOTE: Install new engine front mount retaining
bly. nuts.
Install the engine front mount.
2. Detach the engine and transaxle assembly

from the workshop table.
• Remove the retaining strap.
3. Position the workshop table under the
vehicle and carefully lower the vehicle, 3. Raise the vehicle and remove the
until the engine and transaxle assembly is workshop table.
in the correct position to install the engine Item 21 : Accessory drive belt
mounts. 1. Install the accessory drive belt. For
4. NOTE: Install new engine rear mount retaining additional information, refer to Section 303-05.
nuts. [Accessory Drive, REMOVAL AND
Install the engine rear mount. 2.0L Duratorq-TDCi (DW) Diesel]
Item 22 : Gearshift cables
1. Attach the gearshift cables to the transaxle.
1. Attach the gearshift cable and selector
cable to the bracket.
2. Attach the gearshift cable and selector ca-
ble to the selector levers.
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Item 23 : Clutch slave cylinder supply line 2. Using the special tool, attach the thermo-
stat housing lower coolant hose to the
1. CAUTION: If brake fluid is spilt on the thermostat housing.
water.
Attach the clutch slave cylinder supply line
to the clutch slave cylinder.
• Attach the clutch slave cylinder supply line
to the bracket.
Item 25 : Thermostat housing upper coolant

hose
1. Using the special tool, install the thermo-
stat housing upper coolant hose.
Item 24 : Thermostat housing lower coolant

hose
1. Using the special tool, install the thermo-
stat housing lower coolant hose.
2. Using the special tool, attach the thermo-

stat housing upper coolant hose to the
thermostat housing.
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1. Connect the powertrain control module
(PCM) electrical connectors.
Item 30 : PCM security bracket (if equipped)

1. Install a new PCM security bracket and
security bracket sheer bolt (if equipped).
• Tighten the security bracket sheer bolt until
the head of the sheer bolt is sheered off.
Item 38 : Fuel supply line and fuel return line
1. Connect the fuel supply line and the fuel
return line quick release coupling. For
Coupling]
Item 40 : Coolant expansion tank hoses
expansion tank hoses.
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303-01C-1 Engine — 1.6L (Z6) 303-01C-1
SECTION 303-01C Engine — 1.6L (Z6)

CONTENTS PAGE
SPECIFICATIONS
Engine Data .................................................................................................................... 303-01C-2
Engine Oil Capacity......................................................................................................... 303-01C-2
Cylinder Block ................................................................................................................. 303-01C-2
Crankshaft....................................................................................................................... 303-01C-2
Camshaft......................................................................................................................... 303-01C-2
Valves ............................................................................................................................. 303-01C-2
Cylinder Head ................................................................................................................. 303-01C-3
Oil Pressure Specifications.............................................................................................. 303-01C-3/4
GENERAL PROCEDURES
Valve Clearance Adjustment ............................................................................................ 303-01C-5/8
IN-VEHICLE REPAIR
Intake Manifold................................................................................................................. 303-01C-9/13

Valve Cover ..................................................................................................................... 303-01C-14/16
Crankshaft Front Seal ...................................................................................................... 303-01C-17/18
Valve Seals...................................................................................................................... 303-01C-19/22
Camshafts........................................................................................................................ 303-01C-23/26
Timing Chain.................................................................................................................... 303-01C-27/31
Exhaust Manifold .......................................................................................... (21 187 0) 303-01C-32/32
Cylinder Head .................................................................................................................. 303-01C-33/41
Oil Pan............................................................................................................................. 303-01C-42/43
Oil Pump .......................................................................................................................... 303-01C-44/44
Crankshaft Rear Seal....................................................................................................... 303-01C-45/47
Engine — Vehicles With: Manual Transaxle..................................................................... 303-01C-48/60
DISASSEMBLY
Engine ............................................................................................................................. 303-01C-61/71
Cylinder Head .................................................................................................................. 303-01C-72/76
ASSEMBLY
Engine ............................................................................................................................. 303-01C-77/89
INSTALLATION
Engine — Vehicles With: Manual Transaxle..................................................................... 303-01C-90
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303-01C-2 Engine — 1.6L (Z6) 303-01C-2
SPECIFICATIONS
Engine Data
Description
Engine code G9
Firing order 1-3-4-2
Emission level Stage III
Bore 78 mm
Stroke 83.6mm
Cubic capacity 1598 cm³
Power output at 6000 rpm 77 kW (105 PS)
Torque at 4000 rpm 145 Nm
Maximum engine speed (intermittent) 6850 rpm
Maximum engine speed (continuous) 6500 rpm
Idle speed - vehicles with manual transaxle 700 ± 50 rpm
Idle speed - vehicles with automatic transaxle FN4AL 750 ± 50 rpm
Oil consumption 0.1L / 1000 Km

Item Specification
Engine oil WSS-M2C913-B
Coolant WSS-M97B44-D
Sealant WSE-M4G323-A4
Engine Oil Capacity

Description Liters
Initial fill including oil filter 4.2
Service fill including oil filter 3.9
Service fill without oil filter 3.7
Cylinder Block
Description mm
Maximum distortion 0.10
Cylinder bore diameter 78.000 - 78.013
Crankshaft
Description mm
Crankshaft end play 0.080 - 0.282
Camshaft
Description mm
Camshaft runout 0.030
Camshaft lobe lift - intake 41.373
Camshaft lobe lift - exhaust 41.495
Camshaft bearing journal diameter 25.940 - 25.965
Camshaft bearing journal clearance 0.035 - 0.081
Valves
Description mm
Valve clearance 0.270 - 0.330
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303-01C-3 Engine — 1.6L (Z6) 303-01C-3
Description mm
Valve stem diameter - intake valve 5.470 - 5.485
Valve stem diameter - exhaust valve 5.465 - 5.480
Valve head diameter - intake valve 27.8
Valve head diameter - exhaust valve 24.7
Valve guide inner diameter 5.510 - 5.530
Valve stem to valve guide clearance — intake valve 0.025 - 0.060
Valve stem to valve guide clearance — exhaust valve 0.030 - 0.065
Valve tappet bore diameter 30.000 - 30.025
Valve tappet diameter 29.959 - 29.975
Valve tappet clearance 0.025 - 0.066
Cylinder Head
Description mm
Maximum distortion — measured longitudinally and diagonally 0.10
Oil Pressure Specifications

Description bar
Oil pressure at 3000 rpm 3.3 - 3.8
Transaxle wiring harness bracket retaining bolts 23 17 -
Engine rear mount center bolt 80 59 -
Engine front mount retaining nuts 53 39 -
Ground cable to engine front mount retaining nut 10 - 89
Engine roll restrictor to transaxle bracket bolt 80 59 -
Engine roll restrictor to front axle crossmember 80 59 -
bolts
Thermostat housing retaining nuts 22 16 -
Crankshaft pulley retaining bolt 162 119 -
Flywheel retaining bolts 100 74 -
Crankcase vent oil separator retaining bolts 9 - 80
Power steering pump fluid reservoir retaining bolt 10 - 89
Power steering pump lower retaining bolt 35 26 -
Power steering pump upper retaining bolt 35 26 -
Power steering pump to steering gear pressure line 33 25 -
retaining bolt
Valve cover retaining bolts 9 - 80
Ignition coil-on-plug retaining bolts 9 - 80
Camshaft bearing caps retaining bolts 13 10 -
Camshaft sprocket retaining bolts 55 41 -
Camshaft position (CMP) sensor retaining bolt 9 - 80
Variable camshaft timing (VCT) solenoid retaining 9 - 80
bolt
VCT solenoid oil filter retaining bolt 39 29 -
Timing chain tensioner retaining bolt 9 - 80
Timing chain tensioner arm retaining bolt 22 16 -
G384590 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-4 Engine — 1.6L (Z6) 303-01C-4

Timing chain guide retaining bolt 22 16 -
Engine front cover retaining bolts a) - -
Engine front cover blanking plugs 4 - 35
Engine wiring harness bracket retaining 22 16 -
Idler pulley retaining nut 46 34 -
Coolant pump retaining bolts 22 16 -
Coolant outlet connector retaining bolts 22 16 -
Oil pump pickup tube retaining bolts 9 - 80
Oil pump retaining bolts 22 16 -
Oil pan drain plug 15 11 -
Oil pan retaining bolts 9 - 80
Oil filter 25 18 -
Oil level indicator pipe retaining bolt 9 - 80
Cylinder head retaining bolts a) - -
Catalytic converter heat shield retaining bolts 9 - 80
Catalytic converter support bracket retaining bolts 23 17 -
Catalytic converter to muffler and tailpipe muffler 45 33 -
retaining bolts
Exhaust manifold studs 35 - 89
Floor panel brace retaining bolts 30 22 -
EGR valve tube to exhaust manifold retaining nuts 9 - 80
EGR valve tube bracket to exhaust manifold re- 9 - 80
taining nuts
EGR valve tube to exhaust manifold retaining nut 39 29 -
Exhaust gas recirculation (EGR) pipe to intake 9 - 80
manifold retaining bolts
EGR pipe retaining bracket retaining bolts 9 - 80
EGR valve retaining bracket retaining bolts 22 16 -
EGR pipe to EGR valve retaining nut 39 29 -
Generator lower retaining bolts 45 33 -
Generator upper retaining bolts 45 33 -
Intake manifold retaining bolts 44 32 -
Crankshaft position (CKP) sensor retaining bolt 8 - 71
Knock sensor (KS) 27 20 -
Spark plugs 18 13 -
Torque converter retaining nuts 37 27 -
Crash box retaining bolts 40 30 -
Battery positive lead retaining nut 6 - 53
G384590 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-5 Engine — 1.6L (Z6) 303-01C-5
GENERAL PROCEDURES
Valve Clearance Adjustment

4. Disconnect the ignition coil-on-plug elec-

Special Tool(s) trical connectors.
Clamp
303-397
General Equipment
Feeler gauges
Name Specification
All vehicles 5. Disconnect the positive crankcase ventila-
1. Remove the engine cover. tion (PCV) hose from the valve cover.
2. Disconnect the battery ground cable. For 6. Remove the ignition coil-on-plug.
Disconnect]
G384594 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-6 Engine — 1.6L (Z6) 303-01C-6
7. Remove the spark plugs. 11. NOTE: Only rotate the crankshaft in the
at TDC and measure the valve clearances.
12. NOTE: Only carry out the following steps
when the valve clearance(s) require
adjustment. For additional information, refer to
Specifications in this section.
Remove the camshafts. For additional
section.
13. NOTE: The number on the valve tappet is the
valve tappet thickness, however only the
decimal places are marked (for example .650 =
8. Remove the valve cover. 3.650).
Determine the valve tappet thickness
required:
1. Remove the valve tappet and read the
thickness from the underside.
2. Calculate the valve tappet thickness
required (thickness of currently installed
valve tappet, + the measured valve
clearance, - the required valve clearance).
3. Install the correct valve tappet.
14. NOTE: Do not install the valve cover at this
stage.
9. NOTE: Only rotate the crankshaft in the normal Install the camshafts. For additional
direction of rotation. information, refer to Camshafts in this
Rotate the crankshaft until piston No. 1 is section.
at top dead center (TDC). 15. NOTE: Only rotate the crankshaft in the
10. NOTE: Note down each cylinder number and normal direction of rotation.
the valve clearances measured. Rotate the crankshaft until each piston is
Using a suitable set of feeler gauges, at TDC and measure the valve clearances.
measure the valve clearances. 16. Repeat this procedure as necessary until
all valve clearances are within the
specified tolerance.
G384594 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-7 Engine — 1.6L (Z6) 303-01C-7
17. Apply a small bead of sealant to the areas 20. Install the ignition coil-on-plug.
as shown.

18. NOTE: Install a new valve cover gasket if tion (PCV) hose to the valve cover.
necessary.
22. Connect the ignition coil-on-plug electri-

cal connectors.
19. Install the spark plugs.
G384594 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-8 Engine — 1.6L (Z6) 303-01C-8


Disconnect]

26. Initialize the door window regulator
motors. For additional information,
refer to Section 501-11.[Glass, Frames and
Mechanisms, GENERAL PROCEDURES,
Door Window Motor Initialization]
G384594 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-9 Engine — 1.6L (Z6) 303-01C-9
IN-VEHICLE REPAIR
Intake Manifold
IN-VEH ICLE R EPAIR

Special Tool(s) information, refer to Section 414-01.
Remover/Installer, Hose GENERAL PROCEDURES, Battery
Clamp Disconnect]
303-397 3. Remove the air cleaner. For additional
1. Remove the engine cover. (Z6)]
table(s).
G384710 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-10 Engine — 1.6L (Z6) 303-01C-10
IN-VEHICLE REPAIR

Number
1 - Positive crankshaft
ventilation (PCV) hose
See Removal Detail
2 - Evaporative emission
(EVAP) vacuum hose
See Removal Detail
3 - Fuel injectors electrical
connector
connector
5 - Knock sensor (KS) electrical
connector
6 - Intake manifold runner con-
trol (IMRC) electrical con-
nector
7 - Idle air control (IAC) electri-
cal connector
8 - Throttle position sensor
9 - Swirl plate servo motor elec-
trical connector
10 - Engine wiring harness clip
11 - Throttle body coolant hose
See Removal Detail
See Removal Detail
13 - EVAP hose
See Removal Detail
14 - Accelerator cable
See Removal Detail
See Removal Detail
G384710 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-11 Engine — 1.6L (Z6) 303-01C-11
IN-VEHICLE REPAIR
Item 11 : Throttle body coolant hose

Item Part Description 1. Using the special tool, disconnect the
Number coolant hose from the throttle body.
(EGR) pipe retaining bolts
17 - EGR pipe bracket retaining
bolt
18 - EGR pipe retaining bolt
19 - EGR pipe gasket
20 - Intake manifold retaining
bolts
21 - Intake manifold gaskets
Removal Details
Item 1 : Positive crankshaft ventilation (PCV)

hose
1. Detach the PCV hose from the bracket.
Item 2 : Evaporative emission (EVAP) vacuum
hose
1. Detach the EVAP vacuum hose from the
bracket.
G384710 en 09/2004 2004.75 Focus
TO MODEL INDEX
303-01C-12 Engine — 1.6L (Z6) 303-01C-12
Item 12 : Brake booster vacuum hose 2. Detach the accelerator cable from the
1. Using the special tool, disconnect the throttle body.
brake booster vacuum hose from the intake 1. Detach the accelerator cable from the
manifold. bracket.
2. Detach the accelerator cable from the
throttle lever.
Item 13 : EVAP hose

EVAP hose from the intake manifold.
Item 15 : Fuel supply line
1. Disconnect the fuel supply line quick
connector. For additional information, refer
to Section 310-00.[Fuel System - General
Quick Release Coupling]

1. Connect the fuel supply line quick
connector. For additional information, refer
to Section 310-00.[Fuel System - General
Item 14 : Accelerator cable
1. Detach the accelerator cable retaining Item 14 : Accelerator cable
bracket from the intake manifold. 1. Attach the accelerator cable to the throttle
body.
1. Attach the accelerator cable to the throttle
lever.
2. Attach the accelerator cable to the bracket.
G384710 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-13 Engine — 1.6L (Z6) 303-01C-13
Item 11 : Throttle body coolant hose

2. Attach the accelerator cable retaining
bracket to the intake manifold.
hose to the throttle body.
Item 13 : EVAP hose

Item 2 : Evaporative emission (EVAP) vacuum
1. Using the special tool, connect the EVAP
hose
hose to the intake manifold.
1. Attach the EVAP vacuum hose to the
bracket.
Item 1 : Positive crankshaft ventilation (PCV)
hose
1. Attach the PCV hose from the bracket.
Item 12 : Brake booster vacuum hose

1. Using the special tool, connect the brake
booster vacuum hose to the intake mani-
fold.
G384710 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-14 Engine — 1.6L (Z6) 303-01C-14
IN-VEHICLE REPAIR
Valve Cover

Special Tool(s)
Clamp
303-397
Name Specification

Disconnect]
table(s).
G384714 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-15 Engine — 1.6L (Z6) 303-01C-15

Number Number
1 - Positive crankcase 3 - Ignition coil-on-plug electrical
ventilation (PCV) hose connector
See Removal Detail
2 - Engine wiring harness clips

Number
5 - Ignition coil-on-plug retaining
bolts
6 - Ignition coil-on-plug
7 - Valve cover retaining bolts
8 - Valve cover gasket
G384714 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-16 Engine — 1.6L (Z6) 303-01C-16
4. To install, reverse the removal procedure. 2. NOTE: Install a new valve cover gasket.
Removal Details
Item 1 : Positive crankcase ventilation (PCV)
hose
1. Using the special tool, disconnect the PCV
hose from the valve cover.

hose
1. Using the special tool, connect the PCV
hose to the valve cover.
Item 7 : Valve cover retaining bolts

as shown.
G384714 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-17 Engine — 1.6L (Z6) 303-01C-17
IN-VEHICLE REPAIR
Crankshaft Front Seal

Special Tool(s) information, refer to Section 414-01.
Wrench
Disconnect]
205-072
2. Remove the accessory drive belt. For additi-
Adapter for 205-072 [Accessory Drive, REMOVAL AND
205-072-01 1.6L (Z6)]
Remover, Seal table(s).
303-112
Remover, Timing Cover Seal

303-501
G384720 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-18 Engine — 1.6L (Z6) 303-01C-18

Number
1 - Crankshaft pulley retaining Item 2 : Crankshaft front seal
bolt 1. NOTE: Install a new crankshaft front seal
See Removal Detail Using the special tool and the crankshaft
See Installation Detail pulley retaining bolt, install the crankshaft
2 - Crankshaft front seal front seal.
See Removal Detail
Removal Details

hose
1. Using the special tool, remove the crank-

hose
1. Using the special tool, install the crank-

G384720 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-19 Engine — 1.6L (Z6) 303-01C-19
IN-VEHICLE REPAIR
Valve Seals
Special Tool(s)
Compressor, Valve Spring WARNING: Do not smoke or use any kind
of naked flame when working on or near
303-361A any fuel-related components. Highly
flammable vapors are always present and
may ignite. Failure to observe this
instruction can lead to injury.
1. Remove the camshafts. For additional
Adapter for 303-361A information, refer to Camshafts in this
303-361-04 section.
2. Position the appropriate piston at top dead
center (TDC).
Adapter for 303-361A table(s).
303-361-05

303-362

303-508
Connector, Air Supply

(Cylinder Head)
303-363
G384730 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-20 Engine — 1.6L (Z6) 303-01C-20
IN-VEHICLE REPAIR

Number
Removal Details
1 - Valve collets
See Removal Detail
1. Install the special tools.
See Removal Detail
3 - Valve spring
See Removal Detail
4 - Valve seals
See Removal Detail
G384730 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-21 Engine — 1.6L (Z6) 303-01C-21
2. Using the special tool, apply compressed Installation Details

air (7-10 bar) to the cylinder.
3. Using the special tools, compress the valve Item 4 : Valve seals
springs. 1. Cover the valve collet grooves on the valve
4. Using the special tool, remove the valve stem with a protective sleeve (valve shown
collets. removed for clarity).

Item 2 : Valve spring retainer Using the special tool, install the valve
CAUTION: Keep the valve spring retainers seals.
CAUTION: Keep the valve springs in order
for installation.
Item 4 : Valve seals
seals.
• Discard the valve seals.

1. Using the special tools, compress the valve
springs.
G384730 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-22 Engine — 1.6L (Z6) 303-01C-22
2. Using the special tool, install the valve

collets.
G384730 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-23 Engine — 1.6L (Z6) 303-01C-23
IN-VEHICLE REPAIR
Camshafts
Disconnect]
2. Remove the valve cover. For additional
General Equipment information, refer to Valve Cover in this
M10 x 25 mm bolt section.
table(s).

Number
4 - Camshaft bearing caps
1 - Exhaust camshaft sprocket retaining bolts
retaining bolt See Removal Detail
5 - Camshaft bearing caps
2 - Exhaust camshaft sprocket See Removal Detail
3 - Intake camshaft sprocket See Installation Detail
retaining bolt
See Installation Detail 7 - Intake camshaft
G384742 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-24 Engine — 1.6L (Z6) 303-01C-24
4. To install, reverse the removal procedure. 3. Detension the timing chain.

1. Using a suitable screwdriver on the
Removal Details left-hand blanking plug hole, unlock the
timing chain tensioner ratchet.
Item 1 : Exhaust camshaft sprocket retaining 2. Carefully rotate the crankshaft counter-
bolt clockwise to detension the timing chain
NOTE: Hold the camshaft by the hexagon with an tensioner.
open-ended wrench to prevent it from rotating.
NOTE: Do not remove the exhaust camshaft
sprocket retaining bolt at this stage.
1. Loosen the exhaust camshaft sprocket
retaining bolt.
Item 2 : Exhaust camshaft sprocket
1. Remove the engine front cover blanking
plugs.
2. Install a bolt M10 x 25 mm to the right-hand

blanking plug hole.
• Loosen the bolt M10 x 25 mm by two turns.
4. NOTE: Fingertighten the M10 x 25mm bolt.
Tighten the bolt M10 x 25 mm until it stops
on the left-hand timing chain tensioner
arm.
G384742 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-25 Engine — 1.6L (Z6) 303-01C-25
5. Remove the exhaust camshaft sprocket Item 5 : Camshaft bearing caps

retaining bolt and the exhaust camshaft 1. Install the camshaft bearing caps.
sprocket.
Item 4 : Camshaft bearing caps retaining bolts
1. Remove the camshaft bearing cap retain-
ing bolts in the sequence shown.
Item 4 : Camshaft bearing caps retaining bolts

1. NOTE: Working in several stages, evenly
tighten the camshaft bearing cap retaining bolts
one half turn at a time.
Tighten the camshaft bearing caps retain-
Item 5 : Camshaft bearing caps ing bolts in the sequence shown.
NOTE: Keep the camshaft bearing caps in order
for installation.
Item 7 : Intake camshaft

1. Rotate the crankshaft in the normal direc-
tion of rotation until piston No. one is at top
dead center (TDC).
2. Install the intake camshaft approximately

in the valve overlap position cylinder No. 4.
Item 6 : Exhaust camshaft
1. Install the exhaust camshaft approximately
in the valve overlap position cylinder No. 4.
G384742 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-26 Engine — 1.6L (Z6) 303-01C-26
Item 3 : Intake camshaft sprocket retaining 2. Remove the bolt M10 x 25 mm from the
bolt right-hand blanking plug hole.
1. CAUTION: The timing mark of the intake
camshaft sprocket must align with the
upper surface of the engine front
cover.
NOTE: Hold the camshaft by the hexagon with an
open-ended wrench to stop it from rotating.
Install the intake camshaft sprocket to-
gether with the timing chain.

Rotate the crankshaft two revolutions,
check the valve timing and correct as
necessary.
4. Install the engine front cover blanking
Item 2 : Exhaust camshaft sprocket plugs.
1. CAUTION: The timing mark of the

exhaust camshaft sprocket must align
with the upper surface of the engine
front cover.
Install the exhaust camshaft sprocket to-
gether with the timing chain.
Item 1 : Exhaust camshaft sprocket retaining

bolt
NOTE: Hold the camshaft by the hexagon with an
open-ended wrench to prevent it from rotating.
G384742 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-27 Engine — 1.6L (Z6) 303-01C-27
IN-VEHICLE REPAIR
Timing Chain
Special Tool(s) 5. Install the special tools.
Support Bar, Engine
303-290A

303-290-03A

303-290-13
6. Remove the crankshaft front seal. For
Adapter for 303-290A Front Seal in this section.
303-290-15 7. Lower the vehicle.
8. Detach the coolant expansion tank and
1. Remove the valve cover. For additional

information, refer to Valve Cover in this
section.
2. Remove the headlamp assembly on both
sides. For additional information,
refer to Section 417-01.[Exterior Lighting,
REMOVAL AND INSTALLATION, Headlamp
Assembly]
3. Attach the special tool on both sides
(right-hand side shown).
9. Detach the power steering pump fluid res-

ervoir and secure it to one side.
4. Raise and support the vehicle. For additi-

G401932 en 09/2004 2004.75 Focus
TO MODEL INDEX
303-01C-28 Engine — 1.6L (Z6) 303-01C-28
10. Detach the ground cable from the engine 13. Disconnect the crankshaft position (CKP)
front mount. sensor electrical connector.
11. Remove the engine front mount. 14. Detach the power steering pump from the
cylinder block.
1. Remove the power steering pump upper
retaining bolt.
2. Loosen the power steering pump lower re-
taining bolt.
12. Disconnect the variable camshaft timing

(VCT) intake solenoid electrical connec-
tor.

and table(s).
G401932 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-29 Engine — 1.6L (Z6) 303-01C-29
IN-VEHICLE REPAIR

Number
10 - Engine front cover retaining
1 - VCT intake solenoid retain- bolt seal washer
ing bolt
11 - Engine front cover
2 - VCT intake solenoid O-ring See Installation Detail
seal
12 - Engine front cover O-ring
3 - Idler pulley retaining nut seals
4 - VCT intake solenoid oil filter 13 - Timing chain
retaining bolt See Removal Detail
5 - VCT intake solenoid oil filter See Installation Detail
See Installation Detail 14 - Timing chain tensioner arm
6 - Accessory drive belt ten- retaining bolt
sioner retaining bolts 15 - Timing chain guide retaining
7 - Oil level indicator pipe re- bolt
taining bolt 16 - Timing chain tensioner re-
8 - Oil level indicator pipe O-ring taining bolt
seal
bolts
G401932 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-30 Engine — 1.6L (Z6) 303-01C-30
Removal Details Item 13 : Timing chain

Item 13 : Timing chain tion of rotation until piston No. one is at top
1. Rotate the crankshaft in the normal direc- dead center (TDC).
dead center (TDC).
2. Rotate the camshafts until the camshaft

timing marks align with the upper surface
2. Detension the timing chain. of the engine front cover.
pin punch.
3. Install the timing chain.

4. Remove the suitable pin punch, tension the
timing chain.
G401932 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-31 Engine — 1.6L (Z6) 303-01C-31
5. NOTE: Only rotate the crankshaft in the normal Item 9 : Engine front cover retaining bolts
direction of rotation. 1. Tighten the engine front cover retaining
check the valve timing and correct as • Bolt 9: 9 Nm.
necessary. • Bolts 1 through 6, 8, 10, 12 through 15, 17,
18: 22 Nm.
Item 11 : Engine front cover
1. Clean the mating faces of the cylinder • Bolts 7, 11, 16: 45 Nm.
block and of the front cover with cleaner.
2. CAUTION: Install the engine front cover
within four minutes of applying the
sealer.
Apply a bead of sealant to the areas as
shown.
Item 5 : VCT intake solenoid oil filter

1. Inspect the VCT intake solenoid oil filter
and clean if necessary.
G401932 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-32 Engine — 1.6L (Z6) 303-01C-32
IN-VEHICLE REPAIR
Exhaust Manifold (21 187 0)

IN-VEH ICLE R EPAIR
1. NOTE: The exhaust manifold and catalytic

converter are serviced as one component and
can not be renewed separately.
Remove the catalytic converter. For
[Exhaust System, REMOVAL AND
INSTALLATION, Catalytic Converter - 1.6L
(Z6)]
G405612 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-33 Engine — 1.6L (Z6) 303-01C-33
IN-VEHICLE REPAIR
Cylinder Head

Special Tool(s) electrical connector.
Clamp
303-397
Gauge, Bolt Angle

303-174

AND INSTALLATION, Air Cleaner - 1.6L 8. Remove the components in the order
(Z6)] indicated in the following illustration(s) and
2. Remove the battery tray. For additional table(s).
Tray - 1.6L (Z6)]
3. Remove the intake manifold. For additional
information, refer to Intake Manifold in this
section.
information, refer to Timing Chain in this
section.
information, refer to Section 303-03C.
[Engine Cooling - 1.6L (Z6),
GENERAL PROCEDURES, Cooling System
Draining, Filling and Bleeding]
6. Disconnect the heated oxygen (H02S)
G384760 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-34 Engine — 1.6L (Z6) 303-01C-34
IN-VEHICLE REPAIR

Number
connector.
bracket
4 - Heater core coolant hose
See Removal Detail
G384760 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-35 Engine — 1.6L (Z6) 303-01C-35
IN-VEHICLE REPAIR

Number
5 - Coolant outlet connector re-
taining bolts
6 - Coolant outlet connector
gasket
G384760 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-36 Engine — 1.6L (Z6) 303-01C-36
IN-VEHICLE REPAIR

Number
10 - Exhaust manifold to EGR
7 - Exhaust manifold to exhaust valve tube gasket
gas recirculation (EGR) valve
tube retaining nuts 11 - EGR valve electrical con-
nector
valve tube bracket retaining 12 - EGR valve retaining bolts
nut 13 - Wiring harness clip retaining
9 - Exhaust manifold to EGR bolt
valve tube retaining nut 14 - Wiring harness clip
G384760 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-37 Engine — 1.6L (Z6) 303-01C-37
IN-VEHICLE REPAIR
15 - Catalytic converter heat

shield upper retaining nuts
shield lower retaining nuts
17 - Catalytic converter to muffler
and tailpipe assembly re-
taining nuts
19 - Catalytic converter support
nuts
21 - Exhaust manifold gasket
22 - Catalytic converter
See Removal Detail
G384760 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-38 Engine — 1.6L (Z6) 303-01C-38
IN-VEHICLE REPAIR
G384760 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-39 Engine — 1.6L (Z6) 303-01C-39
Item Part Description Item 24 : Cylinder head retaining bolts

Number 1. Remove the cylinder head retaining bolts in
the sequence shown.
23 - Camshaft bearing cap
retaining bolts
See Removal Detail
24 - Cylinder head retaining bolts
See Removal Detail
Removal Details
Item 4 : Heater core coolant hose

heater core coolant hose from the cylinder Installation Details
head.
Item 24 : Cylinder head retaining bolts
1. CAUTION: Do not reuse the cylinder
head bolts if the length is more than
130.2 mm.
Measure the cylinder head bolts.
Item 22 : Catalytic converter

NOTE: The catalytic converter remains on the
vehicle.
Item 23 : Camshaft bearing cap retaining bolts
1. Remove the camshaft bearing cap retain-
ing bolts in the sequence shown.
G384760 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-40 Engine — 1.6L (Z6) 303-01C-40
2. CAUTION: Install new cylinder head 2. NOTE: Working in several stages, evenly
bolts as necessary. tighten the camshaft bearing cap retaining bolts
Tighten the cylinder head retaining bolts in
the sequence shown in three stages. Tighten the camshaft bearing cap retaining
1. Stage 1: 20 Nm.
2. Stage 2: 90 degrees.
Item 20 : Exhaust manifold retaining nuts

1. NOTE: Install new exhaust manifold retaining
nuts.
Item 23 : Camshaft bearing cap retaining bolts nuts in the sequence shown.
1. Install the camshaft bearing caps.
G384760 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-41 Engine — 1.6L (Z6) 303-01C-41
Item 4 : Heater core coolant hose

1. Using the special tool, connect the heater
core coolant hose to the cylinder head.
G384760 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-42 Engine — 1.6L (Z6) 303-01C-42
IN-VEHICLE REPAIR
Oil Pan

Separator, Oil Pan
table(s).
303-428
Name Specification
Engine Oil - 5W-30 WSS-M2C913-A

Number
3 - Oil pick-up pipe retaining
1 - Oil pan retaining bolts bolts
See Removal Detail
See Installation Detail 4 - Oil pick-up pipe O-ring seal
2 - Oil pan
See Removal Detail
G384771 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-43 Engine — 1.6L (Z6) 303-01C-43

Removal Details Item 2 : Oil pan
1. Clean the mating faces of the oil pan and
Item 1 : Oil pan retaining bolts the cylinder block with cleaner.
additional information, refer to Section 2. CAUTION: Install the oil pan within five
100-02.[Jacking and Lifting, DESCRIPTION minutes of applying the sealant.
AND OPERATION, Jacking] For additional Apply a 3 mm bead of sealant to the mating
information, refer to Section 100-02 face of the oil pan.
.[Jacking and Lifting, DESCRIPTION
2. Drain the engine.
container.
3. NOTE: Inspect the oil drain plug and seal for
damage. Install a new oil drain plug as
necessary.
Item 1 : Oil pan retaining bolts

• Tighten the oil pan retaining bolts in the
sequence shown.
Item 2 : Oil pan

1. Using the special tool, remove the oil pan.

G384771 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-44 Engine — 1.6L (Z6) 303-01C-44
IN-VEHICLE REPAIR
Oil Pump
1. Remove the timing chain. For additional 2. Remove the components in the order
information, refer to Timing Chain in this indicated in the following illustration(s) and
section. table(s).

Number
1 - Oil pump retaining bolts
2 - Oil pump gasket
G384774 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-45 Engine — 1.6L (Z6) 303-01C-45
IN-VEHICLE REPAIR
Crankshaft Rear Seal

Special Tool(s) 2. Remove the clutch disc and pressure plate.
Locking Tool, Flywheel For additional information, refer to Section
308-01A.[Clutch - Vehicles With: 5-Speed
303-254
Manual Transaxle (MTX-75), REMOVAL
AND INSTALLATION, Clutch Disc and
Pressure Plate]
Remover, Crankshaft Seal table(s).
303-293
Installer, Crankshaft Rear

Seal
303-347
G384779 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-46 Engine — 1.6L (Z6) 303-01C-46
Item Part Description 1. Using the special tool, remove the

Number crankshaft rear seal.
1 - Flywheel/ Flexplate retaining
bolts
See Removal Detail Installation Details
2 - Flywheel/ Flexplate 1. NOTE: Install a new crankshaft rear seal.
3 - Crankshaft rear seal Using the special tool, install the crank-
See Removal Detail shaft rear seal.
Removal Details

hose
NOTE: Only rotate the engine in the normal
Using the special tool, lock the flywheel/
flexplate. Item 1 : Positive crankcase ventilation (PCV)
hose
NOTE: Only rotate the engine in the normal
flexplate.
G384779 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-47 Engine — 1.6L (Z6) 303-01C-47
2. Tighten the flywheel/ flexplate retaining

G384779 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-48 Engine — 1.6L (Z6) 303-01C-48
REMOVAL

REMOVAL
Special Tool(s) 3. Disconnect the battery positive cable from

Lifting Bracket, Engine the battery positive cable terminal clamp.
303-122
Clamp
303-397

Failure to follow these instructions may 5. Remove the accessory drive belt. For
result in personal injury. additional information, refer to Section 303-05.
1. Remove the engine cover. [Accessory Drive, REMOVAL AND
1.6L (Z6)]
6. Detach the ground cables from the wheel
housing.

Tray - 1.6L (Z6)]
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-49 Engine — 1.6L (Z6) 303-01C-49
REMOVAL (Continued)
7. Remove the central junction box (CJB) 11. Remove the floor panel brace.
cover.

8. Disconnect the engine wiring harness
13. Remove the left-hand halfshaft. For additi-

9. Remove the cooling fan motor and shroud. [Front Drive Halfshafts, REMOVAL
For additional information, refer to Section AND INSTALLATION, Halfshaft LH]
303-03C.[Engine Cooling - 1.6L (Z6), 14. Remove the right-hand halfshaft in unit
REMOVAL AND INSTALLATION, Cooling with the intermediate shaft. For additional
Fan Motor and Shroud] information, refer to Section 205-04.[Front
10. Raise and support the vehicle. Drive Halfshafts, REMOVAL AND
INSTALLATION, Halfshaft RH]
and table(s).
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-50 Engine — 1.6L (Z6) 303-01C-50
REMOVAL

Number
pressor electrical connector
2 - A/C compressor retaining
bolts
3 - A/C compressor
See Removal Detail
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-51 Engine — 1.6L (Z6) 303-01C-51
REMOVAL

Number
4 - Exhaust manifold to exhaust valve tube gasket
gas recirculation (EGR) valve
tube retaining nuts 8 - EGR valve electrical con-
nector
valve tube bracket retaining 9 - EGR valve retaining bolts
nut 10 - Wiring harness clip retaining
6 - Exhaust manifold to EGR bolt
valve tube retaining nut 11 - Wiring harness clip
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-52 Engine — 1.6L (Z6) 303-01C-52
REMOVAL (Continued)

Number Number
12 - Catalytic converter heat 16 - Catalytic converter support
shield upper retaining nuts bracket retaining bolts
13 - Catalytic converter heat 17 - Exhaust manifold retaining
shield lower retaining nuts nuts
14 - Catalytic converter to muffler 18 - Exhaust manifold gasket
and tailpipe assembly re-
taining nuts
See Removal Detail

Number
20 - Power steering line
See Removal Detail
21 - Power steering fluid supply
hose
See Removal Detail
22 - Coolant hose
See Removal Detail
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-53 Engine — 1.6L (Z6) 303-01C-53
REMOVAL

Number
28 - Heated oxygen sensor
23 - Radiator lower coolant hose (HO2S) electrical connector
See Removal Detail
29 - Catalyst monitor sensor
24 - Coolant outlet connector to electrical connector
coolant expansion tank hose
See Removal Detail 30 - Brake booster vacuum line
See Removal Detail
25 - Cylinder head to heater core
coolant hose 31 - Accelerator cable
26 - Coolant outlet connector to 32 - Fuel supply line

radiator upper coolant hose See Removal Detail
See Removal Detail
See Removal Detail
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-54 Engine — 1.6L (Z6) 303-01C-54
REMOVAL

Number
line
See Removal Detail
34 - Engine rear mount retaining
bolt
See Removal Detail
35 - Engine front mount retaining
nuts
See Removal Detail
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-55 Engine — 1.6L (Z6) 303-01C-55
REMOVAL

Number
36 - Vehicle speed (VSS) sensor
37 - Neutral switch electrical
connector
38 - Reversing lamp switch elec-
trical connector
39 - Transaxle wiring harness
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-56 Engine — 1.6L (Z6) 303-01C-56
REMOVAL
Item 20 : Power steering line

Number 1. CAUTION: Cap the power steering line
to prevent fluid loss or dirt ingress.
40 - Starter motor retaining bolts
41 - Starter motor CAUTION: Cap the power steering pump
See Removal Detail connection to prevent fluid loss or dirt
ingress.
42 - Transaxle
See Removal Detail Remove and discard the power steering
line union washers.
Removal Details
Item 3 : A/C compressor

1. Detach the A/C compressor from the
bracket and secure it to one side.
NOTE: The catalytic converter remains on the
vehicle.
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-57 Engine — 1.6L (Z6) 303-01C-57
REMOVAL (Continued)
Item 21 : Power steering fluid supply hose Item 23 : Radiator lower coolant hose
1. CAUTION: Cap the power steering fluid coolant hose from the cylinder block.
supply hose to prevent fluid loss or
dirt ingress.
CAUTION: Cap the power steering pump
connection to prevent fluid loss or dirt
ingress.
power steering fluid supply hose from the
power steering pump.
tainer.
Item 24 : Coolant outlet connector to coolant

expansion tank hose
coolant hose from the coolant outlet con-
nector.
Item 22 : Coolant hose

coolant hose from the cylinder block.
Item 25 : Cylinder head to heater core coolant

hose
coolant hose from the cylinder head.
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-58 Engine — 1.6L (Z6) 303-01C-58
REMOVAL (Continued)
Item 26 : Coolant outlet connector to radiator Item 30 : Brake booster vacuum line
upper coolant hose 1. Using the special tool, disconnect the
1. Using the special tool, disconnect the brake booster vacuum hose from the intake
coolant hose from the coolant outlet con- manifold.
nector.

Item 27 : Gearshift cables 1. Detach the accelerator cable retaining
1. Detach the gearshift cables from the bracket from the intake manifold.
transaxle.
1. Detach the gearshift and selector cables
from the selector mechanism.
2. Press the locking pins together and detach
the gearshift cables from the bracket.

throttle body.
bracket.
throttle lever.
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-59 Engine — 1.6L (Z6) 303-01C-59
REMOVAL (Continued)

Item 35 : Engine front mount retaining nuts
1. Remove the engine ground cable.
connector.For additional information,
refer to Section 310-00. [Fuel System -
1. CAUTION: If brake fluid comes into
contact with the paintwork, rinse off
the affected areas with cold water
without delay.
cylinder pressure line to prevent fluid
Detach the clutch slave cylinder pressure
line from the clutch slave cylinder. 2. Remove the engine front mount retaining
nuts.
• Detach the clutch slave cylinder pressure
line from the bracket.

Item 34 : Engine rear mount retaining bolt AND OPERATION, Lifting]
1. NOTE: Support the engine and transaxle with 4. Remove the engine and transaxle
suitable wooden blocks. assembly.
Secure the engine and transaxle assembly 5. Install the special tool.
on the workshop table using suitable re-
taining straps.
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-60 Engine — 1.6L (Z6) 303-01C-60
REMOVAL (Continued)
Item 41 : Starter motor

1. Remove the starter motor cable shield.
Item 42 : Transaxle
1. Remove the transaxle right-hand retaining
bolts.

bolts.
G384845 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-61 Engine — 1.6L (Z6) 303-01C-61
DISASSEMBLY
Engine
DISASSEM BLY
Special Tool(s)
Mounting Plate for
303-435-11A
Wrench
205-072
Adapter for 205-072
205-072-01
Remover, Seal
303-112

303-254

303-293
Separator, Oil Pan

303-428
Mounting Stand 3. Mount the engine on the mounting stand.

303-435

303-435-06
G384846 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-62 Engine — 1.6L (Z6) 303-01C-62
4. Remove the special tool. 5. Drain the engine.

container.
6. Install the oil drain plug.

table(s).

Number
2 - Variable camshaft timing
1 - Power steering pump elec- (VCT) solenoid electrical
trical connector connector
G384846 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-63 Engine — 1.6L (Z6) 303-01C-63

Number Number
3 - Wiring harness clip 12 - Wiring harness clips
4 - Crankshaft position (CKP) 13 - Oil pressure switch electrical
sensor electrical connector connector
5 - Wiring harness clip 14 - Battery to generator cable
6 - Generator electrical con-
nector
7 - Wiring harness clip
(EVAP) solenoid electrical
8 - Manifold absolute pressure connector
connector
sensor electrical connector 18 - Intake manifold runner con-
10 - Ignition coil-on-plug electrical
nector
connectors
nectors
G384846 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-64 Engine — 1.6L (Z6) 303-01C-64

Number Number
20 - Knock sensor (KS) electrical 24 - Heated oxygen (HO2S)
connector sensor electrical connector
21 - Idle air control (IAC) electri- 25 - Catalyst monitor sensor
cal connector electrical connector
22 - Throttle position (TP) elec- 26 - Positive crankshaft ventila-
trical connector tion hose
23 - Engine coolant temperature 27 - EVAP solenoid vacuum line
(ECT) electrical connector

Number
(EGR) pipe retaining bolts
bolt
30 - EGR pipe retaining nut
31 - EGR pipe gasket
bolts
G384846 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-65 Engine — 1.6L (Z6) 303-01C-65

Number
34 - Generator upper retaining
bolt
35 - Generator lower retaining
bolt

Number
36 - Power steering pump upper
retaining bolt
37 - Power steering pump lower
retaining bolt

Number
40 - Spark plug
38 - CMP sensor retaining bolt
41 - Valve cover
39 - CMP sensor O-ring seal
G384846 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-66 Engine — 1.6L (Z6) 303-01C-66
DISASSEMBLY
42 - Valve cover gasket

bolt
44 - Crankshaft front seal
45 - VCT intake solenoid retain-
ing bolt
46 - VCT intake solenoid O-ring
seal
47 - Idler pulley retaining nut
48 - VCT intake solenoid oil filter
retaining bolt
50 - Accessory drive belt ten-
sioner retaining bolts
51 - Oil level indicator pipe re-
taining bolt
52 - Oil level indicator pipe O-ring
seal
bolts
bolt seal washer
55 - Engine front cover
56 - Engine front cover O-ring
seals
57 - Timing chain
58 - Timing chain tensioner arm
retaining bolt
59 - Timing chain guide retaining
bolt
60 - Timing chain tensioner re-
taining bolt
G384846 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-67 Engine — 1.6L (Z6) 303-01C-67
DISASSEMBLY
G384846 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-68 Engine — 1.6L (Z6) 303-01C-68

Number Number
61 - Camshaft bearing cap 63 - Valve tappets
retaining bolts See Disassembly Detail
64 - Cylinder head retaining bolts
62 - Camshaft bearing caps See Disassembly Detail

Number
66 - Flywheel/ Flexplate retaining bolts
bolts
See Disassembly Detail 74 - Oil pan retaining bolts
67 - Flywheel/ Flexplate 75 - Oil pan

68 - Spacer plate
69 - Crankshaft rear seal bolts
77 - Oil pick-up pipe O-ring seal
70 - Crankcase vent oil separator
retaining bolts 78 - Oil pump retaining bolts
71 - Crankcase vent oil separator 79 - Oil pump gasket

O-ring seal 80 - Coolant pump retaining bolt
72 - Knock sensor (KS)
G384846 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-69 Engine — 1.6L (Z6) 303-01C-69
Item Part Description Item 44 : Crankshaft front seal

Number 1. Using the special tool, remove the
81 - Coolant pump O-ring seal • Discard the seal.
Disassembly Details
Item 14 : Battery to generator cable electrical

connector
1. Remove the Battery to generator cable

dead center (TDC).

1. Using the special tools, remove the
crankshaft pulley retaining bolt.
G384846 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-70 Engine — 1.6L (Z6) 303-01C-70
2. Detension the timing chain. Item 64 : Cylinder head retaining bolts

1. Unlock the timing chain tensioner ratchet. 1. Remove the cylinder head retaining bolts in
the sequence shown.
pin punch.
Item 66 : Flywheel/ Flexplate retaining bolts

Item 61 : Camshaft bearing cap retaining bolts tool engages correctly.
1. Remove the camshaft bearing cap retain- NOTE: Only rotate the engine in the normal
ing bolts in the sequence shown. direction of rotation.
flexplate.
Item 62 : Camshaft bearing caps

NOTE: Keep the camshaft bearing caps in order
for installation.
Item 63 : Valve tappets
NOTE: Keep the valve tappets in order for
installation.
G384846 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-71 Engine — 1.6L (Z6) 303-01C-71

Item 75 : Oil pan

1. Using the special tool, remove the oil pan.
G384846 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-72 Engine — 1.6L (Z6) 303-01C-72
Cylinder Head
Special Tool(s)
303-361A

303-362
303-361-04
303-508

table(s).
G384847 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-73 Engine — 1.6L (Z6) 303-01C-73

Number
1 - Valve collets
See Removal Detail
See Removal Detail
3 - Valve spring
See Removal Detail
4 - Valve seals
See Removal Detail
G384847 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-74 Engine — 1.6L (Z6) 303-01C-74
G384847 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-75 Engine — 1.6L (Z6) 303-01C-75
Item Part Description Item 3 : Valve spring

Number
CAUTION: Keep the valve springs in order
5 - Exhaust valve for installation.
6 - Intake valve Item 4 : Valve seals
7 - Exhaust manifold studs seals.
• Discard the valve seals.
procedure.
Disassembly Details

Assembly Details
Item 4 : Valve seals

1. Cover the valve collet grooves on the valve
springs.
collets.

CAUTION: Keep the valve spring retainers
G384847 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-76 Engine — 1.6L (Z6) 303-01C-76

seals.

springs.
2. Using the special tool, install the valve

collets.
G384847 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-77 Engine — 1.6L (Z6) 303-01C-77
ASSEMBLY
Engine
ASSEM BLY
Special Tool(s)
Remover, Timing Cover Seal
Wrench
205-072
Name Specification
Adapter for 205-072
205-072-01

Locking Tool, Flywheel procedure.
303-254
Installer, Crankshaft Rear

Seal
303-347
Mounting Stand
303-435

303-435-06
Mounting Plate for

303-435-06
303-435-11A
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-78 Engine — 1.6L (Z6) 303-01C-78
ASSEMBLY

Number
1 - Coolant pump O-ring seal
11 - Crankcase vent oil separator
2 - Coolant pump retaining bolt O-ring seal
3 - Oil pump gasket 12 - Crankcase vent oil separator
4 - Oil pump retaining bolts retaining bolts
5 - Oil pick-up pipe O-ring seal 13 - Crankshaft rear seal

See Assembly Detail
bolts 14 - Spacer plate
7 - Oil pan 15 - Flywheel/ Flexplate

See Assembly Detail 16 - Flywheel/ Flexplate retaining
8 - Oil pan retaining bolts bolts

bolts
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-79 Engine — 1.6L (Z6) 303-01C-79
ASSEMBLY

Number
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-80 Engine — 1.6L (Z6) 303-01C-80

Number Number
18 - Cylinder head retaining bolts 20 - Camshaft bearing caps
19 - Valve tappets 21 - Camshaft bearing cap
retaining bolts
See Assembly Detail
383 Part Description

9Ite Number
383 Part Description m
9Ite Number
m 27 - Engine front cover
See Assembly Detail
22 - Timing chain tensioner re-
taining bolt 28 - Engine front cover retaining
bolt seal washer
23 - Timing chain guide retaining
bolt 29 - Engine front cover retaining
bolts
24 - Timing chain tensioner arm See Assembly Detail
retaining bolt
30 - Oil level indicator pipe O-ring
25 - Timing chain seal
See Assembly Detail
31 - Oil level indicator pipe re-
26 - Engine front cover O-ring taining bolt
seals
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-81 Engine — 1.6L (Z6) 303-01C-81
383 Part Description

9Ite Number
m
(VCT) intake solenoid oil filter
See Assembly Detail
retaining bolt
35 - Idler pulley retaining nut
36 - VCT intake solenoid O-ring Item Part Description
seal Number
37 - VCT intake solenoid retain- 46 - Power steering pump lower

ing bolt retaining bolt
40 - Valve cover gasket 47 - Power steering pump upper
retaining bolt
41 - Valve cover
See Assembly Detail
42 - Valve cover retaining bolt
See Assembly Detail
43 - Spark plug
sensor O-ring seal
45 - CMP sensor retaining bolt

Number
bolt
49 - Generator upper retaining
bolt
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-82 Engine — 1.6L (Z6) 303-01C-82
ASSEMBLY

Number
bolts
(EGR) pipe gasket
53 - EGR pipe retaining nut
bolt
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-83 Engine — 1.6L (Z6) 303-01C-83
ASSEMBLY

Number
(EVAP) solenoid vacuum line
57 - Positive crankshaft ventila-
tion hose
59 - Heated oxygen (HO2S)
(ECT) electrical connector
61 - Throttle position (TP) elec-
trical connector
62 - Idle air control (IAC) electri-
cal connector
63 - Knock sensor (KS) electrical
connector
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-84 Engine — 1.6L (Z6) 303-01C-84
ASSEMBLY
69It Part Description

em Number
69It Part Description
em Number 75 - Manifold absolute pressure
64 - Wiring harness clip connector
65 - Intake manifold runner con- 76 - Wiring harness clip
nector 77 - Generator electrical con-
nector
68 - EVAP solenoid electrical sensor electrical connector
connector
connector 81 - Power steering pump elec-
trical connector
71 - Wiring harness clips
82 - VCT solenoid electrical
72 - Fuel injector electrical con- connector
nectors
connectors
74 - CMP sensor electrical con-
nector
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-85 Engine — 1.6L (Z6) 303-01C-85
1. Install the special tool. 4. Remove the special tool.
2. Remove the engine from the mounting

Assembly Details
stand.
Item 7 : Oil pan
1. CAUTION: Install the oil pan within five
minutes of applying the sealant.

1. NOTE: Install a new crankshaft rear seal.
Using the special tool, install the crank-
shaft rear seal.
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-86 Engine — 1.6L (Z6) 303-01C-86
2. Tighten the flywheel or flexplate retaining

Item 8 : Oil pan retaining bolts
• Tighten the oil pan retaining bolts in the
sequence shown.

Item 18 : Cylinder head retaining bolts
Item 16 : Flywheel/ Flexplate retaining bolts 1. CAUTION: Do not reuse the cylinder
head bolts if the length is more than
130.2 mm.
NOTE: Only rotate the engine in the normal Measure the cylinder head bolts.
Using the special tool, lock the flywheel or
flexplate.
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-87 Engine — 1.6L (Z6) 303-01C-87
2. CAUTION: Install new cylinder head Item 21 : Camshaft bearing cap retaining bolts
bolts as necessary. 1. NOTE: Working in several stages, evenly
tighten the camshaft bearing cap retaining bolts
Tighten the cylinder head retaining bolts in
the sequence shown in three stages.
1. Stage 1: 20 Nm. Tighten the camshaft bearing cap retaining

Item 20 : Camshaft bearing caps dead center (TDC).
1. Install the camshaft bearing caps.
2. Rotate the camshafts until the camshaft

timing marks align with the upper surface
of the engine front cover.
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-88 Engine — 1.6L (Z6) 303-01C-88
3. Install the timing chain. Item 29 : Engine front cover retaining bolts
4. Remove the suitable pin punch, tension the 1. Tighten the engine front cover retaining
timing chain. bolts in the sequence shown.
• Bolt 9: 9 Nm.
• Bolts 1 through 6, 8, 10, 12 through 15, 17,
18: 22 Nm.
• Bolts 7, 11, 16: 45 Nm.

check the valve timing and correct as
necessary.
Item 27 : Engine front cover Item 33 : Variable camshaft timing (VCT)
1. Clean the mating faces of the cylinder intake solenoid oil filter
block and of the front cover with cleaner. 1. Inspect the VCT intake solenoid oil filter
and clean if necessary.
2. CAUTION: Install the engine front cover
within four minutes of applying the
sealer.
Apply a bead of sealant to the areas as
shown.
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-89 Engine — 1.6L (Z6) 303-01C-89
Item 41 : Valve cover

as shown.
Item 42 : Valve cover retaining bolt

1. NOTE: Install a new valve cover gasket.
G384848 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-90 Engine — 1.6L (Z6) 303-01C-90
INSTALLATION

INST ALLAT ION
Special Tool(s)
Special Tool(s) Clamp
303-397
303-122

Number
2 - Starter motor
1 - Transaxle See Installation Detail
G384849 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-91 Engine — 1.6L (Z6) 303-01C-91
INSTALLATION

Number
6 - Neutral switch electrical
4 - Transaxle wiring harness connector
7 - Vehicle speed (VSS) sensor
5 - Reversing lamp switch elec- electrical connector
trical connector
G384849 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-92 Engine — 1.6L (Z6) 303-01C-92
INSTALLATION

Number
9 - Engine rear mount retaining
8 - Engine front mount retaining bolt
nuts See Installation Detail
line

Number
17 - Coolant outlet connector to
11 - Fuel supply line radiator upper coolant hose
12 - Accelerator cable 18 - Cylinder head to heater core
See Installation Detail coolant hose
13 - Brake booster vacuum line See Installation Detail
See Installation Detail 19 - Coolant outlet connector to
14 - Catalyst monitor sensor coolant expansion tank
electrical connector coolant hose
(HO2S) electrical connector 20 - Radiator lower coolant hose
G384849 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-93 Engine — 1.6L (Z6) 303-01C-93
INSTALLATION

Number
21 - Coolant hose
22 - Power steering fluid supply
hose
23 - Power steering pump to
steering gear pressure line
G384849 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-94 Engine — 1.6L (Z6) 303-01C-94
INSTALLATION

Number
29 - Catalytic converter to muffler
24 - Catalytic converter and tailpipe assembly re-
25 - Exhaust manifold gasket taining nuts
26 - Exhaust manifold retaining 30 - Catalytic converter heat

nuts shield lower retaining nuts
See Installation Detail 31 - Catalytic converter heat
27 - Catalytic converter support shield upper retaining nuts
bracket retaining bolts 32 - Wiring harness clip
G384849 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-01C-95 Engine — 1.6L (Z6) 303-01C-95

Number Number
33 - Wiring harness clip retaining 37 - Exhaust manifold to EGR
bolt valve tube retaining nut
34 - Exhaust gas recirculation 38 - Exhaust manifold to EGR
(EGR) valve retaining bolts valve tube bracket retaining
nut
nector 39 - EGR valve tube retaining
nuts
valve tube gasket

Item Part Description AND INSTALLATION, Halfshaft RH]
Number 3. Install the left-hand halfshaft. For additional
pressor
41 - A/C compressor retaining
bolts
42 - A/C compressor electrical
connector
All vehicles
2. Install the right-hand halfshaft. For additi-
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303-01C-96 Engine — 1.6L (Z6) 303-01C-96
4. Install the engine support insulator. 8. Install the central junction box (CJB) cover.
5. Install the floor panel brace. 9. Attach the ground cables to the wheel
housing.

7. Connect the engine wiring harness elec- 10. Install the accessory drive belt. For additi-
trical connector. onal information, refer to Section 303-05.
1.6L (Z6)]
GENERAL PROCEDURES, Gearshift
Cable Adjustment - Vehicles With:
5-Speed Manual Transaxle (F35M-R)]
12. Fill and bleed the clutch system. For additi-
Bleeding]
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303-01C-97 Engine — 1.6L (Z6) 303-01C-97
13. Connect the battery positive lead to the Installation Details

battery positive cable terminal clamp.
Item 1 : Transaxle
1. Attach the engine to the workshop hoist
using the special tool.

2. CAUTION: Ensure that the two guide
Tray - 1.6L (Z6)]
sleeves are installed.
additional information, refer to Section Attach the transaxle to the engine.
303-03C.[Engine Cooling - 1.6L (Z6), 3. Install the transaxle right-hand retaining
GENERAL PROCEDURES, Cooling bolts.

17. Initialize the window regulator motors.
GENERAL PROCEDURES,
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303-01C-98 Engine — 1.6L (Z6) 303-01C-98
4. NOTE: Support the engine and transaxle Item 8 : Engine front mount retaining nuts
assembly with suitable wooden blocks. 1. Position the workshop table under the ve-
hicle and lower the vehicle until the engine
Secure the engine and transaxle assembly
mounts can be installed.
on the workshop table using suitable re-
taining straps.
2. NOTE: Install new engine front mount retaining

nuts.
6. Install the transaxle left-hand retaining Install the engine front mount retaining
bolts. nuts.
Item 2 : Starter motor 3. Install the engine ground cable.

1. Install the starter motor cable shield.
Item 9 : Engine rear mount retaining bolt

NOTE: Remove the retaining strap.
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303-01C-99 Engine — 1.6L (Z6) 303-01C-99
Item 10 : Clutch slave cylinder supply line 2. Attach the accelerator cable retaining
bracket to the intake manifold.
water.
Attach the clutch slave cylinder line to the
clutch slave cylinder.
Item 13 : Brake booster vacuum line

brake booster vacuum hose from the intake
manifold.

1. Connect the fuel supply line quick
connector. For additional information,
refer to Section 310-00. [Fuel System -
body.
lever. Item 16 : Gearshift cables
2. Attach the accelerator cable to the bracket. 1. Attach the gearshift cables to the transaxle.
1. Attach the gearshift cables to the bracket.
2. Attach the gearshift cable to the selector
mechanism.
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303-01C-100 Engine — 1.6L (Z6) 303-01C-100
Item 17 : Coolant outlet connector to radiator Item 20 : Radiator lower coolant hose
upper coolant hose 1. Using the special tool, connect the coolant
1. Using the special tool, connect the coolant hose to the thermostat housing.
hose from the coolant outlet connector.
Item 21 : Coolant hose

Item 18 : Cylinder head to heater core coolant 1. Using the special tool, connect the coolant
hose hose to the cylinder block.
hose the cylinder head.
Item 22 : Power steering fluid supply hose

1. Using the special tool, connect the power
Item 19 : Coolant outlet connector to coolant steering fluid supply hose to the power
expansion tank coolant hose steering pump.
1. Using the special tool, connect the to the
coolant outlet connector.
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303-01C-101 Engine — 1.6L (Z6) 303-01C-101

pressure line
NOTE: Install new washers to the power steering
pump pressure line union.
1. NOTE: Install new exhaust manifold retaining
nuts.
nuts in the sequence shown.
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303-03A-1 Engine Cooling — 1.8L Duratec-HE (MI4)/2.0L 303-03A-1

Duratec-HE (MI4)
SECTION 303-03A Engine Cooling — 1.8L Duratec-HE

CONTENTS PAGE
SPECIFICATIONS
Engine Cooling................................................................................................................. 303-03A-3

1.8L Duratec HE (MI4) engine......................................................................................... 303-03A-3
Engine Cooling................................................................................................................. 303-03A-4

Symptom Chart ............................................................................................................... 303-03A-4/6
Component Tests............................................................................................................ 303-03A-7
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding .............................................. (24 122 0) 303-03A-8
Draining........................................................................................................................... 303-03A-8
Filling and Bleeding......................................................................................................... 303-03A-8
Thermostat Housing......................................................................................................... 303-03A-9/10

Coolant Pump .................................................................................................................. 303-03A-11/12
Radiator ........................................................................................................................... 303-03A-13/14
Cooling Fan Motor and Shroud ........................................................................................ 303-03A-15/17
Coolant Outlet Connector................................................................................................. 303-03A-18
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Duratec-HE (MI4)
SPECIFICATIONS

Item Specification
Motorcraft Super Plus Antifreeze WSS-M97B44–D
Antifreeze
Approximate
Specific Gravity percentage of
(providing no other Anti-Freeze (by
additive is in coolant) volume) Remains Fluid to Solidifies at
1.061 at +15°C 50% –25°C (–13°F) –37°C (–35°F)
Cooling System Refill Capacities

Description Liters
Cooling system and heater - Vehicles with 1.8L engine 6.51
Cooling system and heater - Vehicles with 2.0L engine 6.31
Cooling System Pressure Specification

Description Pressure kpa (psi)
Radiator pressure test 138 (20)
Coolant expansion tank cap release pressure 130 to 150 (18 to 21)
Radiator support bracket retaining bolts 25 18 -
Thermostat housing retaining bolts 10 - 89
Coolant pump pulley retaining bolts 25 18 -
Coolant outlet connector retaining bolts 10 - 89
Vacuum solenoid valve retaining bracket screws 6 - 53
Cooling fan motor retaining bolts 10 - 89
Radiator upper coolant hose retaining clamp 9 - 80
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Duratec-HE (MI4)

Engine Cooling
Thermostat housing

Number
2 - Bypass coolant hose
Due to the greater space requirements of the

alternator it was necessary to modify the
thermostat housing. The connection piece now
has a different angle and is longer overall.
The coolant hose from the thermostat housing to
the coolant distributor is routed closer to the
cylinder block and has different bending radii.
The previously used electrically heated thermostat
has been replaced with a thermostat with an
expansion element.
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Duratec-HE (MI4)

Engine Cooling
• Coolant leak(s) • Fuse(s)
Special Tool(s) • Gasket(s) or seal(s) • Wiring harness
• Hose(s) or hose • Electrical
Pressure Tester, Cooling joints connector(s)
System
• Coolant expansion • Engine coolant
303-396 (24-001 A) tank pressure cap temperature (ECT)
and seal sensor
• Coolant expansion • Cooling fan
Adaptor for 303-396
tank • Powertrain control
303-396-05 (24-001A-05)
• Radiator module (PCM)
• Coolant pump
• Thermostat housing
• Heater core
• Accessory drive belt
Inspection and Verification • Coolant outlet con-
1. Verify the customer concern. nector
2. Visually inspect for obvious signs of 3. If an obvious cause for an observed or
mechanical or electrical damage. reported concern is found, correct the cause
(if possible) before proceeding to the next step
Visual Inspection Chart 4. If the cause is not visually evident, verify the
Symptom Chart
• Loss of coolant • Hose(s) or hose joint(s). • INSPECT the hoses and hose
joints. INSTALL a new hose(s)
as necessary.
• Radiator. • INSPECT the radiator for leaks.
CARRY OUT the Pressure Test
INSTALL a new radiator as
necessary. REFER to Radiator
in this section.
• Coolant pump. • INSPECT the coolant pump for
leaks. CARRY OUT the Pres-
sure Test Component Test in this
section. INSTALL a new coolant
pump or coolant pump gasket as
necessary. REFER to Coolant
Pump in this section.
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Duratec-HE (MI4)

• Thermostat housing. • INSPECT the thermostat hous-
ing for leaks. CARRY OUT the
Pressure Test Component Test
in this section. INSTALL a new
thermostat housing and thermo-
stat housing gasket as neces-
sary. REFER to Thermostat
Housing in this section.
• Coolant expansion tank pressure • CHECK the coolant expansion
cap or seal(s). tank pressure cap for tightness
and damage. INSTALL a new
coolant expansion cap as nec-
essary.
• Coolant expansion tank. • INSPECT the coolant expansion
tank for damage. INSTALL a
new coolant expansion tank as
necessary.
• Heater core. • CHECK the heater core for
leaks.
• Engine. • INSPECT the engine, cylinder
head, cylinder block and cylinder
head gasket.
• The engine overheats (signs of • Cooling system does not hold • INSPECT the coolant expansion
coolant boiling) pressure. tank for damage. INSTALL a
necessary.
– INSPECT the coolant pump
or coolant pump gasket for
damage. INSTALL a new
coolant pump or coolant
pump gasket as necessary.
REFER to Coolant Pump in
this section.
– INSPECT the engine, cylin-
der head, cylinder block and
cylinder head gasket.
• Air in system. • BLEED the cooling system.
REFER to Cooling System
Draining, Filling and Bleeding in
this section.
• Coolant expansion tank pressure • CHECK the coolant expansion
essary.
• Coolant expansion tank. • INSPECT the coolant expansion
tank for damage. INSTALL a
necessary.
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Duratec-HE (MI4)

• Coolant level or condition. • CHECK the coolant level.
REFILL the cooling system as
necessary. REFER to Cooling
System Draining, Filling and
Bleeding in this section.
• CHECK the coolant condition. If
the coolant is in poor condition
drain and refill with new coolant.
this section.
• Coolant concentration. • REFER to Specifications in this
section.
• Radiator grille. • INSPECT the radiator grille for
air restrictions or damage.
REPAIR or INSTALL new parts
as necessary.
• Coolant pump. • CARRY OUT the Pressure Test
INSPECT the coolant pump for
leaks. INSTALL a new coolant
pump or coolant pump gasket as
necessary. REFER to Coolant
Pump in this section.
• Thermostat. • CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat housing and thermostat
housing gasket as necessary.
REFER to Thermostat Housing
in this section.
• Accessory drive belt. • CHECK the condition of the ac-
cessory drive belt. REFER to
Section 303-05.[Accessory
Drive, DIAGNOSIS AND
TESTING, Accessory Drive]
• Cooling fan. • CHECK the operation of the
cooling fan. REFER to WDS.
head gasket.
• The engine does not reach • Thermostat. • CARRY OUT the Thermostat
normal operating temperature. Test Component Test in this
mostat housing and thermostat
housing gasket as necessary.
REFER to Thermostat Housing
in this section.
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Duratec-HE (MI4)
Component Tests
Pressure Test
WARNING: When releasing the system

pressure, cover the coolant expansion Clean the radiator thoroughly before leak testing it,
tank cap with a thick cloth to prevent the to prevent contamination of the water in the test
possibility of coolant scalding. Failure to tank. Leak test the radiator in clean water with 138
follow this instruction may result in kpa (20 psi) air pressure. Check it thoroughly for
personal injury. air leaks. Install a new radiator if necessary.
NOTE: If the coolant expansion tank pressure cap REFER to Radiator in this section.
is rotated counterclockwise by 1/2 a full turn, the
pressurized coolant will be vented to the
underside of the coolant expansion tank.
1. Remove the coolant expansion tank pressure
cap.
2. Install the special tools 303-396 and
303-396-05 to the coolant expansion tank.
3. Pressurize the system to the coolant
expansion tank cap release pressure.
REFER to Specifications in this section.
4. Observe the cooling system pressure tester
gauge reading for approximately two minutes.
The pressure should not drop during this time.
If the system holds pressure, proceed to Step
7. If the system does not hold pressure, check
it thoroughly for coolant leaks.
5. Check the engine for coolant leaks. Drain the
cooling system, repair any coolant leaks found
and fill and bleed the cooling system as
necessary. REFER to Cooling System
Draining, Filling and Bleeding in this section.
6. Recheck the system by repeating Steps 3 and
4 at least twice.
Thermostat Test
Remove the thermostat housing and immerse it in
water. Heat the water until it reaches 90º C (194º
F). At this temperature the thermostat should
begin to open. If it does not begin to open,
INSTALL a new thermostat housing and
thermostat housing gasket as necessary.
REFER to Thermostat Housing in this section.
Radiator Leak Test, Removed From Vehicle
CAUTION: Radiator internal pressure

must not exceed 130 kpa (20 psi) or
damage may result.
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Duratec-HE (MI4)
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding (24 122 0)
Draining
1. WARNING: When releasing the cooling NOTE: If the cooling system has been drained
system pressure, cover the coolant from any coolant system hose(s) other than the
expansion tank cap with a thick cloth radiator drain plug. Fill the coolant expansion tank
to prevent the possibility of scalding. to the top of the coolant expansion tank filler neck.
Failure to follow this instruction may 3. Install the coolant expansion tank cap.
result in personal injury. 4. Start the engine, maintain the engine speed
NOTE: The cooling system pressure will be at 2500 revolutions per minute (RPM) for
vented to the underside of the coolant expansion eight minutes or until the engine reaches
tank. normal operating temperature.
Release the cooling system pressure by 5. Maintain the engine speed at 2500 RPM for
slowly turning the coolant expansion tank three minutes after the engine has reached
cap between 2 and 3 turns. normal operating temperature.
2. Remove the coolant expansion tank cap. 6. Increase the engine speed to 4000 RPM for
3. Raise and support the vehicle. five seconds.
For additional information, 7. Decrease the engine speed to 2500 RPM for
refer to Section 100-02. three minutes.
4. NOTE: To avoid the removal of an excessive 8. Switch the engine off.
volume of coolant, the cooling system should 9. Check the cooling system for leaks.
only be drained from the radiator drain plug. 10. Allow the engine to cool.
Drain the cooling system. 11. Fill the coolant expansion tank to the MAX
• Allow the coolant to drain into a suitable mark.
container.
5. Install the radiator drain plug.

Filling and Bleeding

NOTE: Make sure the interior heater temperature
control switch is in the hot position.
1. Switch the interior heater blower off.
2. Fill the coolant expansion tank 15 mm over
the MAX mark.
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Duratec-HE (MI4)

Thermostat Housing
Draining, Filling and Bleeding in this

section.
2. Remove the accessory drive belt tensioner.
Special Tool(s) For additional information,
Remover/Installer, Coolant refer to Section 303-05.
Hose Clamp 3. Remove the components in the order
table(s).

information, refer to Cooling System
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Duratec-HE (MI4)

Item Part Description Item 2 : Radiator lower to thermostat housing
Number coolant hose
1. Using the special tool, disconnect the ra-
1 - Thermostat housing to diator lower to thermostat housing coolant
coolant expansion tank and hose.
heater core return coolant
hose
See Removal Detail
2 - Radiator lower to thermostat
See Removal Detail
Removal Details
Item 1 : Thermostat housing to coolant

expansion tank and heater core return
coolant hose
thermostat housing to coolant expansion
tank and heater core return coolant hose.
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Duratec-HE (MI4)

Coolant Pump
Name Specification 4. Remove the accessory drive belt.

Merpol grease ESE-M99M144-B For additional information,
1. Drain the cooling system. For additional 5. Remove the components in the order
information, refer to Cooling System indicated in the following illustration(s) and
Draining, Filling and Bleeding in this table(s).
section.
3. Loosen the coolant pump pulley retaining

bolts.
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Duratec-HE (MI4)

Number
2 - Coolant pump
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Duratec-HE (MI4)

Radiator

Special Tool(s)
Remover/Installer, Coolant section.
Hose Clamp 3. Remove the cooling fan motor and shroud.
303-397 For additional information, refer to Cooling
Fan Motor and Shroud in this section.
1. Secure the air conditioning (A/C) table(s).
condenser to the front panel (if equipped).
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Duratec-HE (MI4)

Item Part Description Item 5 : Radiator lower coolant hose retaining
Number clamp
1 - Radiator upper coolant hose diator lower coolant hose.
retaining clamp
2 - Radiator upper coolant hose
3 - Radiator degas coolant
hose retaining clamp
See Removal Detail
4 - Radiator degas coolant hose
5 - Radiator lower coolant
hose retaining clamp
See Removal Detail
6 - Radiator lower coolant hose
7 - Radiator support bracket
See Removal Detail
Item 7 : Radiator support bracket
1. With the aid of another technician, support
8 - Radiator the radiator.
See Removal Detail Item 8 : Radiator
9 - Radiator lower insulators
See Installation Detail CAUTION: Care must be taken not to
damage the cooling fins of the coolant
10 - Radiator upper insulators radiator and the A/C condenser when
removing the radiator. Failure to follow
5. To install, reverse the removal procedure. this instruction could result in coolant
leaks or engine overheat.
Removal Details
Item 3 : Radiator degas coolant hose retaining
clamp Item 9 : Radiator lower insulators
diator degas coolant hose retaining clamp. CAUTION: Inspect the radiator lower
insulators for signs of cracking, splitting
or damage. Install new radiator lower
insulators as necessary. Failure to follow
this instruction may result in damage to
the radiator.
1. With the aid of another technician, install
the radiator support bracket.
• Install the 30mm M8 bolts leaving 15mm of
thread exposed.
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Duratec-HE (MI4)

Cooling Fan Motor and Shroud

WARNING: The cooling fan motor is under additional information, refer to Section 414-01.
the control of the powertrain control [Battery, Mounting and Cables,
module (PCM) and the cooling fan can GENERAL PROCEDURES, Battery
become active after the ignition key has Disconnect]
been removed. Before working on or near
the cooling fan, disconnect the battery
ground cable. Failure to follow these 3. Remove the components in the order
instructions may result in personal injury. indicated in the following illustration(s) and
table(s).

Number
1 - Engine under shield
See Removal Detail
2 - Radiator splash shield
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Duratec-HE (MI4)

Number
3 - Radiator support bracket Item 1 : Engine under shield
front retaining bolts 1. Release the locking tangs.
See Removal Detail • Rotate the locking tang counterclockwise.
4 - Radiator support bracket rear
retaining bolts
5 - Air conditioning (A/C)
condenser
See Removal Detail
6 - Cooling fan motor electrical
connector
7 - Cooling fan motor and
shroud
See Removal Detail

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Duratec-HE (MI4)

Item 3 : Radiator support bracket front Item 7 : Cooling fan motor and shroud
retaining bolts 1. Press in the cooling fan motor and shroud
1. Install temporary radiator support bracket retaining clips. Lift up the cooling fan
front retaining bolts. shroud until clear of the retaining brackets.
• Remove the radiator support bracket front Remove the cooling fan motor and shroud.
retaining bolts.
• Install 30mm M8 bolts leaving 15mm of
thread exposed.
Item 5 : Air conditioning (A/C) condenser Installation Details

1. Detach the A/C condenser from the radiator
(if equipped).
Item 3 : Radiator support bracket front
1. Press in the radiator A/C condenser retaining bolts
retaining clip. 1. Install the radiator support bracket front
2. Slide the A/C condenser upwards retaining bolts.
• Remove the temporary radiator support
bracket 30mm M8 retaining bolts.
• Install the radiator support bracket front
retaining bolts.
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Duratec-HE (MI4)

Coolant Outlet Connector

Remover/Installer, Coolant indicated in the following illustration(s) and
Hose Clamp table(s).
303-397

section.
3. Disconnect the engine coolant temperature

(ECT) sensor electrical connector and the
vacuum solenoid valve electrical connec-
tors.
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Duratec-HE (MI4)

Number
4 - Radiator lower to coolant
1 - Vacuum solenoid valve re- outlet connector coolant
taining bracket hose
2 - Coolant expansion tank to See Removal Detail
coolant outlet connector 5 - Thermostat housing to
coolant hose coolant outlet connector
See Removal Detail coolant hose
3 - Coolant outlet connector to 6 - Coolant outlet connector
heater core coolant hose
See Removal Detail
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Duratec-HE (MI4)

5. To install, reverse the removal procedure. Item 4 : Radiator lower to coolant outlet
connector coolant hose
Removal Details 1. Using the special tool, disconnect the ra-
diator lower to coolant outlet connector
Item 2 : Coolant expansion tank to coolant coolant hose.
outlet connector coolant hose
coolant expansion tank to coolant outlet
connector coolant hose.
Item 3 : Coolant outlet connector to heater

core coolant hose
coolant outlet connector to heater core
coolant hose.
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303-03B-1 Engine Cooling — 2.0L Duratorq-TDCi (DW) Diesel 303-03B-1
SECTION 303-03B Engine Cooling — 2.0L

Duratorq-TDCi (DW) Diesel
CONTENTS PAGE
SPECIFICATIONS
Engine Cooling................................................................................................................. 303-03B-3

Coolant circuit ................................................................................................................. 303-03B-3
Thermostat housing ........................................................................................................ 303-03B-4
Operating principle .......................................................................................................... 303-03B-5/6
Engine Cooling................................................................................................................. 303-03B-7

Inspection and Verification .............................................................................................. 303-03B-7
Symptom Chart ............................................................................................................... 303-03B-7/8
Component Tests............................................................................................................ 303-03B-9/11
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding — 2.0L.................................. (24 122 0) 303-03B-12
Draining........................................................................................................................... 303-03B-12
Filling and Bleeding......................................................................................................... 303-03B-12/13
Thermostat....................................................................................................................... 303-03B-14/15
Thermostat Housing......................................................................................................... 303-03B-16/21
Coolant Pump .................................................................................................................. 303-03B-22/23
Radiator ........................................................................................................................... 303-03B-24/27
Cooling Fan Motor and Shroud ........................................................................................ 303-03B-28/31
Coolant Bypass Pipe........................................................................................................ 303-03B-32/37
Coolant Shutoff Valve ...................................................................................................... 303-03B-38
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SPECIFICATIONS

Description Specification
Motorcraft Super Plus antifreeze WSS-M97B44-D
Premium Cooling System Flush ESR-M14P7-A
Antifreeze
Specific gravity
(providing no other Approximate
additive is in the percentage of
coolant) antifreeze (by volume) Remains fluid to Solidifies at
1.061 at +15°C 50% -25°C (-13°F) -37°C (-35°F)

Description Liters
Cooling system and heater 8.41
Cooling System Pressure Specification

Description Pressure kpa (psi)
Coolant expansion tank cap release pressure 135 to 155 (19.6 to 22.5)
Item Nm lb-ft lb-in
Charge air cooler retaining bolts 5 - 44
Charge air cooler intake pipe support bracket re- 8 - 71
taining bolts
Thermostat retaining bolts 6 - 53
Battery terminal clamp retaining nuts 6 - 53
Battery retaining strap retaining nuts 6 - 53
Battery tray retaining bolts 12 9 -
Battery tray support bracket retaining nuts 48 35 -
Battery tray support bracket retaining bolts 25 18 -
Turbocharger variable vain vacuum regulator 18 13 -
support bracket retaining nuts
Thermostat housing retaining nuts and bolt 10 - 89
Engine coolant shutoff valve retaining bolts 6 - 53
Engine coolant pump retaining bolts 16 12 -
Windshield wiper arm retaining nuts 15 11 -
Catalytic converter retaining clamp 47 35 -
Catalytic converter retaining nuts 25 18 -
Catalytic converter support bracket retaining nuts 25 18 -
Turbocharger to turbocharger support bracket re- 30 22 -
taining bolt
Turbocharger support bracket retaining bolts 15 11 -
Turbocharger intake pipe retaining bolts 9 - 80
Coolant bypass pipe support bracket retaining bolt 9 - 80
Coolant bypass pipe retaining bolts 18 13 -
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Engine Cooling
Coolant circuit

Number
1 - Heat exchanger
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Number Number
3 - Bypass solenoid valve 9 - Cylinder block
4 - Thermostat 10 - Coolant pump
5 - Shutoff solenoid valve 11 - EGR cooler
6 - Radiator
7 - Oil/coolant heat exchanger Thermostat housing
8 - Coolant reservoir

Number
6 - Connection to coolant pump
1 - Bypass solenoid valve
7 - Connection to heat ex-
2 - Connection to coolant res- changer
ervoir
8 - engine coolant temperature
3 - Connection to radiator inlet (ECT) sensor
4 - Connection to the oil/coolant
heat exchanger
5 - Connection to radiator outlet
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WARNING: The ECT sensor must not be Bypass solenoid valve

removed while the cooling system is
pressurised.
The thermostat housing is attached to the cylinder
head on the transmission side of the engine.
The ECT sensor is located on the thermostat
housing and is attached by means of a clip.
The thermostat housing contains the thermostat
and the bypass solenoid valve. The thermostat is
a conventional design.
The thermostat housing is made of plastic and
cannot be disassembled when the vehicle is
serviced. The ECT sensor can be replaced
separately.
Number
Operating principle
1 - Wiring harness electrical
The shut-off solenoid valve is located in the feed
connector
from the thermostat housing to the coolant
reservoir. It limits coolant flow to the coolant 2 - External seal
reservoir during the engine warm up phase.
3 - Seal
The bypass solenoid valve is located between the
coolant outlet on the cylinder head and the supply 4 - Seal
to the coolant pump. It limits the coolant flow to the 5 - Solenoid valve
coolant pump during the warm up phase.
Using a bypass solenoid valve enables the engine
Most of the coolant is passed to the heat
to reach operating temperature more quickly.
exchanger and flows back to the coolant pump via
the exhaust gas recirculation (EGR) cooler. According to the value supplied by the PCM, the
bypass solenoid valve partly or completely
At a certain coolant temperature, the bypass
prevents the coolant flow between the coolant
solenoid valve starts to open and remains open
outlet on the cylinder head and the coolant pump.
until the operating temperature of the engine is
reached. It cannot be replaced by itself.
As soon as the engine reaches operating
temperature, the thermostat is opened and the Coolant pump
bypass solenoid valve closes proportionally in
relation to the thermostat.
When the engine is warmed up, the thermostat is
wide open, as is the shutoff solenoid valve, and
the bypass solenoid valve is fully closed. The
large coolant circuit is open in this state.
Using a shutoff solenoid valve and a bypass
solenoid valve speeds up the warm up phase of
the engine, and a faster temperature rise in the
passenger compartment is achieved.
The bypass solenoid valve and the shutoff
solenoid valve are controlled by the powertrain
control module (PCM).
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Number
1 - Seal
2 - Coolant pump
The coolant pump is installed on the timing end of
the engine and is driven by the timing belt.
The coolant pump housing is made of an
aluminium alloy and is secured with five bolts.
The impeller of the coolant pump is made of
plastic.
The joint between the coolant pump and the
cylinder block is made using a rubberised metal
gasket.
Radiator fan control

Number
1 - Vehicle battery
2 - Battery junction box
3 - Cooling fan module
4 - PCM
Radiator fan speed is controlled by the radiator fan
module as a function of input signals from the
PCM.
The radiator fan module is located on the radiator
fan housing.
Communication between the radiator fan module
and the PCM is done on the CAN bus using pulse
width modulation.
The cooling fan speed is regulated steplessly.
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Engine Cooling
Special Tool(s) – Gaskets/seals – Wiring harness
– Core plug(s) – Electrical
Pressure Tester, Cooling connector(s)
System – Hose(s)/hose joints
– Coolant expansion – Engine coolant
303-396 (24-001 A) temperature (ECT)
tank cap and seal(s)
sensor
– Coolant expansion
tank – Cooling fan motor
Adaptor for 303-396
– Radiator – Cooling fan module
303-396-05 (24-001A-05)
– Coolant pump – Powertrain control
module (PCM)
– Thermostat
– Coolant shutoff
– Heater core
valve
– Exhaust gas recir-
General Equipment – Coolant degas
culation (EGR)
shutoff valve
cooler
Worldwide Diagnostic System (WDS)
(418-F224) 3. If an obvious cause for an observed or
Inspection and Verification 4. If the cause is not visually evident, verify the
Symptom Chart
• Loss of coolant • Coolant expansion tank cap or • CHECK the coolant expansion
seal(s). tank cap for tightness and
damage. INSTALL a new coolant
expansion pressure cap as
necessary.
• Cooling system. • INSPECT the cooling system for
section. INSTALL new compo-
nent(s) as necessary.
head gasket. REFER to Section
303-01B.[Engine - 2.0L Dura-
torq-TDCi (DW) Diesel,
IN-VEHICLE REPAIR, Cylinder
Head]
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• The engine overheats (signs of • Air in cooling system. • BLEED the cooling system.
coolant boiling) REFER to Cooling System
Draining, Filling and Bleeding -
2.0L in this section.
• Cooling system does not hold • CHECK the coolant expansion
pressure. tank cap for tightness and
damage. INSTALL a new coolant
expansion tank cap as
necessary.
• INSPECT the engine, cylinder
Head]
• Coolant level/condition. • CHECK the coolant level.
Bleeding - 2.0L in this section.
• CHECK the coolant condition
and concentration. If the coolant
is contaminated or the concen-
tration is below specifications,
Draining, Filling and Bleeding -
2.0L in this section.
air restrictions/damage. REPAIR
or INSTALL new parts as nec-
essary.
• Cooling fan motor. • CHECK the operation of the
mostat as necessary. REFER to
Thermostat in this section.
• Coolant shutoff valve. • CARRY OUT the Coolant Shut-
off Valve Test in this section.
INSTALL a new coolant shutoff
valve as necessary. REFER to
Coolant Shutoff Valve in this
section.
• Coolant degas shutoff valve. • CARRY OUT the Coolant Degas
shutoff Valve Test in this section.
INSTALL a new coolant degas
shutoff valve as necessary.
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• Coolant pump. • REMOVE AND INSPECT the
coolant pump/impeller. INSTALL
a new coolant pump/coolant
REFER to Coolant Pump in this
section.
Head]
• The engine does not reach • ECT sensor. • CHECK the engine coolant
normal operating temperature. temperature. REFER to WDS.
• Temperature gauge. • CHECK the instrument cluster
engine temperature gauge.
[Instrument Cluster,
Instrument Cluster]
If the cooling system holds pressure, Install a
new coolant expansion tank cap. If the cooling
Component Tests system does not hold pressure, check the
cooling system thoroughly for coolant leaks.
5. Check the cooling system by repeating steps
Pressure Test
3 and 4 at least twice.
WARNING: When releasing the cooling 6. If a coolant leak cannot be found, check the
system pressure, cover the coolant engine for cylinder leakage. REFER to
expansion tank cap with a thick cloth to Section 303-00.[Engine System - General
prevent the possibility of coolant Information, DIAGNOSIS AND TESTING,
scalding, Failure to follow this instruction Engine] Drain the cooling system. Repair any
may result in personal injury. coolant leaks found and fill and bleed the
NOTE: If the coolant expansion tank cap is rotated cooling system as necessary. REFER to
counterclockwise by between 2 and 3 full turns, Cooling System Draining, Filling and Bleeding
the pressurized coolant will be vented to the - 2.0L in this section.
underside of the coolant expansion tank.
1. Remove the coolant expansion tank cap. Thermostat Test
2. Install the special tools 303-396 and 1. Remove the thermostat. REFER to
303-396-05 to the coolant expansion tank. Thermostat in this section.
3. Pressurize the cooling system to the coolant 2. Immerse the thermostat in a water and
expansion tank cap release pressure. antifreeze mixture. Heat the fluid mixture to 88
4. Observe the cooling system pressure tester ºC (190 ºF). At this temperature the
gauge reading for approximately two minutes. thermostat should begin to open. If it does not
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begin to open, install a new thermostat. 3. Using a suitable fused jumper wire, connect
REFER to Thermostat in this section. the coolant shutoff valve pin 1, component
side to battery positive.
Coolant Shutoff Valve Test 4. Observe the coolant shutoff valve piston. The
piston should pull into the valve and return to
1. Remove the coolant shutoff valve. REFER to the extended position when the 12 volt supply
Coolant Shutoff Valve in this section. is removed. If the coolant shutoff valve does
not return to the extended position, install a
new coolant shutoff valve. REFER to Coolant
Shutoff Valve in this section.
Coolant Degas Shutoff Valve

1. Remove the coolant degas shutoff valve.
2. Using a suitable piece of wire, connect the

coolant shutoff valve pin 2, component side to
battery ground.
2. Connect a workshop water supply hose to one

side of the coolant degas shutoff valve coolant
pipe connector.
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3. Using a suitable piece of wire, connect the

coolant degas shutoff valve pin 2, component
side to battery ground.
4. Using a suitable fused jumper wire, connect

the coolant degas shutoff valve pin 1,
component side to battery positive.
5. Turn on the workshop water supply. No water
should flow.
6. Remove the 12 volt fused supply. Water
should flow thorough the coolant degas
shutoff valve.
7. If no water flows, install a new coolant degas
shutoff valve.
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GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding — 2.0L (24 122 0)

Draining 5. NOTE: To avoid the removal of an excessive

volume of coolant, the cooling system should
1. WARNING: When releasing the cooling only be drained from the radiator drain plug.
system pressure, cover the coolant
Drain the cooling system.
expansion tank cap with a thick cloth
to prevent the possibility of scalding. • Allow the coolant to drain into a suitable
Failure to follow this instruction may container.
NOTE: The cooling system pressure will be
vented to the underside of the coolant expansion
tank.
Release the cooling system pressure by
slowly turning the coolant expansion tank
cap between 2 and 3 turns.
2. Remove the coolant expansion tank cap.
1. Rotate the locking tangs counterclockwise.

2. Fill the coolant expansion tank to level with
the bottom of the coolant expansion tank
filler neck.
3. Start the engine.
CAUTION: Do not allow the coolant level
in the coolant expansion tank to fall
below the minimum mark.
4. Raise the engine speed to 2000 revolutions
per minute (RPM) and maintain for 2
minutes.
5. Top up the coolant expansion tank coolant
level to the MAX mark.
6. Install the coolant expansion tank cap.
7. Raise the engine speed to 2000 RPM and
maintain for approximately 13 minutes until
the thermostat opens.
8. Increase the engine speed to 4000 RPM and
maintain for 5 seconds.
9. Decrease the engine speed to 2000 RPM
and maintain for 15 minutes.
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10. Switch the engine off.

11. Check the cooling system for leaks.
12. Allow the engine to cool.
13. Top up the coolant expansion tank to the
MAX mark.
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Thermostat
Special Tool(s)
Remover/Installer, Cooling
Hose Clamp
303-397 (24-003)

information,

table(s).
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Item Part Description Item 2 : Radiator to thermostat coolant hose

Number retaining clamp
1. Using the special tool, detach the radiator
1 - Coolant expansion tank to to thermostat coolant hose retaining
thermostat coolant hose clamp.
quick release coupling
See Removal Detail
2 - Radiator to thermostat
coolant hose retaining clamp
See Removal Detail
3 - Radiator to thermostat cool-
ant hose
4 - Thermostat and cooling fan
switch
5 - Thermostat seal
Removal Details
Item 1 : Coolant expansion tank to thermostat

coolant hose quick release coupling
1. Disconnect the coolant expansion tank to
thermostat coolant hose quick release
coupling.
1. Press the locking tang release bar.
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Thermostat Housing

Remover/Installer, Cooling indicated in the following illustration(s) and
Hose Clamp table(s).
303-397 (24-003)
1. Drain the cooling system.


4. Remove the battery tray support bracket.
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Number
1 - Turbocharger variable vain coolant hose retaining clamp
vacuum regulator and See Removal Detail
support bracket
See Removal Detail 4 - Radiator to thermostat cool-
ant hose
2 - Coolant expansion tank to
thermostat coolant hose 5 - Radiator to thermostat
quick release coupling housing coolant hose
See Removal Detail retaining clamp
See Removal Detail
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connector
9 - Heater core to thermostat
housing coolant hose quick
release coupling
See Removal Detail
retaining clamp
See Removal Detail
12 - Engine wiring harness sup-
port clip
nuts and bolt
14 - Oil cooler to thermostat
retaining clamp
See Removal Detail
15 - Oil cooler to thermostat
16 - Thermostat housing, engine
coolant shutoff valve and
thermostat
17 - Thermostat housing O-ring
seal
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Number
Removal Details
18 - ECT sensor retaining clip
19 - ECT sensor Item 1 : Turbocharger variable vain vacuum
regulator and support bracket
20 - Engine coolant shutoff valve 1. Detach the turbocharger variable vain
21 - Thermostat housing vacuum regulator and support bracket and
secure to one side.
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Item 2 : Coolant expansion tank to thermostat

Item 9 : Heater core to thermostat housing
1. Disconnect the coolant expansion tank to
1. Disconnect the heater core to thermostat
thermostat coolant hose quick release
housing coolant hose quick release
coupling.
coupling.
• Press the locking tang release bar.
• Remove the coolant hose quick release
coupling retaining clip.
Item 3 : Radiator to thermostat coolant hose

retaining clamp
1. Using the special tool, detach the radiator Item 10 : Coolant bypass to thermostat
to thermostat coolant hose retaining housing coolant hose retaining clamp
clamp. 1. Using the special tool, disconnect the
coolant bypass to thermostat housing
coolant hose.
Item 5 : Radiator to thermostat housing

diator to thermostat housing coolant hose.
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Item 14 : Oil cooler to thermostat housing

1. Using the special tool, disconnect the oil
cooler to thermostat housing coolant hose.
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Coolant Pump
1. Remove the timing belt. For additional 3. Remove the components in the order
information, refer to Section 303-01B. indicated in the following illustration(s) and
[Engine - 2.0L Duratorq-TDCi (DW) table(s).
Diesel, IN-VEHICLE REPAIR, Timing Belt]
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Number
1 - Coolant pump retaining bolts
See Removal Detail
2 - Coolant pump
3 - Coolant pump gasket
Removal Details
Item 1 : Coolant pump retaining bolts

1. Tighten the coolant pump retaining bolts in
the sequence indicated.
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Radiator
Special Tool(s)
5. Remove the cooling fan motor and shroud.
Remover/Installer, Cooling For additional information, refer to Cooling
Hose Clamp Fan Motor and Shroud in this section.
303-397 (24-003) 6. Remove the components in the order
table(s).
1. Secure the air conditioning (A/C)

2. Remove the right-hand head lamp
assembly. For additional information,
Assembly]
3. Remove the charge air cooler outlet pipe
support bracket retaining bolt.

Draining, Filling and Bleeding - 2.0L in this
section.
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Number
9 - Radiator
1 - Charge air cooler retaining See Removal Detail
bolts
See Removal Detail 10 - Radiator lower insulators
retaining clamp 11 - Radiator upper insulators
See Removal Detail
retaining clamp
See Removal Detail
radiator coolant hose
retaining clamp
See Removal Detail
See Removal Detail
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7. To install, reverse the removal procedure. Item 4 : Radiator upper coolant hose retaining
clamp
diator upper coolant hose.
Item 1 : Charge air cooler retaining bolts
1. Detach the charge air cooler from the ra-
diator charge air cooler support brackets.
Item 6 : Coolant expansion tank to radiator

coolant expansion tank to radiator coolant
2. Secure the charge air cooler to the front
hose retaining clamp.
body panel.
Item 2 : Radiator lower coolant hose retaining
clamp
diator lower coolant hose.

the radiator.
2. Disconnect the relay electrical connector
(if equipped).
Item 9 : Radiator
CAUTION: Care must be taken not to
damage the cooling fins and tubes of the
coolant radiator and the A/C condenser
when removing the coolant radiator.
Failure to follow this instruction could
result in coolant leaks or engine
overheat.
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Item 10 : Radiator lower insulators

CAUTION: Inspect the radiator lower
the radiator.
1. With the aid of another technician, install
the radiator support bracket.
• Install the 30mm M8 bolts leaving 15mm of
thread exposed.
2. Connect the relay electrical connector (if
equipped).
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414-01.[Battery, Mounting and Cables, 4. Remove the radiator splash shield.
Disconnect]

table(s).
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Number
1 - Charge air cooler intake hose support clip
to charge air cooler intake
pipe retaining clamp 5 - Radiator support bracket
front retaining bolts
2 - Charge air cooler intake hose See Removal Detail
to charge air cooler retaining See Installation Detail
clamp
3 - Charge air cooler intake hose retaining bolts
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Item Part Description Item 7 : Air conditioning (A/C) condenser

Number 1. Detach the A/C condenser from the radiator
(if equipped).
7 - Air conditioning (A/C) 1. Press in the radiator A/C condenser
condenser retaining clip.
See Removal Detail
2. Slide the A/C condenser upwards
8 - Cooling fan electrical con-
nector
shroud
See Removal Detail

Removal Details

retaining bolts
1. Install temporary radiator support bracket Item 9 : Cooling fan motor and shroud
front retaining bolts. 1. Press in the cooling fan motor and shroud
• Remove the radiator support bracket front retaining clips. Lift up the cooling fan
retaining bolts. shroud until clear of the retaining brackets.
• Install 30mm M8 bolts leaving 15mm of Remove the cooling fan motor and shroud.
thread exposed.
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retaining bolts
1. Install the radiator support bracket front
retaining bolts.
• Remove the temporary radiator support
bracket 30mm M8 retaining bolts.
retaining bolts.
Item 3 : Charge air cooler intake hose
NOTE: Make sure that the inside of the charge air
cooler intake hose is clean and free from any oil
residue, as this will reduce the installation grip of
the hose to the charge air cooler intake pipe and
the charge air cooler.
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Coolant Bypass Pipe

5. Remove the windshield wiper arms.
Special Tool(s)
Remover/Installer, Coolant
Hose Clamp
303-397

Draining, Filling and Bleeding - 2.0L in this
section.
2. NOTE: Make sure that the windshield wiper
motor is in the park position. 6. Remove the cowl panel.
Disconnect the battery ground cable. For 1. Detach the cowl panel from the retaining
additional information, refer to Section 414-01. clips.
[Battery, Mounting and Cables, 2. Remove the cowl panel by detaching it from
GENERAL PROCEDURES, Battery the windshield glass lower weatherstrip.
Disconnect]
7. Remove the bulkhead extension panel.

1. Remove the bulkhead extension panel
4. Detach the brake fluid reservoir from the retaining screws.
bulkhead extension panel. 2. Detach the bulkhead extension panel from
the retaining clips.
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8. Disconnect the positive crankcase 11. Remove the components in the order
ventilation (PCV) breather hose from the indicated in the following illustration(s)
intake manifold PCV valve. and table(s).
• Press in the release clip.
9. Remove the turbocharger intake support

bracket retaining bolt.

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Number
1 - Turbocharger outlet pipe re- bracket
taining clamps
2 - Turbocharger outlet pipe bracket retaining bolt
3 - Catalytic converter retaining bracket
clamp
See Removal Detail 9 - Turbocharger variable vane
See Installation Detail solenoid vacuum supply line
See Removal Detail
4 - Catalytic converter retaining
nuts 10 - Turbocharger variable vane
See Installation Detail solenoid wiring harness
See Removal Detail
See Removal Detail
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Number Number
11 - Turbocharger intake pipe 12 - Engine support insulator
retaining bolts retaining bolt

Number
18 - Coolant bypass pipe
13 - Heater core coolant hose to retaining bolts
coolant bypass pipe retaining See Installation Detail
clamp
See Removal Detail 19 - Coolant bypass pipe
See Removal Detail
14 - Heater core coolant hose to
coolant bypass pipe 20 - Coolant bypass pipe seal
15 - Coolant bypass hose to 12. To install, reverse the removal procedure.

coolant bypass pipe retaining
NOTE: Before installation, make sure that the
clamp
See Removal Detail PCV hose quick release coupling is clean and free
from any oil residue.
16 - Coolant bypass hose to 13. Vehicles with global closing, initialize the
coolant bypass pipe door window motors. For additional
17 - Coolant bypass pipe support
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Removal Details Item 13 : Heater core coolant hose to coolant

bypass pipe retaining clamp
Item 3 : Catalytic converter retaining clamp 1. Using the special tool, detach the heater
1. Make a note of the position of the catalytic core coolant hose to coolant bypass pipe
converter retaining clamp before removal. retaining clamp.
Item 5 : Catalytic converter Item 15 : Coolant bypass hose to coolant

1. Detach the catalytic converter from the bypass pipe retaining clamp
turbocharger and secure it to one side. 1. Using the special tool, detach the coolant
Item 9 : Turbocharger variable vane solenoid bypass hose to coolant bypass pipe re-
vacuum supply line taining clamp.
1. Detach the turbocharger variable vane
solenoid vacuum supply line from the
turbocharger intake pipe.
Item 10 : Turbocharger variable vane solenoid
wiring harness
solenoid wiring harness from the
Item 12 : Engine support insulator retaining
bolt
1. CAUTION: Take care not to crush or put
excessive force on the components
between the engine and radiator.
Item 19 : Coolant bypass pipe
Slide the engine towards the radiator.
CAUTION: Take care not to place
excessive strain on the surrounding
power steering lines, fuel lines and
engine compartment wiring harness
when removing the coolant bypass pipe.
1. With the aid of another technician, remove
the coolant bypass pipe.
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Installation Details 1. Install the catalytic converter retaining

clamp.
Item 18 : Coolant bypass pipe retaining bolts
1. NOTE: Do not tighten the coolant bypass pipe
Install the coolant bypass pipe retaining
bolts.
Item 17 : Coolant bypass pipe support bracket
retaining bolt
support bracket retaining bolt at this stage.
Install the coolant bypass pipe support
2. Tighten the coolant bypass pipe retaining
bolts. 2. Tighten the catalytic converter retaining
3. Tighten the coolant bypass pipe support nuts.
Item 2 : Turbocharger outlet pipe
4. Slide the engine back to the original
position and install the engine support NOTE: Make sure that the inside of the
insulator bolt. turbocharger outlet pipe is clean and free from any
oil residue, as this will reduce the installation grip
Item 11 : Turbocharger intake pipe retaining of the pipe to the turbocharger and charge air
bolts cooler intake pipe.
NOTE: Make sure that the inside of the
turbocharger outlet pipe is clean and free from any
of the pipe to the turbocharger and charge air
cooler intake pipe.
Item 4 : Catalytic converter retaining nuts
1. NOTE: Do not tighten the catalytic converter
retaining nuts at this stage.
Install the catalytic converter retaining
nuts.
Item 3 : Catalytic converter retaining clamp
CAUTION: Never use jointing compound
forward of the catalytic converter.
NOTE: The catalytic converter retaining clamp
must be installed in the same position as
removed.
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Coolant Shutoff Valve
1. Drain the cooling system. For additional 3. Remove the components in the order
information, refer to Cooling System indicated in the following illustration(s) and
Draining, Filling and Bleeding - 2.0L in this table(s).
section.
2. Remove the brake vacuum pump. For
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Number
1 - Coolant shutoff valve elec-
trical connnector
2 - Coolant shutoff valve
3 - Coolant shutoff valve O-ring
seals
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303-03C-1 Engine Cooling — 1.6L (Z6) 303-03C-1
SECTION 303-03C Engine Cooling — 1.6L (Z6)

CONTENTS PAGE
SPECIFICATIONS
Engine Cooling................................................................................................................. 303-03C-3/5

Coolant Flow Diagram..................................................................................................... 303-03C-6
Engine Cooling................................................................................................................. 303-03C-7

Inspection and Verification .............................................................................................. 303-03C-7
Symptom Chart ............................................................................................................... 303-03C-7/8
Component Tests............................................................................................................ 303-03C-9
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding .............................................. (24 122 0) 303-03C-10
Draining........................................................................................................................... 303-03C-10
Filling and Bleeding......................................................................................................... 303-03C-10
Thermostat....................................................................................................................... 303-03C-11/12
Coolant Pump .................................................................................................................. 303-03C-13/14
Radiator ........................................................................................................................... 303-03C-15/18
Cooling Fan Motor and Shroud ........................................................................................ 303-03C-19/20
Coolant Outlet Connector................................................................................................. 303-03C-21
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SPECIFICATIONS

Description Specification
Motorcraft Super Plus Anti-freeze 3M81-97B44-AA
Anti-freeze
Specific Gravity Approximate
(providing no other percentage of
additive is in coolant) anti-freeze (by volume) Remains fluid to Solidifies at
1.061 at +15°C 50% -25°C (-13°F) -37°C (-35°F)

Description Liters
Cooling system and heater 6.5
Cooling system pressure specification

Description Pressure Kpa (Psi)
Coolant expansion tank cap pressure release 135 to 155 (19.6 to 22.5)
Item Nm lb-ft lb-in
Coolant pump retaining bolts 22 16 -
Thermostat cover retaining bolts 22 16 -
Radiator support bracket front retaining bolts 25 18 -
Radiator support bracket rear retaining bolts 25 18 -
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Engine Cooling

Number
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Number
2 - Coolant pump
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Number
4 - Radiator
shroud
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Coolant Flow Diagram

Number
1 - Coolant reservoir
2 - Radiator
3 - Thermostat
4 - Coolant pump
5 - Engine block
6 - Cylinder head
7 - Heater
8 - Idle air control (IAC) valve
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Engine Cooling
Special Tool(s) – Gaskets/seals – Wiring harness
– Core plug(s) – Electrical
Pressure Tester, Cooling connector(s)
System – Hose(s)/hose joints
– Coolant expansion – Engine coolant
303-396 (24-001 A) temperature (ECT)
tank pressure cap
and seal(s) sensor
– Coolant expansion – Cooling fan motor
Adaptor for 303-396
tank – Auxiliary Heater
303-396-05 (24-001A-05)
– Radiator – Powertrain control
– Water pump module (PCM)
– Thermostat housing
– Heater core
General Equipment – Heater control valve
Worldwide Diagnostic System (WDS) – Accessory drive belt
(418-F224) – Cooling Fan
Inspection and Verification (if possible) before proceeding to the next step
1. Verify the customer concern. 4. If the cause is not visually evident, verify the
Symptom Chart
• Loss of coolant • Coolant expansion tank pressure • CHECK the coolant expansion
essary.
• Cooling system. • INSPECT the cooling system for
section. INSTALL new compo-
nent(s) as necessary.
303-01B.[Engine - 1.6L (Z6),
Head]
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• The engine overheats (signs of • Air in cooling system. • BLEED the cooling system.
coolant boiling) REFER to Cooling System
this section.
• Cooling system does not hold • CHECK the coolant expansion
pressure. tank pressure cap for tightness
coolant expansion cap as
necessary.
• INSPECT the engine, cylinder
303-01B.[Engine - 1.6L (Z6),
Head]
• Coolant level/condition. • CHECK the coolant level.
Bleeding in this section.
• CHECK the coolant condition
and concentration. If the coolant
is contaminated or the concen-
tration is below specifications,
this section.
air restrictions/damage. REPAIR
or INSTALL new parts as nec-
essary.
• Cooling fan. • CHECK the operation of the
• Coolant pump. • REMOVE AND INSPECT the
coolant pump/impeller. INSTALL
a new coolant pump/coolant
REFER to Coolant Pump in this
section.
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303-01B.[Engine - 1.6L (Z6),
Head]
• The engine does not reach • ECT sensor. • CHECK the engine coolant
normal operating temperature. temperature. REFER to WDS.
• Temperature gauge. • CHECK the instrument cluster
engine temperature gauge.
[Instrument Cluster,
REMOVAL AND
INSTALLATION, Instrument
Cluster]
system does not hold pressure, check the
cooling system thoroughly for coolant leaks.
Component Tests 5. Check the system by repeating steps 3 and 4
at least twice.
Pressure Test 6. If a coolant leak cannot be found, check the
engine for cylinder leakage. REFER to
WARNING: When releasing the system Section 303-01B.[Engine - 1.6L (Z6),
pressure, cover the expansion tank cap IN-VEHICLE REPAIR, Cylinder Head]Drain
with a thick cloth to prevent the the cooling system, repair any coolant leaks
possibility of coolant scalding, Failure to found and fill and bleed the cooling system as
follow this instruction may result in necessary. REFER to Cooling System
personal injury. Draining, Filling and Bleeding in this section.
NOTE: If the coolant expansion tank pressure cap
is rotated counterclockwise by between 2 and 3 Thermostat Test
full turns, the pressurized coolant will be vented to
the underside of the coolant expansion tank. 1. Remove the thermostat. REFER to
1. Remove the coolant expansion tank pressure 2. Immerse the thermostat in a water and
cap. antifreeze mixture. Heat the fluid mixture to
above 88 ºC (190 ºF). At this temperature the
2. Install the special tools 303-396 and thermostat should begin to open. If it does not
303-396-05 to the coolant expansion tank. begin to open, install a new thermostat.
3. Pressurize the cooling system to the coolant REFER to Thermostat in this section.
expansion tank cap release pressure.
4. Observe the cooling system pressure tester
gauge reading for approximately two minutes.
If the system holds pressure, Install a new
coolant expansion tank pressure cap. If the
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GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding (24 122 0)

Draining
1. WARNING: When releasing the cooling 3. Install the coolant expansion tank cap
system pressure, cover the coolant
expansion tank cap with a thick cloth CAUTION: Do not allow the engine
to prevent the possibility of scalding. coolant temperature indicator to rise
Failure to follow this instruction may above the normal working parameters of
result in personal injury. the engine. If the engine temperature
NOTE: The cooling system pressure will be rises above the upper limit of the normal
vented to the underside of the coolant expansion working temperature, switch off the
tank. engine and allow to cool.
Release the cooling system pressure by CAUTION: Do not allow the coolant level
slowly turning the coolant expansion tank in the coolant expansion tank to fall
cap between 2 and 3 turns. below the minimum mark.
2. Remove the coolant expansion tank cap. 4. Start the engine.
3. Raise and support the vehicle. For 5. Allow the engine to idle until the engine
additional information, refer to Section 100-02. coolant temperature indicator is mid scale.
[Jacking and Lifting, DESCRIPTION 6. Raise the engine speed to 2500 revolutions
AND OPERATION, Lifting] per minute (RPM) and maintain for 5
4. NOTE: To avoid the removal of an excessive minutes.
volume of coolant, the cooling system should 7. Increase the engine speed to 3000 RPM and
only be drained from the radiator drain plug. maintain for 5 seconds.
Drain the cooling system. 8. Decrease the engine speed to idle.
• Allow the coolant to drain into a suitable 9. Increase the engine speed to 3000 RPM and
container. maintain for 5 seconds.
10. Decrease the engine speed to idle.
11. Increase the engine speed to 3000 RPM
and maintain for 5 seconds.
12. Decrease the engine speed to idle.
13. Switch the engine off.
14. Check the cooling system for leaks.
15. Allow the engine to cool.
16. Top up the coolant expansion tank to the
MAX mark.


2. Fill the cooling system to the MAX mark of
the coolant expansion tank.
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Thermostat
1. Disconnect the battery ground cable. For 4. Detach the air conditioning (A/C) com-
additional information, refer to Section 414-01. pressor and secure to one side.
Disconnect]
section.
1.6L (Z6)]

table(s).
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Number
1 - Thermostat cover retaining
bolts
2 - Thermostat cover
See Removal Detail
3 - Thermostat
4 - Thermostat O-ring seal

8. Vehicles with global closing, initialize the
door window motors. For additional
information, refer to Section 501-11.[Glass,
Frames and Mechanisms, GENERAL
PROCEDURES, Door Window Motor
Initialization]
Removal Details
Item 2 : Thermostat cover

1. Detach the thermostat cover and position
to one side.
Item 3 : Thermostat
1. Align the thermostat with the engine in-
dent.
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Coolant Pump

[Accessory Drive, REMOVAL AND 5. Remove the generator. For additional
INSTALLATION, Accessory Drive Belt - information, refer to Section 414-02.
1.6L (Z6)] [Generator and Regulator,
REMOVAL AND INSTALLATION, Generator
- 1.6L (Z6)]
Draining, Filling and Bleeding in this 6. Remove the components in the order
section. indicated in the following illustration(s) and
table(s).
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Number
1 - Coolant pump retaining bolts
2 - Coolant pump
3 - Coolant pump gasket

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Radiator
2. Remove the air deflector.
Special Tool(s)
Hose Clamp
303-397 (24-003)

Disconnect]
3. Secure the air conditioning (A/C)
section.
5. Remove the cooling fan motor and shroud.
For additional information, refer to Cooling
Fan Motor and Shroud in this section.
table(s).
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Number
9 - A/C condenser (If equipped)
1 - Radiator lower coolant hose See Removal Detail
retaining clamp
See Removal Detail 10 - Radiator
See Removal Detail
2 - Radiator lower coolant hose See Installation Detail
3 - Radiator upper coolant hose 11 - Radiator upper insulators
retaining clamp
See Removal Detail 12 - Radiator lower insulators
retaining clamp
See Removal Detail
7 - Temporary radiator support
bracket front retaining bolts
See Removal Detail
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7. To install, reverse the removal procedure. Item 5 : Coolant expansion tank to radiator
diator degas coolant hose
Item 1 : Radiator lower coolant hose retaining
clamp
diator lower coolant hose.

the radiator.
Item 9 : A/C condenser (If equipped)
Item 3 : Radiator upper coolant hose retaining 1. Detach the radiator from the A/C condenser
clamp (If equipped).
1. Using the special tool, disconnect the ra- 1. Press in the radiator A/C condenser
diator upper coolant hose. retaining tang.
2. Slide the radiator downwards.
Item 10 : Radiator
damage the cooling fins of the coolant
radiator and the A/C condenser when
removing the coolant radiator. Failure to
follow this instruction could result in
coolant leaks or engine overheat.
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Item 12 : Radiator lower insulators

CAUTION: Inspect the radiator lower
the radiator.
Item 10 : Radiator
the radiator.
Item 7 : Temporary radiator support bracket
front retaining bolts
1. Install the radiator support bracket
temporary front 30mm M8 retaining bolts
leaving 15mm of thread exposed.
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[Battery, Mounting and Cables, 3. Raise and support the vehicle.
GENERAL PROCEDURES, Battery 4. Remove the radiator splash shield.
Disconnect]
2. Disconnect the cooling fan motor electrical
connector.

table(s).
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Item Part Description Item 3 : Cooling fan motor and shroud
Number 1. Press in the cooling fan motor and shroud
retaining clips. Lift up the cooling fan
1 - Radiator support bracket shroud until clear of the retaining bracket.
front retaining bolts Remove the cooling fan motor and shroud.
See Removal Detail
retaining bolts
shroud
See Removal Detail

Initialization]
Removal Details
Item 1 : Radiator support bracket front Installation Details

retaining bolts
1. Install temporary radiator support bracket Item 1 : Radiator support bracket front
front retaining bolts. retaining bolts
• Remove the radiator support bracket front 1. Install the radiator support bracket front
retaining bolts. retaining bolts.
• Install 30mm M8 bolts leaving 15mm of • Remove the temporary radiator support
thread exposed. bracket 30mm M8 retaining bolts.
retaining bolts.
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Coolant Outlet Connector
Special Tool(s) 4. Drain the cooling system. For additional

Remover/Installer, Cooling Draining, Filling and Bleeding in this
Hose Clamp section.
303-397 (24-003) 5. Lower the vehicle.
table(s).
Disconnect]

(Z6)]
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Number
3 - Engine wiring harness and
1 - Cylinder head temperature engine emission pipe support
(CHT) sensor electrical bracket retaining bolts
connector See Installation Detail
2 - Coolant expansion tank 4 - Fuel charging wiring harness
coolant degas hose retaining ground electrical connector
clip
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Number
5 - Engine wiring harness and
engine emission pipe support
bracket
See Removal Detail

Number
6 - Radiator lower coolant hose coolant outlet connector
to coolant outlet connector coolant hose retaining clamp
retaining clamp
See Installation Detail 12 - Coolant expansion tank to
coolant outlet connector
7 - Radiator lower coolant hose coolant hose
to coolant outlet connector
8 - Coolant outlet connector re-
taining bolts 14 - Coolant outlet connector
O-ring seal
9 - Throttle body to coolant out-
let connector coolant hose 7. To install, reverse the removal procedure.
retaining clamp
10 - Throttle body to coolant out- door window motors. For additional
let connector coolant hose information, refer to Section 501-11.[Glass,
Initialization]
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Removal Details
Item 5 : Engine wiring harness and engine

emission pipe support bracket
1. Position the engine wiring harness and
engine emission pipe support bracket to
one side to gain access to the coolant
outlet connector.
Item 3 : Engine wiring harness and engine

emission pipe support bracket retaining
bolts
1. Position the engine harness ground
connector under the upper engine wiring
harness and engine emission pipe support
Item 6 : Radiator lower coolant hose to coolant
outlet connector retaining clamp
1. Using the special tool, detach the radiator
lower coolant hose from the coolant outlet
connector.
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303-04A-1 Fuel Charging and Controls — 1.8L Duratec-HE 303-04A-1

SECTION 303-04A Fuel Charging and Controls —

1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)
CONTENTS PAGE
SPECIFICATIONS
Fuel Charging and Controls ............................................................................................. 303-04A-3/5
Fuel Charging and Controls ............................................................................................. 303-04A-6

Throttle Body ................................................................................................................... 303-04A-7/9

Fuel Injectors ................................................................................................ (23 455 0) 303-04A-10
Fuel Charging Wiring Harness ......................................................................................... 303-04A-11/13
Fuel Injection Supply Manifold ......................................................................................... 303-04A-14
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SPECIFICATIONS
Throttle body retaining bolts 10 — 89
Fuel injection supply manifold retaining bolts 25 18 —
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Fuel Charging and Controls
Fuel Injection Supply Manifold

Item Part Description The fuel injection supply manifold is retained to
Number the engine by two bolts. The fuel injection supply
1 - Fuel injection supply mani- manifold has pressed steel cups to house the fuel
fold injectors.
2 - Fuel injector retaining clip The fuel injectors are fitted directly into the fuel
injection supply manifold and are retained by the
3 - Fuel injector O-ring seals fuel injector retaining clips. Sealing between the
4 - Fuel injector fuel injector to fuel injection supply manifold and
the intake manifold is achieved by means of upper
and lower O-ring seals.
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The fuel injectors are activated sequentially by the times according to the engine operating
powertrain control module (PCM) which modifies conditions.
the fuel quantity by adjusting fuel injector opening
the accelerator pedal position sensor. The system

Item Part Description is fully electronic and does not use any cables.
Number The signal from the PCM is used to control a DC
1 - Throttle body motor within the throttle body which is connected
to the throttle butterfly through gears.
Throttle Body
The throttle body also gives inputs back to the
The throttle butterfly position is controlled by a PCM. This information allows the PCM to
signal from the PCM which receives an input from compensate for factors such as carbon build up
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within the throttle body and throttle body wear.
The throttle body also provides information to the
PCM to enable the flagging of a DTC.
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General Equipment


–Fuel leak(s) – Powertrain control
–Vacuum line(s) module (PCM)
–Gasket(s) – Wiring harness
–Seal(s) – Electrical
connector(s)
–Fuel injector(s)
– Throttle body
–Throttle body
– Fuel injector(s)
–Fuel injection supply
manifold
– Fuel supply line
step.
symptom and refer to WDS to diagnose the
system.
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Throttle Body

Special Tool(s)
Hose Clamp
303-397 (24-003)
General Equipment
Worldwide Diagnostic System (WDS) -
418-F224
NOTE: If a new throttle body is being installed
connect WDS. Upload the throttle body
configuration information using the programmable 4. Remove the components in the order
modules installation routine prior to commencing indicated in the following illustration(s) and
the removal of the throttle body. table(s).
information,
refer to Section 303-03A / 303-03B.
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Number
1 - Throttle body electrical con-
nector
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Item Part Description Item 3 : Throttle body to exhaust gas
Number recirculation (EGR) valve coolant hose
1. Using the special tool, remove throttle
2 - Radiator to throttle body body to EGR valve coolant hose from the
coolant hose throttle body.
See Removal Detail
3 - Throttle body to exhaust gas
recirculation (EGR) valve
coolant hose
See Removal Detail
4 - Throttle body

NOTE: If a new throttle body is being installed
connect WDS. Download the throttle body
configuration information using the programmable
modules installation routine after the installation of
the throttle body.
Removal Details
Item 2 : Radiator to throttle body coolant hose

diator to throttle body coolant hose from
the throttle body.
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Fuel Injectors (23 455 0)
1. Remove the fuel injection supply manifold.

For additional information, refer to Fuel
Injection Supply Manifold in this section.
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Fuel Charging Wiring Harness

refer to Section 414-01. 3. Remove the components in the order
table(s).
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Number
4 - Throttle body electrical con-
1 - Powertrain control module nector
(PCM) electrical connector
See Removal Detail 5 - Knock sensor (KS) electrical
connector
2 - Swirl plates solenoid valve
electrical connector 6 - Ignition coil-on-plug electrical
connectors
3 - Air shut off solenoid valve
electrical connector 7 - Camshaft position (CMP)
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Number
nectors
9 - Fuel charging wiring harness
electrical connectors
See Removal Detail

Removal Details
Item 1 : Powertrain control module (PCM)

1. Remove the PCM. For additional
Item 10 : Fuel charging wiring harness
1. Disconnect the fuel charging wiring
harness retaining clips from the fuel
injection supply manifold and remove the
fuel charging wiring harness.
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tobacco or open flame of any type when 4. Remove the components in the order
working on or near any fuel related indicated in the following illustration(s) and
components. Highly flammable vapors table(s).
injury.
1. Release the fuel system pressure. For
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Number
4 - Fuel injection supply
1 - Fuel pulse damper vacuum manifold fuel supply line
line See Removal Detail
2 - Fuel injector(s) electrical 5 - Fuel injection supply mani-
connector(s) fold and fuel injectors
3 - Fuel charging wiring harness 6 - Fuel injector retaining clips
7 - Fuel injector(s)
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injury.
Removal Details

1. Detach the fuel charging wiring harness
retaining clips from the fuel injection
supply manifold.
Item 4 : Fuel injection supply manifold fuel
supply line
1. Disconnect the fuel supply line from the
fuel injection supply manifold. For
Item 6 : Fuel injector retaining clips
1. Remove the fuel injector retaining clips.
• Discard the fuel injector retaining clips.
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303-04B-1 Fuel Charging and Controls — 2.0L Duratorq-TDCi 303-04B-1

(DW) Diesel
SECTION 303-04B Fuel Charging and Controls —

2.0L Duratorq-TDCi (DW) Diesel
CONTENTS PAGE
SPECIFICATIONS
Fuel Charging and Controls ............................................................................................. 303-04B-3

Overview ......................................................................................................................... 303-04B-3/6
Fuel Charging and Controls ............................................................................................. 303-04B-7

Principles of Operation .................................................................................................... 303-04B-7/8
Symptom Chart ............................................................................................................... 303-04B-9/26
GENERAL PROCEDURES
Fuel Injection Component Cleaning ................................................................................. 303-04B-27
Fuel Injectors — VIN Plate Emission Level Code: S ........................................................ 303-04B-28/38

Fuel Injection Supply Manifold — VIN Plate Emission Level Code: S............................... 303-04B-39/49
Fuel Pump ....................................................................................................................... 303-04B-50/54
Intake Air Shutoff Throttle — VIN Plate Emission Level Code: S...................................... 303-04B-55
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(DW) Diesel
SPECIFICATIONS
Item Nm lb-ft lb-in
Fuel filter crash protection shield retaining bolts 9 - 80
Fuel filter support bracket retaining bolts 9 - 80
High-pressure fuel injection supply pipe unions 23 17 -
Fuel injection supply manifold retaining bolts 22 16 -
Intake manifold retaining bolts 9 - 80
Timing belt upper cover retaining bolts 7 - 62
Fuel injector retaining bracket nuts a - -
Fuel pump retaining bolts 20 15 -
a) Refer to the relevant procedure in this section.
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(DW) Diesel

Overview
high pressure pump elements, in accordance with

Item Part Description driving conditions.
Number At high pressure, the fuel is fed to the common rail
1 - Injector valve and to the injectors ready for injection. Depending
on engine operating conditions, the injection
2 - Fuel metering valve pressure varies between approx. 350 bar and
3 - Fuel pressure control valve 1650 bar.
4 - Fuel pump Fuel pressure is measured using a fuel pressure

sensor on the common rail. The fuel pressure
5 - Common rail sensor converts the fuel system pressure into a
6 - Fuel pressure sensor voltage signal. This voltage signal acts as an input
signal to the powertrain control module (PCM) for
calculation of the injection quantity.
General The PCM calculates the time of injection and the
A Siemens common rail diesel injection system is injection quantity depending on various input
used on the 2.0L Duratorq TDCi (DW10) engine. variables.
In the fuel pump is an integral fuel transfer pump The specified quantity of fuel is injected into the
which transports the fuel from the fuel tank to the respective combustion chamber via the
fuel pump. piezo-electrically actuated injectors. In doing so, a
pre-injection and a main injection occur each time.
A fuel metering valve is located in the feed port to
the high-pressure chamber of the fuel pump; this The excess fuel is returned to the fuel tank via the
valve varies the quantity of fuel supplied to the fuel return pipe.
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(DW) Diesel

The fuel pressure control valve on the The fuel metering valve is located in the feed port
high-pressure outlet of the fuel pump regulates the between the high-pressure pump elements and
fuel pressure and thereby also the pressure in the the fuel transfer pump. It is actuated by the PCM
common rail. using pulse width modulation.
The high-pressure outlets of the three
Fuel pump high-pressure pump elements are grouped
together in a high-pressure connection.
The fuel pressure control valve is located on the
high-pressure outlet to the common rail. The fuel
pressure regulator operates electromagnetically
and is actuated by the PCM .
Common rail

Number
1 - Fuel pressure sensor
NOTE: The fuel pressure sensor on the common
Item Part Description rail must not be detached or removed.
Number The common rail is made from forged steel and is
1 - High-pressure outlet to the attached directly to the cylinder block.
common rail. The fuel is transported via one high-pressure line
2 - Feed to the fuel filter from the fuel pump to the common rail.
3 - Fuel metering valve From the common rail, the fuel travels via four
more high-pressure fuel lines to the injectors.
4 - Return to the fuel tank
5 - Fuel pressure control valve
The fuel pump is attached to the cylinder head on

the transmission side and is driven directly by the
exhaust camshaft via a flange.
The fuel pump has three pump elements, each
offset from each other by 120°.
The fuel transfer pump is incorporated into the fuel
pump and is located on the drive flange. The fuel
transfer pump is a vane type pump.
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(DW) Diesel

Fuel filter Fuel injectors

Number
1 - Feed from the fuel tank
2 - Connection to fuel pump
3 - Electrical fuel pre-heat
4 - Drain plug
The fuel filter is located above the common rail
and is attached to the cylinder head by means of a
bracket.
The fuel filter has an electric fuel heater which is
located centrally on the fuel filter between the feed
connection and the drain connection.
The fuel filter forms a single component with the Item Part Description
housing and can only be renewed as a complete Number
unit.
1 - Connection - high-pressure
The fuel filter also has a water trap. This must be fuel line
drained regularly in accordance with maintenance
instructions. 2 - Connector
3 - Retainer
4 - Copper sealing ring
5 - Plastic bush
6 - Connection - return line
The injectors are located centrally on the cylinder

head upper section and are attached by means of
retainers.
The guide bushes in the cylinder head lower
section and the plastic guide bushes on the
injectors ensure that they are centred properly.
They are sealed off from the combustion chamber
by means of a copper sealing washer located
between the injector and the cylinder head. This
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(DW) Diesel

must always be renewed when carrying out
installation work.
The injectors are actuated directly by the PCM.
The injectors are actuated by piezo-electric
elements.
The return lines are attached to the top of the
injector and are connected in series.
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(DW) Diesel


Number
General Equipment 3 - Fuel metering valve
Worldwide Diagnostic System (WDS) 4 - high-pressure fuel pump

(418-F224) chamber
5 - Fuel pump fuel return outlet
6 - High pressure fuel control
Principles of Operation valve
The 2.0L DW10 engine uses a second generation
Siemens common rail fuel injection system. The The fuel pump is made up of a transfer pump and
systems main components consist of a fuel pump, a high-pressure fuel delivery pump. The transfer
fuel rail, electrically operated fuel injectors and a pump draws fuel from the fuel tank through the
fuel temperature sensor. fuel filter and delivers the fuel to the three
high-pressure fuel pump chambers via a fuel
metering valve. The fuel metering valve controls
Fuel Pump the quantity of fuel that is allowed to enter the
high-pressure fuel pump chambers. Excess fuel
volume developed by the transfer pump is
returned to the fuel tank. The fuel metering valve
is controlled by the powertrain control module
(PCM) using a pulse-width modulated signal. The
high-pressure fuel pump outlet pressure is
controlled by a electronic fuel control valve which
is also controlled by the PCM.
Fuel Rail

Number
1 - Fuel rail
Item Part Description 2 - Fuel pressure sensor

Number The fuel rails function is to supply a reservoir of
1 - Fuel pump fuel inlet fuel to all four injectors with no variations in fuel
pressure for any one injector. The fuel rail acts as
2 - Fuel pump high-pressure fuel a pulse damper eliminating surges in fuel pressure.
outlet Attached to the fuel rail is a fuel pressure sensor.
The fuel pressure sensor monitors the fuel
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(DW) Diesel

pressure at the fuel injectors. The sensor according to there flow characteristics into one of
develops a pressure conscious variable three grades. The grade is printed on the top of
resistance which provides a controlled variable the fuel injector and can be the number 4, 5, or 6.
voltage signal to the PCM. All four fuel injectors must be of a matching grade
for any one engine application. The grade value is
used by the PCM to adjust the fuel injector
Fuel Injectors injection signal to achieve optimum efficiency. The
fuel injectors are designed to allow a quantity of
fuel to return to the fuel system. The returned fuel
is developed during the opening cycle of the
injector control valve. This returned fuel is used to
lubricate the injector moving components and is
essential to the operation of the injector. This
lubricating fuel is returned to the fuel tank via the
fuel injector fuel return line. Only by accurate
measurement, at precise engine conditions, can
the volumes of fuel from the fuel injector fuel
return be used to diagnose concerns with the fuel
charging control system.
Fuel Temperature Sensor

Number
Item Part Description 1 - Fuel injector fuel return line
Number
2 - Fuel pump fuel return line
1 - High-pressure fuel inlet
3 - Fuel temperature sensor to
2 - Piezoelectric actuator fuel tank fuel return line
3 - Injection valve 4 - Fuel temperature sensor
4 - Fuel injector fuel return The fuel temperature sensor is fitted in to the fuel
pump to fuel tank fuel return line. The temperature
The fuel injectors have a Piezoelectric actuator. sensor monitors the temperature of the fuel
The advantages of using Piezoelectric instead of returning to the fuel tank from the fuel pump and
traditional solenoid actuators are the reduction in the fuel injectors. The fuel temperature sensor
reaction switching times and the lower switching housing acts as a venturi. The venturi assists with
currents. Both of which improve the control and the fuel return from the fuel injectors by creating a
therefore the efficiency of the injector. During pressure reduction in the fuel injector fuel return
manufacture, the fuel injectors are graded line.
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(DW) Diesel

Inspection and Verification 1. Verify the customer concern.
tobacco of any type when working on or
near any fuel related components. Highly
flammable mixtures are always present Visual Inspection Chart
and may ignite. Failure to follow these Mechanical Electrical
instructions may result in personal injury. - Fuel leak(s) - Fuse(s)
- Fuel filter - Relay(s)
WARNING: This procedure involves fuel - Air cleaner element - Wiring harness
handling. Be prepared for fuel spillage at - Vacuum - Electrical connec-
all times. Failure to follow this instruction line(s)/vacuum con- tor(s)
may result in personal injury. nections
- Hose(s)/hose con- - Sensor(s)
nections
- Tube(s)/tube connec-
tions
- Contaminated fuel
- Fuel supply line(s)
with these components. Always fit
- Fuel return line(s)
- High-pressure fuel
lines.
supply line(s)
NOTE: As well as carrying out its normal function - Fuel injectors
the glow plug indicator also acts as an engine - Fuel injection supply
check lamp which will flash continuously when a manifold
hard diagnostic trouble code (DTC) is detected by - Fuel pump
the powertrain control module (PCM). Soft DTCs
are also stored by the PCM but will only be known 3. If an obvious cause for an observed or
if the system is checked for DTCs using WDS. reported concern is found, correct the cause
NOTE: If a DTC is detected, all DTCs must be step.
cleared after the concern is rectified. Failure to
clear all DTCs may cause driveability concerns. 4. If the cause is not visually evident, verify the
symptom and refer to WDS to retrieve the
NOTE: If the fuel level in the fuel tank drops below diagnostic trouble codes (DTCs).
approximately four litres, rough running will occur.
This is to signal to the driver that the vehicle 5. If no DTCs related to the concern are retrieved,
requires refuelling in order to prevent the fuel proceed to the Symptom Chart below to
system from running dry. continue diagnostics.
Symptom Chart
Symptom Chart
• Engine does not crank and pas- • PATS system fault detected. • REFER to Section 419-01B.
sive anti-theft system (PATS) [Anti-Theft - Passive,
LED is flashing DIAGNOSIS AND TESTING,
Anti-Theft - Passive]
• Engine does not crank and glow • DTC detected. • REFER to WDS.
plug indicator is flashing
• Engine does not crank • Starting system. • REFER to Section 303-06.
[Starting System,
Starting System]
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• Engine cranks but does not start • DTC detected. • REFER to WDS.
and glow plug indicator is flash-
ing
• Engine cranks but does not start • Low fuel tank fuel level. • CHECK the fuel tank fuel level is
greater than four litres. If the fuel
tank fuel level is less then four
litres, FILL with fuel.
• Fuel filter blocked. • INSTALL a new fuel filter.
REFER to Section 310-01.[Fuel
Tank and Lines, REMOVAL AND
INSTALLATION, Fuel Filter -
2.0L Duratorq-TDCi (DW) Die-
sel, Vehicles Without: Wa-
ter-in-Fuel Sensor]
Tank and Lines, REMOVAL AND
INSTALLATION, Fuel Filter -
sel, Vehicles With: Water-in-Fuel
Sensor]
• Fuel lines damaged or blocked. •
• Air ingress into the fuel lines. •
• Glow plugs. • REFER to WDS.
• Incorrect valve timing. • CHECK the valve timing. REFER
to Section 303-01B.[Engine -
sel, IN-VEHICLE REPAIR, Tim-
ing Belt]
• Low cylinder compression. • REFER to Section 303-01B.
[Engine - 2.0L Dura-
Engine]
• Crankshaft position (CKP) sen- • REFER to WDS.
sor.
• Camshaft position (CMP) sen- • REFER to WDS.
sor.
• Engine coolant temperature • REFER to WDS.
(ECT) sensor.
• PCM. • REFER to WDS.
• Fuel injection supply manifold • REFER to WDS.
fuel pressure sensor.
• Fuel pump fuel pressure regu- • REFER to WDS.
lator.
• Fuel pump. • REFER to WDS.
• Fuel injector(s). • REFER to WDS.
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• Poor starting and glow plug in- • DTC detected. • REFER to WDS.
dicator is flashing
• Poor starting • Low fuel tank fuel level. • CHECK the fuel tank fuel level is
• Fuel filter blocked. • INSTALL a new fuel filter ele-
ment.
• Air cleaner element blocked. • INSTALL a new air cleaner
element.
• Glow plugs. • REFER to WDS.
• Fuel system leak. • CHECK the system for fuel
leak(s). REPAIR the system as
necessary.
• Fuel system restriction. •
• Incorrect engine oil. • INSTALL a new engine oil filter
and engine oil.
• Catalytic converter blocked. • REMOVE and visually INSPECT
the catalytic converter for dam-
age. INSTALL a new catalytic
converter as necessary. REFER
to Section 309-00.[Exhaust
System, REMOVAL AND
INSTALLATION, Catalytic Con-
verter - 2.0L Duratorq-TDCi
(DW) Diesel]
Engine]
• CKP sensor. • REFER to WDS.
• ECT sensor. • REFER to WDS.
• Fuel temperature sensor. • REFER to WDS.
• Mass air flow (MAF) sensor. • REFER to WDS.
• Manifold absolute pressure • REFER to WDS.
(MAP) sensor.
lator.
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• Intake manifold Exhaust gas • CHECK the intake manifold EGR
recirculation (EGR) throttle. throttle butterfly for obstructions
and correct operation.
• REFER to WDS.
• Intake manifold EGR throttle • CHECK the intake manifold EGR
vacuum control solenoid. throttle vacuum control solenoid
vacuum lines for kinks or
restrictions.
• REFER to WDS.
• Engine starts but immediately • DTC detected. • REFER to WDS.
stops and glow plug indicator is
flashing
• Engine starts but immediately • Air cleaner element blocked. • INSTALL a new air cleaner
stops element.
• PCM relay. • CARRY OUT the relay compo-
nent test. REFER to Wiring Dia-
grams.
• Dual mass flywheel. • INSPECT the dual mass fly-
wheel for damage. INSTALL a
new dual mass flywheel as
necessary.
• CMP sensor. • REFER to WDS.
• PCM. • REFER to WDS.
lator.
• Intake manifold EGR throttle. • CHECK the intake manifold EGR
throttle butterfly for obstructions
• REFER to WDS.
restrictions.
• REFER to WDS.
• Poor idling and glow plug indi- • DTC detected. • REFER to WDS.
cator is flashing
• Poor idling • Low fuel tank fuel level. • CHECK the fuel tank fuel level is
element.
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ment.
• Incorrect or contaminated fuel. • CHECK for signs of
contamination such as strange
odors from the fuel tank.
• CHECK for signs of water or
petrol in the diesel.
• If contaminated fuel is found,
DRAIN the complete fuel sys-
tem. FLUSH the fuel system
through with clean diesel.
GENERAL PROCEDURES,
Fuel Tank Draining] INSTALL a
new fuel filter element. INSTALL
a new fuel pump, fuel injectors,
fuel injection supply manifold,
and high-pressure fuel supply
lines. REFER to Fuel Pump
/ Fuel Injectors - VIN Plate
Emission Level Code: S
/ Fuel Injection Supply Manifold -
VIN Plate Emission Level Code:
S in this section.
• EGR valve incorrect operation. •
necessary.
• MAF sensor. • REFER to WDS.
• MAP sensor. • REFER to WDS.
lator.
• REFER to WDS.
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(DW) Diesel

restrictions.
• REFER to WDS.
• Engine stumbling and glow plug • DTC detected. • REFER to WDS.
indicator is flashing
• Engine stumbling • Low fuel level. • CHECK the fuel tank level is
tank level is less than four litres,
FILL with fuel.
necessary.
• Accelerator pedal position (APP) • REFER to WDS.
sensor.
• Engine lacks power and glow • DTC detected. • REFER to WDS.
• Engine lacks power • Brakes binding. • CHECK the braking system.
• Vehicle overloaded, or excessive • ADVISE the customer about the
wind resistance (roof racks, effects of overloading the vehicle
towing etc). and wind resistance on the fuel
consumption.
element as necessary.
ment.
• Kinked or restricted fuel lines. •
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• Turbocharger. • INSPECT the vacuum line(s) for
• Turbocharger vacuum dia- visible signs of damage or
phragm unit. blockage. CLEAN, REPAIR or
INSTALL new parts as neces-
sary. REFER to Section 303-04C.
[Fuel Charging and
Controls - Turbocharger,
REMOVAL AND
INSTALLATION, Turbocharger -
sel]
ing Belt]
Engine]
System, REMOVAL AND
(DW) Diesel]
• Charge air cooler blocked or • INSPECT for visible signs of
cracked. damage or blockage. CLEAN,
• Charge air cooler pipes split or REPAIR or INSTALL new parts
cracked. as necessary.
• Charge air cooler pipe retaining
clips missing or loose.
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GENERAL PROCEDURES,
S in this section.
• Vehicle speed sensor (VSS). • REFER to WDS.
• APP sensor. • REFER to WDS.
• Fuel temperature sensor. • REFER to WDS.
lator.
• REFER to WDS.
restrictions.
• REFER to WDS.
• Black smoke at idle and glow • DTC detected. • REFER to WDS.
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(DW) Diesel

• Black smoke at idle • Air cleaner element blocked. • INSTALL a new air cleaner
element as necessary.
• Glow plug system. • REFER to WDS.
ing Belt]
System, REMOVAL AND
(DW) Diesel]
• REFER to WDS.
restrictions.
• REFER to WDS.
• Excessive black smoke during • DTC detected. • REFER to WDS.
acceleration and glow plug in-
dicator is flashing
• Excessive black smoke during • Air cleaner element blocked. • INSTALL a new air cleaner
acceleration element as necessary.
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(DW) Diesel

GENERAL PROCEDURES,
S in this section.
System, REMOVAL AND
(DW) Diesel]
• APP sensor. • REFER to WDS.
• REFER to WDS.
restrictions.
• REFER to WDS.
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• Black smoke at cruising speeds • DTC detected. • REFER to WDS.
and glow plug indicator is flash-
ing
• Black smoke at cruising speeds • Air cleaner element blocked. • INSTALL a new air cleaner
element.
• Turbocharger vacuum dia- • REFER to Section 303-04C.
phragm unit. [Fuel Charging and
Turbocharger - 2.0L Dura-
torq-TDCi (DW) Diesel]
System, REMOVAL AND
(DW) Diesel]
• REFER to WDS.
restrictions.
• REFER to WDS.
• Blue smoke and glow plug indi- • DTC detected. • REFER to WDS.
cator is flashing
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(DW) Diesel

• Blue smoke • Engine burning oil. • CARRY OUT a controlled oil
consumption test over 1000 km
(600 miles). CONFIRM that the
oil consumption is less than 0.1
of a litre per 1000 km (600 miles).
REFER to Section 303-01B.
Engine]
GENERAL PROCEDURES,
S in this section.
• Worn or damaged valve • REMOVE the cylinder head.
guide(s), piston ring(s), cylinder INSPECT the cylinder head,
bore(s), cylinder head or gasket. pistons and cylinder bores for
signs of wear or damage.
Head]
• Positive crankcase ventilation • INSPECT for visible signs of
(PCV) system. damage or blockage. CLEAN,
REPAIR or INSTALL new parts
as necessary.
• Turbocharger oil return tube • REFER to Section 303-04C.
blocked or damaged. [Fuel Charging and
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(DW) Diesel

• White smoke and glow plug in- • DTC detected. • REFER to WDS.
dicator is flashing
• White smoke • Water in fuel. • CHECK for signs of water in the
diesel.
GENERAL PROCEDURES,
S in this section.
ing Belt]
• Coolant in the combustion • CARRY OUT a cooling system
chamber. pressure test. REFER to Section
303-03B.[Engine Cooling - 2.0L
Duratorq-TDCi (DW) Diesel,
Engine Cooling] REMOVE the
cylinder head. INSPECT the
cylinder head, cylinder head
gasket and cylinder bores for
wear or damage. REFER to
Section 303-01B.[Engine - 2.0L
Head]
• Engine misfire and glow plug • DTC detected. • REFER to WDS.
indicator is flashing
• Engine misfire • Low fuel tank level. • CHECK the fuel tank level is
tank level is less than four litres,
FILL with fuel.
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GENERAL PROCEDURES,
S in this section.
• Low cylinder compression. • REFER to Section 303-00.
[Engine System - Gen-
eral Information, DIAGNOSIS
AND TESTING, Engine]
• Worn or damaged valve(s), • REMOVE the cylinder head.
tappet(s) or camshaft(s). INSPECT the cylinder head,
valves, tappets and camshafts
for signs of wear or damage.
Head]
• Damaged cylinder head gasket. • REMOVE the cylinder head.
INSPECT the cylinder head
gasket and cylinder bores for
wear or damage. REFER to
Section 303-01B.[Engine - 2.0L
Head]
• Engine overheats. • REFER to Section 303-03B.
Engine Cooling]
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(DW) Diesel

• CMP sensor. • REFER to WDS.
• REFER to WDS.
restrictions.
• REFER to WDS.
• Engine knock at idle and glow • DTC detected. • REFER to WDS.
• Engine knock at idle • Low engine oil level. • CHECK the engine oil level.
REFILL as necessary.
GENERAL PROCEDURES,
S in this section.
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(DW) Diesel

necessary.
ing Belt]
• Excessive carbon build up. • REMOVE the cylinder head.
INSPECT the cylinder head and
pistons for signs carbon build up.
Head]
• Worn or damaged oil pump. • REFER to Section 303-01B.
• Major mechanical engine failure. [Engine - 2.0L Dura-
Engine]
• Engine knock during accelera- • DTC detected. • REFER to WDS.
tion and glow plug indicator is
flashing
• Engine knock during accelera- • Fuel injector(s). • REFER to WDS.
tion
• Major mechanical engine failure. • REFER to Section 303-01B.
Engine]
lator.
• Excessive fuel consumption and • DTC detected. • REFER to WDS.
glow plug indicator is flashing
• Excessive fuel consumption • Brakes binding. • CHECK the braking system.
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(DW) Diesel

• Vehicle overloaded, or excessive • ADVISE the customer about the
wind resistance (roof racks, effects of overloading the vehicle
towing etc). and wind resistance on the fuel
consumption.
element.
ment.
• Fuel system leak(s). • CHECK the system for fuel
leak(s). REPAIR or INSTALL
new parts as necessary.
necessary.
• Incorrect engine oil. • INSTALL a new oil filter and en-
gine oil.
• Generator. • REFER to WDS.
• Turbocharger vacuum dia- • REFER to Section 303-04C.
phragm unit. [Fuel Charging and
ing Belt]
• Turbocharger. • REFER to Section 303-04C.
[Fuel Charging and
• Slipping clutch. If equipped. •
• Low cylinder compression. • REFER to Section 303-00.
[Engine System - Gen-
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(DW) Diesel

• REFER to WDS.
restrictions.
• REFER to WDS.
• Engine cuts out during hard ac- • CMP sensor. • REFER to WDS.
celeration
lator.
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GENERAL PROCEDURES
Fuel Injection Component Cleaning
General Equipment
Pneumatic vacuum gun CAUTION: Make sure that any protective
clothing worn is clean and made from
lint-free non-flocking material.
Name Specification
CAUTION: Make sure that any protective
Cleaning Fluid W-M5B411-A gloves worn are new and are of the
non-powdered latex type.
CAUTION: Before using the cleaning fluid,
WARNING: Do not smoke or carry lighted protect all electrical components and
tobacco or open flame of any type when connectors with lint-free non-flocking
working on or near any fuel related material.
components. Highly flammable mixtures 1. Using a new brush that will not lose its
are always present and may ignite. bristles, brush cleaning fluid onto the
Failure to follow these instructions may components being removed and onto the
result in personal injury. surrounding area.
WARNING: Do not carry out any repairs to 2. Using the pneumatic vacuum gun, remove
the fuel injection system with the engine all traces of cleaning fluid and foreign
running. The fuel pressure within the material.
system can be as high as 1600 bar. 3. Dispose of any unused cleaning fluid and
Failure to follow this instruction may the brush after completing the repair.
WARNING: Eye protection must be worn
at all times when working on or near any
fuel related components. Failure to follow
injury.
CAUTION: Make sure that the workshop
area in which the vehicle is being worked
on is as clean and dust-free as possible.
Areas in which work on clutches, brakes
or where welding or machining are
carried out are not suitable in view of the
risk of contamination to the fuel system.
CAUTION: Make sure that clean
non-plated tools are used. Clean tools
using a new brush that will not lose its
bristles and fresh cleaning fluid, prior to
starting work on the vehicle.
CAUTION: Use a steel topped workbench
and cover it with clean, lint-free
non-flocking material.
CAUTION: Make sure that all parts
removed from the vehicle are placed on
the lint-free non-flocking material.
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(DW) Diesel

Fuel Injectors — VIN Plate Emission Level Code: S

Special Tool(s) tolerances and fine clearances. It is
Hand Pressure Pump with cleanliness is observed when working
Adapter Kit with these components. Always install
310-110 blanking plugs to any open orifices or
lines.
Gauge Bolt Angle CAUTION: Do not disassemble fuel
303-174 (21-540) injectors or clean the nozzles, even with
an ultrasonic cleaner. Always install new
fuel injectors when required.
General Equipment
Pneumatic vacuum gun to the fuel injection system components
to prevent foreign matter ingress to the
World Diagnostic System (WDS) (418-F224) components.
1. Remove the EGR valve tube. For additional
tobacco or open flame of any type when Duratorq-TDCi (DW) Diesel, REMOVAL
working on or near any fuel related AND INSTALLATION, Exhaust Manifold to
components. Highly flammable mixtures Exhaust Gas Recirculation (EGR) Valve
are always present and may ignite. Tube]
Failure to follow these instructions may 2. Remove the air cleaner. For additional
result in personal injury. information, refer to Section 303-12.[Intake
WARNING: This procedure involves fuel AND INSTALLATION, Air Cleaner - 2.0L
handling. Be prepared for fuel spillage at Duratorq-TDCi (DW) Diesel]
all times and always observe fuel 3. Remove the turbocharger intake pipe
handling precautions. Failure to follow support bracket retaining bolt.
injury.
system can be as high as 1600 bar.
personal injury.
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(DW) Diesel

4. Detach the fuel injector wiring harness.
• Disconnect the fuel injector electrical
connectors.
• Press in the injector wiring harness retain-
ing clips. Detach the injector wiring harness
and secure to one side.

table(s).
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(DW) Diesel

Number
4 - Camshaft position sensor
1 - Engine wiring harness (CMP) electrical connector
retaining clip
See Removal Detail 5 - Manifold absolute pressure
2 - Fuel filter supply and return connector
fuel lines support bracket
See Removal Detail 6 - Intake air temperature (IAT)
See Removal Detail 7 - Intake manifold intake tube
See Removal Detail
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(DW) Diesel

Number Number
8 - Throttle vacuum control pipe 11 - Intake manifold retaining
See Removal Detail bolts
9 - Positive crankcase
ventilation (PCV) oil return 12 - Intake manifold
hose See Removal Detail
13 - Intake manifold seals
10 - PCV breather hose quick
release coupling
See Removal Detail
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(DW) Diesel

Item Part Description 8. Detach the fuel tank to fuel filter fuel supply
Number line quick release coupling. For additional
14 - Fuel injector high-pressure System - General Information, GENERAL
fuel supply lines PROCEDURES, Quick Release Coupling]
See Removal Detail
fuel supply line support
grommets
16 - Fuel injector fuel return pipe
connections
See Removal Detail
17 - Fuel injector retaining
bracket nuts
18 - Fuel injectors 9. NOTE: Make sure the hand pressure pump
See Installation Detail arrow indicating the direction of fuel flow is
pointing towards the fuel filter.
19 - Fuel injector to cylinder head
sealing washer Install the special tool between the fuel
tank fuel supply line quick release coupling
20 - Fuel injector seals and the fuel filter union.
6. NOTE: Do not install the engine upper cover at

this stage.
7. CAUTION: The generator must be
protected from contamination. Failure
to follow this instruction may cause
premature failure of the generator.
Protect the generator with lint-free material
to prevent contamination.
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(DW) Diesel

10. Using the special tool, prime the fuel 16. Connect the fuel tank to fuel filter fuel
system. supply line quick release coupling. For
• Operate the hand pump until it becomes additional information, refer to Section 310-00.
firm when squeezed. [Fuel System - General Information,
• Squeeze and hold the hand pump for 10 GENERAL PROCEDURES, Quick Release
Coupling]
seconds.
• Release the hand pump.
• Squeeze and hold the hand pump for a
further 10 seconds.
• Release the hand pump.
17. Remove the lint-free material.

18. NOTE: If a set of new fuel injectors are
installed that do not have the same fuel injector
calibration code as those originally fitted, use
WDS Program Module Routine and program
11. Remove the lint-free material. the new fuel injectors calibration code into the
powertrain control module (PCM). Failure to
12. CAUTION: Do not operate the starter follow this instruction may cause injector ticking
motor for longer than 10 seconds at a noise, combustion noise and possibly incorrect
time. After 10 seconds, turn the emissions.
ignition to position 0 and allow the
starter motor to cool for 30 seconds Using WDS, Module Programming
before attempting to start the engine function. Program the PCM with the fuel
again. injector calibration code.
Start the engine and allow to idle until it
reaches normal operating temperature.
13. Stop the engine.
14. Protect the generator with lint-free
material to prevent contamination.

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(DW) Diesel

Removal Details Item 9 : Positive crankcase ventilation (PCV)
oil return hose
Item 1 : Engine wiring harness retaining clip 1. Disconnect the PCV oil return hose from
1. Detach the engine wiring harness retaining the oil filler tube.
clip from the engine timing belt upper Item 10 : PCV breather hose quick release
cover. coupling
Item 2 : Fuel filter supply and return fuel lines 1. Disconnect the PCV breather hose from the
support bracket intake manifold PCV valve.
1. Detach the fuel filter supply and return • Press in the release clip.
lines support bracket from the engine
• Remove the timing belt upper cover
retaining bolts.
• Slide the timing belt upper cover upwards to
disengage the cover retaining tang.
Item 12 : Intake manifold

CAUTION: Take care not to place
excessive strain on the fuel pump fuel
supply lines when removing the intake
manifold.
1. Detach the fuel pump fuel supply line from
Item 7 : Intake manifold intake tube

1. Disconnect the intake manifold intake tube
from the throttle body.
Item 8 : Throttle vacuum control pipe
1. Disconnect the throttle vacuum control
pipe from the throttle vacuum control
actuator.
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(DW) Diesel

Item 14 : Fuel injector high-pressure fuel Installation Details
supply lines
Item 20 : Fuel injector seals
CAUTION: Make sure that the 1. Press the new fuel injector seal into the
high-pressure fuel supply line remains in cylinder head.
injection system.
1. Clean the fuel injectors, fuel injection
supply manifold, high-pressure fuel supply
lines and surrounding areas. For additional
information, refer to Fuel Injection
Component Cleaning in this section.
2. Detach the high-pressure fuel supply line
unions from the fuel injector and the fuel
injection supply manifold.
Item 18 : Fuel injectors
fuel supply line, the fuel injector and the CAUTION: Fuel injectors are in matched
fuel injection supply manifold. sets and all four injectors must have the
4. Remove and discard the high-pressure fuel same calibration code.
supply line. 1. NOTE: The example shown is to indicate the
5. Install new blanking plugs to the open location of the code only.
threaded ports on the fuel injector and the Make sure that the fuel injector calibration
fuel injection supply manifold. codes of all four fuel injectors match.
Item 16 : Fuel injector fuel return pipe
connections
1. Disconnect the fuel injector fuel return
pipes.
1. Pull down the release clip.
2. Remove the fuel injector fuel return pipe
with a twisting motion.
2. Install blanking plugs to the open ends of

the fuel return pipes and the fuel injectors.
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(DW) Diesel

2. Make sure the fuel injector retaining NOTE: Maintain pressure on the high-pressure
bracket retaining clip is correctly installed. fuel supply line to keep the line in contact with the
NOTE: If it is not possible to correctly install the
new high-pressure fuel supply line, it will be
necessary to remove the remaining high-pressure
manifold.
the fuel injection supply manifold and the
3. Remove and discard the blanking cap from fuel injectors.
the injector nozzle. 3. Install the fuel injector high-pressure fuel
Item 17 : Fuel injector retaining bracket nuts supply lines.
1. Install the fuel injector retaining bracket • Finger tighten the high-pressure fuel supply
nuts finger tight. line unions.
Item 16 : Fuel injector fuel return pipe 4. NOTE: Tighten the fuel injector retaining
connections bracket nuts so that the fuel injector retaining
1. Remove and discard the blanking plugs bracket remains level.
from the fuel injectors and the fuel injector Using the special tool tighten the fuel
return pipe connections. injector retaining bracket nuts in two
Item 15 : Fuel injector high-pressure fuel stages.
supply line support grommets 1. Stage 1: 4 Nm
1. Install the fuel injector high-pressure fuel 2. Stage 2: 45 degrees
supply line support grommets to the
cylinder head.
supply lines
the fuel injector and the fuel injection
the fuel injection system.
CAUTION: Do not allow the unions to hit
the ends of the high-pressure fuel supply
line. Failure to follow this instruction may 5. CAUTION: Individual high-pressure fuel
result in damage to the ends of the line supply lines must have both unions
and allow foreign material to enter the tightened before continuing on to the
fuel injection system. next high-pressure fuel supply line.
CAUTION: Make sure the tool used to result in damage to the high-pressure
tighten the high-pressure fuel supply line fuel supply lines.
this is where there is most material. Tighten the high-pressure fuel supply line
Failure to follow this instruction may unions.
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(DW) Diesel

Item 12 : Intake manifold Item 11 : Intake manifold retaining bolts
1. Install the fuel pump fuel supply line to the 1. Tighten the intake manifold retaining bolts
intake manifold. in two stages in the sequence shown.
• Stage 1: 4 Nm
• Stage 2: 9 Nm
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(DW) Diesel

Item 10 : PCV breather hose quick release
coupling
NOTE: Make sure that the PCV hose and quick
release coupling are clean and free from any oil
residue.
oil return hose
NOTE: Make sure that the PCV oil return hose is
clean and free from any oil residue as this will
reduce the installation grip of the PCV hose.
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(DW) Diesel

Fuel Injection Supply Manifold — VIN Plate Emission Level Code: S

Special Tool(s)
Hand Pressure Pump with to the fuel injection system components
Adapter Kit to prevent foreign matter ingress to the
310-110 components.
1. Remove the EGR valve tube. For additional
General Equipment [Engine Emission Control - 2.0L
Pneumatic vacuum gun AND INSTALLATION, Exhaust Manifold to
Exhaust Gas Recirculation (EGR) Valve
Tube]
WARNING: Do not smoke or carry lighted information, refer to Section 303-12.[Intake
tobacco or open flame of any type when Air Distribution and Filtering, REMOVAL
working on or near any fuel related AND INSTALLATION, Air Cleaner - 2.0L
components. Highly flammable mixtures Duratorq-TDCi (DW) Diesel]
Failure to follow these instructions may 3. Remove the turbocharger intake pipe
result in personal injury. support bracket retaining bolt.

injury.
WARNING: Wait at least one minute after 4. Detach the fuel injector wiring harness.
the engine stops before commencing any • Disconnect the fuel injector electrical
repair to the fuel injection system. Failure connectors.
to follow this instruction may result in • Press in the injector wiring harness retain-
personal injury. ing clips. Detach the injector wiring harness
CAUTION: Diesel fuel injection equipment and secure to one side.
lines.
CAUTION: Do not disassemble fuel
injectors or clean the nozzles, even with
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(DW) Diesel

table(s).

Number
1 - Engine wiring harness See Removal Detail
retaining clip
See Removal Detail 4 - Camshaft position sensor
(CPS) electrical connector
2 - Fuel filter supply and return
fuel lines support bracket 5 - Manifold absolute pressure
See Removal Detail (MAP) sensor electrical
connector
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(DW) Diesel

7 - Intake manifold intake tube
See Removal Detail
8 - Throttle vacuum control pipe
See Removal Detail
9 - Positive crankcase
ventilation (PCV) oil return
hose
See Removal Detail
10 - PCV breather hose quick
release coupling
See Removal Detail
bolts
12 - Intake manifold
See Removal Detail
13 - Intake manifold seals
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(DW) Diesel

Number
17 - Fuel pump to fuel filter fuel
14 - Fuel filter heater electrical supply line retaining clip
connector See Removal Detail
15 - Fuel filter crash protection 18 - Fuel pump to fuel filter fuel
shield supply line quick release
16 - Fuel tank to fuel filter fuel coupling
supply line quick release See Removal Detail
coupling See Installation Detail
See Removal Detail
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(DW) Diesel

Number Number
19 - Engine wiring harness 21 - Fuel filter
retaining clips See Removal Detail
See Removal Detail
22 - Fuel filter support bracket
20 - Fuel filter splash shield

Number
23 - Fuel injection supply fuel supply line support
manifold high-pressure fuel grommets
supply line See Installation Detail
See Removal Detail
See Installation Detail 26 - Fuel injection supply mani-
fold fuel pressure sensor
24 - Fuel injector high-pressure electrical connector
fuel supply lines
See Removal Detail
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(DW) Diesel

Item Part Description 9. Using the special tool, prime the fuel
Number system.
• Operate the hand pump untill it becomes
27 - Fuel injection supply firm when squeezed.
manifold retaining nuts
See Installation Detail • Squeeze and hold the hand pump for 10
seconds.
28 - Fuel injection supply mani- • Release the hand pump.
fold
• Squeeze and hold the hand pump for a
further 10 seconds.
6. NOTE: Do not install the engine upper cover at
this stage. • Release the hand pump.

7. Remove and discard the fuel filter fuel
supply line quick release coupling blanking
plugs.
8. NOTE: Make sure the hand pressure pump
arrow indicating the direction of fuel flow is
Install the special tool between the fuel
tank fuel supply line quick release coupling
and the fuel filter union.

11. CAUTION: Do not operate the starter
motor for longer than 10 seconds at a
time. After 10 seconds, turn the
starter motor to cool for 30 seconds
before attempting to start the engine
again.
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(DW) Diesel

15. Connect the fuel filter to fuel tank fuel Item 3 : Timing belt upper cover
supply line quick release coupling. For 1. Remove the timing belt upper cover.
additional information, refer to Section 310-00. • Remove the timing belt upper cover
[Fuel System - General Information, retaining bolts.
GENERAL PROCEDURES, Quick Release • Slide the timing belt upper cover upwards to
Coupling]
disengage the cover retaining tang.

Item 7 : Intake manifold intake tube

18. Initialize the door window motors. For 1. Disconnect the intake manifold intake tube
additional information, refer to Section 501-11. from the throttle body.
[Glass, Frames and Mechanisms, Item 8 : Throttle vacuum control pipe
GENERAL PROCEDURES, Door Window 1. Disconnect the throttle vacuum control
Motor Initialization] pipe from the throttle vacuum control
actuator.
Removal Details Item 9 : Positive crankcase ventilation (PCV)
oil return hose
Item 1 : Engine wiring harness retaining clip 1. Disconnect the PCV oil return hose from
1. Detach the engine wiring harness retaining the oil filler tube.
clip from the engine timing belt upper
cover.
Item 2 : Fuel filter supply and return fuel lines
support bracket
1. Detach the fuel filter supply and return
lines support bracket from the engine
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(DW) Diesel

Item 10 : PCV breather hose quick release 2. Using a suitable length of fuel resistant
coupling tube, drain the fuel filter into a suitable
1. Disconnect the PCV breather hose from the container.
intake manifold PCV valve.
3. Clean the fuel filter and surrounding area.

Item 12 : Intake manifold refer to Fuel Injection Component
Cleaning in this section.
CAUTION: Take care not to place 4. Detach the fuel filter fuel line quick release
excessive strain on the fuel pump fuel couplings. For additional information, refer
supply lines when removing the intake to Section 310-00.[Fuel System - General
manifold. Information, GENERAL PROCEDURES,
1. Detach the fuel pump fuel supply line from Quick Release Coupling]
unions of the fuel filter and fuel supply
lines.
Item 17 : Fuel pump to fuel filter fuel supply
line retaining clip
1. Detach the fuel pump fuel return line from
the fuel line retaining clip.
Item 19 : Engine wiring harness retaining clips
1. Detach the engine harness retaining clip
from the fuel filter.
Item 21 : Fuel filter
1. Remove the fuel filter from the fuel filter
support bracket.
Item 16, 18 : Fuel tank to fuel filter fuel supply
line quick release coupling
CAUTION: The generator must be
protected from contamination. Failure to
follow this instruction may cause
1. Protect the generator with lint-free material
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(DW) Diesel

Item 23 : Fuel injection supply manifold 5. Install new blanking plugs to the open
high-pressure fuel supply line threaded ports on the fuel injectors and the
high-pressure fuel supply line remains in Installation Details
contact with both the fuel pump and the
Item 27 : Fuel injection supply manifold
retaining nuts
1. Install the fuel injection supply manifold
nuts finger tight.
injection system.
1. Clean the fuel pump, fuel injection supply Item 25 : Fuel injector high-pressure fuel
manifold, high-pressure fuel supply lines supply line support grommets
and surrounding areas. For additional 1. Install the fuel injector high-pressure fuel
information, refer to Fuel Injection supply line support grommets to the
Component Cleaning in this section. cylinder head.
2. Detach the high-pressure fuel supply line Item 24 : Fuel injector high-pressure fuel
unions from the fuel pump and the fuel supply lines
3. Using the pneumatic vacuum gun, vacuum CAUTION: Remove the blanking plugs
foreign material from the high-pressure from the high-pressure fuel supply line,
fuel supply line, the fuel pump and the fuel the fuel injector and the fuel injection
injection supply manifold. supply manifold at the last possible
supply line.
threaded ports on the fuel pump and the CAUTION: Do not allow the unions to hit
fuel injection supply manifold. the ends of the high-pressure fuel supply
line. Failure to follow this instruction may
supply lines
CAUTION: Make sure that the fuel injection system.
high-pressure fuel supply line remains in
injection system.
1. Clean the fuel injectors, fuel injection NOTE: Maintain pressure on the high-pressure
supply manifold, high-pressure fuel supply fuel supply line to keep the line in contact with the
lines and surrounding areas. For additional fuel injector cone and fuel injection supply
information, refer to Fuel Injection manifold while installing the unions.
Component Cleaning in this section. NOTE: If it is not possible to correctly install the
2. Detach the high-pressure fuel supply line new high-pressure fuel supply line, it will be
unions from the fuel injector and the fuel necessary to remove the remaining high-pressure
injection supply manifold. fuel supply lines and to loosen the fuel injection
fuel supply line, the fuel injector and the
manifold.
supply line.
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(DW) Diesel

the fuel injection supply manifold and the Item 18 : Fuel pump to fuel filter fuel supply
fuel injectors. line quick release coupling
3. Install the fuel injector high-pressure fuel 1. Clean the fuel filter and fuel filter to fuel
supply lines. pump fuel supply line. For additional
• Hand tighten the high-pressure fuel supply
line unions.
2. Remove and discard the blanking plug.
Item 23 : Fuel injection supply manifold
3. Connect the fuel filter to fuel pump fuel
high-pressure fuel supply line
supply line quick release coupling
foreign material from the area around the Item 16 : Fuel tank to fuel filter fuel supply line
fuel pump and the fuel injection supply quick release coupling
manifold. 1. Do not connect the fuel tank to fuel filter
2. Remove and discard the blanking plugs fuel supply line at this stage.
from the high-pressure fuel supply line, the Item 12 : Intake manifold
fuel injection supply manifold and the fuel 1. Install the fuel pump fuel supply line to the
pump. intake manifold.
high-pressure fuel supply line.
line unions.
4. Tighten the fuel injection supply manifold
retaining nuts.
5. CAUTION: Individual high-pressure fuel
supply lines must have both unions
tightened before continuing on to the
next high-pressure fuel supply line.
result in damage to the high-pressure
fuel supply lines.
Tighten the fuel injector and the fuel Item 11 : Intake manifold retaining bolts
injection supply manifold high-pressure 1. Tighten the intake manifold retaining bolts
fuel supply line unions. in two stages in the sequence shown.
• Stage 1. 4Nm
Item 20 : Fuel filter splash shield
• Stage 2. 9Nm
NOTE: Do not trap the lint-free material with the
fuel filter splash shield.
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(DW) Diesel
Item 10 : PCV breather hose quick release

coupling
NOTE: Make sure that the PCV hose and quick
release coupling are clean and free from any oil
residue.
oil return hose
NOTE: Make sure that the PCV oil return hose is
clean and free from any oil residue as this will
reduce the installation grip of the PCV hose.
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(DW) Diesel

Fuel Pump

Special Tool(s)
Hand Pressure Pump with tolerances and fine clearances. It is
Adapter Kit therefore essential that absolute
310-110 cleanliness is observed when working
General Equipment lines.
Pneumatic vacuum gun CAUTION: Do not disassemble fuel

injectors or clean the nozzles, even with
tobacco or open flame of any type when CAUTION: Always carry out the cleaning
working on or near any fuel related process before carrying out any repairs
components. Highly flammable mixtures to the fuel injection system components
are always present and may ignite. to prevent foreign matter ingress to the
Failure to follow these instructions may components.
result in personal injury. 1. Remove the EGR valve tube. For additional
WARNING: This procedure involves fuel 303-08B / 303-08C.
handling. Be prepared for fuel spillage at 2. Remove the air cleaner. For additional
all times and always observe fuel information, refer to Section 303-12.
handling precautions. Failure to follow 3. Remove the turbocharger intake pipe
these instructions may result in personal support bracket retaining bolt.
injury.
personal injury.

table(s).
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(DW) Diesel

Number
1 - Positive crankcase sensor electrical connector
ventilation (PCV) oil return
hose 5 - Fuel pump fuel pressure
See Removal Detail regulator electrical connector
2 - Brake booster vacuum pipe 6 - Fuel pump fuel supply line

to vacuum pump quick quick release coupling
release connector See Removal Detail
3 - Turbocharger vacuum con- 7 - Fuel pump fuel return line

trol pipe and fuel pump fuel quick release coupling
return line retaining clip See Removal Detail
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(DW) Diesel

Item Part Description 9. NOTE: Make sure the hand pressure pump
Number arrow indicating the direction of fuel flow is
8 - Fuel injection supply mani-
fold high pressure fuel supply Install the special tool between the fuel
line support bracket tank fuel supply line quick release coupling
manifold high pressure fuel
supply line
See Removal Detail
10 - Fuel pump

6. Do not install the engine upper cover at this
stage.
10. Operate the hand pressure pump at least
30 times.
8. Detach the fuel filter to fuel tank fuel supply
pipe quick release coupling. For additional

again.
Start the engine and allow it to idle until it
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(DW) Diesel

15. Remove the hand pressure pump. Removal Details

oil return hose
1. Remove the PCV oil return hose.
• Disconnect the PCV oil return hose from the
oil filler tube.
• Disconnect the PCV oil return hose from the
intake manifold PCV valve and remove.
Item 2 : Brake booster vacuum pipe to vacuum
pump quick release connector
1. Detach the brake booster vacuum pipe
quick release coupling from the vacuum
pump. For additional information,
16. Connect the fuel filter to fuel tank fuel
supply pipe quick release coupling. For Item 6, 7 : Fuel pump fuel supply line quick
additional information, release coupling
refer to Section 310-00. 1. Clean the fuel pump and surrounding areas.
refer to Fuel Injection Component
Cleaning in this section.
2. Detach the fuel pump fuel supply and fuel
return line quick release couplings. For
3. Install new blanking plugs to the open ends
of the fuel pump fuel supply and fuel return
lines and fuel pump unions.
Item 9 : Fuel injection supply manifold high
pressure fuel supply line
17. Remove the lint-free material. high-pressure fuel supply line remains in
18. Install the engine upper cover. contact with both the fuel pump and the
injection system.
1. Clean the fuel pump, fuel injection supply
manifold, high-pressure fuel supply line
and surrounding areas. For additional
2. Detach the high-pressure fuel supply line
unions from the fuel pump and the fuel
19. Initialize the door window motors. For foreign material from the high-pressure
additional information, fuel supply line, the fuel pump and the fuel
refer to Section 501-11. injection supply manifold.
supply line.
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(DW) Diesel

5. Install new blanking plugs to the open Item 7, 6 : Fuel pump fuel return line quick
threaded ports on the fuel pump and the release coupling
fuel injection supply manifold. 1. Remove and discard the blanking plugs.
2. Connect the fuel pump fuel supply and fuel
Installation Details return line quick release couplings. For
Item 9 : Fuel injection supply manifold high refer to Section 310-00.
pressure fuel supply line
the fuel pump and the fuel injection
CAUTION: Do not allow the unions to hit
the ends of the high-pressure fuel supply
line. Failure to follow this instruction may
fuel injection system.
NOTE: Maintain pressure on the high-pressure
fuel supply line to keep the line in contact with the
NOTE: If it is not possible to correctly install the
new high-pressure fuel supply line, it will be
necessary to remove the remaining high-pressure
fuel pump and the fuel injection supply
manifold.
from the high-pressure fuel supply line, the
fuel injection supply manifold and the fuel
pump.
high-pressure fuel supply line.
line unions.
4. Tighten the fuel injection supply manifold
high-pressure fuel supply line unions.
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(DW) Diesel

Intake Air Shutoff Throttle — VIN Plate Emission Level Code: S

table(s).
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(DW) Diesel

Number
1 - Intake air shutoff throttle air
intake pipe
See Removal Detail
2 - Charge air temperature
connector
4 - Intake air shutoff throttle
vacuum control pipe
See Removal Detail
O-ring seal
7 - Charge air temperature
sensor
8 - MAP sensor
Removal Details
Item 1 : Intake air shutoff throttle air intake

pipe
1. Disconnect the air intake pipe from the
intake air shutoff throttle.
Item 4 : Intake air shutoff throttle vacuum
control pipe
1. Disconnect the intake air shutoff throttle
vacuum control pipe from the air intake
shutoff throttle.
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303-04C-1 Fuel Charging and Controls - Turbocharger 303-04C-1
SECTION 303-04C Fuel Charging and Controls -

Turbocharger
CONTENTS PAGE
SPECIFICATIONS
Turbocharger — 2.0L Duratorq-TDCi (DW) Diesel ........................................................... 303-04C-3

Turbocharger with variable turbine geometry .................................................................. 303-04C-3

Symptom Chart ............................................................................................................... 303-04C-4/5
Pinpoint Tests ................................................................................................................. 303-04C-6/16
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SPECIFICATIONS
Torque Specifications - vehicles with 2.0L diesel engines
Catalytic converter retaining clamp 25 18 -
Catalytic converter retaining nuts 25 18 -
Catalytic converter support bracket retaining nuts 25 18 -
Turbocharger to turbocharger support bracket re- 30 22 -
taining bolt
Turbocharger support bracket retaining bolts 15 11 -
Turbocharger intake pipe retaining bolts 9 - 80
Coolant bypass pipe support bracket retaining bolt 9 - 80
Coolant bypass pipe retaining bolts 18 13 -
Turbocharger oil supply tube to engine block re- 40 30 -
taining bolt
Turbocharger oil supply tube to turbocharger re- 28 21 -
taining bolt
Turbocharger oil return pipe retaining bolts 10 - 89
Turbocharger retaining nuts 25 18 -
Turbocharger retaining stud 10 - 89
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Turbocharger — 2.0L Duratorq-TDCi (DW) Diesel

Turbocharger with variable turbine geometry
The movable guide vanes on the turbine wheel

Item Part Description are adjusted by the turbocharger vacuum canister
Number by means of a connecting rod.
1 - Turbocharger position sen- A position sensor is located centrally on the
sor turbocharger vacuum canister; this forwards the
2 - Turbocharger housing position of the guide vanes to the powertrain
control module (PCM) as an input variable.
3 - Seal
The vacuum to the turbocharger vacuum canister
4 - Connector is metered by the boost control solenoid valve.
The boost control solenoid valve is controlled by
5 - Connecting hose - oil return
the PCM .
6 - Bracket
The bearings of the turbocharger are lubricated by
7 - Banjo bolt the engine's oil circuit via a rigid oil pipe.
8 - Oil line
9 - Banjo bolt
To ensure an optimum torque curve, a Garrett

turbocharger with variable turbine geometry is
used.
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Special Tool(s) 1. Verify the customer concern.

Hand Vacuum/Pressure mechanical or electrical damage.
Pump
416 - D001 (23 - 036A) Visual Inspection Chart
• Oil leak(s) • Wiring harness
Fuel Pressure Gauge • Air cleaner element • Vane adjustment
310-053 (23-046) • Air cleaner outlet solenoid valve
pipe • PCM
• Air cleaner intake
pipe
• Turbocharger oil
General Equipment supply or oil return
tube
Worldwide Diagnostic System (WDS) • Turbocharger intake
(418-F224) pipe
• Turbocharger
vacuum diaphragm
Inspection and Verification unit
NOTE: It is normal for a small amount of • Turbocharger
combustion gas to pass into the crankcase. This housing
gas is scavenged into the air intake system • Charge air cooler
through the positive crankcase ventilation (PCV) • Charge air cooler
system, which incorporates an oil separator. intake pipe and
Some engine oil, in the form of a vapor is carried hose(s)
into the air intake system with the blow-by gases
• Charge air cooler
(this engine oil also contributes to valve seat
outlet pipe and
durability). This means that oil will collect inside
hose(s)
the air intake components and the turbocharger.
This is not an indication that the turbocharger oil 3. If an obvious cause for an observed or
seal has failed. The turbocharger oil seal will not reported concern is found, correct the cause
fail unless the bearings fail first, which will cause (if possible) before proceeding to the next
the turbocharger to become noisy or seize. Do not step.
install a new turbocharger due to oil inside the 4. If the cause is not visually evident, verify the
turbocharger or the air intake components. If a symptom and refer to the Symptom Chart.
leak is detected in the oil supply or return tubes or
connections, locate and rectify the source. Do not
install a new turbocharger due to an oil leak.
Symptom Chart
NOTE: The vacuum diaphragm unit is a fixed part of the turbocharger and cannot be adjusted or re-
newed.
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• Blue smoke with excessive tur- • Turbocharger compressor • GO to Pinpoint Test A
bocharger noise rubbing on housing walls.
• Turbocharger turbine rubbing on
housing walls.
• Turbocharger bearings and oil
seal(s).
• Turbocharger oil supply tube
blocked or damaged.
• Blue smoke without excessive • Turbocharger oil return tube • GO to Pinpoint Test B
turbocharger noise blocked or damaged.
• Poor engine performance • Vacuum diaphragm unit vacuum • CHECK all vacuum line(s) are
line(s). installed and no signs of air leaks
are present. REPAIR as neces-
sary.
• Charge air cooler system. • CHECK the charge air cooler,
charge air cooler pipes and
charge air cooler hoses for leaks
and obstructions. REPAIR as
necessary.
• Air cleaner intake pipe. • CHECK the air cleaner intake
pipe for obstruction. REPAIR the
necessary.
• Unauthorized adjustment of the • The turbocharger boost pressure
vacuum diaphragm unit actuator is factory set and must not be
rod. adjusted. CHECK the paint seal
on the vacuum diaphragm unit
actuator rod has not been bro-
ken. If the paint seal has been
broken, INSTALL a new turbo-
charger. REFER to Turbo-
charger - 2.0L Duratorq-TDCi
(DW) Diesel in this section.
• Vacuum diaphragm unit actuator • CHECK the vacuum diaphragm
rod. unit actuator rod moves freely, If
the vacuum diaphragm unit ac-
tuator rod does not move freely.
CHECK for signs of damage or
signs of foreign material.
REPAIR as necessary.
• Turbocharger boost pressure. • GO to Pinpoint Test C
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Pinpoint Tests
PINPOINT TEST A: BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
1 Remove the engine upper cover.
2 Disconnect the positive crankcase ventilation

(PCV) breather hose from the intake manifold
PCV valve.
- Press in the release clip.
3 Remove the turbocharger intake pipe support

4 Raise and support the vehicle. For additional

information,
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5 Remove the engine undershield.
- Rotate the locking tangs counterclockwise.
6 Detach the turbocharger intake pipe.
7 Inspect the turbocharger rotor vanes for dam-

age.
• Is there visible damage to the rotor vanes?

→ Yes
Go to A2
→ No
Go to A3
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
1 Check the intake air system components for
signs of foreign material.
• Are there any signs of foreign material?
→ Yes
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CLEAN the intake air system components.
INSTALL a new turbocharger. REFER to
Turbocharger - 2.0L Duratorq-TDCi (DW)
Diesel in this section. TEST the system for
normal operation.
→ No
Go to A4
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE: A small amount of movement in the bearings is normal.
1 Make sure the turbocharger rotor spins freely
within the housing.
- 1. With the turbocharger stationary, gently lift
the shaft (the shaft will naturally lay in the
bottom of the bearings).
- 2. Make sure the rotor spins freely within the
housing.
• Does the rotor spin freely within the housing

with no excessive movement?
→ Yes
Go to A4
→ No
Diesel in this section.TEST the system for
normal operation.
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
NOTE: Discard the copper washers.
1 Remove the turbocharger oil supply tube.
2 Using workshop compressed air and a com-

pressed air nozzle, check the oil supply tube for
blockage.
• Is the oil supply tube free from blockage?
→ Yes
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Go to A5
→ No
INSTALL a new turbocharger and turbo-
charger oil supply tube. REFER to Turbo-
charger - 2.0L Duratorq-TDCi (DW) Diesel in
this section.TEST the system for normal
operation.
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE
1 Using a suitable welding filler rod, check the oil
supply tube oil gallery for blockage.
• Is the oil supply tube oil gallery free from

blockage?
→ Yes
Go to A6
→ No
REMOVE the blockage. INSTALL a new
turbocharger. REFER to Turbocharger -
2.0L Duratorq-TDCi (DW) Diesel in this sec-
tion.TEST the system for normal operation.
A6: CHECK THE TURBOCHARGER OIL SUPPLY TUBE NON RETURN VALVE FOR CORRECT
OPERATION AND BLOCKAGE
1 Remove the turbocharger oil supply pipe union
non return valve.
2 Inspect the turbocharger oil supply pipe union

for blockage.
• Is the oil supply pipe union non return valve free
to move and the union free from blockage?
→ Yes
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normal operation.
→ No
INSTALL a new turbocharger and oil supply
pipe non return valve. REFER to Turbo-
charger - 2.0L Duratorq-TDCi (DW) Diesel in
this section.TEST the system for normal
operation.
PINPOINT TEST B: BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER NOISE
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE
information,
NOTE: Discard the gasket.

3 Remove the turbocharger oil return pipe.
4 Check the turbocharger oil return pipe for a

blockage or signs of damage.
• Is the turbocharger oil return pipe free from
blockage and signs of damage?
→ Yes
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GO to Fuel Charging and Controls for further
diagnostics. REFER to Section 303-04B.
[Fuel Charging and Controls - 2.0L
AND TESTING, Fuel Charging and Controls]
→ No
INSTALL a new turbocharger oil return pipe.
PINPOINT TEST C: POOR ENGINE PERFORMANCE
C1: CHECK THE VACUUM CONTROL CIRCUIT FOR VACUUM
1 Disconnect the vacuum line from the turbo-
charger vacuum control solenoid.
2 Install the special tool between the turbocharger

vacuum control solenoid and vacuum line.
3 Start and run the engine.

• With the engine at idle does the special tool in-
dicate a vacuum of 0.325 bar or above?
→ Yes
Go to C2
→ No
Go to C4
C2: CHECK THE VACUUM DIAPHRAGM UNIT ACTUATOR ROD MOVEMENT
information,
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4 Disconnect the vacuum line from the vane ad-

justment diaphragm unit.
5 Install the special tool to the vane adjustment

diaphragm unit.
6 Operate the special tool until a vacuum of 35

Kpa is achieved. Measure the distance travelled
by the vane adjustment diaphragm unit actuator
rod.
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• Does the vane adjustment diaphragm unit ac-

tuator rod move between 9 and 11 mm?
→ Yes
Go to C3
→ No
CHECK for signs of damage or signs of for-
eign material in the turbocharger vanes.
normal operation.
C3: CHECK THE TURBOCHARGER BOOST PRESSURE
1 Remove special tool 416-D001.
2 Connect the vacuum line to the vane adjust-
ment diaphragm unit.
3 Lower the vehicle.
4 Connect WDS to the vehicle data link connector
(DLC).
5 Select the dataloger function.
6 Configure dataloger to read the intake manifold
pressure via the manifold absolute pressure
(MAP) sensor.
8 With the aid of another Technician, raise the
engine speed to 2000 rpm.
9 Observe the readings of special tool 310-053
and the WDS manifold pressure display.
• Is a vacuum of 0.325 bar on the special tool and
boost pressure of 1.5 bar on the WDS manifold
pressure display indicated?
→ Yes
Continue the diagnostic of the engine man-
agement system using WDS.
→ No
normal operation.
C4: CHECK THE VACUUM DIAPHRAGM UNIT VACUUM LINE FOR LEAKS
2 Remove the special tool 310-053.
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3 Install the special tool to the vacuum diaphragm
unit vacuum line.
4 Operate the special tool and observe the

reading.
• Does the special tool hold vacuum?
→ Yes
Go to C5
→ No
Go to C6
C5: CHECK THE TURBOCHARGER VANE ADJUSTMENT SOLENOID VALVE DUTY CYCLE
1 Disconnect Turbocharger vain adjustment so-
lenoid C585.
3 Measure the voltage between C585 pin 1, cir-
cuit 15S-RL50 (GN/BU) harness side and C585
pin 2, circuit 91S-RL50 (BK/BU) harness side.
• With the engine at idle, is the voltage greater

than 10 volts?
→ Yes
INSTALL a new turbocharger vacuum control
solenoid. TEST the system for normal op-
eration.
→ No
Continue the diagnostic of the engine man-
agement system using WDS.
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C6: CHECK THE VACUUM DIAPHRAGM UNIT FOR LEAKS
information,
3 Disconnect the vacuum line from the vacuum

diaphragm unit.
4 Install the special tool to the vane adjustment

diaphragm unit.
5 Operate the special tool and observe the

reading.
• Does the special tool hold vacuum?
→ Yes
INSTALL a new vacuum line. TEST the
→ No
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normal operation.
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Special Tool(s)
Hose Clamp
303-397 (24-003)

2. NOTE: Make sure that the windshield wiper 6. Remove the cowl panel.
motor is in the park position. 1. Detach the cowl panel from the retaining
Disconnect the battery ground cable. For clips.
additional information, refer to Section 414-01. 2. Remove the cowl panel by detaching it from
[Battery, Mounting and Cables, the windshield glass lower weatherstrip.
Disconnect]

bulkhead extension panel.
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7. Remove the bulkhead extension panel. 9. Remove the engine mount retaining bolts.
retaining screws.
2. Detach the bulkhead extension panel from
10. Remove the turbocharger intake pipe

support bracket retaining bolt.
8. Disconnect the positive crankcase

ventilation (PCV) breather hose from the

and table(s).
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Number
1 - Turbocharger outlet pipe re- bracket
taining clamps
2 - Turbocharger outlet pipe bracket retaining bolt
3 - Catalytic converter retaining bracket
clamp
See Removal Detail 9 - Turbocharger variable vane
See Installation Detail solenoid vacuum supply line
See Removal Detail
4 - Catalytic converter retaining
nuts 10 - Turbocharger variable vane
See Installation Detail solenoid wiring harness
See Removal Detail
See Removal Detail
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Number Number
11 - Turbocharger intake pipe 12 - Engine support insulator
retaining bolts retaining bolt

Number
17 - Coolant bypass pipe support
13 - Heater core coolant hose to bracket retaining bolt
coolant bypass pipe retaining See Installation Detail
clamp
See Removal Detail 18 - Coolant bypass pipe
retaining bolts
14 - Heater core coolant hose to See Installation Detail
coolant bypass pipe
19 - Coolant bypass pipe
15 - Coolant bypass hose to See Removal Detail
coolant bypass pipe retaining
clamp 20 - Coolant bypass pipe seal
See Removal Detail
16 - Coolant bypass hose to
coolant bypass pipe
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Number
26 - Turbocharger oil return pipe
21 - Turbocharger variable vane union seal
27 - Turbocharger to exhaust
22 - Turbocharger variable vane manifold lower retaining nuts
solenoid vacuum supply tube
28 - Turbocharger to exhaust
23 - Turbocharger oil supply tube manifold upper retaining nut
to engine block banjo bolt
See Installation Detail 29 - Turbocharger
to engine block banjo seals 30 - Turbocharger oil supply tube
to turbocharger banjo bolt
25 - Turbocharger oil return pipe
union 31 - Turbocharger oil supply tube
banjo seals
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Item Part Description Item 12 : Engine support insulator retaining

Number bolt
32 - Turbocharger oil supply tube 1. CAUTION: Take care not to crush or put
excessive force on the components
33 - Turbocharger retaining stud between the engine and radiator.
13. To install, reverse the removal procedure. Slide the engine towards the radiator.
NOTE: Before installation, make sure that the Item 13 : Heater core coolant hose to coolant
PCV hose quick release coupling is clean and free bypass pipe retaining clamp
from any oil residue. 1. Using the special tool, detach the heater
14. Vehicles with global closing, initialize the core coolant hose to coolant bypass pipe
door window motors. For additional retaining clamp.
Removal Details
Item 3 : Catalytic converter retaining clamp

1. Make a note of the position of the catalytic
converter retaining clamp before removal.
Item 15 : Coolant bypass hose to coolant

bypass pipe retaining clamp
1. Using the special tool, detach the coolant
bypass hose to coolant bypass pipe re-
taining clamp.

1. Detach the catalytic converter from the
turbocharger and secure it to one side.
vacuum supply line
solenoid vacuum supply line from the
Item 19 : Coolant bypass pipe
wiring harness
1. Detach the turbocharger variable vane CAUTION: Take care not to place
solenoid wiring harness from the excessive strain on the surrounding
turbocharger intake pipe. power steering lines, fuel lines and
engine compartment wiring harness
when repositioning the coolant bypass
pipe.
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1. Position the coolant bypass pipe to one Item 4 : Catalytic converter retaining nuts
side to gain access to the turbocharger 1. NOTE: Do not tighten the catalytic converter
retaining nuts. retaining nuts at this stage.
Install the catalytic converter retaining
nuts.
Item 23 : Turbocharger oil supply tube to Item 3 : Catalytic converter retaining clamp
engine block banjo bolt
1. Install the turbocharger oil supply tube in CAUTION: Never use jointing compound
line filter into the engine block turbo- forward of the catalytic converter.
charger oil supply tube banjo bolt. NOTE: The catalytic converter retaining clamp
removed.
1. Install the catalytic converter retaining
clamp.
Item 18 : Coolant bypass pipe retaining bolts

Install the coolant bypass pipe retaining 2. Tighten the catalytic converter retaining
bolts. nuts.
Item 17 : Coolant bypass pipe support bracket Item 2 : Turbocharger outlet pipe
retaining bolt NOTE: Make sure that the inside of the
1. Install the coolant bypass pipe support turbocharger outlet pipe is clean and free from any
bracket retaining bolt hand tight. oil residue, as this will reduce the installation grip
2. Tighten the coolant bypass pipe retaining of the pipe to the turbocharger and charge air
bolts. cooler intake pipe.
3. Tighten the coolant bypass pipe support
4. Slide the engine back to the original
position and install the engine support
insulator bolt.
Item 11 : Turbocharger intake pipe retaining
bolts
NOTE: Make sure that the inside of the
turbocharger outlet pipe is clean and free from any
of the pipe to the turbocharger and charge air
cooler intake pipe.
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303-04D-1 Fuel Charging and Controls — 1.6L (Z6) 303-04D-1
SECTION 303-04D Fuel Charging and Controls —

1.6L (Z6)
CONTENTS PAGE
SPECIFICATIONS
Specifications................................................................................................................... 303-04D-2
Fuel Charging and Controls ............................................................................................. 303-04D-3

Throttle body ................................................................................................................... 303-04D-3
Fuel injection supply manifold ......................................................................................... 303-04D-4
Fuel injector .................................................................................................................... 303-04D-4
Fuel Charging and Controls ............................................................................................. 303-04D-5

Inspection and Verification .............................................................................................. 303-04D-5
Throttle Body ................................................................................................................... 303-04D-6/9

Fuel Injectors ................................................................................................ (23 455 0) 303-04D-10
Fuel Injection Supply Manifold ......................................................................................... 303-04D-11/13
Fuel Charging Wiring Harness ......................................................................................... 303-04D-14
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SPECIFICATIONS

Emission pipe support bracket retaining bolt 21 15 -
Throttle body retaining bolts 21 15 -
Idle air control (IAC) valve retaining bolts 5 - 44
Fuel injection supply manifold retaining bolts 20 15 -
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The throttle body consists of:

Number • Throttle plate
• Accelerator cable cam
1 - Throttle body
• Throttle position (TP) sensor
2 - Fuel injection supply mani- • Idle air control (IAC) valve
fold
The throttle body is mounted to a plastic intake
3 - Fuel injectors manifold and remote from the engine block.
Engine coolant is piped through the throttle body
to assist with rapid warm up of the IAC valve
Throttle body intake air temperature.
The throttle body base idle settings are set during
manufacture and should not be adjusted during
the service life of the component.
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Fuel injection supply manifold
The fuel injection supply manifold acts as a

reservoir of fuel supplying equal fuel pressure to
all four fuel injectors. The reservoir of fuel reduces
the pressure pulsing effect created by the
operation of the fuel injectors.
Fuel injector
The fuel injectors are individualy controled by the

powertrain control module (PCM) by switching the
ground connection of each fuel injector.
Fuel pressure to the fuel injectors is controlled by
the fuel pump. Excess fuel pressure is returned to
the fuel tank through a fuel bypass line located on
the fuel tank.
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General Equipment


• Fuel leaks • Loose or corroded
• Damaged fuel connector(s)
supply manifold • Wiring harness
• Damaged fuel line • Fuel injector(s)
connections
• Throttle body air
leaks
step.
symptom and refer to WDS.
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Throttle Body

table(s).
Brake hose clamp
(Z6)]
3. Detach the accelerator cable.

1. Detach the accelerator cable locking nut.
2. Pull the accelerator outer cable through the
accelerator cable grommet.
3. Detach the accelerator cable grommet from
the accelerator cable support bracket.
4. Rotate the throttle lever clockwise and de-
tach the accelerator inner cable from the
throttle lever.
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Number
1 - Idle Air Control (IAC) valve
2 - Throttle Position (TP) Sensor
3 - Evaporative emission pipe
support bracket retaining bolt
4 - Throttle body retaining bolts
5 - Throttle body coolant hoses
See Removal Detail
6 - Throttle body and IAC valve
assembly
7 - Throttle body O-ring seal
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Number 6. Adjust the accelerator cable.
7 - IAC valve 1. Make sure the throttle body linkage is
against the throttle stop screw.
8 - IAC valve gasket 2. Adjust the throttle cable using the throttle
cable locking nuts.
3. Check the accelerator inner cable free play.
The free play should not be less than 1mm
and not exceed 3mm.
7. Top up the cooling system.
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Removal Details
Item 5 : Throttle body coolant hoses

1. Detach the throttle body coolant hoses and
clamp the coolant hoses using a suitable
brake hose clamp.
Item 5 : Throttle body coolant hoses

1. Connect the throttle body coolant hoses.
2. Remove the brake hose clamp.
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Fuel Injectors (23 455 0)

Removal
1. Remove the fuel injection supply manifold.
For additional information, refer to Fuel
Injection Supply Manifold in this section.
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Name Specification 3. Remove the engine upper cover.

Engine Oil - 5W-30 WSS-M2C911-A
1. WARNING: Do not smoke or carry

lighted tobacco or open flame of any
type when working on or near any fuel
related components. Highly flammable
vapors are always present and may
ignite. Failure to follow these
instructions may result in personal
injury.
all times and always observe fuel 4. Remove the components in the order
handling precautions. Failure to follow indicated in the following illustration(s) and
these instructions may result in personal table(s).
injury.
injury.
Release the fuel system pressure. For
GENERAL PROCEDURES, Fuel System
Pressure Release]
Disconnect]
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Number
nectors
manifold fuel supply line
See Removal Detail
fold retaining bolts
fold assembly
5 - Fuel injector to intake
manifold O-ring seals
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Item Part Description Coupling]
Number
6 - Fuel injector retaining clips
7 - Fuel injectors Item 8 : Fuel injector to fuel supply manifold
O-ring seals
8 - Fuel injector to fuel supply
manifold O-ring seals CAUTION: Do not use silicone grease to
See Installation Detail lubricate O-ring seals as it will block the
fuel injectors.
5. To install, reverse the removal procedure. 1. Lubricate the fuel injector seals with clean
6. Vehicles with global closing, initialize the engine oil to assist with installation.
door window motors. For additional Item 5 : Fuel injector to intake manifold O-ring
information, refer to Section 501-11.[Glass, seals
PROCEDURES, Door Window Motor CAUTION: Do not use silicone grease to
Initialization] lubricate O-ring seals as it will block the
fuel injectors.
Removal Details 1. Lubricate the fuel injector seals with clean
engine oil to assist with installation.
Item 2 : Fuel injection supply manifold fuel
supply line quick release coupling
1. Disconnect the fuel supply line from the
fuel injection supply manifold. For
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Fuel Charging Wiring Harness
1. Disconnect the battery ground cable. For 4. Remove the components in the order
414-01.[Battery, Mounting and Cables, table(s).
Disconnect]

(Z6)]
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Number
1 - Powertrain control module wiring harness electrical
(PCM) upper cover connector
2 - Battery cable wiring harness See Removal Detail
to fuel charging wiring har- 5 - Heated oxygen sensor
ness electrical connector (HO2S) wiring harness
3 - PCM electrical connector electrical connector
See Removal Detail
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Number
retaining clips
See Removal Detail

Number
11 - Intake manifold tuning (IMT)
7 - Engine coolant temperature valve electrical connector
connector 12 - Knock sensor (KS) wiring
harness electrical connector
8 - Throttle position (TP) sensor
electrical connector 13 - Evaporative emissions can-
ister vent solenoid electrical
9 - Idle air control (IAC) valve connector
10 - Intake manifold runner con- retaining clips
trol (IMRC) actuator electrical
connector
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Number
15 - Barometric pressure sensor (VCT) oil control solenoid
electrical connector electrical connector
16 - Generator electrical con- 19 - Power steering pressure
nector (PSP) switch electrical con-
17 - Air conditioning (A/C) com- nector
pressor electrical connector 20 - Fuel charging wiring harness
retaining clips
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Number Number
21 - Fuel charging wiring harness 23 - CKP sensor electrical
retaining clip connector
sensor wiring harness
retaining clip

Number
24 - Camshaft position (CMP) retaining clips
See Removal Detail 29 - Fuel charging wiring harness
25 - Fuel injector electrical con- 5. To install, reverse the removal procedure.

nectors
26 - Ignition coil-on-plug electrical Removal Details
connectors
Item 4 : Catalyst monitor sensor wiring
(EGR) valve electrical con-
nector
wiring harness electrical connector and
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detach the fuel charging wiring harness

from the connector support bracket.
Item 5 : Heated oxygen sensor (HO2S) wiring
1. Disconnect the HO2S wiring harness
electrical connector and detach the fuel
charging wiring harness from the
connector support bracket.
Item 6 : Fuel charging wiring harness retaining
clips
from the fuel charging wiring harness
retaining clips.
retaining clip
retaining clip.
Item 24 : Camshaft position (CMP) sensor
2. Disconnect the CMP electrical connector.
Item 23 : CKP sensor electrical connector

2. Connect the CKP sensor electrical
connector.
Item 22 : Crankshaft position (CKP) sensor
wiring harness retaining clip
CAUTION: The CKP sensor wiring
harness retaining clip must be securely
attached to the CKP wiring harness.
result in damage to the CKP sensor
wiring harness when it comes in contact
with the A/C compressor pulley.
retaining clips
2. Install the fuel charging wiring harness
retaining clips to the engine components.
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303-05-1 Accessory Drive 303-05-1
SECTION 303-05 Accessory Drive

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 303-05-2
Specifications — 1.6L (Z6) ................................................................................................ 303-05-3
Accessory Drive — 1.8L Duratec-HE (MI4) ....................................................................... 303-05-4

1.8L Duratec HE (MI4) engine.......................................................................................... 303-05-4
Accessory Drive — 2.0L Duratorq-TDCi (DW) Diesel........................................................ 303-05-5
Accessory drive system.................................................................................................... 303-05-5
Accessory Drive — 1.6L (Z6) ............................................................................................ 303-05-6/7
Accessory Drive ................................................................................................................ 303-05-8

Accessory Drive Belt Concerns ........................................................................................ 303-05-8/11
Symptom Chart ................................................................................................................ 303-05-12/15
Component Tests............................................................................................................. 303-05-16/17
Accessory Drive Belt — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)........ (31 413 0) 303-05-18/19
Accessory Drive Belt — 2.0L Duratorq-TDCi (DW) Diesel............................. (31 413 0) 303-05-20/21
Accessory Drive Belt — 1.6L (Z6) ................................................................. (31 413 0) 303-05-22/23
Accessory Drive Belt Tensioner — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) ........... 303-05-24/25
Accessory Drive Belt Tensioner — 2.0L Duratorq-TDCi (DW) Diesel ................................ 303-05-26/27
Accessory Drive Belt Tensioner — 1.6L (Z6) .................................................................... 303-05-28
Air Conditioning (A/C) Compressor Belt — 1.8L Duratec-HE (MI4)/2.0L (34 612 0)
Duratec-HE (MI4) ......................................................................................... 303-05-29
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SPECIFICATIONS
Specifications
SPECIFIC ATIONS
Torque Specifications - vehicles with 1.8L or 2.0L engines

Accessory drive belt tensioner re- 25 18 -
taining bolt

Accessory drive belt tensioner re- 48 35 -
taining bolt
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SPECIFICATIONS
Specifications — 1.6L (Z6)
Item Nm lb-ft lb-in
Accessory drive belt tensioner retaining bolts 25 18 -
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Accessory Drive — 1.8L Duratec-HE (MI4)

The short drive belt is an elastic multi-groove belt

which drives the A/C compressor without an
additional tensioning pulley.
The longer drive belt drives the alternator and the
coolant pump. A self-adjusting belt tensioner is
used to tension the belt.

Number
1 - Crankshaft belt pulley
Item Part Description The crankshaft pulley has two running surfaces to
Number drive the multi-groove belts.
1 - Belt tensioner
2 - Coolant pump
3 - Alternator
4 - Elastic multi-groove belt
5 - Air Conditioning (A/C) com-
pressor
6 - Crankshaft belt pulley
7 - Conventional multi-groove
belt
NOTE: The elastic multi-groove belt must not be
re-used.
NOTE: The elastic multi-groove belt of the A/C
compressor is supplied in a service kit containing
the special tools required for installation.
The drive belts for the auxiliary systems are
multi-groove belts.
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Accessory Drive — 2.0L Duratorq-TDCi (DW) Diesel
Accessory drive system

Number
1 - Belt tensioner
2 - Alternator
3 - air conditioning (A/C) com-
pressor
The accessories are driven by the crankshaft via a
poly-V belt.
A self-adjusting belt tensioner is used to tension
the belt.
Wear markings are provided on the housing of the
belt tensioner to indicate belt wear.
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Accessory Drive — 1.6L (Z6)
Vehicles with air conditioning (A/C)

Number
sioner pulley
2 - Power steering pump pulley
3 - Accessory drive belt idler
pulley
4 - Generator
pulley
6 - A/C compressor
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TO MODEL INDEX
Vehicles without air conditioning (A/C)

Number
sioner pulley
2 - Power steering pump pulley
pulley
4 - Generator
5 - Accessory drive belt guide
pulley
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TO MODEL INDEX
Accessory Drive

1. Verify the customer concern. missing from the belt, is the belt condition
2. Visually inspect for obvious signs of considered to be unacceptable.
mechanical damage.

Mechanical
– Damaged or contaminated accessory drive
belt
– Damaged or contaminated pulley(s)
– Incorrect accessory drive belt
– Incorrect fitment of the accessory drive belt
– Accessory drive belt tensioner
– Accessory drive belt idler pulley
– Generator
– Power steering pump Check the accessory drive belt for cracks. If the
– Power steering pump leakage damage exceeds the acceptable limit, install a
– Air conditioning (A/C) compressor new accessory drive belt.
– Pulley(s) • Vehicles with 1.4/1.6L engine and air
– Loose hardware conditioning,
3. If an obvious cause for an observed or • Vehicles with 1.4/1.6L engine, without air
reported concern is found, correct the cause conditioning,
(if possible) before proceeding to the next • Vehicles with 1.8L or 2.0L engine, REFER to
step. Accessory Drive Belt - 1.8L Duratec-HE
(MI4)/2.0L Duratec-HE (MI4) in this section.
• Vehicles with 2.0L diesel engine, REFER to
Accessory Drive Belt Concerns Accessory Drive Belt - 2.0L Duratorq-TDCi
CAUTION: Do not lubricate the accessory (DW) Diesel in this section.
drive belt, accessory drive belt tensioner • Air conditioning compressor belt for vehicles
or idler pulley(s) as potential damage to with 1.4/1.6L engine,
the accessory drive belt material • Air conditioning compressor belt for vehicles
construction, accessory drive belt with 1.8L or 2.0L engine, REFER to Air
tensioner damping mechanism, Conditioning (A/C) Compressor Belt - 1.8L
accessory drive belt tensioner pulley Duratec-HE (MI4)/2.0L Duratec-HE (MI4) in
bearing and idler pulley(s) bearing may this section.
occur. Chunking
Cracking
Chunking describes the condition where long
Accessory drive belts are made from rubber which lengths of rubber become detached from the ribs
hardens with time and can develop cracks. As the of the belt. This is considered to be a failure of the
belt runs on the back of some of the pulleys, the belt.
cracks are opened up. Small cracks are not
considered to be a failure of the belt and up to 15
cracks in a belt rib over a distance of 100 mm may
be considered acceptable. Only if the crack is
deep enough to reach the bottom of the groove to
expose the cord, the cracks exceed the
acceptable limit or any chunks are found to be
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Check the accessory drive belt for damage. If any

chunks are found to be missing, install a new
accessory drive belt.
• Vehicles with 1.4/1.6L engine and air
conditioning,
• Vehicles with 1.4/1.6L engine, without air
conditioning,
• Vehicles with 1.8L or 2.0L engine, REFER to
Accessory Drive Belt - 1.8L Duratec-HE
Accessory Drive Belt - 2.0L Duratorq-TDCi
(DW) Diesel in this section. Check the accessory drive belt for pilling. The
• Air conditioning compressor belt for vehicles condition of the belt should be compared against
with 1.4/1.6L engine, the illustration.
• Air conditioning compressor belt for vehicles
with 1.8L or 2.0L engine, REFER to Air
Conditioning (A/C) Compressor Belt - 1.8L
Duratec-HE (MI4)/2.0L Duratec-HE (MI4) in
this section.
Pilling
Pilling is dust that forms in between the ribs of the
belt from rubber that is worn off the belt when it is
new. There may also be loose particles left on the
belt during the manufacturing process. These are
worn off and form into small balls of rubber that
then get trapped in the grooves of the belt. This
condition will usually clear itself within 4800 km -
8000 km (3000 miles - 5000 miles) of normal
driving.
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• Small scattered pills. Not considered a • Vehicles with 2.0L diesel engine, REFER to
concern. No action required. Accessory Drive Belt - 2.0L Duratorq-TDCi
• Small scattered pills. Not considered a (DW) Diesel in this section.
concern. No action required. • Air conditioning compressor belt for vehicles
• Longer pills up to 50% of the rib height. with 1.4/1.6L engine,
Possible noise concern. INSTALL a new belt if • Air conditioning compressor belt for vehicles
noise is apparent. with 1.8L or 2.0L engine, REFER to Air
• Longer pills up to 50% of the rib height. Conditioning (A/C) Compressor Belt - 1.8L
Possible noise concern. INSTALL a new belt if Duratec-HE (MI4)/2.0L Duratec-HE (MI4) in
noise is apparent. this section.
Fraying
• Heavy deposits in the grooves. Possible noise
and stability concern. INSTALL a new belt. Due to the manufacturing process, the belt edge
1. INSTALL a new accessory drive belt as may appear frayed, but this frayed appearance
necassary. does not necessarily affect the durability or
performance of the belt. If a concern is raised
during a service or repair over the level of fraying
conditioning,
he condition of the belt should be compared ,
• Vehicles with 1.4/1.6L engine, without air against the illustrations.
conditioning, t
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TO MODEL INDEX
Check the accessory drive belt for fraying.
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• No fraying (new belt). Not considered a • Air conditioning compressor belt for vehicles
concern. No action required. with 1.8L or 2.0L engine, REFER to Air
• Fraying just starting. Not considered a concern. Conditioning (A/C) Compressor Belt - 1.8L
No action required. Duratec-HE (MI4)/2.0L Duratec-HE (MI4) in
this section.
• Slight fraying. Not considered a concern. No
Incorrect fitment
action required.
• High amount of fraying without cord cuts. Belt noise can be generated by the belt being
INSTALL a new accessory drive belt. incorrectly fitted on the pulley as shown in the
• High amount of fraying with cord cuts. following illustration. Make sure that all the V
INSTALL a new accessory drive belt. grooves on the belt contact correctly with the
pulley.
2. INSTALL a new accessory drive belt as
necassary.
conditioning,
• Vehicles with 1.4/1.6L engine, without air
conditioning,
Accessory Drive Belt - 2.0L Duratorq-TDCi
(DW) Diesel in this section.
• Air conditioning compressor belt for vehicles
with 1.4/1.6L engine, 3. If the cause is not visually evident, verify the
Symptom Chart
• Accessory drive belt noise • Accessory drive system • CHECK the system with the
engine running and the
accessory drive belt removed
(only run the engine for a very
short period). If a noise is
apparent, the cause is not the
accessory drive system. If a
noise is not apparent, the cause
is the accessory drive system.
CHECK where the noise is
coming from and INSTALL new
TEST the system for normal
operation.
• Use a stethoscope or other lis-
tening device to determine the
source of the noise. INSTALL
new components as necessary.
TEST the system for normal op-
eration.
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• Accessory drive belt incorrectly • CHECK the accessory drive belt
installed. is correctly installed in the pulley
grooves. INSTALL a new ac-
cessory drive belt as necessary.
Vehicles with 1.4/1.6L engine
and air conditioning, Vehicles
with 1.4/ 1.6L engine and without
air conditioning, Vehicles with
1.8L or 2.0L engine, REFER
to Accessory Drive Belt - 1.8L
ratec-HE (MI4) in this section.
Vehicles with 2.0L diesel engine,
REFER to Accessory Drive Belt -
in this section. Air conditioning
compressor belt for vehicles with
1.4/1.6L engine, Air condi-
tioning compressor belt for vehi-
cles with 1.8L or 2.0L engine,
REFER to Air Conditioning (A/C)
Compressor Belt - 1.8L Du-
(MI4) in this section. TEST the
• Pulley(s). • CHECK the pulley(s) for dam-

age, freedom of rotation, stone
entrapment and alignment.
INSTALL new components as
necessary. TEST the system for
normal operation.
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• Lubricant or other contamination. • CHECK the accessory drive belt
for contamination or damage.
RECTIFY the source of the leak
and INSTALL a new accessory
drive belt. Vehicles with 1.4/1.6L
engine and air conditioning,
Vehicles with 1.4/ 1.6L engine
and without air conditioning,
Vehicles with 1.8L or 2.0L en-
gine, REFER to Accessory
Drive Belt - 1.8L Duratec-HE
(MI4)/2.0L Duratec-HE (MI4) in
this section. Vehicles with
2.0L diesel engine, REFER to
Accessory Drive Belt - 2.0L Du-
ratorq-TDCi (DW) Diesel in this
section. Air conditioning com-
pressor belt for vehicles with
1.4/1.6L engine, Air condi-
tioning compressor belt for vehi-
cles with 1.8L or 2.0L engine,
REFER to Air Conditioning (A/C)
Compressor Belt - 1.8L Du-
(MI4) in this section. TEST the
NOTE: Squeal is defined as a • Accessory drive belt tensioner • CHECK the accessory drive belt
continuous shriek, most worn, damaged or contaminated tensioner for correct operation,
noticeable when the engine is with oil. damage or contamination.
being accelerated or with REFER to the Accessory Drive
electrical load. Belt Tensioner Component Test
• Accessory drive belt squeal in this procedure. INSTALL a
new accessory drive belt ten-
sioner as necessary. Vehicles
with 1.8L or 2.0L engine,
REFER to Accessory Drive Belt
Tensioner - 1.8L Duratec-HE
this section.Vehicles with 2.0L
diesel engine, REFER to Ac-
cessory Drive Belt Tensioner -
in this section. TEST the system
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NOTE: Whine is defined as a • Poor surface finish on accessory • REMOVE the accessory drive
continuous noise at the same drive belt idler pulley flat sur- belt. Vehicles with 1.8L or 2.0L
frequency, generally associated face(s). engine, REFER to Accessory
with plastic pulleys. Drive Belt - 1.8L Duratec-HE
• Accessory drive belt whine (MI4)/2.0L Duratec-HE (MI4) in
section. INSPECT the idler pul-
ley(s) for surface finish. INSTALL
a new idler pulley(s) as neces-
sary. TEST the system for nor-
mal operation.
• Accessory drive belt idler pulley • REMOVE the accessory drive

bearing failure. belt. Vehicles with 1.8L or 2.0L
engine, REFER to Accessory
Drive Belt - 1.8L Duratec-HE
section. INSPECT the idler pul-
ley(s) for smooth rotation.
INSTALL a new idler pulley(s) as
necessary. TEST the system for
normal operation.
NOTE: Chirp is defined as a • Pulley misalignment (usually • CHECK that the accessory drive
twittering noise, often intermittent evident at idle). belt is running centrally on the
• Accessory drive belt chirp flat pulleys. TEST the system for
normal operation.
• CHECK the pulleys for excessive
end float and bent flanges.
• With the engine running at idle,
use a stethoscope to identify the
source of the noise. INSTALL
new components as necessary.
eration.
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NOTE: Rattle is defined as a • Accessory drive belt tensioner • CHECK the accessory drive belt
metallic knocking noise hitting the end stops. tensioner for correct operation or
• Accessory drive belt rattle damage. REFER to the Acces-
sory Drive Belt Tensioner Com-
ponent Test in this procedure.
INSTALL a new accessory drive
belt tensioner as necessary.
Vehicles with 1.8L or 2.0L en-
gine, REFER to Accessory Drive
Belt Tensioner - 1.8L Du-
(MI4) in this section.Vehicles with
Accessory Drive Belt Tensioner -
in this section. TEST the system
• Loose components or hardware. • CHECK the components or

hardware for correct installation
and tighten as necessary. TEST
• Accessory drive belt fraying • Accessory drive belt. • CHECK the extent of the fraying
• Pulley(s). by referring to the illustrations
shown in the Visual Inspection
section. Only INSTALL a new
belt if the fraying is within the
criteria quoted in the Visual
Inspection section. TEST the
• CHECK the pulley(s) for dam-
age, freedom of rotation and
alignment. INSTALL new com-
ponents as necessary. TEST the
Component Tests
Accessory Drive Belt Tensioner - Static Check

The accessory drive belt tensioner may be
checked statically as follows:
1. Inspect the area surrounding the accessory
drive belt tensioner for lubricant or other
contamination. Rectify any leaks before
installing a new accessory drive belt tensioner.
If the accessory drive belt tensioner is
contaminated, do not attempt to clean it as the
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damping mechanism inside may be damaged. in this section. TEST the system for normal
INSTALL a new accessory drive belt tensioner operation.
as necessary. Vehicles with 1.8L or 2.0L
engine, REFER to Accessory Drive Belt
Tensioner - 1.8L Duratec-HE (MI4)/2.0L Accessory Drive Belt Tensioner - Dynamic Check
Duratec-HE (MI4) in this section. The accessory drive belt tensioner may be
Vehicles with 2.0L diesel engine, checked dynamically as follows:
1. With the engine running, observe the
Tensioner - 2.0L Duratorq-TDCi (DW) Diesel
accessory drive belt tensioner movement. The
in this section. TEST the system for normal
accessory drive belt tensioner should move
operation.
(respond) when the engine is accelerated
2. Detach the accessory drive belt in the area of rapidly or when the A/C clutch cycles ON and
the accessory drive belt tensioner. OFF (the degree of movement can be up to 4
NOTE: The accessory drive belt tensioner has a mm). If the accessory drive belt tensioner
damping feature, which is usually a friction device, movement is not constant without engine
therefore some friction within the system is acceleration or A/C clutch cycling, a pulley or
normal. shaft is possibly bent, out of round, or the
3. Using the correct tool, move the accessory damping mechanism inside the accessory
drive belt tensioner from its relaxed position drive belt tensioner may be damaged.
through its full stroke and back to the relaxed INSTALL a new accessory drive belt tensioner
position to make sure there is no excessive as necessary. TEST the system for normal
stick, grab or bind, and to make sure there is operation.
tension on the accessory drive belt tensioner 2. Excessive accessory drive belt rideout
spring. (uneven depth of grooves in the accessory
4. Rotate the accessory drive belt tensioner drive belt) may cause excessive accessory
pulley and check for damage, freedom of drive belt tensioner movement. Check the
rotation and alignment. INSTALL a new condition by installing a new accessory drive
accessory drive belt tensioner as necessary. belt. Vehicles with 1.4/1.6L engine and air
Vehicles with 1.8L or 2.0L engine, REFER to conditioning, Vehicles with 1.4/ 1.6L engine
Accessory Drive Belt Tensioner - 1.8L and without air conditioning, Vehicles with
Duratec-HE (MI4)/2.0L Duratec-HE (MI4) in 1.8L or 2.0L engine, REFER to Accessory
this section. Drive Belt - 1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4) in this section.
Vehicles with 2.0L diesel engine, REFER to
Accessory Drive Belt Tensioner - 2.0L
REFER to Accessory Drive
Duratorq-TDCi (DW) Diesel in this section.
Belt - 2.0L Duratorq-TDCi (DW) Diesel in this
section. Air conditioning compressor belt for
5. If the accessory drive belt tensioner meets the vehicles with 1.4/1.6L engine, Air
above criteria, proceed to test the accessory conditioning compressor belt for vehicles with
drive belt tensioner dynamically. If the 1.8L or 2.0L engine, REFER to Air
accessory drive belt tensioner does not meet Conditioning (A/C) Compressor Belt - 1.8L
the above criteria, INSTALL a new accessory Duratec-HE (MI4)/2.0L Duratec-HE (MI4) in
drive belt tensioner. Vehicles with 1.8L or 2.0L this section. TEST the system for normal
engine, REFER to Accessory Drive Belt operation.
Tensioner - 1.8L Duratec-HE (MI4)/2.0L
Tensioner - 2.0L Duratorq-TDCi (DW) Diesel
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Accessory Drive Belt — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (31 413 0)
Removal
1. Remove the air conditioning (A/C) Installation
compressor belt. For additional
information, refer to Air Conditioning (A/C) 1. NOTE: Vehicles without A/C shown, vehicles
Compressor Belt - 1.8L Duratec-HE with A/C similar.
All vehicles

1. Rotate the accessory drive belt tensioner
counterclockwise.
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Accessory Drive Belt — 2.0L Duratorq-TDCi (DW) Diesel (31 413 0)
General Equipment 4. Raise and support the vehicle. For

Dowel with a diameter of 5mm
Removal • Rotate the locking tangs counterclockwise.

Installation
3. Detention the accessory drive belt.
2. Install the accessory drive belt to the ac-
cessery drive belt pulleys in the order in-
counterclockwise.
dicated.
2. Install a suitable dowel with a diameter of
5mm into the hole of the accessory drive
belt tensioner bracket.
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Accessory Drive Belt — 1.6L (Z6) (31 413 0)
Removal and Installation 3. Rotate the accessory drive belt tensioner

clockwise and remove the accessory drive
All vehicles belt.
Vehicles without air conditioning

2. Raise and support the vehicle. 4. To install, reverse the removal procedure.

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Accessory Drive Belt Tensioner — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)


3. Detach the engine wiring harness retaining
additional information, refer to Accessory
clips from the engine.
Drive Belt - 1.8L Duratec-HE (MI4)/2.0L
and position to one side.
• Detach the fuel charging wiring harness
from the retaining clip.
• Disconnect the fuel charging wiring harness
4. Detach the engine wiring harness electrical

connector from the retaining clip and posi-
tion the engine wiring harness one side.

table(s).
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Number
sioner
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Accessory Drive Belt Tensioner — 2.0L Duratorq-TDCi (DW) Diesel
1. Remove the accessory drive belt, For

General Equipment additional information, refer to Accessory
Drive Belt - 2.0L Duratorq-TDCi (DW) Diesel
Dowel with a diameter of 5mm in this section.
table(s).

Number
1 - Accessory drive belt Item 1 : Accessory drive belt tensioner
tensioner CAUTION: Make sure the accessory drive
See Removal Detail belt tensioner locating pin is aligned with
See Installation Detail the corresponding hole in the accessory
drive belt tensioner mounting bracket.
Removal Details
Item 1 : Accessory drive belt tensioner

1. Detention the accessory drive belt
tensioner and remove the dowel with a
diameter of 5mm.
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1. Reset the accessory drive belt tensioner to

the detention position.
counterclockwise.
2. Install a suitable dowel with a diameter of
5mm into the hole of the accessory drive
belt tensioner bracket.
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Accessory Drive Belt Tensioner — 1.6L (Z6)
1. Remove the accessory drive belt. For 2. Remove the components in the order
additional information, refer to Accessory indicated in the following illustration(s) and
Drive Belt - 1.6L (Z6) in this section. table(s).

Number
sioner
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Air Conditioning (A/C) Compressor Belt — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE

(MI4) (34 612 0)

General Equipment • Rotate the locking tangs counterclockwise.
Knife
Removal
CAUTION: The A/C compressor belt must
not be reused as it is designed to be
stretched onto the pulleys only once.
Failure to follow this instruction may lead
to premature failure of the belt.
CAUTION: It is not necessary to remove
the A/C compressor cover to remove the
A/C compressor belt. Failure to follow
this instruction may result in damage to 4. Using a suitable knife, cut the A/C
the A/C compressor. compressor belt and remove.
1. Remove the right-hand front wheel and tire.
204-04.[Wheels and Tires, REMOVAL AND Installation
2. Remove the right-hand front splash shield. NOTE: Install a new A/C compressor belt.
1. Wipe clean both of the pulleys to make sure
that the A/C compressor belt does not slip
during installation.
2. Install the installation tool (supplied in the
parts kit) to the crankshaft pulley at the 9
o'clock position (A/C compressor cover
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3. Install the A/C compressor belt (A/C 6. NOTE: Only turn the engine in the normal
compressor cover shown removed for direction of rotation.
clarity). NOTE: Guide the A/C compressor belt onto the
1. Install the belt around the A/C compressor pulleys as the engine is rotated.
pulley.
Turn the engine until the installation tool is
2. Install the belt around the installation tool. at the 6 o'clock position (A/C compressor
cover shown removed for clarity).
4. Install the belt guide tool (supplied in the

parts kit) to the A/C compressor belt 7. Remove the installation tool.
8. NOTE: Only turn the engine in the normal
• The curved end of the tool fits around the direction of rotation.
belt and the flat end of the tool fits between
the A/C compressor and the oil pan. Turn the engine through 360 degrees.
9. Check that the A/C compressor belt is
correctly positioned in the grooves of the
pulleys.
• Repeat the installation procedure if the A/C
compressor belt is misaligned.
• Discard the installation tool if the A/C
compressor belt is fitted correctly.
10. Remove the belt guide tool from the A/C
compressor belt.
• Discard the belt guide tool.
• Rotate the locking tangs clockwise.
5. Make sure that the A/C compressor belt is

correctly positioned in the grooves of the
A/C compressor pulley.
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12. Install the right-hand front splash shield.
13. Install the right-hand front wheel and tire.

refer to Section 204-04.[Wheels and Tires,
REMOVAL AND INSTALLATION, Wheel
and Tire]
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303-06-1 Starting System 303-06-1
SECTION 303-06 Starting System

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 303-06-2
Torque Specifications - vehicles with 1.8L or 2.0L engines .............................................. 303-06-2
Starting System — 2.0L Duratorq-TDCi (DW) Diesel ........................................................ 303-06-3

Starting system ................................................................................................................ 303-06-3
Starting System................................................................................................................. 303-06-4

Symptom Chart ................................................................................................................ 303-06-4
Pinpoint Tests .................................................................................................................. 303-06-5/13
Starter Motor — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) ....................................... 303-06-14/16

Starter Motor — 2.0L Duratorq-TDCi (DW) Diesel............................................................. 303-06-17/18
Starter Motor — 1.6L (Z6) ................................................................................................. 303-06-19
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SPECIFICATIONS
Torque Specifications - vehicles with 1.6L engines

Ignition switch to starter motor cable 7 - 62
retaining nut
Starter motor positive cable retaining 12 9 -
nut

retaining nut
nut
Starter motor wiring harness support 20 15 -
bracket retaining nuts
Starter motor retaining studs 25 18 -

retaining nut
nut
Torque Specifications - vehicles with 1.6L (Z6) engines

Starter motor positive cable retaining 10 - 89
nut
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Starting System — 2.0L Duratorq-TDCi (DW) Diesel

Starting system
The starter motor is supplied with a voltage until

the rotational speed of the engine is higher than
the rotational speed of the starter motor, or until a
time stored in the PCM has elapsed.
The speed signal provided by the CKP sensor is
used for monitoring the starting procedure.
Fuel feed is interrupted by the PCM if the engine
does not start.

Number
1 - Ignition switch
2 - Starter relay
3 - Starter motor
4 - powertrain
control module (PCM)
5 - crankshaft
position (CKP) sensor
The starter system is equipped with the so-called
"Smart Starting" strategy. This makes starting
faster and protects the starter.
The "Smart Starting" strategy is stored in the
PCM.
The starter motor relay is supplied with voltage
from the PCM when the ignition switch is turned to
position III.
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Starting System
Refer to Wiring Diagrams Section 303-06, for Mechanical Electrical

schematic and connector information. • Starter motor • Fuse(s)
• Battery
• Starter relay
• Start inhibit relay
1. Verify the customer concern. • Wiring harness(es)
2. Visually inspect for obvious signs of • Loose or corroded
mechanical or electrical damage. connector(s)
Visual Inspection Chart 3. If an obvious cause for an observed or
Symptom Chart
• The engine does not crank and • Battery • GO to Pinpoint Test A
relay does not click • Starter motor
• Starter relay
• Start inhibit relay
• Battery junction box (BJB)
• Powertrain control module
(PCM)
• Circuit(s)
• The engine does not crank but • Battery • GO to Pinpoint Test B
relay clicks • Starter relay
• Circuit(s)
• Starter motor
• Ignition switch
• The engine cranks slowly • Battery • GO to Pinpoint Test C
• Circuit(s)
• Starter motor
• Unusual starter motor noise • Starter motor • CHECK flywheel ring gear.
• Flywheel ring gear • INSPECT starter motor for
alignment or cracked casing.
Make sure the mounting bolts
are tightened. If necessary,
INSTALL a new starter motor.
REFER to Starter Motor - 1.8L
ratec-HE (MI4)
/ Starter Motor - 2.0L Dura-
torq-TDCi (DW) Diesel in this
section. TEST the system for
normal operation.
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• The starter spins but the engine • Starter motor • INSPECT the flywheel ring gear
does not crank for missing teeth. REFER to
Section 303-00.[Engine System -
PROCEDURES, Flywheel In-
spection] CHECK starter motor
for correct mounting. If concern
persists, INSTALL a new starter
motor. REFER to Starter Motor -
Duratec-HE (MI4)
/ Starter Motor - 2.0L Dura-
torq-TDCi (DW) Diesel in this
section. TEST the system for
normal operation..
Pinpoint Tests
PINPOINT TEST A: THE ENGINE DOES NOT CRANK AND THE RELAY DOES NOT CLICK
A1: CHECK THE BATTERY
1 CHECK the battery voltage using WDS.
• Is the battery OK?
→ Yes
Vehicles with manual transaxle.
GO to A5
Vehicles with automatic transaxle.
GO to A2
→ No
INSTALL a new battery. REFER to Section
REMOVAL AND INSTALLATION, Battery -
1.4L Duratec-16V (Sigma)/1.6L (Z6 )/1.6L
A2: CHECK THE STARTER INHIBIT RELAY FOR VOLTAGE
1 Disconnect Start Inhibit Relay C1001.
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3 Measure the voltages between the start inhibit
relay C1001 pin 1, circuit 15-BB16 (GN/OG),
harness side and ground; and the starter inhibit
relay C1001 pin 3, circuit 50-BB16 (GY/BK),
• Are the voltages greater than 10 volts?

→ Yes
GO to A3
→ No
REPAIR the circuit 15-BB16 (GN/OG) or
circuit 50-BB16 (GY/BK) as necessary.
A3: CHECK CIRCUIT 31S-TA36 (BK/GN) FOR OPEN
2 Disconnect Transmission Control Unit C812.
3 Measure the resistance between the start inhibit
relay C1001 pin 2, circuit 31S-TA36 (BK/GN),
harness side and the transmission control unit
C812 pin 10, circuit 31S-TA36 (BK/GN), har-
ness side.

→ Yes
GO to A4
→ No
REPAIR the circuit. TEST the system for
normal operation. If the concern persists,
INSTALL a new transmission control unit.
A4: CHECK CIRCUIT 50-BB16A (GY/BK) TO 50-BB16B (GY/BK) FOR OPEN
1 Connect Transmission Control Unit C812.
2 Disconnect Starter Relay C1013.
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3 Measure the resistance between the start inhibit
relay C1001 pin 5, circuit 50-BB16A (GY/BK),
harness side and the starter relay C1013 pin 1,
circuit 50-BB16B (GY/BK), harness side.

→ Yes
INSTALL a new start inhibit relay. TEST the
system for normal operation. If the concern
persists. GO to A5
→ No
CHECK and REPAIR circuit 50S-BB16
(GY/BK). If the circuit is OK. INSTALL a new
BJB. TEST the system for normal operation.
A5: CHECK THE STARTER RELAY FOR VOLTAGE
1 Connect Start Inhibit Relay C1001.
2 Disconnect Starter Relay C1013.
4 Measure the voltage between the starter relay
C1013 pin 1, circuit 50-BB16 (GY/BK) harness
side and ground; and the starter relay pin 3,
circuit 30-BB17 (RD), harness side and ground.

→ Yes
Vehicles with 1.6L engine. GO to A6
Vehicles with 1.8L or 2.0L engine.
GO to A7
Vehicles with 2.0L diesel engine.

GO to A9
→ No
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REPAIR the circuit 50-BB16 (GN/OG) or
circuit 30-BB17 (RD) as necessary. TEST
A6: CHECK CIRCUIT 31S-BB16 (BK/RD) FOR OPEN
2 Disconnect PCM C594.
3 Measure the resistance between the starter
relay C1013 pin 2, circuit 31S-BB16 (BK/RD),
harness side and the PCM C594 pin F30, circuit
31S-BB16 (BK/RD), harness side.

→ Yes
INSTALL a new starter relay. TEST the
→ No
INSTALL a new PCM. TEST the system for
normal operation.
harness side and the PCM C690 pin 4, circuit

→ Yes
→ No
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303-14.[Electronic Engine Controls,
REMOVAL AND INSTALLATION, Power-
train Control Module (PCM) - 1.8L Du-
ratec-HE (MI4)/2.0L Duratec-HE (MI4), Ve-
hicles Without: PCM Security Shield]
REFER to Section 303-14.[Electronic Engine
Controls, REMOVAL AND INSTALLATION,
Powertrain Control Module (PCM) - 1.8L
Vehicles With: PCM Security Shield] TEST
harness side and the PCM C419 pin A1, circuit

→ Yes
→ No
train Control Module (PCM) - 1.6L Dura-
torq-TDCi (DV) Diesel/2.0L Duratorq-TDCi
(DW) Diesel] TEST the system for normal
operation.
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harness side and the PCM C418 pin D1, circuit

→ Yes
→ No
train Control Module (PCM) - 1.6L Dura-
torq-TDCi (DV) Diesel/2.0L Duratorq-TDCi
(DW) Diesel] TEST the system for normal
operation.
PINPOINT TEST B: THE ENGINE DOES NOT CRANK AND THE RELAY CLICKS
B1: CHECK THE STARTER MOTOR FOR SWITCHED VOLTAGE
1 Disconnect Starter Motor C110b.
3 Measure the voltage between the starter motor
C110b, circuit 50-BB12 (GY), harness side and
ground.

→ Yes
GO to B2
→ No
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REPAIR the circuit 50-BB12 (GY). TEST the
persists. INSTALL a new CJB. TEST the
B2: CHECK THE STARTER MOTOR FOR BATTERY VOLTAGE
1 Connect Starter Motor C110b.
2 Disconnect Starter Motor 110a.
C110a, circuit 30-BB10 (RD), harness side and
ground.

→ Yes
REFER to Starter Motor - 1.8L Duratec-HE
/ Starter Motor - 2.0L Duratorq-TDCi (DW)
normal operation.
→ No
CLEAN and TIGHTEN all positive battery
cable connections. TEST the system for
normal operation. If the concern persists.
INSTALL a new battery to starter motor ca-
ble. REFER to Section 414-01.[Battery,
Mounting and Cables, REMOVAL AND
INSTALLATION, Battery Cables - 1.8L Du-
ratec-HE (MI4)/2.0L Duratec-HE (MI4)]
REFER to Section 414-01.[Battery, Mounting
and Cables, REMOVAL AND
ratorq-TDCi (DW) Diesel] TEST the system
PINPOINT TEST C: THE ENGINE CRANKS SLOWLY
C1: CHECK THE STARTER MOTOR LOAD
1 Carry out the starter motor Component Test
using WDS.
• Is the starter motor OK?
→ Yes
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GO to C2
→ No
REFER to Starter Motor - 1.8L Duratec-HE
/ Starter Motor - 2.0L Duratorq-TDCi (DW)
normal operation.
C2: CHECK FOR VOLTAGE DROP
pin 30, component side and the battery positive
terminal with the ignition switch in position III.
• Is the voltage less than 0.5 volts?

→ Yes
GO to C3
→ No
CLEAN and TIGHTEN all positive battery
cable connections. TEST the system for
normal operation. If the concern persists.
INSTALL a new battery to starter motor ca-
ble. REFER to Section 414-01.[Battery,
Mounting and Cables, REMOVAL AND
ratec-HE (MI4)/2.0L Duratec-HE (MI4)]
REFER to Section 414-01.[Battery, Mounting
and Cables, REMOVAL AND
ratorq-TDCi (DW) Diesel] TEST the system
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C3: CHECK FOR GROUND CONNECTION
case and battery negative terminal with the ig-
nition switch in position III.
• Is the voltage less than 0.5 volts?

→ Yes
DIAGNOSE the battery and charging sys-
tem. REFER to Section 414-00.[Charging
System - General Information, DIAGNOSIS
AND TESTING, Charging System]
→ No
CLEAN and TIGHTEN all battery negative
connections, starter motor mounting and
body to engine ground straps. TEST the
persists, INSTALL a new battery negative
cable. TEST the system for normal opera-
tion.
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Starter Motor — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)


table(s).
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Number
3 - Starter motor
1 - Starter motor electrical See Removal Detail
connectors See Installation Detail
See Removal Detail
See Installation Detail 5. To install, reverse the removal procedure.
2 - Starter motor wiring harness 6. Initialize the door window motors. For
support bracket additional information,
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Removal Details Item 3 : Starter motor

1. Install a new starter motor gasket into the
Item 1 : Starter motor electrical connectors transaxle housing prior to installing the
1. Disconnect the ignition switch and battery starter motor.
to starter motor solenoid cables.

1. Discard the starter motor gasket.
Item 1 : Starter motor electrical connectors

1. Connect the ignition switch and battery to
starter motor solenoid cables.
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Starter Motor — 2.0L Duratorq-TDCi (DW) Diesel

2. Remove the engine upper cover
table(s).

Number
2 - Ignition switch to starter mo-
1 - Battery to starter motor so- tor solenoid cable electrical
lenoid cable electrical con- connector retaining nut
nector retaining nut
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Number
3 - Starter motor electrical con-
nector
4 - Starter motor


CAUTION: The starter motor locating
dowel must be fitted to the starter motor
before the starter motor is installed to the
engine.
1. Install the starter motor locating dowel.
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Starter Motor — 1.6L (Z6)
1. Disconnect the battery ground cable. For 2. Raise and support the vehicle.
table(s).
Disconnect]

Number
6 - Starter motor
1 - Ignition switch to starter mo-
tor solenoid cable electrical 4. To install, reverse the removal procedure.
connector
2 - Battery to starter motor door window motors. For additional
solenoid cable electrical information, refer to Section 501-11.[Glass,
connector shield Frames and Mechanisms, GENERAL
See Removal Detail PROCEDURES, Door Window Motor
Initialization]
3 - Battery to starter motor so-
lenoid cable retaining clips
lenoid cable electrical con-
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Removal Details
Item 2 : Battery to starter motor solenoid cable

electrical connector shield
1. Unclip the battery to starter motor solenoid
electrical connector shield.
Item 5 : Starter motor retaining bolts

NOTE: Make sure that the engine earth cable
bracket is installed behind the starter motor lower
retaining bolt.
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303-07A-1 Engine Ignition — 1.8L Duratec-HE (MI4)/2.0L 303-07A-1

Duratec-HE (MI4)
SECTION 303-07A Engine Ignition — 1.8L Duratec-HE

CONTENTS PAGE
SPECIFICATIONS
Specifications................................................................................................................. 303-07A-2
Engine Ignition ............................................................................................................... 303-07A-3

1.8l Duratec HE (MI4) engine ........................................................................................ 303-07A-3
Engine Ignition ............................................................................................................... 303-07A-4

Inspection and Verification ............................................................................................ 303-07A-4
Symptom Chart ............................................................................................................. 303-07A-4
Ignition Coil-On-Plug — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)......................... 303-07A-5
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Duratec-HE (MI4)
SPECIFICATIONS
Item Nm lb-ft lb-in
Ignition coil-on-plug retaining bolt(s) 10 - 89
Spark plug(s) 12 10 -
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Duratec-HE (MI4)

Engine Ignition
1.8l Duratec HE (MI4) engine
Ignition system
The CMP sensor identifies cylinder "1" by

Item Part Description scanning the camshaft timing pulley.
Number
The ignition system requires this information in
1 - Direct ignition coil order to synchronise the ignition sparks of the
individual ignition coils.
An ignition system with direct ignition coils is used.
If the CMP sensor should fail, the system uses the
This provides a more stable combustion process
signal from the CKP and ignites cylinders "1" and
with reduced exhaust gas emissions.
"4" or "2" and "3" together. Here ignition takes
On this ignition system, a direct ignition coil is place in the working cycle of one cylinder and in
needed for each spark plug, and this is located the exhaust cycle of the other.
directly on the spark plug.
WDS can be used to diagnose the system.
Only one ignition spark is generated for each
direct ignition coil in the compression stroke.
To do this, the Powertrain Control Module (PCM)
evaluates the signals from the Camshaft Position
(CMP) sensor and the Crankshaft Position (CKP)
sensor.
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Duratec-HE (MI4)

Engine Ignition

Worldwide Diagnostic System (WDS) (if possible) before proceeding to the next
step.
Inspection and Verification symptom and refer to the Symptom Chart.
2. Visually inspect for obvious signs of electrical
damage.

Electrical
• Circuit(s)
• Wiring harness
• Electrical connector(s)
• Spark plug(s)
• Ignition coil-on-plug(s)
• Powertrain control module (PCM)
Symptom Chart
• Engine misfire • Spark plug(s). • CARRY OUT a KV test using
WDS.
• Circuit(s) • REFER to WDS.
• PCM.
• PCM calibration.
• Engine stumbling • Spark plug(s). • CARRY OUT a KV test using
WDS.
• PCM.
• PCM calibration.
• Engine lacks power • Spark plug(s). • CARRY OUT a KV test using
WDS.
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Duratec-HE (MI4)

Ignition Coil-On-Plug — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)

table(s).
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Duratec-HE (MI4)

Number
connector(s)
2 - Ignition coil-on-plug(s)
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303-07B-1 303-07B-1
Glow Plug System — 2.0L Duratorq-TDCi (DW) Diesel
SECTION 303-07B Glow Plug System — 2.0L Duratorq-

TDCi (DW) Diesel
CONTENTS PAGE
SPECIFICATIONS
Glow Plug System............................................................................................................ 303-07B-3

Pre-heating control.......................................................................................................... 303-07B-3
Glow Plug System............................................................................................................ 303-07B-4

Glow Plugs — 2.0L Duratorq-TDCi (DW) Diesel .............................................................. 303-07B-5
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303-07B-2 303-07B-2
SPECIFICATIONS
Fuel pump fuel supply line support 5 - 44
EGR tube support bracket retaining 10 - 89
bolt
EGR tube to EGR valve retaining 10 - 89
bolts
EGR cooler to EGR valve retaining 10 - 89
bolts
EGR valve retaining bolts 5 - 44
EGR valve lower retaining bolt 8 - 71
EGR cooler tube heat shield retaining 20 15 -
nut
EGR cooler support bracket retaining 30 22 -
nut
EGR cooler tube retaining nuts 10 - 89
Glow plug wire electrical connector 2 - 18
retaining nuts
Glow plugs 10 - 89
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303-07B-3 303-07B-3

Glow Plug System
Pre-heating control
The PCM receives information on current coolant

temperature from the engine coolant temperature
(ECT) sensor.
The PCM controls the per-heating and
post-heating phases, using the coolant
temperature and engine speed as control
parameters.
The post-heating phase begins after the engine
has started. After approx. 30 seconds, the
pencil-type glow plugs are switched off by the
PCM .
The pencil-type glow plugs are also shut off if the
engine speed reaches 2500 rev/min.

Number
1 - Battery junction box
2 - Connections to the power-
train control module (PCM)
3 - Ground connection
4 - Pencil-type glow plugs
5 - Pre-heating control module
The pre-heating system consists of one
pencil-type glow plug per combustion chamber, a
pre-heating control module, the PCM and a glow
plug indicator light and the corresponding
electrical connections.
The pre-heating control module and the glow-plug
indicator light are actuated by the PCM.
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303-07B-4 303-07B-4

Glow Plug System

damage.

Electrical
• Fuse(s)
• Relay
• Wiring harness
• Glow plug(s)
• Glow plug wire
system.
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303-07B-5 303-07B-5

Glow Plugs — 2.0L Duratorq-TDCi (DW) Diesel
1. Remove the exhaust gas recirculation REMOVAL AND INSTALLATION, Exhaust

(EGR) valve. For additional information, Gas Recirculation (EGR) Valve]
refer to Section 303-08B.[Engine Emission 2. Remove the components in the order
Control - 2.0L Duratorq-TDCi (DW) Diesel, indicated in the following illustration(s) and
table(s).
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303-07B-6 303-07B-6

Number
1 - Positive crankcase hose
ventilation (PCV) hose
NOTE: Make sure that the PVC hose and quick
See Removal Detail
See Installation Detail release coupling are clean and free from any oil
residue
2 - EGR cooler tube heat shield
3 - EGR cooler tube retaining
nuts
4 - EGR cooler support bracket
retaining nut
5 - EGR cooler and EGR cooler
tube
See Removal Detail
6 - EGR cooler tube gasket
7 - Glow plug wire electrical
connectors
8 - Glow plugs
Removal Details

hose
1. Disconnect the PCV breather hose from the
Item 5 : EGR cooler and EGR cooler tube

1. Detach the EGR cooler and EGR cooler
tube from the exhaust manifold and
position to one side.
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303-07C-1 Engine Ignition — 1.6L (Z6) 303-07C-1
SECTION 303-07C Engine Ignition — 1.6L (Z6)

CONTENTS PAGE
SPECIFICATIONS
Engine Ignition ................................................................................................................. 303-07C-3

Ignition coil ...................................................................................................................... 303-07C-4
Engine Ignition ................................................................................................................. 303-07C-5

Symptom Chart ............................................................................................................... 303-07C-5
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SPECIFICATIONS
Spark plugs
Description mm
Spark plug gap 1.0
Ignition coil retaining bolt 9 - 80
Spark plug 18 13 -
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Engine Ignition

Number
1 - Ignition coils
2 - Spark plugs
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Ignition coil
Each engine cylinder has its own ignition coil. The

ignition coil is bolted to the camshaft cover and the
ignition coil retaining bolt makes up part of the
high tension ignition circuit. By using four ignition
coils, the work load on the coils is reduced. The
ignition coil is connected to the spark plug by an
integrated high tension plug cap. The close
proximity of the ignition coil to the spark plug
reduces the losses of energy from the high tension
circuit.
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Engine Ignition

1. Verify the customer concern. reported concern is found, correct the cause
Electrical
• Wiring harness
• Spark plug(s)
• Ignition coil pack(s)
Symptom Chart
• Engine cranks but does not start • Spark plug(s). • CARRY OUT a Power Balance
• Ignition coil pack(s) spark plug test using WDS. INSTALL a new
connection. spark plug(s) or ignition coil
pack(s) as necessary. TEST the
• Ignition coil pack(s). • CARRY OUT an engine diag-
• PCM. nostic using WDS. INSTALL new
ignition components as neces-
mal operation.
• Engine misfire • Spark plug(s). • CARRY OUT a Power Balance
• Ignition coil pack(s). NOTE:
• PCM. • Only install an updated module
• PCM calibration. calibration if the vehicle exhibits
a concern related to the
calibration update.
• CARRY OUT an engine diag-
nostic using WDS. INSTALL new
sary. CARRY OUT a module
programming routine using
WDS. TEST the system for
normal operation.
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• Low fuel pressure. • CHECK the fuel pressure.
• Fuel pump. INSTALL new fuel system
eration.
• Low cylinder compression. • CARRY OUT an engine com-
pression check.
• Worn or damaged vale(s), valve • REMOVE the cylinder head.
[Engine - 1.6L (Z6),
Head]
• Engine stumbling • Spark plugs. • CARRY OUT a Power Balance
• Ignition coil pack(s). NOTE:
• PCM. • Only install an updated module
• PCM calibration. calibration if the vehicle exhibits
a concern related to the
calibration update.
• CARRY OUT an engine diag-
sary. CARRY OUT a module
programming routine using
WDS. TEST the system for
normal operation.
eration.
pression check.
Head]
G384942 en 09/2004 2004.75 Focus

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• Engine lacks power • Spark plugs. • CARRY OUT a Power Balance
• Ignition coil pack(s). • CARRY OUT an engine diag-
mal operation.
eration.
pression check.
Head]
G384942 en 09/2004 2004.75 Focus

TO MODEL INDEX
303-08A-1 Engine Emission Control — 1.8L Duratec-HE 303-08A-1

SECTION 303-08A Engine Emission Control — 1.8L

Duratec-HE (MI4)/2.0L Duratec-HE (MI4)
CONTENTS PAGE
SPECIFICATIONS
Engine Emission Control.................................................................................................. 303-08A-3

Symptom Chart ............................................................................................................... 303-08A-3
Exhaust Gas Recirculation (EGR) Valve .......................................................................... 303-08A-4/6

Crankcase Vent Oil Separator.......................................................................................... 303-08A-7
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SPECIFICATIONS
Exhaust gas recirculation (EGR) valve bolts 25 18 –
EGR valve outlet tube union 55 41 –
Crankcase vent oil separator retaining bolts 10 – 89
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Engine Emission Control

step.

– Hose(s)/hose joints – Electrical
– Gasket(s) connector(s)
– Positive crankcase – Wiring harness
ventilation (PCV) – Fuse(s)
valve – Relay
– PCV separator – EGR valve
– Exhaust gas recir- – Powertain control
culation (EGR) valve module (PCM)
Symptom Chart
• Poor engine performance • EGR valve. • Using WDS, CHECK the EGR
Valve Duty Cycle input signal to
the EGR vacuum regulator
valve. If the result is 0%,
REMOVE the EGR valve.
REFER to Exhaust Gas Recir-
culation (EGR) Valve in this sec-
tion. INSPECT the EGR valve
and valve seat for damage.
Make sure that the EGR valve is
in the closed position. If the EGR
valve is not closed. INSTALL a
new EGR valve. TEST the sys-
tem for normal operation. If the
result is not 0% continue the
engine diagnostic using WDS.
• Excessive crankcase pressure • Blocked or damaged PCV • CHECK the PCV system com-
hose(s). ponents for blockages, CLEAN
• Blocked crankcase vent oil or INSTALL new components as
separator. necessary.
• Worn or damaged engine com- • REFER to Section 303-01A /
ponents. 303-01B.
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Special Tool(s)
Hose Clamp
303-397

information,
3. Remove the upper engine cover. 5. Remove the components in the order
table(s).
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Number 7. Initialize the door window motors. For
nector
2 - Throttle body to EGR valve
coolant hose
See Removal Detail
3 - EGR valve
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Removal Details
Item 2 : Throttle body to EGR valve coolant

hose
1. Using the special tool, remove the throttle
body to EGR valve coolant hose from the
throttle body.
2. Using the special tool, remove the throttle

body to EGR valve coolant hose from the
EGR valve.
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Crankcase Vent Oil Separator
Removal 4. Remove the crankcase vent oil separator.

1. Remove the intake manifold. For additional • Discard the gasket.
[Engine - 1.8L Duratec-HE
(MI4)/2.0L Duratec-HE (MI4), IN-VEHICLE
REPAIR, Intake Manifold]
tion (PCV) hose from the PCV valve.
Installation
1. NOTE: Install a new crankcase vent oil
separator gasket.
NOTE: Make sure that the PCV hose is clean and
3. Remove the PCV valve from the crankcase free from any oil residue as this will reduce the
vent oil separator. installation grip of the PCV hose.
1. Push in the locking tangs. To install, reverse the removal procedure.
2. Twist the PCV valve to remove.
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303-08B-1 Engine Emission Control — 2.0L Duratorq-TDCi (DW) 303-08B-1

Diesel
SECTION 303-08B Engine Emission Control — 2.0L

Duratorq-TDCi (DW) Diesel
CONTENTS PAGE
SPECIFICATIONS
Engine Emission Control.................................................................................................. 303-08B-3

EGR system.................................................................................................................... 303-08B-3
Engine Emission Control.................................................................................................. 303-08B-4

Principles of Operation .................................................................................................... 303-08B-4
Symptom Chart ............................................................................................................... 303-08B-5
Pinpoint Tests ................................................................................................................. 303-08B-5/7
Exhaust Gas Recirculation (EGR) Valve .......................................................................... 303-08B-8/9

Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube ................................. 303-08B-10/12
Exhaust Gas Recirculation (EGR) Cooler......................................................................... 303-08B-13/16
Positive Crankcase Ventilation (PCV) Valve ................................................. (29 623 0) 303-08B-17
Crankcase Vent Oil Separator.......................................................................................... 303-08B-18
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Diesel
SPECIFICATIONS
Item Nm lb-ft lb-in
Exhaust gas recirculation (EGR) tube to EGR valve 10 - 89
retaining bolts
Fuel pump fuel supply line support bracket retaining 5 - 44
nut
EGR tube support bracket retaning bolt 10 - 89
EGR cooler to EGR valve retaining bolts 10 - 89
EGR valve retaining bolts 5 - 44
EGR valve lower retaining bolt 8 - 71
EGR cooler tube heat shield retaining nut 10 - 89
EGR cooler support bracket retaining nut 30 22 -
EGR cooler tube retaining nuts 10 - 89
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Diesel

EGR system
The EGR stepper motor is actuated directly by the

Item Part Description Powertrain Control Module (PCM) using
Number pulse-width modulated signals.
1 - Exhaust Gas The drawn in mass air flow, is calculated by the
Recirculation (EGR) cooler Mass Air Flow (MAF) sensor and used as an input
2 - Connecting pipe to the inlet variable.
manifold The recirculated exhaust gas is cooled by an EGR
3 - Valve cover/air filter housing cooler before it is forwarded to the inlet manifold.
connecting pipe
4 - EGR stepper
motor
5 - Connection to the cylinder
head
The EGR system consists of an EGR stepper

motor, the EGR cooler and a connecting pipe to
the inlet manifold.
The recirculated quantity of exhaust gas is
regulated by an EGR stepper motor and can
thereby be adjusted accurately.
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Diesel

Positive Crankcase Ventilation (PCV) system

General Equipment
(418-F224)
Principles of Operation
Exhaust Gas Recirculation (EGR) system

To maintain the standards of low exhaust
emission levels required of today's engines, the
EGR system on this engine is fully electronically
controlled.
The EGR valve is a proportional electric motor
controlled directly by a duty-cycle signal from the
powertrain control module (PCM). Integrated into
Number
the EGR valve is a valve position sensor. The
signal from the EGR valve position sensor allows 1 - PCV valve diaphragm
for the precise control of the timing and the
quantity of exhaust gas to be recirculated. If the 2 - PCV valve
EGR valve becomes inoperative or fails to close The PCV system is made up of an oil separator
completely, the PCM will raise a diagnostic trouble chamber connected to the crankcase by a hose.
code (DTC) and the instrument cluster The oil separator chamber is an integral part of the
malfunction indicator lamp (MIL) will be engine intake manifold.
illuminated.
The crankcase pressure is controlled by a
If a new EGR valve is installed. The base setting diaphragm operated PCV valve built into the oil
(closed position) value must be configured to the separator. As the pressure in the oil separator
PCM. This is initiated using WDS. If the base reduces, the diaphragm valve closes against the
setting is not configured to the PCM, the setting force of the PCV valve spring, so closing the PCV
from the previous EGR valve will be used and the valve. As the crankcase pressure rises, the PCV
control function of the EGR system will be valve is pushed open assisted by the PCV valve
incorrect. spring. This allows the positive crankcase gasses
The EGR system is fitted with an EGR cooler. The to be scavenged by the air intake system.
EGR cooler reduces the temperature of the
exhaust gasses being returned to the intake
system. By reducing the EGR temperature, the Inspection and Verification
intake air charge density is not adversely affected,
so maintaining the optimum fueling
characteristics. 2. Visually inspect for obvious signs of
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Diesel
Mechanical Electrical 3. If an obvious cause for an observed or

• Exhaust gas • Electrical connector reported concern is found, correct the cause
recirculation (EGR) • Wiring harness (if possible) before proceeding to the next step
valve 4. If the cause is not visually evident, verify the
• EGR tube symptom and refer to the Symptom Chart.
• EGR cooler
• EGR tube clamp
• Gasket
• PCV hose
• PCV oil separator
Symptom Chart
• Excessive exhaust black smoke • EGR valve. • GO to Pinpoint Test A
• Excessive crankcase pressure • Blocked or damaged PCV • GO to Pinpoint Test B
hose(s).
• Blocked PCV oil separator.
• Worn or damaged engine com- • REFER to Section 303-01B.
ponents. [Engine - 2.0L Dura-
Engine]
Pinpoint Tests
PINPOINT TEST A: EXCESSIVE EXHAUST BLACK SMOKE
A1: CHECK THE EXHAUST GAS RECIRCULATION VALVE DUTY CYCLE
1 Using WDS, CHECK the Exhaust Gas Recir-
culation Valve Duty Cycle input signal to the
EGR valve.
• With the engine at idle and below 30ºC, is the
Exhaust Gas Recirculation Valve Duty Cycle in-
put signal 0%?
→ Yes
GO to A2
→ No
Continue the diagnostic using WDS.
A2: CHECK THE EXHAUST GAS RECIRCULATION VALVE FOR DAMAGE
1 Remove the EGR valve. REFER to Exhaust
Gas Recirculation (EGR) Valve in this section.
2 INSPECT the EGR valve and valve seat for
damage.
• Is the EGR valve undamaged and in the closed
position?
→ Yes
G357258 en 09/2004 2004.75 Focus
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Diesel

To continue diagnostics, REFER to Section
AND TESTING, Fuel Charging and Controls]
→ No
INSTALL a new EGR valve. REFER to Sec-
tion 303-08C.[Engine Emission Control -
1.6L (Z6), REMOVAL AND INSTALLATION,
Exhaust Gas Recirculation (EGR) Valve]
PINPOINT TEST B: EXCESSIVE CRANKCASE PRESSURE
B1: CHECK THE PCV HOSE FOR BLOCKAGE
1 Remove the PCV hose.
2 Inspect the PCV hose for blockage.

• Is the PCV hose free from blockage?
→ Yes
GO to B2
→ No
CLEAN or INSTALL a new PCV hose as
necessary. TEST the system for normal op-
eration.
B2: CHECK THE PCV VALVE FOR DAMAGE
1 Inspect the PCV valve for damage or blockage.
• Is the PCV valve spring undamaged and the

PCV valve free from blockage?
G357258 en 09/2004 2004.75 Focus
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Diesel

→ Yes
TEST the system for normal operation. If the
concern persists, REFER to Section 303-01B.
[Engine - 2.0L Duratorq-TDCi (DW)
Diesel, DIAGNOSIS AND TESTING, Engine]
→ No
CLEAN the PCV oil separator and PCV valve
assembly or INSTALL a new intake manifold
as necessary. REFER to Section 303-01B.
[Engine - 2.0L Duratorq-TDCi (DW)
Diesel, IN-VEHICLE REPAIR, Intake Mani-
fold - VIN Plate Emission Level Code: K]
REFER to Section 303-01B.[Engine - 2.0L
Duratorq-TDCi (DW) Diesel, IN-VEHICLE
REPAIR, Intake Manifold - VIN Plate Emis-
sion Level Code: S] TEST the system for
normal operation.
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Diesel

General Equipment 2. Remove the air cleaner. For additional

Worldwide Diagnostic System (WDS) Air Distribution and Filtering, REMOVAL
1. Remove the EGR valve tube. For additional AND INSTALLATION, Air Cleaner - 2.0L
information, refer to Exhaust Manifold to Duratorq-TDCi (DW) Diesel]
Exhaust Gas Recirculation (EGR) Valve 3. Remove the components in the order
Tube in this section. indicated in the following illustration(s) and
table(s).
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Diesel

Number
Item 5 : EGR valve
1 - EGR valve electrical con- 1. To aid installation of a new EGR valve,
nector loosely install the EGR valve lower
2 - EGR cooler to EGR valve retaining bolt to the new EGR valve.
retaining bolts Item 4 : EGR valve retaining bolts
See Installation Detail 1. Install the EGR valve retaining bolts finger
3 - EGR valve lower retaining tight.
bolt Item 3 : EGR valve lower retaining bolt
See Removal Detail 1. Do not tighten the EGR valve lower
See Installation Detail retaining bolt at this stage.
4 - EGR valve retaining bolts Item 2 : EGR cooler to EGR valve retaining
See Installation Detail bolts
5 - EGR valve 1. Install the EGR cooler to EGR valve
See Removal Detail retaining bolts.
See Installation Detail Tighten the EGR valve retaining bolts in the
order indicated.
4. To install, reverse the removal procedure. 1. Tighten the EGR cooler to EGR valve
5. Vehicles with global closing, initialize the retaining bolts.
door window motors. For additional 2. Tighten the EGR valve retaining bolts.
information, refer to Section 501-11.[Glass, 3. Tighten the EGR valve lower retaining bolt.
Initialization]
6. If a new EGR valve is installed, reset the
EGR valve base value using Worldwide
Diagnostic System (WDS).
Removal Details
Item 3 : EGR valve lower retaining bolt

NOTE: Do not remove the EGR valve lower
retaining bolt.
1. Loosen the EGR valve retaining bolt.
Item 5 : EGR valve
1. Slide the EGR valve off the EGR valve
support bracket.
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Diesel

Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube
1. NOTE: Make sure that the windshield wiper

motor is in the park position.
5. Remove the cowl panel.
Disconnect the battery ground cable. For 1. Detach the cowl panel from the retaining
additional information, refer to Section 414-01. clips.
2. Remove the cowl panel by detaching it from
the windshield glass lower weatherstrip.
Disconnect]

retaining screws.

table(s).
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Diesel

Number
4 - EGR valve tube to EGR
1 - Fuel pump fuel supply line valve retaining bolts
support bracket See Installation Detail
See Removal Detail
5 - EGR valve tube
2 - EGR valve tube support
bracket retaining bolt 8. To install, reverse the removal procedure.
3 - EGR valve tube retaining 9. Vehicles with global closing, initialize the
clamp door window motors. For additional
See Removal Detail information, refer to Section 501-11.[Glass,
See Installation Detail Frames and Mechanisms, GENERAL
Initialization]
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Diesel

Removal Details
Item 1 : Fuel pump fuel supply line support

bracket
1. Detach the fuel pump fuel supply line from
the fuel pump fuel supply line support
bracket.
Item 3 : EGR valve tube retaining clamp
1. Make a note of the position of the EGR
valve tube retaining clamp before removal.
Item 4 : EGR valve tube to EGR valve retaining

bolts
1. NOTE: Do not tighten the EGR valve tube to
EGR valve retaining bolts at this stage.
Install the EGR valve tube to EGR valve
retaining bolts.
Item 3 : EGR valve tube retaining clamp
1. NOTE: A new EGR valve tube retaining clamp
removed.
Install a new EGR valve tube retaining
clamp.
2. Tighten the EGR valve tube to EGR valve
retaining bolts.
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Diesel

Exhaust Gas Recirculation (EGR) Cooler

Special Tool(s)
Hose Clamp
303-397 (24-003)

2. NOTE: Make sure that the windshield wiper 6. Remove the cowl panel.
motor is in the park position. 1. Detach the cowl panel from the retaining
Disconnect the battery ground cable. For clips.
additional information, refer to Section 2. Remove the cowl panel by detaching it from
414-01.[Battery, Mounting and Cables, the windshield glass lower weatherstrip.
Disconnect]

retaining screws.
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Diesel

table(s).

Number
2 - Heater core to EGR cooler
1 - Turbocharger intake pipe coolant hose quick release
positive crankcase coupling
ventilation (PCV) hose See Removal Detail
See Removal Detail
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Diesel

Number
Item 1 : Turbocharger intake pipe positive
3 - Coolant bypass pipe to EGR crankcase ventilation (PCV) hose
cooler coolant hose retaining 1. Detach the PCV hose from the turbo-
clamp charger intake pipe.
See Removal Detail
4 - Coolant bypass pipe to EGR
cooler coolant hose
5 - EGR cooler tube heat shield
6 - EGR cooler retaining clamp
See Removal Detail
7 - EGR cooler tube retaining
nuts
8 - EGR cooler tube
9 - EGR cooler tube gasket
Item 2 : Heater core to EGR cooler coolant
10 - EGR cooler support bracket hose quick release coupling
retaining nut 1. Disconnect the heater core to EGR cooler
See Installation Detail coolant hose quick release connector.
11 - EGR cooler retaining bolts • Remove the retaining clip.
12 - EGR cooler

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Diesel

Item 3 : Coolant bypass pipe to EGR cooler Item 6 : EGR cooler retaining clamp
coolant hose retaining clamp 1. NOTE: A new EGR cooler retaining clamp must
1. Using the special tool, detach the coolant be installed in the same position as removed.
bypass pipe to EGR cooler coolant hose
retaining clamp. Install a new EGR cooler retaining clamp.
Item 6 : EGR cooler retaining clamp 2. Tighten the EGR cooler components in the
1. Make a note of the position of the EGR order indicated.
cooler retaining clamp before removal. 1. EGR cooler retaining bolts.
2. EGR cooler tube retaining nuts.
3. EGR cooler retaining nut.
Item 11 : EGR cooler retaining bolts

1. NOTE: Do not tighten the EGR cooler retaining
Install the EGR cooler retaining bolts.
Item 10 : EGR cooler support bracket retaining
nut
1. NOTE: Do not tighten the EGR cooler support
bracket retaining nut at this stage.
Install the EGR cooler support bracket
retaining nut.
Item 7 : EGR cooler tube retaining nuts
1. NOTE: Do not tighten the EGR cooler tube
Install the EGR cooler tube retaining nuts.
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Diesel

Positive Crankcase Ventilation (PCV) Valve (29 623 0)
NOTE: The PCV valve and the intake manifold are

one component and can not be serviced
separately.
303-01B / 303-01C.
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Diesel

1. NOTE: The crankcase vent oil separator and

intake manifold are one component and can
not be serviced separately.
Remove the intake manifold. For additional
303-01B / 303-01C.
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303-08C-1 Engine Emission Control — 1.6L (Z6) 303-08C-1
SECTION 303-08C Engine Emission Control — 1.6L

(Z6)
CONTENTS PAGE
SPECIFICATIONS
Engine Emission Control.................................................................................................. 303-08C-3
Engine Emission Control.................................................................................................. 303-08C-4

Symptom Chart ............................................................................................................... 303-08C-4/5
Exhaust Gas Recirculation (EGR) Valve .......................................................................... 303-08C-6/8

Crankcase Vent Oil Separator.......................................................................................... 303-08C-9/10
Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube ................................. 303-08C-11/13
Exhaust Gas Recirculation (EGR) Valve Outlet Tube....................................................... 303-08C-14
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SPECIFICATIONS
Item Nm lb-ft lb-in
Exhaust manifold to exhaust gas recirculation 9 - 80
(EGR) vale tube support bracket retaining nut
Exhaust manifold to EGR vale tube, EGR valve 9 - 80
retaining nuts
EGR valve retaining nuts 21 15 -
Exhaust manifold to EGR valve tube, exhaust 39 29 -
manifold union
EGR outlet valve tube union 39 29 -
EGR valve outlet tube support bracket retaining bolt 9 - 80
EGR outlet tube to intake manifold retaining bolts 9 - 80
Crankcase vent oil seperator retaining bolts 9 - 80
Oil level indicator tube retaining bolt 9 - 80
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Number
(EGR) valve bracket to intake
manifold EGR tube
2 - EGR valve bracket
3 - EGR valve
valve bracket EGR tube
The EGR system consists of an EGR valve, the

EGR tubes and an EGR valve bracket to which
they are all connected.
The recirculated quantity of exhaust gas is
regulated by the EGR valve which allows for
accurate adjustment.
The EGR valve is actuated directly by the PCM
(Powertrain control module) using pulse-width
modulated signals. The PCM determines the
position of the EGR valve using data from various
other electronic engine controls. The EGR valve
also provides a feedback signal to the PCM which
is used to determine any EGR system fault.
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step.

• Exhaust gas • EGR valve
recirculation (EGR) • EGR valve electrical
valve connector
• EGR valve gasket • EGR valve wiring
• Exhaust manifold to harness
EGR valve tube
• EGR valve to intake
manifold tube
• Positive crankcase
ventilation (PCV)
valve
• Crankcase vent oil
separator
• PCV hose
Symptom Chart
• Excessive exhaust black smoke • EGR valve • CHECK the operation of the
EGR valve using WDS. If the
EGR valve is operating correctly,
REMOVE and INSPECT the
EGR valve and valve seat for
signs of damage. INSTALL a
new EGR valve if necessary.
REFER to Exhaust Gas Recir-
culation (EGR) Valve in this sec-
tion. TEST the system for normal
operation. If the EGR valve is
OK, continue the diagnostic us-
ing WDS.
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• Excessive crankcase pressure • Blocked PCV valve. • CLEAN or INSTALL new PCV
• Blocked crankcase vent oil components as necessary.
separator. TEST the system for normal op-
• Blocked PCV hose. eration.
• Blocked intake manifold PCV
hose union.
• Worn or damaged engine com- • REFER to Section 303-00.
ponents. [Engine System - Gen-
• Oil in the air intake system • Restriction in the PCV crankcase • CLEAN the PCV crankcase vent
vent oil separator. oil separator. REFER to
Crankcase Vent Oil Separator in
this section. TEST the system for
normal operation.
• PCV valve permanently open. • INSTALL a new PCV valve.
eration.
• Worn or damaged engine com- • REFER to Section 303-00.
ponents. [Engine System - Gen-
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1. NOTE: Make sure that the windshield wiper 4. Remove the windshield wiper arms.
Disconnect the battery ground cable. For
Disconnect]
5. Remove the cowl panel grille.

1. Detach the cowl panel grille retaining clips.
2. Detach the cowl panel grille from the
windshield glass lower weatherstrip and
remove.

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retaining screws.
2. Detach the bulkhead extension panel re-
taining clips.

table(s).

Number
1 - Exhaust manifold to EGR nector
valve tube support bracket
retaining nut 4 - EGR valve retaining nuts
2 - Exhaust manifold to EGR 5 - EGR valve

valve tube, EGR valve re- See Removal Detail
taining nuts
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Number
valve tube gasket
7 - EGR valve gasket

Initialization]
Removal Details
Item 5 : EGR valve

CAUTION: When removing the EGR valve,
do not place excessive strain on the EGR
valve to exhaust manifold tube. Failure to
follow this instruction could result in
damage and leaks to the EGR valve to
exhaust manifold tube.
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[Engine - 1.6L (Z6), IN-VEHICLE 3. Remove the components in the order
REPAIR, Intake Manifold] indicated in the following illustration(s) and
table(s).
2. Remove the engine oil level indicator and
tube.
1. Remove the engine oil level indicator.
2. Remove the engine oil level indicator tube
retaining bolt.
3. Remove the engine oil level indicator tube.
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Number
1 - Crankcase vent oil seperator
retaining bolts
seal
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Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube
Disconnect]

remove.

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retaining screws.
taining clips.

table(s).

Number
1 - Exhaust manifold to EGR valve tube, EGR valve
valve tube support bracket retaining nuts
retaining nut See Installation Detail
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Item Part Description 2. Tighten the exhaust manifold to EGR valve

Number tube, EGR valve retaining nuts and the
exhaust manifold to EGR valve tube sup-
3 - Exhaust manifold to EGR port bracket retaining nut in the order in-
valve tube, exhaust manifold dicated.
union
See Removal Detail
valve tube
valve tube gasket

PROCEDURES, Door Window Motor 3. Raise and support the vehicle.
Initialization] 4. Tighten the exhaust manifold to EGR valve
tube, exhaust manifold union.
Removal Details
Item 3 : Exhaust manifold to EGR valve tube,

exhaust manifold union

exhaust manifold union
1. Install the exhaust manifold to EGR valve
tube, exhaust manifold union finger tight.
EGR valve retaining nuts 5. Lower the vehicle.
tube, EGR valve retaining nuts finger tight.
Item 1 : Exhaust manifold to EGR valve tube
support bracket retaining nut
tube support bracket retaining nut finger
tight.
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Exhaust Gas Recirculation (EGR) Valve Outlet Tube
Disconnect]

remove.

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retaining screws.
taining clips.

table(s).

Number
3 - EGR valve outlet tube to
1 - EGR valve outlet tube union intake manifold retaining
See Installation Detail bolts
2 - EGR valve outlet tube See Installation Detail
support bracket retaining bolt 4 - EGR valve outlet tube
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Number
5 - EGR valve outlet tube to in-
take manifold O-ring seal

Initialization]
Removal Details
Item 4 : EGR valve outlet tube

CAUTION: Do not place excessive strain
on the fuel charging wiring harness or
coolant hoses when removing the EGR
valve outlet tube. Failure to follow this
instruction may result in engine coolant
leaks or poor engine run characteristics.
Item 3 : EGR valve outlet tube to intake

manifold retaining bolts
1. Install the EGR valve outlet tube to intake
manifold retaining bolts finger tight.
Item 2 : EGR valve outlet tube support bracket
retaining bolt
1. Install the EGR valve outlet tube support
bracket retaining bolt finger tight.
Item 1 : EGR valve outlet tube union
1. Install the EGR valve outlet tube union
finger tight.
2. Tighten the EGR valve outlet tube in the
order indicated.
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303-12-1 Intake Air Distribution and Filtering 303-12-1
SECTION 303-12 Intake Air Distribution and Filtering

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 303-12-2
Intake Air Distribution and Filtering — 1.8L Duratec-HE (MI4)........................................... 303-12-3

1.8L Duratec HE (MI4) engine.......................................................................................... 303-12-3/5
Intake Air Distribution and Filtering — 2.0L Duratorq-TDCi (DW) Diesel ........................... 303-12-6
Overview .......................................................................................................................... 303-12-6/7
Intake Air Distribution and Filtering — 1.6L (Z6)................................................................ 303-12-8
Intake manifold................................................................................................................. 303-12-9
Intake air resonator .......................................................................................................... 303-12-10
Air cleaner........................................................................................................................ 303-12-10
Intake Air Distribution and Filtering.................................................................................... 303-12-11

Symptom Chart ................................................................................................................ 303-12-11/13
Air Cleaner — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) .......................................... 303-12-14/16

Air Cleaner — 2.0L Duratorq-TDCi (DW) Diesel................................................................ 303-12-17/18
Air Cleaner — 1.6L (Z6) .................................................................................................... 303-12-19/20
Charge Air Cooler —2.0L Duratorq-TDCi (DW) Diesel......................................................... 303-12-21
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SPECIFICATIONS
Item Nm lb-ft lb-in
Charge air cooler retaining bolts 5 - 44
Air cleaner outlet tube retaining clips (vehicles with 4 - 35
1.6L engines)
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Intake Air Distribution and Filtering — 1.8L Duratec-HE (MI4)

Intake manifold and ancillary components
Each plate is actuated by its own dedicated

Item Part Description vacuum motor. The required vacuum is switched
Number by a solenoid valve.
1 - Throttle Po- The solenoid valves are actuated by the
sition (TP) sensor powertrain control module (PCM). The engine
2 - Electronic intake manifold speed and engine load are used as input signals.
valve An electronic intake manifold valve is also used.
3 - Central vacuum supply The housing of the electronic intake manifold
valve is heated by the coolant circuit by means of
4 - Solenoid valve - intake
a connection above the base of the air shutoff
manifold switchover system
throttle. This prevents the intake manifold valve
5 - Swirl valve solenoid valve from icing up.
The intake manifold is made of plastic and is fitted The coolant connection of the exhaust gas
with swirl valves and an intake manifold recirculation (EGR) stepper motor is connected to
switchover system. the housing of the electronic intake manifold valve.
At the other end of the electronic intake manifold
valve housing, the coolant connection is
G334185 en 09/2004 2004.75 Focus

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connected with the feed pipe to the heat Swirl valves

exchanger.

Number
1 - Swirl valves
The swirl valve system from the Mondeo remains
unchanged.
The swirl valves reduce the cross section of the
intake ports in the lower engine speed range,
thereby swirling the intake air.
The improved swirl of the fuel/air mixture makes
the fuel/air mixture easier to ignite. Fuel
consumption and exhaust emissions are reduced
as a result.
The plates are adjusted by means of a vacuum
motor on the intake manifold.
The swirl valves are closed when the engine is not
running.
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Intake manifold switchover system
Now the inlet air is exclusively obtained through

Item Part Description the cylinder specific inlet port from the intake
Number manifold.
1 - Flaps - intake manifold When engine speed is increased to around 4500
switchover system rev/min, the flaps of the intake manifold
2 - Intake manifold switchover switchover system are opened.
vacuum motor When engine speed is reduced to around 4300
3 - Swirl valve vacuum motor rpm, the flaps of the intake manifold switchover
system are closed.
The flaps of the intake manifold switchover system This allows the inlet air to flow out of the other
allow the length of the inlet tract to be varied in intake pipes, via the cylinder specific intake pipe
order to allow engine speed dependent resonance and the cylinder specific flap of the intake manifold
charging of the cylinder. switchover system.
The flaps of the intake manifold switchover system
are open when the engine is not running.
When the engine is started the vacuum generated
is applied via the solenoid to the vacuum motor of
the intake manifold switchover flaps.
The flaps of the intake manifold switchover system
are closed.
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Intake Air Distribution and Filtering — 2.0L Duratorq-TDCi (DW) Diesel
Overview

Number
5 - Connecting pipe between
1 - Connecting hose to the valve turbocharger and intercooler
cover
6 - Connecting pipe between
2 - mass air flow (MAF) sensor inlet manifold and intercooler
3 - Air cleaner housing 7 - Resonance chamber
4 - Resonance chamber in wing
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Operating principle
The resonance chamber is located in the front left
wing and is connected to the air filter housing.
The cleaned air goes through the top of the air
filter housing to the MAF sensor, which is located
at the outlet of the air filter housing.
The fresh air goes via a connecting pipe to the
turbocharger. The gases from the crankcase are
drawn in with it via the connecting hose (1). Air
intake noise is reduced further in the resonance
chamber (7).
In the turbocharger, the drawn in fresh air is
compressed and transported via the connecting
pipe (5) to the intercooler.
The fresh air is cooled by ram air and is
transported via the connecting pipe (6) to the inlet
manifold.
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Intake Air Distribution and Filtering — 1.6L (Z6)

Number
1 - Intake manifold
2 - Intake air resonator
3 - Air cleaner
4 - Air cleaner outlet hose
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Intake manifold
assist in the mixing of the air fuel mixture at the

Item Part Description fuel injectors.
Number During high demand throttle conditions, the IMRC
1 - Throttle body throttle plates are opened and the air charge is
allowed to use both primary and secondary intake
2 - Primary air intake chambers chambers. This means a higher volume of air
3 - Intake manifold runner con- charge can be accommodated by the intake
trol (IMRC) throttle plates manifold. During this high demand throttle
condition, the IMT swirl plates are fully open so as
4 - Intake manifold tuning (IMT) not to restrict the air charge flow.
swirl plates
Built into the intake manifold body, positioned just
5 - Exhaust gas recirculation behind the throttle body is the EGR and the fuel
(EGR) intake port evaporative emissions inlet ports. By having these
6 - Fuel evaporative emissions two ports at the beginning of the intake manifold,
intake port the gasses entering the intake manifold have time
to mix with the air charge from the air cleaner.
Clean air from the air cleaner enters the intake
manifold through the throttle body. The volume of
air is controlled by the throttle body throttle plate.
Under low demand throttle conditions, the air
charge is delivered to the cylinder head intake
ports via the primary air intake chambers. The
charge is then mixed by the IMT swirl plates to
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Intake air resonator
The intake air resonator is fitted under the left

hand fender and extracts intake air from behind
the left hand headlamp. The air from the air intake
resonator is then passed to the air cleaner through
a solid pipe which exits through the inner fender.
Air cleaner
The air cleaner is made up of:

• Air cleaner base
• Air cleaner filter
• Air cleaner cover
The dirty air enters from the air resonator into the
air cleaner base, through the air filter and clean air
passes out through the air cleaner cover. The air
cleaner cover has a secondary filter gauze fitted to
the outlet. Fitted into the air cleaner cover outlet
pipe, is the manifold absolute pressure (MAP)
sensor.
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Intake Air Distribution and Filtering


1. Verify the customer concern. reported concern is found, correct the cause
– Air cleaner element – Mass air flow (MAF)
– Air cleaner intake sensor
hose – Manifold absolute
– Air cleaner outlet pressure (MAP)
hose sensor (Vehicles
– Charge air cooler with
2.0L Diesel engine)
(Vehicles with 1.6L
Diesel and 2.0L – Electrical connec-
Diesel engine) tor(s)
– Charge air cooler
intake hose
(Vehicles with 2.0L
Diesel engine)
– Charge air cooler
outlet hose
(Vehicles with
2.0L Diesel en-
gine)
Symptom Chart

• Excessive intake air noise • Detached air cleaner hose(s). • CHECK the hose(s) for security
• Detached turbocharger hose(s) and leaks to atmosphere.
(Vehicles with 2.0L Diesel engine) INSTALL new intake air com-
• Detached charge air cooler ponents as necessary. TEST the
hose(s) (Vehicles with 2.0L system for normal operation.
Diesel engine).
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• Oil in the air intake system • Blocked or damaged positive • Vehicles with 1.6L engine.
crankcase ventilation (PCV) REFER to Section 303-08A /
valve. 303-08B / 303-08C.
• Blocked or damaged PCV • Vehicles with 1.8L/2.0L engine.
pipe(s)/hose(s). REFER to Section 303-08A /
• Blocked or damaged crankcase 303-08B / 303-08C.
vent oil separator. • Vehicles with 2.0L Diesel engine.
REFER to Section 303-08A /
303-08B / 303-08C.
• Turbocharger • Vehicles with 2.0L Diesel engine.

(Vehicles with 2.0L Diesel en- REFER to Section
gine). 303-04A / 303-04B /
303-04C / 303-04D.
• Water in the air cleaner • Air intake pipe splash shield. • CHECK the air intake pipe
splash shield for correct installa-
tion and alignment.
REPAIR/INSTALL the air intake
pipe splash shield as necessary.
eration.
• Blocked air cleaner drain. • CHECK the air cleaner drain for
blockage. TEST the system for
normal operation.
• Engine lacks power • Air cleaner element blocked. • INSPECT the air cleaner for
signs of blockage. INSTALL a
new air cleaner element as
necessary.
• Charge air cooler pipe(s) • INSPECT the charge air cooler
(Vehi cles with 2.0L pipes for damage. INSTALL a
Diesel engine). new charge air cooler pipe(s) as
necessary.
• Charge air cooler blocked (Ve- • INSPECT the charge air cooler
hicles with 2.0L for blockage. INSTALL a new
Diesel engine). charge air cooler as necessary.
REFER to Charge Air Cooler -
2.0L Duratorq-TDCi (DW)
Diesel in this section.
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• Fuel charging and controls • Vehicles with 1.6L engine.
303-04B / 303-04C / 303-04D.
• Vehicles with 1.8L/2.0L engine.
303-04B / 303-04C / 303-04D.
• Vehicles with 2.0L Diesel engine.
303-04B / 303-04C / 303-04D.
• Turbocharger • Vehicles with 2.0L Diesel engine.

(Vehicles with 2.0L Diesel en- REFER to Section
gine). 303-04A / 303-04B /
303-04C / 303-04D.
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Air Cleaner — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)

1. Remove the upper engine cover.

table(s).
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Number
3 - Air cleaner quick release
1 - Air cleaner outlet pipe retainer
2 - Positive crankcase 4 - Air cleaner
ventilation (PCV) hose quick See Installation Detail
release coupling
G295769 en 09/2004 2004.75 Focus

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Removal Details
Item 1 : Air cleaner outlet pipe

1. Release the air cleaner outlet pipe retaining
clips.
Item 3 : Air cleaner quick release retainer

1. Detach the air cleaner quick release re-
tainer from the air cleaner.
Item 4 : Air cleaner

NOTE: Make sure the two locating pegs on the air
cleaner are located into the rubber grommets on
the support bracket.
hose quick release coupling
NOTE: Make sure that the PCV hose quick
release coupling and air cleaner are clean and
free from any oil residue.
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Air Cleaner — 2.0L Duratorq-TDCi (DW) Diesel

table(s).
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Item Part Description Item 3 : Air cleaner outlet hose

Number NOTE: Make sure that the inside of the air cleaner
outlet hose is clean and free from any oil residue,
1 - Mass air flow (MAF) sensor as this will reduce the installation grip of the hose
electrical connector to the air cleaner.
2 - Coolant degas flow control
valve
See Removal Detail
3 - Air cleaner outlet hose
See Removal Detail
retainer
See Removal Detail
5 - Air cleaner
Removal Details
Item 2 : Coolant degas flow control valve

1. Detach the coolant degas flow control
valve from the coolant degas flow control
valve support bracket and position to one
side.
Item 3 : Air cleaner outlet hose
1. Detach the air cleaner outlet hose.

cleaner are located into the grommets on the
support bracket.
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Air Cleaner — 1.6L (Z6)

table(s).

Number
2 - Evaporative emissions con-
1 - Mass air flow (MAF) sensor trol valve
3 - Crankcase ventilation hose
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Number
4 - Air cleaner outlet hose to
throttle body retaining clamp
retainer
See Removal Detail
6 - Air cleaner

NOTE: Make sure that the inside of the air cleaner
outlet hose is clean and free from any oil residue,
as this will reduce the installation grip of the hose
to the throttle body.
NOTE: Make sure the positive crankcase
ventilation (PCV) hose is clean and free from any
oil residue.
Removal Details


cleaner are located into the rubber grommets on
the support bracket.
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Charge Air Cooler — 2.0L Duratorq-TDCi (DW) Diesel
1. Raise and support the vehicle. 2. Remove the components in the order
table(s).

Number
1 - Engine under shield
See Removal Detail
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Number
7 - Charge air cooler
3 - Charge air cooler outlet hose See Removal Detail
4 - Charge air cooler intake hose
retaining clamp
5 - Charge air cooler intake hose
See Removal Detail
6 - Charge air cooler retaining
bolts
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3. To install, reverse the removal procedure. Item 5 : Charge air cooler intake hose
NOTE: Make sure sure that the inside of the
Removal Details charge air cooler intake hose is clean and free
from any oil residue, as this will reduce the
Item 1 : Engine under shield installation grip of the hose to the charge air
cooler.
Item 3 : Charge air cooler outlet hose
NOTE: Make sure sure that the inside of the
charge air cooler outlet hose is clean and free
from any oil residue, as this will reduce the
installation grip of the hose to the charge air
cooler.
1. Release the crankshaft pulley splash shield

locking tangs.
• Rotate the locking tang counterclockwise.
Item 3 : Charge air cooler outlet hose
CAUTION: The charge air cooler outlet
hose retaining clip is moulded to the
charge air cooler outlet hose. Do not
attempt to detach the retaining clip from
the the hose. Failure to follow this
instruction may cause damage to the
charge air cooler outlet hose.
1. Detach the charge air cooler outlet hose.
Item 7 : Charge air cooler
1. Remove the charge air cooler from the
charge air cooler support brackets.
Item 7 : Charge air cooler

NOTE: Make sure that the charge air cooler is
clean and free from oil residue.
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303-13-1 Evaporative Emissions 303-13-1
SECTION 303-13 Evaporative Emissions

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 303-13-2
Evaporative Emissions...................................................................................................... 303-13-3

Evaporative Emission Canister ......................................................................................... 303-13-4
09/2004 2004.75 Focus

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SPECIFICATIONS
Item Nm lb-ft lb-in
Evaporative emission canister retaining bolts 9 - 80
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Evaporative Emissions


– Vacuum line(s) – Fuse(s)
– Evaporative – Wiring harness
emission canister – Electrical connec-
– Evaporative tor(s)
emission system
hose(s)
– Evaporative emis-
sion canister purge
valve
step.
system.
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Evaporative Emission Canister

1. Raise and support the vehicle. For 2. Remove the components in the order
additional information, indicated in the following illustration(s) and
refer to Section 100-02. table(s).

Number
1 - Evaporative emission canis- canister
ter retaining bolts See Installation Detail
2 - Fuel tank vent pipe to
evaporative emission 3. To install, reverse the removal procedure.
canister quick release
coupling Removal Details
See Removal Detail
Item 2 : Fuel tank vent pipe to evaporative
3 - Evaporative emission purge
emission canister quick release coupling
valve pipe to evaporative
1. Disconnect the fuel tank vent pipe to
emission canister quick
evaporative emission canister. For
release coupling
See Removal Detail
4 - Evaporative emission canis-
ter breather hose
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Item 3 : Evaporative emission purge valve pipe

to evaporative emission canister quick
release coupling
1. Disconnect the evaporative emission purge
valve pipe to evaporative emission canister.
Item 5 : Evaporative emission canister

1. Make sure the evaporative emission can-
ister locating tang is positioned correctly
on to the rear crossmember .
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303-14-1 Electronic Engine Controls 303-14-1
PAGE 1 OF 2
SECTION 303-14 Electronic Engine Controls

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 303-14-3/4
Electronic Engine Controls — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)................... 303-14-5

System overview, 1.8L Duratec HE (MI4) engine ............................................................. 303-14-5
Components..................................................................................................................... 303-14-6/10
Electronic Engine Controls — 2.0L Duratorq-TDCi (DW) Diesel........................................ 303-14-11
System overview .............................................................................................................. 303-14-11
Components..................................................................................................................... 303-14-12/18
Electronic Engine Controls — 1.6L (Z6) ............................................................................ 303-14-19
IMT valve ......................................................................................................................... 303-14-20
PCM................................................................................................................................. 303-14-21
ECT sensor ...................................................................................................................... 303-14-21
TP sensor......................................................................................................................... 303-14-21
IAC valve.......................................................................................................................... 303-14-21
EOP sensor...................................................................................................................... 303-14-22
IMRC actuator .................................................................................................................. 303-14-22
Knock sensor ................................................................................................................... 303-14-22
CMP sensor ..................................................................................................................... 303-14-22
Barometric pressure sensor ............................................................................................. 303-14-23
VCT oil control solenoid ................................................................................................... 303-14-23
CKP sensor...................................................................................................................... 303-14-23
PSP switch....................................................................................................................... 303-14-23
HO2S ............................................................................................................................... 303-14-24
Catalyst monitor sensor.................................................................................................... 303-14-24
MAF sensor...................................................................................................................... 303-14-24
Electronic Engine Controls ................................................................................................ 303-14-25

Camshaft Position (CMP) Sensor — 2.0L Duratorq-TDCi (DW) Diesel ............................. 303-14-26/29
Crankshaft Position (CKP) Sensor — 2.0L Duratorq-TDCi (DW) Diesel ............................ 303-14-30/32
Powertrain Control Module (PCM) — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Ve-
hicles Without: PCM Security Shield ................................................................................ 303-14-33/34
Powertrain Control Module (PCM) — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Ve-
hicles With: PCM Security Shield ..................................................................................... 303-14-35/36
Powertrain Control Module (PCM) — 1.6L (Z6)............................................. (29 200 0) 303-14-37
Powertrain Control Module (PCM) — 2.0L Duratorq-TDCi (DW) Diesel.............................. 303-14-38/40
Front Knock Sensor (KS) — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) ..................... 303-14-41/43
Rear Knock Sensor (KS) — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) ..................... 303-14-44/46
Brake Pedal Position (BPP) Switch ................................................................................... 303-14-47/49
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PAGE 2 OF 2
Engine Coolant Temperature (ECT) Sensor — 2.0L Duratorq-TDCi (DW) (21 190 0)
Diesel .......................................................................................................... 303-14-50/51
Engine Coolant Temperature (ECT) Sensor — 1.6L (Z6) .................................................. 303-14-52
Variable Camshaft Timing (VCT) Oil Control Solenoid — 1.6L (Z6) ................................... 303-14-53/55
Intake Manifold Tuning (IMT) Valve — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)...... 303-14-56/58
Idle Air Control (IAC) Valve — 1.6L (Z6) ............................................................................ 303-14-59
Knock Sensor (KS) — 1.6L (Z6) ........................................................................................ 303-14-60
Clutch Pedal Position (CPP) Switch................................................................................... 303-14-61/63
Throttle Position (TP) Sensor — 1.6L (Z6)......................................................................... 303-14-64
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SPECIFICATIONS

Crankshaft position (CKP) sensor 7 - 62
retaining bolt
Heated oxygen (HO2S) sensor 42 31 -
Camshaft position (CMP) sensor re- 7 - 89
taining bolt
Engine coolant temperature (ECT) 12 - 53
sensor
Variable camshaft timing (VCT) oil 10 - 89
control solenoid retaining bolt (vehi-
cles with 1.6L Duratec-16V Ti-VCT
Sigma engine)

Front Knock Sensor (KS) retaining 20 15 -
bolt
Rear KS retaining bolt 20 15 -
CMP sensor retaining bolt 6 - 53
ECT sensor 12 9 -
CKP sensor retaining bolt 6 - 53

Engine timing belt cover retaining 7 - 62
bolts
Crankshaft pulley retaining bolt a - -
a) For additional information, refer to Crankshaft Position (CKP) Sensor - 2.0L Duratorq-TDCi (DW) Diesel in this
section.

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ECT sensor 20 15 -
Knock Sensor (KS) 26 19 -
Variable camshaft timing (VCT) oil 10 - 89
control solenoid retaining bolt
Heated oxygen (HO2S) sensor 40 30 -
Intake manifold tuning (IMT) valve 5 - 44
retaining bolts
Throttle position (TP) sensor retain- 2 - 18
ing bolts
Idle air control (IAC) valve 5 - 44
Engine oil pressure (EOP) sensor 15 11 -
Intake manifold runner control 9 - 80
(IMRC) actuator retaining bolts
Catalyst monitor sensor 40 30 -
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Electronic Engine Controls — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)

System overview, 1.8L Duratec HE (MI4)

engine
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Number
24 - Exhaust Gas Recirculation
1 - Temperature and Manifold (EGR) stepper motor
Absolute Pressure (T-MAP)
sensor 25 - Solenoid valve - inlet mani-
fold switching system
2 - Throttle Position (TP) sensor
in the electronic intake 26 - Swirl plate solenoid valve
manifold valve 27 - Air Conditioning (A/C) com-
3 - Engine Coolant Temperature pressor
(ECT) sensor 28 - Generator (output signal)
4 - Crankshaft Position (CKP) 29 - Direct ignition coils
sensor
30 - EVAP solenoid valve
5 - Camshaft Position (CMP)
sensor 31 - Electronic air shutoff throttle
6 - Ambient air temperature 32 - Instrument cluster

sensor
7 - Heated Oxygen Sensor
Components
(HO2S), pre- and post-cat
8 - Power Steering Pressure
(PSP) switch PCM
9 - Stoplamp switch
10 - Clutch Pedal Position (CPP)
switch
11 - Brake Pedal Position (BPP)
switch
12 - Accelerator Pedal Position
(APP) sensor
13 - Generator (input signal)
14 - Knock Sensor (KS) sensors
15 - Power supply relay
16 - Battery
The powertrain control module is housed in the
17 - Malfunction Indicator Lamp engine compartment next to the battery.
(MIL)
The PCM is a Visteon Electronic Management
18 - Powertrain Control Module System 7.
(PCM)
It has two connections for the wiring harness.
19 - Data Link Connector (DLC)
A comprehensive diagnosis can be performed
20 - Fuel pump relay through the DLC using the WDS diagnostic
21 - Fuel pump equipment.
22 - Fuel injectors
23 - Passive Anti-theft System
(PATS) LED
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KS sensors Then the PCM calculates a new ignition angle and

the ignition timing of the corresponding cylinder is
retarded.
Electronic throttle flap

Number
1 - Coolant connection, outlet
2 - Coolant connection, intake
Item Part Description 3 - Electronic throttle flap elec-
Number tric motor
1 - Knock sensors 4 - TP sensor
Two knock sensors are used. The knock sensors NOTE: The stop of the throttle flap must never be
are located on the cylinder block between adjusted.
cylinders 1 and 2 and between cylinders 3 and 4. The APP sensor sends the data containing the
As a result, it is possible to maximise the ignition driver's acceleration request to the PCM. This
timing advance, which in turn provides even more information depends directly on the movement of
torque at lower engine speeds. the accelerator pedal.
If the combustion noise exceeds the permissible The PCM processes this information and sends
limits, then the CKP sensor and the CMP sensor output signals for the electronic throttle valve, the
first determine which cylinder is affected. ignition system and the injected fuel quantity.
The electric motor moves the throttle flap shaft
using a set of gears.
The position of the throttle flap is set and
monitored in a closed loop control circuit. The TP
sensor supplies the PCM with the current throttle
flap position information.
Should a fault appear at the electronic throttle flap,
a substitute function is performed. This substitute
function allows the throttle flap to be opened by a
defined amount.
For this purpose, there is an throttle flap
adjustment screw on the throttle housing. The
return spring closes the throttle flap until the stop
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of the toothed wheel touches the stop screw. In Direct ignition coils
this way a defined throttle flap gap is formed for
limp home mode.
With the throttle flap kept in a constant position,
the ignition angle and the injected fuel quantity are
varied according to the position of the APP sensor
in order to enable restricted operation of the
engine.
The vehicle then drives with a limited top speed.
The stop screw of the throttle flap has a
spring-loaded pin which permits the throttle flap to
be closed beyond the emergency running position
(e.g. idle speed control or engine overrun shutoff).
Intake manifold switchover solenoid and swirl

valve solenoid
The direct ignition coils are pushed onto the

relevant spark plug and are bolted onto the valve
cover.
The PCM actuates each direct ignition coil
directly.
Each direct ignition coil is actuated individually by
the PCM.
Because of the direct ignition coils the
specification of the spark plugs has been changed.
Irridium coated spark plugs are now used.
BPP switch and brake light switch
NOTE: The vacuum line leading to the vacuum

motor of the intake manifold switchover system
must not be swapped with the vacuum line leading
to the vacuum motor of the swirl valves.
The solenoid for the intake manifold switching
system is located together with the swirl valve
solenoid on the transmission side of the cylinder
head.
Vacuum is supplied by a central vacuum
connection from the intake manifold.
The solenoid for the intake manifold switching
system is supplied with either the maximum
voltage or zero voltage, i.e. the valves are either
NOTE: Please refer to the current service
fully open or fully closed.
literature for the exact procedures for servicing the
Actuation depends on the engine speed and the stop lamp switch and the BPP switch.
engine load.
The BPP switch and the stop lamp switch are
located on the pedal box and provide the PCM
with the information that the vehicle is being
decelerated.
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The BPP switch is connected to the instrument of the engine according to the driver's request for
cluster via a CAN bus. In its rest state the switch is power.
closed and sends a ground signal to the PCM .
The APP sensor is a double contactless inductive
The stop lamp switch is connected to the PCM sensor.
and is open in its rest state. When the switch is
If a fault of the APP sensor occurs while driving
closed it connects 12V to the PCM .
then a trouble code is stored in the PCM.
The signals from the BPP switch and the stop
If both sensors of the APP sensor fail then, after a
lamp switch are used in the event of failure of the
single operation of the BPP switch and the stop
APP sensor for the emergency operating mode.
lamp switch and a subsequent comparative
In this instance, the PCM compares the signals of plausibility test, the engine is regulated to a
the BPP switch and brake light switch. maximum engine speed of up to 4000 rev/min.
The vehicle can be accelerated to a maximum
speed of 56 km/h.
APP sensor
When the brake pedal is pressed again the engine
speed drops to idle speed. When the brake pedal
returns to its rest position the engine speed is
increased again.
Error messages from the APP sensor

Number
1 - Driver information system
2 - Malfunction Indicator Lamp
(MIL)
If one of the sensors of the APP sensor fails then

the engine runs with reduced power. However, it is
still possible to reach top speed.
If the vehicle is equipped with a driver information
system, the fault message: "REDUCED
ACCELERATION" will be displayed.
If both sensors of the APP sensor fail, the driver
information system displays the fault message:
"LIMITED MAXIMUM SPEED".
The PCM requires the pedal position from the In the event of failure of the electronic throttle flap
APP sensor in order to regulate the power output the error message "LIMITED MAXIMUM SPEED"
is also displayed.
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Number
1 - Engine system fault warning
lamp
2 - Malfunction Indicator Lamp
(MIL)
If the vehicle is not fitted with a driver information

system, the "engine system fault" warning light will
come on to indicate a system fault.
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Electronic Engine Controls — 2.0L Duratorq-TDCi (DW) Diesel
System overview
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Number Number
1 - mass air flow (MAF) sensor 25 - air conditioning (A/C) com-
pressor
2 - manifold absolute pressure
(MAP) sensor 26 - Shutoff solenoid valve
3 - Fuel pressure sensor 27 - Bypass solenoid valve
4 - intake air temperature (IAT) 28 - Electric additional heater
sensor
29 - Generator (output signal)
30 - PCM relay
6 - engine coolant temperature
31 - exhaust gas recirculation
(ECT) sensor
(EGR) stepper motor
7 - camshaft position (CMP)
32 - Instrument cluster
sensor
8 - crankshaft position (CKP)
sensor Components
9 - Turbocharger position sen-
sor
PCM
10 - accelerator pedal position
(APP) sensor
11 - brake pedal position (BPP)
switch
12 - Stoplamp switch
13 - clutch pedal position (CPP)
switch
14 - Generator (input signal)
15 - Start inhibit relay
16 - Ignition switch
The PCM is built into the resonance chamber in
17 - Battery the front left-hand fender and has three electrical
connectors with a total of 128 pins.
18 - data link connector (DLC)
The PCM monitors and processes the signals
19 - powertrain control module from the sensors. The fuel injectors, the fuel
(PCM) metering valve and the fuel pressure control valve
20 - Fuel injectors are also controlled by the PCM .
21 - Air shutoff throttle solenoid The PCM can be diagnosed through the DLC
valve using WDS.
22 - Solenoid valve - boost pres-
sure control
23 - Malfunction indicator lamp
(MIL)
24 - Fuel pump with fuel metering
valve and fuel pressure con-
trol valve
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BPPswitch and brake light switch APP sensor

the exact procedure for installing the brake light
switch and BPP switch.
The BPP switch is connected to the instrument
cluster via the CAN bus.
The BPP switch is closed when de-energised and
sends a ground signal to the PCM.
The brake light switch is connected with the PCM
via a conventional cable connection.
The brake light switch is open when de-energised.
When the brake light switch is closed, it sends 12V
to the PCM .
The signals of the BPP switch and the brake light
switch are used if the APP sensor should fail.
In this instance, the PCM compares the signals of
the BPP switch and brake light switch.
The APP sensor is a double contactless inductive

sensor.
For safety reasons, the APP sensor consists of
two sensors.
If the APP sensor malfunctions when the vehicle is
in operation, a fault code will be stored in the
PCM.
If one of the sensors in the APP sensor should fail,
the engine will operate at reduced power.
However, it is still possible to reach top speed.
If the vehicle is fitted with a driver information
system, the fault message "REDUCED
ACCELERATION" will be displayed.
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If the both sensors of the APP switch fail, after a CMP sensor
single operation of the BPP switch and the brake
light switch and then after a plausibility check, the
engine is controlled up to a speed of 1200 rev/min.
The vehicle can be accelerated to a maximum
speed of 56 km/h.
When the BPP switch and the brake light switch
are actuated again, engine speed will drop to idle
speed. Once the BPP switch and the brake light
switch are de-energised again, engine speed is
increased again.
If the vehicle is fitted with a driver information
system, the fault message "REDUCED TOP
SPEED" will be displayed.
The CMP sensor is located behind the exhaust
If the vehicle is not fitted with a driver information camshaft timing pulley.
system, the engine system fault warning light will
come on to indicate a system fault. The CMP sensor is attached to the valve cover by
means of a slot on the sensor housing.
When carrying out installation work, ensure that
CKP sensor
the gap between the CMP sensor and exhaust
camshaft timing pulley is correct.
The CMP sensor uses the Hall effect principle.
For detection of cylinder "1" different sized
windows have been milled into the exhaust
camshaft timing pulley.
During starting, the CKP sensor and the CMP
sensor are synchronised. If both signals are
present, the engine will be started.
If the signal from the CMP sensor fails while the
engine is running, the engine continues to run
using the signals from the CKP sensor.
If the CMP signal is missing at the next starting
The CKP sensor is attached to the oil pump operation, it will not be possible to start the engine.
housing, behind the crankshaft timing pulley.
The CKP sensor detects a magnetic disc with MAF sensor
58+2 magnetic pole pairs on it, arranged around
the circumference.
The CKP sensor uses the Hall effect principle.
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Item Part Description Turbocharger position sensor

Number
1 - MAF sensor
2 - Mark showing installation
orientation
The MAF sensor (1) is located on the outlet of the

air filter housing.
When installing the connecting piece, ensure
correct orientation; the arrow (2) must be pointing
in the direction of flow of the drawn-in air.
The MAF sensor calculates the quantity of fresh
air drawn in.
The signal from the MAF sensor is used by the
PCM to regulate the EGR system and the amount
of recirculated exhaust gas.
The turbocharger position sensor is located
centrally on the turbocharger vacuum canister and
MAP sensor
calculates the position of the guide vanes.
The signal is sent to the PCM.
This input signal is compared with the signal from
the MAP sensor and allows a preliminary
calculation of the absolute intake manifold
pressure.
IAT sensor
The MAP sensor is positioned in the inlet manifold,

behind the air shutoff throttle.
The MAP sensor measures the absolute intake
pipe pressure, which is a reference value for
engine load.
The signal from the MAP sensor is required by the
PCM to control the boost pressure of the variable
turbocharger.
The IAT sensor is positioned in the inlet manifold,
behind the air shutoff throttle.
The signal from the IAT sensor is used as a
correction variable for calculating the injection
quantity.
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Solenoid valve - boost pressure control Shutoff solenoid valve
The boost pressure control solenoid valve applies

vacuum to the turbocharger vacuum canister,
which then adjusts the turbocharger's variable The shutoff solenoid valve is attached to the front
guide vanes in accordance with the signals from module next to the air filter housing; during the
the PCM. engine warm-up phase, it shuts off the flow of
coolant to the coolant reservoir.
Air shutoff throttle solenoid valve It is actuated by the PCM using pulse width
modulation.
The PCM processes the signals from the ECT
sensor to calculate how long the shutoff solenoid
valve is to be actuated for.
Bypass solenoid valve
In accordance with commands from the PCM, the

air shutoff throttle solenoid valve applies a
vacuum to the air shutoff throttle vacuum canister;
as a result when the engine is switched off, the air
supply is shut off by the air shutoff throttle closing. The bypass solenoid valve is located in the
This prevents any run-on. thermostat housing and shortens the engine
warm-up phase by shutting off the bypass port to
the coolant pump.
Using the signals from the ECT sensor as input,
the PCM controls the bypass solenoid valve.
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EGR stepper motor Fuel pressure control valve
The fuel pressure control valve is screwed directly

onto the high pressure outlet of the fuel pump.
The fuel pressure control valve regulates the fuel
pressure at the high-pressure outlet and thereby
the fuel pressure in the common rail.
An EGR stepper motor is used to ensure that the
quantity of recirculated exhaust gas is adjusted In addition, the fuel pressure control valve
accurately. dampens pressure fluctuations which arise when
the fuel pump is supplying fuel and as a result of
This reduces the combustion temperature and the the injection process.
formation of NOx.
The EGR stepper motor is actuated by the PCM Fuel pressure sensor
using pulse width modulation.
Fuel metering valve
The fuel pressure sensor is located at the side on

The fuel metering valve adjusts the quantity of fuel the common rail and measures the fuel pressure
to the high-pressure pump elements as a function in the common rail.
of engine operating conditions. This improves
engine efficiency. The fuel pressure sensor consists of a
piezoelectric element that sends a variable
The fuel metering valve is controlled by the PCM voltage signal to the PCM, as a function of fuel
using pulse-width modulation. pressure.
The fuel metering valve is closed when The PCM uses this signal to calculate how long
de-energised. the injectors are to be actuated for and to regulate
the fuel pressure by means of the fuel pressure
control valve.
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Fuel temperature sensor
The fuel temperature sensor is located in the fuel

return system in a T-piece above the fuel rail.
The fuel temperature sensor is designed as a
resistor with a negative temperature coefficient
(NTC).
The signal is required by the PCM for making fine
adjustments to the injection timing and the
injection quantity.
Diesel fuel heater

Number
1 - Diesel fuel heater
The electric diesel fuel heater (1) is located

centrally on the top of the fuel filter and cannot be
renewed as a separate component.
When the ignition is switched on, the bimetallic
controlled diesel fuel heater is activated through a
relay by the generic electronic module (GEM),
independent of whether the engine is running or
not.
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Electronic Engine Controls — 1.6L (Z6)

Number
1 - Intake manifold tuning (IMT)
valve
2 - Powertrain control module
(PCM)
(ECT) sensor
4 - Throttle position (TP) sensor
5 - Idle air control (IAC) valve
6 - Engine oil pressure (EOP)
sensor
7 - Intake manifold runner con-
trol (IMRC) actuator
sensor
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Number IMT valve
sensor
10 - Barometric pressure sensor
(VCT) oil control solenoid
sensor
13 - Power steering pressure
(PSP) switch
(HO2S) The IMT valve controls swirl plates within the
15 - Catalyst monitor sensor intake manifold which are positioned close to the
union of the intake manifold and cylinder head
16 - Mass air flow (MAF) sensor intake ports. The function of the swirl plates is to
reduce the cross-section of the intake ports at low
speeds. The IMT valve is controlled by a
pulse-width modulated signal from the PCM.
Output from the IMT valve is transmitted to the
swirl plates by a transfer gear in the IMT valve
working directly on to the swirl plate shaft.
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PCM TP sensor
This engine installation uses a Denso PCM. The The TP sensor measures the current position of
PCM is attached to the battery tray and shielded the throttle body throttle plate using a swept
from direct engine temperatures. variable resistor. The variable voltage output
generated by the TP sensor is used by the PCM to
calculate the drivers demand. The TP sensor
ECT sensor requires no setup or adjustment. But care must be
taken to install the sensor to the correct torque
value to avoid distortion of the sensor body and
subsequent failure.
IAC valve
The ECT sensor is fitted directly into the cylinder

head next to the coolant outlet connector. The
ECT sensor is a resistor with a negative
temperature coefficient (NTC resistor). Using the
voltage drop across the ECT sensor, the PCM
calculates the coolant temperature. The signal
from the ECT is used by the PCM to control the The IAC valve is attached to the underside of the
cooling fan motor and to determine the precise throttle body. By locating the IAC so close to the
fueling and ignition characteristics for the current throttle body throttle plate, the length of the IAC
engine condition. The ECT output is also used for inlet and outlet tracks have been kept to a
the instrument cluster temperature gauge input. minimum. This results in a more precise control of
the engine Idle with a smooth transition between
open and closed throttle.
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EOP sensor Knock sensor
The EOP sensor is located in the engine oil filter The knock sensor is screwed directly into the
housing above the engine oil cooler. The EOP engine block and is located under the intake
sensor provides a ground connection to the manifold. The knock sensor registers increased
instrument cluster oil pressure indicator lamp if the vibration in the engine block developed during
oil pressure drops below a predetermined increased combustion noise. The PCM uses the
pressure. knock sensor signal to adjust the ignition and
fueling characteristics to prevent fuel
pre-detonation.
IMRC actuator
CMP sensor
The IMRC actuator controls a set of throttle plates

located in the intake manifold, which in turn control
the volume of air allowed to pass through the The CMP sensor is a hall effect sensor located in
intake manifold dependant on engine demand. the camshaft cover. The CMP sensor signal is
The IMRC actuator is controlled by a pulse-width taken from a intake camshaft lobe on cylinder
modulated signal from the PCM. Output from the number 1. The CMP sensor is non adjustable and
IMRC actuator is transmitted to the throttle plates requires no setup procedure when installed.
by a transfer gear in the IMRC actuator working
directly on to the throttle plate shaft. With the
engine at idle, the IMRC throttle plates would
normally be in the closed position.
G426418 en 09/2004 2004.75 Focus

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Barometric pressure sensor CKP sensor
The barometric pressure sensor is clipped to the The CKP sensor is a hall effect sensor located on
intake manifold. The signal from the barometric the engine timing belt cover. The CKP sensor
pressure sensor is used by the PCM to adjust the signal is taken from a toothed wheel attached to
ignition and fueling characteristics for changes in the rear of the crankshaft pulley. The CKP sensor
atmospheric pressure in relation to altitude. is non adjustable and requires no setup procedure
when installed.
VCT oil control solenoid

PSP switch
The VCT oil control solenoid controls the camshaft

timing by adjusting the oil flow being delivered to The PSP switch is fitted into the body of the power
the camshaft VCT elements. The VCT oil solenoid steering pump. The signal from the PSP switch is
is controlled by a duty cycle signal from the PCM. used to control the idle speed when the steering
The oil gallery slots in the VCT oil control solenoid wheel is rotated with the engine at idle.
are calibrated to give optimum positioning of the
Intake camshaft in relation to the exhaust
camshaft to achieve an optimized engine torque
output.
G426418 en 09/2004 2004.75 Focus

TO MODEL INDEX
HO2S MAF sensor
The HO2S is located in the exhaust manifold The MAF sensor is located at the outlet of the air
before the exhaust catalyst and monitors the filter. The MAF sensor is used to calculate the
Oxygen content of the gasses produced after mass of air being demanded by the engine and so
detonation of the fuel air mixture in the combustion the engine load conditions. Combined with the
chamber. The signal from the HO2S is received by MAF sensor is the air intake temperature (IAT)
the PCM and is used to adjust the fuel injector sensor, which takes the form of a hot wire sensor.
pulse width. As the intake air flows across the IAT sensor the
resistance changes and the voltage output is
changed proportionately.
Catalyst monitor sensor
The catalyst monitor sensor measures the

Oxygen content of the exhaust gases after the
gases have passed through the exhaust catalyst.
If the measured amount of Oxygen content, is not
significantly different from the measured quantity
of Oxygen seen at the HO2S, with the engine at
working temperature, a diagnostic trouble code
(DTC) will be generated and the malfunction
indicator lamp (MIL) will be illuminated.
G426418 en 09/2004 2004.75 Focus

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Electronic Engine Controls



Electrical
– Fuse(s)
– Wiring harness
– Electrical connector(s)
– Relay(s)
– Sensor(s)
– Switch(es)
– Powertrain control module (PCM)
system.
G165604 en 09/2004 2004.75 Focus

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Camshaft Position (CMP) Sensor — 2.0L Duratorq-TDCi (DW) Diesel

Disconnect]
5. Remove the cowl panel.

1. Detach the cowl panel from the retaining
clips.
2. Remove the cowl panel by detaching it from
the windshield glass lower weatherstrip.

G410795 en 09/2004 2004.75 Focus

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1. Remove the bulkhead extension panel indicated in the following illustration(s) and
retaining screws. table(s).
G410795 en 09/2004 2004.75 Focus

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Number
1 - Fuel filter fuel supply and fuel See Removal Detail
filter fuel return lines support
bracket 4 - CMP sensor electrical con-
See Removal Detail nector
2 - Engine wiring harness 5 - CMP sensor retaining bolt

retaining clip 6 - CMP sensor
G410795 en 09/2004 2004.75 Focus

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door window motors. For additional Item 6 : CMP sensor
Frames and Mechanisms, GENERAL CAUTION: The CMP sensor tip must rest
PROCEDURES, Door Window Motor on the back of one of the three webs of
Initialization] the camshaft pulley. Incorrect installation
may result in the CMP sensor being
damaged.
Removal Details
NOTE: Only turn the engine in the normal
Item 1 : Fuel filter fuel supply and fuel filter direction of rotation.
fuel return lines support bracket 1. Turn the engine until the back of one of the
1. Detach the fuel filter fuel supply and fuel three webs of the camshaft pulley is in line
filter fuel return lines support bracket from with the CMP sensor hole in the timing belt
the timing belt upper cover. cover back plate.
2. Install the CMP sensor until the tip of the
Item 2 : Engine wiring harness retaining clip sensor touches the back of the camshaft
1. Detach the engine wiring harness retaining pulley.
clip from the timing belt upper cover.
1. Remove the timing belt upper cover
retaining bolts.
2. Slide the timing belt upper cover upwards to
disengage the retaining tang.
G410795 en 09/2004 2004.75 Focus

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Crankshaft Position (CKP) Sensor — 2.0L Duratorq-TDCi (DW) Diesel

Locking Tool, Flywheel indicated in the following illustration(s) and
table(s).
303-393 (21-168)

3. Remove the transaxle clutch housing dust
shield.
• Remove the dust shield retaining clip.
4. Using the starter motor retaining bolts and

suitable nuts. Install the special tool.
G344529 en 09/2004 2004.75 Focus

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Number
5 - CKP sensor retaining bolt
bolt 6 - CKP sensor
2 - Crankshaft pulley 6. To install, reverse the removal procedure.

3 - CKP sensor electrical con- 7. Initialize the door window motors. For
nector additional information,
4 - Engine timing belt lower
cover retaining bolts
G344529 en 09/2004 2004.75 Focus

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Removal Details
Item 6 : CKP sensor

1. To remove the CKP sensor.
• Move the engine timing belt lower cover
away from the engine block.
• Remove the CKP sensor from its locating
dowel hole.

1. Install a new crankshaft pulley retaining
bolt.
2. Tighten the crankshaft retaining bolt in two
stages.
• Stage 1: 70Nm
• Stage 2: 82°
G344529 en 09/2004 2004.75 Focus

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Powertrain Control Module (PCM) — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4),

Vehicles Without: PCM Security Shield
NOTE: If a new PCM is being installed connect 2. Remove the engine upper cover.
WDS. Upload the PCM configuration information
using the programmable modules installation
routine prior to commencing the removal of the
PCM.

table(s).

Number
1 - PCM cover
See Removal Detail
G295792 en 09/2004 2004.75 Focus

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Number
3 - PCM

NOTE: If a new PCM is being installed connect
WDS. Download the PCM configuration
information using the programmable modules
installation routine after the installation of the
PCM.
Removal Details
Item 1 : PCM cover

1. Release the locking tang and remove the
PCM cover.
G295792 en 09/2004 2004.75 Focus

TO MODEL INDEX
Powertrain Control Module (PCM) — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4),

Vehicles With: PCM Security Shield
NOTE: If a new PCM is being installed connect 2. Remove the engine upper cover.
the Worldwide Diagnostic System (WDS). Upload
the PCM configuration information using the
programmable modules installation routine prior to
commencing the removal of the PCM.

table(s).

Number
2 - PCM security shield
1 - PCM security bracket shear See Installation Detail
bolts
See Removal Detail 3 - PCM electrical connectors
G295793 en 09/2004 2004.75 Focus

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Item Part Description Item 4 : PCM

Number 1. Remove the PCM from the PCM security
bracket.
4 - PCM
See Removal Detail
5 - PCM security bracket

NOTE: If a new PCM is being installed connect
WDS. Download the PCM configuration
information using the programmable modules
installation routine after the installation of the
PCM.
Removal Details Installation Details

Item 1 : PCM security bracket shear bolts Item 2 : PCM security shield
1. Remove the PCM security bracket shear 1. Install the PCM security shield locating
bolts (battery tray shown removed for tangs into the PCM security bracket (bat-
clarity). tery tray shown removed for clarity).
• Drill a 3mm pilot hole in the center of the
PCM security bracket shear bolts.
• Drill a 8mm hole in the PCM security
bracket shear bolts and remove the PCM
security shield.
G295793 en 09/2004 2004.75 Focus

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Powertrain Control Module (PCM) — 1.6L (Z6) (29 200 0)

Removal
Tray - 1.6L (Z6)]
G426600 en 09/2004 2004.75 Focus

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Powertrain Control Module (PCM) —2.0LDuratorq-TDCi (DW) Diesel
General Equipment 5. Remove the components in the order

table(s).
(418-F224)
1. If a new PCM is being installed, upload the
PCM configuration information using
Worldwide Diagnostic System (WDS) ,
programmable modules installation
routine.
Disconnect]
3. Remove the left-hand wheel and tire. For
4. Remove the left-hand fender splash shield.
G325350 en 09/2004 2004.75 Focus

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Number 7. If a new PCM is being installed, download
the PCM configuration information using
1 - PCM cover
Worldwide Diagnostic System (WDS) ,
2 - PCM programmable modules installation
See Removal Detail routine.
3 - PCM security bracket (if 8. If a new PCM is being installed, reset the
equipped) EGR valve base value using Worldwide
See Removal Detail Diagnostic System (WDS).
See Installation Detail 9. Vehicles with 1.6L Duratorq-TDCI engine,
VIN plate emission level code K. If a new
4 - PCM electrical connectors PCM is being installed, reset the intake air
See Removal Detail shutoff throttle base value using
Worldwide Diagnostic System (WDS).
G325350 en 09/2004 2004.75 Focus

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10. Vehicles with global closing, initialize the Item 4 : PCM electrical connectors
door window motors. For additional 1. Detach the PCM electrical connectors in
information, refer to Section 501-11. the sequence shown.
Removal Details
Item 2 : PCM
CAUTION: Do not place excessive strain
on the PCM wiring harness.
1. Detach the PCM from the air intake.
1. File a flat across the PCM security bracket
welded nut.

1. Install a new PCM security bracket and
security bracket sheer bolt (if equipped).
• Tighten the security bracket sheer bolt until
the head of the sheer bolt is sheered off.
2. Remove the PCM security bracket sheer

bolt.
• Drill a 2mm pilot hole 3mm from the outer
edge of the security bracket welded nut at
an angle of approximately 2°.
• Drill a 5mm hole in the security bracket
welded nut and remove the security bracket
sheer bolt.
3. Slide the security bracket off of the PCM.
G325350 en 09/2004 2004.75 Focus

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Front Knock Sensor (KS) — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)
Name Specification
Metal Surface Cleaner WSE-M5B392-A 3. Remove the components in the order
1. Remove the intake manifold. For additional indicated in the following illustration(s) and
information, refer to Section 303-01A / table(s).
303-01B / 303-01C.
2. Disconnect the front KS electrical con-
nector.
G338639 en 09/2004 2004.75 Focus

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Number
Removal Details
1 - Front KS
See Removal Detail
Item 1 : Front KS
NOTE: Make a note of the position of the front KS
and make sure it is positioned in the same position
when installed.
G338639 en 09/2004 2004.75 Focus

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Item 1 : Front KS
NOTE: Prior to installing the front KS, clean the
engine block and front KS mating surfaces with
metal surface cleaner.
NOTE: Make sure the front KS is installed in the
same position as removed
G338639 en 09/2004 2004.75 Focus

TO MODEL INDEX
Rear Knock Sensor (KS) — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)

Name Specification indicated in the following illustration(s) and
table(s).
Metal Surface Cleaner WSE-M5B392-A
303-01B / 303-01C.
2. Disconnect the rear KS electrical connec-
tor.
G338640 en 09/2004 2004.75 Focus

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Number
Removal Details
1 - Rear KS
See Removal Detail
Item 1 : Rear KS
NOTE: Make a note of the position of the rear KS
and make sure it is positioned in the same position
when installed.
G338640 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 1 : Rear KS
NOTE: Prior to installing the rear KS, clean the
engine block and rear KS mating surfaces with
metal surface cleaner.
NOTE: Make sure the rear KS is installed in the
same position as removed
G338640 en 09/2004 2004.75 Focus

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Brake Pedal Position (BPP) Switch

Number
2 - Instrument panel insulation
1 - Instrument panel lower trim pad.
panel
G341783 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
3 - Instrument panel lower trim
panel retaining clips.

Number
4 - BPP switch electrical con-
nector
5 - BPP switch
See Removal Detail

G341783 en 09/2004 2004.75 Focus

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Removal Details
Item 3 : Instrument panel lower trim panel
retaining clips.
Item 5 : BPP switch 1. Install the instrument panel lower trim
1. CAUTION: Make sure that the brake panel retaining clips to the instrument
pedal is kept in the rest position and is panel lower trim panel.
not pressed or moved during the
removal of the BPP switch. Failure to
follow this may result in damage to the
BPP switch.
Remove the BPP switch.
• Rotate the BPP switch counter clockwise
and remove.
Item 5 : BPP switch

installation of the BPP switch. Failure
to follow this may result in damage to
the BPP switch.
Install the BPP switch.
1. Install the BPP switch.
2. Rotate the BPP switch.
G341783 en 09/2004 2004.75 Focus

TO MODEL INDEX
Engine Coolant Temperature (ECT) Sensor — 2.0L Duratorq-TDCi (DW) Diesel

(21 190 0)

303-03B / 303-03C. 3. Remove the battery tray. For additional
table(s).

Number
1 - Heater coolant hose to
thermostat housing quick
release coupling retaining
clip
G295867 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
2 - Heater coolant hose to
thermostat housing quick
release coupling
3 - ECT sensor electrical con-
nector
4 - ECT sensor retaining clip
5 - ECT sensor
G295867 en 09/2004 2004.75 Focus

TO MODEL INDEX
Engine Coolant Temperature (ECT) Sensor — 1.6L (Z6)
1. Remove the exhaust gas recirculation Exhaust Gas Recirculation (EGR) Valve
(EGR) valve outlet tube. For additional Outlet Tube]
information, refer to Section 303-08C. 2. Remove the components in the order
[Engine Emission Control - 1.6L indicated in the following illustration(s) and
(Z6), REMOVAL AND INSTALLATION, table(s).

Number
1 - ECT sensor electrical con- Item 2 : ECT sensor
nector NOTE: Make sure the plastic body of the ECT
sensor is not damaged during installation.
2 - ECT sensor
See Removal Detail
3 - ECT sensor sealing washer
Removal Details
Item 2 : ECT sensor

NOTE: Make sure the plastic body of the ECT
sensor is not damaged during removal.
G424992 en 09/2004 2004.75 Focus

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Variable Camshaft Timing (VCT) Oil Control Solenoid — 1.6L (Z6)
3. Detach the brake fluid reservoir and secure

Special Tool(s) to one side.
Support Bar, Engine

303-290A

303-290-13

303-290-15
4. Unclip the throttle cable and power as-
sisted steering (PAS) hose.
5. Detach the PAS reservoir and secure to

one side.
2. Remove the headlamps on both sides. For
[Exterior Lighting, REMOVAL AND
G426549 en 09/2004 2004.75 Focus

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6. Attach the special tool on both sides 9. Lower the vehicle.

(right-hand side shown). 10. Detach the ground cable from the engine
front mount.

additional information, refer to Section 100-02. 11. Remove the components in the order
[Jacking and Lifting, DESCRIPTION indicated in the following illustration(s)
AND OPERATION, Lifting] and table(s).
G426549 en 09/2004 2004.75 Focus

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Number
1 - Engine front mount to chas-
sis retaining bolts.
Item 2 : Engine front mount to engine retaining
2 - Engine front mount to engine nuts.
retaining nuts. NOTE: Hand tighten the front engine mount to
See Installation Detail engine retaining nuts, install and tighten the front
3 - Engine front mount. engine mount to chassis retaining bolts and then
tighten the front engine mount to engine retaining
4 - VCT oil control solenoid nuts.
5 - VCT oil control solenoid re-
taining bolt.
6 - VCT oil control solenoid
O-ring seal.
G426549 en 09/2004 2004.75 Focus

TO MODEL INDEX
Intake Manifold Tuning (IMT) Valve — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)
1. Remove the throttle Body. For additional

303-04B / 303-04C / 303-04D. 3. Remove the components in the order
2. Detach the vacuum lines from the IMT valve
table(s).
(intake manifold shown removed for clar-
ity).
G295911 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
1 - IMT valve vacuum pipe
2 - IMT valve retaining screws
3 - IMT valve
See Removal Detail
G295911 en 09/2004 2004.75 Focus

TO MODEL INDEX
Removal Details
Item 3 : IMT valve

1. Detach the IMT valve actuator rod from the
intake manifold (intake manifold shown
G295911 en 09/2004 2004.75 Focus

TO MODEL INDEX
Idle Air Control (IAC) Valve — 1.6L (Z6)
1. Raise and support the vehicle. 2. Remove the components in the order
table(s).

Number
1 - IAC valve electrical connec-
tor
Item 2 : IAC valve retaining bolts
2 - IAC valve retaining bolts
See Installation Detail CAUTION: Do not overtighten the IAC
valve retaining bolts. Failure to follow
3 - IAC valve this instruction may result in damage to
4 - IAC valve gasket the brass inserts in the throttle body.
G413459 en 09/2004 2004.75 Focus

TO MODEL INDEX
Knock Sensor (KS) — 1.6L (Z6)
1. Remove the intake manifold. For additional 2. Remove the components in the order
information, refer to Section 303-01C. indicated in the following illustration(s) and
[Engine - 1.6L (Z6), IN-VEHICLE table(s).
REPAIR, Intake Manifold]

Number
1 - KS
G384979 en 09/2004 2004.75 Focus

TO MODEL INDEX
Clutch Pedal Position (CPP) Switch

table(s).

Number
1 - Instrument panel lower trim pad
panel
G414676 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
panel retaining clips

Number
Removal Details
4 - CPP switch wiring harness
retaining clip
Item 4 : CPP switch wiring harness retaining
See Removal Detail
clip
5 - CPP switch electrical con- 1. Detach the CPP switch wiring harness
nector retaining clip from the clutch pedal support
bracket.
6 - CPP switch locking tang
See Removal Detail
7 - CPP switch
G414676 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 6 : CPP switch locking tang Item 3 : Instrument panel lower trim panel
retaining clips
1. CAUTION: Make sure that the clutch 1. Install the instrument panel lower trim
pedal is kept in the rest position and is panel retaining clips to the instrument
not pressed or moved during the panel lower trim panel before installation.
removal of the CPP switch. Failure to
damage to the CPP switch.
Detach the CPP switch from the clutch
pedal support bracket.
1. Release the locking tang.
2. Slide the CPP downwards.
Item 7 : CPP switch

1. CAUTION: Make sure that the clutch
installation of the CPP switch. Failure
damage to the CPP switch.
Install the CPP switch.
G414676 en 09/2004 2004.75 Focus

TO MODEL INDEX
Throttle Position (TP) Sensor — 1.6L (Z6)

(Z6)]
table(s).

Number
1 - TP sensor electrical con-
nector
2 - TP sensor retaining bolts
3 - TP sensor
G417011 en 09/2004 2004.75 Focus

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307-01-1 Automatic Transmission/Transaxle — Vehicles With: 307-01-1

4-Speed Automatic Transaxle (4F27E)
PAGE 1 OF 3
SECTION 307-01 Automatic Transmission/Transaxle

— Vehicles With: 4-Speed Automatic Transaxle
(4F27E)
CONTENTS PAGE
SPECIFICATIONS
Specifications................................................................................................................... 307-01-4
Differential Shaft Shim Selection Chart ........................................................................... 307-01-4
Clutch Plate Usage and Clearance Specification Chart ................................................... 307-01-5
Intermediate/Overdrive Band Bolt Chart .......................................................................... 307-01-5
Line Pressure Chart ........................................................................................................ 307-01-5
Stall Speed Chart ............................................................................................................ 307-01-6
Transaxle Description ...................................................................................................... 307-01-7/37
Diagnostic Strategy.......................................................................................................... 307-01-38

Preliminary Inspection ..................................................................................................... 307-01-38
Diagnostics ..................................................................................................................... 307-01-38
Diagnostic Flow Chart ...................................................................................................... 307-01-39
Preliminary Inspection...................................................................................................... 307-01-40
Know and Understand the Concern................................................................................. 307-01-40
Verification of Condition .................................................................................................. 307-01-40/41
Shift Point Road Test ....................................................................................................... 307-01-42
Torque Converter Diagnosis ............................................................................................ 307-01-43
Torque Converter Operations Test .................................................................................. 307-01-43
Visual Inspection.............................................................................................................. 307-01-44
Shift Linkage Check ........................................................................................................ 307-01-44
Check TSBs and OASIS ................................................................................................. 307-01-44
Carry Out On-Board Diagnostics (KOEO, KOER) ........................................................... 307-01-44
Transaxle Drive Cycle Test .............................................................................................. 307-01-45
After On-Board Diagnostics............................................................................................. 307-01-45
Before Pinpoint Tests ...................................................................................................... 307-01-45
Diagnostic Trouble Code Charts ...................................................................................... 307-01-46/50
Pinpoint Tests - OSC Equipped Vehicle........................................................................... 307-01-51
Shift Solenoid Pre-Diagnosis........................................................................................... 307-01-51
Pinpoint Test A - Shift and Torque Converter Clutch Solenoids (ONLY).......................... 307-01-52/57
Pinpoint Test B - Transmission Fluid Temperature (TFT) Sensor .................................... 307-01-58/63
Pinpoint Test C - Transmission Range (TR) Sensor ........................................................ 307-01-64/68
Pinpoint Test D - Electronic Pressure Control Solenoid (PCA) ........................................ 307-01-69/73
Pinpoint Test E - Turbine Shaft Speed (TSS) Sensor and Output Shaft Speed (OSS)
Sensor.......................................................................................................................... 307-01-74/78
Special Testing Procedures ............................................................................................. 307-01-79
Engine Idle Speed Check................................................................................................ 307-01-79
Line Pressure Test .......................................................................................................... 307-01-79
Stall Speed Test.............................................................................................................. 307-01-80
Air Pressure Tests........................................................................................................... 307-01-81
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PAGE 2 OF 3
Leakage Inspection ......................................................................................................... 307-01-82
Fluid Leakage in Torque Converter Area ........................................................................ 307-01-83
Leak Check Test............................................................................................................. 307-01-84
Leak Check Test With Black Light .................................................................................. 307-01-84
Diagnosis By Symptom.................................................................................................... 307-01-85
Diagnosis by Symptom Chart Directions......................................................................... 307-01-85
Diagnosis by Symptom Index.......................................................................................... 307-01-85
Diagnostic Routines........................................................................................................ 307-01-86
Engagement Concern: No Forward in O/D ONLY ........................................................... 307-01-86
Engagement Concern: No Forward ONLY (All Positions) ............................................... 307-01-87
Engagement Concern: No Reverse ................................................................................ 307-01-88
Engagement Concern: Harsh Reverse ONLY................................................................. 307-01-88
Engagement Concern: Harsh Forward ONLY ................................................................. 307-01-89
Engagement Concern: Harsh Forward ONLY ................................................................. 307-01-90
Engagement Concern: Delayed/Soft Reverse ONLY ...................................................... 307-01-90
Engagement Concern: Delayed/Soft Forward................................................................. 307-01-90
Engagement Concerns: No Forward and No Reverse .................................................... 307-01-91
Engagement Concerns: Harsh Forward and Reverse..................................................... 307-01-92
Engagement Concerns: Delayed/Soft Forward and Reverse .......................................... 307-01-93
Shift Concerns: Some/All Shifts Missing (AUTOMATIC MODE ONLY) ........................... 307-01-94
Shift Concerns: Timing Concerns - Early/Late ................................................................ 307-01-95
Shift Concerns: Timing Concerns - Erratic/Hunting ......................................................... 307-01-96
Shift Concerns: Feel - Soft/Slipping ................................................................................ 307-01-97
Shift Concerns: Feel - Harsh (Some/All) ......................................................................... 307-01-98
Shift Concerns: No 1st Gear in Drive, Engages In Higher Gear ...................................... 307-01-99
Shift Concerns: No First Gear in Manual 1st ................................................................... 307-01-100
Shift Concerns: No Manual 2nd Gear ............................................................................. 307-01-100
Shift Concern: No 1-2 Shift ............................................................................................. 307-01-101
Shift Concern: Soft/Slipping 1-2 ...................................................................................... 307-01-106
Shift Concern: Harsh 1-2 Shift ........................................................................................ 307-01-110
Torque Converter Clutch Operation Concerns: Does Not Apply...................................... 307-01-114
Torque Converter Operation Concerns: Always Applied/Stalls Vehicle ........................... 307-01-115
Torque Converter Clutch Concerns: Cycling/Shudder/Chatter ........................................ 307-01-116
Other Concerns: Shift Lever Efforts High ........................................................................ 307-01-116
Other Concerns: External Leaks ..................................................................................... 307-01-117
Other Concerns: Poor Vehicle Performance ................................................................... 307-01-117
Other Concerns: Noise/Vibration - Forward or Reverse .................................................. 307-01-118
Other Concerns: Engine Will Not Crank.......................................................................... 307-01-118
Other Concerns: No Park Range .................................................................................... 307-01-119
Other Concerns: Overheating ......................................................................................... 307-01-119
Other Concerns: No Engine Braking in Manual 1............................................................ 307-01-120
09/2004 2004.75 Focus

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PAGE3 OF 3
Other Concerns: Fluid Venting or Foaming ..................................................................... 307-01-121
Other Concerns: Slips/Chatters in 1st Gear..................................................................... 307-01-121
Other Concerns: Slips/Chatters in 2nd Gear ................................................................... 307-01-122
Other Concerns: Slips/Chatters in 3rd Gear .................................................................... 307-01-123
Other Concerns: No Engine Braking in ALL Gears.......................................................... 307-01-123/124
GENERAL PROCEDURES
Transmission Fluid Drain and Refill.................................................................................. 307-01-125/127
IN-VEHICLE REPAIR
Fluid Pan, Gasket and Filter............................................................................................. 307-01-128

Main Controls................................................................................................................... 307-01-129/131
Turbine Shaft Speed (TSS) Sensor.................................................................................. 307-01-132
Output Shaft Speed (OSS) Sensor................................................................................... 307-01-133
Halfshaft Seal LH ............................................................................................................. 307-01-134/135
Halfshaft Seal RH ............................................................................................................ 307-01-136/137
Transmission Range (TR) Sensor ................................................................. (17 705 0) 307-01-138/140
Transaxle — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)......................... (17 214 0) 307-01-141/147
DISASSEMBLY
Transaxle ...................................................................................................... (17 214 8) 307-01-148/158
Final Drive Carrier and Differential Assembly................................................................... 307-01-159/160

Pump Assembly ............................................................................................................... 307-01-161/162
Transfer Shaft .................................................................................................................. 307-01-163/164
Forward Clutch................................................................................................................. 307-01-165/168
Direct and Reverse Clutch Assembly ............................................................................... 307-01-169/171
Direct Clutch .................................................................................................................... 307-01-172/174
Reverse Clutch ................................................................................................................ 307-01-175/177
Planetary Assembly ......................................................................................................... 307-01-178/182
Main Control Valve Body.................................................................................................. 307-01-183/186
Transaxle Case................................................................................................................ 307-01-187/189
Torque Converter............................................................................................................. 307-01-190
Torque Converter Leak Check ......................................................................................... 307-01-191/192
Torque Converter End Play Check................................................................................... 307-01-193
ASSEMBLY
Transaxle ...................................................................................................... (17 214 8) 307-01-194/210
INSTALLATION
Transaxle — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)......................... (17 214 0) 307-01-211
09/2004 2004.75 Focus

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SPECIFICATIONS

Item Specification
Automatic transmission fluid WSS-M2C202-B
Thread sealer SD-M4G9107-A
Loctite 5699 WSS-M4G320-A3
Capacities
Litres
Transmission fluid (including cooler and tubes) 6.7
Transfer Shaft Shim Selection Chart

Tool Reading mm Shim Thickness mm (in)
0.34 - 0.39 0.48 - 0.52 (0.0188 - 0.0204)
0.39 - 0.44 0.53 - 0.57 (0.0208 - 0.0224)
0.44 - 0.49 0.58 - 0.62 (0.0228 - 0.0244)
0.49 - 0.54 0.63 - 0.67 (0.0248 - 0.0263)
0.54 - 0.59 0.68 - 0.72 (0.0267 - 0.0283)
0.59 - 0.64 0.73 - 0.77 (0.0287 - 0.0303)
0.64 - 0.69 0.78 - 0.82 (0.0307 - 0.0322)
0.69 - 0.74 0.83 - 0.87 (0.0326 - 0.0342)
0.74 - 0.79 0.88 - 0.92 (0.0346 - 0.0362)
0.79 - 0.84 0.93 - 0.97 (0.0366 - 0.0381)
0.84 - 0.89 0.98 - 1.02 (0.0381 - 0.0401)
0.89 - 0.94 1.03 - 1.07 (0.0405 - 0.0421)
0.94 - 0.99 1.08 - 1.12 (0.0425 - 0.0440)
0.99 - 1.04 1.13 - 1.17 (0.0444 - 0.0460)
1.04 - 1.09 1.18 - 1.22 (0.0464 - 0.0480)
1.09 - 1.14 1.23 - 1.27 (0.0488 - 0.0500)
1.14 - 1.19 1.28 - 1.32 (0.0503 - 0.0519)
Differential Shaft Shim Selection Chart

0.28 - 0.33 0.48 - 0.52 (0.0188 - 0.0204)
0.33 - 0.38 0.53 - 0.57 (0.0208 - 0.0224)
0.38 - 0.43 0.58 - 0.62 (0.0228 - 0.0244)
0.43 - 0.48 0.63 - 0.67 (0.0248 - 0.0263)
0.48 - 0.53 0.68 - 0.72 (0.0267 - 0.0283)
0.53 - 0.58 0.73 - 0.77 (0.0287 - 0.0303)
0.58 - 0.63 0.78 - 0.82 (0.0307 - 0.0322)
0.63 - 0.68 0.83 - 0.87 (0.0326 - 0.0342)
0.68 - 0.73 0.88 - 0.92 (0.0346 - 0.0362)
0.73 - 0.78 0.93 - 0.97 (0.0366 - 0.0381)
0.78 - 0.83 0.98 - 1.02 (0.0385 - 0.0401)
0.83 - 0.88 1.03 - 1.07 (0.0405 - 0.0421)
0.88 - 0.93 1.08 - 1.12 (0.0425 - 0.0440)
0.93 - 0.98 1.13 - 1.17 (0.0444 - 0.0460)
0.98 - 1.03 1.18 - 1.22 (0.0464 - 0.0480)
1.03 - 1.08 1.23 - 1.27 (0.0484 - 0.0500)
1.08 - 1.13 1.28 - 1.32 (0.0503 - 0.0519)
1.13 - 1.18 1.33 - 1.37 (0.0523 - 0.0539)
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1.18 - 1.23 1.38 - 1.42 (0.0543 - 0.0559)
1.23 - 1.28 1.43 - 1.47 (0.0562 - 0.0578)
1.28 - 1.33 1.48 - 1.52 (0.0582 - 0.0598)
1.33 - 1.38 1.53 - 1.57 (0.0602 - 0.0618)
Clutch Plate Usage and Clearance Specification Chart

Steel Friction Selective Snap Ring
Clutch Plates Plates Clearance mm (in) Thickness mm (in)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 1.15 - 1.25 (0.0452 - 0.0492)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 1.35 - 1.45 (0.0531 - 0.0570)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 1.55 - 1.65 (0.0610 - 0.0649)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 1.75 - 1.85 (0.0688 - 0.0728)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 1.95 - 2.05 (0.0767 - 0.0807)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 2.15 - 2.25 (0.0846 - 0.0885)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 1.15 - 1.25 (0.0452 - 0.0492)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 1.35 - 1.45 (0.0531 - 0.0570)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 1.55 - 1.65 (0.0610 - 0.0649)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 1.75 - 1.85 (0.0688 - 0.0728)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 1.95 - 2.05 (0.0767 - 0.0807)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 2.15 - 2.25 (0.0846 - 0.0885)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 1.15 - 1.25 (0.0452 - 0.0492)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 1.35 - 1.45 (0.0531 - 0.0570)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 1.55 - 1.65 (0.0610 - 0.0649)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 1.75 - 1.85 (0.0688 - 0.0728)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 1.95 - 2.05 (0.0767 - 0.0807)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 2.15 - 2.25 (0.0846 - 0.0885)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 1.75 - 1.85 (0.0688 - 0.0728)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 1.95 - 2.05 (0.0767 - 0.0807)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 2.15 - 2.25 (0.0846 - 0.0885)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 2.35 - 2.45 (0.0925 - 0.0964)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 2.55 - 2.65 (0.1003 - 0.1043)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 2.75 - 2.85 (0.1082 - 0.1122)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 2.95 - 3.05 (0.1161 - 0.1200)
Intermediate/Overdrive Band Bolt Chart

Bolt Length Bolt Head Number
39.0 mm 7
38.5 mm 6
38.0 mm 5
37.5 mm 4
37.0 mm 3
36.5 mm 2
36.0 mm 1
Line Pressure Chart

Transmission Range Idle (kPa) Idle (psi) Stall (kPa) Stall (si)
4F27E P. N 345 - 450 50 - 65 1240 - 1450 180 - 210
4F27E R 450 - 585 65 - 85 1930 - 2310 280 - 335
4F27E D. 2. 1 345 - 450 50 - 65 1240 - 1450 180 - 210
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Stall Speed Chart
Engine rpm
1.8L 2300 - 2650
Description Nm lb - ft lb - in
Transaxle flange bolts 48 35 -
Torque converter to flexplate 36 27 -
Main control lever 22 16 -
Floor panel brace 30 22 -
Crashbox 40 30 -
Radiator support bracket 25 18 -
Starter motor bracket retaining nuts 20 15 -
Engine rear mount bracket bolts 90 66 -
Rear engine mount nut 133 98 -
Engine support insulator 80 59 -
Front exhaust pipe flange 47 35 -
Output shaft speed (OSS) sensor 10 - 89
Oil pan to transaxle 7 - 62
Transmission range (TR) sensor 10 - 89
Turbine shaft speed (TSS) sensor 10 - 89
Intermediate/overdrive servo piston cover 13 10 -
Manual lever shaft locking shaft 13 10 -
Final drive input gear bearing retaining nut rota- 0.6 - 0.9 - 5.3 - 8.1
tional torque
Final drive input gear bearing retaining nut preload 400 - 450 256 - 332 -
Parking pawl 13 10 -
Torque converter housing 22 16 -
Main control assembly 9 - 80
Solenoid cable clip 10 - 89
Intermediate/overdrive band anchor 45 33 -
Transaxle housing cover 22 16 -
Fluid pump to transaxle 22 16 -
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Transaxle Description
The 4F27E automatic transmission is an

electronically controlled four-speed transmission The individual ratios are achieved through two
designed for front wheel drive vehicles. planetary gear sets connected one behind the
other.
4F27E stands for:
The individual components of the planetary gear
– 4 - 4 forward drive gears sets are driven or held by means of three
– F - front-wheel drive multiplate clutches, a multiplate brake, a brake
– 27 - maximum input torque of 365 Nm (270 band and a roller one-way clutch.
lb-ft) The torque is transmitted to the final drive
– E - fully electronic control assembly through an intermediate gear stage.
The automatic transmission fluid is changed as
directed by the Scheduled Maintenance Guide
that is supplied with the vehicle.
The manual selector lever gives the driver a
choice of "P" (PARK), "R" (REVERSE), "N"
(NEUTRAL), "D" (DRIVE), "M" (MANUAL MODE),
"+" (TIP UP) and "-" (TIP DOWN).
The transmission has electronic synchronous shift
control (ESSC) which guarantees extremely
smooth gear shifting over the entire life of the
transmission.
The transmission can be diagnosed and tested
using worldwide diagnostic system (WDS)
through the data link connector (DLC), in the
passenger compartment.
Transmission ratios in the individual gears:

Gear Transmission ratio
1st gear 2.816
2nd gear 1.498
3rd gear 1.000
4th gear 0.726
Reverse gear 2.649
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Torque Converter Housing with Torque Converter Assembly and Transmission Fluid Pump Assembly

Number
5 - Transmission fluid pump seal
1 - Torque converter assembly assembly
2 - Transmission differential seal 6 - Transmission fluid pump seal
assembly
7 - Transmission fluid pump
3 - Output shaft speed (OSS) assembly
sensor
8 - Forward clutch cylinder seal
4 - Torque converter housing
9 - Transmission fluid pump
support thrust washer
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Forward Clutch

Number
6 - Transmission forward clutch
1 - Transmission turbine shaft separator steel plates
assembly
2 - Transmission forward clutch friction plate assembly
piston assembly
8 - Transmission forward/direct
3 - Transmission forward piston clutch pressure plate
return spring assembly
9 - Forward clutch retaining ring
balance piston 10 - Transmission forward clutch
cylinder hub
balance piston snap ring
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Differential Assembly and Final Drive Input
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Number
1 - Differential bearing shim
2 - Differential bearing cup
3 - Differential taper roller bear-
ing
4 - Differential bearing assembly
5 - Output shaft speed (OSS)
sensor ring
6 - Differential gear assembly
7 - Pinion thrust washers
8 - Differential pinion gears
9 - Differential side gears
10 - Differential side gear thrust
washer
11 - Retaining pin
12 - Differential pinion shaft
13 - Transfer shaft roller bearing
shim
14 - Transfer shaft roller bearing
cup
15 - Transfer shaft taper roller
bearing
16 - Transfer shaft bearing as-
semblies
17 - Transfer shaft gear assembly
18 - Transfer shaft oil funnel
19 - Transmission final drive gear
20 - Final drive taper roller bear-
ing
21 - Final drive bearing cup
22 - Final drive bearing assem-
blies
23 - Final drive spacer
24 - Final drive snap ring
25 - Final drive retaining nut
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Low/Reverse Clutch and Planetary Gears
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Number
1 - Low/reverse clutch piston
2 - Low/reverse clutch return
spring
3 - Low one-way clutch (OWC)
inner race
4 - Low OWC snap ring
5 - Low/reverse clutch wave
spring
6 - Low/reverse clutch separator
plate assembly
7 - Low/reverse clutch friction
plate assembly
8 - Low/reverse clutch pressure
plate
9 - Low/reverse clutch selective
plate snap ring
10 - Low gear OWC retainer
11 - Low OWC assembly
12 - Snap ring
13 - Front ring gear
14 - Front planetary gear assem-
bly
15 - Front planetary carrier thrust
bearing assembly
16 - Snap ring
17 - Front planetary sun gear
assembly
18 - Front sun gear thrust bearing
assembly
19 - Rear planetary gear assem-
bly
20 - Snap ring
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Clutches and Band
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Number
1 - Reverse clutch snap ring
2 - Rear sun gear assembly
3 - Rear sun gear thrust bearing
assembly
4 - Direct clutch hub assembly
5 - Snap ring
6 - Forward/direct clutch pres-
sure plate
7 - Forward/direct clutch friction
plate assembly
8 - Direct clutch separator plates
9 - Direct clutch balance piston
snap ring
11 - Forward/direct clutch piston
return spring assembly
12 - Direct clutch piston assembly
13 - Direct clutch thrust bearing
assembly
14 - Direct clutch cylinder as-
sembly
15 - Reverse clutch pressure
plate snap ring
16 - Reverse clutch pressure
plate
17 - Reverse clutch separator
plate
18 - Reverse clutch friction plate
assembly
19 - Reverse clutch spring re-
tainer snap ring
20 - Reverse clutch spring re-
tainer
21 - Reverse clutch piston return
spring
22 - Reverse clutch piston as-
sembly
23 - Intermediate drum assembly
24 - Intermediate band assembly
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Transmission Main Control Assembly
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Number Number
1 - Manual control valve as- 18 - Main fluid pressure regulator
sembly valve
2 - Spring retainer plates 19 - Solenoid regulator valve
spring
3 - Bypass clutch control springs
20 - Solenoid regulator valve
4 - Bypass clutch control valves
21 - Intermediate servo accumu-
5 - Modulation valve spring
lator spring
6 - Pressure line modulator
22 - Intermediate servo accumu-
valves
lator piston
7 - Control valve body retaining
23 - Converter regulator valve
bolts M6 x 50
spring
24 - Valve - lock up control and
bolts M6 x 63
3-4 shift (2)
9 - Control valve body seal
25 - Solenoid body gasket
26 - Solenoid body shift control
bolts M6 x 60
valves
11 - Control valve upper body
27 - Solenoid body electrical
12 - Control valve body gasket pressure control valve
13 - Control valve body separator 28 - Solenoid body valve retaing
gasket bolts M6 x 12
14 - Control valve lower body 29 - Solenoid body valve retaing
bolts M6 x 14
15 - Main regulator valve stop
30 - Solenoid shift control throttle
16 - Main regulator valve retain- pressure body
ing plate
17 - Main fluid pressure regulator valve assembly
valve spring
32 - Solenoid shift control bracket
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Transmission Housing Assembly
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Number Number
1 – Parking pawl shaft 19 – Servo piston return spring
2 – Parking pawl brake 20 – Intermediate servo piston
and seal assembly
3 – Parking pawl return spring
21 – Intermediate band servo
4 – Transmission housing dow-
cover retaining bolt M6 x 20
els
5 – Transmission housing
cover
6 – Transmission housing orifice
plug
cover seal
7 – Service identification tag
24 – N/D shift accumulator piston
8 – Turbine shaft speed (TSS)
25 – N/D shift accumulator outer
sensor
spring
9 – TSS sensor retaining bolt
26 – N/D shift accumulator inner
M6-1 x 20
spring
10 – TSS sensor o-ring
27 – 1/2 shift accumulator piston
11 – Transmission rear mount
28 – 1/2 shift accumulator outer
retaining stud
spring
12 – Transmission ventilation cap
29 – 1/2 shift accumulator inner
13 – Breather tube spring
14 – Intermediate band anchor 30 – Line tap plug
stud
31 – Fluid transfer pipe
15 – Differential seal
32 – Parking pawl actuating ad-
16 – 1/8-27 Hex socket justment
17 – Connector ¼ x 5/8 x 22.9 33 – Parking pawl actuating plate
18 – Fluid pan dowels
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Seals, O-rings and Gaskets
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Number
1 - Reverse clutch piston as-
sembly
2 - Direct clutch piston assembly
4 - Low/reverse clutch piston
5 - Turbine shaft speed (TSS)
sensor o-ring
6 - Forward clutch balance pis-
ton
7 - Forward clutch piston as-
sembly
8 - Forward and direct clutch
cylinder seals
9 - Fluid pump seal assembly
10 - Fluid pump seal
11 - Differential seal assembly
12 - Output shaft speed (OSS)
sensor o-ring
13 - Valve body seals
14 - Manual shaft fluid seals
15 - Fluid filter seal
16 - Intermediate band servo
cover seal
17 - Iintermediate band servo
piston and seal assembly
18 - Solenoid body gasket
19 - Control valve body gasket
20 - Transmission housing cover
seals
21 - Reverse clutch cylinder seals
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Snap Rings
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Number
2 - Low/reverse clutch selective
plate snap ring
3 - Final drive retainer snap ring
4 - Forward clutch balance pis-
ton snap ring
5 - Forward/direct clutch selec-
tive plate snap ring
6 - Front sun gear snap ring
7 - Low one-way clutch (OWC)
snap ring
9 - DC balance piston snap ring
10 - Ring - forward/direct clutch
planet retaining
11 - Reverse clutch spring snap
ring
12 - Forward/direct clutch selec-
tive plate snap ring
13 - Rear planetary assembly
snap ring
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Bearings, Bushings and Thrust Washers
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Number
1 - Rear sun gear bearing as-
sembly
2 - Front sun gear bearing as-
sembly
3 - Front planetary carrier bear-
ing assembly
4 - Input shaft taper roller bear-
ings
5 - Input shaft bearing cups
6 - Fluid pump support thrust
washer
7 - Differential taper roller bear-
ings
8 - Differential bearing cups
9 - Differential side gear thrust
washers
10 - Pinion thrust washers
11 - Transfer shaft bearing cups
12 - Transfer shaft taper roller
bearings
13 - Rear planetary carrier bear-
ing assembly
14 - Rear sun gear bearing as-
sembly
15 - Direct clutch cylinder bearing
assembly
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Overview of Construction and Function
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Number Number
1 - Intermediate/overdrive band 1 - Converter housing and im-
peller
2 - Front ring gear planetary
gear sets 2 - Turbine
3 - Low/reverse clutch 3 - Stator
4 - Forward clutch 4 - Torque converter lock-up
clutch
5 - Fluid pump and stator sup-
port 5 - Transmission input shaft
6 - Torque converter The torque converter transmits the engine torque
7 - Transmission input shaft hydraulically to the transmission input shaft.
8 - Differential The stator boosts the torque to the input shaft

(approximately 85 % difference in speed between
9 - Transfer shaft assembly the impeller and the turbine).
10 - Final drive input gear The stator is made of synthetic resin to reduce
weight.
11 - Low one-way clutch
To increase the efficiency of the automatic
12 - Reverse clutch transmission, the torque converter has a lock-up
13 - Direct clutch clutch. When the torque converter lock-up clutch
is closed, the torque is transmitted directly from
the crankshaft through the torque converter
Torque Converter and Torque Converter Lock-up housing to the transmission input shaft.
Clutch
Transmission Fluid Pump and Stator Support
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The stator support is part of the transmission fluid
Item Part Description pump. Splines on the support locate and hold the
Number converters stator.
1 - Stator support Planetary gear sets
2 - Transmission fluid pump The individual gears are shifted by means of two
planetary gear sets connected one behind the
3 - Converter impeller hub other.
4 - Stator Clutches and bands
The transmission fluid pump is a crescent gear The individual ratios are selected by means of four
pump and is driven directly from the crankshaft by multiplate clutches, a brake band and a roller
means of drivers on the converter impeller hub. one-way clutch.
The transmission fluid pump is bolted to the The components are controlled by the
transmission housing. transmission control module (TCM) through pulse
width modulation (PWM) solenoid valves.
Valve Body

Number
3 - Solenoid body electrical
1 - Solenoid body shift control pressure control valve
valve assembly
(on/off) valves The valve body contains six solenoid valves:
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– three solenoid body shift control valves (pulse Solenoid body shift control valves
width modulation solenoid valves),
The solenoid body shift control valves control the
– two solenoid body shift control (on/off) valves, pressure to the bands and clutches.
– one solenoid body electrical pressure control
Solenoid body shift control (on/off) valves
valve (variable force solenoid).
The solenoid body shift control (on/off) valves
The individual clutches and bands are supplied
switch the different oil passages in the valve body
pressure from the solenoid body shift control
to direct the pressure to the individual clutches
valves and the solenoid body shift control (on/off)
and bands.
valves and thus the gears are shifted.
Solenoid body electrical pressure control valve
The solenoid body shift control valves allow direct
(VFS)
actuation of the clutches and bands to ensure
extremely smooth gear shifting through precise The solenoid body electrical pressure control
pressure regulation. valve (variable force solenoid) controls the
The solenoid body electrical pressure control required main line pressure for the individual
valve (variable force solenoid) ensures that transmission ranges.
sufficient hydraulic pressure is available in all The main line pressure is dependent on engine
operating conditions. load.
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Internal Shift Mechanism
The shift lever is secured on a square on the

Item Part Description manual shaft. Axial movement of the selector
Number lever cable is changed into rotational movement of
1 - Lever on manual shaft the manual shaft.
2 - Manual shaft The manual shaft operates the parking pawl
engaging lever and the actuating lever of the
3 - Parking pawl engaging lever manual valve.
4 - Lever and bracket assembly The manual valve, a valve operated entirely
5 - Manual valve manually, is moved by means of the manual valve
actuating lever in the valve body.
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The manual valve guarantees the functions during Manual selector lever position "R"
hydraulic emergency operation.
In manual selector lever position "R" reverse gear
is selected. REVERSE allows the vehicle to be
External Shift Mechanism operated in a rearward direction, at a reduced
gear ratio.
Manual selector lever position "N"
In manual selector lever position "N" no gear is
selected. The drive line is not locked, so the
wheels are free to rotate.
The vehicle may be started in NEUTRAL.
Manual selector lever position "D"
In manual selector lever position "D" the
transmission control allows all the gears to be
selected.
Manual selector lever position "M"
In manual selector lever position "M" the gears
can be selected manually by moving the selector
Number
lever to the "-" or "+" positions.
1 - Manual release mechanism The transmission control only allows the up or
2 - Shift selector gate downshift to take place when the corresponding
vehicle speed has been reached.
3 - Automatic shift gate
The selector levers allow for manual shifting of the
Range selection
transmission.
The transaxle range selector has seven positions: Changing from automatic mode to manual mode
"P", "R", "N", "D", "M", "-" and "+". is achieved by moving the selector lever from
Manual selector lever position "P" position "D" in the automatic shift gate to position
"M" in the select shift gate.
NOTE: For safety reasons always apply the
parking brake whenever the vehicle is parked. In select shift mode, gears can be selected
manually by moving the selector lever to the "-" or
In manual selector lever position "P" no gear is
"+" positions.
selected. The parking pawl is engaged manually
by the manual selector lever cable and the shift
shaft.
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which is located above the transmission range

Item Part Description (TR) sensor.
Number The selector lever cable adjustment mechanism is
1 - Selector lever cable - trans- locked at the transaxle end of the selector lever
axle end cable.
2 - Gearshift cable bushing re- At the selector lever end the cable is clipped onto
taining nuts a pin.
3 - Selector lever cable - selec-

tor lever end
The selector lever adjustment mechanism is
connected to the transaxle selector lever pin,
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Intermediate Gear Stage and Final Drive Assembly Transmission Control System
The transmission control module (TCM) is

separate from the PCM mounted on the firewall on
the left-hand side in the vehicle's direction of
travel.
During routine servicing, the TCM must be
calibrated using the WDS.
Together with the new TCM, numerous modes
were changed or added in the transmission
control system of the 4F27E:
•Select Shift mode
•Fast-off mode
•Kick down mode
In select shift mode, the gears can be selected
Item Part Description manually using the gear selector lever.
Number
Fast-off mode prevents the transmission from
1 - Final drive input gear shifting to a higher gear when the driver suddenly
takes his foot off the accelerator. By staying in the
2 - Transfer shaft input gear lower gear, the engine braking effect can be better
3 - Transfer shaft output gear taken advantage of.
4 - Differential The kick down mode allows the transmission
control system to differentiate between kick down
The final drive input gear is splined to the planet and wide open throttle (WOT).
carrier of the front planetary gear set and drives
the transfer shaft input gear of the intermediate
gear stage. Electronic Synchronous Shift Control (ESSC)
The transfer shaft output gear of the intermediate Control of shift operations
gear stage drives the final drive assembly.
The torque is transmitted to the halfshafts through
the final drive assembly. During a shift operation certain elements are
released while others are actuated. Ideally this
The differential offsets differences in the speed of process takes place simultaneously
rotation of the halfshafts. (synchronously) to avoid jerky gear shifting.
The intermediate gear stage is designed so that The time for the shift operation should remain
the final drive ratio can be adapted to within the time limits provided.
requirements when the automatic transmission is
used in conjunction with different engines. When the shift operation is controlled
conventionally, the pressure build up and
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reduction at the shift elements are set and defined In both cases a jerk will be felt during the shift
for ideal conditions (synchronous shifting). operation.
As there is no way of influencing the control in the In addition, wear in the shift elements leads to a
event of different levels of wear in the shift lengthening of the shift operation. Therefore,
elements, when the transmission has been used shifting takes longer when the transmission has
for a fairly high mileage, it is possible that the accumulated a higher mileage.
pressure build up and reduction may no longer be
Control of shift operations with ESSC
synchronous.
ESSC monitors the shift operations and is able to
The result or premature pressure reduction at the
adapt to the wear in the shift elements over the life
element to be switched off is an unwanted rise in
of the transmission.
the turbine shaft speed as the element to be
switched on cannot transmit the input torque. The system monitors the shift time whether the
shift operation is synchronous.
The result of delayed pressure reduction at the
element to be switched off is an unwanted If the TCM detects a deviation from the stored
decrease in the turbine shaft speed as both shift values for the shift time and synchronization of the
elements transmit the input torque. In the process shift operation, the pressure build up or reduction
the torque is transmitted to the transmission is adapted accordingly.
housing through internal locking.
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Turbine Shaft Speed (TSS) Sensor
The TSS sensor is located on the transmission If the TSS sensor fails, the signal of the output
housing over the transmission input shaft. shaft speed (OSS) sensor is used as a substitute
signal.
The TSS sensor is an inductive sensor which
senses the speed of rotation of the transmission
input shaft.
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Output Shaft Speed (OSS) Sensor
The OSS sensor is located on the transmission

housing above the rotor in the differential.
The OSS sensor is an inductive sensor which
detects the vehicle speed by means of a rotor on
the differential.
If the OSS sensor fails, the signal of the TSS
sensor is used as a substitute signal.
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Transmission Range (TR) Sensor Item Part Description
Number
3 - Manual release mechanism
When the ignition is switched on, the manual
selector lever shift lock solenoid is actuated by
depressing the brake pedal (signal from the
stoplamp switch). This retracts the locking pin so
that the manual selector lever can be moved out of
position "P".
Substitute Function
The TR sensor is located on the manual shaft on

the transmission housing.
If the connection is cut the vehicle cannot be
started.
Manual Selector Lever Shift Lock Solenoid

Number
1 - Manual release mechanism
cover
If the brake signal should fail, due to a malfunction,

manual unlocking is possible.
NOTE: If position "P" is selected again the manual
Item Part Description selector lever is locked again.
Number
Remove the manual release mechanism cover
1 - Solenoid and using a suitable object (ignition key) press into
the opening until the manual selector lever can be
2 - Retaining pin moved out of position "P".
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Diagnostic Strategy
Troubleshooting an electronically controlled Preliminary Inspection

automatic transaxle is simplified by using the
proven method of diagnosis. One of the most • Know and understand the customers concern.
important things to remember is that there is a • Verify the concern by operating the vehicle.
definite procedure to follow. • Check the fluid levels and condition.
NOTE: Do not take any short cuts or assume that • Check for non-factory add-on items.
critical checks or adjustments have already been • Check shift linkages for correct adjustment.
made. • Check TSBs and OASIS messages regarding
Follow the procedures as written to avoid missing the concern.
critical components or steps.
To correctly diagnose a concern have the
Diagnostics
following publications available:
• Carry out on-board diagnostic procedures key
• Powertrain Control/Emissions Diagnosis
on engine off (KOEO) and key on engine
(PCED) Manual.
running (KOER).
• TSBs and OASIS Messages.
• Record all diagnostic trouble codes (DTCs).
• Wiring Diagram.
• Repair all non-transaxle codes first.
These publications provide the necessary • Repair all transaxle codes second.
information when diagnosing transaxle concerns.
• Erase all continuous codes and attempt to
Use the Diagnostic Flow Chart as a guide and repeat them.
follow the steps as indicated. • Repair all continuous codes.
• If only pass codes are obtained, proceed to the
Diagnosis by Symptom Index for further
information and diagnosis.
Follow the diagnostic sequence to diagnose and
repair the concern the first time.
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Diagnostic Flow Chart
Test Result Action

Know and understand the customer
concerns
Check the fluid level and condition
Verify the concern by operating the
vehicle
Check for non factory installed items
and verify correct installation
Check the shift linkage adjustments
Check TSBs and OASIS messages for
vehicle concerns
Carry out quick test both KOER and
KOEO
Record all codes
1) Did you record any Diagnostic Yes Repair all hard Diagnostic Trouble Codes. Follow
Trouble Codes? the pinpoint tests. Refer to the PCED first, then
this Workshop Manual.
No REFER to Diagnosis by Symptom in this section.
then GO to Step 5.
2) Are any continuous test memory Yes Clear codes and carry out drive cycle test.
codes present?
No GO to Step 4.
3) Did the continuous test memory Yes Repair all continuous test memory codes. Follow
codes reappear? the pinpoint tests. Refer to the PCED then the
transaxle reference manual, then this Workshop
Manual, then GO to Step 4
No GO to Step 4.
4) Is the concern repaired? Yes Carry out the final quick test to verify that no Di-
agnostic Trouble Codes are present. Clear
memory codes. Return vehicle to customer.
No REFER to Diagnosis by Symptom in this section.
5) Are there any electrical concerns? Yes Install the scan tool and carry out output state
control test, then GO to Step 6.
No Refer to the hydraulic and mechanical routine to
diagnose and repair the concern, then GO to Step
7.
6) Was the transaxle concern cor- Yes Refer to the PCED, intermittent fault diagnosis
rected when the scan tool was in- section and use the scan tool to diagnose cause
stalled? of concern in the processor, vehicle harness or
external inputs (sensors or switches).
No Refer to the hydraulic and mechanical routine to
diagnose the concern, then GO to Step 7.
7) Is the concern repaired? Yes Carry out the final quick test to verify that no di-
agnostic trouble codes are present. Clear mem-
ory codes. Return the vehicle to the customer.
No Get assistance from Technical Hotline.
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Preliminary Inspection
dependent, shift dependent, gear dependent,

The following items must be checked prior to
range dependent, or temperature dependent.
beginning the diagnostic procedures:
Check Fluid Level

Know and Understand the Concern
Under normal conditions, there is no requirement
In order to correctly diagnose a concern, first to check the transaxle fluid level. However, if the
understand the customer complaint or condition. transaxle is not functioning correctly, the transaxle
Customer contact may be necessary in order to may slip, shift slowly or there may be some sign of
begin to verify the concern. Understand the fluid leakage, the fluid level should be checked.
conditions as to when the concern occurs, for
example: CAUTION: The vehicle should not be
driven if the fluid level is below the
• hot or cold vehicle temperature. bottom line on the fluid level indicator
• hot or cold ambient temperature. and the ambient temperature is above
• vehicle driving conditions. 10°C (50°F).
• vehicle loaded/unloaded. NOTE: Automatic transmission fluid expands
when warmed. To obtain an accurate fluid level
After understanding when and how the concern
check, drive the vehicle until normal operating
occurs, proceed to verify the concern.
temperature is reached, approximately 30 km (20
miles).
Verification of Condition NOTE: If the vehicle has been operated for an
extended period at high speeds, in city traffic
This section provides information that must be during hot weather or pulling a trailer the vehicle
used in both determining the actual cause of should be turned OFF for approximately 30
customer concerns and executing the appropriate minutes to allow the fluid to cool before checking.
procedures. NOTE: Incorrect fluid level may affect the
The following procedures must be used when transaxle operation and could result in transaxle
verifying customer concerns for the engine. damage. To correctly check and add fluid to the
transaxle, refer to the procedures in this section.
Determine Customer Concern
NOTE: Some transaxle conditions can cause
engine concerns. The torque converter clutch not
disengaging will stall the engine.
Determine customer concerns relative to vehicle
use and dependent driving conditions, paying
attention to the following items:
• hot or cold vehicle operating temperature
• hot or cold ambient temperatures
• type of terrain
• vehicle loaded/unloaded
• city/highway driving
• upshift
• downshift
• coasting
• engagement
• noise/vibration - check for dependencies,
either RPM dependent, vehicle speed
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1. Drive the vehicle 30 km (20 miles) or until the Adding Fluid
vehicle reaches normal operating
temperature. CAUTION: The use of any other type of
transaxle fluid than specified could result
2. Park the vehicle on a level surface and
in transaxle damage.
engage the parking brake.
3. With your foot on the brake, start the engine If fluid needs to be added, add fluid in 0.25L (1/2
and move the range selector lever through all pint) increments through the oil filler tube. Do not
the gear ranges. Allow sufficient time for each overfill the fluid. For fluid type, refer to the General
gear to engage. Specification chart in this section.
4. Place the range selector in "P" (park) and
leave the engine running. Check The Fluid Condition
5. Remove the fluid level indicator and wipe it 1. Check the fluid level. For additional
clean with a lint free cloth. information, refer to check fluid level in this
6. Install the fluid level indicator, making sure section.
that it is fully seated in the filler tube. 2. Observe the color and the odor. The color
7. Remove the fluid level indicator. The fluid under normal circumstances should be
should be within the designated areas. reddish, not brown or black.
3. Allow the fluid to drip onto a facial tissue and
examine the stain.
4. If evidence of solid material is found, the
transaxle fluid pan should be removed for
further inspection.
5. If fluid contamination or transaxle failure is
confirmed by the sediment in the bottom of the
transaxle fluid pan, the transaxle must be
disassembled and completely cleaned.
6. Carry out diagnostic checks and adjustments.
REFER to Diagnosis by Symptom in this
section.
Item Description
1 Maximum fluid level
2 Normal operating fluid level
range 66°C-77°C (150°F-170°F)
3 Minimum fluid level
High Fluid Level

A fluid level that is too high may cause the fluid to
become aerated due to the churning action of the
rotating internal parts. This will cause erratic
control pressure, foaming, loss of fluid from the
vent tube and possible transaxle damage. If an
overfill reading is indicated, adjust fluid to correct
level.
Low Fluid Level

A low fluid level could result in poor transaxle
engagement, slipping, or damage. This could also
indicate a leak in one of the transaxle seals or
gaskets.
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Shift Point Road Test
shift from third to second, or third to first,

This test verifies that the shift control system is
depending on vehicle speed, and torque
operating correctly.
converter clutch should release.
1. Bring engine and transaxle up to normal 6. With vehicle speed above 48 km/h (30 mph),
operating temperature. move the transaxle range selector lever from
2. Operate the vehicle with the selector lever in D position to first position and release the
the D position (overdrive switch ON). accelerator pedal. The transaxle should
3. Apply minimum throttle and observe the immediately downshift to second gear. When
speeds at which upshift occurs and torque vehicle speed drops below 32 km/h (20 mph),
converter engages. Refer to the following Shift the transaxle should downshift into first gear.
Speeds Chart for the appropriate final drive 7. If transaxle fails to upshift/downshift or torque
ratio (FDR). (Also refer to the Automatic converter clutch does not apply/release.
Transaxle Specifications Issue.) REFER to Diagnosis by Symptom in this
4. Stop the vehicle. Select the D position section. for possible causes.
(overdrive switch OFF). Repeat Step 3. The
transaxle will make all upshifts except third to
fourth and torque converter clutch apply
should occur above 80 km/h (50 mph).
5. Press the accelerator pedal to the floor, wide
open throttle (WOT). The transaxle should
Shift Speeds Chart

Throttle Position Shift Final Drive Ratio Final Drive Ratio Final Drive Ratio
3.67:1 3.90:1 4.15:1
km/h mph km/h mph km/h mph
Closed 4-3 35-19 22-12 35-19 22-12 30-20 48-32
Closed 3-2 19-3 12-2 19-3 12-2 35-19 22-12
Closed 2-1 19-3 12-2 19-3 12-2 51-35 32-22
Minimum monitor PID 1-2 12-28 8-18 11-27 7-17 11-27 7-17
TP volt = 1.25
TP volt = 1.25
TP volt = 1.25
Wide Open 1-2 41-57 26-36 45-61 28-38 43-59 27-37
Wide Open 2-3 88-104 55-65 96-112 60-70 88-104 55-65
Wide Open 3-4 123-140 77-87 135-151 84-94 138-154 86-96
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Torque Converter Diagnosis
Prior to installing a new torque converter, all 1. Carry out the Quick Test; refer to On-Board
diagnostic procedures must be followed. This is to Diagnostics With Diagnostic Tool in this
prevent the unnecessary installation of new or section. Check for DTCs.
remanufactured torque converters. Only after a Refer to the Diagnostic Trouble Code Chart.
complete diagnostic evaluation can the decision 2. Connect a tachometer to the engine.
be made to install a new torque converter.
3. Bring the engine to normal operating
Begin with the normal diagnostic procedures as temperature by driving the vehicle at highway
follows: speeds for approximately 15 minutes in O/D
position.
1. Preliminary Inspection.
4. After normal operating temperature is reached,
2. Know and Understand the Customer
maintain a constant vehicle speed of about 80
Concern.
km/h (50 mph) and tap the brake pedal with
3. Verify the Concern - Carry out the Torque the left foot.
Converter Clutch Operation Test; refer to
5. The engine RPM should increase when brake
Torque Converter Operation Test in this
pedal is tapped, and decrease about five
section.
seconds after pedal is released. If this does
4. Carry out Diagnostic Procedures. not occur, refer to Torque Converter
• Run on-board diagnostics; refer to On-Board Operation Concerns in the Diagnosis by
Diagnostics With Diagnostic Tool in this Symptom Index.
section. 6. If the vehicle stalls in O/D or manual 2 at idle
- Repair all non-transaxle related DTCs first. with vehicle at a stop, move the position
- Repair all transaxle DTCs. selector lever to manual 1 position. If the
- Rerun on-board diagnostic to verify repair. vehicle stalls, refer to Torque Converter
Operation Concerns in the Diagnosis by
• Carry out the Line Pressure Test; Symptom section. Repair as necessary. If the
refer to Line Pressure Test in this section. vehicle does not stall in O/D position.
• Carry out the Stall Speed Test; refer to Stall REFER to Diagnosis by Symptom in this section.
Speed Test in this section.
• Carry out the Diagnosis by Symptom Index.
section.
- Use the index to locate the appropriate
routine that best describes the symptom(s).
The routine will list all possible components
that may cause or contribute to the symptom.
Check each component listed; diagnose and
repair as necessary before replacing the
torque converter.
Torque Converter Operations Test

This test verifies that the torque converter clutch
control system and the torque converter are
operating correctly.
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Visual Inspection
This inspection will identify modifications or

additions to the vehicle operating system that may
affect diagnosis. Inspect the vehicle for non-Ford Carry Out On-Board Diagnostics (KOEO,
factory add-on devices such as: KOER)
• Electronic add-on items: After a road test, with the vehicle warm and before
disconnecting any connectors, carry out the Quick
- air conditioning Test using scan tool. Refer to the PCED for
- generator (alternator) diagnosis and testing of the powertrain control
- engine turbo system.
- cellular telephone
- cruise control
- cb radio
- linear booster
- backup alarm signal
- computer
• Vehicle modification:
These items, if not installed correctly, will affect
the powertrain control module (PCM), or transaxle
function. Pay particular attention to add-on wiring
splices in the PCM harness or transaxle wiring
harness, abnormal tire size, or axle ratio changes.
• leaks;
refer to Leakage Inspection in this section.
• correct linkage adjustments;
Shift Linkage Check

Check shift linkage adjustment by matching the
detents in the transaxle range selector lever with
those in the transaxle. If they match, the error is in
the indicator. Do not adjust the shift linkage.
Hydraulic leakage at the manual control valve can
cause delay in engagements and slipping while
operating if the linkage is not correctly adjusted;
refer to Section 307-05 for shift linkage
adjustment.
Check TSBs and OASIS

Refer to all TSBs and OASIS messages which
pertain to the transaxle concern and follow the
procedure as outlined.
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Transaxle Drive Cycle Test
NOTE: Always drive the vehicle in a safe manner condition and symptoms. This chart will be helpful
according to driving conditions and obey all traffic in referring to the correct manual(s) and aids in
laws. diagnosing internal transaxle concerns and
external non-transaxle inputs. The pinpoint tests
NOTE: The Transaxle Drive Cycle Test must be
are used in diagnosing transaxle electrical
followed exactly. Transaxle failure must occur four
concerns. Make sure that the vehicle wiring
times consecutively for shift error DTC code to be
harness and the PCM are diagnosed as well. The
set, and five times consecutively for continuous
PCED will aid in diagnosing non-transaxle
torque converter clutch code to set.
electronic components.
NOTE: When carrying out the Transaxle Drive
Cycle Test, refer to the Solenoid Application Chart
for correct solenoid operation. Before Pinpoint Tests
After carrying out the Quick Test, use the NOTE: Before entering pinpoint tests, check the
Transaxle Drive Cycle Test for checking powertrain control module wiring harness for
continuous codes. correct connections, bent or broken pins,
1. Record and then erase Quick Test codes. corrosion, loose wires, correct routing, correct
2. Warm engine to normal operating seals and their condition. Check the PCM,
temperature. sensors and actuators for damage. Refer to the
PCED.
3. Make sure transaxle fluid level is correct.
NOTE: If a concern still exists after electrical
4. With transaxle in O/D position, moderately
diagnosis. REFER to Diagnosis by Symptom in
accelerate from stop to 80 km/h (50 mph).
this section.
This allows the transaxle to shift into fourth
gear. Hold speed and throttle open steady for If DTCs appear while carrying out the on-board
a minimum of 15 seconds. diagnostics, refer to the Diagnostic Trouble Code
NOTE: PCA, EPC and VFS all refer to the Chart for the appropriate repair procedure. Prior to
solenoids. PCA is preffered for this transmission entering pinpoint tests, refer to any TSBs and
because the scan tool displays PCA. OASIS messages for transaxle concerns.
5. With transaxle in fourth gear and maintaining
steady speed and throttle opening, lightly
apply and release brake to operate stop lamps.
Then hold speed and throttle steady for a
minimum of five seconds.
6. Brake to a stop and remain stopped for a
minimum of 20 seconds.
7. Repeat steps 4 through 6 at least five times.
8. Carry out Quick Test and record continuous
DTCs.
After On-Board Diagnostics

NOTE: The vehicle wiring harness, powertrain
control module and non-transaxle sensors may
affect transaxle operations. Repair these
concerns first.
After the on-board diagnostic procedures are
completed, repair all DTCs.
Begin with non-transaxle related DTCs, then
repair any transaxle related DTCs. Refer to the
Diagnostic Trouble Code Chart for information on
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Diagnostic Trouble Code Charts
Diagnostic Trouble Code Chart

Five
Digit
DTC Component Description Condition Symptom Action
P0705 TR Sensor TR Circuit failure TR circuits, indicating Increase in con- Inspect the tail
an invalid pattern in trol pressure lamp ground cir-
TR_D. Condition (harsh shifts). cuit. Refer to
caused by a short to Defaults to D for Pinpoint Test C.
ground or an open in an invalid posi-
P/N, D, R, 2 or 1 tion.
circuits. Open in the
tail lamp ground cir-
cuit. This DTC can be
set by an incorrectly
adjusted TR sensor.
P0712 TFT 157°C (315°F) Voltage drop across Possible firm shift Refer to Pinpoint
indicated TFT TFT sensor too low feel. Test B.
sensor circuit for scale set for
grounded temperature 157°C
(315°F).
P0713 TFT -40°C (-40°F) in- Voltage drop across Possible firm shift Refer to Pinpoint
dicated TFT TFT sensor too high feel. Test B.
sensor circuit for scale set tem-
open perature -40°C
(-40°F).
P0715 TSS Insufficient input PCM detected a loss Harsh shifts, no Refer to Pinpoint
from turbine shaft of TSS signal during torque converter Test E.
speed sensor operation. clutch activation,
and harsh en-
gagement.
P0717 TSS Turbine shaft PCM detected a loss Harsh shifts, no Refer to Pinpoint
speed sensor of TSS signal during torque converter Test E.
signal intermittent operation. clutch activation,
and harsh en-
gagement.
P0718 TSS TSS sensor sig- PCM has detected an Harsh shifts, no Refer to Pinpoint
nal erratic erratic TSS signal torque converter Test E.
clutch activation,
and harsh en-
gagement.
P0720 OSS Insufficient input PCM detected a loss Harsh shift, pos- Refer to Pinpoint
from OSS sensor. of OSS signal during sible abnormal Test E.
operation. shift schedule.
P0721 OSS OSS sensor sig- PCM has detected an Harsh shift, ab- Refer to Pinpoint
nal noisy erratic OSS signal. normal shift Test E.
schedule.
P0722 OSS OSS sensor sig- PCM has detected an Harsh shift, ab- Refer to Pinpoint
nal intermittent intermittent OSS sig- normal shift Test E.
nal. schedule.
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Five
Digit
P0731 SSA, SSB, 1st gear error No 1st gear Incorrect gear Refer to Solenoid
SSC or inter- selection de- On/Off Charts.
nal parts pending on failure Refer to Pinpoint
or mode and Test A.
manual lever po-
sition. Shift errors
may also be due
to other internal
transmission
concerns (stuck
valves, damaged
friction material).
Engine RPM
could be higher or
lower than ex-
pected.
P0732 SSA, SSB, 2nd gear error No 2nd gear. Incorrect gear Refer to Solenoid
or mode and Test A.
manual lever po-
may also be due
to other internal
transmission
concerns (stuck
valves, damaged
friction material).
Engine RPM
could be higher or
lower than ex-
pected.
P0733 SSA, SSB, 3rd gear error No 3rd gear. Incorrect gear Refer to Solenoid
or mode and Test A.
manual lever po-
may also be due
to other internal
transmission
concerns (stuck
valves, damaged
friction material).
Engine RPM
could be higher or
lower than ex-
pected.
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Five
Digit
P0734 SSA, SSB, 4th gear error No 4th gear. Incorrect gear Refer to Solenoid
or mode and Test A.
manual lever po-
may also be due
to other internal
transmission
concerns (stuck
valves, damaged
friction material).
Engine RPM
could be higher or
lower than ex-
pected.
P0741 TCC TCC slippage The PCM picked up TCC slip- REFER to Diag-
detected an excessive amount page/erratic or no nosis by Symp-
of TCC slippage torque converter tom in this sec-
during normal vehicle clutch operation. tion.
operation.
P0750 SSA SSA solenoid SSA circuit failed to No reverse gear Refer to Pinpoint
circuit failure provide voltage drop (short) or no Test A.
across solenoid. fourth gear
Circuit open or (open).
shorted or PCM
driver failure during
on-board diagnostic.
P0751 SSA SSA functional Mechanical or hy- Not all gearsREFER to Diag-
failure draulic failure of the present. nosis by Symp-
shift solenoid. tom in this sec-
tion.
P0755 SSB SSB solenoid SSB circuit fails to Not all gears Refer to Pinpoint
circuit failure provide voltage drop present. No con- Test A.
across solenoid. verter clutch ap-
Circuit open or ply in third and
shorted or PCM fourth gears.
P0756 SSB SSB functional Mechanical or hy- Not all gears REFER to Diag-
failure draulic failure of the present. No con- nosis by Symp-
shift solenoid. verter clutch ap- tom in this sec-
ply in third and tion.
fourth gears.
P0760 SSC SSC solenoid SSC circuit fails to Not all gears Refer to Pinpoint
circuit failure provide voltage drop present. Test A.
across solenoid.
Circuit open or
shorted or PCM
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Five
Digit
P0761 SSC SSC functional Mechanical or hy- Not all gears Refer to Pinpoint
failure draulic failure of the present. Test A.
shift solenoid.
P0765 SSD SSD solenoid SSD circuit fails to Not all gears Refer to Pinpoint
across solenoid.
Circuit open, shorted
or PCM driver circuit
failure during
on-board diagnos-
tics.
P0766 SSD SSD functional Mechanical or hy- Not all gears Refer to Pinpoint
shift solenoid.
P0770 SSE SSE solenoid SSE circuit failed to Not all gears Refer to Pinpoint
across solenoid.
Circuit open. Shorted
or PCM driver circuit
failed during
on-board diagnos-
tics.
P0771 SSE SSE functional Mechanical or hy- Not all gears Refer to Pinpoint
shift solenoid.
P1700 — Undetermined Transmission failed TransmissionWhen this code is
failure to neutral. functional failure.
shown in con-
junction with
other codes, re-
pair the other
codes first, then
retest. If this code
reappears,
REFER to Diag-
nosis By Symp-
tom in this sec-
tion.
P1705 TR Sensor TR not in PARK KOEO/KOER not run Harsh shifts or Refer to Pinpoint
or NEUTRAL in PARK or engagements. Test C. Rerun
during NEUTRAL; or TR KOEO/KOER in
KOEO/KOER. circuit failure. PARK or
NEUTRAL.
P1710 TFT Stuck in mid- PCM never detects a Occasional hard Refer to Pinpoint
range. change in fluid tem- shifts. Test B.
perature.
P1711 TFT TFT out of Transmission not at DTC set-vehicle Warm or cool ve-
on-board diag- operating tempera- cold or over- hicle to normal
nostic range ture during on-board heated. operating tem-
diagnostic. perature. Refer to
Pinpoint Test B.
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Five
Digit
P1713 TFT No change in TFT PCM has detected no Incorrect TCC Refer to Pinpoint
- low range TFT change at low engagement Test B.
range during opera- schedule, harsh
tion. engagement,
harsh shifts.
P1718 TFT No change in TFT PCM has detected no Incorrect TCC Refer to Pinpoint
- high range TFT change at high engagement Test B.
range during opera- schedule, harsh
tion. engagement,
harsh shifts.
P1746 EPC EPC solenoid Voltage through EPC Open cir- Refer to Pinpoint
circuit open solenoid is checked. cuit-causes Test D.
Error is noted if tol- maximum EPC
erance is exceeded. pressure, harsh
engagements
and shifts.
P1747 EPC EPC solenoid Voltage through EPC Short circuit Refer to Pinpoint
circuit failure, solenoid is checked. causes maximum Test D.
shorted circuit An error will be noted EPC pressure,
if tolerance is ex- harsh engage-
ceeded. ment and shifts.
P1780 TCS TCS input incor- TCS voltage incor- No overdrive Rerun on-board
rect for selected rect cancel when lever diagnostic and
position is moved. cycle switch.
REFER to Sec-
tion 307-05A /
307-05B.
P1783 TFT Transmission Transmission fluid Increase in con- Refer to Pinpoint
overtemp condi- temperature ex- trol pressure. Test B.
tion indicated ceeded 135°C
(275°F).
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Pinpoint Tests - OSC Equipped Vehicle
Special Tool(s)
EEC-V104 Pin Breakout Box
Special Tool(s) 014–00950 or equivalent
73III Automotive Meter
105-R0057 or equivalent
Any time an electrical connector or solenoid body

is disconnected, inspect the connector for terminal
condition, corrosion and contamination. Also
inspect the connector seal for damage. Clean,
repair or install new as necessary.
Worldwide Diagnostic System
(WDS) 418 - F224, or
equivalent scan tool Shift Solenoid Pre-Diagnosis
Use the shift solenoid operation chart when
carrying out Pinpoint Test A.
Pressure Gauge Assembly
307–004 (T57L-77820–A)
Solenoid Operation Chart - Converter Disengaged

Base
Gearshift PCM Shift Shift Shift Shift Shift
Selector Commanded Solenoid A Solenoid B Solenoid C Solenoid D Solenoid E
Position Gear (on/off) (on/off) (PWM) (PWM) (PWM)
P/N P/N On Off Off Off Off
R R Off Off Off Off Off
D 1 Off Off Off On On
1(M) On On Off Off On
2 Off Off Off Off On
3 Off Off Off Off Off
4 On Off On Off Off
With an on/off solenoid, OFF = No Hydraulic Flow With an PWM solenoid, OFF = Full Hydraulic Flow
Solenoid Operation Chart - Converter Engaged

Base
Gearshift PCM Shift Shift Shift Shift Shift
Selector Commanded Solenoid A Solenoid B Solenoid C Solenoid D Solenoid E
Position D Gear (on/off) (on/off) (PWM) (PWM) (PWM)
D 3 Off On On Off Off
4 On On On Off Off
With an on/off solenoid, OFF = No Hydraulic Flow.
With an PWM solenoid, OFF = Full Hydraulic Flow
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Pinpoint Test A - Shift and Torque Converter Clutch Solenoids (ONLY)
PINPOINT TEST A: SHIFT AND TORQUE CONVERTER CLUTCH SOLENOIDS (ONLY)
NOTE: Refer to the Transaxle Vehicle Harness Connector illustration preceding these pinpoint tests.
NOTE: Refer to the Transaxle Internal Harness Diagram illustration preceding these pinpoint tests.
NOTE: Read and record all DTCs. All TR Sensor and OSS DTCs must be repaired before entering
Output State Control (OSC).
A1: ELECTRONIC DIAGNOSTICS SET UP
2 Shift selector lever to position P.
3 Make sure the transaxle harness connector is
fully seated, terminals are fully engaged in
connector and in good condition before pro-
ceeding.
4 Connect the diagnostic tool.Scan Tool
6 Enter the following diagnostic mode: Diagnostic
Data Link.
7 Enter the following diagnostic mode: PCM.
8 Enter the following diagnostic mode: Active
Command Modes.
9 Enter the following diagnostic mode: Output
State Control (OSC).
10 Enter the following diagnostic mode: Trans -
Bench Mode.
• Does vehicle enter Trans - Bench Mode?
→ Yes
REMAIN in Trans - Bench Mode. GO to A2
→ No
REPEAT procedure to enter Trans - Bench
Mode. If vehicle did not enter Trans - Bench
Mode, REFER to the PCED for diagnosis of
PCM.
A2: WIGGLE TEST
1 Remain in Trans - Bench Mode.
2 Select PIDs to be monitored.
- SSA
- SSB
- SSC
- SSD
- SSE
3 Select "ON" to turn suspect solenoid on.
4 Press "SEND".
5 Wiggle all wiring and connectors to the trans-
axle. Monitor the Solenoid State for changes.
6 Select "OFF" to turn solenoid off.
7 Press "SEND".
• Does the suspect solenoid(s) fault state
change?
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→ Yes
normal operation.
→ No
GO to A3
A3: CHECK SOLENOID FUNCTION
1 Turn each solenoid ON and OFF.
• Does the solenoid turn ON and OFF when
commanded and can solenoid activation be
heard?
→ Yes
GO to A4
→ No
GO to A5
A4: OSC TRANS - DRIVE TEST (GEAR OR TCC)
1 Carry out OSC Trans - Drive Mode.
2 Select GEAR for Shift Solenoids or follow pro-
cedures for GEAR as listed in this section.
3 Select TCC for Torque Converter Clutch. Follow
procedures of TCC in Drive Mode as listed in
this section.
• Does the transaxle upshift and downshift or
torque converter engage/disengage when com-
manded?
→ Yes
CLEAR all DTCs. Road test to verify if con-
cern is still present. If concern is still present.
section. to diagnose shift or torque converter
concern.
→ No
GO to A5
A5: CHECK FOR BATTERY VOLTAGE
1 Disconnect Transaxle Vehicle Harness Con-
nector.
2 Visually inspect all wires and connectors for
damage.
3 Measure the voltage between transaxle vehicle
harness connector, harness side, and ground
as follows:
- SSA - Pin 6
- SSB - Pin 8
- SSC - Pin 3
- SSD - Pin 9
- SSE - Pin 1
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→ Yes
GO to A7
→ No
GO to A6
A6: CHECK FOR SHORTS TO GROUND
2 Measure the resistance between transaxle
vehicle harness connector, harness side, and
ground as follows:
- SSA - Pin 6
- SSB - Pin 8
- SSC - Pin 3
- SSD - Pin 9
- SSE - Pin 1

→ Yes
GO to A8
→ No
REPAIR the circuit in question. TEST the
A7: CHECK FOR SHORT TO BATTERY VOLTAGE
1 Disconnect PCM Connector.
as follows:
- SSA - Pin 6
- SSB - Pin 8
- SSC - Pin 3
- SSD - Pin 9
- SSE - Pin 1

→ Yes
→ No
normal operation.
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A8: CHECK FOR OPENS
1 Disconnect Powertrain Control Module.
2 Install the EEC - V - 104 pin breakout box
3 Measure the resistance between PCM

connector pins, harness side, and transaxle
vehicle harness connector pins, harness side,
for the suspected solenoid as follows:
- SSA - EEC - V - 104 pin breakout box pin 73 -
transaxle connector pin 6
- SSB - EEC - V - 104 pin breakout box pin 1 -
- SSC - EEC - V - 104 pin breakout box pin 82 -
- SSD - EEC - V - 104 pin breakout box pin 99 -
- SSE - EEC - V - 104 pin breakout box pin 102 -
→ Yes
GO to A9
→ No
A9: ELECTRICAL SIGNAL CHECK
1 Connect PCM Connector.
for the suspected solenoid as follows:
- SSA - Pin 6
- SSB - Pin 8
- SSC - Pin 3
- SSD - Pin 9
- SSE - Pin 1
Bench Mode.
5 Select Parameter SSA, SSB, SSC, SSD or
SSE.
6 Select "ON".
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7 Press "SEND".
8 Measure the voltage while cycling the solenoid
ON and OFF.
9 Select "OFF", press "SEND".
• Does the voltage change?

→ Yes
GO to A10
→ No
normal operation.
A10: CHECK SOLENOID RESISTANCE
1 Measure the resistance between solenoid pin
and solenoid body component side for
suspected solenoid as follows:
- SSA - Pin 6 and Body - 10.9 - 26.2 ohms
- SSB - Pin 8 and Body - 10.9 - 26.2 ohms
- SSC - Pin 3 and Body - 1.0 - 4.2 ohms
- SSD - Pin 9 and Body - 1.0 - 4.2 ohms
- SSE - Pin 1 and Body - 1.0 - 4.2 ohms
• Is the resistance within specification?
→ Yes
If SSA or SSB is suspected, GO to A12 .
If SSC, SSD or SSE is suspected, GO to
A11
→ No
INSTALL a new SSA, SSB, SSC, SSD or
SSE. TEST the system for normal operation.
A11: CHECK SSC, SSD, SSE FOR SHORT TO GROUND
1 Measure the resistance between suspected
solenoid pin 1, component side and solenoid
body.
→ Yes
INSTALL a new SSC, SSD or SSE. TEST the
→ No
GO to A12
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A12: CHECK THE TRANSAXLE INTERNAL HARNESS FOR OPEN
internal harness connector pins and suspected
solenoid connectors as follows:
- SSA - Between transaxle internal harness
connector pin 6 and transaxle internal harness
solenoid connector pin 6
- SSB - Between transaxle internal harness

→ Yes
GO to A13
→ No
INSTALL a new transaxle internal harness.
A13: CHECK THE TRANSAXLE INTERNAL HARNESS FOR OPEN
internal harness connector pins and suspected
solenoid connectors as follows:
- SSC - Between transaxle internal harness
connector pin 3 and transaxle harness
- SSD - Between transaxle internal harness
- SSE - Between transaxle internal harness

→ Yes
GO to A14
→ No
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A14: CHECK THE TRANSAXLE INTERNAL HARNESS GROUND CIRCUIT
internal harness connector pins and ground eye
hook as follows:
- SSC - Between transaxle internal harness
solenoid connector pin 11 and ground eye
hook
- SSD - Between transaxle internal harness
hook
- SSE - Between transaxle internal harness
hook

→ Yes
normal operation.
→ No
Pinpoint Test B - Transmission Fluid Temperature (TFT) Sensor
PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR
NOTE: Refer to the Transaxle Internal Harness Diagram illustration preceding these pinpoint tests.
B1: ELECTRONIC DIAGNOSTIC SET UP
2 Shift selector lever to position P.
3 Check to make sure the transaxle harness
connector is fully seated, terminals are fully
engaged in connector and in good condition
before proceeding.
6 Select Diagnostic Data Link.
7 Select PCM.
8 Select PID/Data Monitor and Record.
9 Enter the following diagnostic mode: PIDs; TFT,
TFTV.
• Does the vehicle enter PID/Data Monitor and
Record?
→ Yes
REMAIN in PID/Data Control. GO to B2
→ No
REPEAT procedure to enter PID. If vehicle
did not enter PID, REFER to the PCED for
diagnosis of PCM.
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B2: WARM - UP/COOL - DOWN CYCLE VERIFICATION
1 While monitoring the TFT PIDs, carry out the
following test: If transaxle is cold, run transaxle
to warm it up. If transaxle is warm, allow
transaxle to cool down.
• Do the TFT PIDs increase as the transaxle is
warmed up or decrease as the transaxle is
cooled or does the TFT or TFTV drop in and out
of range?
→ Yes
If the TFT PIDs increase as the transaxle is
warmed or decrease as the transaxle is
cooled, CLEAR all DTCs. Road test to verify
if concern is still present. If concern is still
present. REFER to Diagnosis by Symptom
in this section. to diagnose transaxle over-
heating. If the TFT drops in and out of range,
INSPECT for intermittent concern in the in-
ternal/external harness, sensor or connector.
→ No
GO to B3
B3: CHECK POWERTRAIN CONTROL MODULE AND VEHICLE HARNESS FOR POWER
nector.
damage.
harness connector pin 5, harness side and
ground; and between transaxle vehicle harness
connector pin 4, harness side and ground.

→ Yes
GO to B4
→ No
GO to B5
B4: CHECK VEHICLE HARNESS FOR SHORT TO POWER
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→ Yes
normal operation.
→ No
normal operation.
B5: CHECK POWERTRAIN CONTROL MODULE AND VEHICLE HARNESS FOR GROUND
2 Measure the resistance between transaxle ve-
hicle harness connector pin 5, harness side and

→ Yes
GO to B7
→ No
GO to B6
B6: CHECK VEHICLE HARNESS FOR SHORT TO GROUND
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→ Yes
normal operation.
→ No
normal operation.
B7: CHECK VEHICLE HARNESS FOR OPEN
1 Install breakout box
EEC - V - 104 pin breakout box pin 37, harness
side; and between transaxle vehicle harness
connector pin 4, harness side and EEC - V - 104
pin breakout box pin 91, harness side.

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→ Yes
GO to B10
→ No
normal operation.
B8: CHECK THE TRANSAXLE INTERNAL HARNESS FOR SHORT TO GROUND
hicle harness connector pin 5 (component side,
transaxle internal harness), and ground; and
between transaxle vehicle harness connector
pin 4 (component side, transaxle internal har-
ness), and ground.

→ Yes
GO to B9
→ No
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B9: CHECK THE TRANSAXLE INTERNAL HARNESS FOR AN OPEN
transaxle internal harness), and transmission
fluid temperature sensor internal harness con-
nector pin 5; and between transaxle vehicle
harness connector pin 4 (component side,
transaxle internal harness), and transmission
fluid temperature sensor internal harness con-
nector pin 4.

→ Yes
GO to B10
→ No
B10: CHECK RESISTANCE OF TFT SENSOR
transaxle internal harness), and transaxle vehi-
cle harness connector pin 4 (component side,
transaxle internal harness).
2 Record the resistance.
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3 Resistance should be approximately in the
following ranges:
- -20 ° C (-4 ° F) - 236Kohms - 317Kohms
- 0 ° C (32 ° F) - 83.2Kohms - 107Kohms
- 20 ° C (68 ° F) - 33.5Kohms - 41.2Kohms
- 40 ° C (104 ° F) - 14.6Kohms - 17.6Kohms
- 60 ° C (140 ° F) - 7.08Kohms - 8.01Kohms
- 80 ° C (176 ° F) - 3.61Kohms - 4.06Kohms
- 100 ° C (212 ° F) - 1.96Kohms - 2.20Kohms
- 120 ° C (248 ° F) - 1.13Kohms - 1.25Kohms
- 130 ° C (266 ° F) - 0.87Kohms - 0.96Kohms
• Is the resistance in the range?
→ Yes
REFER to Diagnosis By Symptom in this
section. , to diagnose an overheating con-
cern.
→ No
INSTALL a new TFT sensor. TEST the sys-
tem for normal operation.
Pinpoint Test C - Transmission Range (TR) Sensor
PINPOINT TEST C: TRANSMISSION RANGE (TR) SENSOR
NOTE: Refer to the Transmission Range (TR) Sensor Connector illustration preceding these pinpoint
tests.
NOTE: Refer to the Transmission Range (TR) Sensor Diagnosis Chart preceding these pinpoint tests.
NOTE: DTC code P0705 may also be set from an open ground in the tail lamp circuit. Check and repair
tail lamp circuit as necessary.
C1: VERIFY TR SENSOR ALIGNMENT
1 Verify TR sensor alignment.
• Is the TR sensor correctly aligned?
→ Yes
GO to C2
→ No
ADJUST the TR sensor. TEST the system for
normal operation.
C2: VERIFY SHIFT CABLE/LINKAGE ADJUSTMENT
1 Verify that the shift cable/linkage is correctly
adjusted REFER to Section 307 - 05.
• Is the shift cable/linkage correctly adjusted?
→ Yes
GO to C3
→ No
ADJUST the shift cable/linkage REFER to
Section 307 - 05. TEST the system for nor-
mal operation.
C3: CHECK TR SENSOR POWER SUPPLY START CIRCUIT
1 Disconnect TR Sensor Connector.
2 Disconnect Ignition Coil C641.
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4 Measure the voltage between TR sensor con-
nector pin 6, harness side and ground.
• Is the voltage approximately 12 volts?

→ Yes
GO to C4
→ No
REPAIR start circuit 50 - BB14 (GY/RD).
C4: CHECK POWER SUPPLY TRANSAXLE CIRCUIT
1 Connect Ignition Coil C641.
nector pin 1, harness side and ground.

→ Yes
GO to C6
→ No
GO to C5
C5: CHECK VEHICLE HARNESS FOR SHORT TO GROUND
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3 Measure the resistance between TR sensor

→ Yes
GO to C6
→ No
REPAIR circuit. TEST the system for normal
operation.
C6: CHECK VEHICLE HARNESS FOR AN OPEN CIRCUIT
3 Install EEC - V - 104 pin breakout box.
4 Measure the resistance between TR sensor pin
1, harness side and EEC - V - 104 pin breakout
box pin 71, harness side.

→ Yes
GO to C7
→ No
normal operation.
C7: CHECK TR SENSOR CIRCUITRY FOR SHORT TO POWER
2 Select PARK.
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nector pins 2, 3, 4, 5, 7, and 8 harness side and
ground:

→ Yes
GO to C8
→ No
GO to C10
C8: CHECK PCM FOR SHORT TO POWER
nector pins 2, 3, 4, 5, 7, and 8 harness side and
ground:

→ Yes
→ No
normal operation.
C9: CHECK VEHICLE HARNESS FOR SHORT TO GROUND
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connector pins 2, 3, 4, 5, 7, and 8 harness side
and ground:

→ Yes
normal operation.
→ No
C10: CHECK TR SENSOR CIRCUITRY FOR SHORT TO GROUND
connector pins 2, 3, 4, 5, 7, and 8 harness side
and ground:

→ Yes
GO to C11
→ No
GO to C9
C11: CHECK THE TR SENSOR RESISTANCE
1 Connect Fuse 39 (10A).
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connector pins, component side, as follows:
- PARK position - TR sensor pins 6 and 5, 8 and
9 - less than 5 ohms
- REVERSE position - TR sensor pins 1 and 4 -
less than 5 ohms
- NEUTRAL position - TR sensor pins 1 and 8 -
less than 5 ohms
- DRIVE position - TR sensor pins 1 and 2 - less
than 5 ohms
- 2 position - TR sensor pins 1 and 7 - less than
5 ohms
- 1 position - TR sensor pins 1 and 3 - less than
5 ohms
• Are the resistances within the expected values?
→ Yes
normal operation.
→ No
INSTALL a new TR sensor. TEST the system
Pinpoint Test D - Electronic Pressure Control Solenoid (PCA)
PINPOINT TEST D: ELECTRONIC PRESSURE CONTROL SOLENOID (PCA)
NOTE: Read and record all DTCs. All TR Sensor and OSS DTCs must be repaired before entering
Output State Control (OSC).
D1: ELECTRONIC DIAGNOSTICS SET UP
2 Shift selector lever to position "P".
connector is fully seated, terminals are fully
engaged in the connector and in good condition
before proceeding.
4 Install 300 psi pressure gauge into Line tap.
Data Link.
10 Enter the following diagnostic mode: Active
Command Modes.
11 Enter the following diagnostic mode: Output
State Control (OSC).
Bench Mode.
• Does the vehicle enter the Trans - Bench
Mode?
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→ Yes
REMAIN in Trans - Bench Mode. GO to D2
→ No
REPEAT procedure to ENTER Trans -
Bench Mode. If vehicle did not enter OSC,
REFER to Powertrain Control/Emissions
Diagnosis Manual for diagnosis of PCM.
D2: SOLENOID FUNCTIONAL TEST
1 Monitor pressure gauge.
2 Enter the following diagnostic mode: Parame-
ter; PCA.
3 Select PCA
4 Increase engine speed above 1,500 RPM.
5 Select value - 50, 70, 90, 110, 130 or 150 PSI.
6 Press "SEND".
7 Select another value "50-150 psi".
8 Press "SEND".
9 Enter the following diagnostic mode: XXX.
10 Press "SEND".
• Does the pressure reading match the com-
manded pressure?
→ Yes
CLEAR DTCs. TEST the system for normal
operation.
→ No
GO to D3
D3: CHECK VEHICLE HARNESS AND POWERTRAIN CONTROL MODULE FOR SHORT TO
POWER
nector.
damage.

→ Yes
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GO to D4
→ No
GO to D5
D4: CHECK VEHICLE HARNESS FOR SHORT TO POWER

→ Yes
normal operation.
→ No
normal operation.
D5: CHECK ELECTRICAL SIGNAL
transaxle vehicle harness connector pin 2,
harness side.
2 Activate solenoids (ON and OFF) while moni-
toring the voltage reading.
Bench Mode.
4 Enter the following diagnostic mode: Parame-
ter; PCA.
5 Select a value "50-150 psi".
6 Press "SEND".
7 Select another value "50-150 psi".
8 Press "SEND".
9 Enter the following diagnostic mode: XXX.
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10 Press "SEND".
• Does the voltage change?

→ Yes
GO to D6
→ No
CHECK for open or short circuit in harness or
PCM.
D6: CHECK THE TRANSAXLE INTERNAL HARNESS FOR SHORT TO GROUND
2 Disconnect PCA Solenoid Electrical Connector.
transaxle internal harness), and ground; and
between transaxle vehicle harness connector
pin 7 (component side, transaxle internal har-
ness), and ground.

→ Yes
GO to D7
→ No
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D7: CHECK THE TRANSAXLE INTERNAL HARNESS FOR AN OPEN
transaxle internal harness), and transaxle in-
ternal harness connector pin 2; and between
transaxle vehicle harness connector pin 7
(component side, transaxle internal harness),
and transaxle internal harness connector pin 7.

→ Yes
GO to D8
→ No
D8: CHECK SOLENOID RESISTANCE AT SOLENOID
2 Measure and record the resistance between
PCA solenoid pins.
• Is the resistance between 2.4 and 7.3 ohms?
→ Yes
GO to D9
→ No
INSTALL a new PCA solenoid. TEST the
D9: CHECK SOLENOID FOR SHORT TO GROUND
1 Measure and record the resistance between the
PCA solenoid and the solenoid body.
→ Yes
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section. , for diagnosis of pressure concerns.
→ No
INSTALL a new PCA solenoid. TEST the
Pinpoint Test E - Turbine Shaft Speed (TSS) Sensor and Output Shaft Speed (OSS) Sensor
PINPOINT TEST E: TURBINE SHAFT SPEED (TSS) SENSOR AND OUTPUT SHAFT SPEED (OSS)
SENSOR
NOTE: Refer to the turbine shaft speed (TSS) sensor and output shaft speed (OSS) sensor connector
illustrations preceding these pinpoint tests.
E1: ELECTRONIC DIAGNOSTICS SET UP
connectors are fully seated, terminals are fully
engaged in connector and in good condition
before proceeding.
Data Link.
6 Select Trans Priority.
7 Select PID/Data Monitor and Record.
8 Select the following PIDs: TSS or OSS.
• Does vehicle enter PID/Data Monitor and Re-
cord?
→ Yes
REMAIN in PID/Data. GO to E2
→ No
REPEAT procedure to ENTER PID. If vehicle
did not enter PID, REFER to the PCED for
diagnosis of PCM.
E2: DRIVE CYCLE TEST
1 While monitoring the appropriate sensor PID,
drive the vehicle so that the transaxle upshifts
and downshifts through all gears.
• Does the TSS or OSS Speed PID increase and
decrease with engine and vehicle speed?
→ Yes
GO to E3
→ No
If the TSS or OSS Speed PID does not in-
crease and decrease with engine and vehicle
speed, INSPECT for open or short in vehicle
harness, sensor, a PCM concern, or internal
hardware concern. GO to E4
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E3: DRIVE CYCLE TEST ERRATIC
1 While monitoring the appropriate sensor PID,
drive the vehicle so that the transaxle upshifts
and downshifts through all gears.
• Is the TSS or OSS Speed PID signal erratic
(drop to zero or near zero and return to normal
operation)?
→ Yes
If the sensor signal is erratic, INSPECT for
intermittent concern in the harness, sensor,
or connector. GO to E4
→ No
CLEAR all DTCs. Rerun OBD.
E4: CHECK POWERTRAIN CONTROL MODULE AND HARNESS FOR POWER
2 Disconnect TSS Sensor Connector.
3 Disconnect OSS Sensor Connector.
5 For TSS, measure the voltage between TSS
sensor connector pin 1, harness side and
ground; and between TSS sensor connector pin
2, harness side and ground.
6 For OSS, measure the voltage between OSS
connector pin 1, harness side and ground; and
between OSS connector pin 2, harness side
and ground.
• Is there any voltage?

→ Yes
GO to E5
→ No
GO to E6
E5: CHECK HARNESS FOR SHORT TO POWER
4 For TSS, measure the voltage between TSS
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5 For OSS, measure the voltage between OSS
connector pin 1, harness side and ground; and
between OSS connector pin 2, harness side
and ground.
• Is there any voltage?

→ Yes
→ No
normal operation.
E6: CHECK POWERTRAIN CONTROL MODULE AND HARNESS FOR GROUND
2 Connect PCM C415.
3 For TSS, measure the resistance between TSS
4 For OSS, measure the resistance between
OSS connector pin 1, harness side and ground;
and between OSS connector pin 2, harness
side and ground.

→ Yes
GO to E8
→ No
GO to E7
E7: CHECK HARNESS FOR SHORT TO GROUND
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3 For TSS, measure the resistance between TSS
OSS connector pin 1, harness side and ground;
and between OSS connector pin 2, harness
side and ground.

→ Yes
normal operation.
→ No
E8: CHECK RESISTANCE OF TSS SENSOR OR OSS.
1 For TSS sensor, measure the resistance be-
tween TSS sensor connector pin 1, component
side and TSS sensor connector pin 2, compo-
nent side.
OSS connector pin 1, component side and OSS
connector pin 2, component side.
3 Record the resistance. Resistance should be as
follows:
- OSS 675 - 775 ohms at -20 ° C ( - 4 ° F)
- OSS 800 - 920 ohms at 21 ° C (70 ° F)
- OSS 1210 - 1390 ohms at 160 ° C (302 ° F)
- TSS 273 - 333 ohms at -20 ° C ( - 4 ° F)
- TSS 330 - 390 ohms at 21 ° C (70 ° F)
- TSS 487 - 601 ohms at 160 ° C (302 ° F)
• Is the resistance within specification for the

appropriate sensor?
→ Yes
GO to E9
→ No
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INSTALL a new sensor. TEST the system for
normal operation.
E9: CHECK SENSORS FOR SHORT TO GROUND
1 For TSS sensor, measure the resistance be-
tween TSS sensor connector pin 1, component
side and ground.
OSS connector pin 1, component side and
ground.

→ Yes
INSTALL a new TSS sensor or OSS. TEST
→ No
section. for diagnosis of shift or torque con-
verter concerns.
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Special Testing Procedures
NOTE: Certain sensor failures may cause high PC,
FMEM (Failure Mode Effect Management) actions.
Make sure that self test and electrical repairs have
Special Tool(s) been carried out, or test results may be incorrect.
Air Test Plate and Gasket This test verifies that the line pressure is within
307-412 specifications.
1. Connect pressure gauge to the line pressure
tap.
2. Start engine and check line pressures. Refer
to the following Line Pressure chart to
Pressure Gauge Assembly
determine if line pressure is within
307-004 (T57L-77820-A) specifications.
3. If line pressure is not within specification, refer
to line pressure diagnosis chart for line
pressure concern causes.
The special tests are designed to aid the
technician in diagnosing the hydraulic and
mechanical portion of the transaxle.
Engine Idle Speed Check

Refer to the PCED for diagnosis and testing of the
engine idle speed.
Line Pressure Test

CAUTION: Carry out Line Pressure Test
prior to carry out Stall Speed Test. If line
pressure is low at stall, do not carry out Item Part Description
the Stall Speed Test or further transaxle Number
damage will occur. Do not maintain wide
open throttle in any gear range for more 1 - Line pressure tap
than five seconds.
Line Pressure Chart

Trans. Range Idle Stall
KPA PSI KPA PSI
4F27E P,N 345-450 50-65 1240-1450 180-210
R 450-585 65-85 1930-2310 280-335
D, 2, 1 345-450 50-65 1240-1450 180-210
Line Pressure Diagnosis Chart

Test Results Possible Source
Low pressure in all ranges Worn pump.
Low pressure in all ranges Fluid leaking from pump, main control valve body or transaxle
case.
Low pressure in all ranges Pressure control solenoid inoperative.
Low pressure in all ranges Solenoid regulating valve sticking.
Low pressure in D, 2, 1 only Fluid leaking from forward clutch hydraulic circuit.
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Test Results Possible Source
Low pressure in 2 Fluid leaking from intermediate/overdrive band hydraulic circuit.
Low pressure in 1, R only Fluid leaking from low/reverse clutch hydraulic circuit.
Low in R only Fluid leaking from reverse clutch hydraulic circuit.
High pressure in all ranges Pressure control solenoid inoperative or open wire harness.
High pressure in all ranges Pressure regulator valve sticking.
High pressure in all ranges PCM inoperative.
Stall Speed Test CAUTION: Do not maintain wide open

This test checks operation of the following items: throttle in any range for more than five
seconds.
• torque converter clutch
• forward clutch CAUTION: If the engine RPM recorded by
• low one way clutch assembly the tachometer exceeds maximum
specified RPM, release the accelerator
• engine performance
pedal immediately. Clutch or band
WARNING: Apply the parking brake firmly slippage is indicated.
while carrying out each stall test. NOTE: Prolonged use of this procedure may set
Diagnostic Trouble Code P0712, P1783. After
CAUTION: Always carry out the Line Carrying out Stall Speed Test run OBD Test and
Pressure Test procedures prior to clear DTCs from memory.
carrying out the Stall Speed Test. If line
2. Press accelerator pedal to floor (WOT) in
pressure is low at stall, do not carry out
each range. Record RPM reached in each
the Stall Speed Test or further transaxle
range. Stall speeds should be as follows:
damage will occur.
NOTE: The Stall Speed Test should be carried out Stall Speed Chart
with the engine and transaxle at normal operating
temperatures. Engine RPM
2.0L SPI 2406-2811
1. Connect tachometer to the engine.
2.0L ZETEC 2439-2837
CAUTION: After testing each of the 3. If stall speeds were too high, refer to the
following ranges D, 2, 1, and R, move the following Stall Speed Diagnosis Chart. If stall
selector lever to N (NEUTRAL) and run speeds were too low, first check the engine
the engine at 1000 RPM for about 15 idle speed. If engine idle is OK, remove torque
seconds to allow the torque converter to converter and check the torque converter one
cool before testing the next range. way clutch for slippage.
Stall Speed Diagnosis Chart

Transaxle Range Selector Lever Position Possible Cause
Above specification in D, 2, and 1 Forward clutch slipping.
Above specification in 2 Intermediate/overdrive band slipping.
Above specification in 1 and R Low/reverse clutch slipping.
Above specification in R Reverse clutch slipping.
Above specification in R Carry out road test to determine whether problem is
in low/reverse clutch.
Above specification in R Low/reverse clutch is defective.
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Air Pressure Tests

1. Drain transaxle fluid and remove the transaxle
fluid pan. REFER to Oil Pan in this section.
Transaxle Air Pressure Test Plate
2. Remove the main control valve body. REFER
to Main Controls in this section.
3. Install the transmission test plate and gasket.
Use the transmission fluid pan bolts to holt the
Test Plate down. Tighten the bolts to 10 Nm
(89 lb/in).
4. Apply air to the appropriate clutch port (refer
to the diagram). A dull thud may be heard or
movement felt when the component is applied
or released. If clutch seals or check balls are
leaking a hissing sound may be heard.
If test results find that the servos do not operate,
disassemble, clean and inspect them to locate the
source of the concern.
Number If air pressure applied to the clutch passages fails
to operate a clutch, or operates another clutch
1 — Servo release
simultaneously, disassemble and use air pressure
2 — Servo apply to check the fluid passages in the center support
and clutches to detect obstructions.
3 — Direct clutch apply
4 — Reverse clutch apply
5 — Torque converter bypass
6 — Low/reverse clutch
7 — Torque converter charge
8 — Forward clutch apply
9 — Servo accumulator apply
10 — Forward servo accumulator
apply
A no-drive condition can exist even with correct

transaxle fluid pressure because of inoperative
clutches or bands. An erratic shift can be located
through a series of checks by substituting air
pressure for fluid pressure to determine the
location of the failure.
Follow the procedure to determine the location of
the inoperative clutch or band by introducing air
pressure into the various test plate passages.
NOTE: Use only dry, regulated 40 psi maximum)
air pressure.
Apply air to the appropriate passage(s). A dull
thud should be felt or heard or movement could be
observed when the component applies. There
should be no hissing sound when the component
is fully applied.
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Leakage Inspection
should be followed for fluid leaks between the

General Equipment cooler and the cooler line fittings in this section.
REFER to Section 307-02A / 307-02B.
UV fluid leak detection euipment
The cooler can be further checked for leaks.
If leakage is found at the transaxle range selector
CAUTION: Do not try to stop the fluid leak
lever, install a new seal.
by increasing the torque beyond
specifications. This may cause damage If leakage is found at the transaxle wiring harness
to the transaxle case threads. connector, install a new O-ring.
Check the fluid filler tube at the transaxle case. If The transaxle is equipped with the following
any leakage is found, install a new plug. components to prevent external fluid leakage:
Check the fluid tubes and fittings between the • sealer
transaxle and the cooler for looseness, wear or • lip-type seals
damage. If leakage cannot be stopped by • O-ring seals
tightening a fluid tube nut, install new
components. • seal rings
• seal grommets
If the leak continues, install a new cooler line fitting
and tighten to specification. The same procedure • thread sealant
• panfluid
External Sealing
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Number
1 — O-ring - Output speed sensor
2 — Converter housing (sealant
to case)
3 — Seal - Fluid pump
4 — Seal - Pump fluid
5 — Case (sealant to converter
housing)
6 — O-ring - Turbine speed sen-
sor 1. Fluid leaking past the pump seal lip will tend to
7 — Seal assy - Differential move along the impeller hub and onto the rear
of the impeller housing. Except in the case of
8 — O-ring - Bulkhead wiring a total seal failure, fluid leakage past the lip of
harness connector the seal will be deposited on the inside of the
9 — Cover assy - End (sealant to torque converter housing only, near the
case) outside diameter of the housing. Fluid from
the vent assembly may move along the
10 — Seal - Case cover (end cover impeller hub and onto the rear of the impeller
to case) (2) housing. Fluid from a converter hub weld leak
11 — Seal - Manual shaft - Fluid (2) will move along a path on the inside of the
converter housing.
12 — Pan - Fluid (sealant to case) 2. Fluid leakage past the outside diameter of the
pump seal and pump body will follow the
same path that leaks past the inside diameter
Fluid Leakage in Torque Converter Area of the pump seal follow. Fluid from a converter
hub weld leak will move along a path on the
In diagnosing and correcting fluid leaks in the
inside of the converter housing.
pump support and gear and torque converter area,
use the following procedures to locate the exact 3. Fluid that leaks past a pump-to-case screw or
cause of the leakage. Leakage between the pump gasket will be deposited on the inside of
transaxle and engine, as evidenced by fluid the torque converter housing only. Fluid will
around the torque converter housing, may have not be deposited on the rear of the torque
several sources. By careful observation it is converter.
possible, in many instances, to pinpoint the source 4. Fluid leakage from the converter drain plug,
of leak before removing the transaxle from the (model-dependent) converter seal weld or
vehicle. The paths which the fluid may take to converter-to-flexplate stud weld will appear at
reach the bottom of the torque converter housing the outside diameter of the torque converter
are shown in the illustration. The five steps on the rear face of the flexplate, and in the
following correspond to the numbers in the converter housing only near the flexplate.
illustration. Fluid leaks from the torque converter will
leave a ring of fluid around the inside of the
torque converter housing.
NOTE: White facial tissue paper may aid in
determining the color (red is transaxle fluid) and
source of the leaking fluid.
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5. Engine oil leaks are sometimes incorrectly Fluid soluble aniline or fluorescent dyes premixed
diagnosed as transaxle pump gasket leaks. at the rate of 2.5ml (1/2 teaspoon) of dye powder
The following areas of possible leakage to 0.24L (1/2 pint) of automatic transaxle fluid
should also be checked to determine if engine have proven helpful in locating the source of fluid
oil leakage is causing the concern. leakage. Such dyes may be used to determine
a Leakage at the valve cover gasket may allow whether an engine fluid or transaxle fluid leak is
oil to flow over the torque converter housing or present. An ultraviolet light must be used to detect
seep down between the torque converter the fluorescent dye solution.
housing and cylinder block causing oil to be
present in or at the bottom of the torque
converter housing.
b Oil gallery plug leaks will allow oil to flow down
the rear face of the cylinder block to the bottom
of the torque converter housing.
c Leakage at the crankshaft rear oil seal will
work back to the flexplate, and then into the
torque converter housing.
Leak Check Test

1. Original factory fill fluid is dyed red to aid in
determining if leakage is from the engine or
transaxle. The red color should assist in
pinpointing the leak.
2. Clean off any fluid from the top and bottom of
the torque converter housing, of the case, and
the rear face of the engine and oil pan. Clean
the torque converter area by washing with a
suitable nonflammable solvent and blow dry
using compressed air.
3. Wash out the torque converter housing, and
the front of the flexplate. The torque converter
housing may be washed out using cleaning
solvent and a squirt-type oil can. Blow dry all
washed areas using compressed air.
4. Start and run the engine until the transaxle
reaches its normal operating temperature.
Observe the rear of the cylinder block and the
top of the torque converter housing for
evidence of fluid leakage. Raise and support
the vehicle REFER to Section 100-02. Run
the engine at fast idle, then at engine idle,
occasionally shifting to the D and R positions
to increase pressure within the transaxle.
Observe the front of the flexplate, rear of the
cylinder block (in as far as possible), and
inside the torque converter housing and front
of the transaxle case. Run the engine until
fluid leakage is evident and the probable
source of leakage can be determined.
Leak Check Test With Black Light
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Diagnosis By Symptom
Electrical Routines list the possible electrical
components that could cause or contribute to the
symptom described. The Hydraulic/Mechanical
Special Tool(s) Routines list the possible hydraulic or mechanical
components that could cause or contribute to the
12 Volt Master UV Diagnostic
symptom described.
Inspection Kit
164-R0756 or equivalent
Diagnosis by Symptom Chart Directions
1. Using the Symptom Index, select the
Concern/Symptom that best describes the
condition.
2. Refer to the routine indicated in the Diagnosis
73III Automotive Meter by Symptom Index.
105-R0057 or equivalent 3. Always begin diagnosis of a symptom with:
a Preliminary inspections.
b Verifications of condition.
c Checking the fluid levels.
NOTE: Not all concerns and conditions with
electrical components will set a diagnostic trouble
code (DTC). Be aware that the components listed
may still be the cause. Verify correct function of
Worldwide Diagnostic System these components prior to proceeding to the
(WDS) 418-F224, or Hydraulic/Mechanical Routine listed.
equivalent scan tool 4. Begin with the Electrical Routine, if indicated.
Follow the reference or action statements.
Always carry out the on-board diagnostic tests
Pressure Gauge as necessary. Never skip steps. If the concern
307-004 (T57L-77820-A) is still present after electrical diagnosis, then
proceed to the Hydraulic/Mechanical Routine
listed.
5. The Hydraulic/Mechanical Routines list
possible hydraulic or mechanical components
The Diagnosis by Symptom Index gives the that could cause the concern. These
technician diagnostic information, direction, and components are listed in the removal
suggest possible components, using a symptom sequence and by most probable cause. All
as a starting point. components listed must be inspected to make
The Diagnosis by Symptom Index is divided into sure of correct repair.
two categories: Electrical Routines, indicated by
200 series numbers, and Hydraulic/Mechanical
Routines, indicated by 300 series numbers. The
Diagnosis by Symptom Index
4F27E Routines
Electrical Mechanical/Hydraulic
Engagement Concerns:
No forward in O/D only 201A 301A
No forward in O/D only (all posi- 201B 301B
tions)
No reverses only 202 302
Harsh reverse only 203 303
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4F27E Routines
Electrical Mechanical/Hydraulic
Harsh reverse only 204A 304A
Harsh manual 1st gear only 204B 304B
Delayed/soft reverse only 205 305
Delayed/soft forward only 206 306
No forward and no reverse 207 307
Harsh forward and harsh reverse 208 308
Delayed forward and delayed 209 309
reverse
Shift Concerns:
Some/all shifts missing 210 310
Timing concern: early concern 211 311
(some/all)
Timing concern: erratic/hunting 212 312
(some/all)
Feel concerns: soft/slipping 213 313
(some/all)
Feel concerns: harsh (some/all) 214 314
No first gear in drive, engages in a 215 315
higher gear
No first gear in manual 1st 216 316
No manual second gear 217 317
Torque converter clutch opera-
tion concerns:
Does not apply 240 340
Always applied/stalls vehicle 241 341
Cycling/shudder/chatter 242 342
Other Concerns:
Shift lever efforts high 251 351
External leaks 252 352
Poor vehicle performance 253 353
Noise/vibration - forward or re- 254 354
verse
Engine will not crank 255 355
No park range 256 356
Overheating 257 357
No engine braking in manual 1 259 359
Fluid venting or foaming 261 361
Slips/chatters in manual 1st gear 263 363
Slips/chatters in manual 2nd gear 264 364
Slips/chatters in 3rd gear 282 382
No engine braking in all gears 283 383
Diagnostic Routines
Engagement Concern: No Forward in O/D ONLY

Possible Component Reference/Action
201A - ELECTRICAL ROUTINE
Powertrain Control System
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Powertrain control module (PCM), vehicle wiringCarry out on-board diagnostic tests. Refer to the
harness, shift solenoid (SSC) (off = low). Powertrain Control/Emission Diagnosis (PCED)
Manual for diagnosis and testing of the PCM.
Carry out pinpoint test A, refer to Pinpoint Test A.
Repair as required. Clear the DTCs, road test and
rerun on-board diagnosis test.
301A - HYDRAULIC/MECHANICAL ROUTINE
Fluid
Incorrect level Adjust fluid to the correct level.
Condition Carry out the Fluid Condition Check in this section.
Forward Clutch Assembly
Seals, piston damaged
Check balance dam. Inspect for damage. Repair as necessary.
Friction elements damaged or worn.
Return springs damaged.
Servo
Seals (piston and cover) damaged. Inspect for damage. Repair as necessary.
Band
Band damaged.
Servo worn or damaged. Inspect for damage. Repair as necessary.
Not adjusted correctly.
Anchor bolt damaged or worn.
Case
Damaged. Inspect for damage. Repair as necessary.
Engagement Concern: No Forward ONLY (All Positions)

201B - ELECTRICAL ROUTINE
PCM, vehicle wiring harness, SSC, SSD, and SSE. Carry out on-board diagnostic tests. Refer to the
PCED Manual for diagnosis and testing of the
PCM.
Carry out pinpoint test A, refer to Pinpoint Test A.
301B - HYDRAULIC/MECHANICAL ROUTINE
Main Control
Bolts not tightened to specification. Tighten to specifications.
Separator plate damaged. Inspect for damage. If damaged, repair as neces-
sary.
Contamination. Disassemble and clean.
Valves/springs damaged, misassembled, missing, If damaged or parts are missing install new main
stuck, or bore damaged. control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transaxle damage.
Seals, piston damaged.
Forward Planetary Assembly
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Planetary damaged. Inspect for damage. Repair as necessary.
Low One-Way Clutch
Worn, damaged or assembled incorrectly. Inspect for damage. Repair as necessary.
Engagement Concern: No Reverse

202 - ELECTRICAL ROUTINE
PCM, vehicle wiring harness, SSC, SSD and SSE. Carry out on-board diagnostic tests. Refer to the
PCM.
Carry out Pinpoint Tests A and D,
refer to Pinpoint Tests A and D.
302 - HYDRAULIC/MECHANICAL ROUTINE
Main Control
sary.
Valves/springs damaged, misassembled, missing, If damaged or parts are missing install new main
Low/Reverse Clutch Assembly
Friction elements damaged or worn. Inspect for damage. Repair as necessary.
Reverse Clutch Assembly
Engagement Concern: Harsh Reverse ONLY

PCM, vehicle wiring harness, SSD. Carry out on-board diagnostic tests. Refer to the
PCM.
Carry out Pinpoint Test A, refer to Pinpoint Test A.
Incorrect Pressures
High pressures. Check pressure at Line tap.
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Carry out the Line Pressure Test, refer to the pro-
cedure in this section. Follow pressure diagnosis
and repair as required.
Main Control
Bolts not tightened to specification. Tighten to specification.
sary.
Valves/springs damaged, misassembled, missing, If damaged or parts are missing, install a new main
Reverse Clutch Assembly
Return spring damaged.
Engagement Concern: Harsh Forward ONLY

204A - ELECTRICAL ROUTINE
PCM, vehicle wiring harness and SSC. Carry out on-board diagnostic tests. Refer to the
PCM.
304A - HYDRAULIC/MECHANICAL ROUTINE
Incorrect Pressures
High pressures. Check pressure at Line tap. Refer to procedure in
this section. Follow pressure diagnosis and repair
as required.
Main Control
sary.
stuck, or damaged. control assembly. If misassembled, reassemble
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Engagement Concern: Harsh Forward ONLY

204B - ELECTRICAL ROUTINE
PCM, vehicle wiring harness, turbine shaft speed
Carry out on-board diagnostic tests. Refer to the
(TSS) sensor. PCED Manual for diagnosis and testing of the
PCM.
Carry out Pinpoint Test E, refer to Pinpoint Test E.
304B - HYDRAULIC/MECHANICAL ROUTINE
No Hydraulic/Mechanical Concerns.
Engagement Concern: Delayed/Soft Reverse ONLY

PCM, vehicle wiring harness, SSD, PCA. Carry out on-board diagnostic tests. Refer to the
PCM.
Incorrect Pressures
Low pressures. Check pressure at Line tap.
Carry out Line Pressure Test, refer to procedure in
as required.
Main Control
Separator plate damaged. Inspect for damage. If damaged repair as neces-
sary.
Engagement Concern: Delayed/Soft Forward

PCM, vehicle wiring harness, SSC, PCA. Carry out on-board diagnostic tests. Refer to the
PCM.
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Incorrect Pressures
Low pressures. Check pressure at Line tap.
Carry out Line Pressure Test, refer to the procedure
in this section. Follow pressure diagnosis and re-
pair as required.
Main Control
sary.
Engagement Concerns: No Forward and No Reverse

PCM and vehicle wiring harnesses (no electrical Carry out on-board diagnostic tests. Refer to the
activity equals third gear default). PCED Manual for diagnosis and testing of the
PCM.
Fluid
Incorrect level. Adjust to correct level, refer to the procedure in this
section.
Condition. Carry out Fluid Condition Check, refer to the pro-
cedure in this section.
Shift Cable/Transmission Range (TR) Sensor
Cable system or TR sensor damaged, misaligned. Inspect and repair as required. For shift cable in-
formation, refer to Section 307-05. For TR sensor
information, refer to this section.
Main Control
sary.
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Turbine Shaft
Damaged. Inspect for damage. If damaged, repair as neces-
sary.
Fluid Pump Assembly
Gasket damaged. Inspect for damage. If damaged, repair as neces-
sary.
Porosity, cross leaks, plugged hole.
Rear Planetary Assembly
Planetary damaged. Inspect for damage. If damaged, repair as neces-
sary.
Forward Planetary Assembly
sary.
Final Drive Gearset and Differential
sary.
Torque Converter
Damaged flexplate or adapter plate. Inspect for damage. Carry out Torque Converter
checks, refer to procedures in this section. Repair
as necessary.
Damaged impeller hub.
Damaged turbine hub.
Low One-way Clutch
Engagement Concerns: Harsh Forward and Reverse

PCM, vehicle wiring harnesses, TR sensor, trans- Carry out on-board diagnostic tests. Refer to the
mission fluid temperature (TFT) sensor, SSC, and PCED Manual for diagnosis and testing of the
SSD. PCM.
Carry out Pinpoint Tests A, B and C,
refer to Pinpoint Tests A, B and C.
Fluid
Incorrect level. Adjust to correct level, refer to the procedure in this
section.
Condition. Carry out Fluid Condition Check, refer to the pro-
cedure in this section.
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Incorrect Pressures
High pressures. Check pressure at Line tap.
Carry out Line Pressure Test, refer to the procedure
in this section. Follow pressure diagnosis and re-
pair as required.
Main Control
sary.
Reverse and Low/Reverse Clutch Assembly
Check balance dam.
One way clutch
Engagement Concerns: Delayed/Soft Forward and Reverse

PCM, vehicle wiring harnesses, TR sensor, TFT Carry out on-board diagnostic tests. Refer to the
sensor SSC and SSD. PCED Manual for diagnosis and testing of the
PCM.
Fluid
Incorrect level. Adjust to correct level, refer to procedure in this
section.
Condition. Carry out Fluid Condition Check, refer to procedure
in this section.
Incorrect Pressures
High Pressures. Check pressure at Line tap.
as required.
Main Control
sary.
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Fluid Pump Assembly
sary.
Shift Concerns: Some/All Shifts Missing (AUTOMATIC MODE ONLY)

PCM, vehicle wiring harnesses, TR sensor, intake Carry out on-board diagnostic tests. Refer to the
manifold air temperature (IAT) sensor, vehicle PCED Manual for diagnosis and testing of the
speed sensor (VSS) input, SSA, SSB, SSC, SSD PCM.
SSE and pressure control solenoid (PCA).
Carry out Pinpoint Tests A, C, D, and E,
refer to Pinpoint Tests A, C, D and E.
Some Shifts Missing ONLY
If only some of the shifts are missing, determine
which shift(s) is missing.
Refer to the following routine(s) for further No Shift
Concerns: No 1-2 Shift, Routine 220/320 No 2-3
Shift, Routine 221/321 No 3-4 Shift, Routine
222/322 No 4-3 Shift, Routine 223/323 No 3-2 Shift,
Routine 224/324 No 2-1 Shift, Routine 225/325
Fluid
section.
in this section.
Shift Cable/TR Sensor
Incorrect Pressures
High/Low Pressures. Check pressure at Line tap.
as required.
Main Control
sary.
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Fluid Pump Assembly
sary.
Direct Clutch Assembly
Seals, piston damaged
One-way Clutch
Servo
Servo retaining ring damaged Inspect for damage. Repair as necessary.
Shift Concerns: Timing Concerns - Early/Late

PCM, vehicle wiring harnesses, VSS, TSS sensor Carry out on-board diagnostic tests. Refer to the
SSA, SSB, SSC, SSD, SSE and VFS. PCED Manual for diagnosis and testing of the PCM
and TSS sensor.
Some Shifts Early/Late ONLY
If only some of the shifts are early/late, determine
which shift(s) is early/late.
Refer to the following routine(s) for further
Early/Late Shift Concerns: Soft/Slipping 1-2 Shift,
Routine 226/326 Soft/Slipping 2-3 Shift, Routine
227/327 Soft/Slipping 3-4 Shift, Routine 228/328
Soft/Slipping 4-3 Shift, Routine 229/329
Fluid
section.
in this section.
Main Control
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sary.
Servo
Servo retaining ring damaged. Inspect for damage. Repair as necessary.
Seals (piston and cover) damaged.
Band
Band damaged.
Shift Concerns: Timing Concerns - Erratic/Hunting

PCM, vehicle wiring harnesses, VSS, IAT sensor. Carry out on-board diagnostic tests. Refer to the
PCED Manual for diagnosis and testing of the PCM
and TSS sensor.
Fluid
section.
in this section.
Main Control
sary.
Further Diagnosis
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For further diagnosis of timing issues, refer to Ref- Refer to the following routine(s) for specific shift
erence/Actions. diagnosis: No. 1-2 shift see Routine 220/330 No.
2-3 shift see Routine 221/331 No. 3-4 shift see
Routine 222/332 No. 4-3 shift - No. 3-2 shift - No.
2-1 shift - Soft/Slip 1-2 shift see Routine 226/326
Soft/Slip 2-3 shift see Routine 227/327 Soft/Slip 3-4
shift see Routine 228/328 Soft/Slip 4-3 shift see
Routine 229/329 Soft/Slip 3-2 shift - Soft/Slip 2-1
shift - Harsh 1-2 shift see Routine 232/332 Harsh
2-3 shift see Routine 233/333 Harsh 3-4 shift see
Routine 224/334 Harsh 4-3 shift see Routine
235/335 Harsh 3-2 shift see Routine 236/336 Harsh
2-1 shift
Shift Concerns: Feel - Soft/Slipping

PCM, vehicle wiring harnesses, TFT sensor, IAT Carry out on-board diagnostic tests. Refer to the
sensor, VSS input SSA, SSB, SSC, SSD, SSE, PCED Manual for diagnosis and testing of the
VFS, and PCA. PCM, IAT sensor and VSS.
Carry out Pinpoint Tests A, B, D and E,
refer to Pinpoint Tests A, B, D and E.
Some Shifts Soft/Slipping ONLY
If only some of the shifts are soft/slipping, deter-
mine which shift(s) is soft/slipping.
Refer to the following routine(s) for further
Soft/Slipping Shift Concerns: Soft/Slipping 1-2
Shift, Routine 226/326 Soft/Slipping 2-3 Shift,
Routine 227/327 Soft/Slipping 3-4 Shift, Routine
228/328 Soft/Slipping 4-3 Shift, Routine 229/329
Fluid
section.
in this section.
Incorrect Pressures
as required.
Main Control
sary.
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Fluid Pump Assembly
sary.
Intermediate Servo
Intermediate Band
Band damaged.
Case
Shift Concerns: Feel - Harsh (Some/All)

PCM, vehicle wiring harnesses, TR sensor , TFT Carry out on-board diagnostic tests. Refer to the
sensor, IAT sensor, VSS input, SSA, SSB, SSC, PCED Manual for diagnosis and testing of the
SSD, SSE and PCA. PCM, IAT sensor and VSS.
Carry out Pinpoint Tests A, B, C, D and E,
refer to Pinpoint Tests A, B, C, D and E.
Some Shifts Harsh ONLY
If only some of the shifts are harsh, determine
which shift(s) is harsh.
Refer to the following routine(s) for further Harsh
Shift Concerns: Harsh 1-2 Shift, Routine 232/332
Harsh 2-3 Shift, Routine 233/333 Harsh 3-4 Shift,
Routine 234/334 Harsh 4-3 Shift, Routine 235/335
Harsh 3-2 Shift, Routine 236/336 Harsh 2-1 Shift,
Routine 237/337
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


Incorrect Pressures
as required.
Main Control
sary.
Input Shaft
Servo
Band
Band damaged.
Final Drive Gears and Differential
Case
Shift Concerns: No 1st Gear in Drive, Engages In Higher Gear

PCM, vehicle wiring harnesses, TR sensor and Carry out on-board diagnostic tests. Refer to the
SSC. PCED Manual for diagnosis and testing of the
PCM.
Carry out Pinpoint Tests A, and C,
refer to Pinpoint Tests A and C.
Incorrect Pressures
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


Refer to the Band/Clutch Chart in this section to
determine which gears are on. Follow the diagnos-
tic routines to repair the missing gears.
Main Control
sary.
Low One-Way Clutch
Shift Concerns: No First Gear in Manual 1st

PCM and vehicle wiring harnesses. Carry out on-board diagnostic tests. Refer to the
PCM.
Incorrect Pressures
Refer to the Band/Clutch Chart in this section to
determine which gears are on. Follow the diagnos-
tic routines to repair the missing gears.
Main Control
sary.
Seals.
Friction plates. Inspect for damage. If damaged, repair as neces-
sary.
Return spring.
OD Planetary Assembly
sary.
Shift Concerns: No Manual 2nd Gear
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


PCM, vehicle wiring harnesses and SSD. Carry out on-board diagnostic tests. Refer to the
PCM.
Incorrect Pressures
as required.
Main Control
sary.
Servo
Band
Band damaged.
Low/Direct One-way Clutch
Shift Concern: No 1-2 Shift

PCM, vehicle wiring harnesses, VSS, TR sensor, Carry out on-board diagnostic tests. Refer to the
TSS sensor and SSD. PCED Manual for diagnosis and testing of the
PCM, IAT sensor and VSS.
Carry out Pinpoint Tests A, C and E,
refer to Pinpoint Tests A, C and E.
Fluid
section.
Incorrect Pressures
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


as required.
Main Control
sary.
Servo
Band
Band damaged.
sary.

PCM, vehicle wiring harnesses, TR sensor, VSS, Carry out on-board diagnostic tests. Refer to the
SSD and SSE. PCED Manual for diagnosis and testing of the
PCM.
Carry out Pinpoint Tests A, C, and E,
refer to Pinpoint Tests A, C, and E.
Incorrect Pressures
as required.
Main Control
sary.
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


Servo
Seals. Inspect for damage. Repair as necessary.
Intermediate Clutch Assembly

SSC and SSA. PCED Manual for diagnosis and testing of the
PCM.
Incorrect Pressures
as required.
Main Control
sary.
Servo
Band. Inspect for damage. Repair as necessary.
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


SSA, and SSC. PCED Manual for diagnosis and testing of the
PCM.
Incorrect Pressures
as required.
Main Control
sary.
Servo
Seal. Inspect for damage. Repair as necessary.

and SSE. PCED Manual for diagnosis and testing of the
PCM.
Incorrect Pressures
as required.
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


Main Control
sary.
Servo
Band
Band damaged.

PCM, vehicle wiring harnesses, TR sensor, VSS Carry out on-board diagnostic tests. Refer to the
and SSD. PCED Manual for diagnosis and testing of the
PCM.
Incorrect Pressures
as required.
Main Control
sary.
One-way Clutch
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


Band
Shift Concern: Soft/Slipping 1-2

Incorrect Pressures
PCM, vehicle wiring harnesses, TSS sensor, VSS, Carry out on-board diagnostic tests. Refer to the
TFT sensor and SSD. PCED Manual for diagnosis and testing of the
PCM, IAT sensor and VSS.
Carry out Pinpoint Tests A, B and E,
refer to Pinpoint Tests A, B and E.
Fluid
section.
in this section.
Incorrect Pressures
as required.
Main Control
sary.
Servo
Band
Band damaged.

PCM, vehicle wiring harnesses, TSS sensor, TFT Carry out on-board diagnostic tests. Refer to the
sensor, and SSE. PCED Manual for diagnosis and testing of the
PCM.
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TO MODEL INDEX


Carry out Pinpoint Tests A, B, and E,
refer to Pinpoint Tests A, B, and E.
Incorrect Pressures
as required.
Main Control
sary.
Servo
Band
Band damaged.

PCM, SSA, SSC, vehicle wiring harnesses and TFT Carry out on-board diagnostic tests. Refer to the
sensor. PCED Manual for diagnosis and testing of the
PCM.
Carry out Pinpoint Test B, refer to Pinpoint Test B.
Incorrect Pressures
as required.
Main Control
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


sary.
Servo
Band
Band damaged.

PCM, vehicle wiring harnesses, TFT sensor, SSA, Carry out on-board diagnostic tests. Refer to the
and SSC. PCED Manual for diagnosis and testing of the
PCM.
Carry out Pinpoint Tests A, and B,
refer to Pinpoint Tests A and B.
Incorrect Pressures
as required.
Main Control
sary.
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


Servo
Seals, piston damaged. Inspect for damage. Repair as necessary.

PCM, vehicle wiring harnesses, TFT sensor, and Carry out on-board diagnostic tests. Refer to the
SSE. PCED Manual for diagnosis and testing of the
PCM.
Carry out Pinpoint Tests A and B,
Incorrect Pressures
as required.
Main Control
sary.
Servo
Band
Band damaged.

PCM, SSD, VSS, TSS, TR sensor, vehicle wiring Carry out on-board diagnostic tests. Refer to the
harnesses and TFT sensor. PCED Manual for diagnosis and testing of the
PCM.
Carry out Pinpoint Tests.
Incorrect Pressures
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


as required.
Main Control
sary.
Servo
Band
Band damaged.
Shift Concern: Harsh 1-2 Shift

PCM, vehicle wiring harnesses, TSS sensor, TR Carry out on-board diagnostic tests. Refer to the
sensor, TFT sensor and SSD. PCED Manual for diagnosis and testing of the
PCM.
Carry out Pinpoint Tests A, B, C, and E,
refer to Pinpoint Tests A, B, C and E.
Incorrect Pressures
as required.
Main Control
sary.
Servo
Band
Band damaged.
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sensor, TFT sensor, and SSE. PCED Manual for diagnosis and testing of the
PCM.
Incorrect Pressures
as required.
Main Control
sary.
Servo
Band
Band damaged.

sensor, SSA, and SSC. PCED Manual for diagnosis and testing of the
PCM.
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


Incorrect Pressures
as required.
Main Control
sary.

sensor, SSA, SSC. PCED Manual for diagnosis and testing of the
PCM.
Incorrect Pressures
as required.
Main Control
sary.
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


Servo
Band
Band damaged.

sensor, TFT sensor, and SSE. PCED Manual for diagnosis and testing of the
PCM.
Incorrect Pressures
as required.
sary.
Servo
Band
Band damaged.
G17979 en 09/2004 2004.75 Focus

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sensor, TFT sensor, VFS and SSD. PCED Manual for diagnosis and testing of the
PCM.
Incorrect Pressures
as required.
Main Control
sary.
One-way Clutch
Servo
Band
Band damaged.
Torque Converter Clutch Operation Concerns: Does Not Apply

PCM, vehicle wiring harnesses, TFT sensor, SSB Carry out on-board diagnostic tests. Refer to the
and SSC. PCED Manual for diagnosis and testing of the
PCM.
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


Carry out Pinpoint Tests A, and B,
Incorrect Pressures
as required.
Main Control
sary.
Fluid Pump Assembly
sary.
Porosity, cross leaks, plugged hole. Inspect for damage. If damaged, repair as neces-
sary.
Torque Converter Assembly
Torque converter internal failure preventing en- Remove transaxle. Inspect for damage. Carry out
gagement, piston application. torque converter checks, refer to procedures in this
section. If torque converter fails to pass the checks
or is damaged, install a new or remanufactured
torque converter.
Torque Converter Operation Concerns: Always Applied/Stalls Vehicle

PCM, vehicle wiring harnesses, SSC and SSB. Carry out on-board diagnostic tests. Refer to the
PCM.
Main Control
sary.
G17979 en 09/2004 2004.75 Focus

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Low One-Way Clutch
torque converter.
Torque Converter Clutch Concerns: Cycling/Shudder/Chatter

PCM, vehicle wiring harnesses, SSB and SSC. Carry out on-board diagnostic tests. Refer to the
PCM.
Fluid
Condition - contaminated, degrade. Carry out Fluid Condition Check, refer to procedure
in this section. If contaminated, locate source of
contamination. If burnt, inspect mechanical bands
and clutches. Repair as necessary. Change the
transaxle fluid. Carry out drain and refill procedures
as listed in this section. Carry out fluid cooler and
torque converter cleaning procedures as listed in
this section and in Section 307-02.
Main Control
sary.
torque converter.
Other Concerns: Shift Lever Efforts High
G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


TR sensor. Carry out on-board diagnostic tests. Refer to the
PCM.
Carry out Pinpoint Test C, refer to Pinpoint Test C.
formation, refer to Section 307-05. For TR infor-
mation, refer to this section.
Main Control
Case
Manual control lever assembly damage, manual Inspect for damage. If damaged, repair as neces-
valve inner lever pin bent, manual valve inner lever sary.
damaged, spring rod damaged.
Manual valve lever shaft retaining pin damaged.
Other Concerns: External Leaks

VSS, TSS sensor and TR sensor transmission Inspect for leakage. If areas around sensor show
wiring harness. signs of leakage, install a new sensor O-ring. If area
behind TR sensor shows signs of leakage, install a
new manual lever shaft seal.
Fluid
section.
Case
sary.
Seal/Gaskets
Leakage at gaskets, seals, etc. Refer to Leakage Inspection and Fluid Leakage in
the Torque Converter Area diagrams in this section
for potential leak locations.
Remove all traces of lubricant on exposed surfaces
of the transaxle. Check the vent for free breathing.
Operate the vehicle at normal temperatures and
carry out Leak Check Test procedures in this sec-
tion. Repair as necessary.
Other Concerns: Poor Vehicle Performance

G17979 en 09/2004 2004.75 Focus

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PCM, vehicle wiring harnesses, VSS, TSS sensor, Carry out on-board diagnostic tests. Refer to the
TFT sensor, TR sensor, SSA, SSB, SSC, SSD, PCED Manual for diagnosis and testing of the
SSE and PCA. PCM.
Carry out Pinpoint Tests A, B, C, D, and E,
refer to Pinpoint Tests A, B, C, D and E.
Fluid
section.
Input Shaft
Torque converter one-way clutch slipping. Carry out torque converter one-way clutch check as
listed in this section. If the one-way clutch fails the
check install a new or remanufactured torque
converter.
Incorrect torque converter used in rebuild. Inspect for correct torque converter assembly. If not
correct, install the correct torque converter for this
application.
Other Concerns: Noise/Vibration - Forward or Reverse

PCM, vehicle wiring harnesses, SSA, SSB, SSC, Carry out on-board diagnostic tests. Refer to the
SSD, SSE and PCA. PCED Manual for diagnosis and testing of the
PCM.
Fluid Pump Assembly
sary.
Flex Plate or Adapter Plate
Adapter plate not aligned correctly. Remove the transaxle. Align the adapter plate.
Other Concerns: Engine Will Not Crank

G17979 en 09/2004 2004.75 Focus

TO MODEL INDEX


PCM, vehicle wiring harnesses and TR sensor. Carry out on-board diagnostic tests. Refer to the
PCM.
Carry out Pinpoint Test C, refer to Pinpoint Test C.
Flex Plate or Adapter Plate
Other Concerns: No Park Range

No electrical concerns.
Case
Manual control lever assembly damage, manual Inspect for damage. If damaged, repair as neces-
valve inner lever pin bent, manual valve inner lever sary.
damaged, spring rod damaged.
Manual valve lever shaft retaining pin damaged. Inspect for damage. If damaged, repair as neces-
sary.
Park System
Park gear, abutment, abutment plate, parking pawl Inspect for damage. If damaged, repair as neces-
return spring, park or guide plate, parking actuating sary.
rod, parking pawl shaft, manual lever detent spring
damaged or misassembled.
External linkages/brackets damaged.
Other Concerns: Overheating

PCM, vehicle wiring harnesses, TFT sensor and Carry out on-board diagnostic tests. Refer to the
SSB. PCED Manual for diagnosis and testing of the
PCM.
Carry out Pinpoint Tests A and B,
Fluid
section.
G17979 en 09/2004 2004.75 Focus
TO MODEL INDEX


Incorrect Pressures
as required.
Main Control
sary.
Fluid Pump Assembly
sary.
Case
Case vent damaged. Inspect for damage. If damaged, repair as neces-
sary.
torque converter.
Other
Restriction in the transaxle cooling system. Refer to Section 307-02 for information and diag-
nosis of cooling issues.
Excessive trailer tow load. Refer to Owner Guide for specifications on trailer
towing.
Poor engine performance. Check engine performance,
Other Concerns: No Engine Braking in Manual 1

PCM.
Fluid
section.
Incorrect Pressures
G17979 en 09/2004 2004.75 Focus

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as required.
Fluid Pump Assembly
sary.
Return spring damaged.
Other Concerns: Fluid Venting or Foaming

Fluid
section.
in this section.
Fluid Pump Assembly
sary.
Case
Case vent damaged. Inspect for damage. If damaged, repair as neces-
sary.
Other
Transaxle overheating. Refer to routine 257/357 in this section.
Other Concerns: Slips/Chatters in 1st Gear

PCM, vehicle wiring harnesses and SSC. Carry out on-board diagnostic tests. Refer to the
PCM.
Fluid
section.
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in this section.
Incorrect Pressures
as required.
Main Control
sary.
Fluid Pump Assembly
sary.
Low One-Way Clutch
Other Concerns: Slips/Chatters in 2nd Gear

PCM.
Fluid
section.
in this section.
Incorrect Pressures
as required.
Fluid Pump Assembly
G17979 en 09/2004 2004.75 Focus

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Gasket damaged.
sary.
Servo
Band
Band damaged.
sary.
Other Concerns: Slips/Chatters in 3rd Gear

Fluid
section.
in this section.
Incorrect Pressures
as required.
Fluid Pump Assembly
sary.
sary.
Other Concerns: No Engine Braking in ALL Gears

Reference/Action
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Reference/Action
PCM.
No Hydraulic/Mechanical concerns.
G17979 en 09/2004 2004.75 Focus

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GENERAL PROCEDURES
Transmission Fluid Drain and Refill
and Safety Precautions] See - Transmission

Fluids.
Name Specification
Automatic WSS-M2C202-B
Transmission Fluid
AND OPERATION, Lifting] For
4. Attach a length of suitable drain hose to the

transmission fluid cooler return hose.
6. Insert the drain hose into a calibrated 10
liter container.
transaxle do not run the engine above
idle.
NOTE: If the fluid return rate is less than 0.95 liters
in 30 seconds or if the return hose pulsates,
CHECK for restrictions at the pump, cooler or
3. WARNING: When releasing the cooler lines.
transmission fluid, take care to prevent
Run the engine at idle and pump out 3 liters
scalding. Failure to follow this
of automatic transmission fluid.
injury. 8. Switch OFF the engine.
9. Remove the fluid level indicator.
CAUTION: Plug the transmission fluid
cooler lines to prevent fluid loss or dirt
ingress. For additional information, refer
to Section 100-00.[General Information,
DESCRIPTION AND OPERATION, Health
and Safety Precautions] See -
Transmission Fluids.
Detach the transmission return line from
the transmission fluid cooler.
1. Push the transmission fluid cooler line quick
release connector toward the transmission
fluid cooler.
2. Press together the retaining tabs and
detach the transmission fluid line from the
transmission fluid cooler.
tainer. For additional information,
refer to Section 100-00.[General Information,
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10. Add 3 liters of automatic transmission Section 100-02.[Jacking and Lifting,
fluid to the transaxle. DESCRIPTION AND OPERATION,
Jacking]
17. Detach the drain hose from the
transmission fluid return hose.
18. NOTE: Remove the plug from the
transmission fluid cooler return port.
Attach the transmission return line to the
transmission fluid cooler.

idle.
NOTE: If the fluid return rate is less than 0.95 liters
in 30 seconds or if the return hose pulsates,
CHECK for restrictions at the pump, cooler or
cooler lines.
Run the engine at idle and pump out 3 19. Install the radiator undershield.
liters of automatic transmission fluid.
13. Add 3 liters of automatic transmission
fluid to the transaxle.

21. Add 3 liters of automatic transmission
fluid to the transaxle.

idle.
Run the engine at idle and pump out 3
liters of automatic transmission fluid.
G420725 en 09/2004 2004.75 Focus
TO MODEL INDEX


22. Install the fluid level indicator.

idle.
Run the engine and check the automatic
transmission fluid level and top up if
necessary.
G420725 en 09/2004 2004.75 Focus

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IN-VEHICLE REPAIR
Fluid Pan, Gasket and Filter
IN-VEH ICLE R EPAIR
Installation
Special Tool(s)
1. Apply a bead of Loctite 5699 one and a half
Separator, Oil Pan millimeters thick to the fluid pan.
303-428 (21-179)
Name Specification
Metal Surface Cleaner WSE-M5B-392-A
Loctite 5699 WSS-M4G-320-A3
Automatic Transmis- WSS-M2C202-B
sion Fluid
Removal
2. Install the fluid pan.
2. NOTE: Position a suitable container under the
fluid pan.
NOTE: The fluid pan is filled with automatic
transmission fluid and can not be drained before
removing.
Remove the fluid pan.
• Remove the bolts.
• Using the special tool, separate the bead of
sealer.

4. Check the transmission fluid level.
3. Clean the sealer from the fluid pan and

transaxle case surfaces thoroughly with
Metal Surface Cleaner or equivalent.
G17981 en 09/2004 2004.75 Focus

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IN-VEHICLE REPAIR
Main Controls
Removal 4. NOTE: It is necessary to note the location of the

main control wire harness connectors so they
1. Remove the fluid pan. For additional
can be connected in the same positions.
information, refer to Fluid Pan, Gasket and
Connector color letters are cast into the
Filter in this section.
solenoid body.
2. Disconnect the transmission fluid tem-
perature (TFT) sensor electrical connector. Remove the ground wire bolt. Disconnect
the electrical connectors and remove the
main control wiring harness.
1. Solenoid SSC; Color N (Neutral/White).
2. Solenoid SSE; Color G (Green).
3. Solenoid SSD; Color L (Blue).
4. Solenoid EPC; Color B (Black).
5. Solenoid SSA; Color N (Neutral).
6. Solenoid SSB; Color B (Black).
3. Remove the fluid filter.
5. NOTE: Note the locations of the two long bolts.

Remove the main control valve body and
accumulators.
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6. NOTE: Each accumulator is equipped with two 2. CAUTION: Make sure that the manual
springs. All four springs are different sizes. valve is in the manual control valve
NOTE: Note the size and location of the shift lever.
accumulator springs to aid assembly. NOTE: Do not fully tighten the main control valve
Remove the accumulator pistons and bolts at this stage.
springs. Install the main control valve body.
3. Tighten the main control valve body

Installation retaining bolts.
1. NOTE: The thin longer springs are for the
neutral and drive accumulator.
Install the accumulator pistons and
springs.
1. Accumulator 1 and 2.
2. Accumulator N and D.
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4. NOTE: It is necessary to connect the electrical 6. Connect the TFT sensor electrical con-
connectors in the same positions as noted in nector.
disassembly. Connector color letters are cast
into the solenoid body.
Install the main control valve wiring
harness, connect the electrical connectors
and install the ground wire bolt.
1. Solenoid SSC; Color N (Neutral/White).
2. Solenoid SSE; Color G (Green).
3. Solenoid SSD; Color L (Blue).
4. Solenoid EPC; Color B (Black).
5. Solenoid SSA; Color N (Neutral).
6. Solenoid SSB; Color B (Black).
7. Install the fluid pan. For additional

information, refer to Fluid Pan, Gasket and
Filter in this section.
5. Install the fluid filter.
G17983 en 09/2004 2004.75 Focus

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IN-VEHICLE REPAIR
Turbine Shaft Speed (TSS) Sensor
Installation
Name Specification
1. NOTE: Install a new TSS sensor O-ring if
Sealant - Loctite 270 SD-M4G9107-A necessary.
NOTE: Apply a light coat of petroleum jelly to the
O-ring seal before installation.
Removal
1. Disconnect the turbine shaft speed (TSS) • Apply sealant to the TSS sensor retaining
sensor electrical connector. bolt thread.
2. Remove the TSS sensor (transaxle shown

• Check the TSS sensor bore.
• Check the O-ring seal for nicks or cuts.
G401949 en 09/2004 2004.75 Focus

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IN-VEHICLE REPAIR
Output Shaft Speed (OSS) Sensor
Installation
Name Specification
1. NOTE: Apply a light coat of petroleum jelly to
Automatic transmission WSS-M2C202-B the O-ring before installation.
fluid
NOTE: Apply thread sealer to the bolt.
Thread sealer SD-M4G9107-A Install the OSS sensor.
• Connect the electrical connector.
Removal
2. Place a drain pan beneath the output shaft
speed (OSS) sensor.
3. Remove the OSS sensor.
• Disconnect the electrical connector.
• Remove the bolt.
• Inspect the OSS bore.
2. Lower vehicle.
3. Check the transmission fluid level, add
automatic transmission fluid as necessary.
4. Inspect the O-ring seal for nicks or cuts;

install a new as necessary.
4. Start the engine and move the transaxle

range selector lever through all gear
positions.
G17986 en 09/2004 2004.75 Focus

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IN-VEHICLE REPAIR
Halfshaft Seal LH
IN-VEH ICLE R EPAIR
1. Remove the left-hand front drive halfshaft.

Special Tool(s) [Front Drive Halfshafts, REMOVAL
Installer, Transmission
Extension Housing Seal 2. Remove the components in the order
307-028
table(s).

308-208

Number
1 - Halfshaft seal
See Removal Detail
G388139 en 09/2004 2004.75 Focus

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Removal Details
Item 1: Halfshaft seal

1. Remove the halfshaft seal using the special
tool.

1. NOTE: Install a new halfshaft seal.
Install the halfshaft seal using the special
tool.
G388139 en 09/2004 2004.75 Focus

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IN-VEHICLE REPAIR
Halfshaft Seal RH
1. Remove the right-hand front drive

Special Tool(s) halfshaft.
Installer, Transmission 2. Remove the components in the order
Extension Housing Seal indicated in the following illustration(s) and
table(s).
307-028

308-208

Number
1 - Halfshaft seal
See Removal Detail
G388140 en 09/2004 2004.75 Focus

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Removal Details

1. Remove the halfshaft seal using the special
tool.

1. NOTE: Install a new halfshaft seal.
Install the halfshaft seal using the special
tool.
G388140 en 09/2004 2004.75 Focus

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IN-VEHICLE REPAIR
Transmission Range (TR) Sensor (17 705 0)
4. CAUTION: Do not bend the selector

Special Tool(s)
lever.
Alignment Gauge, TR Sensor Detach the selector lever cable from the
307-415 manual shift lever.
manual shift lever.
2. Lift the locking tab, press the locking pins
together and detach the selector lever cable
from the selector lever cable bracket.
Removal
1. Shift the transmission selector lever to the
"D" (DRIVE) position.
3. Disconnect the transmission range (TR)
5. NOTE: Failure to hold the shift lever while

loosening or tightening the manual shift lever
will transmit rotational torque to the TR switch
and shift mechanism.
Remove the TR sensor (automatic
transaxle shown removed for clarity).
1. Remove the manual control lever.
2. Remove the bolts.
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3. CAUTION: Do not use air tools on this

Installation bolt. Hold the manual control lever
while tightening the manual control
1. NOTE: Failure to hold the shift lever while lever bolt, failure to the manual control
loosening or tightening the manual shift lever lever shaft could occur.
will transmit rotational torque to the Install the manual control lever.
transmission range (TR) switch and shift
mechanism.
NOTE: Do not tighten the TR sensor retaining
Install the TR sensor (automatic transaxle
4. NOTE: The transmission range (TR) sensor

mark must be inline with the transaxle selector
lever.
Move the transaxle selector lever to the "D"
(DRIVE) position (TR sensor shown re-
moved for clarity).
2. Using the special tool, align the TR sensor
and tighten the TR sensor retaining bolts.
G401950 en 09/2004 2004.75 Focus

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lever.
Attach the selector lever cable to the
manual shift lever.
1. Attach the selector lever cable to the
selector lever cable bracket, close the
locking tab.
2. Attach the selector lever cable to the lever.
6. Connect the TR sensor electrical connec-

tor.

8. Check the selector lever cable adjustment
by moving the transmission selector lever
through all gear ranges.
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REMOVAL
Transaxle — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (17 214 0)
REMOVAL
4. Install the special tools on both sides

Special Tool(s) (right-hand side shown).
Support Bar, Engine

303-290A

303-290-03A

303-290-13 5. Detach the engine and transaxle assembly
central electrical connector from the fluid
level indicator tube retaining bracket.
303-290-15
General Equipment
Transmission jack
Securing straps
Cable ties
Removal 6. Detach the engine and transaxle assembly

wiring harness from the fluid level indicator
1. Remove the air cleaner. For additional tube retaining bracket.
Assembly]
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REMOVAL (Continued)
7. Detach the ground cable from the trans- 9. WARNING: When releasing the
axle. transmission fluid, take care to prevent
injury.
cooler feed and return lines to prevent
NOTE: The transmission fluid cooler lines are
coloured red (feed line) and black (return line) to
aid installation.
Detach the transmission fluid cooler lines
from the transaxle.
release connector onto the transaxle.
8. Remove the transaxle upper retaining 2. Press together the retaining tabs and
bolts. detach the transmission fluid cooler line
from the transaxle.
tainer.
10. Disconnect the transaxle central electrical

connector.
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REMOVAL (Continued)
11. Disconnect the turbine shaft speed (TSS)
16. Loosen the radiator left-hand retaining
bracket.
• Loosen the front retaining bolt three turns.
• Remove the rear retaining bolt.

INSTALLATION, Starter Motor - 1.8L 17. Disconnect the transmission range (TR)
Duratec-HE (MI4)/2.0L Duratec-HE (MI4)] sensor electrical connector.
refer to Section100-02.[Jacking and Lifting,
DESCRIPTION AND OPERATION,Jacking]
For additional information, refer
to Section 100-02.[Jacking and Lifting,
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REMOVAL (Continued)
18. CAUTION: Do not bend or kink the

selector lever cable. 21. CAUTION: Over bending of the
exhaust flexible pipe may cause
Detach the selector lever cable from the damage resulting in failure.
transaxle.
1. Detach the selector lever cable from the Support the exhaust flexible pipe with a
selector mechanism. suitable support wrap or suitable splint.
from the bracket.
22. Detach the exhaust flexible pipe from the

exhaust hanger insulators.
19. Remove the crashbox (if equipped).
20. Remove the floor panel brace.
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REMOVAL (Continued)
23. CAUTION: Using suitable cable ties, 26. Disconnect the output shaft speed (OSS)
support the exhaust muffler and sensor electrical connector.
muffler and tailpipe assembly.

29. Remove the engine rear mount retaining
bolt.
25. Remove the halfshafts. For additional

information, refer to Section 205-04.[Front
Drive Halfshafts, REMOVAL AND
INSTALLATION, Halfshaft LH]
Section 205-04.[Front Drive Halfshafts,
REMOVAL AND INSTALLATION, Halfshaft
RH]
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REMOVAL (Continued)
30. Remove the engine rear mount bracket 33. Remove the torque converter retaining
(engine rear mount shown removed for nuts.
clarity). • Turn the crankshaft to gain access to the
four retaining nuts.
• Discard the torque converter retaining nuts.

DESCRIPTION AND OPERATION,
bolts.
Jacking] For additional
[Jacking and Lifting,
32. Using the special tools, lower the engine
and transaxle assembly slightly.
35. Remove the transaxle right-hand retain-

ing bolts.
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REMOVAL (Continued)
36. Using suitable securing straps and
wooden blocks, secure the transaxle to
the transmission jack.

bolt.
38. CAUTION: Make sure that the torque

converter remains in the transaxle
housing.
Support the transaxle using the
transmission jack and remove the
transaxle.
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DISASSEMBLY
Transaxle (17 214 8)
DISASSEM BLY
Special Tool(s)
Socket, Final Drive Input Nut
Special Tool(s) 307-414 (17-080)
Remover, O - Ring
100-010 (17-063)
Plate wrenching
Adapter 307-420 (17-085)
205-071-02 (15-026-51)
Remover, Mainshaft Needle

Bearing Sleeve
Mounting Bracket, Engine
Differential 308-191 (16-056)
205-329 (15-105A)
Name Specification
Automatic Transmis- WSS–M2C202–B
303-364 (21-158) sion Fluid
Metal Surface Cleaner WSE–M5B392–A
Screw M10 x 1.25
Separator, Oil Pan

303-428 (21-179) Disassembly
1. CAUTION: If, during repair work,
abrasive particles are found in the
Mounting Stand transaxle fluid (particles from the
303-435 (21-187) clutch, metal chips or foreign material),
the transaxle must be disassembled
completely and cleaned. Also, clean
the fluid pipes, fluid cooler and torque
converter carefully. In the case of
Mounting Bracket for 303-435 extreme soiling of the fluid pipes,
install a new fluid cooler and torque
303-435-06 (21-031B) converter.
NOTE: In case of clutch abrasion, rinse the torque
converter with clean Automatic Transmission
Fluid or equivalent meeting Ford specification.
Holding Tool, Final Drive Inspect the transaxle during disassembly.
Input Gear
307-413 (17-079)
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2. Remove the output shaft speed (OSS) 5. Remove the transmission range (TR) sen-
sensor. sor.
3. Remove the turbine shaft speed (TSS) 6. Remove the special tool.
sensor.
7. CAUTION: Do not tilt the torque

4. CAUTION: Do not use air tools. converter when removing it, to avoid
While holding the lever remove the manual damaging the torque converter hub.
control lever. NOTE: The torque converter is filled with fluid.
Drain into a suitable container.
Remove the torque converter.
8. Using the special tool, mount the transaxle.
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9. Remove the fluid pump bolts. 12. Remove the forward clutch thrust washer.
10. Remove the fluid pump. 13. Remove the forward clutch assembly.
• Install two M10 x 1.25 bolts into the fluid
pump and remove the fluid pump.
14. NOTE: Small levers will aid in the removal of

the forward clutch hub.
11. Remove the fluid pump seals. Remove the forward clutch hub.
15. Rotate the transaxle 180 degrees.
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16. Remove the end cover. 20. Remove the end cover to case seals.
17. Clean the silicone sealant from the end 21. Using the special tool, remove the direct
cover and transaxle case surfaces clutch cylinder thrust bearing.
thoroughly with Metal Surface Cleaner or
equivalent to Ford specification.
18. Remove the direct clutch hub bearing
shim.
22. Remove the intermediate and overdrive

brake band anchor bolt.
19. Using the special tool, remove the end

cover seals.
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23. Remove the intermediate and overdrive 26. Remove the low and reverse clutch plate
brake band. retaining ring.
24. Remove the intermediate and overdrive 27. Remove the low and reverse clutch plates,
brake drum assembly. pressure plate and bevel ring.
25. Remove the planet gear assembly. 28. Remove the low gear one-way clutch re-
taining ring.
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29. Remove the low gear one-way clutch in- 32. Remove the transaxle fluid pan and drain
ner race. transmission fluid, using a suitable tray.
2. Using the special tool, separate the trans-
axle fluid pan from the transaxle.
30. Remove the low and reverse gear clutch

return spring.
33. Clean the silicone sealant from the

transaxle fluid pan and transaxle case
surfaces thoroughly with Metal Surface
Cleaner or equivalent to Ford
specification.
34. Remove the transmission fluid tempera-
ture (TFT) sensor.
31. Remove the low and reverse gear clutch

piston.
35. Remove the fluid filter.
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38. NOTE: Squeeze the tabs on the side of the
36. NOTE: It is necessary to note the location of
the main control wire harness connectors so
they can be connected in the same positions. Remove the transaxle internal harness
Connector color letters are cast into the electrical connector.
solenoid body.
Remove the ground wire bolt. Disconnect
the electrical connectors and remove the
wire harness.
1. Solenoid SSC; Color W (White)
2. Solenoid SSE; Color G (Green)
3. Solenoid SSD; Color L (Blue)
4. Solenoid EPC; Color B (Black)
5. Solenoid SSA; Color N (Neutral)
6. Solenoid SSB; Color B (Black)
39. NOTE: Each of the two accumulators have

two springs. All four springs are different sizes.
NOTE: Note the size and location of the
accumulator springs for assembly.
Remove the accumulator pistons and
springs.
37. NOTE: Note the location of the longer bolts.

Remove the 13 main control valve body
retaining bolts.
40. Remove the manual lever shaft roll pin.
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41. Remove the manual lever shaft. 44. CAUTION: The intermediate and
overdrive brake band servo cover plate
is spring loaded. The bolts should be
removed evenly until the plate is
unloaded, then remove the bolts.
Remove the intermediate and overdrive
piston servo cover.
• Remove the intermediate and overdrive
piston servo cover.
42. Remove the O-ring seals from the manual

lever shaft.
45. Remove the O-ring seal.
43. Remove the control lever assembly.
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46. Remove the intermediate and overdrive 50. Remove the differential assembly.
servo piston.
51. Remove the parking pawl assembly

47. Remove the intermediate and overdrive cover.
servo piston return spring.
52. Remove the parking pawl abutment.

48. Rotate the transaxle 180 degrees. 1. Unclip the spring.
49. Remove the bolts and separate the con- 2. Remove the pin.
verter housing from the transaxle case.
3. Remove the lever.
4. Remove the parking pawl abutment.
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53. Remove the spring. 57. NOTE: Release the locking sleeve away from
the final drive input gear bearing retaining nut.
Using the special tool, remove the final
drive input gear bearing retaining nut.
54. Remove the transfer shaft gear.

55. Using the special tool, lock the final drive

input gear.
60. CAUTION: Hold the final drive input

gear while removing the bearing to
prevent it from falling out of the
transaxle case.
Rotate the transaxle 180 degrees.
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61. Remove the final drive input gear bearing
by lightly tapping on the end of the final
drive input gear. Remove the final drive
input gear.
62. Remove and discard the collapsible

spacer.
63. Using the special tool, remove the final

drive input gear bearing.
64. Clean the converter housing and

transaxle case surfaces thoroughly with
Metal Surface Cleaner or equivalent
meeting Ford specification.
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Final Drive Carrier and Differential Assembly
Disassembly
Special Tool(s)
1. CAUTION: Do not damage the speed
Installer Differential Bearing sensor wheel.
205-062 (15-025A) NOTE: Left-hand side shown, right-hand side
similar.
Using the special tools, remove the differ-
Remover, Bearing (Main ential case bearings.
Tool)
205-295 (15-050A)
Collet for 205-295

308-197 (16-062)
Adapter
205-071-01 (15-026A-01)
2. NOTE: The roll pin can be driven through the

Name Specification housing.
Remove the differential pinion shaft.
Automatic Transmis- WSS–M2C202–B
sion Fluid • Remove and discard the pin.
• Remove the differential pinion shaft.
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3. Remove the differential side gears. 2. Install the different pinion gears and thrust
1. Turn the differential pinion gears 90 washers.
degrees and remove the differential pinion 1. Install the differential side gears and thrust
gears with the thrust washers. washers.
2. Remove the differential side gears with the 2. Install the differential pinion gears and
thrust washers. thrust washers by rotating 90 degrees.
4. Clean all parts thoroughly in suitable 3. Install the differential pinion shaft.
solvent and blow dry with moisture-free 1. Push the pinion shaft in place.
regulated compressed air.
2. Install a new pin.
5. Inspect the differential parts for damage
and wear.
• Pinion gear teeth and bores
• Side gear teeth and five plines
• Thrust washers
• Differential pinion shaft
• Differential case bearing and surfaces
Assembly
1. Lubricate the gears and thrust washers
with clean Automatic Transmission Fluid.
4. Using the special tool, install the differen-

tial case bearings.
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Pump Assembly
3. Remove the pump seal.
Special Tool(s)
Installer, Drive Pinion Oil Seal
205-115 (15-058)
Name Specification
Automatic transmission WSS–M2C202–B
fluid
Disassembly 4. Inspect the upper portion of the pump for

nicks, scratches or gouges.
1. Remove the top portion of the pump.
5. Inspect the pump gears for nicks,

2. Inspect the lower portion of the pump and scratches or gouges.
gear pocket for nicks, scratches, gouges or
wear.
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Assembly 3. Install the top portion of the pump.
1. NOTE: The smaller gear has a recess on both

sides.
NOTE: The smaller recess must face away from
the torque converter seal.
NOTE: The larger recess, with the beveled edge,
must face toward the torque converter.
Lubricate the gears and thrust washers
with clean automatic transmission fluid.
2. Using the special tool, install the pump

seal.
• Lubricate the gears and thrust washers with
automatic transmission fluid.
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Transfer Shaft
2. Using the special tool and a press, remove

Special Tool(s) the left-hand side transfer shaft gear bear-
Collet for 205-295 ing while separating the gears.
308-197 (16-062)
Remover, Bearing (Main

Tool)
205-295 (15-050A)
Adapter
205-071-01 (15-026A-01)
Installer, Drive Pinion Bearing Assembly

205-068 (15-042) 1. Using the special tool, install the
right-hand side transfer shaft gear and park
assembly.
Adapter
204-158-01 (14-038-01)
Disassembly
right-hand side transfer shaft gear bearing.
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2. Using the special tool, assemble the gears
and install the left-hand side transfer shaft
gear bearing.
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Forward Clutch
General Equipment
Feeler gauge
Special Tool(s)
Compressor, Spring Washer Name Specification
307-209 (17-040) Automatic Transmis- WSS–M2C202–B
sion Fluid

Number
6 – Steel plates - forward clutch
1 – Shaft assembly - turbine separator
2 – Piston assembly - forward 7 – Friction plate assembly -
clutch forward clutch
3 – Spring assembly - forward 8 – Plate - forward clutch pres-
piston return sure
4 – Piston - forward clutch bal- 9 – Retaining ring
ance
10 – Hub - forward clutch cylinder
5 – Ring - forward clutch balance
piston snap thrust bearing
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4. CAUTION: If damage is found to the

Disassembly balance piston seals, install a new
forward clutch balance piston.
1. Remove the forward clutch plates. Remove and inspect the forward clutch
1. Remove the snap ring. balance piston.
2. Remove the pressure plate, the friction
plates and the steel plates.
5. Remove the return spring assembly.
2. Using the special tool, place the forward

clutch assembly in a press.

forward clutch piston seals, install a
new forward clutch piston assembly.
3. Using the special tool, remove the forward
clutch balance piston snap ring. Remove the forward clutch piston assem-
bly.
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Assembly 5. Lubricate and install the forward clutch

balance piston.
1. Soak the internal spline clutch plates in
clean Automatic Transmission Fluid for 15
minutes before assembly.
2. Inspect the forward clutch piston bore
surfaces for nicks or scratches. Install a
new forward clutch balance piston if
necessary.
3. Lubricate and install the forward clutch
piston assembly.
6. Using the special tool, install the forward

clutch assembly using a press.
4. Install the return spring assembly.
7. Using the special tool, install the forward

clutch balance piston snap ring.
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8. Install the forward clutch plates.
1. Install the steel plates, the friction plates
and the pressure plate.
2. Install the snap ring.
• Using a feeler gauge, check clearance. For
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Direct and Reverse Clutch Assembly
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3. Remove the bearing.
Number
1 – Snap ring
2 – Rear sun gear assembly
3 – Thrust bearing assembly
4 – Direct clutch hub assembly
5 – Direct clutch thrust bearing
6 – Direct Clutch cylinder as-
sembly
7 – Intermediate and overdrive
band assembly
4. Remove the direct clutch hub.
Disassembly
1. Remove the snap ring from the reverse
drum.
5. Remove the direct clutch thrust bearing.
2. Remove the sun gear.
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6. Remove the direct clutch cylinder assem-
bly.
Assembly
procedure.
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Direct Clutch
Name Specification
Automatic transmission WSS–M2C202–B
Special Tool(s) fluid
Compressor, Spring Washer
307-209 (17-040)

Number Disassembly
1 – Retaining ring 1. Remove the direct clutch pressure plate
and plates.
2 – Direct clutch pressure plate
1. Remove the selective direct clutch pressure
3 – Friction plates plate retaining ring.
4 – Steelplates - forward clutch 2. Remove the direct clutch pressure plate and
separator plates.
5 – Selective snap ring
6 – Direct clutch balance piston
7 – Direct clutch return spring
8 – Direct clutch piston
9 – Bearing - direct clutch thrust
10 – Cylinder assembly - direct
clutch
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2. Using the special tool, remove the snap 5. CAUTION: If damage is found on the
ring. direct clutch piston seals, install a new
direct clutch piston.
Remove and inspect the direct clutch pis-
ton.
3. Remove the direct clutch balance piston.
Assembly
clean automatic transmission fluid for 15
2. Inspect the direct clutch piston bore
surfaces for nicks or scratches. Install a
new direct clutch piston if necessary.
3. Lubricate and install the direct clutch pis-
ton.
4. Remove the direct clutch return spring.
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4. Install the direct clutch return spring. 7. Install the direct clutch pressure plate
retaining ring. For additional information,
1. Install the direct clutch plates and pressure
plate.
2. Install the selective direct clutch pressure
plate retaining ring.
5. Install the direct clutch balance piston.
6. Using the special tool, install the snap ring.
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Reverse Clutch
Name Specification
Automatic Transmis- WSS-M2C202-B
Special Tool(s) sion Fluid
Clutch Spring Compressor
307-015 (17-058)

Number
1 – Retaining ring
2 – Pressure plate
3 – Steel plate
4 – Friction plate assembly
5 – Spring retainer ring
6 – Spring retainer
7 – Piston return spring
8 – Piston assembly
9 – Intermediate and overdrive
drum assembly
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Disassembly 4. Remove the reverse clutch piston assem-
bly.
1. Remove the reverse clutch pressure plate
and clutch plates.
1. Remove the reverse clutch pressure plate
retaining snap ring.
2. Remove the pressure plate and clutch
plates.

reverse clutch piston seals, install a
new reverse clutch piston.
Inspect the seal bore, inner and outer
seals.
2. Using the special tool, remove the reverse
clutch snap ring and retainer.
Assembly
3. Remove the reverse clutch return spring.
clean Automatic Transmission Fluid for 15
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2. Lubricate and install the reverse clutch 5. Install the reverse clutch pressure plate
piston assembly. retaining snap ring. For additional
information,
1. Install the reverse clutch plates and
pressure plate.
2. Install the reverse clutch pressure plate
retaining snap ring.
3. Install the reverse clutch return spring.
4. Using the special tool, install the reverse

clutch retainer and snap ring.
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Planetary Assembly
Disassembly 4. Remove the thrust bearing.

1. Inspect the planetary assembly internal
bearing for damage.
5. Remove the forward planet sun gear.
2. Remove the snap ring.
6. Remove the thrust bearing.
3. Remove the rear planet assembly.
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7. Remove the forward planet assembly. 10. Remove the one-way clutch upper ring.
8. Inspect the low and reverse ring gear. 11. Remove the low one-way clutch assem-
bly.
9. Remove the one-way clutch upper retainer.

12. Remove the one-way clutch lower ring.
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Assembly 4. Install the low one-way clutch assembly.
1. Install the one-way clutch lower ring.
5. Install the one-way clutch upper ring.
2. Inspect the rollers and the springs of the

one-way clutch assembly.
6. Install the one-way clutch upper retainer.
3. Make sure the one-way clutch assembly is

installed with the tab pointing in the direc-
tion as shown.
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7. Install the forward planet assembly. 10. Install the forward planet sun gear.
8. NOTE: Make sure the locking tabs face 11. NOTE: Make sure the tab faces downwards.
downwards.
Install the thrust bearing.
Install the thrust bearing.
12. Install the rear planet assembly.

9. Inspect the forward planet sun gear re-
taining ring.
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Main Control Valve Body
Disassembly
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Number
26 Solenoid plate
1 Manual control valve
27 Regulator body gasket
2 Spring retainer plate
28 Shift control solenoid
3 Bypass clutch control plate
spring 29 Electrical pressure control
solenoid
4 Bypass clutch control valve
30 Solenoid bracket screws
5 Modulator valve spring
31 Solenoid body bolt
6 Line pressure modulator
valve 32 Solenoid body
7 Main control valve body bolt 33 Shift control solenoids
8 Main control valve body bolt 34 Shift solenoids hold down

bracket
9 Main control valve body seal 1. Remove the solenoid body.
10 Main control valve body bolt
11 Main control upper valve
body
12 Main control valve body
gasket
13 Main control valve body
separator plate (bonded
gasket)
14 Main control valve lower
body
15 Main regulator valve stop
16 Throttle valve plunger sleeve 2. Remove and discard the solenoid body
clip gaskets.
17 Main fluid pressure regulator
valve spring
18 Main fluid pressure regulator
valve
19 Solenoid regulator valve
spring
20 Shift solenoid valve
21 Intermediate servo accumu-
lator spring
22 Intermediate servo accumu-
lator valve
23 Converter regulator valve
spring
24 Lock up control valve
25 Solenoid body gasket
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3. Remove and discard the valve body seals. Assembly
1. NOTE: The top side of the separator plate has a
bonded gasket. Separate gasket goes on the
bottom side.
Inspect and clean the main control valve
body and install a new separator plate as-
sembly and gasket.
4. Disassemble the main control valve body.
2. Assemble the upper and lower main con-

trol valve bodies and loosely install the
bolts.
5. Remove and discard the separator plate

and gasket.
3. Install the new solenoid body gaskets.
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4. Install the solenoid body and install the two 6. Install new valve body seals.
bolts as shown.
5. Install the remaining bolts and tighten in

the sequence shown.
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Transaxle Case
Disassembly
Special Tool(s)
1. Remove the halfshaft seals (left-hand side
Installer, Rear Wheel Hub shown).
Seal
205-075 (15-036)
Installer, Differential Double

Lip Seal
308-203 (16-066)
Remover, Differential Bearing

Cone
205-176 (15-074)
2. Using the special tool, remove the differ-
ential bearing cups (left-hand side shown).
Installer, Transmission
Extension Housing Seal
307-028 (17-002)
Remover, Drive Pinion Seal

205-078 (15-048)
Adapter for 206-066 3. Using the special tool, remove the final
205-066-03 (15-033-3) drive input gear bearing cup.
Installer, Rear Wheel Hub

Seal
205-075 (15-036)
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4. Using the special tool, remove the transfer Assembly
shaft gear bearing cups (left-hand side
shown). 1. NOTE: The converter housing side bearing
cups for the transfer shaft bearing and
differential case bearing will be installed during
the assembly of the transaxle.
Using the special tool, install the final drive
input gear bearing cup.
5. NOTE: Note the location of the bleed hole in the

funnel in relation to the bottom of the case.
NOTE: Inspect the bleed hole for foreign material.
Remove the funnel.
3. NOTE: Note the location of the bleed hole.
NOTE: Inspect the bleed hole for foreign material.
Install the funnel.

7. Using the special tool, remove the final
drive input gear bearing cup.
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4. Using the special tool, install the transfer 7. Using the special tool, install the halfshaft
shaft gear bearing cups (left-hand side seals (left-hand side shown).
shown).
5. Using the special tool, install the final drive

input gear bearing cup (left-hand side
shown).

tial case bearing cups (left-hand side
shown).
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Torque Converter
1. A new torque converter must be installed if

one or more of the following statements are
true:
• A torque converter malfunction has been
detected based on completed diagnostic
procedures.
• Impeller hub or bushing is damaged.
• If there is a discoloration of the torque
converter (due to overheating).
• The torque converter is found to be out of
specification, when carrying out the
following checks:
• torque converter pump insert check
• torque converter end play check
• torque converter turbine torque check
• torque converter leakage check
• If there is evidence of transaxle assembly
damage or fluid contamination due to the
following transaxle or converter failure
modes:
• major metallic failure
• multiple clutches or clutch plate failures
• sufficient component wear which results
in metallic contamination
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Torque Converter Leak Check
4. CAUTION: Use only clean, dry shop air.

Special Tool(s)
Connect the airline to the special tool and
Torque Converter Leak apply air pressure.
Check Tool and Gasket
307-421
1. Clean the outside surface of the torque

converter.
2. Install the special tool onto the converter
hub.
5. With air pressure applied to the valve, in-

spect for leaks at the converter hub, the
seams and the studs. A soap bubble solu-
tion can be applied around these areas to
aid in the diagnosis. If any leaks are pre-
sent, install a new converter.
3. WARNING: Always follow correct safety

procedures while using a press.
Install the torque converter with the special
tool installed onto the arbor press.
• Apply only enough force from the press to
seal the special tool into the torque con-
verter.
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6. Remove the air hose. Release the pressure,
and then slowly release the press. Remove
the converter. Remove the special tool.
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Torque Converter End Play Check
Special Tool(s)
Gauge, Torque Converter
Clutch
307-409 (17-078)
1. Using the special tool, measure the torque

converter clutch end play.
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ASSEMBLY
ASSEM BLY
Special Tool(s)
Socket, Final Drive Input Nut
Special Tool(s) 307-414 (17-080)
Preload Gauge
205-067 (15-041)
Alignment Gauge, TR Sensor

307-415 (17-081)
Installer, Differential Bearing
Cone
205-073 (15-034)
Adjustment Bolt,
Installer, Rear Wheel Hub Transmission Band
Seal
307-416 (17-082)
205-075 (15-036)
Installer, Timing Cover Seal

303-255 (21-136) Gauge, Differential/Transfer
Gear Bearing Shim
307-417 (17-083)

303-364 (21-158)
Holding Fixture, Final drive

Installer, Extension Housing 307-420 (17-085)
Seal
307-028 (17-002)
Depth Gauge, Shim Selection Remover, Input Shaft Fifth

Gear
307-300-02 (17-055-02)
308-082 (16-035)
Spacer, Transmission
Holding Tool, Final Drive Housing
Input Gear 308-164 (17-084)
307-413 (17-079)
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Special Tool(s) 3. Using the special tool, position the final
drive input gear.
Installer, Differential Double
Lip Seal
308-203 (16-066)
Name Specification
Thread sealer TN-YS5J-M4G9107-AA
Loctite 5699 WSS-M4G-320-A3
Assembly
4. CAUTION: Hold the final drive input
1. Using an arbor press and the special tool, gear while installing the final drive
seat the final drive input gear bearing. input gear bearing to prevent it from
falling out of the transaxle case.
Rotate the transaxle 180 degrees.
5. Using the special tools, install the final
drive input gear bearing.
2. Install a new collapsible spacer.

7. Using the special tool, lock the final drive
input gear.
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8. Rotate the transaxle 180 degrees. 13. CAUTION: Make sure the bearing
9. NOTE: A high tightening torque specification preload is within specification.
(between 400-450 Nm) is necessary to crush NOTE: Rotate the gear ten times to make sure
the collapsible spacer for correct bearing that the bearings are correctly seated.
preload.
Using the special tools, measure the ro-
NOTE: If the preload is too high a new collapsible
tating torque.
spacer must be installed.
Using the special tools, tighten the nut to
achieve the preload specification.
14. After achieving the correct torque, stake

the nut to prevent movement.

11. NOTE: Make sure that the final drive rotates.
Unlock the special tool.

16. Position the transfer shaft gears in the
transaxle case.
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20. Install the differential case assembly.
17. Install the parking pawl return spring.
21. Install the bearing cups.

18. Connect the parking pawl return spring.
1. Install the parking pawl abutment.
2. Install the lever.
3. Install the pin.
4. Reconnect the pawl spring.
19. Install the parking pawl cover.
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23. NOTE: The converter housing cover must be 25. NOTE: Do not move the special tool plunger,
installed evenly or an incorrect reading will settings are made.
result.
Remove the special tools.
Assemble the transaxle for end play
measurement.
1. Install the converter housing.
2. Install the long bolts and seat the converter
housing.
3. Install the short bolts.
26. NOTE: If the plunger is above the contact

surface, the reading will be incorrect.
To determine the correct transfer shaft
shim, measure the depth of the plunger
on the special tool and select the correct
transfer shaft shim. For additional infor-
24. Remove the converter housing. mation, refer to Specification in this section.
2. Remove the converter housing.
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27. NOTE: If the plunger is above the contact 29. Using the special tool, install the correct
surface, the reading will be incorrect. differential shaft shim and differential
case bearing cup in to the converter
To determine the correct differential shaft
housing.
shim, measure the depth of the plunger
on the special tool and select the correct
differential shaft shim. For additional in-
formation,
refer to Specification in this section.
30. NOTE: The components must be assembled

within 15 minutes.
Apply a one millimeter thick bead of Loc-
tite 5699.
28. Using the special tool, install the correct
transfer shaft shim and differential case
bearing cup into the converter housing.
31. Install the converter housing.
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32. Install the servo piston return spring. 35. NOTE: The three bolts need to be loosely
installed, then tightened in sequence to
compress the servo piston return spring evenly.
Install the servo piston cover.
33. Install the servo piston.
36. Install the shifter assembly and bolt.
34. Install the O-ring seal.
37. NOTE: Lubricate the O-ring prior to assembly.

Install the new O-rings on the manual
lever shaft.
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38. Install the manual lever shaft. 41. NOTE: The neutral drive accumulator springs
are thinner than the 1-2 accumulator springs.
Install the neutral drive accumulator
springs.
39. NOTE: The roll pin does not need to sit flush
with the shifter assembly.
Install the manual lever shaft roll pin.
42. Install the neutral drive accumulator pis-
ton.
40. Loosely install the transmission range

(TR) sensor.
43. Install the 1-2 accumulator springs.
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44. Install the 1-2 accumulator piston. 47. Tighten the main control valve body bolts.
45. NOTE: Inspect the seals.

Lubricate and install the transaxle internal 48. NOTE: It is necessary to connect the
harness electrical connector. connectors in the same positions as noted in
disassembly. Connector color letters are cast
into the solenoid body.
Install the main control wire harness,
connect the electrical connectors and
install the ground wire bolt.
1. Solenoid SSC; Color W (/Neutral/White)
2. Solenoid SSE; Color G (Green)
3. Solenoid SSD; Color L (Blue)
4. Solenoid EPC; Color B (Black)
5. Solenoid SSA; Color N (Neutral)
6. Solenoid SSB; Color B (Black)
46. NOTE: Make sure that the manual valve is in

the manual control valve shift lever.
NOTE: Do not fully tighten the bolts at this stage.
Install the main control valve body.
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49. Install the fluid filter. 52. Install the transaxle fluid pan and bolts.
50. Connect the transmission fluid tempera-

ture (TFT) sensor.
54. Install the low and reverse clutch piston.
51. Apply a one and a half millimeter thick

bead of Loctite 5699 to the transaxle fluid 55. NOTE: Make sure that the clutch return spring
pan. is inserted with the tabs facing upwards
Install the low and reverse clutch return
spring.
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56. Install the bevel ring with the outer edge 59. NOTE: The opening of the retaining ring must
uppermost. be at the ten o'clock position.
Install the low one-way clutch retaining
ring.
57. Inspect the position of the bevel ring.

1. Make sure the low and reverse clutch piston
is seated. 60. Install the low and reverse gear plate and
2. Make sure the bevel ring is installed with the pressure plate.
inside edge facing down.
61. Install the low reverse gear clutch plate

58. Install the low one-way clutch inner race. selective retaining ring.
• Check the clutch clearance. For additional
information,refer to Specification in this section.
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62. NOTE: Make sure that the snap ring is 64. CAUTION: The planet assembly must
installed before installing the planet assembly. only rotate counterclockwise.
Install the planet assembly. Check that the one way clutch is installed
correctly.
• Rotate the planet assembly clockwise and
counterclockwise.
63. CAUTION: The edge of the planet

assembly must fit flush with the
transaxle case.
Inspect the planet assembly installation. 65. Install the intermediate and overdrive
drum assembly.
66. Install the intermediate and overdrive

brake band.
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67. Install the direct clutch cylinder thrust 70. Install the direct clutch hub bearing shim
bearing with the rollers facing up. and an additional shim to increase the
total shim thickness to specification
shown.
68. Install new end cover to case seals.
71. NOTE: Make sure the cover is seated down on

both shims.
NOTE: Take measurements from several
positions and calculate the average gap.
Measure the gap between the transaxle
end cover and the transaxle assembly.
1. Install the transaxle end cover on the
transaxle assembly.
2. Measure the gap between the transaxle end
cover and the transaxle assembly.
69. Install new end cover seals.
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72. Remove the transaxle end cover. 74. CAUTION: Make sure that the sealant
does not enter the fluid return holes.
Apply a one millimeter thick bead of Loc-
tite 5699 to the transaxle end cover.
73. Select and install the correct direct clutch

hub bearing shim:
• Step 1 (total amount of shim thickness used
during transaxle end cover mock up). 75. Install the transaxle end cover.
• Step 2 (measure the gap between transaxle
end cover and transaxle case).
• Step 3 (subtract Step 2 from Step 1 to
obtain the correct total shim thickness).
• Step 4 (subtract total amount in Step 3 from
minimum and maximum clearance). For
• Measurement: 0.25-0.50 mm
76. Using the special tool, collapse the band

to specification then slacken three and a
half turns.
77. Holding the special tool, lightly seat the

nut against the transaxle case, then re-
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move the special tool without changing 81. Install the forward clutch hub.
the relationship of the nut on the bolt.
82. Install the forward clutch assembly.

78. Using the special tool, select a band bolt
that measures from the end of the bolt to
the face of the nut as shown.
83. Install the forward clutch thrust washer.
79. NOTE: Apply thread sealer to the bolt.

Install the band anchor bolt.
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84. Lubricate and install new fluid pump 87. Install the output shaft speed (OSS) sen-
seals. sor.
85. NOTE: Do not force the pump down at this 88. NOTE: Apply thread sealer to the bolt.
time.
Install the turbine shaft speed (TSS)
Install the fluid pump. sensor.
86. Install the fluid pump. 89. Using the special tool, align the TR sen-
• Use the bolts to seat the fluid pump. sor and tighten the retaining bolts.
• Tighten the retaining bolts in an alternating
sequence.
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90. CAUTION: Do not use air tools on this

bolt. Hold the manual control lever
while tightening the manual control
lever retaining bolt.
Install the manual control lever.
91. Install the torque converter.
92. Using the special tool, secure the torque

converter.
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INSTALLATION
Transaxle — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (17 214 0)
INST ALLAT ION
2. CAUTION: The torque converter hub

Special Tool(s)
must engage fully with the oil pump
Support Bar, Engine drive gear.
303-290A Check the installation depth of the torque
converter.
1. Position a steel straightedge on the
transaxle flange.
2. Measure the installation depth between the
303-290-03A
automatic transaxle flange and the torque
converter guide collar.

303-290-13

303-290-15
General Equipment
Transmission jack
Securing straps
Installation
All vehicles
CAUTION: Make sure that the two dowel
pins are installed.
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3. CAUTION: The torque converter must 7. Install the transaxle right-hand retaining
remain at the correct installation depth bolts.
during the entire installation.
NOTE: Using suitable securing straps and
wooden blocks, secure the transaxle to the
transmission jack.
Using a transmission jack, install the
transaxle.

bolt.
9. CAUTION: Make sure that the torque

converter retaining nuts do not fall into
the torque converter housing.
NOTE: Install new torque converter retaining nuts.
Install the torque converter retaining nuts.
• Turn the crankshaft to gain access to the
torque converter studs.
5. Remove the securing straps.
6. Remove the transmission jack.
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10. Using the special tools, raise the engine 14. Raise and support the vehicle. For
and transaxle assembly. additional information,
refer to Section 100-02.[Jacking and
Lifting, DESCRIPTION AND OPERATION,
Jacking] For additional information,

12. Install the engine rear mount bracket (en-
gine rear mount shown removed for clar-
ity).
16. Connect the output shaft speed (OSS)

13. NOTE: Install a new rear engine mount

retaining bolt.
Install the engine rear mount retaining
bolt.
17. Install the halfshafts. For additional
Drive Halfshafts, REMOVAL AND
Section 205-04.[Front Drive Halfshafts,
REMOVAL AND INSTALLATION, Halfshaft
RH]
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18. Install the engine support insulator. 21. Remove the support wrap or splint.
19. NOTE: Install a new gasket and new nuts. 22. Install the floor panel brace.
Attach the exhaust flexible pipe to the
• Discard the cable ties.
23. Install the crashbox (if equipped).

1. Install one retaining bolt M10 x 16.
2. Install two retaining bolts M10 x 25.
20. Attach the exhaust flexible pipe to the
exhaust hanger insulators.
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24. CAUTION: Do not bend or kink the 26. Tighten the radiator left-hand retaining
selector lever cable. bracket.
• Install the rear retaining bolt.
Attach the selector lever cable to the
transaxle.
1. Press the locking pins together and attach
the selector lever cable to the bracket, press
down the locking tab.
2. Attach the selector lever cable to the se-
lector mechanism.

28. Install the starter motor. For additional
INSTALLATION, Starter Motor - 1.8L
29. Connect the turbine shaft speed (TSS)
25. Connect the transmission range (TR)
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30. CAUTION: The automatic transaxle 32. Install the transaxle upper retaining bolts.
contains components and assemblies
which are sensitive to electrostatic
charging.
Connect the transaxle central electrical
connector.
33. Attach the ground cable to the transaxle.
31. NOTE: The transmission fluid cooler lines are

coloured red (feed line) and black (return line)
to aid installation.
Attach the transmission fluid cooler feed
and return lines to the transaxle.
34. Attach the engine and transaxle assembly

wiring harness to the fluid level indicator
tube retaining bracket.
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35. Attach the engine and transaxle assembly 40. Install the air cleaner. For additional
central electrical connector to the fluid information, refer to Section 303-12.
level indicator tube retaining bracket. [Intake Air Distribution and
Duratec-HE (MI4)]
41. Fill the transaxle with automatic
transmission fluid. For additional
information, refer to Transmission Fluid
Drain and Refill in this section.
36. Remove the special tools on both sides 43. Install the radiator undershield.
37. Install the headlamp assembly on both

REMOVAL AND INSTALLATION,
Headlamp Assembly]
38. Adjust the selector lever cable. For
refer to Section 307-05A.[Automatic
Transmission/Transaxle External
Controls - Vehicles With: 4-Speed
Automatic Transaxle (4F27E), GENERAL
PROCEDURES, Selector Lever Cable
Adjustment] 45. Lower the vehicle.
39. Install the battery tray. For additional Vehicles with global closing
information, refer to Section 414-01. 46. Initialize the window regulator motors.
[Battery, Mounting and Cables, For additional information,
REMOVAL AND INSTALLATION, Battery refer to Section 501-11.[Glass, Frames and
Tray - 1.4L Duratec-16V (Sigma)/1.6L Mechanisms, GENERAL PROCEDURES,
Duratec-16V (Sigma)/1.8L Duratec-HE Door Window Motor Initialization]
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307-02-1 Transmission/Transaxle Cooling — Vehicles With: 307-02-1

SECTION 307-02 Transmission/Transaxle Cooling —

Vehicles With: 4-Speed Automatic Transaxle (4F27E)
CONTENTS PAGE
SPECIFICATIONS
Specifications................................................................................................................... 307-02-2
Transaxle Cooling ............................................................................................................ 307-02-3

Transaxle Cooling ........................................................................................................... 307-02-3
Powertain warning indicator ............................................................................................ 307-02-3
Transmission fluid temperature (TFT) sensor.................................................................. 307-02-3
Transaxle Cooling ............................................................................................................ 307-02-4

Inspection and Verification .............................................................................................. 307-02-4
Symptom Chart ............................................................................................................... 307-02-4
Transmission Fluid Cooler ............................................................................ (17 834 0) 307-02-5/6

Transmission Fluid Cooler Tubes.................................................................. (17 857 0) 307-02-7
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SPECIFICATIONS

Item Specification
Automatic Transmission Fluid WSS-M2C202-B
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Transaxle Cooling
Transaxle Cooling Powertain warning indicator

CAUTION: Do not repair a leak through
thightening more as the required torque
in the specifications.
Overview
Location
The powertrain warning indicator is located in the
instrument cluster and is coloured orange.
Function
It tells the driver that the transaxle control has
switched to the emergency operating program or
Number
that the transmission fluid temperature is too high.
1 Return tube
2 Feed tube
Transmission fluid temperature (TFT) sensor
3 Transmission fluid cooler
The transmission fluid temperature (TFT) sensor
The transmission fluid cooler is installed in front of located on the internal wiring harness in the oil
the engine cooling radiator. pan is an NTXC resistor and measures the
transmission fluid temperature.
If the transmission fluid temperature is excessively
high (> 135°C) the transmission warning light is
illuminated and a failure code is stored indicating a
transmission malfunction.
Under low temperature conditions there is no
lock-up function between 0°C to 40°C
transmission temperature.
Vehicles with air conditioning:

Before removing the transmission fluid cooler the
air conditioning condensor has to be removed.
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Transaxle Cooling
Inspection and Verification CAUTION: Do not repair a leak through

1. Verify the customer concern by operating the tightening more as the required torque in
transaxle. the specification.
mechanical damage. Overview

Mechanical
– Feed and return tubes
– Connections to the automatic transaxle and
the automatic transmission fluid cooler
– Automatic transmission fluid level
step.
CAUTION: Do not overtighten cooler line Item Part Description
fittings. Case of fitting damage may Number
result. 1 Return tube
2 Feed tube
3 Transmission Fluid Cooler
Symptom Chart
• Loss of automatic transmission • Connections to the automatic • Check the torque of the tubes, if
fluid transmission and the automatic correct, check the condition of
transmission fluid cooler. the tubes and connections.
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Transmission Fluid Cooler (17 834 0)
Removal
5. WARNING: When releasing the
1. Raise and support the vehicle. For transmission fluid, take care to prevent
additional information, refer to Section scalding. Failure to follow this
100-02.[Jacking and Lifting, DESCRIPTION instruction may result in personal
AND OPERATION, Jacking] For injury.
ingress. For additional information,
2. Remove the engine undershield (if refer to Section 100-00.[General Information,
equipped). DESCRIPTION AND OPERATION, Health
3. Remove the radiator lower splash shield. and Safety Precautions] See -
NOTE: The position of the feed line (yellow) and
return line (blue) to the transmission fluid cooler is
marked on the connectors.
from the transmission fluid cooler.
fluid cooler.
detach the transmission fluid cooler line
4. Remove the right-hand and left-hand air from the transmission fluid cooler.
deflector. • Allow the fluid to drain into a suitable con-
Fluids.
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6. Unclip the transmission fluid cooler on the
left-hand side (headlamp shown removed
for clarity).
• Pull the clip forwards and hold, then pull the
transmission fluid cooler upwards out of the
bracket.
7. Unclip the transmission fluid cooler on the

right-hand side (headlamp shown removed
for clarity).
bracket.
8. Remove the transmission fluid cooler.
Installation
2. Check the automatic transmission fluid
level and fill if necessary.
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Transmission Fluid Cooler Tubes (17 857 0)
Removal
1. Raise and support the vehicle. transmission fluid, take care to prevent
equipped).
injury.
3. Remove the radiator lower splash shield.
and Safety Precautions] See -
NOTE: The position of the feed line (yellow) and
return line (blue) to the transmission fluid cooler is
marked on the connectors.
4. Remove the left-hand air deflector. from the transmission fluid cooler.
fluid cooler.
from the transmission fluid cooler.
Fluids.
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transmission fluid, take care to prevent
injury.
and Safety Precautions]
See - Transmission Fluids.
NOTE: The position of the feed line (black) and
return line (red) to the transmission is marked on
the connectors.
Remove the transmission fluid cooler lines
from the transmission (fluid cooler lines
shown from above for clarity).
release connector toward the transmission.
from the transmission.
and Safety Precautions]
See - Transmission Fluids.
Installation
2. Check the automatic transmission fluid
level and fill if necessary.
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307-05-1 Automatic Transmission/Transaxle External Controls 307-05-1

— Vehicles With: 4-Speed Automatic Transaxle (4F27E)
SECTION 307-05 Automatic Transmission/Transaxle

External Controls — Vehicles With: 4-Speed
Automatic Transaxle (4F27E)
CONTENTS PAGE
SPECIFICATIONS
Specifications................................................................................................................... 307-05-2
External Controls ............................................................................................................. 307-05-3

Selector lever cable......................................................................................................... 307-05-4
Selector Lever ................................................................................................................. 307-05-4
Function .......................................................................................................................... 307-05-4
Selector lever spring loaded button ................................................................................. 307-05-4
External Controls ............................................................................................................. 307-05-5

Inspection and Verification .............................................................................................. 307-05-5
Symptom Chart ............................................................................................................... 307-05-5
Pinpoint Tests ................................................................................................................. 307-05-5/9
GENERAL PROCEDURES
Selector Lever Cable Adjustment ..................................................................................... 307-05-10
Selector Lever Cable........................................................................................................ 307-05-11/13

Selector Lever.................................................................................................................. 307-05-14
Selector Lever.................................................................................................................. 307-05-15
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SPECIFICATIONS
Tightening Torques
Item Nm lb-ft lb-in
Selector lever cable nuts 9 - 80
Bolts - centre console reinforcing elements 25 18 -
Bolts - selector mechanism assembly 9 - 80
Selector lever knob bolt 1,5 - 13
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External Controls
Overview

Number
1 Selector lever cable - trans-
axle end
2 Gearshift cable bushing re-
taining nuts
3 Selector lever cable - selec-
tor lever end
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Selector lever cable the brake pedal (signal from the stoplamp switch).
This retracts the locking pin so that the selector
– The selector lever adjustment mechanism is
lever can be moved out of position "P" (PARK).
connected to the transaxle selector lever pin,
which is located above the transmission range
(TR) sensor.
Function
– The cable abutments are secured firstly to the
transaxle housing and secondly to the selector –
lever bracket. NOTE: If "P" (PARK) is selected again the
– The selector lever cable adjustment selector lever is locked.
mechanism is Locked at the transaxle end of If the brake signal should fail due to a
the selector lever cable. malfunction, the selector lever can be
– At the selector lever end the cable is clipped manually unlocked as follows:
onto a pin. – The cover of the release mechanism must be
– Adjustment is required if the transaxle or the opened and a suitable object (ignition key)
selector lever has been removed, if the engine pressed into the opening until the selector
does not start in "P" (PARK) or "N" lever can be moved out of position "P"
(NEUTRAL), in cases of shift quality concerns, (PARK).
or if the switch catches are incorrect.
Selector lever spring loaded button
– To move the selector lever from the "P"
(PARK) position, the ignition lock must be set
to "II", the brake pedal must be depressed and
shift release button pressed in.
– The spring loaded button must also be
pressed.
To adjust the selector lever cable, the selector

lever must be in position "D" (DRIVE).
– The selector lever cable must not be stressed.
The selector lever cable must be free from
binding.
The selector lever cable adjustment mechanism is
locked by pressing the selector lever mechanism
locking clip fully, after making sure that the shift
mechanism is in "D" (DRIVE).
For additional information, refer to Selector Lever
Cable Adjustment in this section.
Selector Lever
Location
The selector lever shift lock solenoid is located in
the selector lever bracket.
When the ignition is switched on, the selector
lever shift lock solenoid is actuated by depressing
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External Controls

step.
Inspection and Verification 4. If the concern is not visually evident, verify the
WARNING: Danger of accident. Apply the
parking brake. Shift the transaxle to "P".
result in personal injury. Mechanical Electrical
Because fault diagnosis starts as soon as the – Visibly damaged or – Fuse.
vehicle is taken in for repair we recommend the worn parts. – Wiring harness.
following procedure: – Loose or missing – Loose or corroded
nuts or bolts. connector(s).
1. Verify the customer concern by operating the
system.
Symptom Chart
• The shift interlock system does • Damaged brake shift interlock • GO to Pinpoint Test A.
not release/lock properly/is actuator.
blocked • Circuitry open/shorted.
• Damaged brake pedal position
(BPP) switch.
• Damaged selector lever.
• The shift interlock system is • Circuitry shorted. • GO to Pinpoint Test A.
blocked or not operating • Park interlock solenoid stick-
ing/defect.
• Selector lever damaged. • REPAIR selector lever.
• The shift control is out of proper • Shift linkage out of adjustment. • ADJUST linkage/selector lever
gear relationship cable.
• It is impossible to get gearshift • Linkage/selector lever cable out • ADJUST linkage/selector lever
lever into position "P" or "1". of adjustment. cable.
• Selector lever defect (mechani- • REPAIR selector lever.
cal).
Pinpoint Tests
PINPOINT TEST A: THE SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK PROPERLY/IS
BLOCKED
A1: CHECK IF STOPLAMPS LIGHT
1 Switch ON ignition. Depress brake pedal.
• Are the stoplamps ON?
→ Yes
GO to A3
→ No
GO to A2
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A2: CHECK FUSE 54 IN CJB
2 CHECK F54 (15 A).
• Is fuse F54 OK?
→ Yes
→ No
INSTALL a new fuse. RECHECK system, if
fuse fails again. REFER to Section 417-01.
A3: CHECK KEY REMOVAL INHIBIT CIRCUIT
1 Turn ignition ON, gear selection in "P" (PARK)
position.
• Can ignition switch be turned into position "0"
and can key be removed only when gear selector
in "P"?
→ Yes
GO to A4
→ No
GO to A8
A4: CHECK VOLTAGE TO PARK INTERLOCK SOLENOID
1 Disconnect Gearshift lever unit (C931).
2 Measure the voltage between C931 pin 3
(GN/WH) and ground.
• Is the voltage 0 V when brake pedal is not de-

pressed, and is battery voltage indicated when
brake pedal is depressed?
→ Yes
GO to A5
→ No
REPAIR circuit 15S-TA33 between C444
(stoplamp switch), Pin 1 and C931, pin 3 for
open.
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A5: CHECK GROUND TO PARK INTERLOCK SOLENOID
1 Measure resistance between C931, pin 1 (BK)
and ground.
• Is resistance less than 5 ohms?

→ Yes
GO to A6
→ No
REPAIR circuit 31-TA34 between C931, pin
1 and ground for open.
A6: CHECK SELECTOR LEVER CIRCUIT
1 Measure resistance at the connector of the
gearshift lever unit (C931), between pins 3 and
1. Gearshift lever in position "P".
• Is resistance between 20 ohms and 35 ohms?
→ Yes
GO to A7
→ No
REPLACE park interlock solenoid.
A7: CHECK FUNCTION OF PARK INTERLOCK SOLENOID
1 Position gearshift lever into positions "R", "N",
"D", "1" and "2".
- If necessary, release mechanically as de-
scribed in this section.
• Is resistance greater than 10 ohms in all men-
tioned positions?
→ Yes
Park interlock solenoid is electrically OK,
CHECK for mechanical fault.
→ No
REPLACE park interlock solenoid.
A8: CHECK FUSE F8 IN CJB
1 CHECK F8 (30 A).
• Is the fuse F8 OK?
→ Yes
GO to A9
→ No
INSTALL a new fuse. RECHECK the system.
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A9: CHECK PARK INTERLOCK SWITCH
1 Disconnect Gearshift lever unit (C931).
2 Connect a jumper wire between C931, pin 2
(BK/YE) and ground.
- Be sure that only pin 2 and not another pin is
grounded.
• Can ignition key be removed when jumper wire
is connected?
→ Yes
GO to A10
→ No
GO to A11
A10: CHECK GROUND TO SELECTOR LEVER UNIT
1 Measure resistance between C931, pin 1 (BK)
and ground.
• Is resistance less than 5 ohms?

→ Yes
REPLACE the gearshift lever unit.
→ No
REPAIR circuit 31-TA34 between C931, pin
1 and ground for open.
A11: CHECK VOLTAGE AT FUSE F8
1 Measure voltage at fuse F8 (30A).
• Is battery voltage indicated?
→ Yes
GO to A12
→ No
REPAIR supply circuit to F8 for open.
A12: CHECK VOLTAGE AT IGNITION SWITCH
1 Disconnect Ignition switch (C456).
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2 Measure the voltage between C456, pin 4 (RD)
and ground.

→ Yes
GO to A13
→ No
REPAIR circuit between fuse F8 (30 A) and
C456, pin 4 for open.
A13: CHECK CIRCUIT 31S-TA34
1 Measure resistance between C456, pin 3
(BK/WH) and C931, pin 2 (BK/YE).
• Is resistance less than 1 ohm?

→ Yes
Key removal inhibit solenoid within the igni-
tion switch is damaged. REPLACE the igni-
tion switch. REFER to Section 211-05.
→ No
REPAIR circuit 31S-TA34 between C456, pin
3 and C931, pin 2 for open.
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GENERAL PROCEDURES
Selector Lever Cable Adjustment
Adjustment
1. Shift the selector lever to the "D" (DRIVE) 6. NOTE: Ensure that the selector lever cable
position. adjustment mechanism is locked.
2. Raise and support the vehicle. Press in the selector lever cable adjust-
3. Remove the engine undershield (if ment mechanism locking clip fully.
equipped).
4. Release the selector lever cable adjust-
ment mechanism locking clip.
7. Install the engine undershield (if equipped).

9. Start the engine and move the selector
5. NOTE: The transmission range (TR) sensor lever through all the gear positions. Wait
mark must be inline with the transaxle selector until each gear engages when moving
lever. through the gear positions.
Move the transaxle selector lever to the "D" 10. Check that the selector lever position
(DRIVE) position (TR sensor shown re- indicator corresponds to the position of
moved for clarity). the selector lever, repeat the adjustment
procedure if necessary.
11. Move the selector lever into the "P"
(PARK) position and switch off the
engine.
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Selector Lever Cable
1. Remove the center console.

3. Remove the center console reinforcing
2. Remove the center console reinforcing element right-hand bracket.
element left-hand bracket.
• Detach the wiring harness bracket from the
center console reinforcing element bracket.

table(s).
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Number
2. CAUTION: Do not kink the selector
1 - Transmission-side selector lever cable.
lever cable Detach the selector lever cable from the
See Removal Detail selector lever.
2 - Selector lever-side selector 1. Detach the selector lever cable from the
lever cable selector lever.
See Removal Detail 2. Lift the locking tab, press the locking pins
3 - Selector lever cable nuts together and detach the selector lever cable
See Removal Detail from the abutment.

additional information, refer to Selector
Lever Cable Adjustment in this section.
Removal Details
Item 1: Transmission-side selector lever cable

2. Remove the engine undershield (if fitted).
lever cable.
Item 3: Selector lever cable nuts
Detach the selector lever cable from the 1. Raise the vehicle.
transmission. 2. Remove the front heat shield.
selector mechanism.
from the abutment.
Item 2: Selector lever-side selector lever cable

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3. CAUTION: Do not kink the selector 6. CAUTION: Do not kink the selector
lever cable. lever cable.
Detach the selector lever cable from the Remove the selector lever cable.
clip. • Discard the selector lever cable nuts.

lever cable.
Remove the selector lever cable from the
bracket.
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Selector Lever
Removal 4. Remove the selector lever assembly.

1. Remove the floor console. For additional
[Instrument Panel and Console,
REMOVAL AND INSTALLATION, Floor
Console]
lever.
Detach the selector lever cable from the
selector lever and cable bracket.
selector lever.
from the cable bracket.
Installation
additional information, refer to Selector
Lever Cable Adjustment in this section.
3. Disconnect the selector lever assembly

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Selector Lever
Disassembly 3. Unclip the selector lever unit bezel from the

selector lever unit (six clips).
1. Remove the selector lever knob.
• Remove the bolt.
4. Remove the selector lever unit bezel.

1. Disconnect the connector for the selector
lever lock solenoid.
2. Pull out the plunger and spring of the se- 2. Detach the ignition key interlock switch from
lector lever lock. the gear selector housing.
3. Detach the selector lever central connector
from the gear selector housing.
• Unhook the selector lever unit cable from
the cable guide.
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5. Remove the cover for the manual selector Assembly
lever lock.
• Press down the retaining clip of the manual 1. CAUTION: Check that the cable of the
selector lever lock cover until the cover of selector lever unit is in the correct
the manual selector lever lock can be pulled installation position.
out. NOTE: Apply thread locking compound to the bolt
of the selector lever knob.
To assemble, reverse the disassembly
procedure.
6. NOTE: Solenoid - gear selector cover plate

faces upwards.
Remove the selector lever bezel.
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308-00-1 Manual Transmission/Transaxle and Clutch - General 308-00-1

Information
SECTION 308-00 Manual Transmission/Transaxle and

Clutch - General Information
CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 308-00-2
Clutch ..................................................................................................... 308-00-2
Manual Transaxle and Clutch............................................................................................ 308-00-3

Principles of Operation ..................................................................................................... 308-00-3
Inspection and Checking .................................................................................................. 308-00-3
Inspection and Verification - Manual Transmission........................................................... 308-00-3
Gear Shifting Concerns .................................................................................................... 308-00-3
Transmission Noise Concerns.......................................................................................... 308-00-3
Fluid Leakage Concerns .................................................................................................. 308-00-3
Symptom Chart - General Concerns ................................................................................ 308-00-3/4
Symptom Chart - Transmission Noises ............................................................................ 308-00-5/7
Symptom Chart - Fluid Leakage....................................................................................... 308-00-8
Symptom Chart - Clutch ................................................................................................... 308-00-8
System Check .................................................................................................................. 308-00-9/16
GENERAL PROCEDURES
Clutch System Bleeding ................................................................................ (16 843 0) 308-00-17/18

Gearshift Cable Adjustment — Vehicles With: 5-Speed Manual Transaxle (16 513 0)
(MTX-75)...................................................................................................... 308-00-19
(MMT6) ........................................................................................................ 308-00-20/21
(F35M-R)...................................................................................................... 308-00-22
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Information
SPECIFICATIONS
Lubricants, Sealers and Adhesives

Item Specification
Transmission fluid WSD-M2C200-C
High-temperature grease ESD-M1C220-A
Filling Capacities
Liters
iB5 manual transmission (5 - 10 mm below lower edge of check hole) 2.3
MTX -75 manual transmission (0 - 5 mm below lower edge of check hole) 1.9
MMT6 manual transmission (0 - 5 mm below lower edge of check hole) 1.75
Clutch
Description mm
Clutch pedal travel - MTX-75 manual transmission 135 ± 3
Clutch pedal travel - MMT6 manual transmission 140 ± 3
Tightening Torques
Clutch bleed nipple - iB5 manual transmission 5 - 44
Clutch bleed nipple - MTX-75 manual transmission 5 - 44
Clutch bleed nipple - MMT6 manual transmission 5 - 44
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Information

Manual Transaxle and Clutch
Manual Transaxle (MTX-75), DIAGNOSIS

AND TESTING, External Controls]
Principles of Operation REFER to Section 308-06B.[Manual
Transmission/Transaxle External Controls -
Vehicles With: 6-Speed Manual Transaxle
Inspection and Checking (MMT6), DIAGNOSIS AND TESTING,
External Controls - Vehicles With: 6-Speed
1. Verify the customer concern. Manual Transaxle (MMT6)]
2. Visually check for any obvious mechanical or
electrical damage.
3. If an obvious cause for an observed or Transmission Noise Concerns
• Check the engine and transmission mountings
for sufficient clearance to the transmission and
step.
the body.
4. If the concern persists, check the symptoms
• Any other noise excluding shift noises.
and proceed according to WDS instructions.
Fluid Leakage Concerns

Inspection and Verification - Manual
Transmission • Check that the leaking fluid is actually
transmission fluid and not hydraulic fluid (from
The following checks should be carried out before the hydraulically-operated clutch) or engine
repairing or installing a new transmission. oil.
Inspection and checking for vehicles with manual • Check the transmission fluid level. If
transmission can be divided into three main areas. necessary, drain off any excess fluid.
• Locate the fluid leak with the aid of a
fluorescent tracer dye and an ultraviolet
Gear Shifting Concerns inspection lamp.
• Clutch does not operate correctly • Clean the transmission and the adjacent areas
• External shift mechanism. REFER to Section thoroughly before road testing.
308-06A.[Manual Transmission/Transaxle
External Controls - Vehicles With: 5-Speed
Symptom Chart - General Concerns

• High-effort gear shifting in one or • Synchronizer ring or synchroni- • RENEW the synchronizer hub
more gears zation damaged with synchronizer ring set and, if
necessary, the relevant gear
wheel.
– Because of various modifica-
tions and the difficulty in es-
timating the degree of wear,
replacement of the complete
unit (as described above) is
recommended.
• Clutch does not operate correctly • CHECK the clutch function and
the brake fluid level.
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Information

• Internal gearshift mechanism. • Remove the internal gearshift
mechanism and check the
components. If necessary,
RENEW.
• Rattling or scratching noise dur- • Synchronizer hub or synchro- • RENEW the synchronizer hub
ing gear shifting nizer ring damaged with synchronizer ring set and, if
necessary, the relevant gear
wheel.
– Because of various modifica-
tions and the difficulty in es-
timating the degree of wear,
replacement of the complete
unit (as described above) is
recommended.
• Clutch does not operate cor- • CHECK the clutch function and
rectly. the brake fluid level.
• Gear engagement not function- • External gearshift mechanism • CHECK the external gearshift
ing correctly damaged mechanism for damage. If no
concern is determined,
REMOVE the transmission.
[Manual Transmis-
sion/Transaxle - Vehicles With:
5-Speed Manual Transaxle
(MTX-75), REMOVAL, Trans-
axle - 2.0L Duratec-HE (MI4)]
[Manual Transmis-
(MMT6), REMOVAL, Transaxle -
sel] REFER to Section 308-03C.
[Manual Transmis-
(F35M-R), REMOVAL, Trans-
axle]
• Gear jumps out of engagement • Missing snap rings; synchroni- • RENEW gear wheels, synchro-
while driving zation components damaged or nizer and selector fork as nec-
worn clutch splines essary. CHECK the transmission
for damage, particularly to the
sliding sleeve.
• Incorrect sliding sleeve; worn • RENEW gear wheels, synchro-
clutch splines nizer and selector fork as nec-
essary. CHECK the transmission
for damage, particularly to the
sliding sleeve.
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Information

• Selector forks • RENEW gear wheels, sliding
sleeves and selector forks as
necessary. CHECK the trans-
mission for damage, particularly
to the sliding sleeve.
• Gear lever feels loose • Gear lever mounting • Check the external gearshift
mechanism; replace if neces-
sary. Check gear lever mounting,
external gearshift mechanism
and shift cables; tighten if nec-
essary. REFER to Section
308-06A.[Manual Transmis-
sion/Transaxle External Controls
- Vehicles With: 5-Speed Manual
Transaxle (MTX-75),
External Controls] REFER to
Section 308-06B.[Manual
Transmission/Transaxle Exter-
nal Controls - Vehicles With:
(MMT6), DIAGNOSIS AND
TESTING, External Controls -
Vehicles With: 6-Speed Manual
Transaxle (MMT6)]
• Internal shift mechanism • Check the internal shift mecha-
nism for play at the transmission.
Symptom Chart - Transmission Noises

• Gear wheels grating when shift- • Clutch worn • Check clutch
ing • REFER to Section 308-01A.
(MTX-75), REMOVAL AND
INSTALLATION, Clutch Disc
and Pressure Plate] REFER to
Section 308-01B.[Clutch - Vehi-
cles With: 6-Speed Manual
Transaxle (MMT6), REMOVAL
AND INSTALLATION, Clutch
REFER to Section 308-01C.
(F35M-R), REMOVAL AND
INSTALLATION, Clutch Disc
and Pressure Plate]
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Information

• Air in the clutch system; fluid loss • Check clutch system for leaks;
bleed the clutch system. REFER
to Clutch System Bleeding in this
section.
• Slight buzzing, rattling or metallic • Rotational vibration from the en- • These noises do not affect the
scraping noise from the trans- gine not sufficiently damped by operation and service life of the
mission at 2500 to 3500 rpm the clutch. transmission.
when on overrun or driving
without load (particularly in 2nd
and 3rd gear)
• Engine speed-dependent • CHECK transmission input shaft
transmission noise bearings. REMOVE the trans-
mission. REFER to Section
308-03A.[Manual Transmis-
[Manual Transmis-
[Manual Transmis-
axle]
• Vehicle speed-dependent • CHECK driveshaft tripode joints.
transmission noise
• Steering angle-dependent • CHECK differential splines for
transmission noise damage. Turn the differential
bevel gears against one another.
For this purpose, REMOVE the
halfshafts. REFER to Section
205-04.[Front Drive Halfshafts,
REMOVAL AND
Drive Halfshafts, REMOVAL
AND INSTALLATION, Interme-
diate Shaft]
• The engine/transmission as- • Visually inspect for evidence of
sembly is in contact with the contact and REPAIR as neces-
body sary.
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Information

• Engine/transmission • TIGHTEN the transmission re-
washer-head bolts taining bolts.
[Manual Transmis-
(MTX-75), INSTALLATION,
Transaxle - 2.0L Duratec-HE
(MI4)] REFER to Section
308-03B.[Manual Transmis-
(MMT6), INSTALLATION,
Transaxle - 2.0L Duratorq-TDCi
(DW) Diesel] REFER to Section
308-03C.[Manual Transmis-
(F35M-R), INSTALLATION,
Transaxle]
• Transmission fluid level too low. • Check the transmission fluid
level. REFER to Specifications
in this section.
• Transmission bearings and gear • REMOVE the transmission.
wheels (usually on high-mileage CHECK the transmission bear-
vehicles) ings and gear wheels and
RENEW as necessary.
[Manual Transmis-
[Manual Transmis-
[Manual Transmis-
axle]
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Information

• Rattling noises or vibration • External gearshift mechanism • CHECK the external gearshift
mechanism.
[Manual Transmis-
sion/Transaxle External Controls
- Vehicles With: 5-Speed Manual
Transaxle (MTX-75),
External Controls] REFER to
Section 308-06B.[Manual
Transmission/Transaxle Exter-
nal Controls - Vehicles With:
(MMT6), DIAGNOSIS AND
TESTING, External Controls -
Vehicles With: 6-Speed Manual
Transaxle (MMT6)]
• Engine front and rear mounting • CHECK engine front and rear
defective mounting; RENEW if necessary.
Symptom Chart - Fluid Leakage

• Fluid leakage • Oil seals or O-rings • CHECK the mating surfaces and
INSTALL a new gasket.
• Fluid leak between the • DISMANTLE the transmission
clutch-side and transmis- and clean the mating surfaces.
sion-side housing halves. CHECK the mating surfaces for
damage. Seal the transmission
using WSK-M2G348-A5 sealer.
• Fluid leak at transmission hous- • Tighten transmission housing
ing bolt bolts to specified tightening
torque.
Symptom Chart - Clutch

• Clutch slips • No clutch pedal free play • GO to Pinpoint Test A
• Clutch Belleville springs broken
• Clutch disc facing broken
• Hardened or oil-contaminated
clutch disc facing
• Clutch juddering • Engine mounting defective • GO to Pinpoint Test B
• Tilted clutch disc
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Information

• Clutch disengages too late or not • Insufficient brake fluid • GO to Pinpoint Test C
at all; high-effort gear shifting • Air in hydraulic system
• Excessive clutch pedal free play
• Clutch Belleville springs broken
• Clutch disc deformed or broken
• Clutch disc splines corroded
• Clutch pedal pulsating • Non-uniform Belleville spring • GO to Pinpoint Test D
fingers
• Frequency modulator defective
(if present)
• Excessive noise • Release bearing defective • GO to Pinpoint Test E
• Input shaft pilot bearing
• Excessive crankshaft end float
• Fluid leakage • Clutch master cylinder • GO to Pinpoint Test F
• Clutch slave cylinder
• Hydraulic lines in area of engine
and transmission
System Check
PINPOINT TEST A: CLUTCH SLIPS
A1: CHECK THE CLUTCH FOR SLIPPAGE
1 Chock the wheels and apply the parking brake.
3 Start the engine, depress the clutch pedal and
engage 4th gear.
4 Run the engine at approx. 2000 rpm.
5 Release the clutch pedal slowly.
• Does the engine stall when the clutch pedal is
fully released?
→ Yes
Clutch OK.
→ No
GO to A2
A2: CHECK THE CLUTCH PEDAL FREE PLAY
1 Measure the clutch pedal free play.
2 Depress the clutch pedal manually to the point
of resistance and release, record clutch pedal
travel.
• Is the travel within 10 mm?
→ Yes
Clutch pedal free play OK.
→ No
GO to A3
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Information

A3: CHECK THE CLUTCH BELLEVILLE SPRINGS
1 REMOVE the transmission. CHECK the clutch
Belleville springs.
REFER to Section 308-03A.[Manual Transmis-
sion/Transaxle - Vehicles With: 5-Speed Man-
ual Transaxle (MTX-75), REMOVAL, Transaxle
- 2.0L Duratec-HE (MI4)]
REFER to Section 308-03B.[Manual Transmis-
ual Transaxle (MMT6), REMOVAL, Transaxle -
REFER to Section 308-03C.[Manual Transmis-
ual Transaxle (F35M-R), REMOVAL, Transaxle]
• Are clutch Belleville springs broken?
→ Yes
REPLACE the clutch pressure plate.
→ No
GO to A4
A4: CHECK THE CLUTCH DISC
1 Remove the clutch disc and clutch pressure
plate. REFER to Section 308-01A.[Clutch - Ve-
hicles With: 5-Speed Manual Transaxle
(MTX-75), REMOVAL AND INSTALLATION,
Clutch Disc and Pressure Plate]
REFER to Section 308-01B.[Clutch - Vehicles
With: 6-Speed Manual Transaxle (MMT6),
REMOVAL AND INSTALLATION, Clutch Disc
and Pressure Plate] REFER to Section 308-01C.
[Clutch - Vehicles With: 5-Speed
Manual Transaxle (F35M-R), REMOVAL AND
Plate]
• Is the clutch disc or the clutch pressure plate
broken, contaminated with oil or hardened?
→ Yes
CHECK the engine and transmission for
leaks. REFER to Section 303-00.[Engine
System - General Information, DIAGNOSIS
RENEW the clutch pressure plate and the
clutch disc.
→ No
CHECK the operation of the system.
PINPOINT TEST B: CLUTCH JUDDERING
B1: CHECK FOR CLUTCH JUDDER
2 Start the engine, depress the clutch pedal and
engage 1st gear.
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Information

3 Run the engine at between 1200 and 1500 rpm.
4 Release the clutch pedal slowly.
• Does the vehicle judder when it starts off?
→ Yes
GO to B2
→ No
Clutch OK.
B2: CHECK ENGINE/TRANSMISSION MOUNTINGS AND ROLL RESISTOR
1 Check the engine/transmission mountings and
roll resistor for damage or loose bolted connec-
tions.
• Are the engine/transmission mountings or roll
restrictor loose or damaged?
→ Yes
TIGHTEN the bolts or REPLACE as neces-
sary. CHECK the operation of the system.
→ No
GO to B3
B3: CHECK THE CLUTCH PRESSURE PLATE
1 Remove the clutch pressure plate.
REFER to Section 308-01A.[Clutch - Vehicles
With: 5-Speed Manual Transaxle (MTX-75),
and Pressure Plate] REFER to Section
308-01B.[Clutch - Vehicles With: 6-Speed
Manual Transaxle (MMT6), REMOVAL AND
Plate] REFER to Section 308-01C.[Clutch -
(F35M-R), REMOVAL AND INSTALLATION,
• Does the clutch pressure plate show signs of
wear or damage?
→ Yes
→ No
GO to B4
B4: CHECK THE CLUTCH DISC
1 CHECK the clutch disc.
• Does the clutch disc show evidence of damage
due to tilting?
→ Yes
REPLACE the clutch disc.
→ No
CHECK the flywheel. REFER to Section
303-00.[Engine System - General Informa-
tion, GENERAL PROCEDURES, Flywheel
Inspection]
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Information

PINPOINT TEST C: CLUTCH DISENGAGES TOO LATE OR NOT AT ALL
C1: CLUTCH DISENGAGES TOO LATE OR NOT AT ALL
1 Bleed the clutch system. REFER to Clutch
System Bleeding in this section.
• Does the clutch show improved disengaging
characteristics following bleeding of the system?
→ Yes
Clutch OK.
→ No
GO to C2
C2: CHECK THE BRAKE FLUID LEVEL
1 Check the brake fluid level.
• Is the brake fluid level in the reservoir between
the MAX and MIN marks?
→ Yes
GO to C3
→ No
Top up the brake fluid, CHECK the brake and
clutch systems for leaks.
C3: CHECK THE CLUTCH PEDAL FREE PLAY
1 Measure the clutch pedal free play.
2 Depress the clutch pedal until resistance is felt,
then release it again.
• Is the travel within 10 mm?
→ Yes
GO to C4
→ No
CHECK that the clutch pedal moves freely;
remove if necessary. REFER to Section
308-02A.[Clutch Controls - Vehicles With:
Master Cylinder]
C4: CHECK THE CLUTCH BELLEVILLE SPRINGS
1 Remove the transmission; CHECK clutch
Belleville springs.
• Are clutch Belleville springs broken?
→ Yes
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Information

REFER to Section 308-01A.[Clutch - Vehi-
cles With: 5-Speed Manual Transaxle
REFER to Section 308-01B.[Clutch - Vehi-
(MMT6), REMOVAL AND INSTALLATION,
REFER to Section 308-01C.[Clutch - Vehi-
Clutch Disc and Pressure Plate] CHECK the
operation of the system.
→ No
GO to C5
C5: CHECK THE CLUTCH DISC
1 Remove the clutch disc. REFER to Section
308-01A.[Clutch - Vehicles With: 5-Speed
Manual Transaxle (MTX-75), REMOVAL AND
Plate] REFER to Section 308-01B.[Clutch -
REFER to Section 308-01C.[Clutch - Vehicles
With: 5-Speed Manual Transaxle (F35M-R),
and Pressure Plate]
• Is the clutch disc deformed or broken?
→ Yes
RENEW the clutch disc.
→ No
GO to C6
C6: CHECK THE CLUTCH DISC SPLINES
1 CHECK clutch disc splines for corrosion.
• Are the clutch disc splines corroded?
→ Yes
RENEW the clutch disc.
→ No
Check the transmission input shaft for
damage or corrosion.
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Information

PINPOINT TEST D: CLUTCH PEDAL PULSATING
D1: CHECK THE BELLEVILLE SPRING FINGERS FOR UNIFORMITY
1 REMOVE the transmission.
CHECK the Belleville spring fingers for uni-
formity.
• Are the Belleville spring fingers uniform?
→ Yes
Check the frequency modulator and RENEW
if necessary (if present)
→ No
REFER to Section 308-01A.[Clutch - Vehi-
REFER to Section 308-01B.[Clutch - Vehi-
REFER to Section 308-01C.[Clutch - Vehi-
PINPOINT TEST E: EXCESSIVE NOISE
E1: CHECK THE TRANSMISSION IN NEUTRAL
2 Start the engine.
3 Depress the clutch pedal fully.
• Is noise audible when the clutch is operated?
→ Yes
GO to E2
→ No
The transmission is the cause of the concern.
REFER to Symptom Chart(s).
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Information

E2: CHECK THE CLUTCH RELEASE BEARING
1 Remove the clutch slave cylinder/release
bearing assembly. REFER to Section 308-02A.
[Clutch Controls - Vehicles With:
REMOVAL AND INSTALLATION, Clutch Slave
Cylinder] REFER to Section 308-02B.[Clutch
Controls - Vehicles With: 6-Speed Manual
Transaxle (MMT6), REMOVAL AND
INSTALLATION, Clutch Slave Cylinder]
REFER to Section 308-02C.[Clutch Controls -
Clutch Slave Cylinder]
2 Check the release bearing for wear and corro-
sion.
• Are there signs of wear or corrosion?
→ Yes
REPLACE the release bearing.
→ No
CHECK the crankshaft for excessive end
float. REFER to Section 303-00.[Engine
PROCEDURES, Crankshaft End Play]
PINPOINT TEST F: FLUID LEAKAGE
F1: CHECK THE CLUTCH SLAVE CYLINDER
1 Check the clutch master cylinder for leaks.
• Is the clutch master cylinder OK?
→ Yes
GO to F2
→ No
RENEW the clutch master cylinder.
REFER to Section 308-02A.[Clutch Controls
- Vehicles With: 5-Speed Manual Transaxle
Clutch Master Cylinder]
F2: CHECK THE CLUTCH SLAVE CYLINDER
1 Check the clutch slave cylinder for leaks.
• Is the clutch slave cylinder OK?
→ Yes
GO to F3
→ No
G426304 en 09/2004 2004.75 Focus

TO MODEL INDEX

Information

REPLACE the clutch slave cylinder.
REFER to Section 308-02A.[Clutch Controls
- Vehicles With: 5-Speed Manual Transaxle
Clutch Slave Cylinder] REFER to Section
308-02B.[Clutch Controls - Vehicles With:
6-Speed Manual Transaxle (MMT6),
Slave Cylinder] REFER to Section 308-02C.
5-Speed Manual Transaxle (F35M-R),
Slave Cylinder]
F3: CHECK THE HYDRAULIC PIPES
1 Check the hydraulic lines in area of engine and
transmission for loose or damaged unions.
• Are the hydraulic lines OK?
→ Yes
PERFORM a road test to verify the customer
concern.
→ No
REPAIR or REPLACE components as nec-
essary. PERFORM road test.
G426304 en 09/2004 2004.75 Focus

TO MODEL INDEX

Information
GENERAL PROCEDURES
Clutch System Bleeding (16 843 0)
Special Tool(s) 6. Fill the reservoir of the special tool with

approximately 100 ml of new brake fluid.
Hand Vacuum 7. NOTE: Make sure that the special tool reservoir
Pump/Pressure Pump is positioned lower than the bleed nipple.
416-D001 (23-036A)
Name Specification
BASF Hydraulan 417-1
-
(DOT4++)
WARNING: Brake fluid contains

polyglycol ethers and polyglycols. Avoid
contact with the eyes. Wash hands
thoroughly after handling. If brake fluid
minutes with cold running water. Get 8. Using the special tool, bleed the clutch
medical attention if irritation persists. If system.
taken internally, drink water and induce
vomiting. Get medical attention • Pump approximately 80 ml of brake fluid
immediately. Failure to follow these into the clutch system.
instructions may result in personal injury. 9. Close the bleed nipple.
paintwork, the affected area must be 11. Lower the vehicle, if necessary.
immediately washed down with cold 12. In order to remove any small amounts of
water. trapped air remaining in the system,
NOTE: If proprietary brake bleeding equipment is operate the clutch pedal several times
available, this can be used to bleed the clutch (maximum five times), using the full
system, following the method below. The clutch pedal travel.
maximum pressure must not exceed 1.5 bar. 13. Check the fluid level in the brake fluid
NOTE: The clutch control system is self-venting. reservoir and top up to the MAX mark with
The components are arranged in such a way that brake fluid if necessary.
small amounts of air trapped in the system are 14. Install the battery tray, if necessary.
removed automatically during clutch operation. 15. Install the battery, if necessary. For
1. Remove the air cleaner, if necessary.For additional information,
refer to Section 303-12. 16. Install the air cleaner, if necessary. For
2. Remove the battery, if necessary. For additional information,
refer to Section 414-01. 17. Test the clutch control system for normal
3. Remove the battery tray, if necessary. operation.
4. Drain the brake fluid reservoir. • Start the engine, depress the clutch pedal,
5. Raise and support the vehicle, if necessary. wait two seconds, then carefully engage
For additional information, reverse gear. If there are any abnormal
refer to Section 100-02. noises, or reverse gear is difficult to engage,
G183752 en 09/2004 2004.75 Focus

TO MODEL INDEX
Information

repeat the clutch system bleeding
procedure.
18. Initialize the door window motors, if
G183752 en 09/2004 2004.75 Focus

TO MODEL INDEX

Information
GENERAL PROCEDURES
Gearshift Cable Adjustment — Vehicles With: 5-Speed Manual Transaxle (MTX-75)
(16 513 0)
1. Engage 4th gear.

2. NOTE: Only adjust the selector cable.
Release the selector cable adjuster (air
cleaner shown removed for clarity).
3. NOTE: Ensure that the gearshift lever is in the

4th gear position and ensure that 4th gear is
engaged in the transmission.
The selector cable is automatically
adjusted to the correct length.
4. Lock the selector cable adjuster (air
G402258 en 09/2004 2004.75 Focus

TO MODEL INDEX

Information
GENERAL PROCEDURES
Gearshift Cable Adjustment — Vehicles With: 6-Speed Manual Transaxle (MMT6)
(16 513 0)
4. NOTE: Only adjust the selector cable.
Release the selector cable adjuster (air
Special Tool(s) cleaner shown removed for clarity).
Aligner, Gearshift Lever

308-451
1. Detach the gearshift lever gaiter and trim

panel from the centre console and pull
upwards.
5. The selector cable is automatically

adjusted to the correct length.
6. Lock the selector cable adjuster (air
2. Lock the gear lever in the 3rd / 4th gear

gate using the special tool (gear lever gai-
ter shown removed for clarity).
7. Remove the special tool (gear lever gaiter

3. Engage 4th gear.
G402259 en 09/2004 2004.75 Focus

TO MODEL INDEX

Information

8. Attach the gearshift lever gaiter and trim
panel to the center console.
G402259 en 09/2004 2004.75 Focus

TO MODEL INDEX

Information
GENERAL PROCEDURES
Gearshift Cable Adjustment — Vehicles With: 5-Speed Manual Transaxle (F35M-R)
(16 513 0)

information, refer to Air Cleaner - 1.6L (Z6) -303-12
(Intake Air Distribution and Filtering,
Removal and Installation).
2. NOTE: Only adjust the selector cable. The
gearshift cable is automatically adjusted to the
correct length.
Release the selector cable adjuster.
3. Make sure that the gearshift lever and the

transaxle are in the neutral position.
4. Lock the selector cable adjuster.

information, refer to Air Cleaner - 1.6L (Z6)
(303-12 Intake Air Distribution and Filtering,
Removal and Installation).
G420952 en 09/2004 2004.75 Focus

TO MODEL INDEX
308-01A-1 Clutch — Vehicles With: 5-Speed Manual Transaxle 308-01A-1

(MTX-75)
SECTION 308-01A Clutch — Vehicles With: 5-Speed

Manual Transaxle (MTX-75)
CONTENTS PAGE
SPECIFICATIONS
Clutch.............................................................................................................................. 308-01A-2
Clutch .............................................................................................................................. 308-01A-3
Clutch Disc and Pressure Plate..................................................................... (16 724 4) 308-01A-4
09/2004 2004.75 Focus

TO MODEL INDEX

(MTX-75)
SPECIFICATIONS
Clutch
Type Single-plate dry clutch
Actuation Hydraulic
External diameter 228 mm
Tightening Torques
Clutch pressure plate to flywheel 29 21 -
G296635 en 09/2004 2004.75 Focus

TO MODEL INDEX

(MTX-75)

Clutch
G18068 en 09/2004 2004.75 Focus

TO MODEL INDEX

(MTX-75)

Clutch Disc and Pressure Plate (16 724 4)

Special Tool(s) disc and pressure plate.

308-204
Removal
2. Loosen the clutch pressure plate retaining
bolts by two turns at a time in the sequence
shown. 3. NOTE: Install new clutch pressure plate
retaining bolts.
fied torque.

Installation
1. Using the special tool, centralize the clutch
disc on the pressure plate. 5. Install the transaxle. For additional
G325408 en 09/2004 2004.75 Focus

TO MODEL INDEX
308-01B-1 Clutch — Vehicles With: 6-Speed Manual Transaxle 308-01B-1

(MMT6)
SECTION 308-01B Clutch — Vehicles With: 6-Speed

Manual Transaxle (MMT6)
CONTENTS PAGE
SPECIFICATIONS
Clutch Disc and Pressure Plate..................................................................... (16 724 4) 308-01B-3
09/2004 2004.75 Focus

TO MODEL INDEX

(MMT6)
SPECIFICATIONS
General specifications
Item mm inches
New clutch disc nominal thickness 7.3 0.29
Worn clutch disc discard thickness * 2 0.08
* When the discard thickness has been reached, install a new clutch disc.
Clutch pressure plate retaining bolts 29 21 –
G296637 en 09/2004 2004.75 Focus

TO MODEL INDEX

(MMT6)

Clutch Disc and Pressure Plate (16 724 4)

Special Tool(s) • Discard the bolts.
308-204 Installation
1. Using the special tool, centralize the clutch
disc on the pressure plate.
Removal
308-03B / 308-03C.
2. Loosen the clutch pressure plate retaining
bolts by two turns at a time in the sequence
shown.

G325410 en 09/2004 2004.75 Focus

TO MODEL INDEX

(MMT6)

3. NOTE: Install new clutch pressure plate
retaining bolts.
fied torque.

5. Install the transaxle. For additional
308-03B / 308-03C.
G325410 en 09/2004 2004.75 Focus

TO MODEL INDEX
308-01C-1 Clutch — Vehicles With: 5-Speed Manual Transaxle 308-01C-1

(F35M-R)
SECTION 308-01C Clutch — Vehicles With: 5-Speed

Manual Transaxle (F35M-R)
CONTENTS PAGE
SPECIFICATIONS
Clutch .............................................................................................................................. 308-01C-3
Clutch Disc and Pressure Plate........................................................................................ 308-01C-4
09/2004 2004.75 Focus

TO MODEL INDEX

(F35M-R)
SPECIFICATIONS
Clutch
Type Single plate dry clutch
Actuation Hydraulic
General specifications
Item mm inches
Clutch disc diameter 200 7.874
Maximum clutch disc runout * 0.7 0.028
Minimum depth between clutch disc surface and 0.3 0.012
rivet head *
* When the minimum depth or maximum runout has been reached, install a new clutch disc.
Item Nm lb-ft lb-in
Clutch pressure plate retaining bolts 29 21 -
G385289 en 09/2004 2004.75 Focus

TO MODEL INDEX

(F35M-R)

Clutch
G18068 en 09/2004 2004.75 Focus

TO MODEL INDEX

(F35M-R)

Clutch Disc and Pressure Plate
Special Tool(s) 1. Remove the transaxle. For additional

Aligner, Clutch Disk
[Manual Transmission/Transaxle -
308-204 Vehicles With: 5-Speed Manual Transaxle
(F35M-R), REMOVAL, Transaxle]
table(s).
Name Specification
High-Temperature ESD-M1C220-A
Grease

Number
2 - Clutch pressure plate
1 - Clutch pressure plate See Installation Detail
retaining bolts
See Removal Detail 3 - Clutch disc
G385292 en 09/2004 2004.75 Focus

TO MODEL INDEX

(F35M-R)

Item Part Description Item 3 : Clutch disc
Number 1. Clutch installation position.
• X = Transaxle side
4 - Clutch release lever and
release bearing • Y = Engine side
5 - Pilot bearing
Removal Details
Item 1 : Clutch pressure plate retaining bolts

CAUTION: Loosen the clutch pressure
plate retaining bolts evenly by two turns
at a time.
Item 4 : Clutch release lever and release

bearing 2. Using the special tool, centralize the clutch
1. Apply a thin film of grease to the clutch disc on the clutch pressure plate.
release bearing, the clutch release lever
and to the transaxle input shaft.
G385292 en 09/2004 2004.75 Focus

TO MODEL INDEX
(F35M-R)

Item 2 : Clutch pressure plate
1. CAUTION: Tighten the clutch pressure
plate retaining bolts finger tight and
then evenly by two turns at a time to
the specified torque.
Using the special tool, install the clutch
• Working in stages, tighten the bolts in the
sequence shown.
Item 1 : Clutch pressure plate retaining bolts
G385292 en 09/2004 2004.75 Focus

TO MODEL INDEX
308-02A-1 Clutch Controls — Vehicles With: 5-Speed Manual 308-02A-1

Transaxle (MTX-75)
SECTION 308-02A Clutch Controls — Vehicles With:

5-Speed Manual Transaxle (MTX-75)
CONTENTS PAGE
SPECIFICATIONS
Clutch Controls ................................................................................................................ 308-02A-3
Clutch Master Cylinder..................................................................................................... 308-02A-4/8

Clutch Slave Cylinder.................................................................................... (16 862 0) 308-02A-9
09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MTX-75)
SPECIFICATIONS

Item Specification
Sealer, clutch slave cylinder ESK-M4G269-A
Clutch Control
Actuation Hydraulic
Adjustment Automatic
Pedal travel (not adjustable) 135 ± 3 mm
Tightening Torques
Bolts, clutch slave cylinder 11 8 -
Nuts, clutch pedal bracket 25 18 -
G402260 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MTX-75)

Clutch Controls
G18080 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MTX-75)

Clutch Master Cylinder
5. Remove the footwell crash padding.
Special Tool(s)
Remover/Installer, Clutch
Master Cylinder
308-554
Name Specification
Grease WSD-M1C230-A
6. Remove the lower footwell trim.

CAUTION: If brake fluid comes into
contact with the paintwork, rinse off the
affected areas with cold water without
delay.
1. Remove the air cowl grille. For additional
End Body Panels, REMOVAL AND
INSTALLATION, Cowl Panel Grille]
All vehicles
2. Remove the air cleaner.
303-12.[Intake Air Distribution and Filtering,
REMOVAL AND INSTALLATION, Air
Cleaner - 1.8L Duratec-HE (MI4)/2.0L 7. Detach the data link connector (DLC) from
Duratec-HE (MI4)] the footwell lower trim.
For additional information, refer to Section • Detach the data link connector clips.
Cleaner - 1.6L (Z6)]
3. Remove the battery carrier. For additional
All vehicles
4. Extract brake fluid from the brake fluid
reservoir until the level reaches the MIN
mark.
G402261 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MTX-75)

8. Detach the steering column shaft joint from 9. Remove the components in the order
the steering. indicated in the following illustration(s) and
• Remove the steering column shaft joint bolt. table(s).

Number
3 - Nuts, clutch pedal bracket
1 - Clutch master cylinder pipes. See Removal Detail
See Removal Detail
4 - Clutch pedal bracket
2 - Clutch pedal return See Removal Detail
spring(vehicles with1.6L,
1.8L, 2.0L engines 5 - Catch for clutch master
shown) cylinder actuating rod
See Removal Detail
G402261 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MTX-75)

Item Part Description 5. Install the lower footwell trim.
Number
6 - Clutch master cylinder

All vehicles
3. Attach the steering column shaft joint to
the steering.
• Tighten the steering column shaft joint bolt.
6. Install the footwell crash padding.
4. Attach the data link connector (DLC) at the

footwell lower trim.
• Install the data link connector clips.
7. Bleed the clutch system. For additional

Bleeding]
8. Install the battery carrier. For additional
All vehicles
9. Install the air cleaner.
Cleaner - 1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4)]
G402261 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MTX-75)

Left-hand drive vehicles Item 3: Nuts, clutch pedal bracket
10. Install the air cowl grille. For additional 1. Remove the clutch pedal bracket nuts.
information, refer to Section 501-02.[Front • Discard the nuts.
11. Initialize window operating motors.
Mechanisms, GENERAL PROCEDURES,
Removal Details
Item1: Clutch master cylinder pipes.

1. CAUTION: Close off the clutch master
cylinder line to prevent fluid loss or
dirt ingress. Item 4: Clutch pedal bracket
Detach the clutch master cylinder pipes 1. Detach the clutch pedal position (CPP)
from the clutch master cylinder. switch from the clutch pedal bracket.
1. Press the clutch master cylinder supply line • Detach the cable from the wiring harness
lock button. bracket.
2. Remove the clutch slave cylinder pressure
line securing clip.
2. Detach the clutch master cylinder from the

bulkhead using the special tool.
• Turn the clutch master cylinder 60 degrees
counter-clockwise.
G402261 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MTX-75)

3. Remove the clutch master cylinder Installation Details
together with the clutch pedal bracket.
• Turn the clutch pedal bracket to the position Item 6: Clutch master cylinder
shown. 1. NOTE: Coat the clutch master cylinder gaiter
with grease before installing.
Install the clutch master cylinder.
Item 5: Catch for clutch master cylinder

actuating rod
clutch pedal bracket.
• Press together the catch for the clutch
master cylinder actuating rod.
G402261 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MTX-75)

Clutch Slave Cylinder (16 862 0)

Name Specification
Sealer ESK-M4G269-A immediately washed down with cold
water.
NOTE: Install a new clutch slave cylinder/release
Removal bearing assembly.
Install the clutch slave cylinder/release
1. Remove the transmission.
bearing assembly.
2. Clean the input shaft splines.
• Attach the boot.
water.
CAUTION: Wrap the input shaft splines
with adhesive tape to protect the input
shaft oil seal.
Remove the clutch slave cylinder/release
bearing assembly.
• Detach the boot.
• Discard the clutch slave cylinder/release
bearing assembly.
3. Remove the adhesive tape from the input

shaft splines.
4. Install the transmission.
Bleeding]
Installation
1. Apply sealer to the clutch slave
cylinder/release bearing assembly.
G325459 en 09/2004 2004.75 Focus

TO MODEL INDEX
308-02B-1 Clutch Controls — Vehicles With: 6-Speed Manual 308-02B-1

Transaxle (MMT6)
SECTION 308-02B Clutch Controls — Vehicles With:

6-Speed Manual Transaxle (MMT6)
CONTENTS PAGE
SPECIFICATIONS
Clutch Control........................................................................................ 308-02B-2
Clutch Controls ................................................................................................................ 308-02B-3
Clutch Master Cylinder..................................................................................................... 308-02B-4/8

Clutch Slave Cylinder.................................................................................... (16 862 0) 308-02B-9
09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MMT6)
SPECIFICATIONS

Item Specification
Clutch Control
Description
Operating principle Hydraulic
Adjustment Automatic
Tightening Torques
Bolts, clutch slave cylinder 11 8 -
Nuts, clutch pedal bracket 25 18 -
Bolts, strut top mount 30 22 -
Nuts, stabilizer and link rod to strut mount 25 18 -
G402262 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MMT6)

Clutch Controls
G18080 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MMT6)

5. Remove the footwell crash padding.

Special Tool(s)
Remover/Installer, Clutch
Master Cylinder
308-554
Name Specification
Grease WSD-M1C230-A
CAUTION: If brake fluid comes into 6. Remove the footwell side trim.
affected areas with cold water without 7. Remove the lower footwell trim.
delay.
1. Remove the cowl grille. For additional
All vehicles
2. Remove the air cleaner. For
Duratec-HE (MI4)] For
303-12.[Intake Air Distribution and Filtering, 8. Detach the data link connector (DLC) from
REMOVAL AND INSTALLATION, Air the footwell lower trim.
• Detach the data link connector clips.
(MI4)/2.0L Duratec-HE (MI4)] For
Tray -2.0LDuratorq-TDCi (DW) Diesel]
All vehicles
mark.
G296684 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MMT6)

9. Detach the steering column flexible 10. Remove the components in the order
coupling. indicated in the following illustration(s)
• Remove the steering column flexible cou- and table(s).
pling bolt.

Number
3 - Clutch pedal bracket nuts
See Removal Detail
2 - Clutch pedal return spring See Removal Detail
(vehicles with the 1.6L, 1.8L,
2.0L engine shown)
G296684 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MMT6)

Number
5 - Catch for clutch master
cylinder actuating rod
See Removal Detail

All vehicles
3. Install the steering column flexible
coupling.
• Tighten the steering column flexible cou-
pling bolt.
6. Install the footwell side trim.
4. Attach the data link connector (DLC) at the 7. Install the footwell crash padding.

Bleeding]
G296684 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MMT6)

[Battery, Mounting and Cables, Removal Details
Tray - 1.4L Duratec-16V (Sigma)/1.6L Item 1 : Clutch master cylinder pipes.
(MI4)/2.0L Duratec-HE (MI4)] 1. CAUTION: Close off the clutch master
For additional information, refer to Section cylinder line to prevent fluid loss or
414-01.[Battery, Mounting and Cables, dirt ingress.
REMOVAL AND INSTALLATION, Battery Detach the clutch master cylinder pipes
Tray - Duratorq-TDCi (DW) Diesel]2.0L from the clutch master cylinder.
1. Press the clutch slave cylinder supply line
All vehicles lock button.
line securing clip.
Duratec-HE (MI4)]
Section 303-12.[Intake Air Distribution
and Filtering, REMOVAL AND
INSTALLATION, Air Cleaner - 2.0L
11. Install the cowl grille. For additional
12. Initialize the window winder motors. For Item 3 : Clutch pedal bracket nuts
additional information, refer to Section 501-11 1. Remove the clutch pedal bracket nuts.
.[Glass, Frames and Mechanisms, • Discard the nuts.
G296684 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MMT6)

Item 4 : Clutch pedal bracket 3. Remove the clutch master cylinder
1. Detach the clutch pedal position (CPP) together with the clutch pedal bracket.
switch from the clutch pedal bracket. • Turn the clutch pedal bracket to the position
• Detach the cable from the wiring harness shown.
bracket.

counter-clockwise.
Item 5 : Catch for clutch master cylinder

actuating rod
G296684 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (MMT6)

Clutch Slave Cylinder (16 862 0)
Removal
1. Remove the transmission. Installation
2. CAUTION: If brake fluid is spilt on the 1. CAUTION: If brake fluid is spilt on the
paintwork, the affected area must be paintwork, the affected area must be
immediately washed down with cold immediately washed down with cold
water. water.
Remove the clutch slave cylinder/release NOTE: Install a new clutch slave cylinder/release
bearing assembly. bearing assembly.
• Detach the boot. Install the clutch slave cylinder/release
• Discard the clutch slave cylinder/release bearing assembly.
bearing assembly. • Attach the boot.
2. Install the transmission.

Bleeding]
G325460 en 09/2004 2004.75 Focus

TO MODEL INDEX
308-02C-1 Clutch Controls — Vehicles With: 5-Speed Manual 308-02C-1

Transaxle (F35M-R)
SECTION 308-02C Clutch Controls — Vehicles With:

5-Speed Manual Transaxle (F35M-R)
CONTENTS PAGE
SPECIFICATIONS
Clutch Controls ................................................................................................................ 308-02C-3
Clutch Master Cylinder..................................................................................................... 308-02C-4/8

Clutch Slave Cylinder....................................................................................................... 308-02C-9
09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (F35M-R)
SPECIFICATIONS
Item Nm lb-ft lb-in
Clutch slave cylinder retaining bolts 22 16 -
G385303 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (F35M-R)

Clutch Controls
G18080 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (F35M-R)

All vehicles
Special Tool(s) mark.
Remover/Installer, Clutch 5. Remove the footwell crash padding.
Master Cylinder
308-554
Name Specification
Grease WSD-M1C230-A
CAUTION: If brake fluid comes into

affected areas with cold water without
delay. 6. Remove the lower footwell trim.
1. Remove the air cowl grille. For additional
All vehicles
2. Remove the air cleaner.
Duratec-HE (MI4)] For additional
7. Detach the data link connector (DLC) from
Duratorq-TDCi (DW) Diesel] For additional
the footwell lower trim.
Air Distribution and Filtering, REMOVAL • Detach the data link connector clips.
(Z6)]
(MI4)/2.0L Duratec-HE (MI4)] For additional
Tray -2.0LDuratorq-TDCi (DW) Diesel]
G402261 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (F35M-R)

8. Detach the steering column shaft joint from 9. Remove the components in the order
the steering. indicated in the following illustration(s) and
• Remove the steering column shaft joint bolt. table(s).

Number
3 - Nuts, clutch pedal bracket
See Removal Detail
2 - Clutch pedal return See Removal Detail
spring(vehicles with1.6L,
1.8L, 2.0L engines 5 - Catch for clutch master
shown) cylinder actuating rod
See Removal Detail
G402261 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (F35M-R)

Number

All vehicles
3. Attach the steering column shaft joint to
the steering.
• Tighten the steering column shaft joint bolt.
6. Install the footwell crash padding.
4. Attach the data link connector (DLC) at the


Bleeding]
Tray - 2.0L Duratorq-TDCi (DW) Diesel]
All vehicles
9. Install the air cleaner.
G402261 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (F35M-R)

Duratec-HE (MI4)] Item 3: Nuts, clutch pedal bracket
For additional information, refer to Section 1. Remove the clutch pedal bracket nuts.
303-12.[Intake Air Distribution and Filtering, • Discard the nuts.
10. Install the air cowl grille. For additional
11. Initialize window operating motors.
Mechanisms, GENERAL PROCEDURES, Item 4: Clutch pedal bracket
Door Window Motor Initialization] 1. Detach the clutch pedal position (CPP)
switch from the clutch pedal bracket.
Removal Details • Detach the cable from the wiring harness
bracket.
Item 1: Clutch master cylinder pipes.
dirt ingress.
Detach the clutch master cylinder pipes
from the clutch master cylinder.
1. Press the clutch master cylinder supply line
lock button.
line securing clip.

counter-clockwise.
G402261 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (F35M-R)

3. Remove the clutch master cylinder Installation Details
together with the clutch pedal bracket.
• Turn the clutch pedal bracket to the position Item 6: Clutch master cylinder
shown. 1. NOTE:Coat the clutch master cylinder gaiter
with grease before installing.
Install the clutch master cylinder.
Item 5: Catch for clutch master cylinder

actuating rod
G402261 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (F35M-R)

Clutch Slave Cylinder

100-02.[Jacking and Lifting, DESCRIPTION 3. Remove the components in the order
AND OPERATION, Lifting] indicated in the following illustration(s) and
table(s).

Number
3 - Clutch slave cylinder
line 4. To install, reverse the removal procedure.
See Removal Detail
2 - Clutch slave cylinder retain- [Manual Transmission/Transaxle
ing bolts and Clutch - General Information,
G385307 en 09/2004 2004.75 Focus

TO MODEL INDEX

Transaxle (F35M-R)

GENERAL PROCEDURES, Clutch System Installation Details
Bleeding]
Removal Details 1. NOTE: Make sure that the clutch slave cylinder
supply line O-ring is not damaged.
1. CAUTION: Cap the clutch slave cylinder line.
supply line to prevent fluid loss or dirt 1. Check the O-ring seal and install a new
ingress. O-ring seal if necessary.
Disconnect the clutch slave cylinder 2. Insert the clutch slave cylinder supply line
supply line. into the clutch slave cylinder.
1. Pull the clip to the position shown. 3. Push in the clip.
2. Pull the clutch slave cylinder supply line out
of the clutch slave cylinder.
G385307 en 09/2004 2004.75 Focus

TO MODEL INDEX
308-03A-1 Manual Transmission/Transaxle — Vehicles With: 308-03A-1

SECTION 308-03A Manual Transmission/Transaxle —

Vehicles With: 5-Speed Manual Transaxle (MTX-75)
CONTENTS PAGE
SPECIFICATIONS
Transmission Ratios...................................................................................................... 308-03A-2
Required Shim Thickness............................................................................................ 308-03A-2
Manual Transaxle ............................................................................................................ 308-03A-4

Manual Transmission ...................................................................................................... 308-03A-4/5
Input and Output Shaft .................................................................................................... 308-03A-6
Power Flow ..................................................................................................................... 308-03A-7
General Illustrations ........................................................................................................ 308-03A-8/11
Manual Transaxle — Vehicles With: Manual Transaxle.................................................... 308-03A-12
GENERAL PROCEDURES
Bearing Check ................................................................................................................. 308-03A-13/14
IN-VEHICLE REPAIR
Halfshaft Seal LH .......................................................................................... (14 303 0) 308-03A-15

Halfshaft Seal RH ......................................................................................... (14 304 0) 308-03A-16
Transaxle — 2.0L Duratec-HE (MI4) ............................................................. (16 114 0) 308-03A-17/22
DISASSEMBLY
Transaxle ...................................................................................................... (16 118 8) 308-03A-23/26
Input Shaft ....................................................................................................................... 308-03A-27/31

Output Shaft..................................................................................................................... 308-03A-32/37
Differential..................................................................................................... (16 118 6) 308-03A-38/41
ASSEMBLY
Transaxle ...................................................................................................... (16 118 8) 308-03A-42/53
INSTALLATION
Transaxle — 2.0L Duratec-HE (MI4) ............................................................. (16 114 0) 308-03A-54
09/2004 2004.75 Focus

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SPECIFICATIONS
Lubricants, Sealants and Adhesives

Item Specification
High-temperature grease ESD-M1C220-A
Sealant WSK-M2G348-A5
Manual transmission fluid WSD-M2C200-C
Capacities
Litres
Manual transmission fluid (0-5 mm below the lower edge of the filler hole) 1.9
Transmission Ratios
2.0L engine
First gear 3.417
Second gear 2.136
Third gear 1.448
Fourth gear 1.028
Fifth gear 0.805
Reverse gear 3.727
Final drive 4.067
Required Shim Thickness

Differential
Description Input shaft Output shaft assembly
Measuring shims (mm) 1.00 1.00 1.10
Determined end float (mm) + 0.22 + 0.33 + 0.36
Pre-load figure (mm) - + 0.13 + 0.33
End float (mm) - 0.07 - -
Required shim thickness (mm) = 1.15 = 1.46 = 1.79
Available shims (mm) 1.15 - 1.71 (in 0.01 1.31 - 1.91 (in 0.02 1.40 - 2.20 (in 0.05
mm steps) mm steps) mm steps)
Tightening Torques
Nut - lower suspension arm to steering knuckle 70 52 -
Nut and bolt - lower suspension arm to rear sub- 130 96 -
frame
Bolt for strut top mount 30 22 -
Nuts - intermediate shaft centre bearing 25 18 -
Transmission bolts 48 35 -
Bolts - rear engine mounting bracket 90 66 -
Engine roll restrictor to subframe 80 59 -
Engine roll restrictor to transmission 80 59 -
Rear engine mounting bolt 133 98 -
Rear engine mounting nuts 48 35 -
Ground cable bolt to transmission 18 13 -
Reverse gear idler shaft bolts 24 18 -
Transmission housing bolts 32 24 -
Clutch slave cylinder bolts 11 8 -
Transmission filler pipe blanking plug 35 26 -
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Selector mechanism bolts 26 19 -
Gearshift cable bracket nuts 40 30 -
Subframe bolts 142 105 -
Subframe bracket bolts 10 - 89
Nuts - stabiliser bar connecting rod 25 18 -
Starter motor to transmission housing 35 26 -
Wiring harness bracket to starter motor 20 15 -
Catalytic converter - exhaust pipe 47 35 -
Catalytic converter - exhaust manifold 47 35 -
Intercooler 10 - 89
Intercooler air guide 20 15 -
Catalytic converter bracket 47 35 -
Reverse gear idler shaft mounting 34 25 -
Differential spur gear bolts 83 61 -
Subframe crashbox bolts 40 30 -
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Manual Transaxle
• M: Manual
Manual Transmission • T: Transmission
• X: Transaxle (front wheel drive)
MTX-75 means:
• 75: Distance between input and output shaft in
mm.
• Transmission with different axes (input and
output shafts)
• The final drive is integrated into the
transmission housing.
• 5-speed manual transmission for FWD
• 1st/2nd gear double synchroniser
• 3rd/4th gear and 5th/reverse gear single
synchroniser
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Overview

Number
6 Transaxle housing - trans-
1 Transaxle housing - clutch axle side
side
7 Selector mechanism
2 Input shaft
3 Differential assembly
4 Output shaft
5 Reverse gear idler
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Input and Output Shaft

Number
13 1st/2nd gear synchroniser
1 Reverse gear idler assembly
2 Reverse gear teeth 14 Gear wheel - 2nd gear
3 Gear wheel - 5th gear 15 Gear wheel - 3rd gear
4 Gear wheel - 4th gear 16 Gear wheel - 4th gear
5 3rd/4th gear synchroniser 17 Gear wheel - 5th gear
assembly
18 5th/reverse gear synchro-
6 Gear wheel - 3rd gear nizer assembly
7 Teeth - 2nd gear 19 Gear wheel - reverse gear
8 Teeth - 1st gear All gear wheels are constantly engaged.
9 Input shaft The output shaft teeth are part of the output shaft
10 Output shaft and are constantly engaged with the differential
crown wheel.
11 Teeth - output shaft
In the neutral position, none of the gear wheels is
12 Gear wheel - 1st gear connected with the input or output shaft via the
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corresponding synchroniser assembly. No torque 2nd gear
is transmitted to the differential.
The input and output shafts are respectively
mounted by means of tapered roller bearings in
the halves of the transaxle housing on the clutch
and transaxle sides.
This bearing arrangement requires the shafts to
be preloaded.
The 3rd/4th gear synchroniser assembly is
located on the input shaft.
The 1st/2nd gear and 5th/reverse gear
synchroniser assemblies are located on the output
shaft.

Power Flow Number
1 Input shaft
1st gear
2 Output shaft
assembly
5 Gear wheel - 2nd gear
6 Teeth (2nd gear)
3rd gear

Number
1 Input shaft
2 Output shaft
4 Gear wheel - 1st gear
assembly
6 Teeth - 1st gear Number
1 Input shaft
2 Output shaft
4 Gear wheel - 3rd gear
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Number Number
5 3rd/4th gear synchroniser 1 Input shaft
assembly
2 Output shaft
6 Gear wheel - 3rd gear
4 Gear wheel - 5th gear
4th gear
nizer assembly
6 Gear wheel - 5th gear
Reverse

Number
1 Input shaft
2 Output shaft
4 Gear wheel - 4th gear Number
5 Gear wheel - 4th gear 1 Input shaft
6 3rd/4th gear synchroniser 2 Output shaft
assembly
5th gear nizer assembly
5 Gear wheel - reverse gear
6 Reverse gear idler
7 Teeth - reverse gear
General Illustrations
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Input shaft

Number
9 - Snap ring
1 - Input shaft
10 - Synchronizer ring - 4th gear
2 - Teeth - 2nd gear
11 - Needle roller bearing - 4th
3 - Teeth - 1st gear gear
4 - Tapered roller bearing 12 - Gear wheel - 4th gear
(clutch side)
13 - Gear wheel - 5th gear
5 - Needle roller bearing - 3rd
gear 14 - Snap ring
6 - Gear wheel - 3rd gear 15 - Tapered roller bearing

(transaxle side)
7 - Synchronizer ring - 3rd gear
8 - 3rd/4th gear synchroniser
assembly
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Output shaft

Number
4 - Needle roller bearing - 1st
1 - Tapered roller bearing gear
(clutch side)
5 - Gear wheel - 1st gear
2 - Teeth - output shaft
6 - Inner synchroniser ring - 1st
3 - Output shaft gear
7 - Synchroniser cone - 1st gear
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Item Part Description Reverse gear idler
Number
8 - Outer synchroniser ring - 1st
gear
9 - 1st/2nd gear synchroniser
assembly
10 - Snap ring
11 - Outer synchroniser ring - 2nd
gear
12 - Synchroniser cone - 2nd
gear
13 - Inner synchronizer ring - 2nd
gear
14 - Gear wheel - 2nd gear
15 - Needle roller bearing - 2nd
gear
16 - Gear wheel - 3rd gear
18 - Snap ring
19 - Needle roller bearing - 5th
gear
21 - Synchroniser ring - 5th gear Item Part Description
22 - 5th/reverse gear synchro- Number
nizer assembly 1 Mounting
23 - Snap ring 2 Thrust washer
24 - Reverse gear synchroniser 3 Reverse gear idler
ring
4 Needle roller bearing
25 - Reverse gear needle roller
bearing 5 Thrust washer
26 - Gear wheel - reverse gear
27 - Tapered roller bearing
(transaxle side)
The reverse gear idler runs on a needle roller
bearing on the reverse gear idler spindle.
The reverse gear idler is driven by the input shaft.
Its function is to reverse the direction of rotation of
the output shaft in reverse gear.
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Manual Transaxle — Vehicles With: Manual Transaxle
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GENERAL PROCEDURES
Bearing Check
1. NOTE: Establish the cause of the damage and 3. Check whether the ends of the taper rollers
resolve it. are worn away due to incorrect installation,
Check whether the bearing cage is excessive pre-load or faulty bearing
damaged at the top, side or at the seating.
openings is damaged because of the • Install a new bearing and new seals if
unprofessional use of a special tool or of necessary.
the wrong tool. • Check the bearing is correctly lubricated.
• Install a new bearing if necessary.
4. Check whether the bearing surfaces are

2. Check whether the ends of the taper rollers grey or grey/black with deposits between
are discoloured as a result of inadequate the rollers.
lubrication or overheating, possibly • Install a new bearing and new seals if
through excessive pre-load. necessary.
• Install a new bearing and new seals if • Check the bearing is correctly lubricated.
necessary.
• Check the bearing is correctly lubricated.
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5. Check whether the bearing ring surfaces 7. Check the surfaces for abrasion due to
are grooved caused by static impact. metal fatigue.
• Install a new bearing if its surface is rough, • Install a new bearing and clean all other
or if it is noisy. affected components as necessary.
6. NOTE: Overheating can cause loss of surface

hardness.
Check for a dark blue colour caused by
overheating (yellow or brown is normal)
due to excessive pre-load or inadequate
lubrication.
• Install a new bearing, new seals and check
other components as necessary.
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IN-VEHICLE REPAIR
Halfshaft Seal LH (14 303 0)
IN-VEH ICLE R EPAIR
Installation
Special Tool(s)
1. Install the halfshaft oil seal using the
Installer, Drive Pinion Oil Seal special tool.
205-115 • Drive the oil seal fully home using the spe-
cial tool.
Remover, Halfshaft Oil Seal

308-208
Removal
2. Remove the halfshaft oil seal using the 2. Install the left-hand halfshaft. For additi-
special tool. onal information, refer to Section 205-04.
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IN-VEHICLE REPAIR
Halfshaft Seal RH (14 304 0)
Installation
Special Tool(s)
cial tool.

308-208
Removal
2. Remove the halfshaft oil seal using the
special tool.
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REMOVAL
Transaxle — 2.0L Duratec-HE (MI4) (16 114 0)
REMOVAL

Special Tool(s) (right-hand side shown).
Support Bar, Engine

303-290A

303-290-03A

303-290-13 5. Secure the radiator to the lock panel with
cable ties.
Adapter for 303-290A selector mechanism.
303-290-15 1. Press the selector cable catch and detach
the selector cable from the selector lever.
2. Press the gearshift cable catch and detach
the gearshift cable from the gear lever.
General Equipment
Transmission jack
Retaining straps
Cable ties
Removal
sides. For additional informat ion,
Assembly]
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REMOVAL (Continued)
7. Detach the gearshift cables from the 9. Disconnect the reversing lamp switch
abutment. connector.
1. Release the selector cable by turning the
catch counter-clockwise and detach from
the abutment.
2. Release the gearshift cable by turning the
the abutment.
10. Detach the ground lead from the rear

engine mounting bracket.
rear engine mounting bracket.

without delay.
cylinder pipe to prevent fluid loss or dirt
ingress.
Detach the clutch slave cylinder pipe from
the clutch slave cylinder.
• Detach the clutch slave cylinder pipe from
11. Remove the transmission upper bolts.
the bracket.
• Detach the ground cable from the trans-
mission.
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REMOVAL (Continued)
13. Remove the lower radiator cover. 16. Remove the radiator support bracket
bolts (right-hand side shown).
• Remove the radiator support bracket.
17. Remove the crash box.
15. Remove the radiator support bracket

bolts (left-hand side shown).
18. Remove the engine roll restrictor rubber

mountings.

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REMOVAL (Continued)
21. Remove the cross brace. 24. Detach the flexible pipe from the catalytic
converter.
• Discard the gasket and retaining nuts.
22. Install a support sleeve or reinforcement

on the flexible exhaust pipe.
25. Detach the wiring harness bracket from
the engine.
23. Detach the flexible pipe from the cross-

member rubber insulators.
26. Detach the starter motor from the engine.
• Secure the starter motor to one side.
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REMOVAL (Continued)
27. Install the special tools. 31. Remove the rear engine mounting bracket
(rear engine mounting shown removed for
clarity).

33. Lower the engine / transmission assem-
bly using the special tools.

30. Remove the bolt from the rear engine
mounting.
34. Remove the transmission lower bolts.
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REMOVAL (Continued)
35. Remove the right-hand transmission
bolts.
36. Secure the transmission on the transmis-

sion jack using suitable retaining straps.
37. Remove the left-hand transmission bolt.
38. Support the transmission using the

transmission jack and remove.
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DISASSEMBLY
DISASSEM BLY
Disassembly
Special Tool(s)
1. CAUTION: All bearings are paired and
Remover, Drive Pinion Oil must not be mixed.
Seal
Mount the transmission on the assembly
205-078
stand using the special tool.
Adapter for 205-078

205-078-01
Remover, Differential Bearing

Outer Race
205-176
2. Remove the gearshift cable abutment.

Mounting Bracket,
Engine/Differential
205-329
Mounting Stand
303-435

303-435-06 3. NOTE: Ensure that the selector mechanism is
in the neutral position.
Remove the selector mechanism.

308-208
General Equipment
Two tire levers
Hardwood drift
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4. Remove the input shaft oil seals on both 7. Remove the transmission housing bolts.
sides using the special tool and discard
(left-hand side shown).
8. CAUTION: Do not drive out the

transmission housing locating dowels.
5. CAUTION: Wrap the input shaft splines Separate the clutch housing from the
with adhesive tape in order to protect transmission housing using two tire levers.
the input shaft oil seal.
Degrease the input shaft splines.
6. CAUTION: Only remove the clutch slave
cylinder / release bearing assembly if it
is damaged or leaking.
Remove the clutch slave cylinder / release
bearing assembly.
• Detach the boot.
• Discard the clutch slave cylinder bolts.

shaft splines.
10. NOTE: Tilt the differential slightly.
Remove the differential assembly.
• Remove the magnetic disc.
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11. Remove the bolts from the reverse gear 14. Remove the reverse gear idler shaft
idler shaft mounting. mounting.
• Turn the input shaft and output shaft to the
side in order to move the reverse gear idler
shaft mounting upwards.
• The reverse gear idler remains in the
12. Remove the selector rods.
15. Remove the input shaft together with the

output shaft.
13. Remove the selector forks.

1. Remove the 1st/2nd gear selector fork.
2. Remove the 3rd/4th gear selector fork.
3. Remove the 5th/reverse gear selector fork.
16. Remove the reverse gear idler.

• Remove the needle roller bearing and thrust
washers.
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17. Remove the differential bearing outer race 20. Remove the output shaft bearing outer
using the special tool. race and adjusting shim using the special
tool.
18. Remove the input shaft and output shaft

bearing outer races using the special tool. 21. CAUTION: Only remove the reverse
gear idler shaft if it is damaged.
Remove and discard the reverse gear
idler shaft retaining bolts.
19. Remove the input shaft bearing outer race

and adjusting shim and the differential
bearing outer race and adjusting shim
22. Remove the reverse gear idler shaft using
a suitable hardwood drift.
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Input Shaft
2. Using the special tools, remove the clutch

housing roller bearing.
Special Tool(s)
Tool)
205-295 (15-050A)
Collet for 205-295

308-195 (16-060)
Collet for 205-295

308-196 (16-061)
Support Plate, Gear Removal

308-198 (16-063)
Support Plate, Gear Removal

(Dia 81.2 mm)
308-230 (16-077)
Name Specification
Manual transmission WSD-M2C200-C
fluid
Disassembly
All vehicles
1. NOTE: Use vise jaw protectors for all
operations in a vise.
Clamp the input shaft in a vise.
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3. NOTE: When the roller bearing and the fifth All except vehicles with diesel engine
gear wheel are removed together, refer to the 4. NOTE: Using a suitable press, remove the gear
following steps. wheels.
Using the special tools, remove the trans- Using the special tool, remove the fifth gear
axle housing roller bearing. wheel and the transaxle housing roller
bearing.
1. Slide the snap ring up out of the annular
groove until it sits below the roller bearing.
2. Using the special tool, remove the gear
wheel, snap ring and the roller bearing.
• Discard the snap ring
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Vehicles with diesel engine All vehicles
5. NOTE: Using a suitable press, remove the gear 6. Remove the fourth gear wheel.
wheels. 1. Remove the gear wheel.
Using the special tool, remove the fifth gear 2. Remove the needle roller bearing.
wheel and the transaxle housing roller 3. Remove the synchronizer ring.
bearing.
1. Slide the snap ring up out of the annular
groove until it sits below the roller bearing.
2. Using the special tool, remove the gear
wheel, snap ring and the roller bearing.
7. Remove the third and fourth gear

synchronizer.
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8. NOTE: Mark the position of the selector ring in Assembly
relation to the synchronizer hub to aid
installation. Components are paired. 1. NOTE: Use vise jaws protectors for all
NOTE: The detent balls are spring-loaded. Take operations in a vise.
care when removing the selector ring from the NOTE: Lubricate the synchronizer rings with
synchronizer hub. manual transmission fluid before assembly.
Disassemble the third and fourth gear NOTE: If installing new roller bearings, do not
synchronizer. lubricate the bearings.
1. Remove the selector ring. Carefully clean and check all sliding parts
2. Remove the compression springs, blocker and lubricate them with manual
bars and detent balls. transmission fluid before assembly.
2. Using a suitable length of tube, install the
clutch housing roller bearing.
9. Remove the third gear wheel.

1. Remove the synchronizer ring.
3. Install the third gear wheel.
2. Remove the synchronizer cone.
1. Install the needle roller bearing.
3. Remove the gear wheel.
2. Install the gear wheel.
4. Remove the needle roller bearing.
3. Install the synchronizer cone.
4. Install the synchronizer ring.
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4. NOTE: Observe the markings. 6. Install the fourth gear wheel.
Assemble the third and fourth gear 1. Install the synchronizer ring.
synchronizer. 2. Install the needle roller bearing.
1. Install the compression springs. 3. Install the gear wheel.
2. Install the blocker bars and detent balls.
3. Install the selector ring.
7. NOTE: Install the fifth gear wheel with the large

collar facing outwards.
NOTE: Install a new snap ring.
5. NOTE: Install the third and fourth gear Using a length of suitable tube, install the
synchronizer with the large collar facing fifth gear wheel.
outwards (towards to the fourth gear wheel).
NOTE: Install a new snap ring.
Install the third and fourth gear
synchronizer.
1. Install the synchronizer.
8. Using a length of suitable tube, install the

transaxle housing roller bearing.
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Output Shaft
2. Remove the reverse gear synchronizer
ring.
Special Tool(s) 1. Remove the needle roller bearing.
2. Remove the synchronizer ring.
Installer, Drive Pinion Bearing
205-068 (15-042)
205-310 (15-091)
General Equipment
Separating tool
3. NOTE: If gear changes are difficult, carefully
Name Specification remove the synchronizer hub assembly and the
Transmission fluid WSD-M2C200-C fifth gear gearwheel
Remove the fifth and reverse gear
synchronizer hub assembly.
Disassembly 1. Remove the snap-ring.
1. Press off the transmission housing roller 2. Remove the synchronizer hub assembly.
bearing together with the reverse gear
gearwheel using the special tool.
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4. Remove the fifth gear gearwheel. 6. NOTE: Do not use Special Tool 205-310.
1. Remove the synchronizer ring. NOTE: Use the separating tool with the flat side
2. Remove the fifth gear gearwheel. upwards.
3. Remove the needle roller bearing. Remove the second and third gear gear-
wheel using a suitable separating tool.
5. NOTE: Use the special tool with the flat side

upwards.
7. CAUTION: Be careful when handling
Remove the fourth gear gearwheel using the inner synchronizer ring and the
the special tool. synchronizer cone.
• Remove the snap-ring. Remove the second gear synchronizer
rings.
2. Remove the inner synchronizer ring.
4. Remove the outer synchronizer ring.
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8. Remove the first and second gear 10. NOTE: Only remove the bearing if it is to be
synchronizer hub assembly. renewed.
1. Remove the snap-ring. Remove the transmission housing roller
2. Remove the synchronizer hub assembly. bearing using the special tool.
9. CAUTION: Be careful when handling 11. CAUTION: Carefully remove the

the inner synchronizer ring and the selector ring from the synchronizer
synchronizer cone. hub assembly. The detent balls are
spring-loaded.
Remove the first gear gearwheel.
NOTE: Mark the installed position of the selector
1. Remove the outer synchronizer ring.
ring.
Disassemble the synchronizer hub
3. Remove the inner synchronizer ring.
assembly.
4. Remove the first gear gearwheel.
1. Remove the selector ring.
2. Remove the synchronizer body.
3. Remove the compression springs.
4. Remove the blocker bars.
5. Remove the detent balls.
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Assembly 3. NOTE: Observe the markings.
Assemble the synchronizer hub assembly.
the inner synchronizer ring and the 1. Install the compression springs.
synchronizer cone. Lubricate the 2. Install the blocker bar and the detent balls in
synchronizer rings with transmission the gear synchronizer hub against the force
fluid prior to installation. of the spring.
NOTE: Do not lubricate new roller bearings. 3. Install the spring ring the correct way round
and push it on.
Carefully clean and check all parts and
lubricate sliding surfaces with
transmission fluid prior to assembly.
the inner synchronizer ring and the
synchronizer cone.
Install the first gear gearwheel.
2. Install the first gear gearwheel.
3. Install the inner synchronizer ring.
4. Install the synchronizer cone.
5. Install the outer synchronizer ring.
4. NOTE: Install the synchronizer hub assembly

with the wider collar facing outwards (towards
the second gear gearwheel).
Install the first and second gear
1. Install the synchronizer hub assembly.
2. Install the snap-ring.
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5. Install the second gear gearwheel. 8. Install the fifth gear gearwheel.
1. Install the needle roller bearing. 1. Install the needle roller bearing.
2. Install the outer synchronizer ring. 2. Install the fifth gear gearwheel.
3. Install the synchronizer cone. 3. Install the synchronizer ring.
4. Install the inner synchronizer ring.
5. Install the second gear gearwheel.
9. NOTE: Install the synchronizer hub assembly

with the narrower collar and the annular groove
facing outwards.
6. Install the third gear gearwheel using the
special tool. Installation position of fifth and reverse
gear synchronizer hub assembly.
7. NOTE: Install a new circlip.

Install the fourth gear gearwheel using the
special tool.
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10. NOTE: Install the synchronizer hub assembly 12. Install the transmission housing roller
with the narrower collar and the annular groove bearing using a suitable tube.
facing outwards.
Install the fifth and reverse gear
1. Install the synchronizer hub assembly.
2. Install a new snap ring.
13. Install the clutch housing roller bearing

using a suitable tube.
11. Install the reverse gear gearwheel.

1. Install the synchronizer ring.
3. Install the reverse gear gearwheel.
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Differential (16 118 6)
2. Using the special tools, remove the differ-
ential roller bearing.
Special Tool(s)
Pad)
205-071-01 (15-026A-01)

205-081 (15-032)

Tool)
205-295 (15-050A)
Collet for 205-295

308-197 (16-062)
Name Specification
fluid
Disassembly
All vehicles
NOTE: Use vise jaws protectors for all operations
in a vise.
1. Clamp the differential in a vise.
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3. Using the special tools, remove the differ- Vehicles with diesel engine
ential roller bearing. 5. Remove the speedometer drive gear.
All vehicles
6. NOTE: Leave three ring gear retaining bolts
loosely installed. These should be evenly
distributed around the circumference of the ring
gear.
Remove the ring gear.
1. Loosen the bolts and remove seven
retaining bolts.
2. Using a soft faced hammer, lightly tap the
three remaining retaining bolts to release
the ring gear from the differential case.
All except vehicles with diesel engine
4. Remove the vehicle speed sensor (VSS)
sensor ring.
Assembly
All vehicles
NOTE: If installing new roller bearings, do not
lubricate the bearings.
1. Carefully clean and check all parts and coat
with manual transmission fluid before
assembly.
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2. NOTE: Use vise jaws protectors for all All except vehicles with diesel engine
operations in a vise. 5. NOTE: The VSS sensor ring must snap into
Clamp the differential in a vise. position.
Install the VSS sensor ring.
3. CAUTION: Tighten the ring gear
retaining bolts finger tight and then
evenly by two turns at a time to the
specified torque.
NOTE: Install new ring gear retaining bolts.
Install the ring gear.
All vehicles
6. NOTE: Using a suitable press, install the roller
bearing.
Using the special tool, install the differen-
tial roller bearing.
4. NOTE: The speedometer drive gear must snap
into position.
Install the speedometer drive gear.
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7. NOTE: Using a suitable press, install the roller
bearing.
tial roller bearing.
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ASSEMBLY
ASSEM BLY
Special Tool(s)
Mounting Plate for
303-435-14A
Remover/Installer, Front
Wheel Hub Bearing Race
204-017 Compressor, Valve Spring
303-060
Installer, Front Wheel Hub
Bearing Race/Oil Seal
204-050
Adapter for 303-060
303-060-02
Preload Gauge
205-067
Adapter for 303-060
303-060-07
Installer, Wheel Hub Oil Seal

205-075
Installer, Input Shaft Oil Seal
307-210
Installer, Drive Pinion Oil Seal

205-115 Holding Fixture, Dial Indicator
Gauge (Output Shaft Bearing
End Float)
308-194B
Socket, Drive Pinion Nut
205-175
General Equipment
Mounting Bracket, Hot air gun
Engine/Differential
Dial indicator gauge
205-329
Magnetic base for dial indicator gauge
Temperature reduction spray
Mounting Stand
303-435 Name Specification
Sealer WSK-M2G348-A5
Mounting Bracket for 303-435 Sealer ESKM-4G269-A

303-435-06
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3. CAUTION: The press force must not

Assembly exceed 15 kN.
NOTE: Install the bearing outer race using a
1. NOTE: Check, thoroughly clean and if suitable press.
necessary renew all components.
Using the special tool, install the input
NOTE: Do not oil the taper roller bearing. shaft bearing outer race into the
Coat all running surfaces with clean transmission housing.
transmission fluid before assembly. • Heat up the transmission housing to
2. NOTE: This operation is only necessary if the approximately 80°C using a hot air gun.
reverse gear idler shaft has been removed. • Cool the bearing outer races using tem-
NOTE: Install new reverse gear idler shaft perature reduction spray and install.
retaining bolts.
Install the reverse gear idler shaft.
1. Apply sealer to the housing in the area of
the of the reverse gear idler shaft mating
surface.
2. Install the reverse gear idler shaft with a
locating bolt.
3. Remove the locating bolts and screw in new
bolts (three bolts).

exceed 15 kN.
NOTE: Install the bearing outer race using a
suitable press.
Using the special tool, install the output
shaft bearing outer race into the
• Heat up the transmission housing to
approximately 80°C using a hot air gun.
• Cool the bearing outer races using tem-
perature reduction spray and install.
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5. CAUTION: The press force must not 7. CAUTION: The press force must not
exceed 15 kN. exceed 15 kN.
NOTE: Install the bearing outer race using a NOTE: Install the bearing outer race using a
suitable press. suitable press.
Using the special tool, install the Install the output shaft outer bearing race
differential bearing outer race into the in the clutch housing using the special
transmission housing. tool.
• Heat up the transmission housing to • Install a 1.00 mm measuring shim.
approximately 80°C using a hot air gun. • Heat up the clutch housing to approximately
• Cool the bearing outer races using tem- 80°C using a hot air gun.
perature reduction spray and install. • Cool the bearing outer races using tem-
perature reduction spray and install.

exceed 15 kN. 8. CAUTION: The press force must not
NOTE: Install the bearing outer race using a exceed 15 kN.
suitable press. NOTE: Install the bearing outer race using a
Using the special tool, install the input suitable press.
shaft bearing outer race into the clutch Install the differential bearing outer race in
housing. the clutch housing using the special tool.
• Install a 1.00 mm measuring shim. • Install a 1.10 mm measuring shim.
• Heat up the clutch housing to approximately • Heat up the clutch housing to approximately
80°C using a hot air gun. 80°C using a hot air gun.
• Cool the bearing outer races using tem- • Cool the bearing outer races using tem-
perature reduction spray and install. perature reduction spray and install.
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9. NOTE: Do not oil the taper roller bearing. 11. NOTE: Do not oil the taper roller bearing.
4, gear engaged. Install the differential.
12. NOTE: Ensure that the transmission housing

mating surfaces are clean.
Attach the transmission housing to the
clutch housing.
• Attach the special tool.
10. NOTE: Do not oil the taper roller bearing.

Install the input and output shafts to-
gether.
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13. Tighten the transmission housing bolts. 15. Align the input shaft for measuring using
1. Install the bolts. the special tool.
2. Install the studs. • Turn the input shaft approx. 20 times to
settle the bearings.

• Position the measuring rod on the 4th gear
wheel.
16. Attach the dial indicator gauge.

2. Attach the magnetic base for dial indicator
gauge.
3. Preload the dial indicator gauge to 1 mm
and zero.
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17. NOTE: Perform the measurements three 18. Align the output shaft for measuring.
times and calculate the average value from the • Turn the output shaft approx. 20 times to
measurements. Zero the dial indicator gauge settle the bearings (via input shaft, refer to
after each measurement. previous steps).
Measure the input shaft end float. • Attach the dial indicator gauge, preload to 1
1. Lift the input shaft using a suitable lever. mm and zero.
2. Note the measurement result, e.g. 0.22 mm.
• Example: 0.22 mm + 0.23 mm + 0.21 mm
divided by three = 0.22 mm.
19. NOTE: Carry out this and the following step

three times and calculate the average
measurement.
Measure the output shaft end float.
• Lift the output shaft with a suitable lever and
note the resulting measurement, e.g. 0.32
mm.
• Example: 0.32 m + 0.34 mm + 0.33 mm
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20. Prepare the differential for measuring 22. Calculate the required input shaft shim
using the special tool. thickness.
• Turn the input shaft 20 times while • Installed measurement shim thickness: 1.00
simultaneously pressing down the mm.
differential. • Measured input shaft end float: (e.g.) 0.22
• Preload the dial indicator gauge to 1 mm mm.
and zero. • Preload figure: -0.07 mm.
• Shim required: 0.22 mm - 0.07 mm + 1.00
mm = 1.15 mm.
23. Calculate the required output shaft shim
thickness.
• Installed measurement shim thickness: 1.00
mm.
• Measured output shaft end float: (e.g.) 0.33
mm.
• Preload figure: 0.13 mm.
• Shim required: 1.00 mm + 0.33 mm + 0.13
mm = 1.46 mm.
24. Calculate the required differential shim
thickness.
• Installed measurement shim thickness: 1.10
mm.
• Measured differential end float: (e.g.) 0.36
mm.
• Preload figure: 0.33 mm.
• Shim required: 1.10 mm + 0.33 mm + 0.13
mm = 1.79 mm.
25. Detach the transmission housing from the
clutch housing.
26. Remove the input shaft, output shaft and
21. NOTE: Carry out both this and the following differential.
step three times and calculate the average
value.
Measure the differential end float.
• Lift the differential using the special tool and
note the measurement, e.g. 0.34 mm.
• Example: 0.34 mm + 0.36 mm + 0.38 mm
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27. Remove the bearing outer races, refer to 29. Fabricate an installation hook for the
previous steps. reverse gear idler.
• Remove the input shaft bearing outer race. • Wire diameter: 3 mm
• Remove the output shaft bearing outer race.
• Remove the differential bearing outer race.
• Remove the measurement shims.
28. Install the shims and bearing outer races,
refer to previous steps.
1. Install the required shims, refer to previous
steps.
2. Install the bearing outer races.
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30. Install the reverse gear idler. 32. NOTE: Lubricate the taper roller bearing with
1. Install the lower thrust washer. transmission fluid.
2. Install the needle roller bearing. Install the input shaft and the output
3. Install the reverse gear idler (narrow collar shaft.
facing downwards). 1. Insert the input and output shafts together
4. Install the upper thrust washer. and move them to one side.
5. Install the reverse gear idler shaft mounting. 2. Remove the installation hook.
33. NOTE: The input shaft must be in the neutral

position.
Install the selector forks.
1. Install the 5th/reverse gear selector fork.
2. Install the 3rd/4th gear selector fork.
3. Install the 1st/2nd gear selector fork.
31. NOTE: Install the reverse gear idler with the

narrow collar facing downwards.
Insert the installation hook and install the
reverse gear idler shaft mounting.
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34. NOTE: If the holes for the bolts of the reverse 37. NOTE: Ensure that the threaded holes are
gear idler shaft mounting do not line up exactly, free of sealer.
check the installation position of the reverse
Apply sealer centrally to the indicated
gear idler shaft thrust washers.
areas of the transmission mating surface
Install the reverse gear mounting and apply inside the line of the threaded
retaining bolts. holes (bead diameter: 2 mm).
• Apply sealer to the bolts.
38. NOTE: The transmission housing must not be

35. NOTE: Ensure that the selector rods have the turned before tightening the bolts.
same installation height. Tighten the transmission housing bolts.
Install the selector rods. 1. Install the bolts.
2. Install the studs.
36. Install the differential.

• Install the magnetic disc. 39. Attach the gearshift cable abutment.
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40. NOTE: Ensure that no gear is engaged. 42. NOTE: Install new input shaft oil seals.
NOTE: Ensure that the selector mechanism is in Install the input shaft oil seals on both
the neutral position. sides using the special tool (right-hand
NOTE: Ensure that the threaded holes are free of side shown).
sealer.
NOTE: Observe the installation position of the
long bolt.
Apply sealer centrally to the transmission
mating surface and apply outside the line
of the threaded holes (bead diameter: 2
mm). Install the selector mechanism.
1. Install the long bolt.
2. Install the short bolts.
43. CAUTION: Wrap the input shaft

splines with adhesive tape in order to
protect the input shaft oil seal.
CAUTION: Do not lubricate the clutch
slave cylinder.
NOTE: Install new clutch slave cylinder bolts.
Install the clutch slave cylinder/release
bearing.
• Apply sealer to the mating surfaces of the
41. CAUTION: If the torque is too high, all clutch housing.
the measurements (to establish the
required shim thickness) must be • Attach the boot.
repeated.
Measure the torque using the special
tools.
• 4, gear engaged.

shaft splines.
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transmission from the mounting stand.
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INSTALLATION
Transaxle — 2.0L Duratec-HE (MI4) (16 114 0)
INST ALLAT ION
4. Move the transmission into position using

Special Tool(s) the transmission jack and install.
Support Bar, Engine

303-290A

303-290-03A

303-290-13 5. NOTE: Perform this and the following operation
simultaneously.
Install the right-hand transmission bolt.
303-290-15
General Equipment
Transmission jack
Retaining straps
Name Specification
High-temperature ESD-M1C220-A
grease 6. Install the left-hand transmission bolt.
Installation
All vehicles
CAUTION: Ensure that the two guide
2. Secure the transmission on the
transmission jack using suitable retaining
straps.
3. Thinly coat the input shaft splines with
grease. 7. Remove the retaining straps.
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9. Install the transmission right-hand retain- 13. Install the rear engine mounting bracket
ing bolts. (rear engine mounting shown removed for
clarity).
10. Install the transmission lower retaining

bolts. 14. NOTE: Install new bolt on the rear engine
mounting.
NOTE: Do not tighten the rear engine mounting
bolt for the moment.
Install bolt on the rear engine mounting.
11. Raise the engine / transmission assembly

slightly using the special tools.

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17. Install the radiator support bracket. 20. Attach the wiring harness bracket to the
• Install the radiator support bracket bolts engine.

18. Install the radiator support bracket bolts 22. Remove the special tool on both sides
(right-hand side shown). (right-hand side shown).
19. Attach the starter motor to the engine. 23. Remove the cable ties from the radiator.
24. Install the headlamp assembly on both
Headlamp Assembly]
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26. NOTE: Install new flexible pipe gaskets and 29. Install the cross brace.
nuts.
Attach the exhaust flexible pipe to the
catalytic converter.
30. Install the left-hand halfshaft. For additi-

27. Remove the support sleeve or reinforce-
ment from the flexible exhaust pipe. 31. Install the right-hand halfshaft. For additi-
32. Install the engine roll restrictors.
28. Hook the flexible pipe into the cross-

33. Install the crash box.

1. Insert the M10 x 16 bolt.
2. Insert the M10 x 25 bolts.
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34. Lower the vehicle. 37. CAUTION: If brake fluid comes into
35. Install the transmission upper retaining
bolts.
without delay.
• Attach the ground lead to the transmission.
Connect the clutch slave cylinder line to
• Attach the clutch slave cylinder pipe to the
bracket.
36. Tighten the bolt on the rear engine

mounting.

Bleeding]
abutment.
1. Attach the gearshift cable to the abutment
and secure by turning the catches
clockwise.
2. Attach the selector cable to the abutment
and secure by turning the catches clock-
wise.
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40. Install the gearshift cables on the shift 43. Attach the reversing lamp switch con-
mechanism. nector.
1. Press the gearshift cable catch and attach
the gearshift cable to the gear lever.
2. Press the selector cable catch and attach
the selector cable to the selector lever.

41. Adjust the selector cable. For additional
and Clutch - General Information, 45. Install the air cleaner. For additional
GENERAL PROCEDURES, Gearshift information, refer to Section 303-12.
Cable Adjustment - Vehicles With: [Intake Air Distribution and
5-Speed Manual Transaxle (MTX-75)] Filtering, REMOVAL AND INSTALLATION,
42. Attach the ground lead to the rear engine
Duratec-HE (MI4)]
mounting bracket.
46. With the vehicle on a level surface, fill the
• Attach the wiring harness bracket to the rear
transmission with transmission fluid until
engine mounting bracket.
the fluid level is just below the filler hole.
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48. Install the lower engine cover.
49. Install the lower radiator cover.

51. Initialize window operating motors. For
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308-03B-1 Manual Transmission/Transaxle — Vehicles With: 308-03B-1

SECTION 308-03B Manual Transmission/Transaxle —

Vehicles With: 6-Speed Manual Transaxle (MMT6)
CONTENTS PAGE
SPECIFICATIONS
Transmission Ratios........................................................................................................ 308-03B-2
Manual Transmission ....................................................................................................... 308-03B-4

Construction features, transmission differential side........................................................ 308-03B-4
Construction features, transmission differential side........................................................ 308-03B-5
Construction features on the input shaft side................................................................... 308-03B-5
Input shaft ....................................................................................................................... 308-03B-6
Input shaft ....................................................................................................................... 308-03B-7
Output shaft 1st/4th gear................................................................................................. 308-03B-7
Output shaft 1st/4th gear................................................................................................. 308-03B-8
Output shaft 5th/6th/reverse gear .................................................................................... 308-03B-9
Output shaft 5th/6th/reverse gear .................................................................................... 308-03B-10
Synchroniser assembly ................................................................................................... 308-03B-11
Differential assembly....................................................................................................... 308-03B-11
Power transmission in the individual gears...................................................................... 308-03B-12/14
Internal shift mechanism ................................................................................................. 308-03B-15
Internal shift mechanism ................................................................................................. 308-03B-15/16
Manual Transaxle — Vehicles With: Manual Transaxle.................................................... 308-03B-17
GENERAL PROCEDURES
Bearing Check ................................................................................................................. 308-03B-18/19
IN-VEHICLE REPAIR
Input Shaft Seal ............................................................................................................... 308-03B-20/21

Halfshaft Seal LH .......................................................................................... (14 303 0) 308-03B-22
Halfshaft Seal RH ......................................................................................... (14 304 0) 308-03B-23
Transaxle — 2.0L Duratorq-TDCi (DW) Diesel.............................................. (16 114 0) 308-03B-24/29
INSTALLATION
Transaxle — 2.0L Duratorq-TDCi (DW) Diesel.............................................. (16 114 0) 308-03B-30
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SPECIFICATIONS

Item Specification
Grease ESD-M1C220-A
Sealant WSK-M2G348-A5
Grease SA-M1C9107-A
Filling Capacities
Litres
Transmission fluid (0 - 5 mm below the lower edge of the filler hole) 1.75
Transmission Ratios
Internal Gearbox
2.0L diesel engine Ratio(s) Final Drive Ratio(s) Overall Ratio(s)
First gear 3.077 4.071 12.527
Second gear 1.864 4.071 7.588
Third gear 1.241 4.071 5.054
Fourth gear 0.842 4.071 3.429
Fifth gear 0.886 2.850 2.524
Sixth gear 0.711 2.850 2.025
Reverse gear 1.360 *(2.850 x 3.077) = 8.769 11.926
* The reverse gear final drive ratio is determined by the multiplication of the internal gearbox ratio of the first gear by
the final drive ratio of the 5th/6th/reverse gear output shaft.
Tightening Torques
Lower suspension arm to spindle carrier retaining 70 52 -
nuts
Stabilizer bar link to strut and spring assembly re- 48 35 -
taining nuts
Intermediate shaft center bearing retaining nuts 25 18 -
Transmission retaining bolts 48 35 -
Engine rear mounting bracket bolts 90 66 -
Engine rear mount retaining bolt 133 98 -
Engine rear mount nuts 48 35 -
Ground cable to transmission bolt 15 11 -
Transmission housing retaining bolts 32 24 -
Clutch slave cylinder bolts 10 - 89
Transmission filler pipe blanking plug 35 26 -
Transmission drainage pipe blanking plug 35 26 -
Selector mechanism bolts 26 19 -
Gearshift cable bracket bolts 30 22 -
Differential spur gear bolts 82 60 -
Input shaft bearing bracket retaining bolts 20 15 -
Input shaft retaining bolt 100 74 -
Output shaft retaining bolt - 1st - 4th gear (left-hand 100 74 -
thread)
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Output shaft retaining bolt - 5th/6th/reverse gear 100 74 -
(left-hand thread)
Strut and spring assembly top mount bolts 30 22 -
Catalytic converter to engine support bracket nuts 25 18 -
Radiator bracket bolts 25 18 -
Engine support insulator bolts 80 59 -
Headlamp levelling sensor bracket to suspension 8 - 71
lower arm
Starter motor bolts 35 26 -
Strut and spring assembly top mount brace nuts 25 18 -
Catalytic converter to turbocharger retaining clamp 25 18 -
Front muffler and tailpipe assembly retaining nuts 51 38 -
Crashbox retaining bolts 40 30 -
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Manual Transmission
Construction features, transmission

differential side

Number
6 - 3rd gear wheel
1 - Differential assembly
7 - 3rd/4th gear synchroniser
2 - Reverse gear idler assembly
3 - 1st gear wheel 8 - 4th gear wheel
4 - 1st/2nd gear synchroniser 9 - Output shaft 1st/4th gear
assembly
10 - Input shaft
5 - 2nd gear wheel
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Number Number
11 - Output shaft 5th/6th/reverse 18 - Clutch housing
gear
12 - 6th gear wheel
Construction features, transmission
13 - 5th/6th gear synchroniser differential side
assembly
All gear wheels are helical toothed and are
14 - 5th gear wheel constantly engaged
15 - Reverse gear synchroniser 5th, 6th and reverse gear have simple
assembly synchronisation. 1st to 4th gears are double
16 - Reverse gear wheel synchronised.
17 - Output shaft pinion

5th/6th/reverse gear Construction features on the input shaft side.
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Number Number
1 - Output shaft 5th/6th/reverse 11 - 3rd gear wheel
gear
12 - Shift fork, 5th/6th gear syn-
2 - Input shaft chroniser assembly
3 - Output shaft 1st/4th gear 13 - 4th/6th gear wheel
4 - Shift fork, 3rd/4th gear syn- All driving gear wheels of the transmission are
chroniser assembly located on the input shaft.
5 - Shift fork, 1st/2nd gear syn- The input shaft is a solid shaft and runs on one ball
chroniser assembly bearing and one roller bearing.
6 - Clutch housing Because of this mounting the input shafts runs
without preload and therefore needs no adjusting
7 - 1st gear wheel
shims.
8 - 2nd gear wheel
The input shaft seal nearest the clutch is pressed
9 - 5th gear wheel into the clutch housing.
10 - Shift fork, reverse gear syn-
chroniser assembly
Input shaft

Number
3 - 1st gear wheel
1 - Clutch housing roller bearing
4 - 2nd gear wheel
2 - Oil seal
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Number
5 - 5th gear wheel
6 - 3rd gear wheel
7 - Bearing retainer
8 - Bearing retaining screw
9 - 4th/6th gear wheel
Input shaft
NOTE: Pay attention to the correct seating of the
The gear wheels for 1st and 2nd gear are an oil collector ring during installation.
integral part of the input shaft. The gearwheels for
The oil thrower and the oil collector ring form one
3rd and 5th gears and the gearwheel for 4th/6th
unit which guides the transmission oil into the
gear are pressed on.
oilway of the hollow shaft.
Because of the high force used to press on the
Incorrect seating of the oil collector ring can result
components, the gear wheels cannot be pressed
in a loss of transmission fluid pressure in the
off in service. A faulty input shaft can only be
output shaft and thus in loss of lubrication.
replaced as a complete unit.
Defective bearings can be pressed off and
changed.
Output shaft 1st/4th gear

The 1st/4th gear output shaft runs on tapered
roller bearings.
This bearing arrangement requires the shaft to be
preloaded. Please refer to the workshop literature
for further information on how to measure the
preload.
The output pinion of the 1st/4th gear output shaft
is an integral part of the shaft.
The synchroniser assemblies of the 1st/2nd and NOTE: Adhere to the specified installation depth
the 3rd/4th gears are located on the output shaft. when installing a new oil collector ring.
The 1st/4th gear output shaft is a hollow shaft. Please refer to the workshop literature for the
exact value and procedure.
Internal oilways provide lubrication to the needle
roller bearings and the synchroniser assemblies.
An oil collector ring is installed in each of the two
output shafts on the clutch side.
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Output shaft 1st/4th gear

Number
5 - 4th gear synchroniser cone
1 - Taper roller bearing, trans-
mission housing 6 - Outer synchroniser ring - 4th
gear
2 - 4th gear wheel
7 - Snap ring
3 - Needle bearing
8 - Synchroniser assembly -
4 - Inner synchroniser ring 3rd/4th gear
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Item Part Description The 5th/6th/reverse gear output shaft is a hollow
Number shaft.
9 - Outer synchroniser ring - 3rd Internal oil passages provide lubrication to the
gear needle roller bearings and the synchronizer
assemblies.
10 - 3rd gear synchroniser cone
11 - Inner synchroniser ring
12 - 3rd gear wheel
13 - Needle bearing
14 - Thrust washers
15 - 2nd gear wheel
16 - Needle bearing
18 - 2nd gear synchroniser cone
19 - Outer synchroniser ring - 2nd
gear
20 - Snap ring
21 - Synchroniser assembly -
1st/2nd gear
22 - Outer synchroniser ring - 1st
gear
23 - 1st gear synchroniser cone
25 - 1st gear wheel
26 - Needle bearing
27 - Output shaft 1st/4th gear
28 - Oil collector ring
29 - Taper roller bearing, clutch
housing
30 - Bearing retaining bolt
(left-hand thread)
Output shaft 5th/6th/reverse gear

The 5th/6th/reverse gear output shaft runs on
tapered roller bearings.
pre-load.
The output pinion is an integral part of the shaft.
The synchroniser assemblies for the 5th/6th gears
and the reverse gear are located on the shaft.
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Output shaft 5th/6th/reverse gear

Number
4 - 6th gear synchroniser ring
1 - Transmission housing taper
roller bearing 5 - Snap ring
2 - Needle bearing 6 - Synchroniser assembly -

5th/6th gear
3 - 6th gear wheel
7 - 5th gear synchroniser ring
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Number Number
8 - Thrust washers 1 - Sliding block assembly
9 - Needle bearing 2 - Synchroniser hub
10 - 5th gear wheel 3 - Sliding collar
11 - Snap ring The synchroniser assemblies have been
12 - Oil collector ring reworked for the MMT6/6-speed manual
transmission.
housing The detent balls, springs and sliding blocks form
one unit.
14 - Output shaft 5th/6th/reverse
This arrangement makes it easier to service the
gear
synchroniser assembly.
15 - Reverse gear wheel
16 - Needle bearing
Differential assembly
17 - Reverse gear synchroniser
The differential is identical to the differential of the
ring
MTX-75 (diesel).
18 - Synchroniser assembly, re- Because the Vehicle Speed Sensor (VSS) is
verse gear discontinued, so is the sender wheel.
19 - Bearing retaining bolt The ABS wheel speed sensors send the current
(left-hand thread) wheel speed to the Powertrain Control Module
(PCM).
The differential is mounted on taper roller
Synchroniser assembly bearings.
pre-load.
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NOTE: The three shafts are shown away from

Item Part Description their real positions for clarity.
Number
1 - Taper roller bearing, trans- Power flow, 1st gear
mission housing
2 - Differential assembly
housing
4 - Bearing shell, taper roller
bearing
5 - Crown wheel bolts
6 - Crown wheel
7 - Bearing shell, taper roller
bearing
The 1st gear wheel is positively connected to the

Power transmission in the individual gears 1st to 4th gear output shaft by the 1st/2nd gear
synchroniser assembly so that power can be
The following diagrams show a schematic transmitted.
representation of the power flow.
The power flow occurs though the positively
engaged pair of gears onto the output pinion of the
output shaft/s and thus onto the crownwheel of the
differential.
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Power flow, 2nd gear The 4th gear wheel is positively connected to the
1st to 4th gear output shaft by the 3rd/4th gear
transmitted.
Power flow, 5th gear
The 2nd gear wheel is positively connected to the

1st to 4th gear output shaft by the 1st/2nd gear
transmitted.
Power flow, 3rd gear The 5th gear wheel is positively connected to the
5th/6th/reverse gear output shaft by the 5th/6th
gear synchroniser assembly so that power can be
transmitted.
Power flow, 6th gear
The 3rd gear wheel is positively connected to the

1st to 4th gear output shaft by the 3rd/4th gear
transmitted.
Power flow, 4th gear The gear wheel of the 4th/6th gear drives not only
the gear wheel of the 4th gear but also of the 6th
gear.
The 6th gear wheel is positively connected to the
5th/6th/reverse gear output shaft by the 5th/6th
gear synchroniser assembly so that power can be
transmitted.
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Power flow, reverse gear
The reverse gear idler is welded to the 1st gear

wheel. It is constantly engaged with the reverse
gear wheel (shown separated for clarity).
The reverse gear wheel is positively connected to
the 5th/6th/reverse gear output shaft by the
reverse gear synchroniser assembly so that
power can be transmitted.
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Internal shift mechanism

Number Internal shift mechanism
1 - Counterbalance The internal shift mechanism has been newly
developed for this transmission.
2 - Reverse gear switch
The reverse gear switch is located on the housing
3 - Selector shaft cover of the internal shift mechanism.
4 - Selector gate The counterbalance improves the smoothness of
the gear shifting. Due to its mass, the
synchronization shift resistances that can be felt
during shifting are reduced. The gear shifting
process becomes smoother.
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The internal shift mechanism can only be changed
as a complete unit in service.
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Manual Transaxle — Vehicles With: Manual Transaxle
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GENERAL PROCEDURES
Bearing Check

necessary.
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hardness.
lubrication.
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IN-VEHICLE REPAIR
Input Shaft Seal
IN-VEH ICLE R EPAIR
3. CAUTION: Do not damage the input

Special Tool(s)
shaft roller bearing.
Remover, Crankshaft Rear NOTE: Carry out operation step only at the
Oil Seal position shown.
303-336 (21-151) Using the special tool make a hole in the
input shaft oil seal.
1. Input shaft
Installer, Output Drive 2. Input shaft oil seal
Flange Oil Seal 3. Input shaft roller bearing
308-112 (16-043A)
General Equipment
Self-tapping screw 2.5 x 15 mm
Removal
1. Remove the transmission. For additional
information, refer to Transaxle - 2.0L
2. Remove the clutch slave cylinder. For additi-
onal information, refer to Section 308-02B.
[Clutch Controls - Vehicles With: 4. CAUTION: Do not damage the input
6-Speed Manual Transaxle (MMT6), shaft roller bearing.
REMOVAL AND INSTALLATION, Clutch NOTE: Carry out operation step only at the
Slave Cylinder] position shown.
Remove and discard the input shaft oil
seal.
• Screw a 2.5 x 15 mm self tapping screw no
more than two turns into the input shaft oil
seal.
• Pull out the input shaft oil seal with pliers.
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Installation
1. CAUTION: Apply adhesive tape over
the splines of the input shaft to
prevent the input shaft oil seal being
damaged.
NOTE: Install a new input shaft oil seal.
Install the input shaft oil seal with the spe-
cial tool.

shaft splines.
3. Install the clutch slave cylinder assembly.
For additional information, refer to Section 308-02B.
6-Speed Manual Transaxle (MMT6),
Slave Cylinder]
4. Install the transmission. For additional
information, refer to Transaxle - 2.0L
Bleeding]
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IN-VEHICLE REPAIR
Installation
Special Tool(s)
cial tool.

308-208
Removal
2. Remove the halfshaft oil seal using the 2. Install the left-hand halfshaft. For additi-
special tool. onal information, refer to Section 205-04.
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IN-VEHICLE REPAIR
Installation
Special Tool(s)
cial tool.

308-208
Removal
2. Remove the halfshaft oil seal using the
special tool.
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REMOVAL
Transaxle — 2.0L Duratorq-TDCi (DW) Diesel (16 114 0)
REMOVAL

Special Tool(s) information, refer to Section 303-12.[Intake
Engine support bar AND INSTALLATION, Air Cleaner - 2.0L
303-290A Duratorq-TDCi (DW) Diesel]
303-290-03A Tray - 2.0LDuratorq-TDCi (DW) Diesel]

Adapter for 303-290A without delay.
303-290-13
cylinder pipe to prevent fluid loss or dirt
ingress.
Detach the clutch slave cylinder pipe from
303-290-15
• Detach the clutch slave cylinder pipe from
the bracket.
General Equipment
Transmission jack
Retaining straps
Cable ties
Removal
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REMOVAL (Continued)
5. Disconnect the reversing lamp electrical 8. Detach the starter motor from the transaxle
connector. and secure it to one side.
• Remove the wiring harness bracket.

transaxle. 9. Remove the transaxle upper retaining
1. Detach the gearshift and selector cables bolts.
the gearshift cables from the abutment.

7. Detach the ground cables from the trans- REMOVAL AND INSTALLATION,
axle. Headlamp Assembly]
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REMOVAL (Continued)
12. Secure the radiator on the hood lock 17. Remove the cross brace.
panel using cable ties.
18. Install a support sleeve or reinforcement

on the flexible exhaust pipe.
15. Detach the intercooler outlet pipe from

the intercooler.
• Remove the hose clamps.
19. Detach the flexible pipe from the cross-

16. Remove the crashbox.
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REMOVAL (Continued)
20. Detach the catalytic converter clamp from 23. Remove the engine roll restrictors.
the turbocharger.

21. Detach the catalytic converter from the additional information, refer to Section
flexible pipe. 205-04.[Front Drive Halfshafts, REMOVAL
• Discard the gasket and retaining nuts. AND INSTALLATION, Halfshaft LH]
26. Remove the radiator lower cover.
22. Remove the catalytic converter mounting 27. Disconnect the glow plug relay electrical
bracket. connector.
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REMOVAL (Continued)
28. Remove the radiator support bracket 31. Install the special tools.
bolts (left-hand side shown).
32. Attach the special tools.

29. Remove the radiator support bracket
bolts (right-hand side shown).
• Remove the radiator support bracket.

34. Remove the bolt of the rear engine
mounting.
30. Remove the clutch housing cover. • Discard the bolt.
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REMOVAL (Continued)
35. Remove the bolts of the rear engine 39. Remove the transaxle lower retaining
mounting (rear engine mounting shown bolts.
removed for clarity). • Remove the wiring harness bracket.
36. Raise and support the vehicle. 40. Use suitable retaining straps to secure
37. Lower the engine/transaxle assembly the transaxle to the transmission jack.
41. Remove the left-hand transaxle bolt.

38. Remove the rear engine mounting
bracket.
• Remove the bolts of the rear engine
mounting.
42. Support the transaxle using

thetransmission jack and remove it.
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INSTALLATION
Transaxle — 2.0L Duratorq-TDCi (DW) Diesel (16 114 0)
INST ALLAT ION
4. Move the transaxle into position using the

Special Tool(s) transmission jack and install it.
Engine support bar

303-290A

303-290-03A

303-290-13
bolt.
303-290-15
General Equipment
Transmission jack
Retaining straps
Name Specification
High-temperature ESD-M1C220-A
6. Remove the retaining straps.
grease
grease SA-M1C9107-A
• Install the wiring harness bracket.
Installation
All Vehicles
CAUTION: Ensure that the two guide
2. Use suitable retaining straps to secure the
transaxle to the transmission jack.
3. Coat the input shaft splines with a thin
coating of grease.
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9. Install the rear engine mounting bracket. 13. NOTE: Install a new bolt on the rear engine
• Install the bolts of the rear engine mounting. mounting.
NOTE: Do not tighten the bolt of the rear engine
mounting for the moment.
Install the bolt of the rear engine mount-
ing.
10. Raise the engine / transmission assembly

slightly using the special tools.


12. Install the bolts of the rear engine
mounting (rear engine mounting shown
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18. Remove the special tool on both sides
(right-hand side shown). 23. Connect the glow plug relay electrical
connector.
19. Install the headlamp assembly on both 24. Install the radiator lower cover.
Headlamp Assembly]
21. Install the radiator support bracket.
• Install the radiator support bracket bolts
25. Install the clutch pedal cover.
22. Install the radiator support bracket bolts


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28. Install the engine roll restrictors. 31. Remove the support sleeve or reinforce-
ment from the flexible exhaust pipe.
29. Install the catalytic converter bracket.

32. Hook the flexible pipe into the cross-
30. NOTE: Install a new gasket and new nuts.

Attach the catalytic converter to the
flexible pipe. 33. Attach the catalytic converter clamp to
the turbocharger.
• Coat the catalytic converter studs with
grease before installing.
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34. Install the cross brace. 39. Install the transmission upper bolts.
35. Install the crashbox. 40. Attach the starter motor to the transaxle.
1. Install the M10 x 16 bolt. • Install the wiring harness bracket.
2. Install the M10 x 25 bolts.
41. Install the ground lead on the transaxle.

36. Attach the intercooler outlet pipe to the
intercooler.
• Install the hose clamps.
• Install the bolts.

38. Remove the cable ties from the radiator.
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42. Attach the gearshift cables at the 46. Connect the reversing lamp electrical
transaxle. connector.
1. Attach the gearshift cables at the abutment.
2. Attach the gearshift and selector cables at
the selector mechanism.
47. Tighten the bolt of the rear engine

mounting.
43. Adjust the selector cable. For additional

6-Speed Manual Transaxle (MMT6)]
without delay.
Attach the clutch slave cylinder pipe to
the clutch slave cylinder. 48. Install the battery carrier. For additional
• Install the spring clip. information, refer to Section 414-01.
• Attach the clutch slave cylinder pipe to the [Battery, Mounting and Cables,
bracket. REMOVAL AND INSTALLATION, Battery
Tray - 2.0L Duratorq-TDCi (DW) Diesel]
Air Cleaner - 2.0L Duratorq-TDCi (DW)
Diesel]
45. Bleed the clutch system.
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50. With the vehicle on a level surface, fill the Mechanisms, GENERAL PROCEDURES,
transaxle with transmission fluid until the Door Window Motor Initialization]
fluid level is just below the filler hole.



55. Initialise the window regulator motors.
Section 501-11.[Glass, Frames and
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308-03C-1 Manual Transmission/Transaxle — Vehicles With: 308-03C-1

SECTION 308-03C Manual Transmission/Transaxle —

Vehicles With: 5-Speed Manual Transaxle (F35M-R)
CONTENTS PAGE
SPECIFICATIONS
Specifications................................................................................................................. 308-03C-2/4
Manual Transaxle .......................................................................................................... 308-03C-5
GENERAL PROCEDURES
Bearing Check ............................................................................................................... 308-03C-6/7
IN-VEHICLE REPAIR
Halfshaft Seal LH ..........................................................................................(14 303 0) 308-03C-8

Halfshaft Seal RH .........................................................................................(14 304 0) 308-03C-9
Transaxle ......................................................................................................(16 114 0) 308-03C-10/14
DISASSEMBLY
Transaxle ....................................................................................................................... 308-03C-15/23
Input Shaft ..................................................................................................................... 308-03C-24/32

Output Shaft................................................................................................................... 308-03C-32/39
Differential...................................................................................................................... 308-03C-40/44
ASSEMBLY
Transaxle ....................................................................................................................... 308-03C-45/59
INSTALLATION
Transaxle ......................................................................................................(16 114 0) 308-03C-60
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SPECIFICATIONS

Item Specification
High-Temperature Grease ESD-M1C220-A
Gear wheel clearance

Gear wheel inner Output shaft outer
Gear wheel diameter mm diameter mm (in) Clearance mm (in)
1st gear wheel 39.50 - 39.52 (1.555 - 39.45 - 39.47 (1.553 - 0.03 - 0.07 (0.002 - 0.003)
1.556) 1.554)
2nd gear wheel 35.20 - 35.22 (1.386 - 35.15 - 35.17 (1.384 - 0.03 - 0.07 (0.002 - 0.003)
1.387) 1.385)
Gear wheel inner Input shaft outer
Gear wheel diameter mm (in) diameter mm (in) Clearance mm (in)
3rd gear wheel 35.21 - 35.23 (1.386 - 35.15 - 35.17 (1.384 - 0.040 - 0.080 ( 0.0016 -
1.387) 1.385) 0.0031)
4th gear wheel 32.01 - 31.03 ( 1.260 - 31.95 - 31.97 (1.258 -
1.261) 1.259)
Gear wheel inner Fifth gear wheel sleeve
Gear wheel diameter mm (in) outer diameter mm (in) Clearance mm (in)
5th gear wheel 34.01 - 34.03 (1.3390 - 33.94 - 33.97 (1.3363 - 0.04 - 0.090 (0.0016 -
1.3397) 1.3374) 0.0035)
Thrust clearance
Gear Clearance mm (in) Maximum mm (in)
1st gear 0.05 - 0.28 (0.002 - 0.011) 0.33 (0.013)
2nd gear 0.18 - 0.51 (0.007 - 0.020) 0.56 (0.022)
3rd gear 0.06 - 0.21 (0.002 - 0.008) 0.26 (0.010)
4th gear 0.21 - 0.61 (0.008 - 0.024) 0.66 (0.026)
5th gear 0.06 - 0.26 (0.0024 - 0.0102) 0.31 (0.0122)
Shift fork and hub sleeve clearance

Clearance between Standard mm (in) Maximum mm (in)
1st/2nd shift fork and hub sleeve 0.10 - 0.36 (0.004 - 0.014) 0.86 (0.034)
3rd/4th shift fork and hub sleeve 0.20 - 0.50 (0.008 - 0.020) 1.00 (0.039)
5th shift fork and hub sleeve 0.40 - 0.75 (0.016 - 0.029) 1.25 (0.049)
Synchronizer ring clearance

Clearance between Standard mm (in) Minimum mm (in)
First gear wheel synchronizer cone 1.30 - 1.70 (0.052 - 0.066) 1.00 ( 0.039)
assembly and first gear wheel
Third gear wheel synchronizer ring and 1.12 - 1.88 (0.044 - 0.074) 0.80 (0.031)
third gear wheel
5th/Reverse synchronizer ring and flank
surface of gear
Reverse gear idler and reverse lever clearance

Standard mm (in) Maximum mm (in)
0.10 - 0.32 (0.004 - 0.013) 0.37 (0.015)
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Synchronizer lock size

Size at Length mm (in) Height mm (in) Thickness mm (in)
First, second and reverse gear 19.00 (0.748) 4.25 (0.167) 5.00 (0.197)
synchronizer hub
Third and fourth gear synchro- 17.00 (0.669)
nizer hub
Fifth gear wheel synchronizer 17.00 (0.669)
hub
Input shaft bearing race adjustment shims

Shim Thickness (mm) Shim Thickness (in)
0.10 0.004
0.20 0.008
0.30 0.012
0.40 0.016
0.50 0.020
0.60 0.024
Output shaft bearing race adjustment shims

0.15 0.006
0.20 0.008
0.25 0.010
0.30 0.012
0.35 0.014
0.40 0.016
0.45 0.018
0.50 0.020
0.55 0.022
0.60 0.024
0.65 0.026
0.70 0.028
Differential bearing race adjustment shims

0.10 0.004
0.15 0.006
0.20 0.008
0.25 0.010
0.30 0.012
0.35 0.014
0.40 0.016
0.45 0.018
0.50 0.020
0.55 0.022
0.60 0.024
0.65 0.026
0.70 0.028
0.75 0.030
0.80 0.031
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0.85 0.033
0.90 0.035
Differential pinion gear backlash

Backlash mm (in) Thrust washer thickness mm (in)
0 - 0.1 (0 - 0.004) 2.0, 2.1, 2.2 (0.079, 0.083, 0.087)
Transaxle shaft runout

Shaft Runout mm (in) Thrust Clearance mm (in)
Input shaft runout at third gear wheel 0.050 (0.0020) 0.005 - 0.100 (0.0002 - 0.0039)
position
Output shaft runout at second gear -
wheel position
Description Nm lb - ft lb - in
Engine and transaxle rear mount retaining bracket 80 59 -
retaining nuts
Engine rear mount retaining bolt 80 59 -
Crash-box retaining bolts 40 30 -
Engine support insulator 80 59 -
Exhaust flexible pipe to catalytic converter retaining 51 38 -
nuts
Transaxle wiring harness bracket retaining bolts 23 17 -
Transaxle ground cable retaining bolt 10 - 89
Transaxle housing retaining bolts 22 16 -
Input shaft retaining nut 150 111 -
Output shaft retaining nut 150 111 -
Fifth and reverse gear shift rod extension retaining 13 10 -
bolt
Fluid deflecting plate retaining bolt 10 - 89
Selector mechanism retaining bolts 22 16 -
Selector mechanism control end retaining bolt 30 22 -
Fluid drain plug 49 36 -
Differential guide plate right-hand retaining bolt 10 - 89
Differential guide plate left-hand retaining bolt 22 16 -
Shift lever assembly 22 16 -
Reversing lamp switch 25 18 -
Neutral switch 25 18 -
Differential preload 0.03 - 2.00 - 0.26 - 14.7
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Manual Transaxle
1. REFER to Section 308-00.[Manual

Transmission/Transaxle and Clutch - General
Information, DIAGNOSIS AND TESTING,
Manual Transaxle and Clutch]
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GENERAL PROCEDURES
Bearing Check

necessary.
G21559 en 09/2004 2004.75 Focus

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hardness.
lubrication.
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IN-VEHICLE REPAIR
IN-VEH ICLE R EPAIR
Installation
Special Tool(s)
1. Using the special tool, install the halfshaft
Installer, Drive Pinion Seal seal.
205-115 (15-058)

308-208 (16-074)
Name Specification
Removal 2. Install the left-hand halfshaft. For

1. Remove the left-hand halfshaft. For [Front Drive Halfshafts, REMOVAL
additional information, refer to Section 205-04. AND INSTALLATION, Halfshaft LH]
[Front Drive Halfshafts, REMOVAL 3. With the vehicle on a level surface, fill the
AND INSTALLATION, Halfshaft LH] transaxle with transmission fluid until the
2. Using the special tool, remove the halfshaft fluid level is just below the bottom of the
seal. filler hole.
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IN-VEHICLE REPAIR
Installation
Special Tool(s)
1. Using the special tool, install the halfshaft
Remover, Drive Pinion Seal seal.
205-078 (15-048)
Installer, Halfshaft Seal

308-039 (16-018)
Name Specification
fluid
Removal [Front Drive Halfshafts, REMOVAL
1. Remove the right-hand halfshaft. For additi- 3. With the vehicle on a level surface, fill the
onal information, refer to Section 205-04. transaxle with transmission fluid until the
[Front Drive Halfshafts, REMOVAL fluid level is just below the bottom of the
AND INSTALLATION, Halfshaft RH] filler hole.
2. Using the special tool, remove the halfshaft
seal.
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REMOVAL
REMOVAL
5. Disconnect the reversing lamp and the

Special Tool(s) neutral switch electrical connectors.
Support Bar, Engine

303-290A

303-290-13

303-290-15
6. Disconnect the vehicle speed sensor (VSS)
elecrical connector.
General Equipment
Retaining strap
Transmission jack
Removal
(Z6)] 7. Remove the transaxle wiring harness.
Tray - 1.6L (Z6)]
Assembly]
4. Using suitable cable ties, secure the
radiator to the radiator grille opening panel.
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REMOVAL (Continued)
8. Remove the transaxle wiring harness 12. Remove the right-hand side radiator
bracket. support bracket retaining bolts.
9. Remove the starter motor. For additional 13. CAUTION: Over bending of the
information, refer to Section 303-06. exhaust flexible pipe may cause
[Starting System, REMOVAL AND damage resulting in failure.
INSTALLATION, Starter Motor - 1.6L (Z6)]
onal information, refer to Section100-02.
[Jacking and Lifting,
DESCRIPTION AND OPERATION,Jacking]
11. Remove the left-hand side radiator sup-
port bracket retaining bolts.

crossmember exhaust hanger insulators.
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REMOVAL (Continued)
15. Detach the exhaust flexible pipe from the 19. Install the special tools on both sides
catalytic converter. (right-hand side shown).


205-04.[Front Drive Halfshafts, REMOVAL
18. Remove the right-hand halfshaft. For
205-04.[Front Drive Halfshafts, REMOVAL
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REMOVAL (Continued)
22. Install the special tools. 25. Detach the gearshift cables from the
transaxle.
1. Detach the gearshift and selector cables
the gearshift and selector cables from the
bracket.

water.
Disconnect the clutch slave cylinder
supply line.
26. Remove the engine and transaxle rear
• Remove the spring clip. mount.

27. Remove the engine and transaxle rear
mount retaining bracket.
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REMOVAL (Continued)
28. Raise and support the vehicle. For 33. NOTE: Secure the transaxle with a retaining
additional information, refer to Section strap.
100-02.[Jacking and Lifting,
Using a suitable transmission jack, sup-
port the transaxle.
29. Using the special tools, lower the engine

bolts.

bolts.
35. Using a suitable transmission jack, re-

move the transaxle.

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DISASSEMBLY
Transaxle
DISASSEM BLY
1. Using the special tools, mount the trans-

Special Tool(s)
axle to the mounting stand.
205-175
Mounting Bracket,
Engine/Differential
205-329
Monting Stand
303-435
2. Drain the transaxle fluid.

• Allow the fluid to drain into a suitable
Mounting Bracket for 303-435 container.
303-435-06 3. Disassemble the components in the order
table(s).

Bushing/Seal
308-045
General Equipment
Calliper gauge
Drift
Feeler gauge
CAUTION: Use vise jaw protectors.

CAUTION: Use a copper or plastic mallet
to prevent damage.
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DISASSEMBLY

Number
11 - Fifth gear wheel synchro-
1 - Fifth gear housing cover re- nizer ring
taining bolts
12 - Fifth gear wheel
2 - Fifth gear housing cover See Disassembly Detail
3 - Input shaft retaining nut 13 - Fifth gear wheel sleeve
14 - Fifth gear
4 - Output shaft retaining nut
See Disassembly Detail 15 - Retaining bolt
5 - Fifth gear wheel synchro- 16 - Washer

nizer sleeve 17 - Retaining bolt
6 - Fifth gear wheel synchro- 18 - Reversing lamp switch
nizer cone
19 - Reversing lamp switch
7 - Fifth gear wheel retaining washer
plate
20 - Transaxle housing retaining
8 - Fifth gear wheel selector fork bolts
9 - Fifth gear wheel selector fork 21 - Transaxle housing
retaining pin
22 - Fifth gear synchronizer
10 - Fifth gear wheel synchro- spring
nizer hub
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Number Number
23 - Fifth gear synchronizer 25 - Fifth gear synchronizer hub
24 - Fifth gear synchronizer lock

Number
34 - Fifth and reverse gear shift
26 - Neutral switch rod snap ring
27 - Neutral switch washer 35 - Selector lever retaining pin
28 - Permanent magnet 36 - Selector lever
29 - Reverse gear idler lever 37 - O-ring
30 - Reverse gear idler 38 - Selector lever fork
39 - Push pin
rod extension retaining bolt 40 - Push pin spring
32 - Fifth and reverse gear shift 41 - Selector fork assembly

rod extension See Disassembly Detail
33 - Fifth and reverse gear shift 42 - Input shaft

rod 43 - Output shaft
44 - Differential
G385341 en 09/2004 2004.75 Focus

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Number Number
45 - Clutch housing 50 - Selector fork first/second
gear
46 - Selector fork third/fourth gear
51 - Control rod end
47 - Shift lock
52 - Control rod end retaining pin
48 - Control rod bushing
53 - Control rod
49 - Control rod bushing retaining
pin

Number
61 - Selector retaining pin
54 - Input shaft seal See Disassembly Detail
55 - Output shaft bearing race 62 - Selector
56 - Oil funnel 63 - Selector change arm retain-
57 - Differential guide plate re- ing pin
taining bolts 64 - Selector change arm
58 - Differential guide plate 65 - Control rod
59 - Differential guide plate 66 - Transaxle breather cover
bushing
67 - Transaxle breather
60 - Sealing cap
See Disassembly Detail 68 - Vehicle speed sensor (VSS)
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Number Number
69 - Differential seal 73 - Reverse lever
70 - Differential bearing race 74 - Reverse lever shaft
75 - Reverse lever shaft plug
71 - Reverse lever spring
76 - Fluid drain plug
72 - Reverse lever spring retain-
77 - Fluid drain plug washer
ing pin

Number
83 - Differential seal
78 - Transaxle bearing race
See Disassembly Detail 84 - Selector mechanism retain-
ing bolts
79 - Transaxle bearing race ad-
justment shim 85 - Selector mechanism retain-
ing pin
80 - Transaxle bearing race ad-
justment shim 86 - Selector mechanism
81 - Differential bearing race 87 - Selector mechanism control

See Disassembly Detail end retaining bolt
82 - Differential bearing race ad- 88 - Selector mechanism control

justment shim end washer
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Item Part Description Item 4 : Output shaft retaining nut
Number 1. Using the special tool and a suitable
wrench, lock the input shaft and remove
89 - Selector mechanism control the output shaft retaining nut.
end lock
90 - Selector mechanism control
end
end spring
end spring washer
93 - Selector shaft
94 - Seal
95 - Fluid deflecting plate retain-
ing bolt
96 - Fluid deflecting plate Item 12 : Fifth gear wheel
1. Using a suitable feeler gauge, measure the
Disassembly Details clearance between the fifth gear wheel and
the fifth gear wheel synchronizer ring.
Item 3 : Input shaft retaining nut • If the clearance is less than the minimum
1. Using the special tool and a suitable specification, install a new fifth gear wheel
wrench, lock the input shaft and remove synchronizer ring.
the input shaft retaining nut. • Standard clearance: 1.12 mm - 1.88 mm.
• Minimum clearance: 0.80 mm.
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2. Using a suitable dial indicator gauge and a Item 30 : Reverse gear idler
calliper gauge, measure the clearance 1. Using a suitable feeler gauge, measure the
between the fifth gear wheel and the fifth clearance between the reverse gear idler
gear wheel sleeve. and the reverse gear idler lever.
• If the clearance is not within specification, • If the clearance is greater than the
install new components as necessary. maximum specification, install a new
• Fifth gear wheel inner diameter: 34.01 mm - reverse gear idler and a new reverse gear
34.03 mm. idler lever as a set.
• Fifth gear wheel sleeve outer diameter: • Standard clearance: 0.10 mm - 0.32 mm.
33.94 mm - 33.97 mm. • Maximum clearance: 0.37 mm.
• Standard clearance: 0.04 mm - 0.09 mm
Item 23 : Fifth gear synchronizer

NOTE: Inspect the third and fifth gear
synchronizer for damage and wear and install new
components as necessary. Item 41 : Selector fork assembly
1. Using a suitable feeler gauge, measure the 1. Align the shift lock and the control rod
clearance between the fifth gear bushing.
synchronizer and the selector fork. • Rotate the control rod counterclockwise.
• If the clearance is greater than the
maximum specification, install a new first,
second and reverse gear synchronizer and
a new selector fork as a set.
• Standard clearance: 0.40 mm - 0.75 mm.
• Maximum clearance: 1.25 mm.
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2. Release the control rod end by shifting the 2. Using a suitable drift, remove the sealing
gears. cap.
3. Remove the selector fork assembly.

• Raise the control rod end and the selector
fork assembly. Item 61 : Selector retaining pin
1. Using a suitable drift, remove the selector
retaining pin.
• Align the selector with the clutch housing as
shown.
Item 60 : Sealing cap

1. Move the control rod in the direction
shown. Item 70 : Differential bearing race
ential bearing race.
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Item 78 : Transaxle bearing race
1. Using the special tool, remove the trans-
axle bearing race.
Item 81 : Differential bearing race

ential bearing race.
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Input Shaft
General Equipment
Special Tool(s)
Feeler gauge
Remover, Bearing/Gear Two-leg puller
205-310
Name Specification
Remover, Bearing/Gear 1. Disassemble the components in the order
205-311
table(s).

Bushing/Seal
308-045
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Number Number
1 - Input shaft rear bearing 8 - Input shaft front bearing
See Disassembly Detail See Disassembly Detail
2 - Fourth gear wheel 9 - Input shaft
3 - Fourth gear wheel synchro- 10 - Synchronizer spring
nizer ring
11 - Selector ring
4 - Snap ring
12 - Synchronizer lock
5 - Third and fourth gear
13 - Synchronizer hub
synchronizer hub assembly
6 - Third gear wheel synchro- procedure.
nizer ring
7 - Third gear wheel NOTE: Coat all components with clean
transmission oil before assembly.

Number
5 - Input shaft
1 - Synchronizer hub See Assembly Detail
2 - Synchronizer lock 6 - Input shaft front bearing
3 - Selector ring See Assembly Detail
4 - Synchronizer spring 7 - Third gear wheel

See Assembly Detail
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Item Part Description 4. Using a suitable feeler gauge, measure the
Number clearance between the fourth gear wheel
and the input shaft rear bearing.
8 - Third gear wheel synchro- • If the clearance is greater than the
nizer ring maximum specification, disassemble the
9 - Third and fourth gear input shaft, recheck all components for wear
synchronizer hub assembly and damage and install new components as
See Assembly Detail necessary.
10 - Snap ring • Standard clearance: 0.21 mm - 0.61 mm.
11 - Forth gear wheel synchro-
nizer ring
12 - Fourth gear wheel
See Assembly Detail
13 - Input shaft rear bearing
See Assembly Detail
clearance between the second and third
gear.
maximum specification, disassemble the
input shaft, recheck all components for wear
and damage and install new components as
necessary.
• Maximum clearance: 0.26 mm. Disassembly Details
Item 1 : Input shaft rear bearing

1. Using the special tools, remove the input
shaft rear bearing.
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Item 5 : Third and fourth gear synchronizer 1. Using a suitable dial indicator gauge,
hub assembly measure the input shaft runout at third gear
1. Using the special tools, remove the third wheel position.
and fourth gear synchronizer hub assem- • If the value is greater than the maximum
bly. runout, install a new input shaft.
• Maximum runout: 0.05 mm.
Item 8 : Input shaft front bearing

1. Using a suitable two-leg puller, remove the
input shaft front bearing.
2. Measure the input shaft diameter where the

third and fourth gear wheel is located.
• If the diameter is not within specification,
install new components as necessary.
1. Fourth gear wheel location outer diameter:
31.95 mm - 31.97 mm.
2. Third gear wheel location outer diameter:
35.15 mm - 35.17 mm.
Assembly Details
Item 5 : Input shaft

NOTE: Inspect the input shaft for damage and
wear and install new components as necessary.
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3. Using a suitable dial indicator gauge, Item 6 : Input shaft front bearing
measure the inner diameter of the gear 1. Using the special tool, install the input
wheels. shaft front bearing.
• Fourth gear wheel inner diameter: 32.01
mm - 31.03 mm.
• Third gear wheel inner diameter: 35.21 mm
- 35.23 mm.
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Item 7 : Third gear wheel 2. Measure the synchronizer lock size.
1. Using a suitable feeler gauge, measure the • If the synchronizer lock measurements are
clearance between the third gear wheel and less than specification, install new
the third gear wheel synchronizer ring. synchronizer locks.
• If the clearance is less than the minimum • A: 17 mm.
specification, install a new third gear wheel
• B: 4.25 mm.
synchronizer ring.
• C: 5 mm.
3. Install the synchronizer spring, make sure

that the hooks on the synchronizer are
seated in the groove.
Item 9 : Third and fourth gear synchronizer

hub assembly
NOTE: Inspect the third and fourth gear
synchronizer hub assembly for damage and wear
and replace the components as necessary.
clearance between the selector ring and
the selector fork.
maximum specification, install a new
selector ring and a new selector fork as a
set.
• Maximum clearance: 1 mm.
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4. Align the synchronizer ring grooves with Item 12 : Fourth gear wheel
the synchronizer lock. 1. Using a suitable feeler gauge, measure the
1. Synchronizer ring. clearance between the fourth gear wheel
and the fourth gear wheel synchronizer
2. Synchronizer lock.
ring.
3. Selector ring.
• If the clearance is less than the minimum
specification, install a new fourth gear wheel
synchronizer ring.
5. Install the third and fourth gear synchro-

nizer hub assembly.
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Item 13 : Input shaft rear bearing
1. Using the special tool, install the input
shaft rear bearing.
• Make sure the bearing is fully seated.
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Output Shaft
General Equipment
Special Tool(s)
Feeler gauge
Adapter for 204-158 (Thrust Press
Pad)
204-158-01 Two-leg puller
Name Specification
Installer, Differential Bearing Transmission Fluid WSD-M2C200-C
205-080 1. Disassemble the components in the order
table(s).
Tool)
205-295
205-310
205-311

Bushing/Seal
308-045
Collet for 205-295

308-196
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Number
11 - Output shaft rear taper roller
1 - Output shaft front taper roller bearing
bearing See Disassembly Detail
12 - Output shaft
2 - Fourth gear
13 - Outer synchronizer ring
3 - Snap ring
14 - Synchronizer cone
4 - Third gear
15 - Inner synchronizer ring
5 - Second gear wheel
See Disassembly Detail 16 - Synchronizer spring
6 - Second gear synchronizer 17 - First, second and reverse

cone assembly gear synchronizer
7 - Snap ring 18 - Synchronizer lock
8 - First, second and reverse 19 - Synchronizer hub

gear synchronizer hub as-
sembly 2. To assemble, reverse the disassembly
procedure.
9 - First gear wheel synchro-
nizer cone assembly
NOTE: Coat all components with clean
10 - First gear wheel transmission oil before assembly.
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Number
12 - First, second and reverse
1 - Synchronizer hub gear synchronizer hub
2 - Synchronizer lock assembly
See Assembly Detail
3 - First, second and reverse
gear synchronizer 13 - Snap ring
4 - Synchronizer spring 14 - Second gear wheel

synchronizer cone assembly
5 - Inner synchronizer ring See Assembly Detail
6 - Synchronizer cone 15 - Second gear wheel
7 - Outer synchronizer ring 16 - Third gear
8 - Output shaft 17 - Snap ring
See Assembly Detail
18 - Fourth gear
9 - Output shaft rear taper roller
bearing 19 - Output shaft front taper roller
See Assembly Detail bearing
See Assembly Detail
10 - First gear wheel
See Assembly Detail
11 - First gear wheel
synchronizer cone assembly
See Assembly Detail
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clearance between the first gear wheel and Disassembly Details
the differential drive gear.
• If the clearance is greater than the Item 1 : Output shaft front taper roller bearing
maximum specification, disassemble the 1. Using the special tools, remove the output
output shaft, recheck all components for shaft front taper roller bearing.
wear and damage and install new
Item 5 : Second gear wheel

1. Using the special tools, remove the second
gear wheel and the third gear.
• Shift the gears to first gear.

clearance between the second and third
gear.
maximum specification, disassemble the
output shaft, recheck all components for
wear and damage and install new
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Item 10 : First gear wheel Assembly Details
1. Using a suitable press, remove the first
gear wheel, the first gear wheel synchro- Item 8 : Output shaft
nizer cone assembly, and the first, second NOTE: Inspect the output shaft for damage and
and reverse gear synchronizer hub as- wear and install new components as necessary.
sembly. 1. Using a suitable dial indicator gauge,
measure the output shaft runout at second
gear wheel position.
• If the value is greater than the maximum
runout, install a new output shaft.
• Maximum runout: 0.015 mm
Item 11 : Output shaft rear taper roller bearing

1. Using the special tools, remove the output
shaft rear taper roller bearing.
2. Measure the output shaft diameter where
the first and second gear wheel is located.
1. First gear wheel location outer diameter:
39.45 mm - 39.47 mm.
2. Second gear wheel location outer diameter:
35.15 mm - 35.17 mm.
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3. Using a suitable dial indicator gauge, Item 10 : First gear wheel
measure the inner diameter of the gear 1. Using the special tool and a suitable press,
wheels. install the first gear wheel, the first gear
• If the components are not with specification, wheel synchronizer cone assembly and the
install new components as necessary. first, second and reverse gear synchro-
nizer hub assembly.
• First gear wheel inner diameter: 39.50 mm -
39.52 mm.
• Second gear wheel inner diameter: 35.20
mm - 35.22 mm.
Item 11 : First gear wheel synchronizer cone

assembly
clearance between the first gear wheel
synchronizer cone assembly and the first
gear wheel.
• If the clearance is less than the minimum
specification, install a new first gear wheel
synchronizer ring.
• Minimum clearance: 1 mm.
Item 9 : Output shaft rear taper roller bearing
1. Using the special tool, install the output
shaft rear taper roller bearing.
Item 12 : First, second and reverse gear

synchronizer hub assembly
NOTE: Inspect the third and fourth gear
synchronizer hub assembly for damage and wear
and install new components as necessary.
clearance between the first, second and
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reverse gear synchronizer and the selector 3. Install the synchronizer spring, make sure
fork. that the hooks on the synchronizer are
• If the clearance is greater than the seated in the groove.
maximum specification, install a new first,
second and reverse gear synchronizer and
a new selector fork as a set.
Item 14 : Second gear wheel synchronizer

cone assembly
2. Measure the synchronizer lock size. clearance between the second gear
• If the synchronizer lock size is not with synchronizer cone assembly and the
specification, install new synchronizer second gear.
locks. • If the clearance is not within the minimum
• A: 19 mm. specification, install a new second gear
synchronizer ring.
• B: 4.25 mm.
• C: 5 mm.
• Minimum clearance: 1 mm.
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Item 19 : Output shaft front taper roller bearing
1. Using the special tools, install the output
shaft front taper roller bearing.
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Differential
Special Tool(s)
Collet for 205-295
pad)
204-158-01
General Equipment
Installer, Differential Bearing Draft

205-080 Dial indicator gauge
Name Specification
Tool) Transmission Fluid WSD-M2C200-C
205-295 1. Disassemble the components in the order
table(s).

Number
4 - Pinion gears
1 - Pinion shaft retaining pin
5 - Thrust elements
2 - Pinion shaft
6 - Pinion side gears
3 - Thrust elements
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Number Number
7 - Differential upper taper roller 9 - Differential lower taper roller
bearing bearing
See Disassembly Detail See Disassembly Detail
8 - Vehicle speed sensor (VSS) 10 - Differential case and ring
sensor ring gear
procedure.

Number
5 - Pinion side gears
1 - Differential case and ring
gear 6 - Thrust elements
2 - Differential lower taper roller 7 - Pinion gears

bearing 8 - Thrust elements
See Assembly Detail
9 - Pinion shaft
3 - Vehicle speed sensor (VSS)
sensor ring 10 - Pinion shaft retaining pin
4 - Differential upper taper roller

bearing
See Assembly Detail
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3. CAUTION: Use thrust washers with the Disassembly Details

same thickness on each side.
Using a suitable dial indicator gauge, Item 7 : Differential upper taper roller bearing
measure the backlash of both pinion gears. 1. Using the special tools, remove the differ-
• Attach the left and right-hand halfshaft into ential upper taper roller bearing.
the differential.
• Support the halfshafts on wooden blocks.
• If the backlash is not within specification
(0.0 - 0.1 mm), adjust it by installing thrust
elements between the differential case and
the pinion side gears.
• Thrust washer thickness: 2.0 mm, 2.1 mm,
2.2 mm
• If it does not meet the specification even
with a 2.2 mm thrust element installed, re-
place the differential component.
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Item 9 : Differential lower taper roller bearing Item 3 : Vehicle speed sensor (VSS) sensor
1. Using the special tools, remove the differ- ring
ential lower taper roller bearing. 1. Install the vehicle speed sensor (VSS)
sensor ring in position.
Item 4 : Differential upper taper roller bearing

1. CAUTION: Do not rest the differential
on the lower differential taper roller
bearing.
tial upper taper roller bearing.
Assembly Details
Item 2 : Differential lower taper roller bearing

tial lower taper roller bearing.
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Item 10 : Pinion shaft retaining pin
1. Using a suitable draft, install the pinion
shaft retaining pin in position.
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ASSEMBLY
Transaxle
ASSEM BLY
Special Tool(s)
Special Tool(s) Bushing/Seal
308-045
Preload gauge
205-067
Rotator, Differential
308-165
Installer, Drive Pinion Bearing

205-068
Spacers, Transmission
Housing
308-206
205-080
Measuring Fixture, Bearing
Preload
308-627
205-175
Mounting Bracket,
Engine/Differential General Equipment
205-329 Dial indicator gauge
Feeler gauge
Mounting Stand
303-435 Name Specification
Silicone Sealan WSE-M4G323-A4
High-Temperature ESD-M1C220-A
Grease
1. Clean and check all parts carefully before
303-435-06 assembly.
• Apply clean transmission fluid to all running
surfaces.

procedure.
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ASSEMBLY

Number
11 - Selector mechanism
1 - Fluid deflecting plate
12 - Selector mechanism retain-
2 - Fluid deflecting plate retaining pin
ing bolt
13 - Selector mechanism retain-
3 - Seal ing bolts
4 - Selector shaft 14 - Differential seal
5 - Selector mechanism control See Assembly Detail
end spring washer 15 - Differential bearing race
6 - Selector mechanism control adjustment shim
end spring See Assembly Detail
7 - Selector mechanism control 16 - Differential bearing race

end See Assembly Detail
8 - Selector mechanism control 17 - Transaxle bearing race

end lock adjustment shim
9 - Selector mechanism control 18 - Transaxle bearing race

end washer adjustment shim
See Assembly Detail
end retaining bolt
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Number
19 - Transaxle bearing race
See Assembly Detail

Number
30 - Transaxle breather
20 - Fluid drain plug washer
31 - Transaxle breather cover
21 - Fluid drain plug
32 - Control rod
22 - Reverse lever shaft plug
33 - Selector change arm
23 - Reverse lever shaft
34 - Selector change arm retain-
24 - Reverse lever ing pin
25 - Reverse lever spring retain- 35 - Selector
ing pin
36 - Selector retaining pin
26 - Reverse lever spring
37 - Sealing cap
27 - Differential bearing race
See Assembly Detail 38 - Differential guide plate
bushing
28 - Differential seal
See Assembly Detail 39 - Differential guide plate
29 - Vehicle speed sensor (VSS)
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Number Number
40 - Differential guide plate re- 43 - Output shaft bearing race
taining bolt See Assembly Detail
41 - Differential guide plate re- 44 - Input shaft seal
taining bolt See Assembly Detail
42 - Oil funnel

Number
54 - Differential
45 - Control rod
55 - Output shaft
46 - Control rod end See Assembly Detail
47 - Control rod end retaining pin 56 - Input shaft
48 - Selector fork first/second See Assembly Detail
gear 57 - Selector fork assembly
49 - Control rod bushing See Assembly Detail
50 - Control rod bushing retaining 58 - Push pin spring

pin 59 - Push pin
51 - Shift lock 60 - Selector lever fork
52 - Selector fork third/fourth gear 61 - O-ring
53 - Clutch housing
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Number Number
62 - Selector lever 67 - Fifth and reverse gear shift
See Assembly Detail rod extension retaining bolt
63 - Selector lever retaining pin 68 - Reverse gear idler
64 - Fifth and reverse gear shift 69 - Reverse gear idler lever
rod snap ring See Assembly Detail
65 - Fifth and reverse gear shift 70 - Permanent magnet
rod
71 - Neutral switch washer
72 - Neutral switch
rod extension
See Assembly Detail

Number
78 - Transaxle housing retaining
73 - Fifth gear synchronizer hub bolts
74 - Fifth gear synchronizer lock 79 - Reversing lamp switch
75 - Fifth gear synchronizer washer
76 - Fifth gear synchronizer 80 - Reversing lamp switch

spring 81 - Washer
77 - Transaxle housing 82 - Retaining bolt
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Item Part Description 2. Using a suitable dial indicator gauge,
Number measure the fifth gear thrust clearance.
83 - Retaining bolt maximum specification, disassemble the
84 - Fifth gear transaxle, recheck all components for wear
and damage and install new components as
85 - Fifth gear wheel sleeve necessary.
86 - Fifth gear wheel • Standard clearance: 0.06 mm - 0.26 mm.
87 - Fifth gear wheel synchro- • Maximum clearance: 0.31 mm.
nizer ring
88 - Fifth gear wheel
synchronizer hub
See Assembly Detail
89 - Fifth gear wheel selector fork
retaining pin
90 - Fifth gear wheel selector fork
See Assembly Detail
91 - Fifth gear wheel retaining
plate
nizer cone
nizer sleeve
3. Coat the input shaft splines with a thin
94 - Input shaft retaining nut layer of grease
See Assembly Detail
4. Using the special tools, remove the trans-
95 - Output shaft retaining nut axle from the mounting stand.
See Assembly Detail
96 - Fifth gear housing cover
97 - Fifth gear housing cover re-
taining bolts
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Assembly Details Item 15 : Differential bearing race adjustment
shim
Item 8 : Selector mechanism control end lock 1. Install the differential bearing race.
1. Using a suitable pipe, lock the selector • Make sure the adjustment shims are re-
shaft. moved.
2. Install the selector mechanism control end

lock in the groove.
3. Install the differential bearing race in the

special tool.
• Install the special tool together with the
differential bearing on the differential lower
taper roller bearing.
Item 14 : Differential seal
tial seal.
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4. Install the special tool in the positions 7. Using the special tools, measure the
shown. differential preload.
• Required preload: 0.03 Nm - 2.00 Nm.
5. Using the special tool, tighten the bolts to 8. Using the special tool and a suitable feeler
specification. gauge, measure the clearance.
Adjustment shim thickness (mm)
0.10 0.15 0.20 0.25
0.30 0.35 0.40 0.45
0.50 0.55 0.60 0.65
0.70 0.75 0.80 0.85
0.90 - - -
• Select the thickest adjustment shim nearest
to the measured clearance.
6. Using the special tool, settle the bearings.

• Rotate the special tool by the bars.
• Make sure the special tool gap is eliminated
after the bearings are settled.
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9. Remove the special tools. 12. Install the transaxle housing to the clutch
housing and tighten the bolts to specifi-
cation.
10. Install the selected adjusting shim and the

differential bearing race.
13. Using the special tools, measure the
differential preload.
• Required preload: 0.03 Nm - 2.00 Nm.
• If the preload is not within specification,
repeat the differential preload measuring.

tial bearing race.
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Item 17 : Transaxle bearing race adjustment Item 18 : Transaxle bearing race adjustment
shim shim
1. Install the input shaft to the clutch housing. 1. Install the oil funnel and the output shaft
2. Install the transaxle housing to the clutch bearing race to the clutch housing.
housing and tighten the bolts to specifica-
tion.
2. Install the transaxle bearing race to the

3. Using a suitable dial indicator gauge, transaxle housing.
measure the input shaft clearance.
3. Using a suitable dial indicator gauge,

measure the output shaft end float.
• Example: output shaft end float 0.22 mm
4. Select the closest adjustment shim on the

thin side from the values given.
0.10 0.20 0.30
0.40 0.50 0.60
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4. Calculate the required adjusting shim Item 28 : Differential seal
thickness range. 1. Using the special tool, install the differen-
• Adjusting shim thickness range lower value: tial seal.
output shaft end float + 0.03 mm (Example:
0.22 mm + 0.03 mm = 0.25 mm)
• Adjusting shim thickness range upper
value: output shaft end float + 0.08 mm
(Example: 0.22 mm + 0.08 mm = 0.30 mm)
• Adjusting shim thickness range: 0.25 mm -
0.30 mm
5. Select the thickest adjustment shim in the
range from the values given.
0.15 0.20 0.25 0.30
0.35 0.40 0.45 0.50
0.55 0.60 0.65 0.70
• Adjusting shim thickness range: 0.25 mm - Item 43 : Output shaft bearing race
0.30 mm. Select an 0.30 mm adjustment 1. Using the special tool, install the output
shim shaft bearing race.
Item 19 : Transaxle bearing race

1. Using the special tool, install the transaxle
bearing race.
Item 44 : Input shaft seal

1. Using the special tool, install the input
shaft seal.

tial bearing race.
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Item 55 : Output shaft 2. Using a suitable scraper, install the push
1. Install the output shaft and the input shaft pin spring and the push pin and hold it in
as an assembly. position.
Item 56 : Input shaft 3. Using a suitable scraper, push the selector

1. Install the input shaft and the output shaft fork assembly with the control rod end
as an assembly. against the push pin.
• The control rod lines up automatically with
the control rod coupling hole in the clutch
housing.
Item 57 : Selector fork assembly

1. Shift to second gear and install the selector
fork assembly as shown
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4. Align the push pin with the control rod end Item 66 : Fifth and reverse gear shift rod
center groove. extension
• Shift the gears to neutral position. 1. Install the fifth and reverse gear shift rod
extension.
• Turn the control rod end clockwise to set the
push pin. 1. Install the reverse lever protrusion into the
fifth and reverse gear shift rod extension
groove.
2. Install the fifth and reverse gear shift rod
into the fifth and reverse gear shift rod ex-
tension.
Item 62 : Selector lever

1. Install the selector lever.
• Make sure the selector lever fork is fitted
between the selector change arm and the
control rod end.
• Align the selector lever pin hole with the
clutch housing pin hole. 2. Install the fifth and reverse gear shift rod
extension retaining bolt.
• Make sure the retaining bolt is properly
seated in the groove.
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Item 69 : Reverse gear idler lever 2. Measure the synchronizer lock size.
1. Install the reverse gear idler lever to the • If the synchronizer lock measurements are
marks. less than specification, install new
synchronizer locks.
• A: 17 mm.
• B: 4.25 mm.
• C: 5 mm.
Item 88 : Fifth gear wheel synchronizer hub

1. Assemble the fifth gear wheel synchronizer Item 90 : Fifth gear wheel selector fork
hub. 1. Install the fifth gear wheel selector fork
• Top: fifth gear housing cover side together with the fifth gear wheel synchro-
• Bottom: transaxle housing side nizer hub assembly.
Item 94 : Input shaft retaining nut

1. Using the special tool and a suitable
wrench, lock the input shaft and install the
input shaft retaining nut.
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Item 95 : Output shaft retaining nut
1. Using the special tool and a suitable
wrench, lock the input shaft and install the
output shaft retaining nut.
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INSTALLATION
INST ALLAT ION
Installation
Special Tool(s)
All vehicles
Support Bar, Engine
303-290A 1. CAUTION: Use suitable retaining straps
to secure the transaxle on the
transmission jack.
CAUTION: Make sure that the two locating
dowels are installed.
Using a suitable transmission jack, posi-
303-290-13
tion and install the transaxle.

303-290-15
General Equipment
Retaining strap
Transmission jack
Name Specification
fluid
3. Remove the retaining strap and the

transmission jack.
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5. Install the transaxle upper retaining bolts. 10. NOTE: Install new engine and transaxle rear
mount retaining nuts.
NOTE: Do not tighten the engine and transaxle
rear mount retaining nuts at this stage.
Install the engine and transaxle rear
mount.
6. Install the engine and transaxle rear mount

retaining bracket.

transaxle.
1. Attach the gearshift cables to the bracket.
2. Attach the gearshift cables to the selector
mechanism.

8. Using the special tools, raise the engine

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water.
NOTE: Make sure the spring clip is correctly
seated.
line.
16. Remove the special tools on both sides


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21. NOTE: Install new exhaust flange nuts and a 24. Install the radiator support bracket.
new exhaust flange gasket. • Install the right-hand side radiator support
Attach the exhaust flexible pipe to the bracket retaining bolts.
catalytic converter.
25. Install the radiator support bracket.

22. Attach the exhaust flexible pipe to the • Install the left-hand side radiator support
crossmember exhaust hanger insulator. bracket retaining bolts.
23. Remove the support wrap or suitable 26. Lower the vehicle.
splint from the exhaust flexible pipe. 27. Install the starter motor. For additional
INSTALLATION, Starter Motor - 1.6L (Z6)]
28. Tighten the engine and transaxle rear
mount retaining nuts.
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32. Connect the reversing lamp and the neu-
29. Install the transaxle wiring harness
tral switch electrical connectors.
bracket.
33. Install the headlamp assembly. For additi-

30. Install the transaxle wiring harness. onal information, refer to Section 417-01.
Tray - 1.6L (Z6)]
Air Cleaner - 1.6L (Z6)]
31. Connect the vehicle speed sensor (VSS) information, refer to Section 308-00.
electrical connector. [Manual Transmission/Transaxle
5-Speed Manual Transaxle (F35M-R)]
Bleeding]
38. With the vehicle on a level surface, fill the
transaxle until the transmission fluid level
is just below the bottom of the filler hole.
39. Initialize the power window motors. For additi-
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308-06A-1 Manual Transmission/Transaxle External Controls — 308-06A-1

SECTION 308-06A Manual Transmission/Transaxle

External Controls — Vehicles With: 5-Speed Manual
Transaxle (MTX-75)
CONTENTS PAGE
SPECIFICATIONS
External Controls ............................................................................................................. 308-06A-3

Symptom Chart ............................................................................................................... 308-06A-3
Pinpoint Tests ................................................................................................................. 308-06A-3/4
Gearshift Lever ............................................................................................. (16 524 0) 308-06A-5/6

Gearshift Cables ........................................................................................... (16 575 0) 308-06A-7
09/2004 2004.75 Focus

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SPECIFICATIONS
Gearshift cable bushing retaining nuts 9 - 80
Gearshift linkage retaining bolts 11 8 -
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External Controls

step.
1. Verify the customer concern. symptom and refer to the Symptom Chart.
mechanical damage.
3. Make sure that the gearshift cables are
correctly routed and not under any tension
from other components.
Symptom Chart

• External controls do not operate • Gearshift cables incorrectly ad- • ADJUST the gearshift cables.
freely. justed. REFER to Section 308-00.
[Manual Transmis-
sion/Transaxle and Clutch -
Adjustment - Vehicles With:
(MTX-75)]
• Gearshift lever damaged. • GO to Pinpoint Test A
• Selector mechanism damaged.
• Gearshift cables damaged.
Pinpoint Tests
PINPOINT TEST A: STIFF GEARSHIFT
A1: CHECK THE GEARSHIFT LEVER
1 Detach the gearshift cables from the gearshift
lever.
• Is the gearshift lever difficult to operate?
→ Yes
Install a new gearshift lever. REFER to
Gearshift Lever in this section.
→ No
GO to A2
A2: CHECK THE GEARSHIFT CABLES
1 Attach the gearshift cables to the gearshift
lever.
2 Detach the gearshift cables from the transaxle.
→ Yes
Install new gearshift cables. REFER to
Gearshift Cables in this section.
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→ No
Install a new selector mechanism. REFER to
Section 308-03.[Manual Transmis-
sion/Transaxle - Vehicles With: 5-Speed
Manual Transaxle (MTX-75),
DISASSEMBLY, Transaxle]
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Gearshift Lever (16 524 0)
Removal
1. Remove the center console. 5. Detach the gearshift cables from the
gearshift lever.
element left-hand bracket. 1. Detach the selector cable from the selector
lever.
2. Detach the gearshift cable from the gear-
shift lever.

element right-hand bracket.
center console reinforcing element bracket. 6. Detach the gearshift cables from the
gearshift lever.
the gearshift lever.
4. Unscrew the gearshift lever knob.

• Remove the gearshift lever gaiter.
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7. Remove the gearshift lever.
• Discard the gearshift lever bolts.
Installation
1. NOTE: Install new gearshift lever bolts.
Install the components in the reverse
order.
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Gearshift Cables (16 575 0)
Removal 5. Detach the gearshift cable heat shield and

move it backwards.
selector mechanism.
1. Press the selector cable retainer and detach
the selector cable from the selector lever.
2. Press the shift cable retainer and detach the
shift cable from the shift lever.

gearshift cables.
Detach the gearshift cables from the clip.
3. Detach the gearshift cables from the cable

brackets.
abutment sleeve counterclockwise and
detach from the bracket.
2. Release the shift cable by turning the
abutment sleeve counterclockwise and de-
tach from the bracket. 7. Lower the vehicle.
8. Remove the floor console.
9. Remove the gearshift console reinforcing
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13. Detach the gearshift cables from the cable
brackets.
• Detach the wiring harness from the retain-
abutment sleeve counterclockwise and
ing bracket.
detach from the bracket.
2. Release the shift cable by turning the
abutment sleeve counterclockwise and de-
tach from the bracket.
11. Remove the gearshift lever knob.

• Remove the gearshift lever boot.

gearshift cables.
NOTE: Cut the carpet and the insulation pad to
gain access to the gearshift cable bushing.
Remove the gearshift cables.
• Discard the gearshift cable bushing retain-
ing nuts.

gearshift lever.
1. Detach the selector cable from the selector
lever.
2. Detach the shift cable from the shift lever.
Installation
1. NOTE: Install new gearshift cable bushing
retaining nuts.
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308-06B-1 Manual Transmission/Transaxle External Controls — 308-06B-1

SECTION 308-06B Manual Transmission/Transaxle

External Controls — Vehicles With: 6-Speed Manual
Transaxle (MMT6)
CONTENTS PAGE
SPECIFICATIONS
External Controls — Vehicles With: 6-Speed Manual Transaxle (MMT6) ......................... 308-06B-3
Symptom Chart ............................................................................................................... 308-06B-3
Pinpoint Tests ................................................................................................................. 308-06B-3/4
Gearshift Lever ............................................................................................. (16 524 0) 308-06B-5/6

Gearshift Cables ........................................................................................... (16 575 0) 308-06B-7
09/2004 2004.75 Focus

TO MODEL INDEX

SPECIFICATIONS
Gearshift cable bushing retaining nuts 9 - 80
Gearshift linkage retaining bolts 9 - 80
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External Controls — Vehicles With: 6-Speed Manual Transaxle (MMT6)

step.
1. Verify the customer concern. symptom and refer to the Symptom Chart.
mechanical damage.
3. Make sure that the gearshift cables are
correctly routed and not under any tension
from other components.
Symptom Chart

• External controls do not operate • Gearshift cables incorrectly ad- • ADJUST the gearshift cables.
freely. justed. REFER to Section 308-00.
[Manual Transmis-
sion/Transaxle and Clutch -
Adjustment - Vehicles With:
(MMT6)]
• Gearshift lever damaged. • GO to Pinpoint Test A
• Selector mechanism damaged.
• Gearshift cables damaged.
Pinpoint Tests
PINPOINT TEST A: STIFF GEARSHIFT
A1: CHECK THE GEARSHIFT LEVER
1 Detach the gearshift cables from the gearshift
lever.
→ Yes
Install a new gearshift lever. REFER to
Gearshift Lever in this section.
→ No
GO to A2
A2: CHECK THE GEARSHIFT CABLES
1 Attach the gearshift cables to the gearshift
lever.
2 Detach the gearshift cables from the transaxle.
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→ Yes
Install new gearshift cables. REFER to
Gearshift Cables in this section.
→ No
Install a new selector mechanism.
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Gearshift Lever (16 524 0)
Removal
1. Remove the center console. 5. Detach the gearshift cables from the
gearshift lever.
element left-hand bracket. 1. Detach the gearshift cable from the
gearshift lever.
lever.

center console reinforcing element bracket. 6. Detach the gearshift cables from the
gearshift lever.
4. Unscrew the gearshift lever knob.

• Remove the gearshift lever gaiter.
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7. Remove the gearshift lever.
• Discard the gearshift lever bolts.
Installation
1. NOTE: Install new gearshift lever bolts.
order.
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Gearshift Cables (16 575 0)
Removal
1. Remove the air cleaner. For additional gearshift cables.
information, refer to Section 303-12.[Intake Detach the gearshift cables from the clip.
transaxle.
1. Detach the shift and selector cables from
the selector mechanism.
the gearshift cables from the bracket.

7. Remove the floor console.

4. Detach the gearshift cable heat shield and
move it backwards.
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9. Remove the gearshift console reinforcing 12. Detach the gearshift cables from the cable
element right-hand bracket. bracket.
• Detach the wiring harness from the retain- 1. Press the locking pins together and detach
ing bracket. the shift cable from the bracket.
the selector cable from the bracket.
10. Remove the gearshift lever knob.

• Remove the gearshift lever boot.
gearshift cables.
NOTE: Cut the carpet and the insulation pad to
gain access to the gearshift cable bushing.
Remove the gearshift cables.
• Discard the gearshift cable bushing retain-
ing nuts.

gearshift lever.
1. Detach the shift cable from the shift lever.
lever.
Installation
1. NOTE: Install new gearshift cable bushing
retaining nuts.
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309-00-1 Exhaust System 309-00-1
SECTION 309-00 Exhaust System

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 309-00-2
Catalytic Converter — 1.6L (Z6)........................................................................................ 309-00-3/19

Catalytic Converter — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) .............................. 309-00-20/37
Catalytic Converter — 2.0L Duratorq-TDCi (DW) Diesel ................................................... 309-00-38/41
Exhaust Flexible Pipe.................................................................................... (25 004 0) 309-00-42
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SPECIFICATIONS

Item Specification
Grease SA-M1C9107-A
Catalytic converter heat shield retaining nuts and 10 - 89
bolts
Catalytic converter to turbocharger retaining clamp 25 18 -
- Vehicles with diesel engine
Catalytic converter to front muffler and tailpipe 51 38 -
assembly retaining nuts - Vehicles with diesel en-
gine
Catalytic converter to front muffler and tailpipe 48 35 -
assembly retaining nuts - Vehicles with petrol en-
gine
Catalytic converter support bracket retaining bolts 25 18 -
Exhaust manifold retaining nuts - Vehicles with 1.6L 43 32 -
(Z6)
Heated oxygen sensor (HO2S) 47 35 -
Catalytic monitor sensor 47 35 -
Engine support insulator retaining bolt 80 59 -
Headlamp leveling front sensor bracket retaining 8 - 71
bolt
Power steering lines bracket retaining bolts 23 17 -
Front axle crossmember rear retaining bolt 275 203 -
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Catalytic Converter — 1.6L (Z6)


Special Tool(s) steering gear pinion.
Alignment Pins, Subframe • Discard the retaining bolt.
205-316 (15-097A)

211-020 (13-006)
General Equipment
Transmission jack 3. Remove the engine upper cover.
Securing strap

tion.
4. Remove the cowl panel grille. For additi-

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5. Remove the bulkhead extension panel. 8. Remove the EGR valve outlet tube. For additi-
1. Remove the retaining screws and washers. onal information, refer to Section 303-08C.
(Z6), REMOVAL AND INSTALLATION,
Outlet Tube]
9. Disconnect the EGR valve electrical con-
nector.
6. Disconnect the heated oxygen sensor

(HO2S) and catalytic monitor sensor elec-
trical connectors.
10. Remove the EGR valve and EGR housing

assembly.
7. Remove the exhaust manifold to exhaust

gas recirculation (EGR) valve tube. For
303-08C.[Engine Emission Control - 1.6L
(Z6), REMOVAL AND INSTALLATION, 11. Remove the components in the order
Exhaust Manifold to Exhaust Gas indicated in the following illustration(s)
Recirculation (EGR) Valve Tube] and table(s).
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Number
1 - Catalytic converter heat nuts
shield retaining nuts and
bolts 5 - Catalytic monitor sensor
See Removal Detail
(HO2S) 6 - Catalytic converter to rear
muffler flange retaining nuts
3 - Catalytic converter heat See Removal Detail
shield
See Removal Detail
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Number
8 - Tie-rod end retaining nut
See Removal Detail
nut
See Removal Detail
G407508 en 09/2004 2004.75 Focus

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Number
See Removal Detail
G407508 en 09/2004 2004.75 Focus

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Number
See Removal Detail
G407508 en 09/2004 2004.75 Focus

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Number
1 - Catalytic converter See Installation Detail
2 - Exhaust manifold retaining 5 - Catalytic converter to rear
nuts muffler flange retaining nuts
3 - Catalytic converter to
catalytic converter support
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309-00-10 Exhaust System 309-00-10

Number
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309-00-11 Exhaust System 309-00-11

Number
nut
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309-00-12 Exhaust System 309-00-12

Number
12 - Catalytic converter to rear
10 - Exhaust manifold retaining muffler flange retaining nuts
nuts See Installation Detail
13 - Catalytic monitor sensor
catalytic converter support 14 - Heated oxygen sensor
bracket retaining bolts (HO2S)
See Installation Detail 15 - Catalytic converter heat
shield
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309-00-13 Exhaust System 309-00-13
Item Part Description 17. Connect the HO2S and catalytic monitor
Number sensor electrical connectors.

shield retaining nuts and
bolts
13. Install the EGR valve and EGR housing
assembly.
18. Install the bulkhead extension panel.

1. Attach the panel to the retaining clips.
2. Install the retaining screws and washers.
14. Connect the EGR valve electrical con-

nector.
19. Install the cowl panel grille. For additional

15. Install the EGR valve outlet tube. For 20. Install the engine upper cover.
303-08C.[Engine Emission Control - 1.6L
(Z6), REMOVAL AND INSTALLATION,
Outlet Tube]
tube. For additional information,
refer to Section 303-08C.[Engine Emission
Control - 1.6L (Z6), REMOVAL AND
INSTALLATION, Exhaust Manifold to
Tube]
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309-00-14 Exhaust System 309-00-14
21. WARNING: Install a new steering 2. CAUTION: Over bending of the exhaust
column shaft to steering gear pinion flexible pipe may cause damage
bolt. Failure to follow this instruction resulting in failure.
NOTE: Make sure the road wheels are in the suitable support wrap or suitable splint.
Attach the steering column shaft to the

support the muffler and exhaust
Removal Details
Item 5 : Catalytic monitor sensor rear muffler flange.
1. Raise and support the vehicle. For • Discard the gasket and nuts.
additional information, refer to Section Item 7 : Exhaust hanger insulators
AND OPERATION, Jacking] For additional CAUTION: Take care when removing the
information, refer to Section 100-02. exhaust hanger insulators to prevent
[Jacking and Lifting, DESCRIPTION damage.
Item 6 : Catalytic converter to rear muffler 1. Remove both front wheels and tires. For
flange retaining nuts additional information, refer to Section 204-04.
1. Remove the floor panel brace. [Wheels and Tires, REMOVAL AND
G407508 en 09/2004 2004.75 Focus

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309-00-15 Exhaust System 309-00-15
2. CAUTION: Leave the tie-rod end Item 11 : Front axle crossmember

retaining nut in place to protect the 1. Remove the right-hand front fender splash
ball joint stud. shield.
both sides.
2. Detach the steering gear to power steering

fluid reservoir return line from the vehicle
body.

3. Using a transmision jack and a wooden

Item 9 : Stabilizer bar link retaining nut injury.
1. NOTE: Use a 5 mm Allen key to prevent the ball Using a suitable securing strap, secure the
joint stud from rotating. front axle crossmember, stabilizer bar and
jack.
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309-00-16 Exhaust System 309-00-16
5. Remove the front axle crossmember Item 12 : Catalytic converter

bracket retaining bolts on both sides. 1. Remove the catalytic converter to catalytic
converter support bracket retaining bolts.
6. Remove the front axle crossmember re-

taining bolts (transmission jack removed
for clarity). 2. With the aid of another technician, remove
the catalytic converter.

1. CAUTION: Never use jointing
compound forward of the catalytic
converter.
NOTE: Install a new exhaust manifold gasket and
nuts.
NOTE: Do not fully tighten the exhaust manifold
7. CAUTION: To prevent damage to the Install the exhaust manifold retaining nuts.
front axle crossmember sufficiently to
allow the catalytic converter to be
removed.
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309-00-17 Exhaust System 309-00-17
Item 3 : Catalytic converter to catalytic Item 6 : Front axle crossmember

converter support bracket retaining bolts
1. NOTE: Do not fully tighten the catalytic
converter to catalytic converter support bracket
NOTE: Install new catalytic converter to catalytic injury.
Install the catalytic converter to catalytic tool, position and align the front axle
converter support bracket retaining bolts. crossmember.
pin sleeve.
holes.

1. CAUTION: Take care when installing
prevent damage.
Check the exhaust hanger insulators for
damage. Install new exhaust hanger
insulators if necessary.
Item 5 : Catalytic converter to rear muffler
flange retaining nuts 2. CAUTION: Make sure the front axle
1. NOTE: Install a new catalytic converter to rear
muffler flange gasket and nuts.
retaining bolts.
NOTE: Do not fully tighten the catalytic converter
to rear muffler flange retaining nuts at this stage. Install the front axle crossmember retain-
Install the catalytic converter to rear muf- clarity).
fler flange retaining bolts.
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309-00-18 Exhaust System 309-00-18
3. Install the front axle crossmember bracket Item 8 : Tie-rod end retaining nut
retaining bolts on both sides. 1. NOTE: Use a 5 mm Allen key to prevent the ball
on both sides.
2. Install both front wheels and tires. For
4. Remove the special tool. Item 10 : Exhaust manifold retaining nuts
5. Remove the securing strap. 1. Lower the vehicle to gain access to the
exhaust manifold retaining nuts and bolt.
and the wooden block. 2. Tighten the exhaust manifold retaining
nuts.
7. Attach the steering gear to power steering
fluid reservoir return line to the vehicle
body.

8. Install the right-hand front fender splash [Jacking and Lifting, DESCRIPTION
shield. AND OPERATION, Jacking] For additional
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309-00-19 Exhaust System 309-00-19
Item 11 : Catalytic converter to catalytic 3. CAUTION: Over bending of the exhaust

converter support bracket retaining bolts flexible pipe may cause damage
1. Tighten the catalytic converter to catalytic resulting in failure.
Remove the exhaust flexible pipe support
wrap or splint.
Item 12 : Catalytic converter to rear muffler

flange retaining nuts
1. Fully tighten the catalytic converter to rear Item 15 : Catalytic converter heat shield
muffler flange retaining nuts. 1. Lower the vehicle.
2. Feed the H2OS wiring harness and the
catalytic monitor sensor electrical wiring
harness through the catalytic converter
heat shield.
2. Install the floor panel brace.
G407508 en 09/2004 2004.75 Focus

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309-00-20 Exhaust System 309-00-20
Catalytic Converter — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)

Special Tool(s) steering gear pinion.
Alignment Pins, Subframe • Discard the retaining bolt.
205-316 (15-097A)

211-020 (13-006)
General Equipment
Transmission jack 3. Remove the oil filler pipe.
• Release the securing clip and rotate the oil
Securing strap filler pipe counterclockwise.

tion.

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309-00-21 Exhaust System 309-00-21
[Front End Body Panels, REMOVAL 8. Remove the components in the order
AND INSTALLATION, Cowl Panel Grille] indicated in the following illustration(s) and
6. Remove the bulkhead extension panel. table(s).
1. Remove the retaining screws and washers.
7. Disconnect the heated oxygen sensor

(HO2S) and catalytic monitor sensor elec-
trical connectors.
G418602 en 09/2004 2004.75 Focus

TO MODEL INDEX
309-00-22 Exhaust System 309-00-22

Number
1 - Catalytic converter heat nuts and bolt
2 - Catalytic converter heat See Removal Detail
shield
3 - Heated oxygen sensor muffler flange retaining nuts
(HO2S) See Removal Detail
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TO MODEL INDEX
309-00-23 Exhaust System 309-00-23

Number
See Removal Detail

Number
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TO MODEL INDEX
309-00-24 Exhaust System 309-00-24

Number
See Removal Detail
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TO MODEL INDEX
309-00-25 Exhaust System 309-00-25

Number
See Removal Detail
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TO MODEL INDEX
309-00-26 Exhaust System 309-00-26

Number
1 - Catalytic converter See Installation Detail
2 - Exhaust manifold retaining 5 - Catalytic converter to rear
nuts and bolt muffler flange retaining nuts
catalytic converter support
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TO MODEL INDEX
309-00-27 Exhaust System 309-00-27

Number
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309-00-28 Exhaust System 309-00-28

Number
nut
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309-00-29 Exhaust System 309-00-29

Number
10 - Exhaust manifold retaining muffler retaining nuts
nuts and bolt See Installation Detail
catalytic converter support 14 - Heated oxygen sensor
bracket retaining bolts (HO2S)
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TO MODEL INDEX
309-00-30 Exhaust System 309-00-30
Item Part Description 13. Install the engine upper cover.

Number
shield
10. Connect the heated oxygen sensor
(HO2S) and catalytic monitor sensor
electrical connectors.
14. Install the oil filler pipe.
11. Install the bulkhead extension panel.

1. Attach the panel to the retaining clips.
2. Install the retaining screws and washers.
15. WARNING: Install a new steering

column shaft to steering gear pinion
bolt. Failure to follow this instruction
Attach the steering column shaft to the
12. Install the cowl panel grille. For additional

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309-00-31 Exhaust System 309-00-31
Removal Details 3. CAUTION: Using suitable cable ties,

Item 5 : Catalytic monitor sensor
additional information, refer to Section100-02. Detach the exhaust flexible pipe from the
[Jacking and Lifting, DESCRIPTION rear muffler flange.
AND OPERATION, Jacking] For • Discard the gasket and nuts.
100-02.[Jacking and Lifting, DESCRIPTION Item 7 : Exhaust hanger insulators
AND OPERATION, Lifting] CAUTION: Take care when removing the
Item 6 : Catalytic converter to rear muffler exhaust hanger insulators to prevent
flange retaining nuts damage.
1. Remove the floor panel brace. Item 8 : Tie-rod end retaining nut
ball joint stud.
both sides.

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309-00-32 Exhaust System 309-00-32
3. CAUTION: Protect the ball joint seal 2. Detach the power steering pressure and
using a soft cloth to prevent damage. return lines front bracket from the vehicle
body.
3. Detach the power steering pressure and

return lines center bracket from the vehicle
body.
shield.
4. Using a suitable transmission jack and a

wooden block, support the front axle
crossmember, stabilizer bar and lower arm
assembly.
injury.
jack.
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309-00-33 Exhaust System 309-00-33
6. Remove the front axle crossmember Item 12 : Catalytic converter

bracket retaining bolts on both sides. 1. Remove the catalytic converter to catalytic
7. Remove the front axle crossmember re-

taining bolts (transmission jack removed 2. With the aid of another technician, remove
for clarity). the catalytic converter.
Item 2 : Exhaust manifold retaining nuts and

bolt
1. CAUTION: Never use jointing
compound forward of the catalytic
converter.
NOTE: Install a new exhaust manifold gasket,
nuts and bolt.
NOTE: Do not fully tighten the exhaust manifold
retaining nuts and bolt at this stage.
Install the exhaust manifold retaining nuts
8. CAUTION: To prevent damage to the and bolt.
front axle crossmember sufficiently to
allow the catalytic converter to be
removed.
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309-00-34 Exhaust System 309-00-34
Item 3 : Catalytic converter to catalytic Item 5 : Catalytic converter to rear muffler

converter support bracket retaining bolts flange retaining nuts
1. NOTE: Do not fully tighten the catalytic 1. NOTE: Coat the catalytic converter studs with
converter to catalytic converter support bracket grease.
retaining bolts at this stage. NOTE: Install a new exhaust flexible pipe to rear
NOTE: Install new catalytic converter to catalytic muffler flange gasket and nuts.
converter support bracket retaining bolts. NOTE: Do not fully tighten the exhaust flexible
Install the catalytic converter to catalytic pipe to rear muffler flange retaining nuts at this
converter support bracket retaining bolts. stage.
Install the exhaust flexible pipe to rear
muffler flange retaining nuts.

1. CAUTION: Take care when installing
prevent damage.
Check the exhaust hanger insulators for
damage. Install new exhaust hanger
insulators if necessary.
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309-00-35 Exhaust System 309-00-35
Item 6 : Front axle crossmember 3. Install the front axle crossmember bracket
retaining bolts on both sides.
injury.
tool, position and align the front axle
crossmember.
pin sleeve.
the alignment pins into the chassis aligning 4. Remove the special tool.
holes. 5. Remove the securing strap.
7. Attach the power steering pressure and
return lines center bracket to the vehicle
body.

retaining bolts.
8. Attach the power steering pressure and
return lines front bracket to the vehicle
clarity).
body.
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309-00-36 Exhaust System 309-00-36
9. Install the right-hand front fender splash AND OPERATION, Jacking] For additional
shield. information, refer to Section 100-02.
Item 11 : Catalytic converter to catalytic
converter support bracket retaining bolts
1. Tighten the catalytic converter to catalytic

on both sides.
Item 9 : Stabilizer bar link retaining nut Item 12 : Catalytic converter to rear muffler
1. NOTE: Use a 5 mm Allen key to prevent the ball retaining nuts
joint stud from rotating. 1. Tighten the catalytic converter to rear muf-
Attach the stabilizer bar link to the fler flange retaining nuts.
2. Install both front wheels and tires. For
204-04.[Wheels and Tires, REMOVAL AND
Item 10 : Exhaust manifold retaining nuts and
bolt
1. Lower the vehicle to gain access to the
exhaust manifold retaining nuts and bolt.
2. Tighten the exhaust manifold nuts and bolt.

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309-00-37 Exhaust System 309-00-37
Item 14 : Heated oxygen sensor (HO2S)

Item 15 : Catalytic converter heat shield
1. Feed the heated oxygen sensors (H2OS)
wiring harness and the catalytic monitor
sensor electrical wiring harness through
the heat shield.
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309-00-38 Exhaust System 309-00-38
Catalytic Converter — 2.0L Duratorq-TDCi (DW) Diesel

Name Specification 3. Remove the components in the order
Grease SA-M1C9107-A table(s).
1. Disconnect the temperature sensor elec-
trical connector (if equipped).
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309-00-39 Exhaust System 309-00-39

Number
4 - Catalytic converter to engine
1 - Temperature sensor (if support bracket retaining
equipped) nuts
2 - Front muffler and tailpipe 5 - Catalytic converter to
assembly retaining nuts. turbocharger retaining clamp
3 - Exhaust hanger insulators 6 - Catalytic converter
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309-00-40 Exhaust System 309-00-40
4. To install, reverse the removal procedure. 3. Detach the exhaust flexible pipe from the
front muffler and tailpipe assembly.
Removal Details • Discard the gasket and nuts.
Item 5 : Catalytic converter to turbocharger
Item 2 : Front muffler and tailpipe assembly retaining clamp
retaining nuts.
1. Remove the floor panel brace. 1. NOTE: Note the position of the catalytic
converter to turbocharger retaining clamp to aid
installation.
Remove the catalytic converter to turbo-
charger retaining clamp.

Support the flexible pipe with a support
wrap or suitable splint. Installation Details
Item 5 : Catalytic converter to turbocharger

retaining clamp
CAUTION: Never use jointing compound
forward of the catalytic converter.
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309-00-41 Exhaust System 309-00-41
1. NOTE: Make sure the catalytic converter 2. Install the floor panel brace.
turbocharger retaining clamp and the catalytic
converter to engine support bracket are
correctly aligned.
NOTE: Make sure the catalytic converter to
turbocharger retaining clamp is installed in its
original position.
NOTE: Do not fully tighten the catalytic converter
to support bracket retaining nuts at this stage.
Install the catalytic converter to
turbocharger retaining clamp.
1. Install the catalytic converter to support
bracket retaining nuts.
2. Tighten the retaining clamp.
Item 2 : Front muffler and tailpipe assembly

retaining nuts.
NOTE: Install a new gasket and nuts.
1. Attach the exhaust flexible pipe to the front
• Coat the front muffler and tailpipe assembly
studs with grease.
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309-00-42 Exhaust System 309-00-42
Exhaust Flexible Pipe (25 004 0)


Name Specification catalytic converter.
Grease SA-M1C9107-A • Discard the gasket and nuts.
Removal
Support the exhaust flexible pipe with a crossmember exhaust hanger insulators.
3. Remove the floor panel brace.
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309-00-43 Exhaust System 309-00-43
6. CAUTION: Using suitable cable ties, 3. Tighten the exhaust flexible pipe to cata-
support the rear muffler and exhaust lytic converter retaining nuts.
Remove the exhaust flexible pipe.
4. Tighten the exhaust flexible pipe to rear

muffler flange retaining nuts.
Installation
1. NOTE: Coat the catalytic converter studs with
grease.
NOTE: Coat the exhaust flexible pipe to rear
muffler flange studs with grease.
NOTE: Install new exhaust flexible pipe gaskets
and nuts.
NOTE: Do not fully tighten the exhaust flexible
pipe retaining nuts at this stage.
Install the exhaust flexible pipe.
2. Attach the exhaust flexible pipe to the
crossmember exhaust hanger insulators.
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309-00-44 Exhaust System 309-00-44

Remove the exhaust flexible pipe support
wrap or splint.
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310-00-1 Fuel System - General Information 310-00-1
SECTION 310-00 Fuel System - General Information

CONTENTS PAGE
Fuel System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE

(MI4)/2.0L Duratec-HE (MI4) ............................................................................................ 310-00-2
GENERAL PROCEDURES
Fuel System Pressure Release..................................................................... (23 420 0) 310-00-3

Quick Release Coupling.................................................................................................... 310-00-4/9
Spring Lock Couplings .................................................................................. (23 004 0) 310-00-10/12
Fuel Tank Draining........................................................................................ (23 551 0) 310-00-13
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Fuel System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L



– Fuel level – Electrical
– Fuel leak(s) connector(s)
– Fuel line(s) – Wiring harness
– Fuel filter (if – Inertia fuel shutoff
equipped) (IFS) switch
– Fuel tank – Fuel pump module
– Fuel tank filler pipe
– Fuel filler cap
symptom and refer to WDS.
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GENERAL PROCEDURES
Fuel System Pressure Release (23 420 0)

Release
1. WARNING: Do not smoke or carry
type when working on or near any fuel
related components. Highly flammable
vapors are always present and may
injury.
WARNING: The fuel system remains
pressurized for a long time after the
ignition is switched off. The fuel pressure
must be released before attempting any
repairs. Failure to follow this instruction
Remove the fuel pump fuse.
2. Start the engine and allow to idle until the
engine stalls.
3. Crank the engine for approximately five
seconds to make sure the fuel injection
supply manifold pressure has been
released.
4. Install the fuel pump fuse.
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GENERAL PROCEDURES
Quick Release Coupling
2. Disconnect the fuel line quick release

coupling.
General Equipment
1. Press the fuel line quick release coupling
Flat-bladed screwdriver locking tangs.
2. Disconnect the fuel line quick release cou-
pling.
Disconnection
WARNING: Do not carry lighted tobacco
or open flame of any type when working
on or near any fuel related components.
Highly flammable vapors are always
present and can ignite. Failure to follow
injury.
injury. 3. Disconnect the fuel line quick release
coupling.
CAUTION: Fuel injection equipment is
1. Pull the fuel line quick release coupling
manufactured to very precise tolerances
and fine clearances. It is therefore locking tang.
essential that absolute cleanliness is 2. Push the clip through the fuel line quick
observed when working with these release coupling to release the fuel line.
components. Always install blanking
plugs to any open orifices or lines.
NOTE: Fuel supply line connectors are white or
are identified by a white band. Fuel return line
connectors are red or are identified by a red band.
additional information, refer to Fuel System
Pressure Release in this section.
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4. Disconnect the fuel line quick release 6. Release the fuel tank vent line quick
coupling. release coupling.
1. Press the fuel line quick release coupling • Press the fuel tank vent line quick release
locking tangs. coupling locking release collar.
2. Disconnect the fuel line quick release cou-
pling.
7. Disconnect the fuel tank vent line quick

release coupling.
5. Disconnect the fuel line quick release
coupling.
• Press the fuel line quick release coupling
buttons and pull the fuel line to disconnect.
8. Release the fuel line quick release

coupling.
• Press the fuel line quick release coupling
locking release collar.
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9. Disconnect the fuel line quick release cou- 12. Disconnect the fuel line from the fuel line
pling. quick release coupling.
10. Using a suitable Flat-bladed screwdriver 13. Disconnect the fuel line from the fuel
release the fuel line quick release cou- filter.
pling secondary locking tang. 1. Press the collar into the connector body.
2. Disconnect the fuel line from the fuel filter.
11. Operate the fuel line quick release

coupling primary locking tang.
• Push the fuel line quick release coupling
primary locking tang into from the fuel line Connect
quick release coupling. WARNING: Do not carry lighted tobacco
or open flame of any type when working
on or near any fuel related components.
Highly flammable vapors are always
present and can ignite. Failure to follow
injury.
injury.
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CAUTION: Fuel injection equipment is 3. CAUTION: Make sure the quick release
manufactured to very precise tolerances coupling primary locking tang clicks
and fine clearances. It is therefore into place when installing.
essential that absolute cleanliness is
Insert the fuel line quick release coupling
observed when working with these
secondary locking tang into the fuel line
components. Always install blanking
quick release coupling.
plugs to any open orifices or lines.
NOTE: Fuel supply line connectors are white or
are identified by a white band. Fuel return line
connectors are red or are identified by a red band.
1. Push the connector on to the fuel filter.
4. CAUTION: After installation, to make

sure that the fuel line is fully seated,
pull on the line.
Install the fuel line quick release coupling.
2. Install the fuel line to the fuel line quick
release coupling.
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5. CAUTION: After installation , to make 7. NOTE: Make sure the collar on the fuel line is
sure that the vent line is fully seated, inserted fully into the fuel line quick release
pull on the line. coupling.
Install the fuel tank vent line quick release Install the fuel line quick release coupling.
coupling.
8. NOTE: Make sure the collar on the fuel line is

inserted fully into the fuel line quick release
6. CAUTION: Make sure the fuel line clicks
coupling before the locking tang is locked.
into place when installing the line. To
make sure that the fuel line is fully Install the fuel line quick release coupling.
seated, pull on the line. 1. Install the fuel line quick release coupling
Install the fuel line quick release coupling. locking tang.
2. Rotate the fuel line quick release coupling
locking tang into position.
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9. NOTE: Make sure the collar on the fuel line is

inserted fully into the fuel line quick release
coupling before the locking tang is locked.
Install the fuel line quick release coupling.
1. Install the fuel line quick release coupling.
2. Press the fuel line quick release coupling
locking tang into position.
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GENERAL PROCEDURES
Spring Lock Couplings (23 004 0)

Special Tool(s) additional information, refer to Fuel System
Pressure Release in this section.
Disconnect Tool, Spring Lock
Coupling (3/8”yellow) 2. Install the special tool to the fuel line.
310-D004 (23-039)

Coupling (1/2”green)
310-D005 (23-040)

Coupling (5/8” black)
412-038 (34-003) 3. NOTE: Both sides of the spring lock coupling
fuel line must be pushed together to enable the
special tool to release the spring lock coupling
locking tangs.
Disconnect Tool, Fuel Line
Slide the special tool into the spring lock
(5/16”)
coupling to release the locking tangs.
310-040 (23-041)
Disconnection
repairs. Failure to follow these
injury.
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4. Disconnect the fuel line from the spring 7. Close and push the fuel line spring lock
lock coupling. coupling tool into the open side of the
• Allow the fuel to drain into a suitable con- cage.
tainer.
8. Separate the fuel line spring lock coupling.
5. Remove the safety clips from the fuel line

spring lock couplings.
6. Install the special tool onto the fuel line

spring lock coupling.
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Installation
3. Make sure the fuel line spring lock coupling
WARNING: Do not smoke or carry lighted is engaged by pulling on the lines.
WARNING: This procedure involves fuel 4. NOTE: Make sure the collar on the fuel line is
handling. Be prepared for fuel spillage at inserted fully into the fuel line spring lock
all times and always observe fuel coupling and an audible click is heard.
Install the spring lock coupling to the fuel
line.
injury.
1. Inspect and clean both fuel line spring lock
coupling ends. Install new O-rings and
garter springs if necessary.
2. NOTE: Lubricate the O-rings seals with clean

engine oil.
Insert the male fitting into the female end
and push until the garter spring snaps over
the flared end of the female fitting.
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GENERAL PROCEDURES
Fuel Tank Draining (23 551 0)
General Equipment 4. NOTE: Fuel filler hoses on petrol variants are

fitted with a secondary fuel filler pipe spit back
Fuel tank drainer valve.
All vehicles NOTE: To enable the hose to enter the fuel tank it
must pass through the fuel filler pipe spit back
1. WARNING: Do not smoke or carry valve/valves (if equipped).
type when working on or near any fuel Insert the fuel tank drainer evacuation pipe
related components. Highly flammable down the fuel tank filler pipe and into the
vapors are always present and may fuel tank.
injury.
must be relieved before attempting any
WARNING: The evacuating area must be
clearly identified with signs warning
against smoking and the use of naked
lights or flames within the vicinity. Highly
flammable vapors are always present and
may ignite. Failure to follow these
WARNING: Always disconnect the vehicle
battery ground cable before commencing
any service or repair procedure. Failure
personal injury.
Disconnect]
2. Remove the fuel filler cap.
3. WARNING: Always connect the fuel
tank drainer ground cable to the
vehicle before proceeding to the next
step. Failure to follow this instruction
Connect the fuel tank drainer ground cable
to the vehicle.
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5. WARNING: The fuel tank drainer must

be operated in accordance with the
manufacturer's instructions. Failure to
personal injury.
Drain the fuel tank.
6. Remove the pipe and disconnect the fuel

tank drainer ground cable.
Disconnect]
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310-01-1 Fuel Tank and Lines 310-01-1
SECTION 310-01 Fuel Tank and Lines

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 310-01-2
Fuel Tank and Lines ......................................................................................................... 310-01-3

Vehicles with diesel engine .............................................................................................. 310-01-3/6
Vehicles with 2.0L diesel engine ...................................................................................... 310-01-8
Vehicles with fuel additive system .................................................................................... 310-01-9/11
Vehicles with 1.6L, 1.8L or 2.0L engine............................................................................ 310-01-12/16
Fuel Tank and Lines ......................................................................................................... 310-01-17
Fuel Tank — 1.6L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT (Sigma)/1.8L Du-

ratec-HE (MI4)/2.0L Duratec-HE (MI4), Vehicles Without: Fuel Fired Booster Heater ...... 310-01-18/27
Fuel Tank — 2.0L Duratorq-TDCi (DW) Diesel, Vehicles
Without: Fuel Additive Tank/Fuel Fired Booster Heater .................................................... 310-01-28/36
Fuel Pump Module........................................................................................ (23 534 0) 310-01-37
Fuel Tank Filler Pipe ......................................................................................................... 310-01-38/45
Fuel Filter — 2.0L Duratec-HE (MI4)................................................................................. 310-01-46/47
Fuel Filter — 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor....... 310-01-48/51
Fuel Filter — 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor.. 310-01-52/55
Fuel Supply Line — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4).................................. 310-01-56/59
Fuel Supply Line — 2.0L Duratorq-TDCi (DW) Diesel ........................................................ 310-01-60/62
Fuel Return Line — 2.0L Duratorq-TDCi (DW) Diesel ........................................................ 310-01-63
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SPECIFICATIONS

Item Specification
6.5% Fuel Additive Cerium/Iron Concentration Fluid WSS-M99C127-A1

Fuel tank support strap retaining bolts 25 18 -
Fuel tank filler Pipe bracket retaining screw 10 - 89
Fuel additive tank retaining screws 8 - 71
Fuel additive system module retaining nuts 3 - 27
Fuel pump module locking ring 85 63 -
Fuel tank filler pipe retaining screw 10 - 89
Fuel tank filler hose retaining clamp 4 - 35
Fuel tank vent hose retaining clamp 4 - 35
Fuel filter retaining bracket retaining bolt - vehicles 5 - 44
with 1.6L/1.8L or 2.0L engines (if equipped)
Fuel filter shield retaining bolts - vehicles with 1.6L 10 - 89
diesel engine
Fuel filter crash protection shield - vehicles with 9 - 80
2.0L diesel engine
Rear damper lower retaining bolts 115 201 -
Rear axle crossmember retaining bolts 115 201 -
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Fuel Tank and Lines

System Overview
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Number
1 - Fuel level sensor
2 - Fuel level sensor locking ring
3 - Fuel tank filler pipe retaining
bolts
4 - Fuel tank filler pipe
5 - Fuel tank vent pipe
6 - Fuel filler pipe spit back valve
7 - Fuel tank fuel additive injec- The fuel tank filler pipe vent pipe allows air to
tor (if equipped) escape from the tank when the fuel tank is being
8 - Fuel tank filled.
9 - Fuel tank roll - over valves

10 - Fuel tank support straps
11 - Fuel tank support straps re-
taining bolts
12 - Fuel filter to fuel tank fuel
return line
13 - Fuel tank to fuel filter fuel
supply line
return line
supply line
16 - Fuel level sensor seal
The fuel tank holds approximately 53 liters of

usable fuel and is of a plastic construction. It is
retained to the vehicle by means of two steel
support straps, the fuel tank supports straps are
secured by three retaining bolts onto the
underside of the vehicle chassis.
The fuel tank filler pipe is designed to fill the fuel
tank, it consists of a fuel tank filler pipe and fuel
tank vent pipe. Located within the fuel tank filler
pipe is a fuel filler pipe spit back valve. The spit
back valves have been designed to reduce the
possibility of fuel tank siphoning. To enable the
hose of the fuel tank draining equipment to enter
the fuel tank, it must pass through the fuel filler
pipe spit back valve. For additional information on
fuel tank draining. For additional information,
refer to Section 310-00.[Fuel System - General
Information, GENERAL PROCEDURES, Fuel
Tank Draining]
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The fuel supply and return lines have either spring

Item Part Description lock couplings or quick release couplings at each
Number end to secure them to the fuel tank lines. For
1 - Fuel tank to fuel filter fuel additional information, refer to Section 310-00.
supply line [Fuel System - General Information,
2 - Fuel filter to fuel tank fuel Coupling] For additional information,
return line refer to Section 310-00.[Fuel System - General
3 - Fuel line retaining clips Information, GENERAL PROCEDURES, Spring
Lock Couplings]
4 - Fuel line grounding clip
The fuel supply and return lines are constructed
from a steel material coated with nylon and are
retained by clips which are also made of plastic. At
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the front of the vehicle there is a fuel line

grounding clip equipped with a conductive sleeve
made of steel or conductive plastic which also
holds the fuel supply and return lines against the
body. This clip is made of a conductive material
which is designed to dissipate the static electricity
created when fuel travels through the fuel supply
and return lines.
Fuel tank ventilation is achieved by a fuel tank

roll-over valve which is installed into the top of the
fuel tank and will prevent fuel loss from the fuel
tank if the vehicle becomes inverted.
The fuel tank roll-over valve also acts as fuel tank
breather with filter. If this filter become blocked or
restricted during the vehicle's lifetime the The fuel level sensor is equipped with a fuel tank
customer will experience problems with draining sender unit. The fuel tank sender unit consists of a
the fuel tank and there could be a possibility of fuel mechanical float and a potentiometer. The
tank deformation. potentiometer communicates the fuel level
information via a float directly with the fuel gauge
The fuel level sensor is located in the top of the in the instrument cluster informing the driver the
fuel tank and retained by a fuel level sensor amount of fuel that is currently in the fuel tank.
locking ring and seal, a new seal must installed
after the fuel level sensor is removed. CAUTION: Make sure the fuel level sensor
NOTE: The fuel tank must be completely removed float and arm are not damaged during the
from the vehicle before the fuel level sensor can removal or installation of the fuel level
be removed. sensor.
NOTE: Make sure the arrows on the fuel tank and
For additional information, refer to Fuel Tank - fuel level sensor are aligned correctly. Failure to
1.6L Duratorq-TDCi (DV) Diesel/2.0L follow this may result in incorrect fuel gauge
Duratorq-TDCi (DW) Diesel, Vehicles Without: reading.
Fuel Additive Tank/Fuel Fired Booster Heater in
this section.
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Vehicles with 2.0L diesel engine Fuel Filter
The 2.0L diesel engine fuel filter is located above

Item Part Description the generator and is attached to the cylinder head
Number by means of a fuel filter crash protection shield, a
1 - Fuel tank to fuel filter fuel fuel filter splash shield and a fuel filter retaining
supply line bracket. The fuel filter has an electric fuel heater
which is located next to the fuel filter inlet pipe.
return line When the temperature is below 15ºC, a valve
inside the fuel filter opens allowing fuel which is
3 - Fuel filter to fuel pump fuel pre-heated by the fuel injection pump to be
supply line recirculated back through the fuel filter to the fuel
4 - Fuel heater sensor injection pump. This aids engine performance
during warm up.
5 - Water in fuel sensor (if
Fuel is delivered through the fuel supply lines to
equipped)
the fuel filter. The fuel filter cleans the fuel of water
6 - Fuel filter crash protection and contaminants. Unused fuel is returned to the
shield fuel tank through the fuel pump return line.
7 - Fuel filter The fuel filter is also equipped with a water-in-fuel
sensor which is located at the base of the fuel filter
8 - Fuel filter retaining bracket housing. This sensor measures the amount of
water which has collected in the fuel filter element.
CAUTION: The generator must be If the quantity of water present is greater than 90
protected from contamination. Failure to ml then a warning indicator located on the
follow this instruction may cause instrument cluster is illuminated and the fuel filter
premature failure of the generator. element should then be drained of water.
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When a new fuel filter has been fitted it must be WARNING: Do not smoke or carry lighted
bled with a hand pressure pump. Make sure that tobacco or open flame of any type when
the arrows indicating the direction of fuel flow is working on or near any fuel related
pointing towards the fuel filter. For additional components. Highly flammable vapors
information, refer to Fuel Filter - 2.0L are always present and may ignite.
Duratorq-TDCi (DW) Diesel, Vehicles With: Failure to follow these instructions may
Water-in-Fuel Sensor / Fuel Filter - 2.0L result in personal injury.
Duratorq-TDCi (DW) Diesel, Vehicles Without:
Water-in-Fuel Sensor in this section. CAUTION: Make sure the workshop area
in which the vehicle is being worked on is
as clean and as dust free as possible.
Vehicles with fuel additive system Foreign matter from work on clutches,
brakes or from machining or welding
operations can contaminate the fuel
System Overview system and may result in later
malfunction.
WARNING: Eye, hand, ear protection and
protective clothing are required to be The fuel additive system supports the diesel
worn during any general service work or particulate filter (DPF) to reduce the pollution
removal and installation of fuel additive generated by diesel vehicles by filtering solid
system components. Failure to follow elements out of the exhaust gases to reach stage
this instruction may result in personal 4 emission levels.
injury.
The additive system consists of a fuel additive
WARNING: In case of fuel additive fluid system module, fuel additive tank to fuel tank line
contact with the skin or the eyes, flush and a fuel additive tank with integral dosing pump.
immediately with water for a minimum of The fuel additive fluid is used to lower the
15 minutes and seek prompt medical combustion temperature of the unburnt fuel
attention. Failure to follow these residues inside the DPF. The additive fluid, which
instructions may result in personal injury. contains cerium and iron must be exactly mixed
with the fuel in the main fuel tank to achieve the
WARNING: If fuel additive fluid is right level when entering the DPF.
swallowed, call a physician immediately.
After fuel tank filling has been completed by the
rinse mouth immediately with water, do
customer the fuel additive system module
not induce vomiting. Failure to follow
communicates information to the additive tank
which injects a calculated dose of additive fluid
injury.
into the main fuel tank when the vehicle reaches
WARNING: Always provide adequate or exceeds a speed of 40 kph or 4 minutes after
ventilation when working on the fuel the fuel tank filling has been completed. The fuel
additive fluid system or related additive system module uses signals and
components. Failure to follow these information from the CAN-bus ,engine on/off
instructions may result in personal injury. signal, vehicle speed sensors and fuel gauge
value from instrument cluster. It will also initially
receive a signal from the fuel filler pipe filler flap
switch to indicate that a fill up procedure may be
about to occur.
Routine service interval maintenance is required
for this system.
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Number
1 - Fuel additive tank to fuel tank
line
2 - Fuel tank
3 - Fuel additive system module
4 - Fuel filler flap magnet
5 - Fuel filler flap switch
7 - Fuel additive tank vent and
filler pipe
8 - Fuel additive tank overflow
port
9 - Fuel additive tank and dosing
pump
The fuel additive tank holds approximately 1.4
liters of usable fuel additive fluid and
approximately 1.8 usable liters when completely
refilled and is of a plastic construction. It is
retained to the vehicle by means of three retaining
bolts which are fitted to the top of the rear
sub-frame on the underside of the vehicle chassis.
The fuel additive tank is also equipped with a
internal dosing pump which is an integral part of
the fuel additive tank. The dosing pump receives a
signal from the fuel additive system module and
adds the correct amount of fuel additive to the
main fuel tank. The fuel additive tank and dosing
pump are a one piece unit and cannot be serviced
separately.
The fuel additive system module controls the
amount and frequency of fuel additive fluid
injecting into the main fuel tank. It is retained to the
vehicle by means of two retaining nuts and is
located underneath the rear seat carpet.
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Vehicles with 1.6L, 1.8L or 2.0L engine
System Overview
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Item Part Description possibility of fuel tank siphoning. To enable the

Number hose of the fuel tank draining equipment to enter
the fuel tank, it must pass through the fuel filler
1 - Fuel tank filler pipe pipe spit back valve. For additional information on
2 - Fuel tank vent pipe fuel tank draining. For additional information,
refer to Section 310-00.[Fuel System - General
3 - Fuel tank to fuel filter fuel Information, GENERAL PROCEDURES, Fuel
supply line (if equipped) Tank Draining]
4 - Fuel tank vent pipe The fuel tank filler pipe vent pipe allows air to
escape from the tank when the fuel tank is being
5 - Fuel pump module locking
filled.
ring
6 - Fuel pump module
7 - Fuel pump module seal
return line (if equipped)
9 - Fuel tank roll - over valves
10 - Fuel tank
11 - Fuel tank to fuel injection
supply manifold fuel supply
line
ter pipe to evaporative emis-
sion purge valve pipe
ter pipe
14 - Fuel tank support straps re-
taining bolts
15 - Fuel tank support straps
16 - Fuel filter (if equipped)
17 - Fuel filter retaining bracket (if
equipped) Fuel tank ventilation is achieved by two fuel tank
18 - Fuel filter to fuel supply line roll - over valves venting through a back pressure
fuel supply line (if equipped) valve and into an evaporative emission canister
which absorbs the fuel vapor. The fuel tank roll -
19 - Fuel filler pipe retaining over valve are installed into the top of the fuel tank
screws and will prevent fuel loss from the fuel tank if the
vehicle becomes inverted.
The fuel tank holds approximately 55 liters of
usable fuel and is of a plastic construction. It is
retained to the vehicle by means of two steel
support straps, the fuel tank supports straps are
secured by three retaining bolts onto the
underside of the vehicle chassis.
The fuel tank filler pipe is designed to fill the fuel
tank it consists of a fuel tank filler pipe and fuel
tank vent pipe, located within the fuel tank filler
pipe is a fuel filler pipe spit back valve. The spit
back valve has been designed to reduce the
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module filter becomes blocked a new fuel pump

module must be installed For additional
information, refer to Fuel Pump Module in this
section. The fuel pump is a turbine type pump
which is an integral part of the fuel pump module.
The fuel tank module fuel sender communicates
directly with the instrument cluster which drives
the fuel gauge informing the driver the amount of
fuel that is currently in the fuel tank.
CAUTION: Make sure the fuel tank level

sensor float and arm are not damaged
during the installation of the fuel pump
module.
The fuel pump module is located in the top of the NOTE: Make sure the arrows on the fuel tank and
fuel tank and retained by a re-usable fuel tank fuel pump module are aligned correctly. Failure to
locking ring. The fuel pump module seal must not follow this may result in incorrect fuel gauge
be re-used once removed from the fuel tank. reading.
The fuel pump module consists of a fuel sender, a The fuel tank must be completely removed from
fuel filter and a high pressure fuel pump with the vehicle before the fuel pump module unit can
pressure regulator. The fuel filter is designed to be removed. For additional information, refer to
reduce the amount of large fuel debris entering the Fuel Tank - 1.6L Duratec-16V (Sigma)/1.6L
main fuel system filter. The fuel tank module filter Duratec-16V Ti-VCT (Sigma)/1.8L Duratec-HE
has been designed as a non serviceable item and (MI4)/2.0L Duratec-HE (MI4), Vehicles Without:
will last the lifetime of the vehicle, if the fuel tank Fuel Fired Booster Heater in this section.
G385139 en 09/2004 2004.75 Focus

TO MODEL INDEX
The fuel supply line has either spring lock

Item Part Description couplings or quick release couplings at each end
Number to secure it to the fuel tank. For additional
1 - Fuel supply line information, refer to Section 310-00.[Fuel System
- General Information, GENERAL PROCEDURES,
2 - Evaporative emission purge Quick Release Coupling] For additional
valve pipe to evaporative information, refer to Section 310-00.[Fuel System
emission canister - General Information, GENERAL PROCEDURES,
3 - Fuel line retaining clips Spring Lock Couplings]
- Fuel line grounding clip The fuel supply line is constructed from a steel
material coated with nylon and is retained by clips
which are also made of plastic. At the front of the
vehicle there is a fuel line grounding clip equipped
G385139 en 09/2004 2004.75 Focus
TO MODEL INDEX
with a conductive sleeve made of steel or

conductive plastic which also holds the fuel supply
line against the body. This clip is made of a
conductive material which is designed to dissipate
the static electricity created when fuel travels
through the fuel supply line.
Vehicles with 1.6L, 1.8L or 2.0L engine are
equipped with a returnless fuel system. The
returnless fuel system eliminates fuel system
recirculation therefore reducing fuel heating and
evaporative emissions. A fuel pressure sensor
located in the fuel tank module controls a constant
fuel rail pressure under all driving conditions.
The inertia fuel shutoff (IFS) switch cuts off the

electrical supply to the fuel pump in the event of an
accident and is located in the right hand footwell
behind the front scuff plate trim panel. For
[Interior Trim and Ornamentation,
REMOVAL AND INSTALLATION, Front Scuff
Plate Trim Panel]
G385139 en 09/2004 2004.75 Focus

TO MODEL INDEX
Fuel Tank and Lines

For vehicles with fuel additive tank.

For vehicles with 1.6L Duratec-16V (Sigma)/1.8L
Duratec-HE (MI4)/2.0L Duratec-HE.
REFER to Section 310-00.[Fuel System - General
Information, DIAGNOSIS AND TESTING, Fuel
System - 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4)]
For vehicles with 2.0L Duratorq-TDCi (DW) Diesel.
G330046 en 09/2004 2004.75 Focus

TO MODEL INDEX
Fuel Tank — 1.6L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT (Sigma)/1.8L

Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Vehicles Without: Fuel Fired Booster

Heater
4. Detach the exhaust system from the middle

Special Tool(s) hanger insulator.
Wrench, Fuel Tank Sender

Unit
(310-069) 23-055
General Equipment
Transmission jack

components. Highly flammable vapors 5. Remove the exhaust flange nuts.
are always present and may ignite. • Discard the gasket and exhaust flange re-
Failure to follow these instructions may taining nuts.
injury.
GENERAL PROCEDURES, Fuel System
Pressure Release]
2. Drain the fuel tank. For additional
PROCEDURES, Fuel Tank Draining]
G295877 en 09/2004 2004.75 Focus

TO MODEL INDEX
6. NOTE: With the aid of another technician 8. Remove the left hand side rear air deflector
support the exhaust. shield.
Detach the exhaust system from the front
hanger insulators.

table(s).
7. NOTE: With the aid of another technician
support the exhaust.
Position the exhaust to one side and se-
cure to the body with tie-straps.
G295877 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
1 - Exhaust pipe center heat
2 - Fuel tank heat shield
G295877 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
5 - Fuel tank vent hose retaining
3 - Fuel tank filler hose retaining clamp
clamps See Removal Detail
6 - Fuel tank vent hose
4 - Fuel tank filler hose See Removal Detail
See Removal Detail
canister vent pipe quick
release coupling
See Removal Detail
G295877 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number Number
8 - Fuel line to fuel tank vent 11 - Fuel tank support straps
pipe quick release coupling See Removal Detail
9 - Fuel tank fuel supply line 12 - Fuel tank
quick release coupling See Removal Detail
10 - Evaporative emission 13 - Fuel pump module electrical
canister to fuel tank vent pipe connector
G295877 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
14 - Fuel tank vent hose retaining Item 3 : Fuel tank filler hose retaining clamps
clamp 1. NOTE: Make a note of the position of the fuel
See Removal Detail tank filler hose retaining clamp. Make sure that
See Installation Detail the new replacement screw type clamp is
positioned so that the screw head is in the
15 - Fuel tank vent hose same position as as the original filler hose
See Removal Detail retaining clamp.
16 - Fuel tank vent pipe Remove and discard the fuel tank filler
17 - Fuel supply line hose retaining clamp.
See Removal Detail
18 - Fuel pump module locking
ring
See Removal Detail
19 - Fuel pump module
See Removal Detail
20 - Fuel pump module seal
21 - Fuel tank

11. Initialize the door window motors. For 2. NOTE: Make a note of the position of the fuel
additional information, refer to Section tank filler hose retaining clamp. Make sure that
501-11.[Glass, Frames and Mechanisms, the new replacement screw type clamp is
GENERAL PROCEDURES, Door Window positioned so that the screw head is in the
Motor Initialization] same position as as the original filler hose
retaining clamp.
Remove and discard the fuel tank filler
hose retaining clamp (rear sub-frame
G295877 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 4 : Fuel tank filler hose Item 7 : Evaporative emission canister vent
pipe quick release coupling
1. CAUTION: When removing the fuel tank 1. Disconnect the evaporative emission
filler hose, do not use any sharp edge canister vent pipe quick release coupling
tools to lever off the pipes. Failure to from the evaporative emission canister.
• Release the locking tangs
damage to the filler hose.
Remove the fuel tank filler hose.
Item 5 : Fuel tank vent hose retaining clamp
1. NOTE: Make a note of the position of the fuel
tank vent hose retaining clamp. Make sure that
the new replacement screw type clamp is
same position as as the original vent hose
retaining clamp.
Remove and discard the fuel tank vent
Item 8 : Fuel line to fuel tank vent pipe quick

release coupling
1. Disconnect the fuel line to fuel tank vent
pipe quick release coupling. For additional
Item 9 : Fuel tank fuel supply line quick
release coupling
1. Disconnect the fuel tank fuel supply line
quick release coupling. For additional
Item 6 : Fuel tank vent hose PROCEDURES, Quick Release Coupling]
1. CAUTION: When removing the fuel tank Item 10 : Evaporative emission canister to fuel
vent hose, do not use any sharp edge tank vent pipe quick release coupling
tools to lever off the pipes. Failure to 1. Disconnect the evaporative emission
follow this instruction may result in canister to fuel tank vent pipe quick release
damage to the vent hose. coupling from the fuel tank.
Disconnect the fuel tank vent hose from the • Release the locking tangs
fuel tank filler pipe.
G295877 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 11 : Fuel tank support straps Item 14 : Fuel tank vent hose retaining clamp
CAUTION: When supporting the fuel tank,
use a suitable packing material to prevent
damage to the underside of the fuel tank.
1. Place a suitable transmission jack under
the fuel tank.
retaining clamp.
Item 12 : Fuel tank

CAUTION: When lowering the fuel tank,
do not place excessive strain on the fuel Item 15 : Fuel tank vent hose
lines and wiring harness.
1. Partially lower the fuel tank. 1. CAUTION: When removing the fuel tank
Item 13 : Fuel pump module electrical vent hose, do not use any sharp edge
connector tools to lever off the pipes. Failure to
1. Disconnect the fuel pump module electrical follow this instruction may result in
connector. damage to the vent hose.
Remove the fuel tank vent hose from the
fuel tank.
release coupling. For additional
G295877 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 18 : Fuel pump module locking ring Item 18 : Fuel pump module locking ring
1. Using the special tool, remove the fuel 1. Using the special tool, install the fuel pump
pump locking ring. locking ring.
Item 19 : Fuel pump module Item 14 : Fuel tank vent hose retaining clamp
1. Install a new fuel tank vent hose retaining
CAUTION: Make sure the fuel tank level clamp in the position shown.
during the removal of the fuel pump
module.
Item 19 : Fuel pump module

1. CAUTION: Make sure the fuel tank level
during the installation of the fuel pump
module.
Make sure the arrows on the fuel tank and
fuel pump module are aligned correctly.
Item 12 : Fuel tank
CAUTION: When installing the fuel tank,
make sure the fuel lines do not get kinked
or trapped.
1. Partially raise the fuel tank.
G295877 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 13 : Fuel pump module electrical

2. Install a new fuel tank filler hose retaining
connector
clamp in the position shown (rear
1. Connect the fuel pump module electrical
sub-frame shown removed for clarity).
connector.
Item 11 : Fuel tank support straps

1. Install the fuel tank support strap retaining
bolts and remove the transmission jack.
Item 3 : Fuel tank filler hose retaining clamps

clamp in the position shown.
G295877 en 09/2004 2004.75 Focus

TO MODEL INDEX
Fuel Tank — 2.0L Duratorq-TDCi (DW) Diesel,Vehicles Without: Fuel Additive

Tank/Fuel Fired Booster Heater
4. Remove the exhaust flange nuts.

Special Tool(s) • Discard the gasket and exhaust flange re-
Wrench, Fuel Tank Sender taining nuts.
Unit
(310-069) 23-055
General Equipment
Transmission jack

are always present and may ignite. 5. NOTE: With the aid of another technician
Failure to follow these instructions may support the exhaust.
result in personal injury. Detach the exhaust system from the front
WARNING: This procedure involves fuel hanger insulators.
injury.
1. Drain the fuel tank. For additional
PROCEDURES, Fuel Tank Draining]
3. Detach the exhaust system from the middle
hanger insulator.
6. Position the exhaust to one side and se-

cure to the body with tie-straps.
G344533 en 09/2004 2004.75 Focus

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table(s).

Number
1 - Exhaust pipe center heat
2 - Fuel tank heat shield
G344533 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
3 - Fuel tank filler hose retaining clamp
clamps See Removal Detail
6 - Fuel tank vent hose
4 - Fuel tank filler hose See Removal Detail
See Removal Detail
7 - Fuel tank fuel return line
See Removal Detail
G344533 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number Number
8 - Fuel tank fuel supply line 10 - Fuel Tank
9 - Fuel tank support straps 11 - Fuel tank module electrical
See Removal Detail connector
G344533 en 09/2004 2004.75 Focus

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Number
clamp
See Removal Detail tank filler hose retaining clamp. Make sure that
See Installation Detail the new replacement screw type clamp is
13 - Fuel tank vent hose same position as as the original filler hose
See Removal Detail retaining clamp.
14 - Fuel tank fuel return line Remove and discard the fuel tank filler
quick release coupling hose retaining clamp.
See Removal Detail
15 - Fuel tank fuel supply line
See Removal Detail
16 - Fuel tank module locking ring
See Removal Detail
17 - Fuel tank module
See Removal Detail
18 - Fuel tank module seal
19 - fuel tank
8. To install, reverse the removal procedure. tank filler hose retaining clamp. Make sure that
9. Initialize the door window motors. For positioned so that the screw head is in the
additional information, refer to Section 501-11. same position as as the original filler hose
[Glass, Frames and Mechanisms, retaining clamp.
Motor Initialization] Remove and discard the fuel tank filler
G344533 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 4 : Fuel tank filler hose System - General Information, GENERAL

PROCEDURES, Spring Lock Couplings]
1. CAUTION: When removing the fuel tank
filler hose, do not use any sharp edge Item 9 : Fuel tank support straps
tools to lever off the pipes. Failure to
CAUTION: When supporting the fuel tank,
use a suitable packing material to prevent
damage to the filler hose.
damage to the underside of the fuel tank.
Remove the fuel tank filler hose. 1. Place a suitable transmission jack under
the fuel tank.
retaining clamp.
Item 10 : Fuel Tank

CAUTION: When lowering the fuel tank,
do not place excessive strain on the fuel
lines and wiring harness.
1. Partially lower the fuel tank.
Item 11 : Fuel tank module electrical
connector
1. Disconnect the fuel tank module electrical
connector.
Item 6 : Fuel tank vent hose
vent hose, do not use any sharp edge
tools to lever off the pipes. Failure to
damage to the vent hose.
Disconnect the fuel tank vent hose from the
fuel tank filler pipe.
Item 7 : Fuel tank fuel return line quick release
coupling
1. Disconnect the fuel tank fuel return line
spring lock coupling. For additional
release coupling
G344533 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 12 : Fuel tank vent hose retaining clamp Item 16 : Fuel tank module locking ring
1. NOTE: Make a note of the position of the fuel 1. Using the special tool, remove the fuel tank
tank vent hose retaining clamp. Make sure that locking ring.
retaining clamp.
Item 17 : Fuel tank module

CAUTION: Make sure the fuel tank level
during the removal of the fuel tank
module.
Item 13 : Fuel tank vent hose Installation Details

1. CAUTION: When removing the fuel tank Item 17 : Fuel tank module
vent hose, do not use any sharp edge
tools to lever off the pipes. Failure to 1. CAUTION: Make sure the fuel tank level
follow this instruction may result in sensor float and arm are not damaged
damage to the vent hose. during the installation of the fuel tank
Remove the fuel tank vent hose from the module.
fuel tank. Make sure the arrows on the fuel tank and
Item 14 : Fuel tank fuel return line quick fuel tank module are aligned correctly.
release coupling
1. Disconnect the fuel tank fuel return line
release coupling
G344533 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 16 : Fuel tank module locking ring Item 11 : Fuel tank module electrical
1. Using the special tool, install the fuel tank connector
locking ring. 1. Connect the fuel tank module electrical
connector.

1. Install a new fuel tank vent hose retaining Item 9 : Fuel tank support straps
clamp in the position shown. 1. Install the fuel tank support strap retaining
bolts and remove the transmission jack.
Item 10 : Fuel Tank

CAUTION: When installing the fuel tank,
make sure the fuel lines do not get kinked
or trapped.
1. Partially raise the fuel tank.
clamp in the position shown.
G344533 en 09/2004 2004.75 Focus

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G344533 en 09/2004 2004.75 Focus

TO MODEL INDEX
Fuel Pump Module (23 534 0)

1. For vehicles fitted with petrol engines. For

additional information, refer to Fuel Tank -
1.6L Duratec-16V (Sigma)/1.6L Duratec-16V
Ti-VCT (Sigma)/1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4), Vehicles Without: Fuel
Fired Booster Heater in this section.
2. For vehicles fitted with diesel engines
without fuel additive tank. For additional
information, refer to Fuel Tank - 2.0L
Duratorq-TDCi (DW) Diesel, Vehicles
Without: Fuel Additive Tank/Fuel Fired
Booster Heater in this section.
3. For vehicles fitted with diesel engines with
fuel additive tank.
G334281 en 09/2004 2004.75 Focus

TO MODEL INDEX
Fuel Tank Filler Pipe
CAUTION: Make sure the workshop area

General Equipment
in which the vehicle is being worked on is
Transmission jack as clean and as dust free as possible.
Foreign matter from work on clutches,
brakes or from machining or welding
operations can contaminate the fuel
WARNING: This procedure involves fuel system and may result in later
additive handling. Be prepared for fuel malfunction.
additive spillage at all times and always NOTE: After the fuel additive tank to fuel tank line
observe fuel handling precautions. has been connected it must be bled. For additional
Failure to follow these instructions may information on fuel additive tank to fuel tank line
result in personal injury. bleeding, Refer to WDS.
WARNING: Eye, hand, ear protection and 1. Drain the fuel tank. For additional
protective clothing are required to be information, refer to Section 310-00.[Fuel
worn during any general service or System - General Information, GENERAL
removal and installation procedure of fuel PROCEDURES, Fuel Tank Draining]
additive system components. Failure to 2. Remove the rear wheels and tires. For
follow this instruction may result in additional information, refer to Section 204-04.
personal injury. [Wheels and Tires, REMOVAL AND
WARNING: In case of fuel additive fluid 3. Remove the right-hand rear splash shield.
contact with the skin or the eyes, flush
immediately with water for a minimum of
15 minutes and seek prompt medical
attention. Failure to follow these
WARNING: If fuel additive fluid is
swallowed, call a physician immediately.
rinse mouth immediately with water, do
not induce vomiting. Failure to follow
injury.
WARNING: Always provide adequate
ventilation when working on the fuel
additive fluid system or related 4. Detach and disconnect the rear end wiring
components. Failure to follow these harness electrical connector.
1. Release the locking tang.
G295879 en 09/2004 2004.75 Focus

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5. Detach the rear end wiring harness from

the chassis and fuel tank filler pipe clamp.
table(s).
6. Disconnect the fuel additive tank to fuel

tank line from the fuel additive tank (if
equipped).
• Drain the fluid into a suitable Oil drainer.
G295879 en 09/2004 2004.75 Focus

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Number
4 - Electronic parking brake
1 - Rear springs retaining nut (if equipped)
5 - Electronic parking brake
2 - Rear damper lower retaining cable
bolt See Removal Detail
See Removal Detail
See Installation Detail 6 - Exhaust
See Removal Detail
3 - Rear lower arm
See Removal Detail 7 - Rear crossmember
G295879 en 09/2004 2004.75 Focus

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Number
10 - Fuel tank filler hose to fuel
8 - Fuel tank filler pipe cover tank filler pipe hose retaining
See Removal Detail clamp
9 - Fuel tank filler pipe cap See Removal Detail
11 - Fuel tank filler hose to fuel
tank filler pipe
See Removal Detail
G295879 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
Item 1 : Rear springs
12 - Fuel tank vent hose to fuel
tank filler pipe retaining 1. WARNING: As the spring is under
clamp extreme tension care must be taken at
See Removal Detail all times. Failure to follow this
See Installation Detail instruction may result in personal
injury.
13 - Fuel tank vent hose to fuel
tank filler pipe NOTE: After the spring has been compressed
See Removal Detail mark the location of tool and spring to aid
installation.
14 - Fuel tank filler pipe retaining
bracket Using the special tools, compress the rear
springs.

10. NOTE: After the fuel additive tank to fuel tank
line has been connected it must be bled. For
additional information on fuel additive tank to
fuel tank line bleeding, Refer to WDS.
Carry out the fuel additive tank to fuel
tank line bleed procedure. Refer to WDS
and follow the on screen instructions.
G295879 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 2 : Rear damper lower retaining bolt Item 7 : Rear crossmember

1. Place a suitable transmission jack under 1. NOTE: The rear axle crossmember must be
the rear suspension and remove the rear supported.
damper lower retaining bolts.
Remove the rear axle crossmember re-
taining bolts.
Item 3 : Rear lower arm

1. Lower the transmission jack and with the Item 8 : Fuel tank filler pipe cover
aid of another technician, pull the rear 1. Open the fuel tank filler pipe cover.
lower arm downwards to remove the rear Item 9 : Fuel tank filler pipe cap
spring. 1. Detach the fuel tank filler pipe cap from the
Item 5 : Electronic parking brake cable fuel filler pipe.
1. Detach the electronic parking brake cable Item 10 : Fuel tank filler hose to fuel tank filler
from the retaining clips. pipe hose retaining clamp
Item 6 : Exhaust 1. NOTE: Make a note of the position of the fuel
1. Detach the exhaust system from the middle tank filler hose to fuel tank filler pipe hose
hanger insulator. retaining clamp. Make sure that the new
replacement screw type clamp is positioned so
that the screw head is in the same position as
as the original filler hose retaining clamp.
Remove and discard the fuel tank filler
hose to fuel tank filler pipe hose retaining
clamp.
G295879 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 11 : Fuel tank filler hose to fuel tank filler Installation Details
pipe
Item 12 : Fuel tank vent hose to fuel tank filler
1. CAUTION: When removing the fuel tank pipe retaining clamp
filler hose to fuel tank filler pipe, do not 1. Install a new fuel tank filler hose to fuel
use any sharp edge tools to lever off tank filler pipe hose retaining clamp in the
the pipes. Failure to follow this position shown.
instruction may result in damage to the
filler hose.
Disconnect the fuel tank filler hose from
the fuel tank filler pipe.
pipe retaining clamp
tank vent hose to fuel tank filler pipe retaining
clamp. Make sure that the new replacement
screw type clamp is positioned so that the
screw head is in the same position as as the
original vent hose retaining clamp.
hose to fuel tank filler pipe retaining clamp. Item 10 : Fuel tank filler hose to fuel tank filler
pipe hose retaining clamp
1. Install a new fuel tank filler hose to fuel
tank filler pipe hose retaining clamp in the
position shown.

pipe
vent hose to fuel tank filler pipe, do not
use any sharp edge tools to lever off Item 3 : Rear lower arm
the pipes. Failure to follow this CAUTION: Make sure the top seat
instruction may result in damage to the mounting is installed, and the spring
vent hose. ends butt correctly against the upper and
Disconnect the fuel tank vent hose from the lower spring seats.
fuel tank filler pipe. 1. With the aid of another technician, pull the
rear lower arm downwards to install the
rear spring and special tools.
G295879 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 2 : Rear damper lower retaining bolt Item 1 : Rear springs

1. Place a suitable transmission jack under
the rear suspension and install the rear 1. WARNING: As the spring is under
damper lower retaining bolts. extreme tension care must be taken at
injury.
CAUTION: Make sure the top seat
mounting is installed, and the spring
ends butt correctly against the upper and
lower spring seats.
Using the special tools, release the com-
pression on the rear spring the rear
springs.
G295879 en 09/2004 2004.75 Focus

TO MODEL INDEX
Fuel Filter — 2.0L Duratec-HE (MI4)
1. Depressurize the fuel system. For

WARNING: Do not smoke or carry lighted additional information, refer to Section 310-00.
tobacco or open flame of any type when [Fuel System - General Information,
working on or near any fuel related GENERAL PROCEDURES, Fuel System
components. Highly flammable vapors Pressure Release]
personal injury.
WARNING: This procedure involves fuel GENERAL PROCEDURES, Battery
handling. Be prepared for fuel spillage at Disconnect]
all times and always observe fuel 3. Raise and support the vehicle. For
handling precautions. Failure to follow additional information, refer to Section 100-02.
these instructions may result in personal [Jacking and Lifting, DESCRIPTION
injury. AND OPERATION, Lifting]
table(s).
G426883 en 09/2004 2004.75 Focus

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Number
supply line
See Removal Detail
2 - Fuel filter to fuel rail fuel
supply line
See Removal Detail
3 - Fuel filter retaining bracket
bolt
4 - Fuel filter
Removal Details
Item 1 : Fuel tank to fuel filter fuel supply line

1. Disconnect the fuel tank to fuel filter fuel
supply line. For additional information,
refer to Section 310-00.[Fuel System -
Item 2 : Fuel filter to fuel rail fuel supply line
1. Disconnect the fuel filter to fuel rail fuel
Item 2 : Fuel filter to fuel rail fuel supply line

1. Connect the fuel filter to fuel rail fuel
Item 1 : Fuel tank to fuel filter fuel supply line
1. Connect the fuel tank to fuel filter fuel
G426883 en 09/2004 2004.75 Focus

TO MODEL INDEX
Fuel Filter — 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor
Special Tool(s) 2. Remove the engine upper cover.

Hand Pressure Pump with
Adaptor Kit
310-110

WARNING: This procedure involves fuel 3. Remove the components in the order
handling. Be prepared for fuel spillage at indicated in the following illustration(s) and
all times and always observe fuel table(s).
injury.
lines.
components.
G295882 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
8 - Fuel filter fuel supply line
1 - Water in fuel sensor electri- quick release coupling
cal connector See Removal Detail
2 - Fuel filter heater electrical See Installation Detail
connector 9 - Fuel filter to fuel pump fuel
3 - Engine wiring harness supply line quick release
retaining clip coupling
shield 10 - Fuel filter
See Removal Detail
See Installation Detail 4. To install, reverse the removal procedure.
6 - Water in fuel sensor NOTE: Do not install the engine upper cover at
See Removal Detail this stage.
See Installation Detail 5. Remove and discard the fuel filter and fuel
filter supply line blanking plugs.
retaining clip
See Removal Detail
G295882 en 09/2004 2004.75 Focus

TO MODEL INDEX
6. NOTE: Make sure the hand pressure pump 12. Remove the hand pressure pump.
Install the special tool between the fuel fil-
ter fuel supply line quick release coupling
13. Connect the fuel filter fuel supply line

quick release coupling. For additional in-
formation, refer to Section 310-00.

30 times.


again.
G295882 en 09/2004 2004.75 Focus

TO MODEL INDEX
Removal Details Item 10 : Fuel filter

1. Remove the fuel filter.
Item 3 : Engine wiring harness retaining clip
clip from the fuel filter.
Item 6 : Water in fuel sensor
2. Using a suitable length of fuel resistant
tube, drain the fuel filter into a suitable
container.
Item 9 : Fuel filter to fuel pump fuel supply line

1. Clean the fuel filter and fuel filter fuel pump
fuel supply line. For additional information,
refer to Fuel Injection Component Cleaning
in this section.
3. Connect the fuel pump to fuel filter fuel
supply line quick release coupling.
Item 8 : Fuel filter fuel supply line quick
release coupling
3. Clean the fuel filter water in fuel sensor and 1. Do not connect the fuel filter fuel supply
surrounding area. For additional line at this stage.
Component Cleaning in this section. Item 6 : Water in fuel sensor
1. Clean the fuel filter and the water in fuel
4. Remove the water in fuel sensor. sensor. For additional information, refer to
5. Install a new blanking plug to the open Fuel Injection Component Cleaning in this
threaded port of the fuel filter. section.
Item 7 : Fuel pump fuel return line retaining 2. Remove and discard the blanking plug.
clip 3. Install the water in fuel sensor.
the fuel line retaining clip. Item 5 : Fuel filter splash shield
Item 8, 9 : Fuel filter fuel supply line quick fuel filter splash shield.
release coupling
1. Clean the fuel filter fuel supply lines and
surrounding area. For additional
2. Detach the fuel filter fuel line quick release
couplings. For additional information,
lines.
G295882 en 09/2004 2004.75 Focus

TO MODEL INDEX
Fuel Filter — 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel

Sensor
Special Tool(s) 1. Disconnect the battery ground cable. For

Adaptor Kit
310-110
General Equipment
Pneumatic vacuum gun

result in personal injury. 3. Remove the components in the order
WARNING: This procedure involves fuel indicated in the following illustration(s) and
handling. Be prepared for fuel spillage at table(s).
injury.
lines.
components.
G334279 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
8 - Fuel filter
1 - Fuel filter heater electrical See Removal Detail
connector
2 - Engine wiring harness 4. To install, reverse the removal procedure.
retaining clip NOTE: Do not install the engine upper cover at
See Removal Detail this stage.
5. Remove and discard the fuel filter and fuel
filter supply line blanking plugs.
shield
retaining clip
See Removal Detail
6 - Fuel filter fuel supply line
See Removal Detail
7 - Fuel filter to fuel pump fuel
supply line quick release
coupling
See Removal Detail
G334279 en 09/2004 2004.75 Focus

TO MODEL INDEX
6. NOTE: Make sure the hand pressure pump 12. Remove the hand pressure pump.
Install the special tool between the fuel fil-
ter fuel supply line quick release coupling
13. Connect the fuel filter to fuel tank fuel

supply line quick release coupling. For

30 times.


again.
G334279 en 09/2004 2004.75 Focus

TO MODEL INDEX
Removal Details Item 8 : Fuel filter

1. Remove the fuel filter.
1. Detach the engine harness retaining clip
from the fuel filter.
Item 5 : Fuel pump fuel return line retaining
clip
1. Detach the fuel pump fuel return pipe from
Item 6, 7 : Fuel filter fuel supply line quick
release coupling
2. Using a suitable length of fuel resistant Item 7 : Fuel filter to fuel pump fuel supply line
tube, drain the fuel filter into a suitable quick release coupling
container. 1. Clean the fuel filter and fuel filter fuel pump
fuel supply line. For additional information,
refer to Fuel Injection Component Cleaning
in this section.
3. Connect the fuel filter fuel pump fuel
supply line quick release coupling. For
Item 6 : Fuel filter fuel supply line quick
release coupling
1. Do not connect the fuel filter fuel supply
line at this stage.
3. Clean the fuel filter fuel supply lines and NOTE: Do not trap the lint-free material with the
surrounding area. For additional fuel filter splash shield.
4. Detach the fuel filter fuel line quick release
couplings. For additional information,
lines.
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Fuel Supply Line — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)
WARNING: Do not smoke or carry lighted 4. Remove the cowl panel grille.
tobacco or open flame of any type when 1. Detach the cowl panel grille retaining clips.
working on or near any fuel related 2. Detach the cowl panel grille from the
components. Highly flammable mixtures windshield glass lower weatherstrip and
are always present and may ignite. remove.
injury.
NOTE: Make sure that the windshield wiper motor
is in the park position.
Disconnect] 5. Remove the bulkhead extension panel.
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7. Detach the fuel supply line from the fuel

supply line retaining clip.
6. Disconnect the fuel supply line quick re-
lease coupling from the fuel supply line.
310-00.[Fuel System - General Information,
Coupling]

table(s).
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Number
1 - Fuel supply line earth
retaining clip 10. To install, reverse the removal procedure.
See Removal Detail
2 - Fuel supply line retaining additional information, refer to Section 501-11.
clips [Glass, Frames and Mechanisms,
See Removal Detail GENERAL PROCEDURES, Door Window
3 - Fuel tank deflector shield
retaining clips
See Removal Detail
5 - Fuel supply line quick
release coupling
See Removal Detail
G295889 en 09/2004 2004.75 Focus

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Removal Details Item 5 : Fuel supply line quick release

coupling
Item 1 : Fuel supply line earth retaining clip 1. Disconnect the fuel supply line quick
1. Remove and discard the fuel supply line release coupling from the fuel tank fuel
earth retaining clip. supply line. For additional information,
Item 2 : Fuel supply line retaining clips

1. Remove and discard the fuel supply line
retaining clips.
Item 3 : Fuel tank deflector shield retaining

clips
1. Remove and discard the fuel tank deflector
shield retaining clips.
G295889 en 09/2004 2004.75 Focus

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Fuel Supply Line — 2.0L Duratorq-TDCi (DW) Diesel
WARNING: Do not smoke or carry lighted 3. Disconnect the fuel supply line connector
tobacco or open flame of any type when quick release coupling (engine shown
working on or near any fuel related removed for clarity). For additional
components. Highly flammable mixtures information, refer to Section 310-00.[Fuel
are always present and may ignite. System - General Information, GENERAL
Failure to follow these instructions may PROCEDURES, Quick Release Coupling]
result in personal injury. • Release the locking tang.

injury.
lines. 4. Detach the fuel supply line from the re-
1. Disconnect the battery ground cable. For taining clip (engine shown removed for
additional information, refer to Section 414-01. clarity).
Disconnect]

table(s).
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Number
1 - Fuel supply line earth
retaining clip 5 - Fuel supply line quick
See Removal Detail release coupling
See Removal Detail
2 - Fuel supply line retaining
clips 6 - Fuel supply line
See Removal Detail
retaining clips
See Removal Detail additional information, refer to Section 501-11.
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GENERAL PROCEDURES, Door Window Item 3 : Fuel tank deflector shield retaining
Motor Initialization] clips
Removal Details shield retaining clips.
Item 1 : Fuel supply line earth retaining clip

1. Remove and discard the fuel supply line
earth retaining clip.
Item 5 : Fuel supply line quick release

coupling
release coupling from the fuel tank fuel
Item 2 : Fuel supply line retaining clips supply line. For additional information,
1. Remove and discard the fuel supply line refer to Section 310-00.[Fuel System -
retaining clips. General Information, GENERAL
G295890 en 09/2004 2004.75 Focus

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Fuel Return Line — 2.0L Duratorq-TDCi (DW) Diesel
WARNING: Do not smoke or carry lighted 3. Disconnect the fuel supply line connector
tobacco or open flame of any type when quick release coupling (Engine shown re-
working on or near any fuel related moved for clarity). For additional informa-
components. Highly flammable mixtures tion, refer to Section 310-00.[Fuel System -
are always present and may ignite. General Information, GENERAL
Failure to follow these instructions may PROCEDURES, Quick Release Coupling]
injury.
blanking plugs to any open orifices or 4. Detach the fuel return line from the retain-
lines. ing clip (Engine shown removed for clar-
1. Disconnect the battery ground cable. For ity).
Disconnect]

table(s).
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Number
5 - Fuel return line quick release
1 - Fuel return line ground coupling
connection retaining clip See Removal Detail
See Removal Detail
2 - Fuel return line retaining clips
3 - Fuel tank deflector shield 8. Initialize the door window motors. For
retaining clips additional information, refer to Section
See Removal Detail 501-11.[Glass, Frames and Mechanisms,
G295892 en 09/2004 2004.75 Focus

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Removal Details Item 5 : Fuel return line quick release coupling

1. Disconnect the fuel return line quick
Item 1 : Fuel return line ground connection release coupling from the fuel tank fuel
retaining clip return line. For additional information, refer
1. Remove and discard the fuel return line to Section 310-00.[Fuel System - General
ground connection retaining clip. Information, GENERAL PROCEDURES,
Item 2 : Fuel return line retaining clips

1. Remove and discard the fuel return line
retaining clips.
Item 3 : Fuel tank deflector shield retaining

clips
shield retaining clips.
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310-02-1 Acceleration Control 310-02-1
SECTION 310-02 Acceleration Control

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 310-02-2
Acceleration Control.......................................................................................................... 310-02-3

Symptom Chart ................................................................................................................ 310-02-3
Accelerator Pedal.............................................................................................................. 310-02-4/6

Accelerator Cable ............................................................................................................. 310-02-7
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SPECIFICATIONS

Accelerator pedal retaining nuts 8 - 71
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Acceleration Control
– Accelerator pedal – Wiring harness(s)
– Throttle body – Wiring harness
1. Verify the customer concern. retaining clips
2. Visually inspect for obvious signs of – Electrical
mechanical or electrical damage. connector(s)
– Accelerator pedal
– Powertrain control
module (PCM)
– Electronic throttle
body
Symptom Chart

• Accelerator pedal is hard to de- • Accelerator pedal incorrectly • CHECK the accelerator pedal for
press or has a rough/raspy or installed. the correct installation.
sticky feel
• Worn or damaged accelerator • INSTALL a new accelerator
pedal. pedal. REFER to Accelerator
Pedal in this section.
• Accelerator pedal does not re- • Accelerator pedal incorrectly • CHECK the accelerator pedal for
turn freely installed. the correct installation.
• Worn or damaged accelerator • INSTALL a new accelerator
pedal. pedal. REFER to Accelerator
Pedal in this section.
• High engine idle speed • Damaged accelerator pedal. • Refer to WDS to diagnose the
system.
• Electronic throttle body. • Refer to WDS to diagnose the
system.
• PCM calibration. • Refer to WDS to diagnose the
system.
• Poor idling • Electronic throttle body. • Refer to WDS to diagnose the
system.
• PCM calibration. • Refer to WDS to diagnose the
system.
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Accelerator Pedal

Number
1 - Instrument panel lower trim pad
panel
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Number
panel retraining clips

Number
4 - Accelerator pedal retaining Item 6 : Accelerator pedal electrical connector
nuts NOTE: The accelerator pedal electrical connector
See Installation Detail can only be disconnected 10 times during the
lifetime of the accelerator pedal. Failure to follow
5 - Accelerator pedal this instruction may cause damage to the
6 - Accelerator pedal electrical accelerator pedal electrical connector.
connector 1. Using a suitable marker, mark the
See Removal Detail accelerator pedal electrical connector
when it has been disconnected from the
accelerator pedal wiring harness.
Item 4 : Accelerator pedal retaining nuts
1. Loosely install all the accelerator pedal
retaining nuts before tightning.
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Item 3 : Instrument panel lower trim panel

retraining clips
1. Install the instrument panel lower trim
panel retraining clips to the instrument
panel lower trim panel.
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Accelerator Cable

table(s).
Draw cord

Number
2 - Accelerator cable to intake
1 - Accelerator cable to throttle manifold retaining clip
body
See Removal Detail 3 - Accelerator cable to body
See Installation Detail retaining clip
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Item Part Description Item 4 : Accelerator cable to accelerator pedal

Number 1. Detach the accelerator cable from the
accelerator pedal.
4 - Accelerator cable to 1. Pull the accelerator inner cable forward.
accelerator pedal
See Removal Detail 2. Lift the accelerator inner cable and grommet
out of the fork of the accelerator pedal.
5 - Accelerator cable to
bulkhead retaining clip
See Removal Detail
6 - Accelerator cable
See Removal Detail
Removal Details
Item 1 : Accelerator cable to throttle body

1. Detach the accelerator cable.
1. Detach the accelerator cable locking nut. Item 5 : Accelerator cable to bulkhead
2. Pull the accelerator outer cable through the retaining clip
accelerator cable grommet. 1. Release the accelerator cable to bulkhead
3. Detach the accelerator cable grommet from retaining clip tangs.
the accelerator cable support bracket.
4. Rotate the throttle lever clockwise and de-
tach the accelerator cable from the throttle
lever.
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1. Remove the accelerator cable.
• Attach a draw cord to the end of the
accelerator inner cable.
• From the engine bay, pull the accelerator
cable out of the bulkhead until the draw cord
can be detached from the accelerator inner
cable.

1. Install the accelerator cable.
• Attach the draw cord to the end of the
accelerator inner cable.
• From inside the vehicle, pull the accelerator
cable through the bulkhead.
• Remove the draw cord.
Item 1 : Accelerator cable to throttle body
1. Adjust the accelerator cable.
1. Make sure the throttle body linkage is
against the throttle stop screw.
2. Adjust the throttle cable using the throttle
cable locking nuts.
3. Check the accelerator inner cable free play.
The free play should not be less than 1mm
and not exceed 3mm.
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310-03-1 Speed Control 310-03-1
SECTION 310-03 Speed Control

CONTENTS PAGE
Speed Control................................................................................................................... 310-03-2/5
Speed Control................................................................................................................... 310-03-6

Diagnostic Trouble Code (DTC) Index.............................................................................. 310-03-6/14
Speed Control Switch........................................................................................................ 310-03-15
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310-03-2 Speed Control 310-03-2
Speed Control
The speed control system is operated by means of

Item Part Description five switches on the steering wheel. The functions
Number are:
1 - Speed control actuator cable The speed control module provides signals to the
2 - Speed control switches actuator. The actuator moves the throttle by
means of an internal geartrain and an actuator
3 - Speed control servo cable. The vehicle speed sensor generates the
4 - Clutch pedal position switch reference signal that the servo compares to the
(vehicles with manual trans- set speed selected by the driver. If a discrepancy
axle) exists the stepper servo will adjust the throttle,
correcting the vehicle speed.
5 - Vehicle speed sensor
6 - Stop lamp switch
7 - Deactivator switch
ON Activate system
OFF De-activate system
+ (SET/ACC) Set/Accelerate and tap up
- (COAST) Coast and tap down
= (RESUME) Resume
will activate the speed control servo by closing the
Any of the switches operated by the brake or
throttle.
clutch pedal (vehicles fitted with manual transaxle)
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310-03-3 Speed Control 310-03-3
Speed Control Actuator Speed Control Switches
The speed control servo is mounted on the When the ON switch is pressed and the vehicle is
bulkhead. The speed control servo incorporates travelling at a speed greater than 48 km/h (30
the following components: mph) the speed control actuator will accept speed
inputs.
– An electronic module
– An actuator consists of a stepper motor and
geartrain electromagnetic coupling and
reduction gearing
Speed Control Servo
The + (SET/ACC) switch is used to set or

accelerate the vehicle at speeds above 48 km/h
(30 mph). The switch can be used in three ways.
The speed control servo evaluates the incoming

speed signal from the speed sensor and switch
inputs. It adjusts the throttle to maintain a constant
vehicle speed.
If the clutch pedal (vehicles with manual transaxle)
or the brake pedal are depressed, the speed
control servo deactivates the speed control. The
servo is will enter a stand by mode.
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310-03-4 Speed Control 310-03-4
– Accelerate the vehicle with the accelerator the stand by mode. Pressing and releasing the =
pedal to the required speed, press and release (RESUME) switch at any speed greater than 48
the + (SET/ACC) switch, the vehicle will then km/h (30 mph) will return the vehicle to the
maintain the required speed. previous set speed.
– Press the + (SET/ACC) switch and hold it
down until the vehicle reaches the required
speed. When released, the speed is stored in
the memory and used to maintain the vehicle
speed.
– Press the + (SET/ACC) switch repeatedly in
order to increase the vehicle speed by
increments of 1.6 km/h (1 mph).
Pressing the OFF switch deactivates the speed

control system. The speed setting stored in
memory will be erased.
Stop Lamp Switch
The - (COAST) switch is used to reduce vehicle

speed. The switch can be used in two ways:
– Press and hold the - (COAST) switch down
until the vehicle slows to the required speed.
When the switch is released, the speed is
stored in the memory and used to maintain the
vehicle speed.
– Press the - (COAST) switch repeatedly to
reduce the vehicle road speed by increments
of 1.6 km/h (1 mph).
If the brake pedal is tapped lightly while the speed
control system is active, the servo receives an
input from the stop lamp switch. This causes the
speed control servo to close the throttle at a
controlled rate. The system is put in stand by
mode.
Pressing the = (RESUME) switch returns the

vehicle to the set speed when speed control is in
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310-03-5 Speed Control 310-03-5
Deactivator Switch
If the brake pedal is depressed rapidly while the

speed control system is active, the speed control
servo receives a input from the deactivator switch.
This causes, the electromagnetic actuated
coupling to disconnect from the stepper motor and
deactivate. This allows the cable and throttle to
close under throttle return spring control. The
system is put in stand by mode.
Clutch Pedal Position (CPP) Switch (with manual

transaxle)
If the clutch pedal is depressed while the speed

control system is active, the speed control servo
receives an input from the clutch pedal position
switch. This causes the speed control servo to
deactivate and close the throttle at a controlled
rate. The system is put in a stand by mode.
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310-03-6 Speed Control 310-03-6
Speed Control

1. Verify the customer concern by operating the 3. If an obvious cause for an observed or
system. reported concern is found, correct the cause
4. If the concern is not visually evident, go to the
Visual Inspection Chart speed control diagnostic trouble code (DTC)
Mechanical Electrical index.
– Brake pedal – Fuse(s) 5. To enter the Ford Diagnostic System WDS
– Clutch pedal – Connections tests, connect the WDS to the data link
connector (DLC) located beneath the
– Wiring harness
instrument panel and select the vehicle to be
– Clockspring tested from the WDS menu.
– Loose or corroded
connector(s)
– Speed control
switch
– Brake pedal position
(BPP) deactivation
switch
– Clutch pedal
position (CPP)
deactivation Switch
– Powertrain control
module (PCM)
– Central junction box
(CJB)
Diagnostic Trouble Code (DTC) Index
DTC Description Possible Source Action
P0581 Speed control input signal • Speed control switches. GO to Pinpoint Test A
low/high resistance. • Clockspring.
• Clockspring to CJB circuit.
P0579 Speed control input signal open • Speed control switches. GO to Pinpoint Test A
circuit. • Clockspring.
• Clockspring to CJB circuit.
P0565 Speed control ON switch fault. • Speed control switches. GO to Pinpoint Test B
P0566 Speed control OFF switch fault. • Speed control switches. GO to Pinpoint Test C
P0567 Speed control RESUME/CANCEL • Speed control switches. GO to Pinpoint Test D
switch fault.
P0568 Speed control SET + switch fault. • Speed control switches. GO to Pinpoint Test E
• Clockspring.
P0569 Speed control SET + switch fault. • Speed control switches. GO to Pinpoint Test F
• Clockspring.
B1483 BPP deactivation switch fault. • BPP deactivation switch REFER to WDS.
• Instrument cluster.
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310-03-7 Speed Control 310-03-7
DTC Description Possible Source Action

B2163 BPP deactivation switch fault. • BPP deactivation switch REFER to WDS.
• Instrument cluster.
1. If the DTCs retrieved are related to the con-
cern, verify the symptom and refer to the
symptom Chart.
Symptom Chart
• The speed control is inoperative • Speed control switch. • GO to Pinpoint Test A
• Clock spring
• PCM. • REFER to Section 303-14.
• BPP deactivation switch • Check the BPP switch for correct
operation. REFER to WDS.
• CPP deactivation switch • Check the BPP switch for correct
operation. REFER to WDS.
• The speed control does not • BPP deactivation switch. • REFER to WDS.
disengage when the brake pedal
is applied
• The speed control does not • CPP deactivation switch. • REFER to WDS.
disengage when the clutch pedal
is applied
• The speed control switch(es) are • Speed control switch. • REFER to the Speed control
inoperative component test in this section.
PINPOINT TEST A: P0561 CHECK SPEED CONTROL SWITCH CIRCUITS FOR HIGH RESISTANCE
A1: CHECK CIRCUIT 9-PG13 (BN) FOR HIGH RESISTANCE
1 Disconnect CJB C103.
2 Disconnect Clockspring C896.
3 Measure the resistance between the CJB C103
pin 10 circuit 9-PG13 (BN), harness side and
the clockspring C896 pin 4 circuit 9-PG13 (BN),
harness side.
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310-03-8 Speed Control 310-03-8

→ Yes
GO to A2
→ No
normal operation.
A2: CHECK CIRCUIT 8-PG13 (WH) FOR HIGH RESISTANCE
1 Measure the resistance between the CJB C103
pin 18 circuit 8-PG13 (WH), harness side and
the clockspring C896 pin 5 circuit 8-PG13 (WH),
harness side.

→ Yes
GO to A3
→ No
normal operation.
A3: CHECK THE SPEED CONTROL SWITCH CIRCUIT
WARNING: To deactivate the air bag module, refer to the procedure in Section 501-20B for
the correct air bag module deactivation procedure. Failure to follow this instruction may
1 Remove the driver air bag module.
2 Disconnect Speed control switch C921.
3 Measure resistance between the speed control
switch C921 pin 2 and pin 3 harness side.
• Is the resistance 211 ohms?

→ Yes
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310-03-9 Speed Control 310-03-9

GO to A4
→ No
INSTALL a new speed control switch.
REFER to Speed Control Switch in this sec-
A4: CHECK THE SPEED CONTROL ON SWITCH FOR CORRECT OPERATION
1 Press and hold the speed control switch in the
ON position.

→ Yes
GO to A5
→ No
A5: CHECK THE SPEED CONTROL OFF SWITCH FOR CORRECT OPERATION
OFF position.

→ Yes
GO to A6
→ No
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310-03-10 Speed Control 310-03-10

A6: CHECK THE SPEED CONTROL SET + SWITCH FOR CORRECT OPERATION
SET + position.

→ Yes
GO to A7
→ No
A7: CHECK THE SPEED CONTROL SET - SWITCH FOR CORRECT OPERATION
SET - position.

→ Yes
GO to A8
→ No
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310-03-11 Speed Control 310-03-11

A8: CHECK THE SPEED CONTROL RESUME/CANCEL SWITCH FOR CORRECT OPERATION
RESUME/CANCEL position.

→ Yes
INSTALL a new clockspring.
→ No
PINPOINT TEST B: P0565 SPEED CONTROL ON SWITCH MALFUNCTION
B1: CHECK THE SPEED CONTROL ON SWITCH FOR CORRECT OPERATION
3 Operate the the speed control ON switch
• Does the resistance vary between 1000 ohms

when the ON switch is pressed and 211 ohms
when the ON switch is released?
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310-03-12 Speed Control 310-03-12

→ Yes
CLEAR the DTCs. TEST the system for
normal operation. IF the concern persists,
→ No
PINPOINT TEST C: P0566 SPEED CONTROL OFF SWITCH MALFUNCTION
C1: CHECK THE SPEED CONTROL OFF SWITCH FOR CORRECT OPERATION
3 Operate the the speed control OFF switch.

when the OFF switch is pressed and 211 ohms
when the OFF switch is released?
→ Yes
→ No
PINPOINT TEST D: P0567 SPEED CONTROL RESUME/CANCEL SWITCH MALFUNCTION
D1: CHECK THE SPEED CONTROL RESUME/CANCEL SWITCH FOR CORRECT OPERATION
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310-03-13 Speed Control 310-03-13

3 Operate the the speed control
RESUME/CANCEL switch.

when the RESUME/CANCEL switch is pressed
and 211 ohms when the RESUME/CANCEL
switch is released?
→ Yes
→ No
PINPOINT TEST E: P0568 SPEED CONTROL SET + SWITCH MALFUNCTION
E1: CHECK THE SPEED CONTROL SET + SWITCH FOR CORRECT OPERATION
3 Operate the the speed control SET + switch.
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310-03-14 Speed Control 310-03-14

when the SET + switch is pressed and 211 ohms
when the SET + switch is released?
→ Yes
→ No
PINPOINT TEST F: P0569 SPEED CONTROL SET - SWITCH MALFUNCTION
F1: CHECK THE SPEED CONTROL SET - SWITCH FOR CORRECT OPERATION
3 Operate the the speed control SET - switch.

when the SET - switch is pressed and 211 ohms
when the SET - switch is released?
→ Yes
→ No
G325352 en 09/2004 2004.75 Focus

TO MODEL INDEX
310-03-15 Speed Control 310-03-15
Speed Control Switch

1. Remove the driver air bag module. For 2. Remove the components in the order
refer to Section 501-20A / 501-20B. table(s).

Number
2 - Speed control switch wiring
1 - Speed control switch elec- harness
trical connector See Removal Detail
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TO MODEL INDEX
310-03-16 Speed Control 310-03-16

Number
3 - Speed control switch
Removal Details
Item 2 : Speed control switch wiring harness

1. Detach the speed control wiring harness
from the steering wheel back plate wiring
harness retainers.
Item 2 : Speed control switch wiring harness

1. CAUTION: Make sure the speed control
wiring harness is correctly attached to
the steering wheel back plate during
installation. Failure to follow this
instruction may cause damage to the
speed control wiring harness.
Attach the speed control wiring harness to
the steering wheel back plate wiring
harness retainers.
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Group
Electrical 4
PAGE
SECTION TITLE
Climate Control System

Climate Control System - General Information ...................................................................... 412-00-1
Air Distribution and Filtering .................................................................................................. 412-01-1
Heating and Ventilation ......................................................................................................... 412-02-1
Air Conditioning..................................................................................................................... 412-03-1
Control Components ............................................................................................................. 412-04-1
Instrumentation and Warning Systems
Instrument Cluster and Panel Illumination ............................................................................. 413-00-1
Instrument Cluster................................................................................................................. 413-01-1
Horn ...................................................................................................................................... 413-06-1
Clock..................................................................................................................................... 413-07-1
Information and Message Center .......................................................................................... 413-08-1
Warning Devices ................................................................................................................... 413-09-1
Battery and Charging System
Charging System - General Information ................................................................................ 414-00-1
Battery, Mounting and Cables ............................................................................................... 414-01-1
Generator and Regulator....................................................................................................... 414-02-1
Entertainment Systems
Entertainment System - General Information......................................................................... 415-00-1
Audio Unit ............................................................................................................................. 415-01-1
Antenna................................................................................................................................. 415-02-1
Speakers............................................................................................................................... 415-03-1
Lighting
Exterior Lighting .................................................................................................................... 417-01-1
Interior Lighting ..................................................................................................................... 417-02-1
Electrical Distribution
Module Communications Network ......................................................................................... 418-00-1
Module Configuration ............................................................................................................ 418-01-1
Electronic Feature Group
Anti-Theft - Active.................................................................................................................. 419-01A-1
Anti-Theft - Passive............................................................................................................... 419-01B-1
Cellular Phone....................................................................................................................... 419-08-1
Multifunction Electronic Modules ........................................................................................... 419-10-1
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412-00-1 Climate Control System - General Information 412-00-1
SECTION 412-00 Climate Control System - General

Information
CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 412-00-2
Climate Control System .................................................................................................... 412-00-3

Refrigerant Circuit - Quick Check ..................................................................................... 412-00-3
Sequence of A/C Request Signal ..................................................................................... 412-00-4
Self-Diagnostic Mode - Vehicles with electronic automatic temperature control (EATC)... 412-00-5
Diagnostic Trouble Code (DTC) Index Chart - vehicles with electronic automatic tem-
perature control (EATC) ................................................................................................ 412-00-5
Symptom Chart ................................................................................................................ 412-00-6/8
Pinpoint Tests .................................................................................................................. 412-00-9/116
Component Tests............................................................................................................. 412-00-117/118
GENERAL PROCEDURES
Spring Lock Coupling ........................................................................................................ 412-00-119/120

Air Conditioning (A/C) Clutch Air Gap Adjustment......................................... (34 628 6) 412-00-121
Fluorescent Dye Leak Detection ....................................................................................... 412-00-122
Electronic Leak Detection ............................................................................. (34 620 7) 412-00-123
Air Conditioning (A/C) System Recovery, Evacuation and Charging ............. (34 620 2) 412-00-124/125
Refrigerant Oil Adding................................................................................... (34 621 1) 412-00-126
Contaminated Refrigerant Handling .............................................................. (34 620 9) 412-00-127
Air Distribution System Cleaning ....................................................................................... 412-00-128/129
Vacuum Leak Detection ................................................................................ (34 620 3) 412-00-130
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TO MODEL INDEX
SPECIFICATIONS

Item Specification
R134a refrigerant WSH-M17B19-A
Air conditioning compressor oil WSH-M1C231-B
Ford A/C cleaning agent F4AZ-19579A -
Fluorescent leak detector additive 164-R-3712 -
Refrigerant Capacities (when charging)

Grammes
Air Conditioning (A/C) System 600 ± 15
Refrigerant Oil Fill Quantities

Milliliters
Air Conditioning (A/C) System 200
Addition of Air Conditioning (A/C) Refrigerant Oil (when replacing components)

Milliliters
Air conditioning compressor (if the amount of refrigerant oil taken from the Add 40 ml.
compressor is less than 90 ml), (Vehicles with petrol engine)
Air conditioning compressor (if the amount of refrigerant oil taken from the Add the same quantity -
compressor is between 90 ml and 150 ml), (Vehicles with petrol engine) 20 ml.
Air conditioning compressor (if the amount of refrigerant oil taken from the Add the same quantity
compressor is more than 150 ml), (Vehicles with petrol engine) -50 ml.
Air conditioning compressor (if the amount of refrigerant oil taken from the add 90.
compressor is less than 90 ml), (Vehicles with diesel engine)
Air conditioning compressor (if the amount of refrigerant oil taken from the Add the same quantity +
compressor is between 90 ml and 150 ml), (Vehicles with diesel engine) 30 ml.
Air conditioning compressor (if the amount of refrigerant oil taken from the Fill with the same quan-
compressor is more than 150 ml), (Vehicles with diesel engine) tity.
Air conditioning condenser add 30.
Air conditioning (A/C) evaporator core add 30.
A/C dehydrator Add the same quantity +
90 ml.
When all lines and components are replaced. Add 60 ml.
Every time if refrigerant oil is collected after refrigerant is extracted. Fill with the same quan-
tity.
Air Conditioning (A/C) Clutch

mm
A/C clutch air gap (vehicles with petrol engine) 0.35 - 0.75
A/C clutch air gap (vehicles with diesel engine) 0.4 - 0.8
A/C compressor drive plate bolt (vehicles with 13 10 -
petrol engine)
diesel engine)
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Climate Control System

Refer to Wiring Diagrams Section 412-00 for cluster (vehicles with EATC: read out the
schematic and connector information. EATC error memory) using the WDS. If an
error code is displayed, CORRECT the cause
Special Tool(s) using the WDS. TEST the system for normal
operation.
Terminal Probe Kit
5. If there is no error code displayed, VERIFY
418-S035
the symptom and REFER to the symptom
chart.
6. After the test or elimination of a concern
CHECK all modules that are installed on the
vehicle by using the WDS. ERASE all error
General Equipment codes. CARRY a road test of the vehicle.
CHECK all modules again.
Digital Multimeter (compatible with K-type ther-
mocouple)
Refrigerant Circuit - Quick Check
Refrigerant center WARNING: The air conditioning systems
is filled with refrigerant R134a. Observe
Temperature sensor - Fluke 80 PK-8 (FSE "Health and Safety Precautions". For
number 260 4102 001 07) further information REFER to Section
100-00.[General Information,
Inspection and Verification and Safety Precautions]
NOTE: Vehicles without DVD Navigation System NOTE: All readings should to be taken at normal
with Touchscreen, the electronic automatic ambient temperature with the engine at normal
temperature control (EATC) module is integrated operating temperature.
into the climate control assembly. Refrigerant Circuit Check
1. VERIFY the customer concern.
2. Visually INSPECT for obvious signs of WARNING: Under certain circumstances,
mechanical or electrical damage. refrigerant lines and A/C components
NOTE: Make sure correct locking of the wiring may be extremely hot or cold. Exercising
harness connector. care, touch the refrigerant lines or A/C
components in order to check this.
Visual Inspection Chart Failure to follow this instruction may lead
Mechanical Electrical to injury.
• Refrigerant lines • Fuses During operation of the air conditioning (A/C)
• Condenser • Wiring harness system, the following conditions shows be
apparent:
• Coolant level • Connectors
• Drive belt • The refrigerant line from the A/C compressor
to the A/C condenser should be hot.
• Compressor
• The refrigerant line from the refrigerant
3. If an obvious cause for an observed or condenser to the fixed orifice tube should be
reported concern is found, CORRECT the warm, but cooler than the previously
cause (if possible) before proceeding to the mentioned refrigerant line.
next step. TEST the system for normal
• Determine the difference in temperature
operation.
upstream and downstream of the A/C
4. If the cause is not visually evident, CHECK the condenser by measuring the temperatures.
powertrain control module (PCM), the generic The temperature difference should be more
electronic module (GEM) and the instrument than 20°, depending on the ambient
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temperature. If the temperature difference is • No or poor cooling performance:

less, check the condenser for contamination or - Blockage or restriction in one of the
damage to the fins as well as operation of the refrigerant lines or in the suction
radiator fan. accumulator: By comparing temperatures at
• The refrigerant line between the fixed orifice the refrigerant lines or at the suction
tube and the evaporator core must be cold accumulator, the location of the blockage or
from the installation position of the fixed orifice restriction can easily be identified. The
tube. Depending on the weather, the blockage or restriction is located at the point
refrigerant line may also be iced up on the where the temperature difference is
outside. identified. Note: A temperature difference
• The refrigerant line between the evaporator in the area of the fixed orifice tube is
core and the A/C compressor should be cold, normal. Once the location of the blockage
including the suction accumulator. or restriction has been detected, check the
Evaporator Outlet Temperature Test relevant component and install new parts as
necessary.
In order to check the A/C output, the temperature
• Sudden poor cooling performance. After the
of the evaporator core outlet line must be
compressor has been switched off for
measured. The following preparations must be
approximately 5 minutes, the cooling
taken for this purpose:
performance returns to normal:
• Open all windows. - Fixed orifice tube iced up. The cause for an
• Set the air distribution to the iced-up fixed orifice tube is moisture in the
defrost/dashboard position and open all the system. In order to ensure that moisture is
ventilation nozzles. completely removed from the refrigerant
• DO NOT switch on recirculated air. circuit, evacuation time must be extended to
• Select lowest blower switch setting. 2-3 hours and a new suction accumulator
must be installed. For further information
• Select lowest temperature setting. REFER to Air Conditioning (A/C) System
NOTE: The temperature measurements cannot Recovery, Evacuation and Charging in this
be carried out using a non-contact thermometer. section.
Incorrect measurements result owing to surface
reflection.
Connect temperature sensor (Fluke 80 PK-8) to Sequence of A/C Request Signal
the evaporator core outlet line. The temperature NOTE: Vehicles without DVD Navigation System
sensor must be positioned as closely as possible with Touchscreen, the electronic automatic
to the evaporator core. Connect the temperature temperature control (EATC) module is integrated
sensor to the digital multimeter. into the climate control assembly.
Start the engine and allow it to run at idle speed for NOTE: The generic electronic module (GEM) is
several minutes. an integral part of the central junction box (CJB).
Switch on the A/C system. After actuating the ON/OFF switch integrated into
the climate control assembly, an A/C request
After three minutes, measure the surface
signal is sent to the GEM from the climate control
temperature of the evaporator core outlet line.
assembly (vehicles with EATC module).
If the temperature measured is 4° C or lower, the
From there, the signal is sent to the instrument
A/C system is OK. If the temperature is higher, the
cluster via the MS CAN-bus. A gateway is
A/C system may be under-filled. For further
installed in the instrument cluster which
information REFER to Air Conditioning (A/C)
establishes the connection between the MS
System Recovery, Evacuation and Charging in
CAN-bus and the HS CAN-bus.
this section.
After the signal has been converted in the
Frequent faults and their causes
gateway, it is relayed to the powertrain control
Should a customer express concern about poor module (PCM) via the HS CAN-bus. Once all the
cooling performance of the A/C system it must be required parameters have been met, the PCM
ensured that actuation of the temperature door(s) switches on the refrigerant compressor and thus
is functioning correctly.
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the A/C system via the refrigerant compressor 9027. The following table gives information on the
clutch relay. possible DTC's and their corresponding meanings.
Self-Diagnosis Mode can be stopped at any time
by PRESSING any button on the EATC module.
Self-Diagnostic Mode - Vehicles with NOTE: If the "Defrost" button is pressed to end the
electronic automatic temperature control Self-Diagnosis Mode, all DTC's in the error
(EATC) memory will be deleted!
The climate control system features a Reading out of stored faults
self-diagnosis function which can detect and store On the climate control assembly, PRESS the
both current permanent faults as well as "OFF" and "FOOTWELL" buttons simultaneously
intermittent faults which have occurred during forexactly 2 seconds, then PRESS
normal operation of the vehicle. It is also possible "HEADROOM" within 1.5 seconds. Any stored
to read out these faults via the display of the EATC. faults are displayed on the EATC display and
To read out the fault memory, the ignition key should be noted for safety reasons. By
must be turned to the "ON" position and the PRESSING the "DEFROST" button, the fault
battery voltage must be between 9 V and 16 V. memory is cleared and the Self-Diagnosis Mode is
Activation of self-diagnosis ended. To end the Self-Diagnosis Mode without
clearing the DTC's, PRESS any other button on
On the climate control assembly, PRESS the the EATC module.
"OFF" and "FOOTWELL" buttons simultaneously
for exactly 2 seconds, then PRESS "AUTO" Reading out the software version
within 1.5 seconds. The self-diagnosis which then On the EATC module, PRESS the "OFF" and
starts lasts a few seconds. An animated display "FOOTWELL" buttons simultaneously forexactly
appears in the EATC display during this time. Any 2 seconds, then PRESS "A/C" within 1.5 seconds.
faults found are displayed on both displays in the The software version is displayed on the EATC
form of diagnostic trouble codes. display. The output mode is ended by PRESSING
Example: Left display indicates "90", right display any button.
indicates "27" - diagnostic trouble code read out
Diagnostic Trouble Code (DTC) Index Chart - vehicles with electronic automatic temperature
control (EATC)
Diagnostic trouble code (DTC) index chart for electronic automatic temperature control (EATC)
DTC Description Action
9027 Air discharge temperature sensor - center register GO to Pinpoint Test M
right-hand circuit short to ground
9028 Air discharge temperature sensor - center register GO to Pinpoint Test M
right-hand open circuit
9029 Air discharge temperature sensor - footwell right-hand GO to Pinpoint Test N
circuit short to ground
9030 Air discharge temperature sensor - footwell right-hand GO to Pinpoint Test N
open circuit
9200 Climate control pushbutton failure CLEAR the error memory and
eration.
If the concern occurs again
INSTALL a new EATC module.
9242 Recirculation blend door actuator circuit failure GO to Pinpoint Test F
9251 In-vehicle temperature sensor open circuit GO to Pinpoint Test P
9253 In-vehicle temperature sensor circuit short to ground GO to Pinpoint Test P
9259 Sunload sensor left-hand open circuit GO to Pinpoint Test O
9261 Sunload sensor left-hand circuit short to ground GO to Pinpoint Test O
9262 Defrost vent/register blend door actuator circuit failure GO to Pinpoint Test J
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DTC Description Action

9263 Air distribution door actuator circuit failure GO to Pinpoint Test I
9342 EATC module internal failure CLEAR the error memory and
eration.
If the concern occurs again
INSTALL a new EATC module.
9676 Voltage out of range (Nominal voltage: 9 V - 16 V) GO to Pinpoint Test D
A266 Temperature blend door actuator left-hand circuit failure GO to Pinpoint Test G
A267 Temperature blend door actuator right-hand circuit fail- GO to Pinpoint Test H
ure
A297 Air discharge temperature sensor - center register GO to Pinpoint Test K
left-hand open circuit
A298 Air discharge temperature sensor - center register GO to Pinpoint Test K
left-hand circuit short to ground
A299 Air discharge temperature sensor - footwell left-hand GO to Pinpoint Test L
open circuit
A307 Air discharge temperature sensor - footwell left-hand GO to Pinpoint Test L
circuit short to ground
A308 In-vehicle temperature sensor blower motor circuit fail- GO to Pinpoint Test Q
ure
A426 Sunload sensor right-hand open circuit GO to Pinpoint Test O
A427 Sunload sensor right-hand circuit short to ground GO to Pinpoint Test O
A516 Blower motor control module circuit failure GO to Pinpoint Test E
Symptom Chart
NOTE: The generic electronic module (GEM) is an integral part of the central junction box (CJB).
• Blower motor without/incorrect • Fuse(s) • GO to Pinpoint Test A
function - vehicles without elec- • Circuit(s)
tronic automatic temperature • Blower motor
control (EATC) • Blower motor resistor
• Blower relay
• Generic electronic module
(GEM)
• Malfunction of the recirculation • Fuse(s) • Vehicles without electronic
blend door • Circuit(s) automatic temperature control
• Climate control assembly (EATC): GO to Pinpoint Test B
• Recirculation blend door • Vehicles with electronic auto-
actuator matic temperature control
• Recirculation blend door (EATC): GO to Pinpoint Test F
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• Air conditioning (A/C) is inopera- • Fuse(s) • GO to Pinpoint Test C
tive (all other functions of climate • Circuit(s)
control assembly OK) • Climate control assembly or
electronic automatic temperature
control module (EATC)
• Air conditioning high-pressure
switch
• Air conditioning pressure
transducer
• Air conditioning low-pressure
switch
• Air conditioning clutch relay
• Air conditioning clutch
• Refrigerant quantity
(GEM)
(PCM)
• Instrument cluster
• Climate control assembly inop- • Fuse(s) • GO to Pinpoint Test D
erative - vehicles with electronic • Circuit(s)
automatic temperature control • Electronic automatic tempera-
(EATC) without DVD Navigation ture control (EATC) module
System with Touchscreen
• Blower motor without/incorrect • Fuse(s) • GO to Pinpoint Test E
function - vehicles with electronic • Circuit(s)
automatic temperature control • Electronic automatic
(EATC) (all other functions of temperature control (EATC)
climate control assembly OK) module
• Blower
• Blower relay
(GEM)
• Central junction box (CJB)
• Malfunction of temperature blend • Circuit(s) • GO to Pinpoint Test G
door left-hand - vehicles with • Temperature blend door actuator
electronic automatic temperature left-hand
control (EATC) • Temperature blend door
left-hand
• Electronic automatic tempera-
ture control (EATC) module
• Malfunction of temperature blend • Circuit(s) • GO to Pinpoint Test H
door right-hand - vehicles with • Temperature blend door actuator
electronic automatic temperature right-hand
control (EATC) • Temperature blend door
right-hand
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• Malfunction of air distribution • Circuit(s) • GO to Pinpoint Test I
door - vehicles with electronic • Air distribution door actuator
automatic temperature control • Air distribution door
(EATC) • Electronic automatic tempera-
• Malfunction of defrost • Circuit(s) • GO to Pinpoint Test J
vent/register blend door - vehi- • Defrost vent/register blend door
cles with electronic automatic actuator
temperature control (EATC) • Defrost vent/register blend door
• Air discharge temperature sen- • Circuit(s) • GO to Pinpoint Test K
sor - center register left-hand • Air discharge temperature
circuit failure - vehicles with sensor - center register left-hand
electronic automatic temperature • Electronic automatic tempera-
control (EATC) ture control (EATC) module
• Air discharge temperature sen- • Circuit(s) • GO to Pinpoint Test L
sor - footwell left-hand circuit • Air discharge temperature
failure - vehicles with electronic sensor - footwell left-hand
(EATC) ture control (EATC) module
• Air discharge temperature sen- • Circuit(s) • GO to Pinpoint Test M
sor - center register right-hand • Air discharge temperature
circuit failure - vehicles with sensor - center register
electronic automatic temperature right-hand
control (EATC) • Electronic automatic tempera-
• Air discharge temperature sen- • Circuit(s) • GO to Pinpoint Test N
sor - footwell right-hand circuit • Air discharge temperature
failure - vehicles with electronic sensor - footwell right-hand
• Sunload sensor circuit failure - • Circuit(s) • GO to Pinpoint Test O
vehicles with electronic auto- • Sunload sensor
matic temperature control • Electronic automatic tempera-
• In-vehicle temperature sensor • Circuit(s) • GO to Pinpoint Test P
circuit failure - vehicles with • In-vehicle temperature sensor
electronic automatic temperature • Electronic automatic tempera-
control (EATC) ture control (EATC) module
• In-vehicle temperature sensor • Circuit(s) • GO to Pinpoint Test Q
blower motor circuit failure - ve- • In-vehicle temperature sensor
hicles with electronic automatic • Electronic automatic tempera-
temperature control (EATC) ture control (EATC) module
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Pinpoint Tests
PINPOINT TEST A: BLOWER MOTOR WITHOUT/INCORRECT FUNCTION - VEHICLES WITHOUT
ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC)
A1: CHECK ALL SPEED SETTINGS OF THE BLOWER MOTOR
2 Switch the blower motor switch through all
speed settings.
• Is the blower motor inoperative in all speed
settings?
→ Yes
GO to A2
→ No
- The blower motor is only inoperative in
switch position 4:
GO to A13
- The blower motor is inoperative in switch
positions 1, 2 and/or 3:
GO to A14
A2: CHECK FUSE F10
2 CHECK fuse F10 (BJB).
• Is the fuse OK?
→ Yes
GO to A3
→ No
INSTALL a new fuse F10 (30 A). TEST the
system for normal operation. If the fuse
blows again, LOCATE and REPAIR the short
using the wiring diagrams.
A3: CHECK THE VOLTAGE AT FUSE F10
1 Connect fuse F10 (BJB).
2 Measure the voltage between fuse F10 (30 A)
and ground.
→ Yes
GO to A4
→ No
REPAIR the power supply of fuse F10 using
the wiring diagrams. TEST the system for
normal operation.
A4: CHECK THE VOLTAGE AT THE BLOWER MOTOR RELAY
1 Disconnect blower motor relay of socket C1010
(BJB).
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2 Measure the voltage between the blower motor
relay, socket C1010, pin 1, circuit 30-FA23
(RD), harness side and ground.

• Is battery voltage indicated in both measure-

ments?
→ Yes
GO to A5
→ No
- One measurement indicated no battery
voltage:
LOCATE and REPAIR the open in the rele-
vant circuit between the blower motor relay
and splice S119 using the wiring diagrams.
- No measurement indicated battery voltage:
LOCATE and REPAIR the open in circuit
30-FA23A (RD) between splice S119 and
fuse F10 using the wiring diagrams. TEST
A5: CHECK THE CIRCUIT OF THE BLOWER MOTOR
1 Switch the blower motor switch to position "0".
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2 Connect a fused jumper wire (30 A) at the
blower motor relay, socket C1010, between pin
3 and pin 5, harness side.
3 Switch the blower motor switch to position "4".

• Does the blower motor operate?
→ Yes
GO to A6
→ No
GO to A8
A6: CHECK THE BLOWER MOTOR RELAY
1 Check the blower motor relay according to the
component test at the end of this section.
• Is the blower motor relay OK?
→ Yes
GO to A7
→ No
INSTALL a new blower motor relay. TEST
A7: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR RELAY AND THE CJB FOR OPEN
1 Disconnect connector C95 from CJB.
2 Measure the resistance between the blower
motor relay, socket C1010, pin 2, circuit
31S-FA23 (BK/BU), harness side and CJB,
connector C95, pin 32, circuit 31S-FA23
(BK/BU), harness side.

→ Yes
CHECK the CJB, if necessary INSTALL a
new the CJB. TEST the system for normal
operation.
→ No
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31S-FA23 (BK/BU) between the blower
motor relay and the CJB using the wiring
diagrams. TEST the system for normal op-
eration.
A8: CHECK THE VOLTAGE AT THE BLOWER MOTOR SWITCH (PIN 4)
1 Disconnect connector C380 of blower motor
switch.
blower motor relay, socket C1010, between pin
3 and pin 5, harness side.

switch, connector C380, pin 4, circuit 31S-FA33
(BK/OG), harness side and ground.

→ Yes
GO to A9
→ No
GO to A11
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A9: CHECK THE GROUND CONNECTION OF THE BLOWER MOTOR SWITCH
motor switch, connector C380, pin 5, circuit
31-FA25 (BK), harness side and ground.

→ Yes
GO to A10
→ No
LOCATE and REPAIR the open in the circuit
between the blower motor switch and ground
G20 using the wiring diagrams. TEST the
A10: CHECK THE BLOWER MOTOR SWITCH
1 Connect blower motor relay on socket C1010.
blower motor switch, connector C380, between
pin 4, circuit 31S-FA33 (BK/OG), harness side
and pin 5, circuit 31-FA25 (BK), harness side.

• Does the blower motor operate?
→ Yes
INSTALL a new blower motor switch. TEST
→ No
INSTALL a new blower motor. TEST the
A11: CHECK THE VOLTAGE AT THE BLOWER MOTOR
1 Disconnect connector C789 of blower motor.
2 Connect blower motor relay on socket C1010.
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4 Measure the voltage between the blower motor,
connector C789, pin 1, circuit 15-FA18
(GN/OG), harness side and ground.

→ Yes
GO to A12
→ No
LOCATE and REPAIR open in circuit
15-FA18 (GN/OG) the between blower motor
relay and the blower motor using the wiring
eration.
A12: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER MOTOR
SWITCH FOR OPEN
motor, connector C789, pin 2, circuit 31S-FA18
(BK/RD), harness side and the blower motor
(BK/OG), harness side.

→ Yes
→ No
31S-FA18 (BK/RD) between the blower
motor and splice S24 using the wiring dia-
grams. TEST the system for normal opera-
tion.
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A13: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER MOTOR
SWITCH FOR OPEN (4TH SPEED INOPERATIVE)
resistor.
switch.
motor resistor, connector C470, pin 4, circuit
31S-FA33A (BK/OG), harness side and the
blower motor switch, connector C380, pin 4,
circuit 31S-FA33 (BK/OG), harness side.

→ Yes
→ No
31S-FA33 (BK/OG) between the blower
motor switch and splice S24 using the wiring
eration.
A14: CHECK THE BLOWER MOTOR SWITCH
switch.
(BK/BU), harness side and ground.
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(BK/YE), harness side and ground.
(BK/WH), harness side and ground.
• Is battery voltage indicated in all measure-
ments?
→ Yes
→ No
- No battery voltage is indicated:
GO to A15
- No battery voltage is indicated in one/two
measurements:
GO to A16
A15: CHECK THE VOLTAGE AT THE BLOWER MOTOR RESISTOR
resistor .
resistor, connector C470, pin 4, circuit
31S-FA33A (BK/OG), harness side and ground.

→ Yes
INSTALL a new blower motor resistor. TEST
→ No
31S-FA33A (BK/OG) between the blower
motor resistor and splice S24 using the wir-
ing diagrams. TEST the system for normal
operation.
A16: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR RESISTOR AND THE BLOWER
MOTOR SWITCH FOR OPEN
resistor .
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31S-FA32 (BK/BU), harness side and the
circuit 31S-FA32 (BK/BU), harness side.

31S-FA31 (BK/YE), harness side and the
circuit 31S-FA31 (BK/YE), harness side.

31S-FA30 (BK/WH), harness side and the
circuit 31S-FA30 (BK/WH), harness side.
• Is the resistance less than 2 ohms in all meas-

urements?
→ Yes
INSTALL a new blower motor resistor. TEST
→ No
vant circuit between the blower motor resis-
tor and the blower motor switch using the
wiring diagrams. TEST the system for normal
operation.
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PINPOINT TEST B: MALFUNCTION OF THE RECIRCULATION BLEND DOOR - VEHICLES

WITHOUT ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC)
NOTE: The recirculation blend door is actuated by a DC motor. This is activated for a maximum of 7
seconds by the climate control assembly following actuation of the recirculated air button. Opening and
closing of the recirculation blend door is carried out by reversing the polarity of the applied voltage.
NOTE: Recirculated air mode is not available or will be deactivated if the air distribution control is set to
"defrost/demist windscreen".
B1: CHECK FUSE F43
2 CHECK fuse F43 (CJB).
• Is the fuse OK?
→ Yes
GO to B2
→ No
B2: CHECK THE VOLTAGE AT FUSE F43
1 Connect fuse F43 (CJB).
and ground.
→ Yes
GO to B3
→ No
normal operation.
B3: CHECK FUSE F70
• Is the fuse OK?
→ Yes
GO to B4
→ No
B4: CHECK THE VOLTAGE AT FUSE F70
and ground.
→ Yes
GO to B5
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→ No
normal operation.
B5: CHECK THE VOLTAGE AT THE RECIRCULATION BLEND DOOR ACTUATOR
2 Disconnect connector C538 of recirculation
blend door actuator.
4 Set the air distribution control to footwell.
5 Measure the voltage at the recirculation blend
door actuator, connector C538, between pin 2
and pin 4, harness side.
6 Actuate the recirculated air switch several times

during the measurement.
• Is a voltage of more than 10 V indicated with
alternating polarity?
→ Yes
CHECK the recirculation blend door for soft
running and correct operation. If the recir-
culation blend door is OK, INSTALL a new
recirculation blend door actuator. TEST the
→ No
GO to B6
B6: CHECK THE VOLTAGE AT THE CLIMATE CONTROL ASSEMBLY (PIN 1)
2 Disconnect connector C378 of climate control
assembly.
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3 Measure the voltage between the climate con-
trol assembly, connector C378, pin 1, circuit
29-FA13 (OG), harness side and ground.

→ Yes
GO to B8
→ No
GO to B7
B7: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE CJB FOR
OPEN
1 Disconnect connector C102 of CJB.
2 Measure the resistance between the climate
control assembly, connector C378, pin 1, circuit
29-FA13 (OG), harness side and the CJB,
connector C102, pin 10, circuit 29-FA13 (OG),
harness side.

→ Yes
new CJB. TEST the system for normal op-
eration.
→ No
between the climate control assembly and
the CJB using the wiring diagrams. TEST the
B8: CHECK THE VOLTAGE AT THE CLIMATE CONTROL ASSEMBLY (PIN 8)
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15-FA13 (GN/RD), harness side and ground.

→ Yes
GO to B10
→ No
GO to B9
B9: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE CJB FOR
OPEN
15-FA13 (GN/RD), harness side and the CJB,
connector C102, pin 5, circuit 15-DA4 (GN/BK),
harness side.

→ Yes
eration.
→ No
between the climate control assembly and
the CJB using the wiring diagrams. TEST the
B10: CHECK THE GROUND CONNECTION OF THE CLIMATE CONTROL ASSEMBLY
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91-FA13 (BK/OG), harness side and ground.

→ Yes
GO to B11
→ No
91-FA13 (BK/OG) between the climate con-
trol assembly and splice S12 using the wiring
eration.
B11: CHECK THE CIRCUIT BETWEEN THE RECIRCULATION BLEND DOOR ACTUATOR AND
THE CLIMATE CONTROL ASSEMBLY FOR OPEN
1 Measure the resistance between the recircula-
tion blend door actuator, connector C538, pin 2
(right-hand drive vehicles: pin 4), circuit
32-FA76 (WH/BU), harness side and the cli-
mate control assembly, connector C378, pin 7,
circuit 32-FA76 (WH/BU), harness side.
2 Measure the resistance between the recircula-

tion blend door actuator, connector C538, pin 4
(right-hand drive vehicles: pin 2), circuit
33-FA76 (YE/BU), harness side and the climate
33-FA76 (YE/BU), harness side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX
• Is the resistance less than 2 ohms in both

measurements?
→ Yes
GO to B12
→ No
vant circuit between the climate control as-
sembly and the recirculation blend door ac-
tuator using the wiring diagrams. TEST the
B12: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE
RECIRCULATION BLEND DOOR ACTUATOR FOR SHORT TO POWER
32-FA76 (WH/BU), harness side and ground.

33-FA76 (YE/BU), harness side and ground.
• Is any voltage indicated?
→ Yes
LOCATE and REPAIR the short to power in
the relevant circuit between the climate con-
trol assembly and the recirculation blend
door actuator using the wiring diagrams.
→ No
GO to B13
B13: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE
RECIRCULATION BLEND DOOR ACTUATOR FOR SHORT TO GROUND
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

2 Measure the resistance the between climate
32-FA76 (WH/BU), harness side and ground.

33-FA76 (YE/BU), harness side and ground.
• Is the resistance greater than 10,000 ohms in
both measurements?
→ Yes
CHECK the climate control assembly, if
necessary INSTALL a new climate control
assembly. TEST the system for normal op-
eration.
→ No
LOCATE and REPAIR the short to ground in
the relevant circuit between the climate con-
trol assembly and the recirculation blend
PINPOINT TEST C: AIR CONDITIONING (A/C) IS INOPERATIVE (ALL OTHER FUNCTIONS OF
CLIMATE CONTROL ASSEMBLY OK)
NOTE: Vehicles without DVD Navigation System with Touchscreen, the electronic automatic tempera-
ture control (EATC) module is integrated into the climate control assembly.
C1: CHECK FUSE F27
• Is the fuse OK?
→ Yes
GO to C2
→ No
C2: CHECK THE VOLTAGE AT FUSE F27
and ground.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

→ Yes
GO to C3
→ No
normal operation.
C3: CHECK FUSE F35
• Is the fuse OK?
→ Yes
GO to C4
→ No
C4: CHECK THE VOLTAGE AT FUSE F35
and ground.
→ Yes
GO to C5
→ No
normal operation.
C5: CHECK VOLTAGE AT THE AIR CONDITIONING CLUTCH RELAY
2 Disconnect air conditioning clutch relay socket
C1011 (BJB).
3 Measure the voltage between the air condi-
tioning clutch relay, socket C1011, pin 3, circuit
30-FA2 (RD), harness side and ground.

→ Yes
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

GO to C6
→ No
30-FA2 (RD) between fuse F27 and the air
conditioning clutch relay using the wiring
eration.
C6: CHECK THE CONTROL VOLTAGE AT THE AIR CONDITIONING CLUTCH RELAY
15-FA11 (GN/YE), harness side and ground.

→ Yes
GO to C7
→ No
15-FA11 (GN/YE) between fuse F35 and the
air conditioning clutch relay using the wiring
eration.
C7: CHECK CIRCUIT OF THE AIR CONDITIONING CLUTCH
2 Connect a fused jumper wire (10 A) at the air
conditioning clutch relay , socket C1011, be-
tween pin 3 and pin 5, harness side.
3 Check the function of the air conditioning clutch.

• Does the air conditioning clutch operate?
→ Yes
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

GO to C14
→ No
- Vehicles with 1.8L and 2.0L engine:
GO to C8
- Vehicles with diesel engine:
GO to C10
- Vehicles with 1.6L engine:
GO to C12
C8: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING CLUTCH RELAY AND THE AIR
CONDITIONING CLUTCH FOR OPEN - VEHICLES WITH 1.8L AND 2.0L ENGINE
1 Disconnect connector C952 of air conditioning
clutch.
2 Measure the resistance between the air condi-
tioning clutch relay , socket C1011, pin 5, circuit
15S-FA6 (GN/YE), harness side and the air
conditioning clutch, connector C952, pin 1, cir-
cuit 15S-FA6 (GN/YE), harness side.

→ Yes
GO to C9
→ No
15S-FA6 (GN/YE) between the air condi-
tioning clutch relay and the air conditioning
clutch using the wiring diagrams. TEST the
C9: CHECK THE GROUND CONNECTION OF THE AIR CONDITIONING CLUTCH - VEHICLES
WITH 1.8L AND 2.0L ENGINE
tioning clutch, connector C952, pin 2, circuit
31-FA6A (BK), harness side and ground.

→ Yes
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

INSTALL a new air conditioning clutch. TEST
→ No
31-FA6 (BK) between the air conditioning
clutch and ground G57 using the wiring dia-
tion.
CONDITIONING CLUTCH FOR OPEN - VEHICLES WITH DIESEL ENGINE
clutch.
conditioning clutch, connector C957, pin 2, cir-
cuit 15S-FA6A (GN/YE), harness side.

→ Yes
GO to C11
→ No
between the air conditioning clutch relay and
the air conditioning clutch using the wiring
eration.
WITH DIESEL ENGINE
tioning clutch, connector C957, pin 1, circuit
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

→ Yes
→ No
tion.
CONDITIONING CLUTCH FOR OPEN - VEHICLES WITH 1.6L ENGINE
clutch.
conditioning clutch, connector C951, pin A,
circuit 15S-FA6A (GN/YE), harness side.

→ Yes
GO to C11
→ No
between the air conditioning clutch relay and
the air conditioning clutch using the wiring
eration.
WITH 1.6L ENGINE
tioning clutch, connector C951, pin B, circuit
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

→ Yes
→ No
tion.
C14: CHECK THE A/C REQUEST SIGNAL AT THE POWERTRAIN CONTROL MODULE (PCM)
1 Connect the diagnostic tool.
2 Turn on the blower motor.
3 Switch on the A/C system.
4 Using the diagnostic tester, select the PCM and
check in the datalogger whether an A/C request
signal is displayed.
• Is an A/C request signal displayed in the data-
logger of the PCM?
→ Yes
GO to C19
→ No
- Vehicles without EATC:
GO to C15
- Vehicles with EATC:
CHECK the EATC module, if necessary
INSTALL a new EATC module. TEST the
C15: CHECK THE A/C REQUEST SIGNAL AT THE GENERIC ELECTRONIC MODULE (GEM)
NOTE: The generic electronic module (GEM) is an integral part of the central junction box (CJB).
1 Turn on the blower motor.
3 Using the diagnostic tester, select the GEM and
check in the datalogger whether an A/C request
signal is displayed.
• Is an A/C request signal displayed in the data-
logger of the GEM?
→ Yes
CHECK the GEM, if necessary INSTALL a
eration.
→ No
GO to C16
C16: CHECK THE A/C ON/OFF SWITCH SIGNAL AT THE GEM
4 Turn the blower motor switch to position "1".
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

6 Measure the voltage between the CJB, con-
nector C103, pin 13, circuit 8-FA9 (WH/GN),

→ Yes
CHECK the GEM, if necessary INSTALL a
eration.
→ No
GO to C17
C17: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE CJB FOR
OPEN
2 Disconnect connector C378 of climate control
assembly.
8-FA9 (WH/GN), harness side and the CJB,
connector C103, pin 13, circuit 8-FA9 (WH/GN).

→ Yes
GO to C18
→ No
8-FA9 (WH/GN) between the climate control
assembly and the CJB using the wiring dia-
tion.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

C18: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE CJB FOR
SHORT TO GROUND
8-FA9 (WH/GN), harness side and ground.
• Is a resistance greater than 10,000 ohms?

→ Yes
CHECK the climate control assembly, if
necessary INSTALL a new climate control
assembly. TEST the system for normal op-
eration.
→ No
LOCATE and REPAIR the short in circuit
8-FA9 (WH/GN) between the climate control
assembly and the CJB using the wiring dia-
tion.
C19: CHECK THE VOLTAGE AT THE AIR CONDITIONING LOW-PRESSURE SWITCH
low-pressure switch.
3 Start the engine and run it at idle speed.
tioning low-pressure switch, connector C692,
pin 4, circuit 91S-RE8 (BK/YE), harness side
and ground.

→ Yes
GO to C24
→ No
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

- Vehicles with 2.0L diesel engine:
GO to C20
GO to C21
- Vehicles with 1.6L engine and manual
transmission :
GO to C22
- Vehicles with 1.6L engine and automatic
transmission:
GO to C23
C20: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING LOW-PRESSURE SWITCH AND
THE PCM FOR OPEN - VEHICLES WITH 2.0L DIESEL ENGINE
2 Disconnect connector C418 of PCM.
and the PCM, connector C418, pin H2, circuit
91S-RE8 (BK/YE), harness side.

→ Yes
CHECK the PCM, if necessary INSTALL a
new PCM. TEST the system for normal op-
eration.
→ No
91S-RE8 (BK/YE) between the air condi-
tioning low-pressure switch and the PCM
using the wiring diagrams. TEST the system
THE PCM FOR OPEN - VEHICLES WITH 1.8L AND 2.0L ENGINE
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

and the PCM, connector C690, pin 13, circuit
91S-RE8A (BK/YE), harness side.

→ Yes
eration.
→ No
between the air conditioning low-pressure
switch and the PCM using the wiring dia-
tion.
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE AND MANUAL TRANSMISSION
and the PCM, connector C681, pin R, circuit

→ Yes
eration.
→ No
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

tion.
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE AND AUTOMATIC TRANSMISSION
and the PCM, connector C682, pin R, circuit

→ Yes
eration.
→ No
tion.
C24: CHECK THE GROUND CONNECTION OF THE AIR CONDITIONING LOW-PRESSURE
SWITCH
pin 1, circuit 91S-FA17 (BK/RD) (vehicles with
diesel engine: circuit 91S-FA17A (BK/RD)),

G427113 en 09/2004 2004.75 Focus
TO MODEL INDEX

→ Yes
GO to C25
→ No
GO to C41
- All except vehicles with diesel engine:
LOCATE and REPAIR the open circuit be-
tween the air conditioning low-pressure
switch and ground G31 using the wiring
eration.
C25: CHECK THE AIR CONDITIONING LOW-PRESSURE SWITCH
1 Measure the resistance at the air conditioning
low-pressure switch, connector C692, between
pin 1 and pin 4, component side.

→ Yes
GO to C26
→ No
CHECK refrigerant quantity. REFER to Air
Conditioning (A/C) System Recovery,
Evacuation and Charging in this section. If
the refrigerant quantity is in accordance with
manufacturer's specifications, INSTALL a
new air conditioning low-pressure switch.
C26: CHECK THE AIR CONDITIONING CLUTCH RELAY
1 Check the air conditioning clutch relay accord-
ing to the component test at the end of this
section.
• Is the air conditioning clutch relay OK?
→ Yes
GO to C27
- All except vehicles with diesel engine:
GO to C28
→ No
INSTALL a new air conditioning clutch relay.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

C27: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING CLUTCH RELAY AND THE PCM
FOR OPEN - VEHICLES WITH DIESEL ENGINE
2 Measure the resistance between the PCM,
connector C418, pin D4, circuit 31S-FA11
(BK/YE), harness side and the air conditioning
clutch relay, socket C1011, pin 2, circuit
31S-FA11 (BK/YE), harness side.

→ Yes
eration.
→ No
31S-FA11 (BK/YE), between the PCM and
the air conditioning clutch relay using the
operation.
C28: CHECK THE VOLTAGE AT THE AIR CONDITIONING PRESSURE TRANSDUCER
pressure transducer.
pin 2, circuit 7-FA88 (YE/VT), harness side and
ground.
• Is the voltage of approximately 5 volts?

→ Yes
GO to C29
→ No
- Vehicles with 1.6L engine:
GO to C37
G427113 en 09/2004 2004.75 Focus
TO MODEL INDEX

- Vehicles with 1.8L and 2.0L engine
GO to C38
C29: CHECK THE CONTROL VOLTAGE AT THE AIR CONDITIONING PRESSURE TRANSDUCER
tioning pressure transducer, connector C965,
pin 3, circuit 8-FA88 (WH/VT), harness side and
ground.
• Is a voltage of approximately 4 V indicated?

→ Yes
GO to C30
→ No
transmission:
GO to C31
transmission:
GO to C32
GO to C35
C30: CHECK THE GROUND CONNECTION OF THE AIR CONDITIONING PRESSURE
TRANSDUCER
pin 1, circuit 9-FA88 (BN/WH), harness side and
ground.

→ Yes
transmission:
GO to C33
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

transmission:
GO to C34
GO to C36
→ No
transmission:
GO to C39
GO to C40
C31: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING PRESSURE TRANSDUCER AND
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE AND MANUAL TRANSMISSION
the PCM, connector C681, pin U, circuit
8-FA88A (WH/VT), harness side.

→ Yes
eration.
→ No
between the air conditioning pressure
transducer and the PCM using the wiring
eration.
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE AND AUTOMATIC TRANSMISSION
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

the PCM, connector C682, pin U, circuit
8-FA88A (WH/VT), harness side.

→ Yes
eration.
→ No
eration.
FOR OPEN - VEHICLES WITH 1.6L ENGINE AND MANUAL TRANSMISSION
connector C681, pin AL, circuit 31S-FA11A

→ Yes
eration.
→ No
between the PCM and the air conditioning
clutch relay using the wiring diagrams. TEST
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

FOR OPEN - VEHICLES WITH 1.6L ENGINE AND AUTOMATIC TRANSMISSION
connector C682, pin AL, circuit 31S-FA11A

→ Yes
eration.
→ No
the PCM, connector C690, pin 13, circuit
8-FA88 (WH/VT), harness side.

→ Yes
eration.
→ No
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

8-FA88 (WH/VT) between the air condition-
ing pressure transducer and the PCM using
normal operation.
FOR OPEN - VEHICLES WITH 1.8L AND 2.0L ENGINE
connector C690, pin 1, circuit 31S-FA11A

→ Yes
eration.
→ No
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE
the PCM, connector C680, pin V, circuit 7-RJ28
(YE), harness side.

→ Yes
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

eration.
→ No
eration.
the PCM, connector C690, pin 28, circuit
7-FA88 (YE/VT), harness side.

→ Yes
eration.
→ No
7-FA88 (YE/VT) between the air conditioning
pressure transducer and the PCM using the
operation.
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

the PCM, connector C680, pin AX, circuit 9-RE8
(BN), harness side.

→ Yes
eration.
→ No
transducer and splice S63 using the wiring
eration.
the PCM, connector C690, pin 25, circuit 9-RE8
(BN), harness side.

→ Yes
eration.
→ No
9-FA88 (BN/WH) between the air condition-
ing pressure transducer and splice S63 using
normal operation.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

C41: CHECK THE GROUND CONNECTION OF THE AIR CONDITIONING HIGH-PRESSURE
SWITCH
high-pressure switch.
tioning high-pressure switch, connector 882, pin
1, circuit 91-FA38 (BK/OG), harness side and
ground.

→ Yes
GO to C42
→ No
91-FA38 (BK/OG) between the air condi-
tioning high-pressure switch and ground G31
C42: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING HIGH-PRESSURE SWITCH AND
THE AIR CONDITIONING LOW-PRESSURE SWITCH FOR OPEN
tioning high-pressure switch, connector 882, pin
4, circuit 91S-FA17 (BK/RD), harness side and
the air conditioning low-pressure switch, con-
nector C692, pin 1, circuit 91S-FA17 (BK/RD),
harness side.

→ Yes
INSTALL a new air conditioning
high-pressure switch. TEST the system for
normal operation.
→ No
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

91S-FA17 (BK/RD) between the air condi-
tioning high-pressure switch and the air
conditioning low-pressure switch using the
operation.
PINPOINT TEST D: CLIMATE CONTROL ASSEMBLY INOPERATIVE - VEHICLES WITH
ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) WITHOUT DVD
NAVIGATIONSYSTEM WITH TOUCHSCREEN
D1: CHECK THE CHARGING SYSTEM
1 Check the charging system. REFER to Section
414-00.[Charging System - General Informa-
tion, DIAGNOSIS AND TESTING, Charging
System]
• Is the charging system OK?
→ Yes
GO to D2
→ No
REPAIR the charging system. TEST the
system for normal opeartion.
D2: CHECK FUSE F43
• Is the fuse OK?
→ Yes
GO to D3
→ No
D3: CHECK THE VOLTAGE AT FUSE F43
and ground.
→ Yes
GO to D4
→ No
normal operation.
D4: CHECK THE VOLTAGE AT THE ELECTRONIC AUTOMATIC TEMPERATURE CONTROL
(EATC) MODULE
1 Disconnect connector C539 of EATC module.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

2 Measure the voltage between the EATC mod-
ule, connector C539, pin 11, circuit 29-FA94
(OG/BK), harness side and ground.

→ Yes
GO to D6
→ No
GO to D5
D5: CHECK THE CIRCUIT BETWEEN THE EATC MODULE AND THE CJB FOR OPEN
2 Measure the resistance between the EATC
module, connector C539, pin 11, circuit
29-FA94 (OG/BK), harness side and the CJB,
(OG/BK), harness side.

→ Yes
eration.
→ No
29-FA94 (OG/BK) between the EATC mod-
ule and the CJB using the wiring diagrams.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

D6: CHECK THE GROUND CONNECTION OF THE EATC MODULE
91-FA94 (BK/GN), harness side and ground.

→ Yes
→ No
91-FA94 (BK/GN) between the EATC mod-
ule and splice S12 using the wiring diagrams.
PINPOINT TEST E: BLOWER MOTOR WITHOUT/INCORRECT FUNCTION - VEHICLES WITH
ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) (ALL OTHER FUNCTIONS OF
CLIMATE CONTROL ASSEMBLY OK)
E1: CHECK FUSE F10
• Is the fuse OK?
→ Yes
GO to E2
→ No
E2: CHECK THE VOLTAGE AT FUSE F10
and ground.
→ Yes
GO to E3
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

→ No
normal operation.
E3: CHECK THE VOLTAGE AT THE BLOWER MOTOR
1 Disconnect connector C537 of blower motor.
3 Measure the voltage between the blower motor,
connector C537, pin 1, circuit 15-FA18A
(GN/OG), harness side and ground.

→ Yes
GO to E4
→ No
GO to E9
E4: CHECK THE GROUND CONNECTION OF THE BLOWER MOTOR
motor, connector C537, pin 6, circuit 31-FA45
(BK), harness side and ground.

→ Yes
GO to E5
→ No
between the blower motor and ground G20
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

E5: CHECK THE CIRCUITS BETWEEN THE ELECTRONIC AUTOMATIC TEMPERATURE
CONTROL (EATC) MODULE AND THE BLOWER MOTOR FOR OPEN
49S-FA45 (BU/WH), harness side and the
blower motor, connector C537, pin 2, circuit
49S-FA45 (BU/WH), harness side.

module, connector C540, pin 16, circuit 9-FA45
(BN/BU), harness side and the blower motor,
connector C537, pin 3, circuit 9-FA45 (BN/BU),
harness side.

measurements?
→ Yes
GO to E6
→ No
vant circuit between the EATC module and
the blower motor using the wiring diagrams.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

E6: CHECK THE CIRCUITS BETWEEN THE EATC MODULE AND THE BLOWER MOTOR FOR
SHORT
49S-FA45 (BU/WH), harness side and the
EATC module, connector C540, pin 16, circuit
9-FA45 (BN/BU), harness side.

→ Yes
GO to E7
→ No
LOCATE and REPAIR the short in the cir-
cuits between the EATC module and the
blower motor using the wiring diagrams.
SHORT TO POWER
ule, connector C540, pin 15, circuit 49S-FA45
(BU/WH), harness side and ground.

ule, connector C540, pin 16, circuit 9-FA45
(BN/BU), harness side and ground.
→ Yes
the relevant circuit between the EATC mod-
ule and the blower motor using the wiring
eration.
→ No
G427113 en 09/2004 2004.75 Focus
TO MODEL INDEX

GO to E8
SHORT TO GROUND
49S-FA45 (BU/WH), harness side and ground.

(BN/BU), harness side and ground.
both measurements?
→ Yes
system for normal operation. If the blower
motor is still inoperative, INSTALL a new
EATC module.
→ No
LOCATE and REPAIR the short in the rele-
vant circuit between the EATC module and
the blower motor using the wiring diagrams.
E9: CHECK THE VOLTAGE AT THE BLOWER MOTOR RELAY
2 Disconnect blower motor relay of socket C1010
(BJB).
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

• Is battery voltage indicated in both measure-

ments?
→ Yes
GO to E10
→ No
- Battery voltage is not indicated in one
measurement:
vant circuit between the blower motor relay
and splice S119 using the wiring diagrams.
- No battery voltage is indicated:
30-FA23A (RD) between splice S119 and
fuse F10 using the wiring diagrams. TEST
E10: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR RELAY AND THE BLOWER
MOTOR FOR OPEN
15-FA18 (GN/OG), harness side and the blower
motor, connector C537, pin 1, circuit 15-FA18A
(GN/OG), harness side.

→ Yes
GO to E11
→ No
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

between the blower motor relay and the
blower motor using the wiring diagrams.
E11: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR RELAY AND THE CJB FOR OPEN
31S-FA23 (BK/BU), harness side and the CJB,
(BK/BU), harness side.

→ Yes
GO to E12
→ No
31S-FA23 (BK/BU) between the blower
motor relay and the CJB using the wiring
eration.
E12: CHECK THE BLOWER MOTOR RELAY
1 Check the blower motor relay according to the
component test at the end of this section.
• Is the blower motor relay OK?
→ Yes
eration.
→ No
INSTALL a new blower motor relay. TEST
PINPOINT TEST F: MALFUNCTION OF THE RECIRCULATION BLEND DOOR - VEHICLES WITH
NOTE: Recirculated air mode is not available or will be deactivated if the air distribution control is set to
"defrost/demist windscreen".
NOTE: Make sure that the recirculation blend door is mechanically OK.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

F1: CHECK THE VOLTAGE AT THE RECIRCULATION BLEND DOOR ACTUATOR
2 Disconnect connector C541 of recirculation
blend door actuator.
4 Measure the voltage between the recirculation
blend door actuator, connector C541, pin 2,
circuit 15S-FA42 (GN/YE), harness side and
ground.

→ Yes
- Left-hand drive vehicles:
GO to F3
- Right-hand drive vehicles:
GO to F4
→ No
GO to F2
F2: CHECK THE CIRCUIT BETWEEN THE RECIRCULATION BLEND DOOR ACTUATOR AND THE
EATC MODULE FOR OPEN
15S-FA42 (GN/YE), harness side and the re-
circulation blend door actuator, connector
C541, pin 2, circuit 15S-FA42 (GN/YE), harness
side.

→ Yes
→ No
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

15S-FA42 (GN/YE) between the EATC
module and the recirculation blend door ac-
tuator using the wiring diagrams. TEST the
F3: CHECK THE CIRCUITS BETWEEN THE RECIRCULATION BLEND DOOR ACTUATOR AND
THE EATC MODULE FOR OPEN - LEFT-HAND DRIVE VEHICLES
31S-FA54 (BK/BU), harness side and the re-
C541, pin 1, circuit 31S-FA54 (BK/BU), harness
side.

31S-FA55 (BK/OG), harness side and the re-
C541, pin 3, circuit 31S-FA55 (BK/OG), harness
side.

31S-FA56 (BK/GN), harness side and the re-
C541, pin 4, circuit 31S-FA56 (BK/GN), harness
side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FA57 (BK/RD), harness side and the re-
C541, pin 6, circuit 31S-FA57 (BK/RD), harness
side.

urements?
→ Yes
GO to F5
→ No
vant circuit between the recirculation blend
door actuator and the EATC module using
normal operation.
THE EATC MODULE FOR OPEN - RIGHT-HAND DRIVE VEHICLES
31S-FA54A (BK/BU), harness side and the re-
C541, pin 4, circuit 31S-FA54A (BK/BU), har-
ness side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FA55A (BK/OG), harness side and the re-
C541, pin 6, circuit 31S-FA55A (BK/OG), har-
ness side.

31S-FA56A (BK/GN), harness side and the re-
C541, pin 1, circuit 31S-FA56A (BK/GN), har-
ness side.

31S-FA57A (BK/RD), harness side and the re-
C541, pin 3, circuit 31S-FA57A (BK/RD), har-
ness side.

urements?
→ Yes
GO to F5
→ No
vant circuit between the recirculation blend
normal operation.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

THE EATC MODULE FOR SHORT TO POWER
(BK/BU) (right-hand drive vehicles: circuit
31S-FA54A (BK/BU)), harness side and ground.

(BK/OG) (right-hand drive vehicles: circuit
31S-FA55A (BK/OG)), harness side and
ground.
(BK/GN) (right-hand drive vehicles: circuit
31S-FA56A (BK/GN)), harness side and
ground.
(BK/RD) (right-hand drive vehicles: circuit
31S-FA57A (BK/RD)), harness side and
ground.
→ Yes
LOCATE and REPAIR short to power in the
relevant circuit(s) between the recirculation
blend door actuator and the EATC module
→ No
GO to F6
THE EATC MODULE FOR SHORT TO GROUND
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FA54 (BK/BU) (Right-hand drive vehicles:
circuit 31S-FA54A (BK/BU)), harness side and
ground.

31S-FA55 (BK/OG) (Right-hand drive vehicles:
circuit 31S-FA55A (BK/OG)), harness side and
ground.
31S-FA56 (BK/GN) (Right-hand drive vehicles:
circuit 31S-FA56A (BK/GN)), harness side and
ground.
31S-FA57 (BK/RD) (Right-hand drive vehicles:
circuit 31S-FA57A (BK/RD)), harness side and
ground.
15S-FA42 (GN/YE), harness side and ground.
• Is the resistance greater than 10,000 ohms in all

measurements?
→ Yes
GO to F7
→ No
vant circuit(s) between the recirculation
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

THE EATC MODULE FOR SHORT
31S-FA54A (BK/BU)), harness side and the
15S-FA42 (GN/YE), harness side.

31S-FA55A (BK/OG)), harness side.

31S-FA56A (BK/GN)), harness side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FA57A (BK/RD)), harness side.

15S-FA42 (GN/YE), harness side and the EATC
31S-FA55A (BK/OG)), harness side.

G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX


31S-FA55A (BK/OG)), harness side and the

31S-FA55A (BK/OG)), harness side and the
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FA56A (BK/GN)), harness side and the

measurements?
→ Yes
INSTALL a new recirculation blend door ac-
tuator. TEST the system for normal opera-
tion.
→ No
LOCATE and REPAIR the short between the
relevant circuits between the recirculation
PINPOINT TEST G: MALFUNCTION OF TEMPERATURE BLEND DOOR LEFT-HAND - VEHICLES
WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC)
NOTE: Make sure that the temperature blend door left is mechanically OK.
G1: CHECK THE VOLTAGE AT THE TEMPERATURE BLEND DOOR ACTUATOR LEFT-HAND
2 Disconnect connector C553 of temperature
blend door actuator left-hand.
4 Measure the voltage between the temperature
blend door actuator left-hand, connector C553,
pin 2, circuit 15S-FA46 (GN/BU), harness side
and ground.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

→ Yes
GO to G3
→ No
GO to G2
G2: CHECK THE CIRCUIT BETWEEN THE TEMPERATURE BLEND DOOR ACTUATOR
LEFT-HAND AND THE EATC MODULE FOR OPEN
15S-FA46 (GN/BU), harness side and the
temperature blend door actuator left-hand,
(GN/BU), harness side.

→ Yes
→ No
15S-FA46 (GN/BU) between the EATC
module and the temperature blend door ac-
tuator left-hand using the wiring diagrams.
G3: CHECK THE CIRCUITS BETWEEN THE TEMPERATURE BLEND DOOR ACTUATOR
LEFT-HAND AND THE EATC MODULE FOR OPEN
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FA58 (BK/OG), harness side and the
(BK/OG), harness side.

31S-FA59 (BK/GN), harness side and the
(BK/GN), harness side.

31S-FA60 (BK/RD), harness side and the
(BK/RD), harness side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FA61 (BK/WH), harness side and the
(BK/WH), harness side.

urements?
→ Yes
GO to G4
→ No
vant circuit between the temperature blend
door actuator left-hand and the EATC mod-
ule using the wiring diagrams. TEST the
LEFT-HAND AND THE EATC MODULE FOR SHORT TO POWER

(BK/GN), harness side and ground.
(BK/RD), harness side and ground.
→ Yes
G427113 en 09/2004 2004.75 Focus
TO MODEL INDEX

relevant circuit(s) between the temperature
blend door actuator left-hand and the EATC
module using the wiring diagrams. TEST the
→ No
GO to G5
LEFT-HAND AND THE EATC MODULE FOR SHORT TO GROUND
31S-FA58 (BK/OG), harness side and ground.

31S-FA59 (BK/GN), harness side and ground.
31S-FA60 (BK/RD), harness side and ground.
31S-FA61 (BK/WH), harness side and ground.
15S-FA46 (GN/BU), harness side and ground.
measurements?
→ Yes
GO to G6
→ No
LOCATE and REPAIR short to ground in the
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

LEFT-HAND AND THE EATC MODULE FOR SHORT
15S-FA46 (GN/BU), harness side.

31S-FA59 (BK/GN), harness side.

31S-FA60 (BK/RD), harness side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FA61 (BK/WH), harness side.

31S-FA59 (BK/GN), harness side.

G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX


31S-FA59 (BK/GN), harness side and the EATC

31S-FA59 (BK/GN), harness side and the EATC
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FA60 (BK/RD), harness side and the EATC

measurements?
→ Yes
INSTALL a new temperature blend door ac-
tuator left-hand. TEST the system for normal
operation.
→ No
relevant circuits between the temperature
PINPOINT TEST H: MALFUNCTION OF TEMPERATURE BLEND DOOR RIGHT-HAND - VEHICLES
NOTE: Make sure that the temperature blend door right-hand is mechanically OK.
H1: CHECK THE VOLTAGE AT THE TEMPERATURE BLEND DOOR ACTUATOR RIGHT-HAND
2 Disconnect connector C534 of temperature
blend door actuator right-hand.
4 Measure the voltage between the temperature
blend door actuator right-hand, connector
C534, pin 2, circuit 15S-FB9 (GN/RD), harness
side and ground.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

→ Yes
GO to H3
→ No
GO to H2
H2: CHECK THE CIRCUIT BETWEEN THE TEMPERATURE BLEND DOOR ACTUATOR
RIGHT-HAND AND THE EATC MODULE FOR OPEN
15S-FB9 (GN/RD), harness side and the tem-
perature blend door actuator right-hand, con-
nector C534, pin 2, circuit 15S-FB9 (GN/RD),
harness side.

→ Yes
→ No
15S-FB9 (GN/RD) between the EATC mod-
ule and the temperature blend door actuator
right-hand using the wiring diagrams. TEST
H3: CHECK THE CIRCUITS BETWEEN THE TEMPERATURE BLEND DOOR ACTUATOR
RIGHT-HAND AND THE EATC MODULE FOR OPEN
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FB10 (BK/GN), harness side and the
temperature blend door actuator right-hand,
connector C534, pin 1, circuit 31S-FB10
(BK/GN), harness side.

31S-FB11 (BK/RD), harness side and the
(BK/RD), harness side.

31S-FB12 (BK/WH), harness side and the
(BK/WH), harness side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FB13 (BK/YE), harness side and the
(BK/YE), harness side.

urements?
→ Yes
GO to H4
→ No
vant circuit between the temperature blend
door actuator right-hand and the EATC
RIGHT-HAND AND THE EATC MODULE FOR SHORT TO POWER
ule, connector C539, pin 9, circuit 31S-FB10

(BK/YE), harness side and ground.
→ Yes
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

blend door actuator right-hand and the EATC
→ No
GO to H5
RIGHT-HAND AND THE EATC MODULE FOR SHORT TO GROUND
31S-FB10 (BK/GN), harness side and ground.

31S-FB11 (BK/RD), harness side and ground.
31S-FB12 (BK/WH), harness side and ground.
31S-FB13 (BK/YE), harness side and ground.
15S-FB9 (GN/RD), harness side and ground.
measurements?
→ Yes
GO to H6
→ No
LOCATE and RECTIFY short to ground in
the relevant circuit(s) between the tempera-
ture blend door actuator right-hand and the
EATC module using the wiring diagrams.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

RIGHT-HAND AND THE EATC MODULE FOR SHORT
31S-FB10 (BK/GN), harness side and the EATC
15S-FB9 (GN/RD), harness side.

31S-FB11 (BK/RD), harness side.

31S-FB12 (BK/WH), harness side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FB13 (BK/YE), harness side.

15S-FB9 (GN/RD), harness side and the EATC

G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX


31S-FB11 (BK/RD), harness side and the EATC

G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FB12 (BK/WH), harness side and the

measurements?
→ Yes
INSTALL a new temperature blend door ac-
tuator right-hand. TEST the system for nor-
mal operation.
→ No
relevant circuits between the temperature
blend door actuator right-hand and the EATC
PINPOINT TEST I: MALFUNCTION OF AIR DISTRIBUTION DOOR - VEHICLES WITH ELECTRONIC
AUTOMATIC TEMPERATURE CONTROL (EATC)
NOTE: Make sure that the air distribution door is mechanically OK.
I1: CHECK THE VOLTAGE AT THE AIR DISTRIBUTION DOOR ACTUATOR
2 Disconnect connector C533 of air distribution
door actuator.
4 Measure the voltage between the air distribu-
tion door actuator, connector C533, pin 2, circuit
15S-FB19 (GN/YE), harness side and ground.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

→ Yes
GO to I3
→ No
GO to I2
I2: CHECK THE CIRCUIT BETWEEN THE AIR DISTRIBUTION DOOR ACTUATOR AND THE EATC
MODULE FOR OPEN
15S-FB19 (GN/YE), harness side and the air
distributor door actuator, connector C533, pin 2,
circuit 15S-FB19 (GN/YE), harness side.

→ Yes
→ No
15S-FB19 (GN/YE) between the EATC
module and the air distribution door actuator
I3: CHECK THE CIRCUITS BETWEEN THE AIR DISTRIBUTION DOOR ACTUATOR AND THE
EATC MODULE FOR OPEN
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FB20 (BK/BU), harness side and the air
distribution door actuator, connector C533, pin
1, circuit 31S-FB20 (BK/BU), harness side.

31S-FB21 (BK/OG), harness side and the air
3, circuit 31S-FB21 (BK/OG), harness side.

31S-FB22 (BK/GN), harness side and the air
4, circuit 31S-FB22 (BK/GN), harness side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FB23 (BK/RD), harness side and the air
6, circuit 31S-FB23 (BK/RD), harness side.

urements?
→ Yes
GO to I4
→ No
vant circuit between the air distribution door
actuator and the EATC module using the
operation.
EATC MODULE FOR SHORT TO POWER
(BK/BU), harness side and ground.

→ Yes
G427113 en 09/2004 2004.75 Focus
TO MODEL INDEX

relevant circuit(s) between the air distribution
normal operation.
→ No
GO to I5
EATC MODULE FOR SHORT TO GROUND
31S-FB20 (BK/BU), harness side and ground.

31S-FB21 (BK/OG), harness side and ground.
15S-FB19 (GN/YE), harness side and ground.
measurements?
→ Yes
GO to I6
→ No
relevant circuit(s) between the air distribution
normal operation.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

EATC MODULE FOR SHORT
31S-FB20 (BK/BU), harness side and the EATC
15S-FB19 (GN/YE), harness side.

31S-FB21 (BK/OG), harness side.

31S-FB22 (BK/GN), harness side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX


15S-FB19 (GN/YE), harness side and the EATC
31S-FB21 (BK/OG), harness side.

G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX


31S-FB21 (BK/OG), harness side and the

G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX


measurements?
→ Yes
INSTALL a new air distribution door actuator.
→ No
vant circuits between the air distribution door
actuator and the EATC module using the
operation.
PINPOINT TEST J: MALFUNCTION OF DEFROST VENT/REGISTER BLEND DOOR - VEHICLES
NOTE: Make sure that the defrost vent/register blend door is mechanically OK.
J1: CHECK THE VOLTAGE AT THE DEFROST VENT/REGISTER BLEND DOOR ACTUATOR
2 Disconnect connector C532 of defrost
vent/register blend door actuator.
4 Measure the voltage between the defrost
vent/register blend door actuator, connector
C532, pin 2, circuit 15S-FB14 (GN/BU), harness
side and ground.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

→ Yes
GO to J3
→ No
GO to J2
J2: CHECK THE CIRCUIT BETWEEN THE DEFROST VENT/REGISTER BLEND DOOR ACTUATOR
AND THE EATC MODULE FOR OPEN
15S-FB14 (GN/BU), harness side and the de-
frost vent/register blend door actuator, con-
nector C532, pin 2, circuit 15S-FB14 (GN/BU),
harness side.

→ Yes
→ No
15S-FB14 (GN/BU) between the EATC
module and the defrost vent/register blend
J3: CHECK THE CIRCUITS BETWEEN THE DEFROST VENT/REGISTER BLEND DOOR
ACTUATOR AND THE EATC MODULE FOR OPEN
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FB15 (BK/OG), harness side and the de-
nector C532, pin 1, circuit 31S-FB15 (BK/OG),
harness side.

31S-FB16 (BK/GN), harness side and the de-
nector C532, pin 3, circuit 31S-FB16 (BK/GN),
harness side.

31S-FB17 (BK/RD), harness side and the de-
nector C532, pin 4, circuit 31S-FB17 (BK/RD),
harness side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

31S-FB18 (BK/WH), harness side and the de-
nector C532, pin 6, circuit 31S-FB18 (BK/WH),
harness side.

urements?
→ Yes
GO to J4
→ No
vant circuit between the defrost vent/register
ACTUATOR AND THE EATC MODULE FOR SHORT TO POWER

→ Yes
G427113 en 09/2004 2004.75 Focus
TO MODEL INDEX

relevant circuit(s) between the defrost
vent/register blend door actuator and the
→ No
GO to J5
ACTUATOR AND THE EATC MODULE FOR SHORT TO GROUND
31S-FB15 (BK/OG), harness side and ground.

31S-FB18 (BK/WH), harness side and ground.
15S-FB14 (GN/BU), harness side and ground.
measurements?
→ Yes
GO to J6
→ No
relevant circuit(s) between the defrost
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

ACTUATOR AND THE EATC MODULE FOR SHORT
15S-FB14 (GN/BU), harness side.


G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX


15S-FB14 (GN/BU), harness side and the

G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX



G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX


measurements?
→ Yes
INSTALL a new defrost vent/register blend
door actuator. TEST the system for normal
operation.
→ No
vant circuits between the defrost
PINPOINT TEST K: AIR DISCHARGE TEMPERATURE SENSOR - CENTER REGISTER LEFT-HAND
CIRCUIT FAILURE - VEHICLES WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL
(EATC)
K1: CHECK THE VOLTAGE AT THE AIR DISCHARGE TEMPERATURE SENSOR - CENTER
REGISTER LEFT-HAND
2 Disconnect connector C542 of air discharge
temperature sensor - center register left-hand.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

5 Measure the voltage between the air discharge
temperature sensor - center register left-hand,
connector C542, pin 1, circuit 8-FA47 (WH/GN),

→ Yes
GO to K3
→ No
- No voltage is indicated:
GO to K2
- Battery voltage is indicated:
the circuit 8-FA47 (WH/GN) between the
EATC module and the air discharge tem-
perature sensor - center register left-hand
using the wiring diagrams. If there is no short
to power, CHECK the EATC module, if
necessary INSTALL a new EATC module.
K2: CHECK THE CIRCUIT BETWEEN THE AIR DISCHARGE TEMPERATURE SENSOR - CENTER
REGISTER LEFT-HAND AND THE EATC MODULE FOR OPEN
3 Measure the resistance between the air dis-
charge temperature sensor - center register
left-hand, connector C542, pin 1, circuit 8-FA47
(WH/GN), harness side and the EATC module,
(WH/GN), harness side.

→ Yes
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

→ No
8-FA47 (WH/GN) between the air discharge
temperature sensor - center register
left-hand and the EATC module using the
operation.
REGISTER LEFT-HAND AND THE EATC MODULE FOR OPEN
left-hand, connector C542, pin 3, circuit 9-FA47
(BN/GN), harness side and the EATC module,
(BN/GN), harness side.

→ Yes
GO to K4
→ No
between the air discharge temperature
sensor - center register left-hand and the
REGISTER LEFT-HAND AND THE EATC MODULE FOR SHORT

→ Yes
GO to K5
G427113 en 09/2004 2004.75 Focus
TO MODEL INDEX

→ No
cuits between the air discharge temperature
REGISTER LEFT-HAND AND THE EATC MODULE FOR SHORT TO GROUND
(WH/GN), harness side and ground.

9-FA47A (BN/GN), harness side and ground.
both measurements?
→ Yes
INSTALL a new air discharge temperature
sensor - center register left-hand. TEST the
→ No
PINPOINT TEST L: AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL LEFT-HAND
(EATC)
L1: CHECK THE VOLTAGE AT THE AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL
LEFT-HAND
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

temperature sensor - footwell left-hand.
temperature sensor - footwell left-hand, con-
nector C544, pin 1, circuit 8-FA48 (WH/GN),

→ Yes
GO to L3
→ No
GO to L2
the circuit 8-FA48 (WH/GN) between the
perature sensor - footwell left-hand using the
wiring diagrams. If there is no short to power,
L2: CHECK THE CIRCUIT BETWEEN THE AIR DISCHARGE TEMPERATURE SENSOR -
FOOTWELL LEFT-HAND AND THE EATC MODULE FOR OPEN
charge temperature sensor - footwell left-hand,
connector C544, pin 1, circuit 8-FA48 (WH/GN),
harness side and the EATC module, connector
C540, pin 9, circuit 8-FA48 (WH/GN), harness
side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

→ Yes
→ No
8-FA48 (WH/GN) between the air discharge
temperature sensor - footwell left-hand and
the EATC module using the wiring diagrams.
FOOTWELL LEFT-HAND AND THE EATC MODULE FOR OPEN
charge temperature sensor - footwell left-hand,
connector C544, pin 3, circuit 9-FA48 (BN/GN),
harness side and the EATC module, connector
C540, pin 20, circuit 9-FA47A (BN/GN), harness
side.

→ Yes
GO to L4
→ No
sensor - footwell left-hand and the EATC
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

FOOTWELL LEFT-HAND AND THE EATC MODULE FOR SHORT

→ Yes
GO to L5
→ No
FOOTWELL LEFT-HAND AND THE EATC MODULE FOR SHORT TO GROUND
(WH/GN), harness side and ground.

both measurements?
→ Yes
sensor - footwell left-hand. TEST the system
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

→ No
PINPOINT TEST M: AIR DISCHARGE TEMPERATURE SENSOR - CENTER REGISTER
RIGHT-HAND CIRCUIT FAILURE - VEHICLES WITH ELECTRONIC AUTOMATIC TEMPERATURE
CONTROL (EATC)
M1: CHECK THE VOLTAGE AT THE AIR DISCHARGE TEMPERATURE SENSOR - CENTER
REGISTER RIGHT-HAND
temperature sensor - center register right-hand.
temperature sensor - center register right-hand,
connector C543, pin 1, circuit 8-FA52 (WH/BK),

→ Yes
GO to M3
→ No
GO to M2
the circuit 8-FA52 (WH/BK) between the
perature sensor - center register right-hand
using the wiring diagrams. If there is no short
to power, CHECK the EATC module, if
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

M2: CHECK THE CIRCUIT BETWEEN THE AIR DISCHARGE TEMPERATURE SENSOR - CENTER
REGISTER RIGHT-HAND AND THE EATC MODULE FOR OPEN
right-hand, connector C543, pin 1, circuit
8-FA52 (WH/BK), harness side and the EATC
(WH/BK), harness side.

→ Yes
→ No
8-FA52 (WH/BK) between the air discharge
temperature sensor - center register
right-hand and the EATC module using the
operation.
REGISTER RIGHT-HAND AND THE EATC MODULE FOR OPEN
9-FA52 (BN/YE), harness side and the EATC
9-FA47A (BN/GN), harness side.

→ Yes
GO to M4
→ No
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

sensor - center register right-hand and the
REGISTER RIGHT-HAND AND THE EATC MODULE FOR SHORT
(WH/BK), harness side and the EATC module,

→ Yes
GO to M5
→ No
REGISTER RIGHT-HAND AND THE EATC MODULE FOR SHORT TO GROUND
(WH/BK), harness side and ground.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

both measurements?
→ Yes
sensor - center register right-hand. TEST the
→ No
PINPOINT TEST N: AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL RIGHT-HAND
(EATC)
N1: CHECK THE VOLTAGE AT THE AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL
RIGHT-HAND
temperature sensor - footwell right-hand.
temperature sensor - footwell right-hand, con-
nector C536, pin 1, circuit 8-FA51 (WH/BK),
• Is a voltage of approximately 5 V measured?

→ Yes
GO to N3
→ No
GO to N2
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

the circuit 8-FA51 (WH/BK) between the
perature sensor - footwell right-hand using
the wiring diagrams. If there is no short to
power, CHECK the EATC module, if nec-
essary INSTALL a new EATC module. TEST
N2: CHECK THE CIRCUIT BETWEEN THE AIR DISCHARGE TEMPERATURE SENSOR -
FOOTWELL RIGHT-HAND AND THE EATC MODULE FOR OPEN
charge temperature sensor - footwell
8-FA51 (WH/BK), harness side and the EATC
(WH/BK), harness side.

→ Yes
→ No
8-FA51 (WH/BK) between the air discharge
temperature sensor - footwell right-hand and
FOOTWELL RIGHT-HAND AND THE EATC MODULE FOR OPEN
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

charge temperature sensor - footwell
9-FA51 (BN/YE), harness side and the EATC
9-FA47A (BN/GN), harness side.

→ Yes
GO to N4
→ No
sensor - footwell right-hand and the EATC
N4: CHECK THE CIRCUIT BETWEEN AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL
RIGHT-HAND AND EATC MODULE FOR SHORT
(WH/BK), harness side and the EATC module,

→ Yes
GO to N5
→ No
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

FOOTWELL RIGHT-HAND AND THE EATC MODULE FOR SHORT TO GROUND
(WH/BK), harness side and ground.

both measurements?
→ Yes
sensor - footwell right-hand. TEST the sys-
→ No
PINPOINT TEST O: SUNLOAD SENSOR CIRCUIT FAILURE - VEHICLES WITH ELECTRONIC
AUTOMATIC TEMPERATURE CONTROL (EATC)
O1: CHECK THE VOLTAGE AT THE SUNLOAD SENSOR
2 Disconnect connector C554 of sunload sensor.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

5 Measure the voltage between the sunload
sensor, connector C554, pin 1, circuit 8-FA53
(WH/BU), harness side and ground.
6 Measure the voltage between the sunload

(GY/VT), harness side and ground.
• Is a voltage of approximately 5 V indicated in
both measurements?
→ Yes
GO to O4
→ No
- No voltage is indicated in one/two
measurement(s):
GO to O2
- Battery voltage is indicated in one/two
measurement(s):
the circuit between the EATC module and the
sunload sensor using the wiring diagrams. If
there is no short to power, CHECK the EATC
module, if necessary INSTALL a new EATC
module. TEST the system for normal opera-
tion.
O2: CHECK THE CIRCUITS BETWEEN THE SUNLOAD SENSOR AND THE EATC MODULE FOR
OPEN
3 Measure the resistance between the sunload
(WH/BU), harness side and the EATC module,
(WH/BU), harness side.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

(GY/VT), harness side and the EATC module,
(GY/VT), harness side.

measurements?
→ Yes
GO to O3
→ No
vant circuit between the sunload sensor and
O3: CHECK THE CIRCUITS BETWEEN THE SUNLOAD SENSOR AND THE EATC MODULE FOR A
SHORT TO GROUND
(WH/BU), harness side and ground.

10-FA53 (GY/VT), harness side and ground.
• Is the resistance greater than 10,000 Ohm in
both measurements?
→ Yes
→ No
vant circuit between the sunload sensor and
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

O4: CHECK THE CIRCUIT BETWEEN THE SUNLOAD SENSOR AND THE EATC MODULE FOR
OPEN (GROUND CONNECTION)
(BN/BU), harness side and the EATC module,
connector C540, pin 17, circuit 9-FA1 (BN/RD),
harness side.

→ Yes
INSTALL a new sunload sensor. TEST the
system for normal operation. If the system is
still inoperative, CHECK the EATC module, if
→ No
between the sunload sensor and the EATC
PINPOINT TEST P: IN-VEHICLE TEMPERATURE SENSOR CIRCUIT FAILURE - VEHICLES WITH
P1: CHECK THE VOLTAGE AT THE IN-VEHICLE TEMPERATURE SENSOR
2 Disconnect connector C776 of in-vehicle tem-
perature sensor.
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

5 Measure the voltage between the in-vehicle
temperature sensor, connector C776, pin 4,
circuit 8-FA95 (WH/GN), harness side and
ground.

→ Yes
GO to P2
→ No
GO to P3
the circuit between the EATC module and the
in-vehicle temperature sensor using the
wiring diagrams. If there is no short to power,
P2: CHECK THE CIRCUIT BETWEEN THE IN-VEHICLE TEMPERATURE SENSOR AND THE EATC
MODULE FOR OPEN (GROUND CONNECTION)
2 Measure the resistance between the in-vehicle
circuit 9-FA95 (BN/GN), harness side and the
9-FA1 (BN/RD), harness side.

→ Yes
G427113 en 09/2004 2004.75 Focus

TO MODEL INDEX

INSTALL a new in-vehicle temperature
sensor. TEST the system for normal opera-
tion. If the system is still inoperative, CHECK
the EATC module, if necessary INSTALL a
new EATC module. TEST the system for
normal operation.
→ No
between the in-vehicle temperature sensor
and the EATC module using the wiring dia-
tion.
MODULE FOR OPEN
circuit 8-FA95 (WH/GN), harness side and the
8-FA95 (WH/GN), harness side.

→ Yes
GO to P4
→ No
8-FA95 (WH/GN) between the in-vehicle
temperature sensor and the EATC module
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MODULE FOR SHORT TO GROUND
(WH/GN), harness side and ground

→ Yes
→ No
LOCATE and REPAIR the short to ground in
circuit 8-FA95 (WH/GN) between the
in-vehicle temperature sensor and the EATC
PINPOINT TEST Q: IN-VEHICLE TEMPERATURE SENSOR BLOWER MOTOR CIRCUIT FAILURE -
VEHICLES WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC)
Q1: CHECK THE VOLTAGE AT THE IN-VEHICLE TEMPERATURE SENSOR
2 Disconnect connector C776 of in-vehicle tem-
perature sensor.
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5 Measure the voltage between the in-vehicle
circuit 15S-FA95 (GN/BK), harness side and
ground.

→ Yes
GO to Q2
→ No
GO to Q3
Q2: CHECK THE CIRCUIT BETWEEN THE IN-VEHICLE TEMPERATURE SENSOR AND THE EATC
MODULE FOR OPEN (GROUND CONNECTION)
circuit 31-FA95 (BK), harness side and the
31-FA95 (BK), harness side.

→ Yes
INSTALL a new in-vehicle temperature
sensor. TEST the system for normal opera-
tion. If the system is still inoperative, CHECK
the EATC module, if necessary INSTALL a
new EATC module. TEST the system for
normal operation.
→ No
31-FA95 (BK) between the in-vehicle tem-
perature sensor and the EATC module using
normal operation.
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Q3: CHECK THE CIRCUIT BETWEEN THE IN-VEHICLE TEMPERATURE SENSOR AND THE EATC
MODULE FOR OPEN
circuit 15S-FA95 (GN/BK), harness side and the
15S-FA95 (GN/BK), harness side.

→ Yes
→ No
15S-FA95 (GN/BK) between the in-vehicle
temperature sensor and the EATC module
1. Check the normally open contact in the

Component Tests unswitched state:
Blower motor relay
1. Measure the resistance at the blower motor
relay, between pin 3 and pin 5, component
side.
2. Is the resistance greater than 10,000 ohms?
3. If yes, go to 2.
4. If no, INSTALL a new blower motor relay.
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2. Check the normally open contact in the 4. Check the normally open contact in the
switched state: switched state:
1. Use a 1 Amp. fused test cable to connect 1. Use a 1 Amp. fused test cable to connect
pin 1 of the blower motor relay, component pin 1 of the air conditioning clutch relay,
side, to the battery positive terminal. component side, to the battery positive
2. Use a test cable to connect pin 2 of the terminal.
blower motor relay, component side, to the 2. Use a test cable to connect pin 2 of the air
battery ground terminal. conditioning clutch relay, component side,
3. Measure the resistance at the blower motor to the battery ground terminal.
relay, between pin 3 and pin 5, component 3. Measure the resistance at the air
side. conditioning clutch relay, between pin 3 and
4. Is the resistance less than 2 ohms? pin 5, component side.
5. If yes, then the blower motor relay is OK. 4. Is the resistance less than 2 ohms?
6. If no, INSTALL a new blower motor relay. 5. If yes, then the air conditioning clutch relay
is OK.
6. If no, INSTALL a new air conditioning clutch
Air conditioning clutch relay relay.
3. Check the normally open contact in the

unswitched state:
1. Measure the resistance at the air
conditioning clutch relay, between pin 3 and
pin 5, component side.
2. Is the resistance greater than 10,000 ohms?
3. If yes, go to 4.
4. If no, INSTALL a new air conditioning clutch
relay.
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GENERAL PROCEDURES
Spring Lock Coupling

1. NOTE: Select special tool to suit the line

diameter.
4. Connect the refrigerant line.
Fit the special tool. • Check the clamping spring for damage.
• Fit the special tool so that the inner collar • Carefully pull out any damaged clamping
can be guided into the clamping spring. springs using a thin piece of wire and install
new one.
2. Press the special tool into the clamping

spring. 5. NOTE: Clean the connections using refrigerant
oil and a lint-free cloth.
Press the indicator ring into the clamping
spring.
3. Disconnect the refrigerant line.

• Discard the O-ring seals.
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6. NOTE: Install new refrigerant line O-ring seals.
NOTE: Coat the refrigerant line O-ring seals in
clean refrigerant oil prior to installation.
Connect the refrigerant lines.
• Check that the clamping spring engages
correctly.
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GENERAL PROCEDURES
Air Conditioning (A/C) Clutch Air Gap Adjustment (34 628 6)
2. Measurement for non recessed pulley

Name Specification Check the air gap A between the drive plate
Spacer washer set and the pulley at 60 degrees intervals
around the circumference. For additional
1. Measurement for recessed pulley information,
Check the air gap A between the drive plate refer to Specifications in this section.
and the pulley at 60 degree intervals 1. Belt pulley
around the circumferance of the pulley,
2. Spacer washer
while operating the A/C clutch several
times by means of a 5A fused jumper wire 3. Drive plate
connected between the battery positive • Air gap A
terminal, A/C clutch and battery ground.
1. Belt pulley
2. Drive plate
• Air gap A (the difference measured between
the A/C clutch engaged and disengaged)
3. Remove the drive plate.
4. Correct air gap A as necessary using

spacer washers.
5. Install the drive plate. For additional
information,
6. Check air gap A as described in step 1 or
step 2. Repeat steps 3-5 if necessary.
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GENERAL PROCEDURES
Fluorescent Dye Leak Detection
General Equipment
UV Spot Lamp
Manifold Gauge Set
Fluorescent Dye Injector
NOTE: Vehicles built 07/1999 onwards have a
fluorescent tracer dye tablet inserted into the air
conditioning (A/C) system. If tracer dye is present,
there is a green cross on the suction accumulator.
NOTE: On vehicles built up to 07/1999 tracer dye
must be added.
1. Using the dye injector, add 7.4 ml of
Fluorescent Tracer Dye.
NOTE: Some vehicles may have signs of
refrigerant oil at the spring lock couplers. This may
be caused from the assembly process which
applies to the fittings before installation to aid in
assembly. When a spring lock coupler is
suspected of leaking, always wipe the fitting clean
and verify the leak with R-134a Automatic
Calibration Halogen Leak Detector.
NOTE: The exact location of leaks can be
pinpointed by the bright yellow - green glow of the
tracer dye. Since more than one leak may exist,
always inspect each component.
2. Check for leaks using a 120 Watt UV Spot
Lamp. Always scan all components,
fittings and lines of the A/C system.
3. After the leak is found and repaired,
remove any traces of dye with a general
purpose oil solvent.
4. Verify the repair by operating the system
for some minutes and inspecting with the
UV lamp again.
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GENERAL PROCEDURES
Electronic Leak Detection (34 620 7)
General Equipment
Automatic Calibration Halogen Leak Detector
Manifold Gauge Set
Refrigerant Identifier
WARNING: Good ventilation before leak

detection is necessary in the area where
it is to be performed. If the surrounding
air is contaminated with refrigerant gas,
the leak detector will indicate this gas all
the time. Odors from other chemicals
such as antifreeze, diesel fuel, disc brake
cleaner, or other cleaning solvents can
cause the same problem. While leak
detection air movement must be
prevented.
1. CAUTION: The refrigerant identification
equipment must be used before the
manifold gauge set is installed,
otherwise the manifold gauge may
become contaminated. Contaminated
refrigerant must be disposed of as
special waste. The manufacturer's
instructions must be followed when
working with the service unit.
NOTE: Both manifold gauges should indicate
4,1-5,5 bar at 24°C with the engine off.
Attach the manifold gauge set to the
service gauge port valves.
1. For the leak test, close the manual valves
on the gauge set.
2. If little or no pressure is indicated, charge
the system with approx. 300g of refrigerant.
2. Use R-134a Automatic Calibration Halogen
Leak Detector to leak test the refrigerant
system. Follow the instructions included
with leak detector for handling and
operation techniques.
3. If a leak is found, recover the A/C system.
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GENERAL PROCEDURES
Air Conditioning (A/C) System Recovery, Evacuation and Charging (34 620 2)
3. NOTE: Larger inner diameter for high-pressure

General Equipment side. Smaller inner diameter for low-pressure
side.
Refrigerant center
Connect the refrigerant center lines to the
Refrigerant analyzer A/C charging connections.
4. WARNING: When recovering the
refrigerant do not allow it to enter the
1. CAUTION: The refrigerant analyzer atmosphere under any circumstances.
must be used before recovery, Failure to follow these instructions
otherwise the refrigerant center may may result in personal injury.
become contaminated. Contaminated NOTE: When removing components of the air
refrigerant must be disposed of as conditioning system, calculate the residual
hazardous waste. Always follow the quantity of refrigerant oil. For additional
manufacturer's instructions when information,
using the refrigerant center and the refer to Refrierant Oill Adding in this section.
refrigerant analyzer.
Recover the refrigerant from the A/C
Unscrew and remove the protective caps system via the low-pressure connection in
from the A/C charging connections. accordance with the refrigerant centre
1. Low-pressure connection manufacturer's instructions.
2. High-pressure connection
5. CAUTION: The A/C system must be
evacuated for about 30 minutes before
recharging, to ensure that it operates
correctly.
CAUTION: If moisture was able to enter an
open system over an extended period
(several hours), install a new suction
accumulator and increase the evacuation
time to 2-3 hours.
Evacuate the A/C system according to the
refrigerant center manufacturer's
instructions.
6. NOTE: If an air conditioning system that was
2. Pull back the catches of the quick-fit un- filled with refrigerant is being evacuated, some
ions on the refrigerant center lines. refrigerant will still be in the refrigerant oil in the
compressor. This remaining refrigerant may
evaporate, causing a slight increase in
pressure during the leak test. The system is
leak-free, provided that this pressure increase
does not exceed 20 mbar (2 kPa, 0.29 psi).
Perform the leak test.
1. For the leak test, close the hand valves on
the pressure gauge set, switch off the
refrigerant center vacuum pump and
observe the low pressure gauge.
2. Locate any leaks in the A/C refrigerant
circuit using a leak tester. For additional
information, refer to Fluorescent Dye Leak
Detection/ Electronic Leak Detection in this
section.
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7. Top up with refrigerant oil. For additional 8. NOTE: Depending on the type of refrigerant
information, refer to Refrigerant Oil Adding centre and the equipment (with or without
in this section. heated filling cylinder), the air conditioning
system is either charged with liquid via the
CAUTION: The A/C system must always high-pressure connection or with gas through
be evacuated before charging. Failure to the low-pressure connection.
observe this instruction can cause NOTE: Charge quantity on sticker in engine
damage to the A/C system. compartment.
Charging the A/C system (with liquid) via
the high-pressure connection.
1. Open the shut-off valve on the
high-pressure side.
2. Switch the refrigerant center to "Fill" mode
and fill with the prescribed quantity of liquid
refrigerant (R134a).
9. CAUTION: Only gaseous charging of
the air conditioning system is
performed via the low-pressure
connection. Failure to follow these
instructions may cause damage to the
compressor.
Charging the A/C system via the
low-pressure connection.
1. Open the shut-off valve on the low-pressure
side.
2. Switch the refrigerant center to "Fill" mode
and charge with gaseous refrigerant.
3. Top up with the remaining amount of
refrigerant with the A/C system switched on.
For this purpose, run the engine at approx.
1200-1500 rpm. Switch the air conditioning
to maximum cooling power and fresh air
mode. Set the blower to maximum speed.
Fill with the remainder of the prescribed fill
quantity.
10. WARNING: Do not detach the
high-pressure hose when the A/C
system is switched on. Failure to
personal injury.
Disconnect the refrigerant center.
1. Close the shut-off valves.
2. Switch off the refrigerant center.
3. Disconnect the service unit line from the
A/C charging connection.
4. Attach the protective caps to the charging
valves.
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GENERAL PROCEDURES
Refrigerant Oil Adding (34 621 1)
CAUTION: Store the refrigerant oil in a

closed, sealed container to prevent the
ingress of moisture.
NOTE: Collect the refrigerant oil in a clean
measuring cylinder when replacing the A/C
compressor, the suction accumulator or
refrigerant lines.
1. NOTE: This step only needs to be carried out
when removing the A/C compressor.
Drain the refrigerant oil from the A/C
compressor.
• Rotate the compressor shaft at least 6 to 8
turns when draining the refrigerant oil.
when removing the suction accumulator.
Drain the refrigerant oil from the suction
accumulator.
when removing refrigerant lines.
Drain the refrigerant oil from the refrigerant
lines.
4. NOTE: If more than one air conditioning system
component is being renewed, the oil quantity to
be added is the sum of each individual quantity.
NOTE: In addition, add the same quantity of new
refrigerant oil as was collected in the oil separator
of the servicing unit when the air conditioning was
drained.
Add the calculated quantity of new
refrigerant oil. For additional information,
see Specifications in this subsection.
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GENERAL PROCEDURES
Contaminated Refrigerant Handling (34 620 9)
CAUTION: Any R134a or R12 refrigerant

which is contaminated with unsuitable
refrigerant should be extracted only by
means of a suitable servicing unit
designed for the purpose of collecting
and storing contaminated refrigerant, so
that the spread to other vehicles can be
prevented.
1. Use refrigerant identification equipment to
check that there is contaminated
refrigerant in the air conditioning system.
2. Inform the customer about the additional
cost to repairing the system caused by the
contamination.
3. Extract the contaminated refrigerant.
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GENERAL PROCEDURES
Air Distribution System Cleaning
General Equipment 9. To dry out the system, switch off the air
conditioning system and ventilate the
Spray gun with hose vehicle for approx. 15 minutes.
Name Specification Only Focus to MY 2004.75 and Galaxy
Odour eliminating 11. Remove the blower motor.
agent (240 ml) (TOX Only Ka, Fiesta 96 to MY 2002.25 and Puma
Number 142040) 12. Remove the blower motor resistor
All vehicles Only Fiesta from MY 2002.25, Focus C-Max and
Focus from MY 2004.75 with pollen filter
1. WARNING: Avoid contact with eyes and 13. Remove the pollen filter.
skin; wear gloves and respiratory Only Fiesta from MY 2002.25, Focus C-Max and
protection. Ensure that you perform Focus from MY 2004.75 without pollen filter
this operation in a well ventilated room. 14. Remove the pollen filter housing cover.
Keep all vehicle doors and windows
All vehicles
open for the duration of the operation.
15. Fill the spray gun with the odour
Do not inhale vapors under any
eliminating agent (240 ml).
circumstances. Do not smoke and
avoid open fire and unprotected light 16. WARNING: The maximum pressure of
sources. Avoid contact with eyes and 13.5 bar must not be exceeded. Failure
skin; wear gloves and respiratory to observe this instruction can lead to
protection. Ensure that you perform injuries.
this operation in a well ventilated room.
Keep all vehicle doors and windows Use the tyre inflator to apply pressure of
open for the duration of the operation. 5.5 to 10 bar (operating pressure) to the
Do not inhale vapors under any spray gun.
circumstances. Do not smoke and 17. Insert the hose of the spray gun as far as
avoid open fire and unprotected light possible into the opening created by
sources. Failure to observe this removal of the above component and
instruction can lead to injuries. point it in the direction of the evaporator.
NOTE: The odour eliminating agent can remove 18. By moving the hose, spray the odour
deposits in the heater housing but cannot prevent eliminating agent over the entire surface
odours that are distributed by the ventilation of the evaporator.
system, for example those caused by damp 19. Spray all of the odour eliminating agent
carpets. into the opening.
Precisely locate the musty or damp odour. • Allow the odour eliminating agent to take
2. Disconnect the low pressure switch effect for 10 minutes.
connector. 20. Install the components in reverse order.
3. Turn on the ignition. 21. Start the engine, switch off the air
4. Open all ventilation nozzles. conditioning system and ventilate the
vehicle for approx. 15 minutes.
5. Set the temperature control to maximum
heating power. 22. Open all ventilation nozzles.
6. Set the blower motor control switch to the 23. Set the temperature control to maximum
highest setting. heating power.
7. Set the air distribution control to the fresh 24. Set the blower motor control switch to the
air position. highest setting.
8. Start the engine and let it warm up to 25. Set the air distribution control to the fresh
operating temperature. air position.
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27. Connect the low pressure switch

connector.
28. Ventilate the vehicle with the doors open
for another 30 minutes.
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GENERAL PROCEDURES
Vacuum Leak Detection (34 620 3)
1. Drain the air conditioning (A/C) system. For

additional information, refer to Air Conditioning
(A/C) System Recovery, Evacuation and
Charging in this section.
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412-01-1 Air Distribution and Filtering 412-01-1
SECTION 412-01 Air Distribution and Filtering

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 412-01-2
Air Distribution and Filtering .............................................................................................. 412-01-3

Pollen filter ....................................................................................................................... 412-01-3
Air Distribution and Filtering .............................................................................................. 412-01-4
Pollen Filter — RHD.......................................................................................................... 412-01-5
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SPECIFICATIONS
Tightening Torques
Accelerator pedal retaining nuts 9 - 80
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Air Distribution and Filtering

Pollen filter
The fresh air flowing into the vehicle through the

air intake housing is cleaned of dirt particles which
are larger than 0.003mm and of pollen by passing
it through a pollen filter which is located on the
left-hand side of the heater core/ evaporator
housing (LHD and RHD vehicles).
The pollen filter must be changed at intervals in
accordance with the service schedule.
A special production pollen filter is installed in the
factory and this must be cut off when the filter is
changed. The service pollen filter is flexible and
can be pushed together during installation or
removal.
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Air Distribution and Filtering

REFER to: Climate Control System (412-00 Cli-

mate Control System - General Information,
DIAGNOSIS AND TESTING).
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Pollen Filter — RHD

1. Remove the footwell side trim.

table(s).

Number
4 - CJB bracket
1 - Central junction box (CJB)
bolts 5 - Pollen filter housing cover
screws
2 - CJB
See Removal Detail 6 - Pollen filter housing cover
See Removal Detail
3 - CJB bracket nuts
7 - Pollen filter
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Removal Details
Item 2 : CJB
1. Detach the CJB from the CJB bracket and
1. Turn the CJB downwards.
2. Pull out the CJB.
Item 6 : Pollen filter housing cover

1. Remove the pollen filter housing cover.
1. Unclip the pollen filter housing cover from
the heater core and evaporator core
housing.
2. Pull out the pollen filter housing cover.
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412-02-1 Heating and Ventilation 412-02-1
SECTION 412-02 Heating and Ventilation

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 412-02-2
Heating and Ventilation ..................................................................................................... 412-02-3

Heater Core and Evaporator Core Housing...................................................................... 412-02-3/7
Heating and Ventilation ..................................................................................................... 412-02-8
Blower Motor..................................................................................................................... 412-02-9/14

Heater Core and Evaporator Core Housing....................................................................... 412-02-15/28
Heater Core — RHD ......................................................................................................... 412-02-29/33
Heater Core and Evaporator Core Housing — Vehicles With: Manual Temperature Control
......................................................................................................................................... 412-02-34/38
Heater Core and Evaporator Core Housing — Vehicles With: Automatic Temperature
Control ............................................................................................................................. 412-02-39
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SPECIFICATIONS

Item Specification
Refrigerant oil WSH-M1C231-B
Reinforcing element bolts 22 16 -
Bolts, reinforcing element bracket 25 18 -
Steering column shaft joint bolt 28 21 -
Dashboard crossmember outer bolts 25 18 -
Dashboard crossmember inner bolts 20 15 -
Clutch pedal bracket retaining nuts 25 18 -
Steering column bracket bolts 25 18 -
Bolt for refrigerant lines to A/C evaporator 25 18 -
Door check strap bolt 23 17 -
Door hinge bolts 15 11 -
Dashboard crossmember side bolts 80 59 -
Bolts for windshield wiper motor with linkage 7 - 62
Nuts, windshield wiper arms 22 16 -
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Heating and Ventilation

pipes of the production heater core must be sawn

through. During servicing, a heater core with
Heater Core and Evaporator Core Housing separate coolant pipes is installed.
The heater core and evaporator core housing
contains the blower motor, the pollen filter, the Evaporator core
heater core, the evaporator core (on vehicles with
air conditioning (A/C)), the electric booster heater
(if equipped) and various diverter flaps.
Blower motor
CAUTION: Do not put the blower motor

down on the blower motor fan wheel.
The evaporator core is located on the right-hand

side of the heater core and evaporator core
housing (LHD and RHD). During servicing, it can
only be removed with the heater core and
evaporator core housing removed .
To prevent damage to the fan wheel vanes, the

fan wheel must not be touched. For this reason, a
special tool (412-131) has been introduced for
removal and installation of the blower motor. This
tool is pushed onto the central shaft in order to lift
out the blower motor.
Heater core
The heater core is accessible from the right-hand

side of the heater core and evaporator core
housing (LHD and RHD). It can be removed and
installed with the heater core and evaporator core
housing installed. During removal, the coolant
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Overview

Number
5 - Electric booster heater (if
1 - Blower motor equipped)
2 - Pollen filter 6 - Temperature blend door
3 - Evaporator core motor
4 - Heater core 7 - Air distribution door - de-

froster vents
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Item Part Description Air flow - defroster vents

Number
8 - Air distribution door - center
vents
9 - Air distribution door - footwell

Number
1 - Warm air
2 - Cold air
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Air flow - center vents

Number
1 - Warm air
2 - Cold air
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Air flow - footwell

Number
1 - Warm air
2 - Cold air
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Blower Motor

table(s).
Remover/Installer, Blower
Motor
412-131 CAUTION: Do not touch the blower motor
fan wheel in order to prevent damage to
the fan wheel blades. Failure to follow
this instruction may result in an
imbalance of the fan wheel.
CAUTION: Do not lay the blower motor
down on the blower motor fan wheel.

Number
4 - Glove compartment
1 - Footwell side trim See Removal Detail
2 - Glove compartment bolts 5 - Auxiliary audio input con-
See Removal Detail nector
3 - Glove compartment cooling 6 - Passenger airbag deactiva-
tube (if equipped) tion switch connector (if
See Removal Detail equipped)
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Number
7 - Glove compartment lid
damper (detach)
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Number
10 - CJB bracket
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Number
Removal Details
11 - Air inlet blend door housing
bolts
Item 2 : Glove compartment bolts
12 - Air inlet blend door housing 1. Push the glove compartment bolt covers
See Removal Detail downwards.
13 - Blower motor
See Removal Detail
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2. Detach the central junction box (CJB) from Item 3 : Glove compartment cooling tube (if
the instrument panel console. equipped)
1. Detach the glove compartment cooling
tube from the glove compartment.
3. Detach the CJB from the bracket.

2. Pull the CJB out of the bracket . Item 4 : Glove compartment
1. Remove the navigation system digital ver-
satile disc (DVD) unit access door (if
equipped).
4. NOTE: RHD vehicles only

Disconnect the engine wiring harness
connectors from the CJB and secure the
CJB to one side. Item 12 : Air inlet blend door housing
1. Disconnect the air inlet blend door actuator
connector.
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Item 13 : Blower motor Installation Details

1. Disconnect the blower motor connector.
Item 13 : Blower motor
1. NOTE: Note the top position on the blower
motor.
Using the special tool, bring the blower
motor into the installation position from the
passenger's side.
• Turn the blower motor into the installation
position with the aid of another technician
from the driver's side, insert and turn
clockwise as far as possible.
2. Release the blower motor.

1. Press the release button.
2. Turn the blower motor counter-clockwise to
the stop.
3. Using the special tool, remove the blower

motor from the passenger's side.
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Heater Core and Evaporator Core Housing

414-01.[Battery, Mounting and Cables, 5. Remove the instrument panel. For additi-
GENERAL PROCEDURES, Battery onal information, refer to Section 501-12.
Disconnect] [Instrument Panel and Console,
Instrument Panel - Vehicles With:
Passenger Air Bag] For additional
[Engine Cooling - 1.8L Duratec-HE
Filling and Bleeding] For additional
Instrument Panel - Vehicles Without:
Passenger Air Bag]
Duratorq-TDCi (DW) Diesel, GENERAL 6. Remove the right and left-hand A-pillar trim
PROCEDURES, Cooling System Draining, panel. For additional information,
Filling and Bleeding - 2.0L] For additi- refer to Section 501-05.[Interior Trim and
onal information, refer to Section 303-03C. Ornamentation, REMOVAL AND
[Engine Cooling - 1.6L (Z6), INSTALLATION, A-Pillar Trim Panel]
GENERAL PROCEDURES, Cooling System 7. Remove the right and left-hand front scuff
Draining, Filling and Bleeding] plate trim panel. For additional information,
3. Drain the air conditioning system. For refer to Section 501-05.[Interior Trim and
additional information, refer to Section 412-00. Ornamentation, REMOVAL AND
[Climate Control System - General INSTALLATION, Front Scuff Plate Trim
Information, GENERAL PROCEDURES, Air Panel]
Conditioning (A/C) System Recovery, 8. Remove the components in the order
Evacuation and Charging] indicated in the following illustration(s) and
4. Remove the engine cover (2.0L diesel en- table(s).
gine shown).
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Number
4 - Instrument panel console
1 - Door check strap bolt side bolts
2 - Door hinge bolts See Removal Detail
See Removal Detail
CAUTION: Ensure that the windshield
3 - Front door (driver's door wiper motor is in the park position.
shown)
See Removal Detail
G421036 en 09/2004 2004.75 Focus

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Number
10 - Windshield wiper motor with
5 - Windshield wiper arm nuts linkage
6 - Windshield wiper arms
CAUTION: Close off the coolant lines to
7 - Cowl grille clips prevent fluid loss or dirt ingress.
8 - Cowl grille CAUTION: Close off the refrigerant lines
9 - Windshield wiper linkage and the evaporator to prevent dirt
bolts ingress.
NOTE: Discard the refrigerant line O-ring seals.
G421036 en 09/2004 2004.75 Focus

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Number
11 - Coolant lines
See Removal Detail
12 - Refrigerant lines bolt
13 - Refrigerant lines
14 - Steering column bracket
upper bolts
G421036 en 09/2004 2004.75 Focus

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Number
15 - Steering column shaft joint
bolt
16 - Front footwell air duct bolt
17 - Front footwell air duct
18 - Heater core and evaporator
core housing side bolt
bracket bolts
bracket
21 - Rear footwell air duct
22 - Passenger compartment
wiring harness connector
23 - Ground cable bolts
G421036 en 09/2004 2004.75 Focus

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Number
24 - Instrument panel wiring bracket bolts
harness retaining clips
25 - Ground cable bolt bracket
core housing side bolt
G421036 en 09/2004 2004.75 Focus

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Number
32 - Engine compartment wiring
29 - Front footwell air duct bolt harness connector
30 - Front footwell air duct 33 - Passenger compartment
31 - Instrument panel wiring wiring harness connector
harness connectors 34 - Ground cable bolt
G421036 en 09/2004 2004.75 Focus

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Number
35 - Heater core upper cover
bolts
36 - Heater core upper cover
G421036 en 09/2004 2004.75 Focus

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Number
37 - Instrument panel console See Removal Detail
inner bolts
CAUTION: Ensure that no coolant gets
outer bolts
into the footwell in order to prevent
See Removal Detail
soiling of the carpet.
G421036 en 09/2004 2004.75 Focus

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Number
40 - Heater core and evaporator Item 2 : Door hinge bolts
core housing water drain 1. Support the door using a trolley jack with
pipe the aid of another technician.

core housing

NOTE: Install new refrigerant line O-rings.
NOTE: Coat the refrigerant line O-rings with clean
refrigerant oil before installation.
G421036 en 09/2004 2004.75 Focus

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Item 3 : Front door (driver's door shown) Item 11 : Coolant lines

1. Detach the front door wiring harness con-
nector from the A-pillar. 1. CAUTION: If brake fluid is spilt on the
water.
NOTE: Only vehicles with 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma) or diesel
engine
Detach the brake fluid retainer from the
bulkhead extension and secure it to one
side.
2. Disconnect the front door wiring harness

connector.
2. NOTE: Only vehicles with 1.4L Duratec-16V

(Sigma)/1.6L Duratec-16V (Sigma) or diesel
engine
Remove the bulkhead extension.
• Pull the bulkhead extension from the clips.
Item 4 : Instrument panel console side bolts

1. CAUTION: Do not remove the
instrument panel console side bolts.
Loosen the instrument panel console right
and left-hand side bolts.
3. Turn the coolant line snap ring

counter-clockwise to the stop and detach
the coolant line.
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Item 38 : Instrument panel console outer bolts 4. Mark the position of the instrument panel
1. Support the heater core and evaporator console relative to the A-pillars (left-hand
core housing with wooden blocks. side shown).
2. Disconnect the air inlet blend door actuator 5. Install M10 x 120 mm guide bolts in the
connector. right and left-hand A-pillar.
3. Disconnect the blower motor resistor 6. Remove the instrument panel console right
connector (if fitted) and the blower motor and left-hand side bolts.
connector.
7. Pull the instrument panel console forward
to the stop.
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Item 39 : Instrument panel console 4. NOTE: Vehicles with EATC only

1. Disconnect the airbag module connector.
Disconnect the left-hand temperature blend
• Unclip the center console wiring harness. door actuator connector and the air distri-
bution door actuator connector.
2. Detach the steering column shaft joint from

the steering column shaft. 5. NOTE: Vehicles with EATC only
Disconnect the air outlet temperature
sensor connector.
3. NOTE: Vehicles with EATC only

Disconnect the right-hand temperature
blend door actuator connector and the de- 6. Disconnect the antenna cable connector.
frost blend door actuator connector.
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7. Disconnect the antenna cable cellular Item 15 : Steering column shaft joint bolt
phone connector (if fitted).
shaft joint bolt. Failure to observe this
instruction can lead to injury.
Item 6 : Windshield wiper arms
CAUTION: Move the windshield wiper
motor to park position before installing
the windshield wiper arms.
Item 2 : Door hinge bolts
1. Apply thread locking compound to the
door hinge bolts.
8. Disconnect the roof console connector.
9. Remove the right and left-hand M10 x 120

mm guide bolts.
Item 38 : Instrument panel console outer bolts

1. Align the instrument panel console to the
A-pillars (left-hand side shown).
G421036 en 09/2004 2004.75 Focus

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Heater Core — RHD
1. Drain the cooling system. For additional 5. Detach the steering column shaft joint from
information, refer to Section 303-03A. the steering.
[Engine Cooling - 1.8L Duratec-HE • Remove the steering column shaft joint bolt.
Filling and Bleeding] For additional
Filling and Bleeding - 2.0L] For additional
dirt ingress. 6. Detach the clutch pedal position (CPP)
Detach the clutch master cylinder pipes switch from the clutch pedal bracket.
from the clutch master cylinder.
1. Press the clutch master cylinder supply line
lock button.
line securing clip.
7. Detach the clutch pedal return spring from

the clutch pedal (if present).
1. Secure the clutch pedal in the depressed
position.

4. Remove the instrument panel.For additi-
Instrument Panel - Vehicles With:
Passenger Air Bag] For additional
Instrument Panel - Vehicles Without:
Passenger Air Bag]
G414187 en 09/2004 2004.75 Focus

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8. Remove the clutch pedal bracket nuts. 9. Remove the clutch pedal together with the
• Discard the nuts. clutch pedal bracket and the clutch master
cylinder.
and table(s).
G414187 en 09/2004 2004.75 Focus

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Number
1 - Instrument panel wiring bracket
harness retaining clips
2 - Ground cable bolt
CAUTION: Ensure that no coolant gets
3 - Heater core / evaporator core into the footwell in order to prevent
housing side bolt soiling of the carpet.
bracket bolts
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CAUTION: Close off the heater core and

coolant lines to prevent fluid loss or dirt
ingress.

Number
8 - Bulkhead aperture spacer
6 - Bulkhead aperture cover
section bolts 9 - Coolant line retaining clips
See Removal Detail
7 - Bulkhead aperture cover
section 10 - Coolant lines
G414187 en 09/2004 2004.75 Focus

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Number
11 - Heater core bracket bolts Item 9 : Coolant line retaining clips
1. Release the coolant line retaining clips.
12 - Heater core bracket • Push the coolant lines forwards.
13 - Heater core

WARNING: Install new clutch pedal
bracket retaining nuts. Failure to follow
injury.
Bleeding]
G414187 en 09/2004 2004.75 Focus

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Heater Core and Evaporator Core Housing — Vehicles With: Manual Temperature
Control

table(s).
Motor
412-131
G414202 en 09/2004 2004.75 Focus

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Number
1 - Pollen filter housing cover
bolts
3 - Pollen filter
4 - Blower motor resistor bolts
5 - Blower motor resistor
6 - Air distribution door actuator
bolts
8 - Temperature blend door ac-
tuator bolts
9 - Temperature blend door ac-
tuator
10 - Air inlet blend door actuator
bolts
bolts
14 - Blower motor
See Assembly Detail
G414202 en 09/2004 2004.75 Focus

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Number
19 - Evaporator core refrigerant
15 - Bulkhead aperture cover line bolts
section bolts
16 - Bulkhead aperture cover lines
section
21 - Coolant line retaining clips
17 - Bulkhead aperture spacer See Disassembly Detail
18 - Heater core and evaporator 22 - Coolant lines
core housing gasket
23 - Heater core bracket bolts
G414202 en 09/2004 2004.75 Focus

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Item Part Description Item 14 : Blower motor

Number 1. NOTE: On LHD vehicles, turn the blower motor
counter-clockwise to release.
24 - Heater core bracket
Release the blower motor.
25 - Heater core
1. Press release button.
26 - Evaporator core housing 2. Turn the blower motor clockwise as far as
cover bolts possible.
27 - Evaporator core housing
cover
28 - Evaporator core
core lower housing bolts
core lower housing clips
core lower housing

procedure.
2. Remove the blower motor using the special
Disassembly Details tool.

1. Unclip the pollen filter housing cover from
the heater core and evaporator core
housing.
Item 21 : Coolant line retaining clips

G414202 en 09/2004 2004.75 Focus

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Assembly Details

1. NOTE: On LHD vehicles, turn the blower motor
clockwise to lock.
NOTE: Note top position on blower motor.
Move the blower motor into the installation
position using the special tool.
position, insert and turn counter-clockwise
as far as possible.
G414202 en 09/2004 2004.75 Focus

TO MODEL INDEX
Heater Core and Evaporator Core Housing — Vehicles With: Automatic

Temperature Control

table(s).
Motor
412-131
G414203 en 09/2004 2004.75 Focus

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Number
bolts
3 - Pollen filter
bolts
6 - Air distribution control as-
sembly bolts
7 - Air distribution control as-
sembly
8 - Passenger-side temperature
blend door actuator bolts
9 - Passenger-side temperature
blend door actuator
bolts
bolts
14 - Blower motor
See Assembly Detail
15 - Air outlet temperature sensor
G414203 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
16 - Bulkhead aperture cover line bolts
section bolts
17 - Bulkhead aperture cover lines
section
22 - Coolant line retaining clips
18 - Bulkhead aperture spacer See Disassembly Detail
19 - Heater core and evaporator 23 - Coolant lines
core housing gasket
24 - Heater core bracket bolts
G414203 en 09/2004 2004.75 Focus

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Item Part Description Item 14 : Blower motor

Number 1. NOTE: On LHD vehicles, turn the blower motor
counter-clockwise to release.
25 - Heater core bracket
Release the blower motor.
26 - Heater core
1. Press release button.
27 - Evaporator core housing 2. Turn the blower motor clockwise as far as
cover bolts possible.
28 - Evaporator core housing
cover
core lower housing bolts
core lower housing clips
core lower housing
33 - Defroster jet/air vent distribu-
tion blend door actuator bolts
34 - Defroster jet/air vent distribu- 2. Remove the blower motor using the special
tion blend door actuator tool.
35 - Driver-side temperature
blend door actuator bolts
36 - Driver-side temperature
blend door actuator

procedure.
Disassembly Details

1. Unclip the pollen filter housing cover from Item 15 : Air outlet temperature sensor
the heater core and evaporator core 1. Turn the air outlet temperature sensor
housing. clockwise through 90 degrees and pull out.
G414203 en 09/2004 2004.75 Focus

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Item 22 : Coolant line retaining clips

Assembly Details

1. NOTE: On LHD vehicles, turn the blower motor
clockwise to lock.
NOTE: Note top position on blower motor.
Move the blower motor into the installation
position using the special tool.
position, insert and turn counter-clockwise
as far as possible.
G414203 en 09/2004 2004.75 Focus

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412-03-1 Air Conditioning 412-03-1
SECTION 412-03 Air Conditioning

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 412-03-2
Air Conditioning................................................................................................................. 412-03-3

Manual temperature control.............................................................................................. 412-03-3/6
Air Conditioning................................................................................................................. 412-03-7
Air Conditioning (A/C) Compressor — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)...... 412-03-8/10
Air Conditioning (A/C) Compressor — 2.0L Duratorq-TDCi (DW) Diesel ........................... 412-03-11
Air Conditioning (A/C) Compressor — 1.6L (Z6) ............................................................... 412-03-12/14
Clutch and Clutch Field Coil — 2.0L Duratorq-TDCi (DW) Diesel .................. (34 628 0) 412-03-15/16
Clutch and Clutch Field Coil — 1.6L (Z6)/1.8L Duratec-HE (MI4)/2.0L Du- (34 628 0)
ratec-HE (MI4).............................................................................................. 412-03-17/18
Compressor to Condenser Discharge Line — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE
(MI4) ................................................................................................................................ 412-03-19/20
Compressor to Condenser Discharge Line — 2.0L Duratorq-TDCi (DW) Diesel ............... 412-03-21/22
Evaporator Core Orifice ................................................................................ (34 624 0) 412-03-23/25
Suction Accumulator ......................................................................................................... 412-03-26/27
Suction Accumulator to Compressor Line — 2.0L Duratorq-TDCi (DW) Diesel ................. 412-03-28/29
Condenser Core................................................................................................................ 412-03-30/32
Condenser to Evaporator Line .......................................................................................... 412-03-33/36
Low-Pressure Cutoff Switch .............................................................................................. 412-03-37/39
High-Pressure Cutoff Switch ............................................................................................. 412-03-40/42
Evaporator Core — RHD .................................................................................................. 412-03-43/46
Evaporator Outlet Line ...................................................................................................... 412-03-47
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SPECIFICATIONS

Item Specification
Refrigerant oil WSH-M1C231-B
A/C Compressor
Type
A/C compressor (vehicles with petrol engine) VS16
A/C compressor (vehicles with diesel engine) 7V16
Evaporator Core Orifice

Color
Evaporator core orifice Red
Tightening Torques
Refrigerant lines to air conditioning compressor 20 15 -
Refrigerant lines to A/C suction accumulator 8 - 71
Refrigerant line to A/C condenser 8 - 71
Bolt for refrigerant lines to A/C evaporator 25 18 -
Bolts for refrigerant lines to A/C evaporator 5 - 44
A/C compressor bolts 25 18 -
A/C condenser bolts. 25 18 -
petrol engine)
diesel engine)
Evaporator core orifice tube threaded connection 25 18 -
A/C suction accumulator bolts 25 18 -
A/C suction accumulator nuts 25 18 -
Refrigerant line bracket bolts 25 18 -
High-pressure switch 8 - 71
Low-pressure switch 2.5 - 23
Wiper linkage bolt 7 - 62
Windshield wiper arm nuts 22 16 -
Clutch pedal bracket nuts 25 18 -
Radiator crossmember 25 18 -
Power steering fluid cooler bracket bolt. 9 - 80
Power steering fluid cooler 9 - 80
Accessory drive belt pulley with bracket 25 18 -
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Air Conditioning
Manual temperature control

The pushbuttons are located in the floor console
instrument panel beneath the multimedia system,
or they are integrated in the touch-screen of the
navigation device where applicable.
The temperature is regulated by changing the
positions of the distribution flaps of the heating
and ventilation system.
Five individual stepper motors are used to control
the following components:
• Temperature control air flaps (2 stepper
motors, one on each side)
• Air distribution door (footwell/instrument
panel)
The manual temperature control is located on the • Defroster flap
floor console instrument panel.
• Air inlet blend door
One buttons controls the air conditioning and one The following functions can be controlled
controls the air inlet blend door. The blower speed, automatically:
the passenger compartment temperature and the • Temperature
air distribution are adjusted by means of three
rotary controls. • Blower setting
• Air distribution
The air conditioning control request signal is
transmitted to the Generic Electronic Module • Air conditioning
(GEM). Data transmission to the GEM is • Recirculated air mode
performed via a single-wire lead. From the GEM Automatic mode is exited by switching off the
this signal is relayed via the CAN bus to the system.
instrument cluster, and from there on to the
Powertrain Control Module (PCM). Automatic mode is partially exited when one of the
following buttons is pressed, in which case any
functions which have not been selected continue
Electronic automatic temperature control (EATC) to operate automatically:
• Blower setting
• Recirculated air mode
• Defrost
Automatic control is reactivated by pressing the
"Auto" button or by pressing the corresponding
button again. The automatic mode is not exited
when the temperature is adjusted or the Air
Conditioning (A/C) button is pressed.
Blower controller: Automatic mode

Based on driver preference, the blower setting is
The Electronic Automatic Temperature Control determined as a function of the following input
(EATC) controls the passenger compartment variables in automatic mode:
temperature automatically for two zones
according to the settings made by the driver/front
passenger.
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• Passenger compartment temperature compartment and ambient temperatures, the

• Ambient temperature system switches to recirculated air in automatic
mode. After reaching the temperature set, the
• Sun load
system automatically switches back to fresh air
• Coolant temperature intake. The recirculated air warning indicator does
• Vehicle speed not illuminate when automatic recirculated air
control is activated.
Blower controller: Manual operation
The first time a blower control button is pressed, Air distribution: Manual operation
the blower symbol is switched on and the Each manual operation causes the automatic
automatic symbol switched off. Each time a display to extinguish and activates the LED of the
blower control button is pressed subsequently, the relevant button, and the previously selected
blower speed is set one step higher or lower. settings are stored.
Continuous pressing of a button adjusts the
The air distribution modes (windshield, instrument
blower speed by one step every 0.4 seconds.
panel and footwell) can be selected individually or
Continuous pressing of the button to adjust the together, i.e. one/two/three mode(s) can be
blower speed downwards does not switch off the selected or deselected by pressing the
blower. The OFF button needs to be pressed to do corresponding buttons.
this.
Operating one of the previously selected buttons
Seven blower speed settings can be adjusted switches off the relevant mode. If all modes are
manually. In the "Defrost" setting the blower deactivated, the system reverts automatically to
operates at 80% of the maximum speed, unless automatic mode and adopts the previously
the maximum value was selected beforehand. selected settings.
Air distribution: Automatic mode Defrost

In automatic mode the air distribution setting is Selection of the "Defrost" mode has the following
determined on the basis of the driver requests as effects:
a function of the following input variables: • The LED is switched on for the "Defrost"
• Passenger compartment temperature button and the symbol for automatic mode
• Ambient temperature goes out.
• Sun load • The system changes over to the specified flap
• Air conditioning status position for maximum warm air temperature,
and the "HI" symbol is displayed.
• Coolant temperature
• The air conditioning and the A/C symbol are
• Vehicle speed switched on.
Cold air comes out of the instrument panel air • All the modes currently selected manually are
vents during air conditioning operation. During stored, terminated and the LEDs are
warm-up phase warm air is directed into the deactivated.
footwell. • The air inlet blend door is moved to the "fresh
When the vehicle and the engine are cold, air is air" position, and the previously selected
directed onto the windshield to prevent cold air recirculated air mode is deactivated.
from entering the footwell. • The blower speed is set to 80% of the
The air only comes out of the footwell and maximum value or remains at a higher setting
defroster vents once the preselected temperature if it was selected beforehand.
has been reached. • The windshield and rear window heating are
switched on.
When the air conditioning system is switched off
"Defrost" mode is terminated and all the previously
(no A/C symbol) the air flow is directed into the
stored modes are activated when one of the
footwell to prevent the windows from misting up.
following settings is selected:
In order to achieve maximum cooling of the
interior air in the case of high passenger
G413400 en 09/2004 2004.75 Focus

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• The "Auto" button is pressed. controls. The display then switches from "Auto" to
• Temperature controllers are actuated. "Mono".
• The "Defrost" button is pressed again (if it was The temperature can be adjusted in steps of
previously set to "OFF" then the system 0.5 °C between 16 °C and 28 °C. Temperature
switches over to "Auto"). values outside this range are indicated on the
• One of the air distribution buttons is pressed. display with either "LO" or "HI".
The maximum difference between the
ECO mode temperature on the driver's and front passenger's
sides is 4 °C in "Auto" mode. If a greater difference
The EATC transmits the A/C request signal to the is selected then the opposite side automatically
GEM via the CAN bus. The signal is then relayed tracks the new temperature setting with a
by the GEM via the instrument cluster to the PCM, difference of 4 °C.
which actuates the A/C compressor clutch and the
cooler fan motor. The EATC request can be When "HI" or "LO" are selected the same
interrupted by the PCM, e.g. during full load temperature settings are set on both sides. On
operation. both sides of the vehicle the temperature is set to
28°C when any button is pressed after the "HI"
In the "Auto A/C" mode, the air conditioning is mode is switched off, and similarly the
activated when the user's temperature selection temperature is set to 16 °C on both sides when
makes this necessary. any button is pressed after the "LO" mode is
Pressing the "A/C" button in "Auto A/C" mode switched off.
switches the system to the "ECO" status and the In the "HI" setting the system limits the maximum
compressor is switched off. temperature to 28 °C.
Each press of the button increases or decreases
Recirculated air mode the temperature by one step. Continuous pressing
of the button changes the temperature setting
Selection of the "Auto" mode results in automatic
every 0.4 seconds.
recirculated air control without the recirculated air
LED being switched on. In vehicles with "Bluetooth & Voice Control"
function (activation via the "Voice" button on the
Pressing the "Recirculated air" button while the
steering column stalk) the temperature and blower
LED is switched off selects recirculated air mode;
speed can be modified via the voice function.
pressing the button again cancels the recirculated
air mode and returns the air inlet blend door to the
fresh air position. External controller - EATC
Recirculated air mode is activated automatically
by switching the system off (pressing the "OFF"
button). After the system has been activated (i.e.
any button has been pressed), the previous
settings are called back up.
Temperature adjustment
In "dual mode" the driver and front passenger
temperature settings are combined together. As a
result, any adjustment of the control elements on
the driver's side will adjust the temperature on
both sides of the vehicle.
The temperature can be individually adjusted by
pressing the driver's side control elements. In vehicles equipped with the touch-screen DVD
navigation system, the control components for the
Press the "Auto" button for longer than two EATC are integrated in the unit. The information
seconds to switch back and forth between dual exchange takes place on the mid-speed CAN bus
temperature controls and individual temperature (MS-CAN).
G413400 en 09/2004 2004.75 Focus

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The following display values are transmitted via exit the diagnostic mode without deleting the
the MS CAN bus: trouble codes press any other button.
• Blower setting
• Temperature on the driver's side System off
• Temperature on the front passenger's side When the system is switched off the blower motor,
• A/C or ECO A/C compressor, LCD and LEDs are also shut off.
• Diagnostic code The air inlet blend door is moved to the fresh air
The following warning indicators are actuated via position.
the MS CAN bus: The EATC module stores both the dual and the
• Air distribution manual temperature blend door position settings.
• Recirculated air, Auto, Defrost Pressing "OFF" again starts the system with the
The following request signals are transmitted via previously-stored settings.
the MS CAN bus:
• Raise/lower blower setting
• Temperature adjustment
• Manual air distribution
• Diagnostic information
Switch over from Celsius to Fahrenheit

Adjustment between Celsius and Fahrenheit is
performed via the instrument cluster display and is
transmitted to the EATC module via the MS CAN
bus.
Special service modes

By pressing the appropriate buttons on the control
panel, various special service modes can be
selected in the EATC module:
• Read out the stored (DTC): The (DTCs) are
displayed in the EATC. In order to start
read-out of the stored faults, the "OFF" and
"Footwell" buttons must be pressed and held
for two seconds. Release the buttons and
press the "Headroom" button within 1.5
seconds.
• Activate on-board diagnostic: Start the
self-test (re-calibration is performed). Any
faults found are displayed in the form of
trouble codes on both displays. Press the
"OFF" and "Footwell" buttons for two seconds.
Release both buttons and then press the
"Auto" button within 1.5 seconds.
• Read out the software version indicated on
both displays: Press the "Off" and "Footwell"
buttons for two seconds, release them and
then press the "A/C" button within 1.5
seconds.
• To delete the trouble codes and exit the
diagnostic mode press the "Defrost" button. To
G413400 en 09/2004 2004.75 Focus

TO MODEL INDEX
Air Conditioning
REFER to Section 412-00.[Climate Control

System - General Information, DIAGNOSIS AND
TESTING, Climate Control System]
G167186 en 09/2004 2004.75 Focus

TO MODEL INDEX
Air Conditioning (A/C) Compressor — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)

1. Evacuate the air conditioning (A/C) system. 1.8L Duratec-HE (MI4)/2.0L Duratec-HE
For additional information, refer to Section (MI4)]
412-00.[Climate Control System - General 3. Remove the components in the order
Information, GENERAL PROCEDURES, Air indicated in the following illustration(s) and
Conditioning (A/C) System Recovery, table(s).
Evacuation and Charging]
2. Remove the air conditioning (A/C)
compressor belt. For additional CAUTION: Cap the refrigerant lines and
information, refer to Section 303-05. the A/C compressor to prevent dirt
[Accessory Drive, REMOVAL AND ingress.
G421020 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
Item 13 : A/C compressor drive plate
1 - A/C compressor clutch con- 1. Remove the A/C compressor drive plate
nector bolt
2 - Bolt for A/C compressor re-
frigerant line to dehydrator
3 - A/C compressor refrigerant
line to dehydrator
4 - Seal for A/C compressor re-
frigerant line to condenser
line to condenser
Item 14 : Air conditioning compressor pulley
1. NOTE: If necessary, remove a seized A/C
pressor retaining bolts
compressor pulley using a suitable remover.
9 - Bolt, A/C compressor heat Remove the A/C compressor pulley snap
shield ring.
10 - A/C compressor heat shield • Remove the distance washers.
11 - A/C compressor retaining • Discard the pulley snap ring.
bolt
12 - A/C compressor
13 - A/C compressor drive plate
See Removal Detail
14 - Air conditioning compressor
pulley
See Removal Detail
15 - A/C compressor solenoid coil
See Removal Detail

5. Check the A/C clutch air gap. For additional
[Climate Control System - General
Information, GENERAL PROCEDURES, Air
Conditioning (A/C) Clutch Air Gap
Adjustment]
G421020 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 15 : A/C compressor solenoid coil

1. Remove the clutch field coil snap ring.
2. NOTE: Mark the installation position of the A/C

compressor clutch connector in relation to the
compressor housing.
Detach the solenoid coil.
Item 15 : A/C compressor solenoid coil

CAUTION: Do not tilt the clutch field coil
when installing in the A/C compressor.
NOTE: Installation position of the A/C compressor
clutch connector in relation to the compressor
housing.
Item 14 : Air conditioning compressor pulley
NOTE: Install a new A/C compressor pulley snap
ring.
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TO MODEL INDEX
Air Conditioning (A/C) Compressor — 2.0L Duratorq-TDCi (DW) Diesel
1. Evacuate the air conditioning (A/C) system. INSTALLATION, Accessory Drive Belt -
For additional information, refer to Section 2.0L Duratorq-TDCi (DW) Diesel]
412-00.[Climate Control System - General 3. Remove the components in the order
2. Detach the accessory drive belt. For
additional information, refer to Section 303-05 CAUTION: Cap the refrigerant lines and
.[Accessory Drive, REMOVAL AND the A/C compressor to prevent dirt
ingress.

Number
1 - A/C compressor clutch con- frigerant line to condenser
nector
2 - Bolt for A/C compressor re- pressor retaining bolts
9 - A/C compressor
line to dehydrator 4. To install, reverse the removal procedure.
line to condenser
G421022 en 09/2004 2004.75 Focus

TO MODEL INDEX
Air Conditioning (A/C) Compressor — 1.6L (Z6)
1. Drain the air conditioning system. For INSTALLATION, Accessory Drive Belt -
additional information, refer to Section 412-00. 1.6L (Z6)]
[Climate Control System - General 3. Remove the components in the order
additional information, refer to Section 303-05. CAUTION: Seal the refrigerant lines and
[Accessory Drive, REMOVAL AND the A/C compressor to prevent dirt
ingress.

Number
1 - A/C compressor clutch con- line to suction accumulator
nector
2 - Nut for A/C compressor re- line seals
7 - A/C compressor bolts
line to condenser 8 - A/C compressor
4 - Nut for A/C compressor re-

frigerant line to suction ac-
cumulator
G414207 en 09/2004 2004.75 Focus

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Number
9 - Accessory drive belt pulley Item 13 : A/C compressor pulley
bracket bolts 1. NOTE: If necessary, remove a seized A/C
10 - Accessory drive belt pulley
with bracket Remove the A/C compressor pulley snap
ring.
11 - A/C compressor drive plate • Remove the spacer washers.
bolt
• Discard the pulley snap ring.
12 - A/C compressor drive plate
13 - A/C compressor pulley
See Removal Detail

Adjustment]
G414207 en 09/2004 2004.75 Focus

TO MODEL INDEX
2. Remove the solenoid coil snap ring.

compressor housing.
Remove the solenoid coil.
Item 13 : A/C compressor pulley

CAUTION: Do not tilt the solenoid coil
housing.
ring.
G414207 en 09/2004 2004.75 Focus

TO MODEL INDEX
Clutch and Clutch Field Coil — 2.0L Duratorq-TDCi (DW) Diesel (34 628 0)
Removal 4. NOTE: If necessary, remove a seized A/C

1. Remove the A/C compressor.For additional
information, refer to Air Conditioning (A/C) Remove the A/C compressor pulley.
Compressor - 2.0L Duratorq-TDCi (DW) • Remove the distance washers.
Diesel in this section. • Discard the pulley snap ring.
2. Detach the clutch field coil wiring harness
from the air conditioning compressor.
5. Remove the clutch field coil snap ring.
3. Remove the A/C compressor drive plate.
G421024 en 09/2004 2004.75 Focus

TO MODEL INDEX

compressor clutch wiring harness in relation to
the compressor housing.
Remove the clutch field coil.
Installation
clutch wiring harness in relation to the compressor
housing.
ring.
Adjustment]
G421024 en 09/2004 2004.75 Focus

TO MODEL INDEX
Clutch and Clutch Field Coil — 1.6L (Z6)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE
(MI4) (34 628 0)
Removal 4. Remove the clutch field coil snap ring.

1. Remove the A/C compressor. For
additional information, refer to Air
Conditioning (A/C) Compressor - 1.6L (Z6)
/ Air Conditioning (A/C) Compressor - 1.8L
Duratec-HE (MI4)/2.0L Duratec-HE (MI4) in
this section.
2. Remove the A/C compressor drive plate.

compressor housing.
Remove the clutch field coil.
3. NOTE: If necessary, remove a seized A/C

Remove the A/C compressor pulley.
• Remove the distance washers.
• Discard the pulley snap ring.
Installation
housing.
ring.
1. Install the components in the reverse
order.
G414211 en 09/2004 2004.75 Focus

TO MODEL INDEX

Adjustment]
G414211 en 09/2004 2004.75 Focus

TO MODEL INDEX
Compressor to Condenser Discharge Line — 1.8L Duratec-HE (MI4)/2.0L

Duratec-HE (MI4)
1. Evacuate the air conditioning (A/C) system. 2. Remove the components in the order
For additional information, refer to Section indicated in the following illustration(s) and
412-00.[Climate Control System - General table(s).
Evacuation and Charging] CAUTION: Close off the A/C condenser to
stop dirt from entering.

CAUTION: Close off the A/C compressor
Number
to stop dirt from entering.
1 - Nut, refrigerant line to A/C
condenser
G422496 en 09/2004 2004.75 Focus

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Number
2 - Bolt, refrigerant line to A/C
compressor
See Removal Detail
3 - Outlet line, compressor to
condenser
4 - Bracket, compressor outlet
line to condenser (unclip)

Removal Details
Item 2 : Bolt, refrigerant line to A/C

compressor
G422496 en 09/2004 2004.75 Focus

TO MODEL INDEX
Compressor to Condenser Discharge Line — 2.0L Duratorq-TDCi (DW) Diesel
Evacuation and Charging] CAUTION: Close off the A/C condenser to

Number
condenser
G422482 en 09/2004 2004.75 Focus

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Number
compressor
See Removal Detail
3 - Outlet line, compressor to
condenser

Removal Details

compressor
G422482 en 09/2004 2004.75 Focus

TO MODEL INDEX
Evaporator Core Orifice (34 624 0)

Special Tool(s)
3. CAUTION: Ensure that the windshield
Remover/Installer, Fixed wiper motor is in the park position.
Orifice
Remove the windshield wiper arms.
412-034 (34-004)
Remover, Broken Orifice

412-035 (34-005)
Removal
All vehicles
1. Evacuate the air conditioning (A/C) system.
Information, GENERAL PROCEDURES, Air 4. Remove the cowl grille.
2. Remove the engine cover (2.0L diesel
shown).
G410626 en 09/2004 2004.75 Focus

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CAUTION: If brake fluid comes into All vehicles

7. CAUTION: Close off the refrigerant line
without delay.
Remove the refrigerant line fixed orifice
Detach the brake fluid reservoir from the
tube.
bulkhead extension and tie it back to one
side. • Discard the O-rings.
6. Remove the bulkhead extension. 8. Using the special tool, remove the fixed
orifice tube.
• Pull the bulkhead extension out of the clips.
• Hook the special tool into the fixed orifice
tube, turn it clockwise and remove the fixed
orifice tube.
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TO MODEL INDEX
9. NOTE: This step is necessary if the evaporator

core orifice is broken.
Using the special tools, remove the broken
fixed orifice tube.
Installation
1. WARNING: Move the windshield wiper
motor to the parked position before
installing the wiper arms.
order.
G410626 en 09/2004 2004.75 Focus

TO MODEL INDEX
Suction Accumulator
1. Remove the right-hand headlamp assembly. Conditioning (A/C) System Recovery,

For additional information, refer to Section Evacuation and Charging]
417-01.[Exterior Lighting, REMOVAL AND 3. Remove the components in the order
INSTALLATION, Headlamp Assembly] indicated in the following illustration(s) and
2. Evacuate the air conditioning (A/C) system. table(s).
Information, GENERAL PROCEDURES, Air CAUTION: Close off the refrigerant lines
and the dehydrator to prevent
contamination.
G421025 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
1 - Nut, dehydrator refrigerant
line to evaporator
2 - Refrigerant line, dehydrator
to evaporator
3 - Seal, dehydrator refrigerant
line to evaporator
4 - Nut, dehydrator refrigerant
line to condenser
5 - Dehydrator refrigerant line to
condenser
6 - Seal, dehydrator refrigerant
line to condenser
7 - Nut, dehydrator
8 - Dehydrator rear bolt
See Removal Detail
9 - Dehydrator front bolt
10 - Dehydrator
Removal Details
Item 8 : Dehydrator rear bolt

2. Remove the right-hand wheelhouse cover
(shown with wheel removed for clarity).
G421025 en 09/2004 2004.75 Focus

TO MODEL INDEX
Suction Accumulator to Compressor Line — 2.0L Duratorq-TDCi (DW) Diesel
Evacuation and Charging] CAUTION: Close off the A/C dehydrator to

Number
dehydrator
G422497 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
compressor
See Removal Detail
3 - Refrigerant line, dehydrator
to compressor

Removal Details

compressor
G422497 en 09/2004 2004.75 Focus

TO MODEL INDEX
Condenser Core
Evacuation and Charging] CAUTION: Cap the refrigerant lines and
the condenser core to prevent dirt
ingress.

Number
6 - Seal for condenser core re-
1 - Nut for condenser core refrigerant line to compressor
frigerant line to fixed orifice
tube 7 - Capacitor
See Removal Detail
2 - Condenser core refrigerant
line to fixed orifice tube 3. To install, reverse the removal procedure.
3 - Seal for condenser core re-
frigerant line to fixed orifice Removal Details
tube
Item 7 : Capacitor
4 - Nut for condenser core re-
frigerant line to compressor
5 - Condenser core refrigerant [Jacking and Lifting, DESCRIPTION
line to compressor AND OPERATION, Lifting]
G421028 en 09/2004 2004.75 Focus

TO MODEL INDEX

6. NOTE: For vehicles with automatic
transmission only
Detach the air deflectors from the front
bumper cover.
3. Remove the lower radiator cover.

transmission only
Remove the air deflector on both sides
4. NOTE: Vehicles with diesel engines only

Remove the charge air cooler. For
REMOVAL AND INSTALLATION, Charge
Air Cooler - 2.0L Duratorq-TDCi (DW) Diesel]
transmission only
Loosen the radiator crossmember (left side
shown).
1. Loosen the rear bolts by four turns.
2. Remove the front bolts.
G421028 en 09/2004 2004.75 Focus

TO MODEL INDEX
8. NOTE: For vehicles with automatic 10. Remove the power steering fluid cooler
transmission only bracket bolt.
Unclip left-hand side of transmission fluid
cooler.
bracket.
11. Detach the power steering fluid cooler

from the radiator crossmember and se-
cure to one side.

transmission only
Unclip the transmission fluid cooler on the
right-hand side and secure to one side.
bracket.
12. Push the condenser core upwards out of

the mountings and remove it downwards.
G421028 en 09/2004 2004.75 Focus

TO MODEL INDEX
Condenser to Evaporator Line

Special Tool(s) shown).
Hose Clamp
303-397
Vehicles with 1.6L diesel engine

All vehicles
2. Evacuate the air conditioning (A/C) system.
Conditioning (A/C) System Recovery, 4. Remove the components in the order
Evacuation and Charging] indicated in the following illustration(s) and
table(s).
CAUTION: Make sure that the windshield

wiper motor is in the park position.
NOTE: Vehicles with diesel engines only
G422498 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number Number
1 - Windshield wiper arm nuts 4 - Cowl panel grille
2 - Windshield wiper arms 5 - Bulkhead extension screws
6 - Bulkhead extension
3 - Clips, cowl panel grille See Removal Detail

CAUTION: Close off the A/C condenser
Number
and A/C evaporator to stop dirt from
entering.
8 - Lay the coolant reservoir to
one side.
G422498 en 09/2004 2004.75 Focus

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Number
13 - Condenser refrigerant line to
9 - High pressure switch con- evaporator
nector
10 - Bolt, refrigerant line to A/C 5. To install, reverse the removal procedure.
evaporator NOTE: Install new refrigerant line O-rings.
11 - Nut, refrigerant line to A/C NOTE: Coat the refrigerant line O-rings with clean
condenser refrigerant oil before installation.
12 - Condenser refrigerant line

bracket to the evaporator
(unclip)
G422498 en 09/2004 2004.75 Focus

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Removal Details
Item 6 : Bulkhead extension

contact with the paintwork, the
affected area must be washed down
immediately with cold water.
side.

G422498 en 09/2004 2004.75 Focus

TO MODEL INDEX
Low-Pressure Cutoff Switch

shown).
table(s).


Number
5 - Bulkhead extension screws
1 - Windshield wiper arm nuts
2 - Windshield wiper arms See Removal Detail
3 - Clips, cowl panel grille
4 - Cowl panel grille
G410623 en 09/2004 2004.75 Focus

TO MODEL INDEX
CAUTION: After removing the low closed, in order to prevent refrigerant

pressure switch, make sure that the low from escaping. Failure to observe this
pressure switch valve is completely instruction can lead to injury.

Number
Removal Details
7 - Low pressure switch con-
nector
8 - Low-pressure switch
9 - Low pressure switch seal contact with the paintwork, the
side.
G410623 en 09/2004 2004.75 Focus

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G410623 en 09/2004 2004.75 Focus

TO MODEL INDEX
High-Pressure Cutoff Switch

shown).
table(s).


Number
5 - Bulkhead extension screws
1 - Windshield wiper arm nuts
2 - Windshield wiper arms See Removal Detail
3 - Clips, cowl panel grille
4 - Cowl panel grille
G410624 en 09/2004 2004.75 Focus

TO MODEL INDEX
CAUTION: Make sure that the high-pressure cutoff switch to prevent

high-pressure cutoff switch valve closes loss of refrigerant. Failure to observe this
completely after removal of the instruction can lead to injury.

Number
7 - High pressure switch con-
nector
8 - High Pressure Switch
9 - High pressure switch seal
G410624 en 09/2004 2004.75 Focus

TO MODEL INDEX
Removal Details

contact with the paintwork, the
side.

G410624 en 09/2004 2004.75 Focus

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Evaporator Core — RHD
1. Drain the air conditioning system. For additi-

table(s).
Evacuation and Charging] CAUTION: Ensure that the windshield
2. Remove the heater core. For additional wiper motor is in the park position.
information, refer to Section 412-02. NOTE: Discard the refrigerant line O-ring seals.
[Heating and Ventilation, REMOVAL
AND INSTALLATION, Heater Core - RHD]
3. Remove the engine cover (2.0L Diesel en-
gine shown).
G414213 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number Number
1 - Windshield wiper arm nuts 7 - Bulkhead extension bolts
2 - Windshield wiper arms 8 - Bulkhead extension
3 - Cowl grille clips 9 - Steering column bracket
upper bolts
4 - Cowl grille
10 - Refrigerant lines bolt
5 - Windshield wiper linkage
bolts 11 - Refrigerant lines
6 - Windshield wiper motor with
linkage

NOTE: Discard the refrigerant line O-ring seals.
Number
lower bolts
See Removal Detail
G414213 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
14 - Evaporator core refrigerant Item 8 : Bulkhead extension
lines bolts 1. CAUTION: If brake fluid is spilt on the
15 - Evaporator core refrigerant paintwork, the affected area must be
lines immediately washed down with cold
water.
16 - Evaporator core cover bolts
NOTE: Only vehicles with 1.4L Duratec-16V
17 - Evaporator core cover (Sigma)/1.6L Duratec-16V (Sigma) or diesel
engine.
Detach the brake fluid retainer from the
5. To install, reverse the removal procedure. bulkhead extension and secure it to one
side.
WARNING: Install new steering column 1. Pull the bulkhead extension from the clips.
retaining bolts. Failure to follow this
NOTE: Lubricate the refrigerant line O-ring seals
with clean refrigerant oil before installation.
NOTE: Install new refrigerant line O-ring seals.
G414213 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 13 : Steering column bracket

1. Unclip the instrument panel wiring harness
from the instrument panel console.
2. Detach the steering column bracket from
the instrument panel console and pull it to
side.

motor to park position before installing
the windshield wiper arms.
G414213 en 09/2004 2004.75 Focus

TO MODEL INDEX
Evaporator Outlet Line

Special Tool(s) shown).
Hose Clamp
303-397

Coupling 3/4" (white)
412-040
Vehicles with 1.6L diesel engine

All vehicles 5. Remove the components in the order
2. Evacuate the air conditioning (A/C) system. indicated in the following illustration(s) and
For additional information, refer to Section table(s).
Information, GENERAL PROCEDURES, Air CAUTION: Make sure that the windshield
Conditioning (A/C) System Recovery, wiper motor is in the park position.
G422499 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number Number
1 - Windshield wiper arm nuts 4 - Cowl panel grille
2 - Windshield wiper arms 5 - Bulkhead extension screws
3 - Clips, cowl panel grille See Removal Detail

Number
8 - Lay the coolant reservoir to
one side.
CAUTION: Close off the A/C dehydrator

and evaporator to stop dirt from entering.
G422499 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
9 - Low pressure switch con- Item 6 : Bulkhead extension
nector 1. CAUTION: If brake fluid comes into
10 - Bolt, refrigerant line to A/C contact with the paintwork, the
evaporator affected area must be washed down
dehydrator Detach the brake fluid reservoir from the
See Removal Detail bulkhead extension and tie it back to one
side.
12 - Bracket, evaporator refrig-
erant outlet line (unclip)
13 - Refrigerant outlet line,
evaporator

G422499 en 09/2004 2004.75 Focus

TO MODEL INDEX
Item 11 : Nut, refrigerant line to A/C dehydrator

(Sigma) or 1.6L Duratec-16V (Sigma)
Remove the retaining clip of the A/C line.

(Sigma) or 1.6L Duratec-16V (Sigma)
Disconnect the refrigerant line from the
dehydrator using the special tool.

G422499 en 09/2004 2004.75 Focus

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412-04-1 Control Components 412-04-1
SECTION 412-04 Control Components

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 412-04-2
Control Components ......................................................................................................... 412-04-3

Heating and Ventilation .................................................................................................... 412-04-3/5
Control Components ......................................................................................................... 412-04-6
Climate Control Assembly — Vehicles With: Manual Temperature Control ....................... 412-04-7/8
Climate Control Assembly — Vehicles With: Automatic Temperature Control................... 412-04-9/10
Blower Motor Switch ......................................................................................................... 412-04-11/12
Center Register Air Discharge Temperature Sensor - Driver Side..................................... 412-04-13/14
Center Register Air Discharge Temperature Sensor - Passenger Side ............................. 412-04-15/18
Footwell Air Discharge Temperature Sensor - Driver Side ................................................ 412-04-19/22
Air Inlet Blend Door Actuator............................................................................................. 412-04-23/28
Footwell Vent/Duct Blend Door Actuator — RHD .............................................................. 412-04-29/32
Blower Motor Resistor — RHD.......................................................................................... 412-04-33
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SPECIFICATIONS
Tightening Torques
Bolts, reinforcing element 22 16 -
Bolts, reinforcing element bracket 25 18 -
Steering column shaft joint bolt 28 21 -
Dashboard crossmember outer bolts 25 18 -
Dashboard crossmember inner bolts 20 15 -
Clutch pedal bracket retaining nuts 25 18 -
Door check strap bolt 23 17 -
Door hinge bolts 15 11 -
Dashboard crossmember side bolts 80 59 -
Bolts for windshield wiper motor with linkage 7 - 62
Windshield wiper arm nuts 22 16 -
G371327 en 09/2004 2004.75 Focus

TO MODEL INDEX
Control Components
Control panel - heating/air conditioning - vehicles

• Switching the air conditioning on and off
equipped with manual temperature control
• Temperature adjustment for the driver's side /
front passenger's side
• Switching the windshield defrost function on
and off
• Switching the electronic automatic
temperature control system and the dual mode
on and off
• Blower control
• Switching off the dual automatic temperature
control system
• Recirculated air control
The heating and air conditioning is controlled by
three rotating switches on vehicles equipped with
manual temperature control. Movement of the air
distribution doors is carried out by the air
distribution door/temperature blend door control
unit, which is connected to the control panel by a
drive. Movement of the temperature blend door is
also performed by the air distribution
door/temperature blend door control unit, which is
connected to the control panel by a actuating
cable.
In addition, on the control panel there is an
operating switch for the recirculated air mode and
an on/off switch for the air conditioning system.
Control panel - heating/air conditioning - vehicles

equipped with automatic temperature control
Vehicles with automatic temperature control have

a control panel with buttons to control the following
functions:
G414217 en 09/2004 2004.75 Focus

TO MODEL INDEX
Overview - heater/evaporator housing - vehicles

equipped with manual temperature control

Number
1 - Actuator - air inlet blend door
2 - Control unit - air distribution
door / temperature blend
door
3 - Actuating lever - temperature
blend door
4 - Actuating lever - air distribu-
tion door - central nozzles
tion door - footwell
tion door - defrost nozzles
7 - Drive - air distribution door
8 - Actuating cable - tempera-
ture blend door
G414217 en 09/2004 2004.75 Focus

TO MODEL INDEX
Overview - heater/evaporator housing - vehicles

equipped with automatic temperature control

Number
1 - Air vent temperature sensors
2 - Actuator - defroster nozzle /
air distribution door - air vent
3 - Actuator - right-hand tem-
perature blend door
4 - Actuator - air inlet blend door
5 - Actuator - air distribution
door
6 - Actuator - left-hand tem-
perature blend door
7 - Actuating unit - air distribu-
tion door
tion door - central nozzles
tion door - footwell
G414217 en 09/2004 2004.75 Focus

TO MODEL INDEX
Control Components
REFER to Section 412-00.[Climate Control

System - General Information, DIAGNOSIS AND
TESTING, Climate Control System
G167212 en 09/2004 2004.75 Focus

TO MODEL INDEX
Climate Control Assembly — Vehicles With: Manual Temperature Control

1. Remove the audio unit. For additional 2. Remove the components in the order
information, refer to Section 415-01.[Audio indicated in the following illustration(s) and
Unit, REMOVAL AND INSTALLATION, table(s).
Audio Unit]

Number
screws
G410627 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
3 - Heating / air conditioning
control panel screws
control panel
control panel electrical con-
nectors
6 - Cable, temperature flap
See Removal Detail
7 - Rod - air distribution flap
Removal Details
Item 2 : Instrument panel console

1. Unclip the instrument panel console.
Item 6 : Cable, temperature flap

1. Detach the temperature flap cable from the
adjusting mechanism.
G410627 en 09/2004 2004.75 Focus

TO MODEL INDEX
Climate Control Assembly — Vehicles With: Automatic Temperature Control
1. Remove the audio unit. For additional 2. Remove the components in the order
information, refer to Section 415-01.[Audio indicated in the following illustration(s) and
Unit, REMOVAL AND INSTALLATION, table(s).
Audio Unit]

Number
screws
G410628 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
control panel screws
control panel
control panel electrical con-
nectors
Removal Details
Item 2 : Instrument panel console

1. Unclip the instrument panel console.
G410628 en 09/2004 2004.75 Focus

TO MODEL INDEX
Blower Motor Switch
1. Remove the heater/air conditioning control 2. Remove the components in the order
panel. For additional information, indicated in the following illustration(s) and
refer to Climate Control Assembly - table(s).
Vehicles With: Manual Temperature
Control in this section.
CAUTION: Ensure that the blower motor
switch is set to switch position 1 during
installation and removal, in order to
prevent damage to the control panel
electronics.
NOTE: The rear cover of the climate control
assembly is shown removed for clarity.

Number
1 - Blower motor switch rotary
knob
2 - Blower motor switch cover
See Removal Detail
3 - Blower motor switch
G413296 en 09/2004 2004.75 Focus

TO MODEL INDEX
Removal Details
Item 2 : Blower motor switch cover

1. Remove the blower motor switch cover.
• Cut through the retaining tabs.
Item 2 : Blower motor switch cover

1. NOTE: The service kit for the motor blower
switch contains a modified cover which can be
attached to the climate control assembly rear
cover by means of the two screws provided.
Install the blower motor switch together
with the blower motor switch cover.
G413296 en 09/2004 2004.75 Focus

TO MODEL INDEX
Center Register Air Discharge Temperature Sensor - Driver Side
1. Remove the instrument cluster. For additi- 2. Remove the components in the order
onal information, refer to Section 413-01. indicated in the following illustration(s) and
[Instrument Cluster, REMOVAL AND table(s).
INSTALLATION, Instrument Cluster]

Number
1 - Electrical connector, air out-
let temperature sensor, cen-
tre nozzles, driver's side
2 - Air outlet temperature
sensor, centre nozzles,
driver's side
See Removal Detail
G413276 en 09/2004 2004.75 Focus

TO MODEL INDEX
Removal Details
Item 2 : Air outlet temperature sensor, centre

nozzles, driver's side
1. Turn the air outlet temperature sensor
clockwise through 90 degrees and remove.
G413276 en 09/2004 2004.75 Focus

TO MODEL INDEX
Center Register Air Discharge Temperature Sensor - Passenger Side

table(s).

Number
1 - Footwell trim panel
2 - Glove compartment screws
See Removal Detail
3 - Hose, glove compartment
cooling (if equipped)
See Removal Detail
See Removal Detail
5 - Electrical connector, audio
unit input (if equipped)
6 - Passenger air bag deactiva-
tion (PAD) switch electrical
connector (if equipped)
G413278 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
7 - Opening damper, glove
compartment cover (unhook)
8 - Glove compartment cover
G413278 en 09/2004 2004.75 Focus

TO MODEL INDEX

Number
Removal Details
let temperature sensor, cen-
Item 2 : Glove compartment screws
tre nozzles, passenger's side
1. Fold down the covering caps of the screws
10 - Air outlet temperature for the glove compartment.
sensor, centre nozzles,
passenger's side
See Removal Detail
Item 3 : Hose, glove compartment cooling (if

equipped)
NOTE: Only vehicles with glove compartment
cooling
G413278 en 09/2004 2004.75 Focus

TO MODEL INDEX
1. Detach the central junction box (CJB) from Item 10 : Air outlet temperature sensor, centre
the reinforcing element. nozzles, passenger's side
anti-clockwise through 90 degrees and
remove.

hose from the glove compartment.
Item 4 : Glove compartment

1. Remove the access flap for the navigation
system DVD mechanism (if equipped).
G413278 en 09/2004 2004.75 Focus

TO MODEL INDEX
Footwell Air Discharge Temperature Sensor - Driver Side

table(s).

Number
1 - Bolt, lower dashboard cover
2 - Lower dashboard cover
3 - Data link connector (DLC)
See Removal Detail
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Number
4 - Remote control, audio unit (if
equipped)
See Removal Detail
5 - Remote control electrical
connector, audio unit (if
equipped)
6 - Bolts, steering column lower
cover
7 - Steering column lower cover
8 - Bolts, dashboard
9 - Bolts, front footwell air duct
10 - Front footwell air duct
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Number
Removal Details
let temperature sensor,
Item 3 : Data link connector (DLC)
driver's side footwell
1. Detach the DLC from the lower dashboard
12 - Air outlet temperature cover.
sensor, driver's side footwell
See Removal Detail
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Item 4 : Remote control, audio unit (if

equipped)
1. Detach the audio unit remote control from
the steering column lower cover.
locking tang.
Item 12 : Air outlet temperature sensor,

driver's side footwell
clockwise through 90 degrees and remove
it.
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Air Inlet Blend Door Actuator

table(s).

Number
1 - Footwell side trim
2 - Glove compartment bolts
See Removal Detail
3 - Glove compartment cooling
tube (if equipped)
See Removal Detail
See Removal Detail
5 - Auxiliary audio input con-
nector
6 - Passenger airbag deactiva-
tion switch connector (if
equipped)
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Number
damper (detach)
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Number
10 - CJB bracket
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Number
Removal Details
bolts
Item 2 : Glove compartment bolts
12 - Air inlet blend door housing 1. Push the glove compartment bolt covers
See Removal Detail downwards.
bolts
See Removal Detail
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2. Detach the central junction box (CJB) from Item 3 : Glove compartment cooling tube (if
the instrument panel console. equipped)
tube from the glove compartment.
3. Detach the CJB from the bracket.

2. Pull the CJB out of the bracket . Item 4 : Glove compartment
1. Remove the navigation system digital ver-
satile disc (DVD) unit access door (if
equipped).
4. NOTE: RHD vehicles only

Disconnect the engine wiring harness
connectors from the CJB and secure the
CJB to one side. Item 12 : Air inlet blend door housing
1. Turn the air inlet blend door housing
downwards to gain access to the air inlet
blend door actuator bolts.
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Item 14 : Air inlet blend door actuator

1. Detach the air inlet blend door actuator
connector.
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Footwell Vent/Duct Blend Door Actuator — RHD

table(s).

Number
1 - Footwell trim panel See Removal Detail
2 - Glove compartment screws 5 - Electrical connector, audio
See Removal Detail unit input (if equipped)
3 - Hose, glove compartment 6 - Passenger air bag deactiva-
cooling (if equipped) tion (PAD) switch electrical
See Removal Detail connector (if equipped)
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Number
7 - Opening damper, glove
compartment cover (unhook)
8 - Glove compartment cover
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Number
Removal Details
9 - Connector, footwell air vent
flap actuator
Item 2 : Glove compartment screws
10 - Bolts, footwell air vent flap 1. Fold down the covering caps of the screws
actuator for the glove compartment.
11 - Actuator, footwell air vent
flap
Item 3 : Hose, glove compartment cooling (if

equipped)
NOTE: Only vehicles with glove compartment
cooling
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1. Detach the central junction box (CJB) from 3. Remove the glove compartment cooling
the reinforcing element. hose.
2. Detach the centre console side trim on the

left-hand side.
• Remove the caps.
Item 4 : Glove compartment

1. Remove the access flap for the navigation
system DVD mechanism (if equipped).
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Blower Motor Resistor — RHD

1. Information not available at this time
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413-00-1 Instrument Cluster and Panel Illumination 413-00-1
SECTION 413-00 Instrument Cluster and Panel

Illumination
CONTENTS PAGE
Instrument Cluster and Panel Illumination ......................................................................... 413-00-2

Instrument Cluster and Dimmable Backlighting ................................................................ 413-00-2
Symptom Chart ................................................................................................................ 413-00-2
Pinpoint Tests .................................................................................................................. 413-00-3
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Instrument Cluster and Panel Illumination

Refer to Wiring Diagrams Section 413-00 for

• ashtray
• cigar lighter
• transmission control lever
Principles of Operation • heater control panel
NOTE: A new instrument cluster must be • audio unit
configured. REFER to Section 413-01.[Instrument • navigation system display module
Cluster, REMOVAL AND INSTALLATION, • instrument cluster
Instrument Cluster]
• climate control module
The instrument cluster and panel illumination • hazard switch
consists of dimmable and non-dimmable
illumination. The dimmable panel illumination is • traction control system disable switch
controlled by the panel illumination switch (part of • right-hand and left-hand heated front seat
the headlamp switch), which allows the brightness switch(es)
level of the backlights to be adjusted dependent
on the customer preference. When the headlamp
switch is in the parking lamps ON or headlamps Inspection and Verification
ON position, the intensity of the backlighting can 1. Verify the customer concern.
be adjusted using the panel dimmer switch. The
non dimmable illumination allows for full intensity 2. Visually inspect for obvious signs of
dependant on the ignition switch position. mechanical or electrical damage.

Instrument Cluster and Dimmable Mechanical Electrical
Backlighting – Engine/engine – Fuse(s)
The dimmable illumination utilizes light emitting compartment or – Loose or corroded
diodes (LEDs) and bulb(s). The following underbody connector(s)
dimmable components are backlight using LEDs components
– Instrument cluster
only: – Fluid levels
– Wiring Harness
– Accessory installa-
– Circuit
tion
– LED(s)
– Bulb(s)
Symptom Chart
• The control illumination is inop- • Fuse. • GO to Pinpoint Test A
erative • Headlamp switch.
• Circuit.
• The Instrument cluster illumina- • Circuit(s). • GO to Pinpoint Test B
tion is inoperative • Instrument cluster.
• The climate control illumination • Circuit(s). • GO to Pinpoint Test C
is inoperative • Climate control assembly.
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• The audio system illumination is • Circuit(s). • GO to Pinpoint Test D
inoperative • Audio unit.
• The navigation system display • Circuit(s). • GO to Pinpoint Test E
module illumination (vehicles • Navigation system display mod-
with DVD Navigation System ule.
with Touchscreen) is inoperative
• The gearshift illumination is in- • Circuit(s). • GO to Pinpoint Test F
operative • Transmission Selector Lever.
• The cigar lighter illumination is • Circuit(s). • GO to Pinpoint Test G
inoperative • Cigar lighter.
• The traction control switch illu- • Circuit(s). • GO to Pinpoint Test H
mination is inoperative • Traction control switch.
• The hazard switch illumination is • Circuit(s). • GO to Pinpoint Test I
inoperative • Hazard switch.
• The front seat heater switch(es) • Circuit(s). • GO to Pinpoint Test J
illumination is inoperative • Front seat heater switch(es).
• The front window defrost switch • Circuit(s). • GO to Pinpoint Test K
illumination is inoperative • Front window defrost switch.
• The rear window defrost switch • Circuit(s). • GO to Pinpoint Test L
illumination is inoperative • Rear window defrost switch.
• The rear auxiliary audio control • Circuit(s). • GO to Pinpoint Test M
illumination is inoperative • Rear auxiliary audio control.
• The instrument panel illumina- • Dimmer switch. • INSTALL a new head-
tion does not dim lamp/dimmer switch unit.
Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A: THE CONTROL ILLUMINATION IS INOPERATIVE
A1: CHECK PARKING LAMP OPERATION
2 Place the side lamps in the ON position.
• Do the side lamps and license plate lamps il-
luminate?
→ Yes
INSTALL a new headlamp switch. TEST the
→ No
CHECK fuse F49 (10A).
If the fuse is OK then diagnose exterior
lighting.
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If the fuse has failed, INSTALL a new fuse.
fuse fails again, CHECK for a short to
ground, REPAIR as necessary.
PINPOINT TEST B: THE INSTRUMENT CLUSTER ILLUMINATION IS INOPERATIVE
B1: CHECK THE INSTRUMENT CLUSTER ILLUMINATION
1 Place the headlamp switch in the headlamps
ON position.
• Is only the instrument cluster illumination inop-
erative?
→ Yes
Place the headlamp switch in the OFF posi-
tion. GO to B2
→ No
If the exterior lighting is inoperative, If all of
the control illumination is inoperative,
GO to Pinpoint Test A
B2: CHECK CIRCUIT 29S-GG14 (OG) FOR VOLTAGE
1 Disconnect Instrument Cluster C809.
2 Make sure that the illumination dimmer switch is
in the full illumination position.
3 Place the headlamp switch in the headlamp ON
position.
4 Measure the voltage between the instrument
cluster C809 pin 9, circuit 29S-GG14 (OG),

→ Yes
GO to B3
→ No
normal operation.
B3: CHECK CIRCUIT 91-GG14 (BK/OG) FOR OPEN
1 Place the headlamp switch in the OFF position.
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2 Measure the resistance between instrument
cluster C809 pin 6, circuit 91-GG14 (BK/OG),

→ Yes
INSTALL a new instrument cluster. REFER
to Section 413-01.[Instrument Cluster,
REMOVAL AND INSTALLATION, Instru-
ment Cluster] TEST the system for normal
operation.
→ No
normal operation.
PINPOINT TEST C: THE CLIMATE CONTROL ILLUMINATION IS INOPERATIVE
C1: CHECK CIRCUIT 29S-LE10 (OG/GN) FOR VOLTAGE
1 Disconnect Climate Control Assembly C378 -
vehicles without electronic automatic tempera-
ture control (EATC) module or C540 - vehicles
with electronic automatic temperature control
(EATC) module.
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trol assembly C378 (vehicles without electronic
automatic temperature control (EATC) module)
or C540 (vehicles with electronic automatic
temperature control (EATC) module) pin 3,
circuit 29S-LE10 (OG/GN), harness side and
ground.

→ Yes
Vehicles without electronic automatic
temperature control (EATC) module.
GO to C2
Vehicles with electronic automatic tempera-
ture control (EATC) module.
GO to C3
→ No
normal operation.
C2: CHECK CIRCUIT 91-FA13 (BK/OG) TO GROUND
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control assembly C378 pin 4, circuit 91-FA13

→ Yes
INSTALL a new climate control assembly.
REFER to Section 412-04.[Control Compo-
nents, REMOVAL AND INSTALLATION,
Climate Control Assembly - Vehicles With:
Manual Temperature Control] TEST the
→ No
normal operation.
C3: CHECK CIRCUIT 91-FA94 (BK/GN) TO GROUND
2 Connect Climate Control Assembly C540.
3 Disconnect Climate Control Assembly C539.
control assembly C539 pin 24, circuit 91-FA94

→ Yes
INSTALL a new climate control assembly.
REFER to Section 412-04.[Control Compo-
nents, REMOVAL AND INSTALLATION,
Climate Control Assembly - Vehicles With:
Automatic Temperature Control] TEST the
→ No
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normal operation.
PINPOINT TEST D: THE AUDIO SYSTEM ILLUMINATION IS INOPERATIVE
D1: CHECK VOLTAGE TO THE AUDIO UNIT CIRCUIT 29S-LK34 (OG/BK)
2 Disconnect Audio Unit C442.
ON position.
5 Measure the voltage between audio unit C442
pin 14, circuit 29S-LK34 (OG/BK), harness side
and ground.

→ Yes
GO to D2
→ No
normal operation.
D2: CHECK CIRCUIT 91-MD5 (BK/BU) TO GROUND
2 Measure the resistance between the audio unit
C442 pin 11, circuit 91-MD5 (BK/BU), harness
side and ground.

→ Yes
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INSTALL a new audio unit. REFER to Sec-
tion 415-01.[Audio Unit, REMOVAL AND
INSTALLATION, Audio Unit] TEST the sys-
→ No
normal operation.
PINPOINT TEST E: THE NAVIGATION SYSTEM DISPLAY MODULE ILLUMINATION (VEHICLES
WITH DVD NAVIGATION SYSTEM WITH TOUCHSCREEN) IS INOPERATIVE
E1: CHECK VOLTAGE TO THE NAVIGATION SYSTEM DISPLAY MODULE CIRCUIT 29S-LK40
(OG/BU)
2 Disconnect Navigation System Display Module
C487.
ON position.
5 Measure the voltage between navigation sys-
tem display module C487 pin 3, circuit
29S-LK40 (OG/BU), harness side and ground.

→ Yes
GO to D2
→ No
normal operation.
E2: CHECK THE NAVIGATION SYSTEM DISPLAY MODULE GROUND CIRCUITS FOR OPEN
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2 Measure the resistance between the navigation
system display module C487 pin 11, circuit
91-GK49 (BK/GN), harness side and ground;
and between the navigation system display
module C487 pin 12, circuit 91-GK49A
• Are the resistances less than 5 ohms?

→ Yes
INSTALL a new navigation system display
module. TEST the system for normal op-
eration.
→ No
REPAIR circuit 91-GK49 (BK/GN) or
91-GK49A (BK/GN). TEST the system for
normal operation.
PINPOINT TEST F: THE GEARSHIFT ILLUMINATION IS INOPERATIVE
F1: CHECK CIRCUIT 29S-PF35 (OG/BK) FOR VOLTAGE
1 Disconnect Transmission Selector Lever C383.
ON position.
5 Measure the voltage between the transmission
selector lever C383 pin 2, circuit 29S-PF35

→ Yes
GO to F2
→ No
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normal operation.
F2: CHECK CIRCUIT 31-PF35 (BK) FOR VOLTAGE
2 Measure the voltage between the transmission
selector lever C383 pin 4, circuit 31-PF35 (BK),

→ Yes
INSTALL a new transmission selector lever.
REFER to Section 307-05A.[Automatic
Transmission/Transaxle External Controls -
Vehicles With: 4-Speed Automatic Transaxle
(4F27E), REMOVAL AND INSTALLATION,
Selector Lever] TEST the system for normal
opertion.
→ No
normal operation.
PINPOINT TEST G: THE CIGAR LIGHTER ILLUMINATION IS INOPERATIVE
G1: CHECK CIRCUIT 29S-LK15 (OG) FOR VOLTAGE
1 Disconnect Cigar Lighter C160.
4 Place the headlamp switch in the headlamp ON
position.
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5 Measure the voltage between the cigar lighter
C160 pin 1, circuit 29S-LK15 (OG), harness
side and ground.

→ Yes
→ No
normal operation.
G2: CHECK CIRCUIT 31-HA6 (BK) FOR OPEN
1 Connect Cigar Lighter C160.
2 Disconnect Cigar Lighter C912.
3 Measure the resistance between the cigar
lighter C912 pin 1, circuit 31-HA6 (BK), harness
side and ground.

→ Yes
INSTALL a new cigar lighter. TEST the sys-
→ No
normal operation.
PINPOINT TEST H: THE TRACTION CONTROL SWITCH ILLUMINATION IS INOPERATIVE
H1: CHECK CIRCUIT 29S-LH45 (OG/WH) FOR VOLTAGE
1 Disconnect Traction Control Switch C717.
4 Place the headlamp switch in the ON position.
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5 Measure the voltage between the traction con-
trol switch C717 pin 3, circuit 29S-LH45
(OG/WH) harness side and ground.

→ Yes
GO to H2
→ No
normal operation.
H2: CHECK CIRCUIT 91-CF54 (BK/WH) FOR OPEN
2 Measure the resistance between the traction
control switch C717 pin 2, circuit 91-CF54

→ Yes
INSTALL a new traction control switch. TEST
→ No
normal operation.
PINPOINT TEST I: THE HAZARD SWITCH ILLUMINATION IS INOPERATIVE
I1: CHECK CIRCUIT 29S-LH54 (OG/GN) FOR VOLTAGE
1 Disconnect Hazard Switch C455.
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5 Measure the voltage between the hazard switch
C455 pin 5, circuit 29S-LH54 (OG/GN), harness
side and ground.

→ Yes
GO to I2
→ No
normal operation.
I2: CHECK CIRCUIT 91-LG8 (BK/OG) FOR OPEN
2 Measure the resistance between hazard switch
C455 pin 2, circuit 91-LG8 (BK/OG), harness
side and ground.

→ Yes
INSTALL a new hazard switch. TEST the
→ No
normal operation.
PINPOINT TEST J: THE FRONT SEAT HEATER SWITCH ILLUMINATION IS INOPERATIVE
J1: CHECK INOPERATIVE FRONT SEAT HEATER SWITCH FOR VOLTAGE
1 Disconnect Inoperative Front Seat Heater
Switch - C694 (driver side) or C695 (passenger
side).
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5 Measure the voltage between the inoperative
front seat heater switch:
- C694 (driver side) pin 1, circuit 29S-LH29
(OG/YE), harness side and ground.
- C695 (passenger side) pin 1, circuit 29S-LH43
(OG/BU), harness side and ground.

→ Yes
GO to J2
→ No
REPAIR circuit 29S-LH29 (OG/YE) or circuit
29S-LH43 (OG/BU) as necessary. TEST the
J2: CHECK GROUND TO INOPERATIVE FRONT SEAT HEATER SWITCH FOR OPEN
1 Measure the resistance between the
inoperative front seat heater switch:
- C694 (driver side) pin 2, circuit 31-LH29 (BK),
- C695 (passenger side) pin 2, circuit 31-LH43
(BK), harness side and ground.

→ Yes
INSTALL a new front seat heater switch.
→ No
REPAIR circuit 31-LH29 (BK) or circuit
31-LH43 (BK) as necessary. TEST the sys-
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PINPOINT TEST K: THE FRONT WINDOW DEFROST SWITCH ILLUMINATION IS INOPERATIVE

K1: CHECK THE FRONT WINDOW DEFROST SWITCH FOR VOLTAGE
1 Disconnect Front Window Defrost Switch C382.
5 Measure the voltage between the front window
defrost switch C382 pin 3, circuit 29S-HB9
(OG/WH), harness side and ground.

→ Yes
GO to K2
→ No
REPAIR the circuit 29S-HB9 (OG/WH).
K2: CHECK CIRCUIT 91-HB9 (BK/WH) FOR OPEN
2 Measure the resistance between the front
window defrost switch C382 pin 2, circuit
91-HB9 (BK/WH), harness side and ground.

→ Yes
INSTALL a new front window defrost switch.
→ No
normal operation.
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PINPOINT TEST L: THE REAR WINDOW DEFROST SWITCH ILLUMINATION IS INOPERATIVE

L1: CHECK THE REAR WINDOW DEFROST SWITCH FOR VOLTAGE
1 Disconnect Rear Window Defrost Switch C381.
5 Measure the voltage between the rear window
defrost switch C381 pin 3, circuit 29S-HB22

→ Yes
GO to L2
→ No
REPAIR the circuit 29S-HB22 (OG/BK).
L2: CHECK CIRCUIT 91-HB22 (BK/GN) FOR OPEN
2 Measure the resistance between the rear win-
dow defrost switch C381 pin 2, circuit 91-HB9

→ Yes
INSTALL a new rear window defrost switch.
→ No
normal operation.
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PINPOINT TEST M: THE REAR AUXILAIRY AUDIO CONTROL ILLUMINATION IS INOPERATIVE

M1: CHECK THE REAR AUXILAIRY AUDIO CONTROL FOR VOLTAGE
1 Disconnect Rear Auxilairy Audio Control C451.
5 Measure the voltage between the rear auxilairy
audio control C451 pin 2, circuit 29S-MD16
(OG/GN), harness side and ground.

→ Yes
GO to M2
→ No
REPAIR the circuit 29S-MD16 (OG/GN).
M2: CHECK CIRCUIT 91-MD16 (BK/RD) FOR GROUND
2 Measure the resistance between the rear aux-
iliary audio control C451 pin 3, circuit 91-MD16

→ Yes
INSTALL a new rear auxilairy audio control.
→ No
normal operation.
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413-01-1 Instrument Cluster 413-01-1
SECTION 413-01 Instrument Cluster

CONTENTS PAGE
Instrument Cluster............................................................................................................. 413-01-2

Self-Diagnostic Mode. Vehicles with low series instrument cluster ................................... 413-01-2/4
Self-Diagnostic Mode. Vehicles with mid or high series instrument cluster ....................... 413-01-5/6
Configuration of Instrument Cluster .................................................................................. 413-01-7/8
Instrument Cluster............................................................................................................. 413-01-9
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Instrument Cluster
General Equipment 4. Verify the following warning indicators are

working correctly:
Worldwide Diagnostic System (WDS) • Charging.
(418-F224)
• Turn signals.
• Headlamps.
Inspection and Verification 5. If the cause is not visually evident, verify the
symptom and enter the instrument cluster
1. Verify the customer concern. Self-Diagnostic Mode.
Self-Diagnostic Mode. Vehicles with low series
Visual Inspection Chart instrument cluster
– Engine oil filter – Fuse(s)
– Engine oil level – Wiring harness
– Engine coolant – Electrical
temperature (ECT) connector(s)
sensor – Instrument cluster
– Engine coolant level – Light emitting di-
– Thermostat ode(s) (LED)(s)
– Collapsed or
damaged fuel tank
– Door adjustment NOTE: The instrument cluster tripmeter reset
3. If an obvious cause for an observed or button is located on the right-hand side of the
reported concern is found, correct the cause instrument cluster lens.
step.
NOTE: If none of the following warning indicators
are operating correctly this may indicate a concern
with the central junction box (CJB). If only one or
two of the following warning indicators are not
operating correctly this may indicate an instrument
cluster concern.
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1. To enter the instrument cluster between tests, the instrument cluster will exit
Self-Diagnostic Mode. Simultaneously press the Self-Diagnostic Mode.
and hold the tripmeter RESET button and turn 4. The Self-Diagnostic Mode is deactivated
the ignition switch from position 0, to position when the ignition switch is turned to the OFF
II. position or low battery voltage is detected.
2. Entry to the Self-Diagnostic Mode is 5. If input data to the instrument cluster is
confirmed when 'tESt' is displayed in the missing or invalid, the tripmeter LCD will
odometer tripmeter liquid crystal display display '----'
(LCD). The tripmeter reset button must be
6. If the Self-Diagnostic Mode cannot be
released within three seconds of 'tESt' being
accessed, use WDS to diagnose the
displayed or the instrument cluster will exit the
instrument cluster.
Self-Diagnostic mode.
NOTE: Additional tests are available after the
3. To navigate through or skip any of the
following Self-Diagnostic Mode tests, but are not
instrument cluster Self-Diagnostic Mode tests,
applicable for this diagnostic.
press the tripmeter RESET button. If the reset
button is depressed for more than 3 seconds
Gauge/Indicator/Display
Test Odometer Display Tested Description
1. Self-Diagnostic tESt Instrument cluster Establishes Self-Diagnostic
entry Mode.
2. Gauge sweep gAgE Tachometer, speedometer, All gauges go through a full up
temperature and fuel and down pointer sweep
smoothness check. The point-
ers should take 3 seconds to to
achieve full sweep and 3 sec-
onds to return to the rest posi-
tion.
3. Odometer LCD 888888 Odometer LCD Fills in the LCD,s of the
odometer display.
4. Indicator LED(s) LeD Indicators and warning Illuminates all the LED warning
indicators indicators that are controlled by
the instrument cluster.
5. ROM level r XXXX / FAIL Instrument cluster read only Displays the instrument cluster
memory (ROM) ROM level and type.
6. Not required ErXXXX - Not required.
7. Not required E XX / FAIL - Not required.
8. Manufacturing dtXXXX Instrument cluster Displays the instrument cluster
date manufacturing date date of manufacture.
9. Diagnostic trou- dtc then XXXnonE DTCs Display the individual DTCs at 1
ble code (DTC) second intervals. REFER to
WDS to diagnose the instru-
ment cluster.
10. Vehicle speed SPXXXX Speedometer Displays the speed signal input
m.p.h. in miles per hour.
11. Vehicle speed SPXXXX Speedometer Displays the speed signal input
km/h in kilometers per hour.
12. Not required SgXXXX - Not required.
13. Engine speed tAXXXX Tachometer Displays the engine speed in-
put signal (RPM)
14. Not required tgXXXX - Not required.
15. Odometer count od XXX Odometer Displays the odometer rolling
count
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Gauge/Indicator/Display
Test Odometer Display Tested Description
16. Fuel volume F XXX Fuel sender system Displays the fuel volume signal
input.
• 000 - 009 Short circuit
• 010 - 254 Normal range
• 255 open circuit
17. Not required FgXXXX - Not required.
18. Not required FL XX - Not required.
19. Fuel level per- FP XX Fuel gauge Displays the fuel average
centage percentage level.
• Range of display 00 to 64
• 64 being 100% full
• FF will be displayed for in-
valid data
20. Engine coolant XXX C ECT Displays the engine coolant
temperature (ETC) temperature as a decimal.
• Range 0 to 254
• 255 would indicate invalid
data
21. Not required XXX Cg - Not required.
22. Battery voltage btXXX Battery voltage Displays battery voltage input.
23. to 28. Not re- A0-XX to A5-XX - Not required.
quired
29. to 42. Not re- PA-HH to Pn-HH - Not required.
quired
43. to 46. Not re- P1 XX to P4 XX - Not required.
quired
47. Distance to dtEXXX Trip computer Displays the distance to fuel
empty tank empty.
48. Fuel economy rAFEXX Trip computer Displays the rolling average
fuel economy in miles per UK
gallon.
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and hold the SET button and turn the ignition

switch from position 0, to position II.
Self-Diagnostic Mode. Vehicles with mid or 2. Entry to the Self-Diagnostic Mode is
high series instrument cluster confirmed when 'TEST' is displayed in the
odometer tripmeter liquid crystal display
(LCD). The tripmeter set button must be
released within three seconds of 'TEST' being
displayed or the instrument cluster will exit the
Self-Diagnostic Mode.
3. To navigate through or skip any of the
instrument cluster Self-Diagnostic Mode tests,
press the SET button. If the set button is
depressed for more than 3 seconds between
tests, the instrument cluster will exit the
Self-Diagnostic Mode.
4. The Self-Diagnostic Mode is deactivated
when the ignition switch is turned to the OFF
position or low battery voltage is detected.
5. If input data to the instrument cluster is
missing or invalid, the tripmeter LCD will
display '----'
6. If the Self-Diagnostic Mode cannot be
accessed, use WDS to diagnose the
instrument cluster.
NOTE: Additional tests are available after the
following Self-Diagnostic Mode tests, but are not
applicable for this diagnostic.
NOTE: The set button is located on the steering

column left hand multifunction switch.
1. To enter the instrument cluster
Self-Diagnostic Mode. Simultaneously press
Self-Diagnostic Mode
Gauge/Indicator/Displa
Test Odometer Display y Tested Description
1. Self-Diagnostic • TEST Instrument cluster Establishes
entry Self-Diagnostic Mode.
• no display
2. Gauge sweep • GAUGE SWEEP Tachometer, speed- All gauges go through a
ometer, temperature and full up and down pointer
• no display
fuel sweep smoothness
check. The pointers
should take 3 seconds to
to achieve full sweep and
3 seconds to return to the
rest position.
3. Odometer LCD Filled in black Odometer LCD Fills in the LCD,s of the
odometer display.
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4. Indicator LED(s) • LED TEST Indicators and warning Illuminates all the LED
indicators warning indicators that are
• no display
controlled by the instru-
ment cluster.
5. ROM level • ROM LEVEL Instrument cluster read Displays the instrument
only memory (ROM) cluster ROM level and
• XXXX / FAIL
type.
6. Not required • NVM TARGET ROM - Not required.
• XXXX
7. Not required • NVM EEPROM LVL - Not required.
• XXXX / FAIL
8. Manufacturing • MANUFACTURE Instrument cluster Displays the instrument
date manufacturing date cluster date of manufac-
• HOURS XXXX
ture.
9. Diagnostic trou- • DTC #NN DTCs Display the individual
ble code (DTC) DTCs at 1 second inter-
• XXXX
vals. REFER to WDS to
diagnose the instrument
cluster.
10. Vehicle speed • ROAD SPEED Speedometer Displays the speed signal
m.p.h. input in miles per hour.
• XXX.X MPH
11. Vehicle speed • ROAD SPEED Speedometer Displays the speed signal
km/h input in kilometers per
• XXX.X KM/H
hour.
12. Not required • SPEEDO - Not required.
• XXXX
13. Engine speed • ENGINE SPEED Tachometer Displays the engine speed
input signal (RPM)
• XXXX
14. Not required • TACHO GAUGE - Not required.
• XXXX
15. Odometer count • ODO ROLL COUNT Odometer Displays the odometer
rolling count
• XXX
16. Fuel volume • FUEL A/D INPUT Fuel sender system Displays the fuel volume
signal input.
• XXX
• 000 - 009 Short circuit
• 010 - 254 Normal
range
• 255 open circuit
17. Not required • FUEL GAUGE - Not required.
• XXXX
18. Not required • FUEL FLOW - Not required.
• XXXX
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19. Fuel level per- • FUEL PERCENT Fuel gauge Displays the fuel average
centage percentage level.
• XXXX
• Range of display 00 to
64
• 64 being 100% full
• FF will be displayed for
invalid data
20. Engine coolant • ENGINE TEMP ECT Displays the engine
temperature (ECT) coolant temperature as a
• XXX C
decimal.
• Range 0 to 254
• 255 would indicate
invalid data
21. Not required • TEMP GAUGE - Not required.
• XXXX
22. Battery voltage • BATTERY Battery voltage Displays battery voltage
input.
• XX.X
23. to 28. Not re- • A/D INPUT 00 to A/D - Not required.
quired INPUT 05
• XX
29. to 42. Not re- • PORT A to PORT N - Not required.
quired
• XX
43. to 46. Not re- • PERSONALITY 01 to - Not required.
quired PERSONALITY 04
• XX
47. Distance to • DIST. TO EMPTY Trip computer Displays the distance to
empty fuel tank empty.
• XXX MILES
48. Fuel economy • RAFE Trip computer Displays the rolling aver-
age fuel economy in miles
• XXX MPG
per UK gallon.
7. The above self-test function is to act as a NOTE: The odometer value must be recorded
guide to establish if the concern is instrument from the original instrument cluster before
cluster related. Before any other action is removal.
taken REFER to WDS to continue If the odometer value cannot be obtained from the
diagnostics. original instrument cluster (display failure) the
customer should supply the approximate value.
The following features will need to be configured
Configuration of Instrument Cluster when a new instrument cluster is installed:
The instrument cluster is a programmable module,
which must be configured by selecting the
Programmable Module Installation Routine on
WDS.
NOTE: When the new instrument cluster has been
configured with the odometer value, its
configuration cannot be decreased or matched. A
new configuration will result in an increase in the
displayed odometer value by a minimum of two
units.
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• Anti-lock Brake System (ABS)

• All wheel drive
• Keyless vehicle entry
• Electronic power assisted steering
• Trip computer
• Voice control
• Parking aid
• Belt minder
• Safety belt not fastened
• Right hand drive
• Overspeed warning
• Reverse warning
• Turbocharger boost pressure
• Speed control
• Auxiliary heater
• Suspension control
• Washer fluid sensor
• Navigation
• Fuel cap release
• Engine type
• Display language
In addition the new instrument cluster will require
the original odometer value to be entered.
After the installation and configuration of a new
instrument cluster. The passive anti-theft system
(PATS) will require programming by selecting the
Security Access routine on WDS.
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Instrument Cluster
Special Tool(s) NOTE: If a new instrument cluster is to be

installed, connect WDS and upload the instrument
Remover, Door Trim Panel cluster configuration information using the
501-028A (43-001A) programmable modules installation routine prior to
commencing the removal of the instrument
cluster.
NOTE: If a new instrument cluster is to be
installed, the odometer value must be recorded
from the original instrument cluster before removal
as this will be required when configuring the new
instrument cluster. If the odometer value cannot
be obtained from the instrument cluster (display
CAUTION: At no time should the battery
failure), the customer should supply the
positive terminal be connected with the
approximate odometer value.
audio unit disconnected. The clock
function of the audio unit is controlled by
communication with the instrument
cluster via the control area network
(CAN). If the battery positive terminal is
Disconnect]
connected with the audio unit
disconnected, the instrument cluster will 2. Remove the components in the order
cancel the clock function and --:-- will be indicated in the following illustration(s) and
displayed when the audio unit is table(s).
installed.
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Item Part Description Item 5 : Instrument cluster

Number
CAUTION: Make sure the instrument
1 - Steering column adjustment cluster lens is protected by a clean soft
lever cloth. Failure to follow this instruction
See Removal Detail may result in damage to the instrument
cluster lens.
2 - Instrument cluster bezel 1. Using the special tool, detach the instru-
gaiter to steering column ment cluster from the instrument panel.
upper shroud
3 - Instrument cluster bezel
See Removal Detail
4 - Instrument cluster retaining
screws
5 - Instrument cluster
See Removal Detail
6 - Instrument cluster electrical
connector
See Removal Detail

NOTE: If a new instrument cluster is being Item 6 : Instrument cluster electrical
installed, connect WDS and download the connector
instrument cluster configuration information to the 1. Disconnect the instrument cluster
newly installed instrument cluster using the electrical connector.
programmable modules installation routine.
1. Press the locking tang.
NOTE: If a new instrument cluster is being
2. Detach the self locating electrical connec-
installed, connect WDS and configure the newly
tor.
installed instrument cluster to the PATS system.
Removal Details
Item 1 : Steering column adjustment lever

1. Adjust the steering column to its maximum
extension and lowest position.
Item 3 : Instrument cluster bezel
1. Pull the instrument cluster bezel forward.
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413-06-1 Horn 413-06-1
SECTION 413-06 Horn

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 413-06-2
Horn.................................................................................................................................. 413-06-3
Pinpoint Tests .................................................................................................................. 413-06-3/9
Horn.................................................................................................................................. 413-06-10
Horn Switch .................................................................................................. (33 523 0) 413-06-11
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413-06-2 Horn 413-06-2
SPECIFICATIONS

Horn retaining bolt 25 18 -
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413-06-3 Horn 413-06-3
Horn
Electrical
• Fuse(s)
Principles of Operation
• Wiring harness
The horn system consists of a relay, a steering • Electrical connector(s)
wheel switch and either one or two horns. The
horn(s) receives voltage from the switched side of • Horn switch
the relay, and the relay switch is controlled on its • Horn
ground side by the steering wheel switch. • Clockspring
The horn relay, is located in the Battery junction • Horn relay
box (BJB) and is supplied with a permanent • BJB
voltage from the battery. 3. If an obvious cause for an observed or
The steering wheel horn switch shares the reported concern is found, correct the cause
steering wheel clockspring circuit with the air-bag (if possible) before proceeding to the next
circuit. Each of these systems work completely step.
independent of each other. 4. If the cause is not visually evident, verify the

Symptom Chart
• The horn is inoperative • Circuit(s). • GO to Pinpoint Test A
• Horn.
• Horn relay.
• Clockspring.
• Horn switch.
• The horn is always on • Horn relay. • GO to Pinpoint Test B
• Horn switch.
• Circuit(s).
• Clockspring.
Pinpoint Tests
PINPOINT TEST A: THE HORN IS INOPERATIVE
A1: CHECK POWER TO THE HORN
1 Disconnect Horn C77.
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413-06-4 Horn 413-06-4

2 Measure the voltage between the horn C77 pin
1, circuit 29S-GJ1 (OG/BU), harness side and
ground while pressing the horn switch.

→ Yes
GO to A2
→ No
GO to A3
A2: CHECK GROUND TO THE HORN
1 Measure the resistance between the horn C77
pin 2, circuit 31-GJ1 (BK), harness side and
ground.

→ Yes
INSTALL a new horn. TEST the system for
normal operation.
→ No
REPAIR circuit 31-GJ1 (BK). TEST the sys-
A3: CHECK POWER TO THE HORN RELAY
1 Disconnect Horn Relay C1002.
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413-06-5 Horn 413-06-5

2 Measure the voltage between the horn relay
C1002 pin 1, harness side and ground; and horn
relay C1002 pin 3, harness side and ground.

→ Yes
GO to A4
→ No
INSTALL a new BJB. TEST the system for
normal operation.
A4: CHECK HORN SWITCH CIRCUIT FOR OPEN
1 Measure the resistance between the horn relay
C1002 pin 2, circuit 91S-GJ7 (BK/BU), harness
side and ground while pressing the horn switch.

→ Yes
GO to A5
→ No
GO to A6
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413-06-6 Horn 413-06-6

A5: CHECK CIRCUIT 29S-GJ1 (OG/BU) FOR OPEN
1 Measure the resistance between the horn relay
C1002 pin 5, circuit 29S-GJ1 (OG/BU), harness
side and horn C77 pin 1, circuit 29S-GJ1
(OG/BU), harness side.

→ Yes
INSTALL a new horn relay. TEST the system
→ No
normal operation.
A6: CHECK CIRCUIT 91S-GJ7 (BK/BU) FOR OPEN
WARNING: To deactivate the driver air bag, refer to the procedure in section 501-20B for the
correct air bag deactivation procedure. Failure to follow this instruction, may result in
personal injury.
2 Measure the resistance between the clock-
spring C896 pin 6, circuit 91S-GJ7 (BK/BU),
harness side and horn relay C1002 pin 2, circuit
91S-GJ7 (BK/BU), harness side.

→ Yes
GO to A7
→ No
normal operation.
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413-06-7 Horn 413-06-7

A7: CHECK CIRCUIT 91-PG30 (BK/WH) FOR OPEN
spring C896 pin 7, circuit 91-PG30 (BK/WH),

→ Yes
GO to A8
→ No
normal operation.
A8: CHECK THE HORN SWITCH
1 Detach the drivers air bag module.
3 Measure the resistance between the speed
control switch C921 pin 4, Harness side and
speed control switch C921 pin 5, harness side
while pressing the horn switch.

→ Yes
INSTALL a new clockspring. REFER to Sec-
tion 501-20A / 501-20B. TEST the system
→ No
INSTALL a new driver air bag module.
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413-06-8 Horn 413-06-8
PINPOINT TEST B: THE HORN IS ALWAYS ON

B1: CHECK CIRCUIT 29S-GJ1 (OG/BU) FOR SHORT TO BATTERY POSITIVE
1 Disconnect Horn Relay C1002.
• Does the horn stop sounding with the horn relay
C1002 disconnected?
→ Yes
GO to B2
→ No
normal operation.
B2: CHECK THE HORN SWITCH CIRCUIT FOR CONTINUITY
component side and clockspring C896 pin 7,
circuit 91-PG30 (BK/WH), component side.

→ Yes
GO to B3
→ No
B3: CHECK HORN SWITCH CIRCUIT FOR SHORT TO GROUND
component side and ground.

→ Yes
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413-06-9 Horn 413-06-9

REPAIR circuit 91S-GJ7 (BK/BU). TEST the
→ No
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413-06-10 Horn 413-06-10
Horn
1. Raise and support the vehicle. For 2. Remove the components in the order

Number
2 - Horn electrical connector
3 - Horn
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413-06-11 Horn 413-06-11
Horn Switch (33 523 0)

1. The horn switch is an integral part of the

drivers air bag module. Remove the driver
air bag module. For additional information,
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413-07-1 Clock 413-07-1
SECTION 413-07 Clock

CONTENTS PAGE
Clock................................................................................................................................. 413-07-2
Clock............................................................................................................. (33 374 0) 413-07-3
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413-07-2 Clock 413-07-2
Clock
NOTE: The clock and instrument cluster are one

component and can not be diagnosed separately.
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413-07-3 Clock 413-07-3
Clock (33 374 0)

1. NOTE: The clock and instrument cluster are

one component and can not be removed
separately.
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413-08-1 Information and Message Center 413-08-1
SECTION 413-08 Information and Message Center

CONTENTS PAGE
Information and Message Center ...................................................................................... 413-08-2
Message Center............................................................................................ (33 367 0) 413-08-3
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Information and Message Center

NOTE: The information and message center and

the instrument cluster are one component and can
not be diagnosed separately.
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Message Center (33 367 0)

NOTE: The message center and the instrument

cluster are one component and can not be
removed separately.
1. Remove the instrument cluster. For
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413-09-1 Warning Devices 413-09-1
SECTION 413-09 Warning Devices

CONTENTS PAGE
Warning Devices............................................................................................................... 413-09-2

Symptom Chart ................................................................................................................ 413-09-2/5
GENERAL PROCEDURES
Safety Belt Minder Deactivating/Activating ........................................................................ 413-09-6

Preparation ...................................................................................................................... 413-09-6
Deactivating/Activating ..................................................................................................... 413-09-6
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Warning Devices
Refer to Wiring Diagrams Section 501-20A for 3. If an obvious cause for an observed or
schematic and connector information. reported concern is found, correct the cause
General Equipment step.
Worldwide Diagnostic System (WDS) 4. If the cause is not visually evident, retrieve the
Diagnostic Trouble Codes (DTCs) using .
5. If DTC B2433 is displayed by WDS.
Inspection and Verification 6. If no DTCs are displayed relating to the
symptom, refer to the Symptom Chart.

– Safety belt buckle – Wiring harness
– Electrical
connector(s)
– Safety belt buckle
switch
– Restraints control
module
Symptom Chart
• The safety belt indicator does not • Driver safety belt buckle switch. • GO to Pinpoint Test A
illuminate • Circuit(s).
• Restraints Control Module
(RCM).
• The safety belt indicator is illu- • Driver safety belt buckle switch. • GO to Pinpoint Test B
minated continuously • Circuit(s).
• RCM.
PINPOINT TEST A: THE SAFETY BELT INDICATOR DOES NOT ILLUMINATE

A1: CHECK THE SAFETY BELT BUCKLE SWITCH CIRCUIT FOR OPEN CIRCUIT
WARNING: To avoid accidental deployment, the RCM backup power supply must be de-
pleted. Wait at least one minute after disconnecting the battery ground cable(s) before
commencing any repair or adjustment to the supplemental restraint system (SRS), or any
component(s) adjacent to the SRS sensors. Failure to follow these instructions may result
in personal injury.
1 Deactivate the SRS.
2 Unfasten the driver safety belt.
3 Disconnect Restraints Control Module (RCM)
C423.
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4 Measure the resistance between the RCM
C423 pin 25, circuit 8-JA54 (WH), harness side
and C423 pin 34, circuit 9-JA54 (BN), harness
side.

→ Yes
INSTALL a new RCM. REFER to Section
501-20B.[Supplemental Restraint System,
REMOVAL AND INSTALLATION, Restraints
Control Module (RCM)] TEST the system for
normal operation.
→ No
Go to A2
A2: CHECK CIRCUIT 8-JA54 (WH) FOR OPEN CIRCUIT
1 Disconnect Safety Belt Buckle Switch C335.
2 Measure the resistance between the driver seat
and the RCM C423 pin 25, circuit 8-JA54 (WH),
harness side.

→ Yes
Go to A3
→ No
REPAIR circuit 8-JA54 (WH). TEST the
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A3: CHECK CIRCUIT 9-JA54 (BN) FOR OPEN CIRCUIT
1 Measure the resistance between the drivers
seat C30 pin 13, circuit 9-JA54 (BN), harness
side and the RCM C423, pin 34 (BN) harness
side.

→ Yes
INSTALL a new driver safety belt buckle and
pretensioner. TEST the system for normal
operation.
→ No
REPAIR circuit 9-JA54 (BN). TEST the sys-
PINPOINT TEST B: THE SAFETY BELT INDICATOR IS ILLUMINATED CONTINUOUSLY.
B1: CHECK THE DRIVER SAFETY BELT SWITCH
WARNING: To avoid accidental deployment, the RCM backup power supply must be de-
pleted. Wait at least one minute after disconnecting the battery ground cable(s) before
commencing any repair or adjustment to the SRS, or any component(s) adjacent to the SRS
sensors. Failure to follow these instructions may result in personal injury.
1 Deactivate the SRS.
3 Disconnect Safety Belt Buckle Switch C335.
• Is the safety belt indicator illuminated?
→ Yes
Go to B2
→ No
INSTALL a new safety belt buckle and pre-
tensioner. TEST the system for normal op-
eration.
B2: CHECK CIRCUIT 8-JA54 (WH) AND FOR SHORT TO GROUND
2 Disconnect RCM C423.
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3 Measure the resistance between the RCM
and ground.

→ Yes
INSTALL a new RCM. REFER to Section
501-20B.[Supplemental Restraint System,
REMOVAL AND INSTALLATION, Restraints
Control Module (RCM)] TEST the system for
normal operation.
→ No
REPAIR circuit 8-JA54. TEST the system for
normal operation.
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GENERAL PROCEDURES
Safety Belt Minder Deactivating/Activating

Preparation
1. Apply the parking brake.
2. Place the transmission selector lever in P
(Park) - vehicles with automatic
transmission or the neutral position -
vehicles with manual transmission.
3. Turn the ignition switch to the 0 position.
4. Close all the vehicle doors from the inside
of the vehicle.
5. Unbuckle the drivers safety belt.
Deactivating/Activating
NOTE: Deactivation of the belt minder may also
be carried out using WDS. Follow the instructions
on the screen.
1. Turn the ignition switch to position II. (Do
not start the engine).
2. The safety belt warning indicator will
extinguish within 10 seconds.
3. NOTE: Step 3 must be completed within 60
seconds or the procedure must be repeated.
Buckle then unbuckle the safety belt nine
times, ending with the safety belt
unbuckled.
4. The safety belt warning indicator flashes
three times to confirm the belt minder
status change.
5. To activate the belt minder, repeat Steps 1
through 3.
6. After confirmation, the
deactivation/activation procedure is
complete.
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414-00-1 Charging System - General Information 414-00-1
SECTION 414-00 Charging System - General

Information
CONTENTS PAGE
Charging System .............................................................................................................. 414-00-2

GENERAL PROCEDURES
Battery Charging ........................................................................................... (31 003 0) 414-00-3
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Charging System


WARNING: Batteries contain sulphuric
acid. Avoid contact with skin, eyes, or
clothing. Also, shield your eyes when
working near batteries to protect against
possible splashing of the acid solution. In
case of acid contact with skin or eyes,
flush immediately with water for a
minimum of 15 minutes and get prompt
medical attention. If acid is swallowed,
call a physician immediately. Failure to
personal injury.
WARNING: Batteries normally produce
explosive gases which can cause
personal injury. Therefore, do not allow
flames, sparks or lighted substances to
come near the battery. When charging or
working near a battery, always shield
your face and protect your eyes. Always
provide ventilation. Failure to follow
injury.
– Accessory drive belt – Fuse(s)
– Generator – Wiring harness(es)
– Generator
– Electrical
connector(s)
– Battery
– Battery cables
– Charging warning
indicator
step.
system.
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GENERAL PROCEDURES
Battery Charging (31 003 0)

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GENERAL PROCEDURES
1. WARNING: Keep batteries out of reach

of children. Batteries contain sulphuric
acid, avoid contact with skin, eyes or
clothing. Shield your eyes when
working near the battery to protect
against possible splashing of the acid
solution. In case of acid contact with
the skin or the eyes, flush immediately
with water for a minimum of 15
minutes and seek prompt medical
attention. If acid is swallowed, call a
physician immediately. Failure to
personal injury.
WARNING: Batteries normally produce WARNING: It is important not to overfill a
explosive gases which can cause battery, as this can cause acid leakage
personal injury, therefore do not allow and corrosion damage to the vehicle.
flames, sparks or lighted substances to Failure to follow this instruction may
come near the battery. When charging or result in personal injury.
working near the battery always shield 2. If the level is below the maximum mark,
your face and protect your eyes. Always remove the vent covers and top up the
provide adequate ventilation. Failure to cell(s) to the correct level.
follow these instructions may result in 3. Cold batteries will not readily accept a
personal injury. charge. Therefore batteries should be
allowed to warm up to approximately 5°C.
WARNING: Always observe all (41°F.) before charging. This may require
manufacturers instructions when using four to eight hours at room temperature
any charging equipment. Failure to follow depending on the initial temperature and
this instruction may result in personal the battery size.
injury. 4. A battery which has been completely
WARNING: Connect the charger to the discharged may be slow to accept a charge
battery before switching the charger on. initially, and in some cases may not accept
Failure to follow this instruction may a charge at the normal charger setting.
result in personal injury. When batteries are in this condition,
charging can be started by use of the dead
WARNING: Switch the charger off before battery switch on chargers that have this
disconnecting the charger from the facility equipped.
battery. Failure to follow this instruction 5. To determine whether a battery is
may result in personal injury. accepting a charge, follow the
manufacturer's instructions for the charger,
CAUTION: Batteries should not be
for use of the dead battery switch. If the
charged in the vehicle.
switch is the spring-loaded type, it should
CAUTION: Do not rely on the generator to be held in the ON position for up to three
recharge a discharged battery as it would minutes.
take in excess of eight hours of 6. After releasing the dead battery switch and
continuous driving with no additional with the charger still on, measure the
loads placed on the charging system. battery voltage. If it shows 12 volts or
NOTE: The maximum level mark is approximately higher, the battery is accepting a charge
40mm below the top of the battery. and is capable of being recharged.
However, it may require up to two hour of
Place the battery on a level surface and charging with batteries colder than 5°C
check the electrolyte level through the (41°F) before the charge rate is high
casing, reaches the indicated maximum enough to show a charge on an ammeter. It
mark. has been found that all non-damaged
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batteries can be charged by this procedure.

If a battery cannot be charged by this
procedure, a new one should be installed.
7. A rapid recharger procedure has been
developed for recharging batteries that
have passed the Load Test and only need a
recharge. This can be due to in-service
no-start battery failures (vehicle will not
crank due to low battery state of charge) or
battery discharged in vehicle due to key-off
loads.
8. With the cables then disconnected, the
battery can be rapidly recharged by using
either of the following methods:
• Carry out a two hour charge using 20A
constant current (manual setting on
charger).
• Carry out a two hour charge using a
constant potential (automatic setting on
charger).
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414-01-1 Battery, Mounting and Cables 414-01-1
SECTION 414-01 Battery, Mounting and Cables

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 414-01-2/3
Battery .............................................................................................................................. 414-01-4

Symptom Chart ................................................................................................................ 414-01-4
GENERAL PROCEDURES
Battery Disconnect............................................................................................................ 414-01-5
Battery — 1.4L Duratec-16V (Sigma)/1.6L (Z6)/1.6L Duratec-16V (Sigma)/1.8L Du-

ratec-HE (MI4)/2.0L Duratec-HE (MI4) ............................................................................. 414-01-6/7
Battery Tray — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE
(MI4)/2.0L Duratec-HE (MI4) ............................................................................................ 414-01-8
Battery Tray — 2.0L Duratorq-TDCi (DW) Diesel................................................................ 414-01-9
Battery Tray — 1.6L (Z6) .................................................................................................. 414-01-10/11
Battery Cables — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) ..................................... 414-01-12/16
Battery Cables — 1.6L (Z6)............................................................................................... 414-01-17/19
Battery Cables — 2.0L Duratorq-TDCi (DW) Diesel .......................................................... 414-01-20
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SPECIFICATIONS

Battery ground cable to body electrical 8 - 71
connector retaining bolt
Battery to starter motor solenoid cable 12 9 -
electrical connector retaining nut
Ignition switch to starter motor solenoid 7 - 62
cable electrical connector retaining nut
Battery cable to generator electrical con- 8 - 71
Battery to transaxle ground cable electrical 35 26 -

Battery cable to generator electrical con- 15 11 -
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Battery cable electrical connector to battery 5 - 44
positive terminal clamp retaining nut
Battery to starter motor solenoid cable 10 - 89
Battery to transaxle ground cable electrical 10 - 89
Battery to engine ground cable electrical 10 - 89
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Battery
General Equipment 1. Verify the customer concern.

Battery Tester damage.

Inspection and Verification Electrical
WARNING: Batteries contain sulphuric • Electrical connector(s)
acid. Avoid contact with skin, eyes, or • Battery terminal clamps
clothing. Also, shield your eyes when • Battery cable(s)
working near batteries to protect against
possible splashing of the acid solution. In • Battery
case of acid contact with skin or eyes, 3. If an obvious cause for an observed or
flush immediately with water for a reported concern is found, correct the cause
minimum of 15 minutes and get prompt (if possible) before proceeding to the next
medical attention. If acid is swallowed, step.
call a physician immediately. Failure to 4. If the concern is not visually evident, verify the
follow these instructions may result in symptom and refer to the Symptom Chart.
personal injury.
WARNING: Batteries normally produce
explosive gases which can cause
personal injury. Therefore, do not allow
flames, sparks or lighted substances to
come near the battery. When charging or
working near a battery, always shield
your face and protect your eyes. Always
provide adequate ventilation. Failure to
personal injury.
Symptom Chart
• Vehicle electrical systems inop- • Battery. • CARRY OUT a battery condition
erative test, using the battery tester.
• The engine cranks slowly • Battery. • CARRY OUT a battery condition
test, using the battery tester.
• Battery cable(s). • REFER to Section 303-06.
• Starter motor.
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GENERAL PROCEDURES
Battery Disconnect
Disconnect Connect
WARNING: Batteries normally produce WARNING: Batteries normally produce
explosive gases which may cause explosive gases which may cause
personal injury, therefore do not allow personal injury, therefore do not allow
flames, sparks or lighted substances to flames, sparks or lighted substances to
come near the battery. When charging or come near the battery. When charging or
working near the battery always shield working near the battery always shield
your face and protect your eyes. Always your face and protect your eyes. Always
provide adequate ventilation. Failure to provide adequate ventilation. Failure to
follow these instructions may result in follow these instructions may result in
personal injury. personal injury.
WARNING: Batteries contain sulphuric WARNING: Batteries contain sulphuric
acid, avoid contact with skin, eyes or acid, avoid contact with skin, eyes or
clothing. Shield your eyes when working clothing. Shield your eyes when working
near the battery to protect against near the battery to protect against
possible splashing of the acid solution. In possible splashing of the acid solution. In
case of acid contact with the skin or eyes, case of acid contact with the skin or eyes,
flush immediately for a minimum of 15 flush immediately for a minimum of 15
minutes and seek prompt medical minutes and seek prompt medical
attention. If swallowed, call a physician attention. If swallowed, call a physician
immediately. Failure to follow these immediately. Failure to follow these
instructions may result in personal injury. instructions may result in personal injury.
WARNING: Audio unit key code saving CAUTION: Make sure all electrical
devices must not be used when working systems are switched OFF before
on supplemental restraint or fuel systems. connecting the battery ground cable to
When using these devices the vehicle avoid damage to the vehicle electrical
electrical system is still live but with a system.
reduced current flow. Failure to follow 1. Connect the battery ground cable.
this instruction may result in personal 2. Enter the audio unit keycode and preset
injury. radio frequencies.
CAUTION: Make sure the engine is not 3. Reset the clock to the correct time.
running before disconnecting the battery 4. NOTE: When the battery has been
ground cable to avoid damage to the disconnected and connected, the stored idle
vehicle electrical system. and drive values contained within the
NOTE: Before disconnecting the battery make powertrain control module (PCM) will have
sure that no data is required from the powertrain been erased. The following steps must be
control module (PCM), as battery cable carried out to allow the PCM to relearn its idle
disconnection will erase any fault codes and and drive values.
idle/drive values held in the keep alive memory Start and run the engine at idle for three
(KAM). It is not necessary to disconnect or remove minutes.
electronic control modules. 5. When the engine reaches normal operating
NOTE: This procedure should be used to temperature, increase the engine speed to
disconnect the battery while carrying out repairs 1200 rpm and maintain for approximately
that refer to the battery being disconnected. two minutes.
1. Obtain and record the audio unit keycode 6. Drive the vehicle for approximately five
and preset radio frequencies. miles/eight kilometers of varied driving.
2. Disconnect the battery ground cable.
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Battery — 1.4L Duratec-16V (Sigma)/1.6L (Z6)/1.6L Duratec-16V (Sigma)/1.8L


WARNING: Batteries contain sulphuric information, refer to Section 303-12.
acid, avoid contact with skin, eyes or
clothing. Shield your eyes when working
near the battery to protect against
table(s).
possible splashing of the acid solution. In
case of acid contact with the skin or eyes,
flush immediately for a minimum of 15
minutes and seek prompt medical
attention. If swallowed, call a physician
immediately. Failure to follow these
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Item Part Description Item 6 : Battery tray extension panel

Number 1. Detach the battery cable retaining clips and
remove the battery tray extension panel.
1 - Battery cover
2 - Battery ground cable Installation Details
terminal clamp
See Removal Detail Item 5 : Battery positive cable terminal clamp
CAUTION: Make sure the battery positive
3 - Battery positive cable cable terminal clamp is clean and free of
terminal shield all foreign material to avoid introducing
See Removal Detail starting and other electrical concerns.
4 - Battery positive cable termi- 1. Connect the battery positive cable.
nal clamp cover Item 2 : Battery ground cable terminal clamp
5 - Battery positive cable
additional information, refer to Battery
terminal clamp
Disconnect in this section.
6 - Battery tray extension panel
See Removal Detail
7 - Battery retaining bracket
8 - Battery
Removal Details
Item 2 : Battery ground cable terminal clamp

Item 3 : Battery positive cable terminal shield
1. Release the battery positive cable terminal
shield locking tangs and remove the shield.
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Battery Tray — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L

1. Remove the battery. For additional 2. Remove the powertrain control module
information, refer to Battery - 1.4L (PCM). For additional information,
Duratec-16V (Sigma)/1.6L (Z6)/1.6L refer to Section 303-14.
table(s).

Number
1 - Battery tray
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Battery Tray — 2.0L Duratorq-TDCi (DW) Diesel
1. Remove the battery. 2. Remove the components in the order

table(s).

Number
1 - Battery tray
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Battery Tray — 1.6L (Z6)
1. Remove the battery. For additional 2. Remove the components in the order
information, refer to Battery - 1.4L indicated in the following illustration(s) and
Duratec-16V (Sigma)/1.6L (Z6)/1.6L table(s).

Number
1 - Powertrain control module See Removal Detail
(PCM) upper cover
5 - Battery tray retaining bolts
2 - PCM lower cover
See Removal Detail 6 - Battery tray
3 - PCM wiring harness retain-

ing bracket retaining nut and
bolt
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Number
1. Disconnect the PCM wiring harness from
7 - PCM retaining screws the PCM.
8 - PCM 1. Rotate the PCM electrical connector locking
clips.
3. To install, reverse the removal procedure. 2. Disconnect the PCM electrical connectors.
Removal Details
Item 2 : PCM lower cover

1. Rotate the PCM lower shield away from the
battery tray.
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Battery Cables — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)
Special Tool(s) 5. Remove the air cleaner. For additional

Remover/Installer, Coolant information, refer to Section 303-12.
Hose Clamp 6. Remove the components in the order
table(s).

303-03B / 303-03C.
thermostat housing to coolant expansion
tank and heater core return coolant hose.

diator lower to thermostat housing coolant
hose.
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Number
4 - Battery positive cable
1 - Battery cover terminal clamp cover
2 - Battery ground cable See Removal Detail
terminal clamp 5 - Battery positive cable elec-
See Removal Detail trical connector
6 - Battery positive and battery
3 - Battery retaining bracket negative cable retaining clip
retaining nut
See Removal Detail 7 - Battery ground cable to body
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Number
Removal Details
8 - Battery to transaxle ground
cable electrical connector
9 - Battery cable retaining clip 1. Detach the battery ground cable terminal
clamp. For additional information, refer to
10 - Starter motor solenoid elec- Battery Disconnect in this section.
trical connector
Item 3 : Battery retaining bracket retaining nut
11 - Starter motor solenoid cable 1. Remove the battery retaining bracket
electrical connector(s) retaining nut, to allow the battery ground
See Removal Detail cable to be removed from under the battery
See Installation Detail retaining bracket.
12 - Battery cable retaining clip
13 - Generator battery cable
See Removal Detail
14 - Battery positive and negative
cables
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Item 4 : Battery positive cable terminal clamp 3. Disconnect the ignition switch and battery
cover to starter motor solenoid cables.
Item 13 : Generator battery cable electrical

1. Release the battery positive cable terminal connector
shield locking tangs and remove the shield. 1. Lower the vehicle.
Item 11 : Starter motor solenoid cable Installation Details

electrical connector(s)
Item 11 : Starter motor solenoid cable
electrical connector(s)
2. Remove the engine undershield. additional information,
• Rotate the locking tangs counterclockwise. refer to Section 100-02.
2. Connect the ignition switch and battery to
starter motor solenoid cables.
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• Rotate the locking tangs clockwise.

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Battery Cables — 1.6L (Z6)
1. Remove the battery. For additional

information, refer to Battery Cables - 1.6L
(Z6) in this section. 3. Remove the components in the order
table(s).

Number
2 - Battery cable harness to BJB
1 - Battery junction box (BJB) electrical connector
cover
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Number Number
3 - Battery ground cable to ve- 6 - PCM electrical connector
hicle body electrical con- See Removal Detail
nector retaining bolt
7 - Battery cable harness to fuel
4 - Battery cable electrical con- charging wiring harness
nector to battery positive electrical connector
terminal clamp retaining nut
5 - Powertrain control module
(PCM) upper cover

Number
12 - Battery cable harness to ve-
8 - Battery cable harness re- hicle speed sensor (VSS)
taining clips retaining clip
9 - Reversing lamp switch elec- 13 - Battery cable harness
trical connector ground connector retaining
10 - Battery cable harness re- bolt
verse lamp switch electrical 14 - Battery cable harness re-
connector retaining clip taining clips
11 - Neutral position switch elec- 15 - Battery ground cable to en-
trical connector gine block electrical con-
nector retaining bolt
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Item Part Description Item 17 : Battery to starter motor solenoid

Number cable electrical connector shield
1. Unclip the battery to starter motor solenoid
16 - Ignition switch to starter mo- electrical connector shield.
tor solenoid cable electrical
connector
17 - Battery to starter motor
solenoid cable electrical
connector shield
See Removal Detail
lenoid cable electrical con-
19 - Battery cable to generator
electrical connector retaining
nut
20 - Oil pressure sensor electrical
Item 21 : VSS electrical connector
connector
1. Disconnect the VSS electrical connector.
21 - VSS electrical connector
See Removal Detail
22 - Battery cable harness
Removal Details
Item 6 : PCM electrical connector

1. Disconnect the battery cable wiring
harness from the PCM.
1. Rotate the PCM electrical connector locking
clip.
2. Disconnect the PCM electrical connectors.
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Battery Cables — 2.0L Duratorq-TDCi (DW) Diesel
1. Remove the air cleaner. For additional 2. Remove the components in the order
table(s).

Number
2 - Battery ground cable
1 - Battery cover terminal clamp
See Removal Detail
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Number Number
3 - Battery retaining bracket 5 - Battery positive cable elec-
retaining nut trical connector
See Removal Detail
6 - Battery positive and battery
4 - Battery positive cable negative cable retaining clip
terminal clamp cover
7 - Battery ground cable to body
See Removal Detail

Number
8 - Battery to transaxle ground
cable electrical connector 14 - Generator battery cable
9 - Starter motor solenoid elec-
trical connector 15 - Battery positive and negative
cables
10 - Starter motor battery positive
cable electrical connector 3. To install, reverse the removal procedure.
retaining nut
11 - Starter motor solenoid cable additional information,
electrical connector retaining refer to Section 501-11.
nut
12 - Starter motor solenoid elec-
trical connector
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Removal Details

1. Detach the battery ground cable terminal
clamp. For additional information, refer to
Battery Disconnect in this section.
Item 3 : Battery retaining bracket retaining nut
1. Remove the battery retaining bracket
retaining nut, to allow the battery ground
cable to be removed from under the battery
retaining bracket.
Item 4 : Battery positive cable terminal clamp
cover
1. Release the battery positive cable terminal
shield locking tangs and remove the shield.

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414-02-1 Generator and Regulator 414-02-1
SECTION 414-02 Generator and Regulator

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 414-02-2
Generator.......................................................................................................................... 414-02-3
Generator — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) ............................................ 414-02-4/6

Generator — 1.6L (Z6)...................................................................................................... 414-02-7/9
Generator — 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor....... 414-02-10/16
Generator — 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor.. 414-02-17
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SPECIFICATIONS

Generator retaining stud 46 34 -
Battery to generator cable electrical con- 8 - 71

Battery to generator cable electrical con- 15 11 -

Generator retaining clamp retaining bolt 15 11 -

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Generator
1. REFER to Section 414-00.
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Generator — 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)


2. Remove the left-hand side headlamp. For
table(s).
4. Remove the generator upper retaining bolt.
5. Detach the air conditioning pipe and

position it to one side (if equipped).
• Release the locking tang.
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Number
4 - Generator
1 - Battery to generator cable See Removal Detail
2 - Generator electrical con- 7. Lower the vehicle.
nector
bolts
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8. Install the generator upper retaining bolt. 13. Install the left-hand side headlamp. For
Removal Details
Item 4 : Generator
1. Support the generator before removing the
last generator retaining bolt.
9. Tighten the generator retaining bolts in the
sequence shown (generator shown re- Installation Details
moved for clarity).
Item 3 : Generator lower retaining bolts
1. Loosly install the generator lower retaining
bolts.

11. Attach the air conditioning pipe.
• Apply the locking tang.
12. Install the accessory drive belt. For

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Generator — 1.6L (Z6)

6. Detach the coolant expansion tank and
secure to one side.
Disconnect]
1.6L (Z6)]
7. Detach the power assisted steering (PAS)

reservoir and secure to one side.
5. Remove the coolant expansion tank

coolant hose retaining clips.
1. Detach the expansion tank coolant hoses
from the coolant hose retaining clips.
2. Remove the coolant hose retaining clips
from the hood slam panel.
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8. Remove the barometric pressure sensor.

1. Disconnect the barometric pressure sensor
2. Release the barometric pressure sensor
retaining clip.
3. Pull the barometric pressure sensor up-
wards.

table(s).

Number
1 - Generator electrical con- electrical connector retaining
nector nut
2 - Fuel charging wiring harness 5 - Generator upper retaining
to generator retaining clips bolt
electrical connector cover
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Number
bolt
See Removal Detail
7 - Generator
See Removal Detail

Removal Details
Item 6 : Generator lower retaining bolt

1. The generator lower retaining bolt cannot
be removed at this stage. The bolt must be
pulled out until it is clear of the casting of
the engine generator mounting bracket.
Item 7 : Generator
place excessive strain on the fuel
charging wiring harness and brake
vacuum pipe when removing the
generator.
NOTE: The generator will require a rocking motion
to free the slide spacer during removal.
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Generator — 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor

Special Tool(s)
Adaptor Kit
310-110
General Equipment
Dowel with a diameter of 5mm

working on or near any fuel related 3. Remove the accessory drive belt. For
components. Highly flammable mixtures additional information, refer to Section 303-05.
are always present and may ignite. [Accessory Drive, REMOVAL AND
Failure to follow these instructions may INSTALLATION, Accessory Drive Belt -
result in personal injury. 2.0L Duratorq-TDCi (DW) Diesel]
4. Release the accessory drive belt tensioner.
• Remove the dowel with a diameter of 5mm.
all times and always observe fuel 5. Remove the generator lower retaining bolt.
injury.
lines.
to the fuel injection system components 6. Lower the vehicle.
components.
Disconnect]
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7. Disconnect the manifold absolute pressure 9. Remove the components in the order
(MAP) sensor and the intake air tempera- indicated in the following illustration(s) and
ture (IAT) sensor electrical connectors. table(s).
8. Detach the charge air cooler outlet pipe

from the intake air shutoff throttle.
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Number
1 - Fuel filter heater electrical shield
connector
2 - Water-in-fuel sensor electri- See Installation Detail
cal connector
6 - Water-in-fuel sensor
3 - Engine wiring harness See Removal Detail
retaining clip See Installation Detail
See Removal Detail
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Number Number
7 - Fuel pump fuel return line 8 - Fuel filter
retaining clip See Removal Detail
See Removal Detail

Number
9 - Generator electrical con- See Removal Detail
10 - Battery to generator cable 12 - Generator upper retaining
electrical connector bolts
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Number
14. CAUTION: Do not allow excessive
13 - Generator quantities of fuel to escape from the
See Removal Detail fuel filter bleed screw.
See Installation Detail Open the fuel filter fuel bleed screw.

NOTE: Do not install the engine upper cover at
this stage.
12. Disconnect the fuel filter fuel supply line
quick release coupling. For additional in-
formation, refer to Section 310-00.[Fuel
15. Operate the hand pressure pump until

fuel escapes from the fuel filter bleed
screw.
13. NOTE: Make sure the hand pressure pump

Install the special tool between the fuel
filter fuel supply line quick release cou-
pling and the fuel filter union.
16. Close the fuel filter bleed screw.
17. Operate the hand pressure pump until the
fuel viewed through the clear fuel pump
fuel supply line, is free of large quantities
of air bubbles.
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18. Remove the hand pressure pump.

19. Connect the fuel filter fuel supply line door window motors. For additional
quick release coupling. For additional in- information, refer to Section 501-11.
formation, refer to Section 310-00.[Fuel [Glass, Frames and Mechanisms,
System - General Information, GENERAL GENERAL PROCEDURES, Door Window
PROCEDURES, Quick Release Coupling] Motor Initialization]
Removal Details

Item 6 : Water-in-fuel sensor
2. Drain the fuel filter.
21. CAUTION: Do not operate the starter • Connect a suitable length of fuel resistant
motor for longer than 10 seconds at a tube to the fuel filter drain screw.
time. After 10 seconds, turn the • Drain the fuel filter into a suitable container.
again.
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3. Clean the fuel filter water-in-fuel sensor Installation Details

and surrounding area. For additional
information, refer to Section 303-04B.[Fuel Item 13 : Generator
Charging and Controls - 2.0L 1. Loosely install the generator to the
Duratorq-TDCi (DW) Diesel, GENERAL generator retaining clamp.
PROCEDURES, Fuel Injection Component
Cleaning] Item 11 : Generator retaining clamp
1. Tighten the generator retaining clamp
4. Install a new blanking plug to the open retaining bolt.
threaded port of the fuel filter.
Item 6 : Water-in-fuel sensor
Item 7 : Fuel pump fuel return line retaining 1. Clean the fuel filter and the water in fuel
clip sensor. For additional information,
1. Detach the fuel pump fuel return line from refer to Section 303-04B.[Fuel Charging and
the fuel line retaining clip. Controls - 2.0L Duratorq-TDCi (DW) Diesel,
Item 8 : Fuel filter GENERAL PROCEDURES, Fuel Injection
1. Detach the fuel filter from the fuel filter Component Cleaning]
support bracket and secure it to one side. 2. Remove and discard the blanking plug.
3. Install the water in fuel sensor.
fuel filter splash shield.
Item 11 : Generator retaining clamp

1. Loosen the generator retaining clamp
retaining bolt.
Item 13 : Generator
1. Remove the generator.
• Slide the generator out of the generator
retaining clamp.
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Generator — 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel

Sensor

General Equipment 7. Disconnect the manifold absolute pressure
(MAP) sensor and the intake air tempera-
Dowel with a diameter of 5mm ture (IAT) sensor electrical connectors.
Disconnect]
8. Detach the charge air cooler outlet pipe

from the intake air shutoff throttle.

303-05.[Accessory Drive, REMOVAL AND
INSTALLATION, Accessory Drive Belt
Tensioner - 2.0L Duratorq-TDCi (DW)
Diesel]
4. Release the accessory drive belt tensioner.
• Remove the dowel with a diameter of 5mm.
5. Remove the generator lower retaining bolt.
table(s).
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Number
1 - Fuel filter heater electrical retaining clip
connector See Removal Detail
2 - Engine wiring harness 6 - Fuel filter
retaining clip See Removal Detail
See Removal Detail
shield
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Number
11 - Generator
7 - Generator electrical con- See Removal Detail
8 - Battery to generator cable
electrical connector 10. To install, reverse the removal procedure.
See Removal Detail
10 - Generator upper retaining GENERAL PROCEDURES, Door Window
bolts Motor Initialization]
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Removal Details Item 9 : Generator retaining clamp
1. Tighten the generator retaining clamp
Item 2 : Engine wiring harness retaining clip retaining bolt.
Item 5 : Fuel pump fuel return line retaining
clip
Item 6 : Fuel filter
1. Detach the fuel filter from the fuel filter
support bracket and secure it to one side.
Item 9 : Generator retaining clamp

1. Loosen the generator retaining clamp
retaining bolt.
Item 11 : Generator
1. Remove the generator.
• Slide the generator out of the generator
retaining clamp.
Item 11 : Generator
1. Loosely install the generator to the
generator retaining clamp.
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415-00-1 Entertainment System - General Information 415-00-1
SECTION 415-00 Entertainment System - General

Information
CONTENTS PAGE
Audio System.................................................................................................................... 415-00-2

Self-Diagnostic Mode - Low Series Audio Unit ................................................................. 415-00-2
Self-Diagnostic Mode - High Series Audio Unit................................................................. 415-00-2
Diagnostic Trouble Code (DTC) Index Chart .................................................................... 415-00-3
Symptom Chart ................................................................................................................ 415-00-4
Pinpoint Tests .................................................................................................................. 415-00-5
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Audio System
Refer to Wiring Diagrams Section 415-01 for 1. To enter the audio unit Self-Diagnostic Mode,
schematic and connector information.Refer to switch the audio unit ON. Within four seconds
Wiring Diagrams Section 415-03 for schematic depress the preset buttons 3 and 6 together.
and connector information.
2. Release the preset buttons 3 and 6 and the
General Equipment audio unit will enter the Self-Diagnostic Mode.
3. To exit the Self-Diagnostic Mode, switch the
Worldwide Diagnostic System (WDS) audio unit OFF.
Inspection and Verification Message Displayed Circuit Tested
1. Verify the customer concern. 1. 4CH LF for four Left hand front speaker
2. Visually inspect for obvious signs of channel system 2CH LF circuit.
mechanical or electrical damage. for two channel system.
2. 4CH RF for four Right hand front
channel system 2CH speaker circuit.
RF for two channel
Mechanical Electrical system.
– Audio unit – Fuse(s) 3. 4CH LR for four Left hand rear speaker
– Antenna – Wiring harness channel system. circuit.
– Foreign objects – Electrical 4. 4CH RR for four Right hand rear
contacting speaker connector(s) channel system. speaker circuit.
– Trim poorly – Audio unit 4. If the cause is not evident after the
fitted/resonance Self-Diagnostic Mode, connect WDS to the
– Audio control switch
data link connector (DLC).
– Audio control switch (if equipped)
(if equipped) 5. Retrieve the Diagnostic Trouble Code (DTC)s
– Rear auxiliary audio
and refer to the DTC Index Chart.
– Rear auxiliary audio control (if equipped)
control (if equipped) – CD changer
– Compact disc (CD) – DVD player Self-Diagnostic Mode - High Series Audio Unit
changer
– Central junction box NOTE: The audio unit must be in radio mode
– Digital versatile disc (CJB)
(DVD) player before entering the Self-Diagnostic Mode.
1. To enter the audio unit Self-Diagnostic Mode,
switch the audio unit ON. Within four seconds
depress the preset button 4 and TA together.
step. 2. Release the preset button 4 and TA and the
audio unit will enter the Self-Diagnostic Mode.
symptom and refer to the Self-Diagnostic mode. 3. To exit the Self-Diagnostic Mode, switch the
audio unit OFF.
Self-Diagnostic Mode - Low Series Audio Unit Message Displayed Circuit Tested
NOTE: The audio unit must be in radio mode 1. 4CH LF for four Left hand front speaker
before entering the Self-Diagnostic Mode. channel system 2CH LF circuit.
for two channel system.
2. 4CH RF for four Right hand front
channel system 2CH speaker circuit.
RF for two channel
system.
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Message Displayed Circuit Tested 4. If the cause is not evident after the
3. 4CH LR for four Left hand rear speaker Self-Diagnostic Mode, connect WDS to the
channel system. circuit. data link connector (DLC).
4. 4CH RR for four Right hand rear 5. Retrieve the Diagnostic Trouble Code (DTC)s
channel system. speaker circuit. and refer to the DTC Index Chart.
5. FM frequency re- Antenna cable.
ceived.
Diagnostic Trouble Code (DTC) Index Chart - Audio Unit

DTC Description/Condition Possible Source Action
B1342 Audio unit internal failure Audio unit INSTALL a new audio unit.
REFER to Section 415-01.[Audio
Unit, REMOVAL AND
INSTALLATION, Audio Unit]
B2401 Tape player failure Audio unit INSTALL a new audio unit.
Unit, REMOVAL AND
B2403 CD player internal failure Audio unit INSTALL a new audio unit.
Unit, REMOVAL AND
B2404 Audio control switch circuit Audio control switch GO to Pinpoint Test E
failure
B2406 CD player internal failure Audio unit INSTALL a new audio unit.
Unit, REMOVAL AND
B2408 Speaker line short circuit Speaker(s) GO to Pinpoint Test D
B2409 AM receiving signal error Antenna cable GO to Pinpoint Test B
B2410 FM receiving signal error Antenna cable GO to Pinpoint Test B
B2477 Module configuration failure Audio unit and central REFER to WDS.
junction box (CJB)
P1628 Module ignition supply input CJB REFER to WDS.
Diagnostic Trouble Code (DTC) Index Chart - CD Changer

DTC Description/Condition Possible Source Action
B1342 CD changer defective CD changer INSTALL a new CD changer.
Unit, REMOVAL AND
INSTALLATION, Compact Disc
(CD) Changer]
B2403 CD changer internal failure CD changer INSTALL a new CD changer.
Unit, REMOVAL AND
INSTALLATION, Compact Disc
(CD) Changer]
1. If the cause is still evident,
refer to the Symptom Chart.
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Symptom Chart
• The audio unit is inopera- • Circuit. • GO to Pinpoint Test A
tive/does not operate correctly • Audio unit.
• The display is blank - radio and • Audio unit. • INSTALL a new audio unit.
cassette player operate REFER to Section 415-01.[Audio
Unit, REMOVAL AND
eration.
• The display is blank - radio and • Audio unit. • INSTALL a new audio unit.
CD player operate REFER to Section 415-01.[Audio
Unit, REMOVAL AND
eration.
• Poor reception • Antenna. • GO to Pinpoint Test B
• Antenna cable.
• Audio unit.
• Poor quality/distorted sound • Speaker(s). • GO to Pinpoint Test C
from one or more speakers (not • Circuit.
all speakers) • Audio unit.
• No sound from all speakers • Audio unit. • INSTALL a new audio unit.
Unit, REMOVAL AND
eration.
• No sound from one or more of • Speaker(s). • GO to Pinpoint Test D
the speakers (not all speakers) • Circuit.
• Audio unit.
• The auxiliary audio control is • Circuit. • GO to Pinpoint Test E
inoperative/does not operate • Auxiliary audio control switch.
correctly. • Rear auxiliary audio control.
• Audio unit.
• The CD changer is inopera- • Circuit(s). • GO to Pinpoint Test F
tive/does not operate correctly • CD changer.
• Audio unit.
• The digital versatile disc (DVD) • Circuit(s). • GO to Pinpoint Test G
player is inoperative/does not • DVD player.
operate correctly
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• No sound from headphone(s) • Headphone(s). • Using a known good headphone,
• DVD player. check the headphone in the
right-hand and left-hand sockets.
If sound is heard from each
headphone socket, INSTALL a
new headphone(s). If no sound
is heard from the headphone
socket(s), INSTALL a new DVD
player. TEST the system for
normal operation.
• The audio unit illumination is • Fuse(s). • REFER to Section 413-00.
inoperative • Circuit(s). [Instrument Cluster and
• Audio unit. Panel Illumination, DIAGNOSIS
• Genetic electronic module AND TESTING, Instrument
(GEM). Cluster and Panel Illumination]
• The audio unit clock is not dis- • Audio unit connector. • REFER to Section 413-01.
played • Audio unit. [Instrument Cluster,
• Instrument cluster. DIAGNOSIS AND TESTING,
Instrument Cluster]
Pinpoint Tests
measurements.
PINPOINT TEST A: THE AUDIO UNIT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
A1: CHECK FOR VOLTAGE TO AUDIO UNIT
2 Ignition switch in position I.
3 Measure the voltage between the audio unit
C442 pin 15, circuit 29-MD15 (OG/BK), harness
side and ground, and between the audio unit
C442 pin 16, circuit 75-MD15 (YE/GN), harness
side and ground.

→ Yes
GO to A2
→ No
REPAIR circuit 29-MD15 (OG/BK) or circuit
75-MD15 (YE/GN). TEST the system for
normal operation.
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A2: CHECK THE AUDIO UNIT GROUND CIRCUITS FOR OPEN
C442 pin 11, circuit 91-MD5 (BK/BU), harness
side and ground, and between the audio unit
C442 pin 12, circuit 91-MD15 (BK/GN), harness
side and ground.
• Are the resistances less than 1 ohm?

→ Yes
GO to A3
→ No
REPAIR circuit 91-MD5 (BK/BU) or 91-MD15
(BK/GN). TEST the system for normal op-
eration.
A3: CHECK CIRCUIT 9-MD27 (BN/WH) TO GROUND
1 Connect Audio Unit C442.
C448 pin 6, circuit 9-MD27 (BN/WH), harness
side and ground.
• Is the resistance less than 1 ohm?

→ Yes
→ No
REPAIR circuit 91-MD5 (BK/BU) . TEST the
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PINPOINT TEST B: POOR RECEPTION

B1: CHECK THE ANTENNA CABLE SHIELD
2 Disconnect the antenna cable from the audio
unit.
3 Measure the resistance between the antenna
cable ground connector (shield), and ground.

→ Yes
GO to B2
→ No
CLEAN and TIGHTEN the antenna base
connection to the body. If the concern per-
sists, INSTALL a new antenna cable. TEST
B2: CHECK THE ANTENNA CENTER CONDUCTOR FOR OPEN
1 Remove the antenna mast.
2 Measure the resistance of the center conductor
between the ends of the antenna cable.

→ Yes
GO to B3
→ No
INSTALL a new antenna cable. TEST the
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B3: CHECK ANTENNA CABLE FOR SHORT
1 Measure the resistance between the antenna
center conductor and the antenna ground
(shield).
• Is the resistance greater than 10,000 ohms

(open circuit)?
→ Yes
CLEAN and TIGHTEN the ground connec-
tions at the base of the antenna and battery
negative cable to the body. If concern the
persists, INSTALL a new audio unit. REFER
to Section 415-01.[Audio Unit, REMOVAL
AND INSTALLATION, Audio Unit] TEST the
→ No
INSTALL a new antenna cable. TEST the
persists, INSTALL a new audio unit. REFER
to Section 415-01.[Audio Unit, REMOVAL
AND INSTALLATION, Audio Unit]
PINPOINT TEST C: POOR QUALITY/DISTORTED SOUND FROM ONE OR MORE SPEAKERS (NOT
ALL SPEAKERS)
C1: CHECK THE SPEAKER RESISTANCE
1 Disconnect Affected Speaker.
2 Measure the resistance between the affected
speaker pin 1 and pin 4, component side.
• Is the resistance approximately 4.0 ohms?

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→ Yes
GO to C2
→ No
INSTALL a new speaker. TEST the system
C2: CHECK SPEAKER INPUT FOR SHORT TO GROUND
speaker connector pin 1, harness side and
ground.

(open circuit)?
→ Yes
GO to C3
→ No
REPAIR speaker input circuit. TEST the
C3: CHECK SPEAKER RETURN FOR SHORT TO GROUND
speaker connector pin 4, harness side and
ground.

(open circuit)?
→ Yes
for normal operation. If the concern persists,
→ No
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REPAIR speaker return circuit. TEST the
PINPOINT TEST D: NO SOUND FROM ONE OR MORE OF THE SPEAKERS (NOT ALL SPEAKERS)
D1: CHECK THE SPEAKER RESISTANCE
1 Disconnect Inoperative Speaker.
2 Measure the resistance between the inopera-
tive speaker pin 1 and pin 4, component side.
• Is the resistance approximately 4.0 ohms?

→ Yes
GO to D2
→ No
INSTALL a new speaker(s). TEST the sys-
D2: CHECK THE INOPERATIVE SPEAKER(S) CONNECTOR PIN 1 CIRCUIT
2 Measure the resistance between the following
audio unit C442 pins, harness side and the
inoperative speaker(s) connector pin 1, harness
side:
- (Left front speaker) C937 pin 1, circuit 8-MD28
(WH) to C442 pin 3, circuit 8-MD10 (WH/BK).
- (Right front speaker) C938 pin 1, circuit
8-MD28 (WH) to C442 pin 2, circuit 8-MD17
(WH/RD).
- (Left rear speaker) C939 pin 1, circuit 8-MD29
(WH/VT) to C442 pin 4, circuit 8-MD11
(WH/VT).
- (Right rear speaker) C940 pin 1, circuit
8-MD29B (WH/VT) to C442 pin 1, circuit
8-MD18 (WH).
→ Yes
GO to D3
→ No
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D3: CHECK THE INOPERATIVE SPEAKER(S) CONNECTOR PIN 4 CIRCUIT
audio unit C442 pins, harness side and the
side:
- (Left front speaker) C937 pin 4, circuit
10-MD28 (GY) to C442 pin 7, circuit 10-MD10
(GY/BK).
10-MD28 (GY) to C442 pin 6, circuit 10-MD17
(GY/RD).
- (Left rear speaker) C939 pin 4, circuit
10-MD29 (GY/WH) to C442 pin 8, circuit
10-MD11 (GY/WH).
- (Right rear speaker) C940 pin 4, 10-MD29B
(GY/WH) to C442 pin 5, 10-MD18 (GY).
→ Yes
GO to D4
→ No
D4: CHECK THE INOPERATIVE SPEAKER(S) CIRCUIT FOR SHORT TO GROUND
1 Disconnect Front Door Tweeter Speaker(s)
C941 (left-hand) C943 (right-hand).
2 Disconnect Rear Door Tweeter Speaker(s)
C942 (left-hand) C944 (right-hand).
side and ground:
- (Left front speaker) C937 pin 1, circuit 8-MD28
(WH), to ground.
8-MD28 (WH), to ground.
- (Left rear speaker) C939 pin 1, circuit 8-MD29
(WH/VT), to ground.
- (Right rear speaker) C940 pin 1, 8-MD29B
(WH/VT), to ground.

(open circuit)?
→ Yes
If the front door tweeter speaker(s) are in-
operative, GO to D5
If the rear door tweeter speaker(s) are inop-
erative, GO to D7
→ No
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D5: CHECK THE INOPERATIVE FRONT DOOR TWEETER SPEAKER(S) CIRCUIT FOR SHORT TO
GROUND
inoperative front door tweeter speaker(s)
connector pin 1, harness side and ground:
- (Left front door tweeter speaker) C941 pin 1,
circuit 8-MD28A (WH), to ground.
- (Right front door tweeter speaker) C943 pin 1,
circuit 8-MD28A (WH), to ground.

(open circuit)?
→ Yes
INSTALL a new front door tweeter speaker.
REFER to Section 415-03.[Speakers,
Door Tweeter Speaker] TEST the system for
normal operation.
→ No
GO to D6
D6: CHECK THE FRONT SPEAKER(S) TO FRONT DOOR TWEETER SPEAKER(S) CIRCUIT(S)
FOR OPEN
front speaker(s) and front door tweeter
speaker(s):
- left-hand front door tweeter speaker C941 pin
1, circuit 8-MD28A (WH), harness side and
front speaker C937 pin 2, circuit 8-MD28A
(WH), harness side.
- left-hand front door tweeter speaker C941 pin
3, circuit 10-MD28A (GY), harness side and
(GY), harness side.
- right-hand front door tweeter speaker C943
pin 1, circuit 8-MD28A (WH), harness side and
(WH), harness side.
- right-hand front door tweeter speaker C943
pin 3, circuit 10-MD28A (GY), harness side
and front speaker C938 pin 3, circuit
10-MD28A (GY), harness side.
→ Yes
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INSTALL a new front door tweeter speaker.
REFER to Section 415-03.[Speakers,
Door Tweeter Speaker] TEST the system for
→ No
D7: CHECK THE INOPERATIVE REAR DOOR TWEETER SPEAKER(S) CIRCUIT FOR SHORT TO
GROUND
inoperative rear door tweeter speaker(s)
connector pin 1, harness side and ground:
- (Left rear door tweeter speaker) C942 pin 1,
circuit 8-MD29A (WH/VT), to ground.
- (Right rear door tweeter speaker) C943 pin 1,
circuit 8-MD29C (WH/VT), to ground.

(open circuit)?
→ Yes
INSTALL a new rear door tweeter speaker.
→ No
GO to D8
D8: CHECK THE REAR SPEAKER(S) TO REAR DOOR TWEETER SPEAKER(S) CIRCUIT(S) FOR
OPEN
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rear speaker(s) and rear door tweeter
speaker(s):
- left-hand rear door tweeter speaker C942 pin
1, circuit 8-MD29A (WH/VT), harness side and
rear speaker C939 pin 2, circuit 8-MD29A
(WH/VT), harness side.
- left-hand rear door tweeter speaker C942 pin
3, circuit 10-MD29A (GY/WH), harness side
and rear speaker C939 pin 3, circuit
10-MD29A (GY/WH), harness side.
- right-hand rear door tweeter speaker C944 pin
1, circuit 8-MD29C (WH/VT), harness side and
rear speaker C940 pin 2, circuit 8-MD29C
(WH/VT), harness side.
- right-hand rear door tweeter speaker C944 pin
3, circuit 10-MD29C (GY/WH), harness side
and rear speaker C940 pin 3, circuit
10-MD29C (GY/WH), harness side.
→ Yes
INSTALL a new rear door tweeter speaker.
concern persists, INSTALL a new audio unit.
REFER to Section 415-01.[Audio Unit,
REMOVAL AND INSTALLATION, Audio
Unit]
→ No
PINPOINT TEST E: THE AUXILIARY AUDIO CONTROL SWITCH IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
E1: CHECK THE AUDIO UNIT OPERATES CORRECTLY USING THE AUDIO UNIT CONTROLS
1 Operate the audio unit using the audio unit
controls.
• Does the audio unit operate correctly using the
audio controls?
→ Yes
If the auxiliary audio control switch is
inoperative, GO to E2
If the rear auxiliary audio control is inopera-
tive, GO to E4
→ No
E2: CHECK THE CIRCUIT 8-MD26 (WH/BK) FOR OPEN
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2 Disconnect Auxiliary Audio Control Switch
C437.
C447 pin 6, circuit 8-MD26 (WH/BK) harness
side and the auxiliary audio control switch C437
pin 1, circuit 8-MD26 (WH/BK) harness side.

→ Yes
GO to E3
→ No
normal operation.
E3: CHECK CIRCUIT 9-MD26 (BN/YE) FOR OPEN
C447 pin 8, circuit 9-MD26 (BN/YE) harness
side and the auxiliary audio control switch C437
pin 2, circuit 9-MD26 (BN/YE) harness side.

→ Yes
INSTALL a new auxiliary audio control
switch. TEST the system for normal opera-
tion. If the concern persists, INSTALL a new
audio unit. REFER to Section 415-01.[Audio
Unit, REMOVAL AND INSTALLATION, Au-
dio Unit]
→ No
normal operation.
E4: CHECK CIRCUIT 29-MD16B (OG/GN) FOR VOLTAGE
1 Disconnect Rear Auxiliary Audio Control C451.
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2 Measure the voltage between the rear auxiliary
audio control C451 pin 8, circuit 29-MD16B
(OG/GN), harness side and ground.

→ Yes
GO to E5
→ No
normal operation.
E5: CHECK CIRCUIT 91-MD16 (BK/RD) FOR GROUND

→ Yes
GO to E6
→ No
normal operation.
E6: CHECK CIRCUIT 2-MD16 (GY/BK) FOR OPEN
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(GY/BK), harness side and the audio unit C448
pin 8, circuit 2-MD16 (GY/BK), harness side.

→ Yes
GO to E7
→ No
normal operation.
E7: CHECK CIRCUIT 1-MD16 (WH/BK) FOR OPEN
(WH/BK), harness side and the audio unit C448
pin 2, circuit 1-MD16 (WH/BK), harness side.

→ Yes
GO to E8
→ No
normal operation.
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E8: CHECK CIRCUIT 2-MD19 (GY/RD) FOR OPEN
(GY/RD), harness side and the audio unit C448
pin 7, circuit 2-MD19 (GY/RD), harness side.

→ Yes
GO to E9
→ No
normal operation.
E9: CHECK CIRCUIT 1-MD19 (WH/RD) FOR OPEN
(WH/RD), harness side and the audio unit C448
pin 1, circuit 1-MD19 (WH/RD), harness side.

→ Yes
INSTALL a new rear auxiliary audio control.
→ No
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PINPOINT TEST F: CD CHANGER IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

F1: CHECK THE CD CHANGER FOR VOLTAGE
1 Disconnect CD Changer C440.
2 Measure the voltage between the CD changer
C440 pin 9, circuit 29-MD8 (OG), harness side
and ground.

→ Yes
GO to F2
→ No
REPAIR circuit 29-MD8 (OG). TEST the
F2: CHECK THE CD CHANGER FOR GROUND
1 Measure the resistance between the CD
changer C440 pin 3, circuit 91-MD8 (BK/OG),

→ Yes
GO to F3
→ No
REPAIR the circuit 91-MD8 (BK/OG). TEST
F3: CHECK THE CD CHANGER TO AUDIO UNIT CIRCUIT(S) FOR OPEN
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CD changer circuit(s) and the audio unit
circuit(s):
- CD changer C440 pin 5, circuit 1-MD49
(WH/GN), harness side and audio unit C447
pin 3, circuit 1-MD49 (WH/GN), harness side.
(GY/OG), harness side and audio unit C447
pin 9, circuit 2-MD49 (GY/OG), harness side.
(WH/BK), harness side and audio unit C447
pin 4, circuit 1-MD50 (WH/BK), harness side.
(GY/BK), harness side and audio unit C447
pin 10, circuit 2-MD50 (GY/BK), harness side.
→ Yes
INSTALL a new CD changer. REFER to
Section 415-01.[Audio Unit, REMOVAL AND
INSTALLATION, Compact Disc (CD)
Changer] TEST the system for normal op-
eration.
→ No
REPAIR the circuit(s) as necessary. TEST
the system for normal operation. If the con-
cern persists, INSTALL a new audio unit.
REFER to Section 415-01.[Audio Unit,
REMOVAL AND INSTALLATION, Audio
Unit] TEST the system for normal operation.
PINPOINT TEST G: THE DIGITAL VERSATILE DISC (DVD) PLAYER IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
G1: CHECK THE DVD PLAYER FOR POWER
1 Disconnect DVD Player C437.
2 Measure the voltage between the DVD player
C437 pin 1, circuit 29-MD8 (OG), harness side
and ground.

→ Yes
GO to G2
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→ No
REPAIR circuit 29-MD8 (OG). TEST the
persists, install a new CJB. Test the system
G2: CHECK THE DVD PLAYER FOR SWITCHED POWER

C437 pin 2, circuit 75-MD8 (YE/BU), harness
side and ground.
→ Yes
Go to G3
→ No
REPAIR circuit 75-MD8 (YE/BU). Test the
G3: CHECK THE DVD PLAYER FOR GROUND
2 Measure the resistance between the DVD

player C437 pin 3, circuit 31-MD8 (BK), harness
side and ground.
→ Yes
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Go to G4
→ No
REPAIR circuit 31-MD8 (BK). Test the sys-
G4: CHECK THE DVD PLAYER ILLUMINATION CIRCUIT FOR POWER
1 Turn the multi-function switch to the on position.

C437 pin 15, circuit 29S-LK17 (OG/BK), har-
ness side and ground.
→ Yes
Go to G5
→ No
REPAIR circuit 29S-LK17 (OG-BK). Test the
G5: CHECK THE DVD PLAYER ILLUMINATION CIRCUIT FOR GROUND
1 Measure the resistance between the DVD

player C437 pin 16, 31-LK17 (BK), harness side
and ground.
→ Yes
INSTALL a new DVD player. Test the sys-
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→ No
Repair the circuit(s) 31-LK17 (BK) or
31-MD8. Test the system for normal opera-
tion.
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415-01-1 Audio Unit 415-01-1
SECTION 415-01 Audio Unit

CONTENTS PAGE
Audio System.................................................................................................................... 415-01-2

General ............................................................................................................................ 415-01-2
Different equipment levels................................................................................................ 415-01-2/3
Audio System.................................................................................................................... 415-01-4
Audio Unit ......................................................................................................................... 415-01-5/6

Compact Disc (CD) Changer............................................................................................. 415-01-7
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415-01-2 Audio Unit 415-01-2
Audio System
General
• Volume adjustment ("VOL")
A multimedia system with RDS/EON and mobile • Station search ("SEEK")
telephone compatibility is available. This includes
a radio, navigation system and an entertainment • Track search ("SEEK" when playing a CD)
system for the rear passengers. All systems have • Change to a different preset radio station
AVC, whereby the volume can be set by the user, ("PRESET/DISC")
and are equipped for voice control (Bluetooth). • Change the CD ("PRESET/DISC" when
All units offer the performance and functionality of playing a CD)
earlier systems. • Switch off traffic bulletins (quick press of
"AM/FM")
Every system is capable of performing a self-test;
diagnosis is performed with WDS via the CAN • Switch over to a different frequency band
bus. (press and hold "AM/FM" slightly longer)
The following units are available:

• Audio, basic version Different equipment levels
- Radio/cassette unit 5000 C,
- Radio/individual CD player 6000 CD, Radio/cassette 5000C, basic version
• Entertainment system for rear passengers, 10% more power output than previous units
basic version
- Rear audio control unit (with display and Electronic cassette player mechanism with
control elements) autoreverse and noise suppression
• Audio, luxury version 4 x 17 watt loudspeakers
- Sony radio/individual CD player Auxiliary audio stereo input
(MP3-capable), luxury version
Larger LCD display
- Sony 6 CD radio with integral 6-CD changer
Fittings for voice control
• CDDJ external 6-CD changer (underneath the
seat or in the luggage compartment) Speed-dependent volume control via CAN bus
Navigation, luxury version - distributed system
with:
Radio/individual CD player 6000 CD, basic version
• Navigation control module with maps stored
on DVD (in glove compartment) (Denso) 10% more power output than previous units
• Display with a TFT screen and control keys 4 x 17 watt loudspeakers
(Denso)
Auxiliary audio stereo input
• Navigation/audio unit, installed behind the
display (Visteon) Larger LCD display
• Air conditioning/navigation unit, installed Fittings for voice control
behind the display (Visteon) Speed-dependent volume control via CAN bus
Audio remote controls

Entertainment system for rear passengers, basic
Most current vehicles can be supplied with version - rear audio control unit (with display and
steering wheel buttons for the audio remote control elements)
controls. The steering wheel buttons control the
The entertainment system for rear passengers,
following functions:
which is only available in conjunction with the
luxury audio systems and the luxury navigation
system, includes a control unit and two
headphone sockets.
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415-01-3 Audio Unit 415-01-3
This allows passengers in the rear to select a

different audio source to the driver.
Sony radio/individual CD player, luxury version

CD/CDR/CDRW/MP3 playback
30% more power
4 x 20 watt loudspeakers
Digital sound processing with delay compensation
Entertainment system for rear passengers with
double playback device
Sony 6-CD changer in dashboard

30% more power
4 x 20 watt loudspeakers
CD/CDR playback
Digital sound processing with delay compensation
Entertainment system for rear passengers with
double playback device
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415-01-4 Audio Unit 415-01-4
Audio System
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415-01-5 Audio Unit 415-01-5
Audio Unit
General Equipment NOTE: When installing the audio unit removal

tools, make sure that the wording on the audio unit
Audio unit removal tools (GV3301) removal tools is followed, TOP L (left-hand)
indicates the top of the tool, left-hand side of the
removal tool and TOP R (right-hand) indicates the
top of the tool, right-hand side of the removal tool.
table(s).

Number
3 - Audio unit electrical
1 - Audio unit removal tools connector
2 - Audio unit See Removal Detail
See Removal Detail 4 - Antenna cable
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415-01-6 Audio Unit 415-01-6
NOTE: Remove the audio unit removal tools from

the audio unit before installing the original audio
unit.
NOTE: When installing a new audio unit, the
audio unit must be configured by selecting the
Programmable Module Installation Routine on
WDS.
Removal Details
Item 2 : Audio unit

1. CAUTION: When detaching the audio
unit, do not place excessive strain on
the wiring harness.
Detach the audio unit from the instrument
panel.
Item 3 : Audio unit electrical connector
1. Disconnect the audio unit electrical
connector.
Item 2 : Audio unit

CAUTION: The audio unit wiring harness
and antenna cable must not become
trapped when installing the audio unit.
1. The audio unit rear support must engage
with the audio unit support bracket.
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415-01-7 Audio Unit 415-01-7
Compact Disc (CD) Changer
1. Remove the passenger side front seat. For

General Equipment additional information, refer to Section 501-10.
[Seating, REMOVAL AND
Worldwide Diagnostic System (WDS) INSTALLATION, Front Seat]
table(s).
Item Part Description CAUTION: Make sure that the

Number horizontal/vertical orientation setting on
the CD changer is in the horizontal
1 - CD changer retaining screws position. Failure to follow this instruction
2 - CD changer electrical may result in internal damage to the CD
connector changer.
See Removal Detail NOTE: Before installing a new CD changer,
remove the CD changer transportation retaining
3 - CD changer clips.
NOTE: When installing a new CD changer, the
CD changer must be configured by selecting
the Programmable Module Installation Routine
on WDS.
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415-01-8 Audio Unit 415-01-8
Removal Details
Item 2 : CD changer electrical connector

1. Disconnect the CD changer electrical
connector.
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415-02-1 Antenna 415-02-1
SECTION 415-02 Antenna

CONTENTS PAGE
Antenna ............................................................................................................................ 415-02-2
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415-02-2 Antenna 415-02-2
Antenna
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415-03-1 Speakers 415-03-1
SECTION 415-03 Speakers

CONTENTS PAGE
Speakers........................................................................................................................... 415-03-2
Front Door Tweeter Speaker............................................................................................. 415-03-3
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415-03-2 Speakers 415-03-2
Speakers
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415-03-3 Speakers 415-03-3
Front Door Tweeter Speaker


table(s).

Number
2 - Front door tweeter speaker
1 - Exterior mirror interior trim electrical connector
panel.
See Removal Detail 3 - Front door tweeter speaker
See Removal Detail
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415-03-4 Speakers 415-03-4

CAUTION: Care must be taken when
installing the front door tweeter speaker
to the exterior mirror interior trim panel.
result in damage to the front door tweeter
speaker cone.
CAUTION: Make sure when installing the
front door tweeter speaker, foreign matter
is not attached to the speaker magnet or
cone. Failure to follow this instruction
may result in noise, vibration or
harshness (NVH) issues.
NOTE: When installing the front door tweeter
speaker to the exterior mirror interior trim panel an
audible click should be heard to indicate correct
installation.
Removal Details
Item 1 : Exterior mirror interior trim panel.

1. Detach the exterior mirror electrical
connector from the exterior mirror interior
trim panel.
Item 3 : Front door tweeter speaker
1. Release the locking tangs and remove the
front door tweeter speaker.
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417-01-1 Exterior Lighting 417-01-1
PAGE 1 OF 2
SECTION 417-01 Exterior Lighting

CONTENTS PAGE
SPECIFICATIONS
Specifications.................................................................................................................... 417-01-3
Exterior Lighting ................................................................................................................ 417-01-4

Conventional headlamps.................................................................................................. 417-01-4
High intensity discharge headlamps ................................................................................. 417-01-4/5
Headlamp leveling system................................................................................................ 417-01-6
Combined rain sensor/light sensor ................................................................................... 417-01-7
Adaptive front lighting....................................................................................................... 417-01-7/8
Adaptive front lighting module .......................................................................................... 417-01-9
Steering angle sensor ...................................................................................................... 417-01-9
Rear lighting..................................................................................................................... 417-01-10
Peripheral lights ............................................................................................................... 417-01-10
Headlamp switch-off delay ............................................................................................... 417-01-10/11
Stoplamps......................................................................................................................... 417-01-12
Symptom Chart ................................................................................................................ 417-01-12
Pinpoint Tests .................................................................................................................. 417-01-12/21
Turn Signal and Hazard Lamps......................................................................................... 417-01-22
Symptom Chart ................................................................................................................ 417-01-22
Pinpoint Tests .................................................................................................................. 417-01-23/40
Parking, Rear and License Lamps .................................................................................... 417-01-41
Symptom Chart ................................................................................................................ 417-01-41
Pinpoint Tests .................................................................................................................. 417-01-41/54
Fog Lamps........................................................................................................................ 417-01-55
Symptom Chart ................................................................................................................ 417-01-55
Pinpoint Tests .................................................................................................................. 417-01-55/67
Reversing Lamps .............................................................................................................. 417-01-68
Symptom Chart ................................................................................................................ 417-01-68
Pinpoint Tests .................................................................................................................. 417-01-68/77
Component Test:.............................................................................................................. 417-01-78
Headlamps........................................................................................................................ 417-01-79
Symptom Chart ................................................................................................................ 417-01-79
Pinpoint Tests .................................................................................................................. 417-01-80/96
Headlamp Leveling ........................................................................................................... 417-01-97
Diagnosis and Testing...................................................................................................... 417-01-97
Symptom Chart ................................................................................................................ 417-01-97
Pinpoint Tests .................................................................................................................. 417-01-98/120
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PAGE 2 OF 2
Component Tests ............................................................................................................. 417-01-121
GENERAL PROCEDURES
Headlamp Adjustment .................................................................................. (32 113 0) 417-01-122

Headlamp Adjustment — Vehicles With: Adaptive Front Lighting ................. (32 113 0) 417-01-123
Front Fog Lamp Adjustment .............................................................................................. 417-01-124
High Beam Headlamp Bulb — Vehicles With: High Intensity Discharge Headlamps.......... 417-01-125
Low Beam Headlamp Bulb — Vehicles With: High Intensity Discharge Headlamps .......... 417-01-126
Parking Lamp Bulb — Vehicles With: High Intensity Discharge Headlamps ...................... 417-01-127
Headlamp Switch............................................................................................................... 417-01-128/129
Stoplamp Switch................................................................................................................ 417-01-130/131
Front Fog Lamp ................................................................................................................. 417-01-132
Headlamp Leveling Motor — Vehicles With: High Intensity Discharge Headlamps ............ 417-01-133
Headlamp Leveling Motor.................................................................................................. 417-01-134
Headlamp Assembly.......................................................................................................... 417-01-135/136
Rear Lamp Assembly ........................................................................................................ 417-01-137
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SPECIFICATIONS
Headlamp alignment
Item X value
Headlamp. X = 10 cm/10 m = 0°34' = 1.0%
Front fog lamps X = 22 cm/10 m = 1 degree 16 minutes = 2.2%
Bolt, headlamp 4 - 35
Rear lamp assembly screws 1 - 9
Bolt, front headlamp leveling sensor 8 - 35
Upper bolt, rear headlamp leveling sensor 8 - 71
Lower bolt, rear headlamp leveling sensor 48 35 -
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Exterior Lighting
The transparent plastic cover is made from

polycarbonate, which is coated for protection
Conventional headlamps against scratches and cracks.
In the event of damage to the cover the entire
headlamp unit needs to be replaced.
The turn signal lamps and side lights are also
integrated in the headlamp unit.
The manual headlamp leveling system operates
with an electric motor which is controlled via a
rotary control in the instrument cluster.
For conventional headlamps, adapting the vehicle
to conform to country-specific traffic situations
(left/right-hand side traffic) during travel is
accomplished by affixing punched adhesive strips
to specific areas of the headlamp.
The headlamp units are primarily made of plastic All conventional headlamps use 12 V bulbs with a
and make use of free-form reflectors in order to spiral-wound filament.
optimize light distribution.
Lamp Bulb Current draw Bulb colour
Low beam H7 55W clear
High beam H1 55W clear
Turn Signal Lamp Bayonet base 21W orange
Side Lamp Glass base 5W clear
A single xenon high intensity discharge bulb in the
outer projector is used both for low and high
High intensity discharge headlamps beams.
In order to prevent dazzling the oncoming traffic in
low beam mode, the light cone is modified by
means of a shutter. An additional reflector is
provided for the high beam, which is generated
using a conventional bulb with a spiral-wound
filament. This bulb is switched on when the
headlamps are switched to high beam and when
the headlamp flasher is operated.
The headlamp flasher operates as follows:
• When the low beam is switched off the
headlamp flasher function is provided solely
by means of the conventional bulb in the
additional reflector.
WARNING: High voltages of up to 30 kV • When the low beam is switched on the
are present in the system. Ensure that the headlamp flasher function is provided by
headlamp assembly electrical connector moving the masking screen away from the
is disconnected if the headlamp main reflector and switching on the
assembly is removed. conventional bulb in the additional reflector.
High intensity discharge headlamps are optionally The turn signal lamps and side lights are the same
available. as in conventional headlamps.
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Low beam High intensity discharge 35W clear
lamp
Turn signal lamp Bayonet base 21W orange
Side lamp Glass base 5W clear
For high intensity discharge headlamps, adapting To prevent oncoming traffic from being dazzled,
the vehicle to conform to country-specific traffic the lever controls a second shutter which partially
situations (left/right-hand side traffic) during travel blocks the headlight beams in order to produce
is accomplished using a lever behind the symmetrically-shaped beams of light in low beam
headlamp cover, which is used to alter the mode.
headlamp beam.
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Headlamp leveling system
An automatic headlamp leveling system is a legal • Headlamp leveling sensors on the front and
requirement for vehicles with high intensity rear axles
discharge headlamps. • Control module
The automatic headlamp leveling system is a • Actuator motors for headlamp leveling
second-generation dynamic system which Accordingly, the system needs to be set up with
provides additional benefits for the driver in terms WDS after any components are replaced or any
of improved illumination of the road due to other repairs are carried out.
improved control over the headlamp beam.
The front and rear sensors are Hall sensors, which
In a static system, the vehicle is only considered transmit an analog signal to the control module.
as a stationary object, whereas a dynamic system
also takes into account the dynamic changes to
the inclination of the vehicle owing to load
changes whilst driving.
The system is designed to respond to changes in
the inclination of the vehicle caused by the
long-term effects of aerodynamic forces acting on
the vehicle (e.g. due to continuous driving at high
speeds).
In order to prevent unnecessary changes in the
height of the headlamp beam, the system filters
out surface irregularities and any pitching of the
vehicle under braking and acceleration.
The following components are part of the
headlamp leveling system:
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Combined rain sensor/light sensor If both the ambient light sensor and the front light
sensor detect a sudden reduction in light intensity
at the same time, then an algorithm-based
calculation is used to determine the fact that the
vehicle has entered a tunnel.
In this case the request for switching on the
external lighting and the indicator lamp in the
instrument cluster is transmitted to the Generic
Electronic Module (GEM).
If the sun is shining and the vehicle is suddenly
thrown into the shade by a large truck, the two
sensors will register different light intensities. In
this case, the algorithm-based calculation will not
result in the lights being switched on.

Number Adaptive front lighting
1 - Lens
2 - Front light sensor
3 - Ambient light sensor
The combined rain sensor/light sensor is located

behind the interior rear view mirror.
The ambient light sensor determines the general
light intensity.
For this purpose, it records the light over as wide
an angle as possible, without taking the direction
of incidence into account.
The front light sensor determines the light intensity
directly in front of the vehicle.
Low beam H7 55W clear
Turn signal lamp Bayonet base 21W orange
Side lamp Glass base 5W clear
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maximum correction angle of 9° for the projector

Item Part Description on the outside of the curve and 14° for the
Number projector on the inside of the curve.
1 - Adaptive front lighting ac- When reverse gear is engaged, adaptive front
tuator motor lighting is disabled. When reverse gear is
disengaged again and the vehicle moves at a
2 - Headlamp leveling motor speed above 3 km/h, the adaptive front lighting
3 - Low beam projector follows the relevant steering movements.
4 - High beam reflector When performing parking maneuvers at a speed

below 3 km/h, the adaptive front lighting swivels,
5 - Low beam lamp bulb in accordance with the country-specific
6 - High beam lamp bulb configuration (LHD/RHD), to the relevant edge of
the road in order to avoid dazzling the oncoming
7 - Turn signal lamp bulb traffic when the steering wheel is turned in the
opposite direction.
8 - Parking lamp bulb
The straight ahead position of the steering should
Vehicles with conventional lighting (low beam with be checked using WDS prior to headlamp
projector) can optionally be equipped with the adjustment. For this purpose, the headlamp
newly developed adaptive front lighting. The leveling system must be in the "0" position and the
system is not compatible with automatic headlamp steering wheel in the "0" (+/- 3°) position.
inclination and only works when the lights are
switched on. The adaptive front lighting actuator motors are
stepper motors.
The adaptive front lighting module must be
configured for the various vehicle versions (wagon, The headlamp leveling system motors are DC
3-door, 5-door, engine type, RHD/LHD etc.) using motors.
Worldwide Diagnostic System (WDS). If there is a system fault with the adaptive front
During cornering, the dipped light projectors lighting actuator motors, the fault code "Advance
swivel toward the inside of the curve, with a Front Light Failure (adaptive front lighting
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malfunction)" will be shown in the driver Adaptive front lighting module

information display of the instrument cluster and
The adaptive front lighting module, which is
the indicator will flash.
connected to the high-speed Controller Area
In the event of a headlamp leveling motor fault, Network (CAN), processes the CAN reverse gear
both headlamps are moved to the central position switch, vehicle speed, light switch position and
by means of the adaptive front lighting actuator daytime running lamp signals as well as the
motors and they remain in this position. steering angle sensor and headlamp leveling
In the event of an adaptive front lighting actuator signals and sends control commands to the
motor fault, the headlamp leveling motor moves adaptive front lighting actuator motors and the
the relevant headlamp to the lowest position headlamp leveling motors. The adaptive front
where it remains. The intact headlamp is moved to lighting module must be configured with the
the "0" position by the adaptive front lighting (WDS tester) after it is renewed.
actuator motor. When the ignition and lights are switched on, the
For adaptive front lighting headlamps, adapting adaptive front lighting module performs calibration
the vehicle to conform to country-specific traffic of the headlamps, during which both move
situations (left/right-hand side traffic) during travel inwards and then to the "0" position,
is accomplished using a lever behind the independently of the steering wheel position. The
headlamp cover, which is used to alter the headlamps only turn in the direction of cornering
headlamp beam. when the steering wheel is turned by more than 4°.
Calibration is performed only once during an
To prevent oncoming traffic from being dazzled, operating cycle (ignition key in position "2" and
the lever controls a shutter which partially blocks then in position "0").
the headlight beams in order to produce
symmetrically-shaped beams of light in low beam
mode. Steering angle sensor
brought into the installation position (triangle

The steering angle sensor is located in the section
marking must align with the line in the alignment
of the steering wheel below the steering column
window).
stalk and is clipped to the clock spring. In vehicles
with adaptive front lighting, a sensor with 6 The steering angle sensor does not need to be
connector contacts is used. Vehicles with initialized following renewal.
ABS/ESP without adaptive front lighting are
equipped with a sensor with 4 connector contacts.
Before attaching it to the clock spring, the steering
angle sensor with 6 connector contacts must be
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Rear lighting and in 4-door vehicles it is installed in the

headliner behind the rear window.
Peripheral lights
The purpose of peripheral lights is to illuminate the

ground in the immediate vicinity of the front doors.
The illumination is provided in the form of white
bulbs which are located on the underside of the
mirrors.
The peripheral lights are switched on when a door
or the liftgate are opened or an unlock command
is detected and the following conditions are
fulfilled:
• The ignition key is in position "0" or "I".
The rear lamp assemblies of wagon vehicles • Reverse gear is not engaged.
include all the rear lamp functions except the
• The vehicle speed is below 7 km/h.
license plate lamp and high mounted stoplamp.
The peripheral lights are switched off when one of
In 3-door and 5-door vehicles, the rear fog lamp, the following conditions is fulfilled:
reversing lamp and reflectors are integrated in the • The ignition switch is turned to the position "II"
rear bumper. or "III".
The rear lamp assemblies are replaced as a • Reverse gear is engaged.
complete unit during servicing. • The vehicle speed exceeds 7 km/h.
The rear lamp assemblies need to be removed in • More than 25 seconds have elapsed since the
order to change a bulb. liftgate was closed or a central locking
The individual bulb holders and circuits are command was detected.
integrated in the bulb holder assembly in wagon • The time set for the battery protection function
and 4-door vehicles. In 3-door and 5-door vehicles for the interior lighting has elapsed.
this function is performed by the wiring harness. • More than 5 seconds have elapsed since the
In wagon and 4-door vehicles, a compact doors and the liftgate were closed.
connector is used to connect the bulb holder with • More than 5 seconds have elapsed since a
the wiring harness. In 3-door and 5-door vehicles, central locking command was received and
the wiring harness is connected to the bulb holder the all doors and the liftgate were closed.
by means of two connectors.
The high mounted stoplamp is installed in the Headlamp switch-off delay
centre of the liftgate in wagon vehicles. In 3-door
and 5-door vehicles it is installed in the rear spoiler The headlamp switch-off delay utilizes the low
beam together with the peripheral lights (if
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equipped) to illuminate the area surrounding the

vehicle. The function is activated by operating the
high beam lever when the ignition switch is in the
"0" position.
After the last door has been closed, the function
remains active for a further 30 seconds and then
switches off automatically.
When a door or the liftgate is open, the switch-off
time is extended to 180 seconds. After the last
door has been closed, the switch-off time is reset
to 30 seconds.
The headlamp switch-off delay can be deactivated
prematurely by operating the high beam lever
again or by switching on the ignition.
The switch-off time is adjusted to set values at the
factory and cannot be re-programmed using
WDS.
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Stoplamps
Refer to Wiring Diagrams Section 417-01 for 1. Verify the customer concern.
2. Visually check the following electrical causes
for the concern:
Special Tool(s)
Terminal Probe Kit Visual Inspection Chart
29-011A Mechanical Electrical
• Stop lamp switch • Fuse(s)
adjustment • Lamp(s)
• Connection(s)
• Switches
• Wiring harness
3. Resolve any obvious causes or concerns
NOTE: The generic electronic module (GEM) is found during the visual inspection before
part of the central junction box (CJB). carrying out any further tests.
and continue with the symptom chart.
Symptom Chart
• All stop lamps are inoperative • Fuse • GO to Pinpoint Test A
• Circuit(s)
• Stop lamp switch
• One or more stop lamps inop- • Circuit(s) • GO to Pinpoint Test B
erative • Left/right-hand rear lamp
assembly
• Additional high-mounted stop
lamp
• Stop lamps continuously illumi- • Circuit(s) • GO to Pinpoint Test C
nated • Stop lamp switch
• Transmission selector lever
assembly
(PCM)
Pinpoint Tests
measurements.
PINPOINT TEST A: ALL STOP LAMPS ARE INOPERATIVE
A1: CHECK FUSE F74 (CJB)
2 Disconnect fuse F74 (15 A) (CJB).
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3 CHECK fuse F74 (15 A) (CJB).
• Is the fuse OK?
→ Yes
GO to A2
→ No
RENEW fuse F74 (15 A) and CHECK the
operation of the system. If the fuse blows
again, LOCATE and RECTIFY the short to
ground using the Wiring Diagrams. CHECK
the operation of the system.
A2: CHECK VOLTAGE AT FUSE F74 (CJB)
1 Connect fuse F74 (15 A) (CJB).
and ground.
• Does the meter display battery voltage?
→ Yes
GO to A3
→ No
LOCATE and RECTIFY the break in the
power supply of fuse F74 (CJB) using the
Wiring Diagrams, if necessary RENEW the
CJB. CHECK the operation of the system.
A3: CHECK VOLTAGE AT STOP LAMP SWITCH
2 Disconnect stop lamp switch from connector
C444.
4 Measure the voltage between stop lamp switch,
connector C444, pin 2, circuit 15-LG23
(GN/WH), wiring harness side and ground.

→ Yes
GO to A4
→ No
circuit between fuse F74 (CJB) and the stop
lamp switch using the Wiring Diagrams.
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A4: CHECK STOP LAMP SWITCH
2 Connect a fused jumper wire (15 A) to the stop
lamp switch, connector C444, between pin 2,
circuit 15-LG23 (GN/WH) and pin 1, circuit
15S-LG23 (GN/WH)/15S-LG14 (GN/RD), wiring
harness side.

4 CHECK the operation of the stop lamps.
• Do the stop lamps illuminate?
→ Yes
RENEW the stop lamp switch. CHECK the
→ No
circuit between the stop lamp switch and
soldered connection S112 using the Wiring
Diagrams. CHECK the operation of the sys-
tem.
PINPOINT TEST B: ONE OR MORE STOP LAMPS INOPERATIVE
B1: DETERMINE THE FAULT CONDITION
C444.
3 Connect a fused jumper wire (15 A) to the stop
lamp switch, connector C444, between pin 2,
circuit 15-LG23 (GN/WH) and pin 1, circuit
15S-LG23 (GN/WH)/15S-LG14 (GN/RD), wiring
harness side.

5 Determine the fault condition.
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6 CHECK the stop lamps.
• Is only the additional high-mounted stop lamp
inoperative?
→ Yes
GO to B6
→ No
- Left-hand stop lamp is inoperative:
GO to B2
- Right-hand stop lamp is inoperative:
GO to B4
B2: CHECK VOLTAGE SUPPLY OF THE LEFT-HAND STOP LAMP
NOTE: The jumper lead used of the first step is still connected.
2 Disconnect left-hand rear lamp assembly from
connector.
- 5-door: C472
- 4-door: C476
4 Measure the voltage between left-hand rear
lamp assembly:
- 5-door: connector C472, pin 2, circuit
15S-LG14B (GN/RD), wiring harness side and
ground.
15S-LG14A (GN/RD), wiring harness side and
ground.

→ Yes
GO to B3
→ No
circuit between soldered connection S112
and left-hand rear lamp assembly using the
Wiring Diagrams. CHECK the operation of
the system.
B3: CHECK GROUND CONNECTION OF LEFT-HAND REAR LAMP ASSEMBLY
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2 Measure the resistance between left-hand rear
lamp assembly:
31-LF23B (BK), wiring harness side and
ground.
- 4-door: connector C476, pin 3, circuit 31-LF23
(BK), wiring harness side and ground.
• Is less than 2 Ohm measured?

→ Yes
CHECK and if necessary RENEW the
left-hand rear lamp assembly. CHECK the
→ No
circuit between left-hand rear lamp assembly
and ground connection G77 using the Wiring
tem.
B4: CHECK VOLTAGE SUPPLY OF THE RIGHT-HAND STOP LAMP
2 Disconnect right-hand rear lamp assembly from
connector.
- 5-door: C473
- 4-door: C477
4 Measure the voltage between right-hand rear
lamp assembly:
15S-LG21A (GN/BK), wiring harness side and
ground.
15S-LG21 (GN/BK), wiring harness side and
ground.

→ Yes
GO to B5
→ No
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and the rear lamp assembly using the Wiring
tem.
B5: CHECK GROUND CONNECTION OF THE RIGHT-HAND REAR LAMP ASSEMBLY
2 Measure the resistance between rear lamp
assembly right-hand side:

→ Yes
CHECK and if necessary RENEW the
right-hand rear lamp assembly. CHECK the
→ No
and the right-hand rear lamp assembly using
the Wiring Diagrams. CHECK the operation
of the system.
B6: CHECK VOLTAGE AT THE ADDITIONAL HIGH-MOUNTED STOP LAMP
2 Disconnect additional high-mounted stop lamp
from connector C107.
4 Measure the voltage between additional
high-mounted stop lamp, connector C107, pin 1:
- 5-door: circuit 15S-LG6 (GN/YE), wiring
- 4-door: circuit 15S-LG6C (GN/YE), wiring
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→ Yes
GO to B7
→ No
- 5-door: LOCATE and RECTIFY the break in
the circuit between soldered connection
S112 and the additional high-mounted stop
lamp using the Wiring Diagrams. CHECK the
the circuit between stop lamp switch and the
additional high-mounted stop lamp using the
Wiring Diagrams. CHECK the operation of
the system.
B7: CHECK GROUND CONNECTION OF ADDITIONAL HIGH-MOUNTED STOP LAMP
2 Measure the resistance between additional
high-mounted stop lamp, connector C107, pin 2:
- 5-door: circuit 31-LG6 (BK), wiring harness
side and ground.
- 4-door: circuit 91-LG6 (BK/YE), wiring harness
side and ground.

→ Yes
CHECK and if necessary RENEW the addi-
tional high-mounted stop lamp. CHECK the
→ No
the circuit between the additional
high-mounted stop lamp and soldered con-
nection S196 using the Wiring Diagrams.
the circuit between the additional
high-mounted stop lamp and soldered con-
nection S203 using the Wiring Diagrams.
PINPOINT TEST C: STOP LAMPS CONTINUOUSLY ILLUMINATED
C1: CHECK STOP LAMP SWITCH
C444.
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• Are the stop lamps continuously illuminated?
→ Yes
- Vehicles without automatic transmission:
GO to C4
- Vehicles with automatic transmission:
GO to C2
→ No
RENEW the stop lamp switch. CHECK the
C2: RULE OUT TRANSMISSION SELECTOR LEVER ASSEMBLY AS POSSIBLE CAUSE FOR A
SHORT TO BATTERY VOLTAGE
→ Yes
GO to C3
→ No
RENEW the transmission selector lever as-
sembly. CHECK the operation of the system.
C3: NARROW DOWN THE CAUSE FOR THE SHORT TO BATTERY VOLTAGE
3 Disconnect CJB from connector C102.
→ Yes
GO to C4
→ No
LOCATE and RECTIFY the short to battery
voltage in the circuits connected with CJB,
connector C102, pin 17, using the Wiring
tem.
C4: RULE OUT PCM MODULE AS POSSIBLE CAUSE FOR A SHORT TO BATTERY VOLTAGE
2 Disconnect fuse F34 (10 A) (BJB).
- 1,6l (Z6) engine
- 2,0l Duratorq TDCi engine
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- 1,8l/2,0l Duratec-HE engine
→ Yes
GO to C5
→ No
CHECK the PCM module using WDS,
RENEW if necessary. CHECK the operation
of the system.
2 Connect fuse F34 (10 A) (BJB).
- 1,6l (Z6) engine
- 1,8/2,0l Duratec-HE engine
→ Yes
GO to C6
→ No
voltage in the circuits connected with CJB,
connector C96, pin 31, using the Wiring
tem.
→ Yes
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voltage in the circuits connected to soldered
connection S112 using the Wiring Diagrams.
→ No
CHECK and if necessary RENEW the CJB.
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Turn Signal and Hazard Lamps
Refer to Wiring Diagrams Section 417-01 for 1. Verify the customer concern.
2. Visually check the following electrical causes
for the concern:
Special Tool(s)
Terminal Probe Kit Visual Inspection Chart
29-011A Electrical
• Fuse(s)
• Lamp(s)
• Connector(s).
• Switches
• Wiring harness
3. Resolve any obvious causes or concerns
NOTE: The generic electronic module (GEM) is a found during the visual inspection before
component of the central junction box (CJB). carrying out any further tests.
and continue with the symptom chart.
Symptom Chart
• All turn signal lamps inoperative • Fuse(s) • GO to Pinpoint Test D
• Circuit(s)
• Multifunction switch
(GEM)
• All turn signal lamps illuminate • Central junction box (CJB) • CHECK the generic electronic
continuously • Generic electronic module module (GEM) using WDS and
(GEM) RENEW it if necessary. CHECK
the operation of the system.
• One/several turn signal lamps • Circuit(s) • GO to Pinpoint Test E
are inoperative • Headlamp
• Turn signal side lamp
• Rear lamp assembly/ies
• Multifunction switch
(GEM)
• Left-hand or right-hand turn • Circuit(s) • GO to Pinpoint Test F
signal lamps flash continuously • Multifunction switch
(GEM)
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Symptom

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BACK TO FRONT PAGE VIEW MAIN INDEX

2004.75 Focus C307 South Africa

09/2004 2004.75 Focus

MAIN INDEX: 2004.75 Ford Focus

08/2004 2004.75 Focus

09/2004 2004.75 Focus

100-00-1 General Information 100-00-1

SECTION 100-00 General Information

About This Manual ............................................................................................................ 100-00-3

09/2004 2004.75 Focus

100-00-2 General Information 100-00-2

09/2004 2004.75 Focus

100-00-3 General Information 100-00-3

DESCRIPTION AND OPERATION

About This Manual

G17371 en 09/2004 2004.75 Focus

100-00-4 General Information 100-00-4

DESCRIPTION AND OPERATION (Continued)

There are ten symbols used to give additional

Item Designation Description

100-00-5 General Information 100-00-5

DESCRIPTION AND OPERATION (Continued)

Breakout box-type testers are represented by a

Special Tools and Torque Figures

G17371 en 09/2004 2004.75 Focus

100-00-6 General Information 100-00-6

DESCRIPTION AND OPERATION

Health and Safety Precautions

Display Eye Hazard sign. Air Bags - Do Nots

G17372 en 09/2004 2004.75 Focus

100-00-7 General Information 100-00-7

DESCRIPTION AND OPERATION (Continued)

– Do not store highly flammable material Highly flammable, flammable, combustible –

G17372 en 09/2004 2004.75 Focus

100-00-8 General Information 100-00-8

DESCRIPTION AND OPERATION (Continued)

IMMEDIATE MEDICAL ATTENTION. Do not to general, food preparation or drinking water

G17372 en 09/2004 2004.75 Focus

100-00-9 General Information 100-00-9

DESCRIPTION AND OPERATION (Continued)

Chemical materials such as solvents, sealers, Chemical Materials - Do's

Chemical Materials - Do Nots

G17372 en 09/2004 2004.75 Focus

100-00-10 General Information 100-00-10

DESCRIPTION AND OPERATION (Continued)

– Do not use emptied containers for other Dusts

G17372 en 09/2004 2004.75 Focus

100-00-11 General Information 100-00-11

DESCRIPTION AND OPERATION (Continued)

Exhaust Fumes Splashes in the eye should be flushed carefully

Fibre Insulation Foams - Polyurethane

See also Dusts. See also Fire.

100-00-12 General Information 100-00-12

DESCRIPTION AND OPERATION (Continued)

Freon Kerosene (Paraffin)

G17372 en 09/2004 2004.75 Focus

100-00-13 General Information 100-00-13

DESCRIPTION AND OPERATION (Continued)

Gas Cylinders asbestos-based materials or using spraying

Gases Legal Aspects

G17372 en 09/2004 2004.75 Focus

100-00-14 General Information 100-00-14

DESCRIPTION AND OPERATION (Continued)