C-MAX 2003.75 (06.2003-) Workshop Manual
- Mechanical Repairs
- 1 General Information
- 100 Service Information
- 100-00 General Information
- Description and Operation
- About This Manual
- Health and Safety Precautions
- Standard Workshop Practices
- Solvents, Sealants and Adhesives
- Road-Roller Testing
- Air Conditioning (A-C) System Health and Safety Precautions
- Battery and Battery Charging Health and Safety Precautions
- Engine Cooling System Health and Safety Precautions
- Petrol Fuel System Health and Safety Precautions
- Diesel Fuel System Health and Safety Precautions
- Supplemental Restraint System (SRS) Health and Safety Precautions
- Window Glass Health and Safety Precautions
- Description and Operation
- 100-01 Identification Codes
- Description and Operation
- 100-02 Jacking and Lifting
- Description and Operation
- 100-04 Noise, Vibration and Harshness
- Description and Operation
- Noise, Vibration and Harshness (NVH)
- Diagnosis and Testing
- Noise, Vibration and Harshness (NVH)
- General Procedures
- Description and Operation
- 100-00 General Information
- 100 Service Information
- 2 Chassis
- 204 Suspension
- 204-00 Suspension System - General Information
- 204-00 Suspension System - General Information|Specifications
- Diagnosis and Testing
- Suspension System
- General Procedures
- 204-01 Front Suspension
- 204-01 Front Suspension|Specifications
- Description and Operation
- Diagnosis and Testing
- Front Suspension
- Removal and Installation
- Wheel Hub
- Lower Arm
- Front Stabilizer Bar
- Wheel Knuckle
- Lower Arm Ball Joint
- Strut and Spring Assembly
- Disassembly and Assembly
- Front Suspension
- Diagnosis and Testing
- 204-02 Rear Suspension
- Specifications - Vehicles Built Up To: 07-2004
- Specifications - Vehicles Built From: 07-2004
- Description and Operation
- Rear Suspension
- Diagnosis and Testing
- Rear Suspension
- Removal and Installation
- Wheel Hub
- Upper Arm
- Front Lower Arm
- Rear Lower Arm - Vehicles With: Solid Stabilizer Bar Link
- Rear Lower Arm - Vehicles With: Ball Joint Stabilizer Bar Link
- Stabilizer Bar - Vehicles With: Ball Joint Stabilizer Bar Link
- Stabilizer Bar - Vehicles With: Solid Stabilizer Bar Link
- Wheel Knuckle
- Spring - Vehicles Built From: 07-2004
- Spring - Vehicles Built Up To: 07-2004
- 204-04 Wheels and Tires
- 204-04 Wheels and Tires|Specifications
- Description and Operation
- Wheels and Tires
- Diagnosis and Testing
- Wheels and Tires
- Removal and Installation
- 204-00 Suspension System - General Information
- 205 Driveline
- 205-04 Front Drive Halfshafts
- 205-04 Front Drive Halfshafts|Specifications
- Description and Operation
- Diagnosis and Testing
- Front Drive Halfshafts
- Removal and Installation
- Front Drive Halfshafts
- Diagnosis and Testing
- 205-04 Front Drive Halfshafts
- 206 Brake System
- 206-00 Brake System - General Information
- Description and Operation
- Brake System
- Diagnosis and Testing
- Description and Operation
- 206-03 Front Disc Brake
- Diagnosis and Testing
- Front Disc Brake
- Removal and Installation
- Brake Pads
- Brake Caliper
- Brake Disc
- Disassembly and Assembly
- 206-03 Front Disc Brake|Specifications
- Diagnosis and Testing
- 206-04 Rear Disc Brake
- 206-04 Rear Disc Brake|Specifications
- Diagnosis and Testing
- Rear Disc Brake
- Removal and Installation
- 206-05 Parking Brake and Actuation
- 206-05 Parking Brake and Actuation|Specifications
- Description and Operation
- Parking Brake
- Diagnosis and Testing
- Parking Brake
- Parking Brake - Vehicles With: Electronic Parking Brake
- General Procedures
- 206-06 Hydraulic Brake Actuation
- Diagnosis and Testing
- 206-06 Hydraulic Brake Actuation|Specifications
- 206-07 Power Brake Actuation
- Diagnosis and Testing
- 206-07 Power Brake Actuation|Specifications
- 206-09A Anti-Lock Control
- 206-09A Anti-Lock Control|Specifications
- Diagnosis and Testing
- 206-09B Anti-Lock Control - Traction Control
- Diagnosis and Testing
- Anti-Lock Control - Traction Control
- Removal and Installation
- 206-09B Anti-Lock Control - Traction Control|Specifications
- Diagnosis and Testing
- 206-09C Anti-Lock Control - Stability Assist
- 206-09C Anti-Lock Control - Stability Assist|Specifications
- Description and Operation
- Anti-Lock Control - Stability Assist
- Diagnosis and Testing
- 206-00 Brake System - General Information
- 211 Steering System
- 211-00 Steering System - General Information
- 211-00 Steering System - General Information|Specifications
- Diagnosis and Testing
- Steering System - 1.6L Duratec-16V (Sigma)
- Steering System
- Steering Gear Checks After a Collision
- General Procedures
- Power Steering System Flushing - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Power Steering System Flushing - 1.6L Duratec-16V (Sigma)-1.6L Duratec-16V Ti-VCT (Sigma)
- Power Steering System Bleeding - 1.6L Duratec-16V (Sigma)
- Power Steering System Bleeding - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Power Steering System Filling - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Power Steering System Filling - 1.6L Duratec-16V (Sigma)
- 211-02 Power Steering
- 211-02 Power Steering|Specifications
- Description and Operation
- Power Steering
- Removal and Installation
- Power Steering Pump - 1.6L Duratec-16V (Sigma)
- Steering Gear Bushing
- Power Steering Pump - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Steering Gear to Fluid Cooler Return Hose
- Power Steering Fluid Cooler
- Power Steering Pump to Steering Gear Pressure Line - 1.6L Duratec-16V (Sigma)
- Power Steering Pump to Steering Gear Pressure Line - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Power Steering Pressure Line and Return Line Assembly - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Steering Gear
- Steering Angle Sensor
- Steering Gear to Power Steering Fluid Reservoir Return Line - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Steering Gear to Power Steering Fluid Reservoir Return Line - 1.6L Duratec-16V (Sigma)
- 211-03 Steering Linkage
- Diagnosis and Testing
- Steering Linkage
- Removal and Installation
- 211-03 Steering Linkage|Specifications
- Diagnosis and Testing
- 211-04 Steering Column
- 211-04 Steering Column|Specifications
- Diagnosis and Testing
- Steering Column
- Removal and Installation
- Steering Wheel
- Steering Column
- Disassembly and Assembly
- 211-05 Steering Column Switches
- Removal and Installation
- 211-00 Steering System - General Information
- 204 Suspension
- 3 Powertrain
- 303 Engine
- 303-00 Engine System - General Information
- Description and Operation
- 303-00 Engine System - General Information|Engine
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- General Procedures
- Camshaft Bearing Journal Diameter
- Camshaft Bearing Journal Clearance
- Camshaft End Play
- Camshaft Surface Inspection
- Camshaft Lobe Lift
- Crankshaft End Play
- Crankshaft Main Bearing Journal Diameter
- Piston Inspection
- Cylinder Bore Taper
- Piston Pin to Bore Diameter
- Piston Diameter
- Piston Ring End Gap
- Piston Pin Diameter
- Piston Ring-to-Groove Clearance
- Connecting Rod Large End Bore
- Valve Stem Diameter
- Flywheel Inspection
- Cylinder Head Distortion
- Cylinder Block Distortion
- Exhaust Manifold Cleaning and Inspection
- Bearing Inspection
- Description and Operation
- 303-01A Engine - 1.6L Duratec-16V (Sigma)
- 303-01A Engine - 1.6L Duratec-16V (Sigma)|Specifications
- Description and Operation
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- General Procedures
- Valve Clearance Adjustment
- In-vehicle Repair
- Intake Manifold
- Valve Cover
- Crankshaft Front Seal
- Valve Seals
- In-vehicle Repair|Valves
- Camshafts
- Camshaft Seal
- Timing Belt - Vehicles Built Up To: 04-2005
- Timing Belt - Vehicles Built From: 04-2005
- Cylinder Head
- In-vehicle Repair|Oil Pan
- Oil Pump
- Crankshaft Rear Seal
- Removal
- In-vehicle Repair|Engine
- Disassembly
- In-vehicle Repair|Disassembly|Engine
- Disassembly and Assembly of Subassemblies
- Cylinder Head
- Assembly
- Assembly|Engine
- Installation
- 303-01A Engine - 1.6L Duratec-16V (Sigma)|Engine
- Diagnosis and Testing
- 303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma)
- 303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma)|Specifications
- Description and Operation
- 303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma)|Engine
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- General Procedures
- Valve Clearance Adjustment
- In-vehicle Repair
- Intake Manifold
- Valve Cover
- Crankshaft Front Seal
- Valve Seals
- In-vehicle Repair|Valves
- Camshafts
- Camshaft Seal
- Timing Belt - Vehicles Built Up To: 04-2005
- Timing Belt - Vehicles Built From: 04-2005
- Cylinder Head
- In-vehicle Repair|Oil Pan
- Oil Pump
- Crankshaft Rear Seal
- Removal
- In-vehicle Repair|Engine
- Disassembly
- In-vehicle Repair|Disassembly|Engine
- Disassembly and Assembly of Subassemblies
- Cylinder Head
- Assembly
- Assembly|Engine
- Installation
- 303-01C Engine - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- 303-01C Engine - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)|Specifications
- Description and Operation
- 303-01C Engine - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)|Engine
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- General Procedures
- Valve Clearance Adjustment
- In-vehicle Repair
- Intake Manifold
- Crankshaft Pulley
- Crankshaft Front Seal
- Engine Front Cover
- Valve Seals
- In-vehicle Repair|Valves
- Camshafts
- Timing Chain
- Cylinder Head
- In-vehicle Repair|Oil Pan
- Oil Pump
- Crankshaft Rear Seal
- Removal
- 303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel
- 303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel|Specifications
- Description and Operation
- 303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel|Engine
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- General Procedures
- 303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel
- 303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel|Specifications
- Description and Operation
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- General Procedures
- Valve Clearance
- In-vehicle Repair
- Intake Manifold
- Valve Cover
- Crankshaft Front Seal
- Valve Seals
- Camshafts
- Camshaft Seal
- Timing Belt
- Exhaust Manifold
- Cylinder Head
- In-vehicle Repair|Oil Pan
- Crankshaft Rear Seal
- Oil Pump
- Removal
- In-vehicle Repair|Engine
- Disassembly
- In-vehicle Repair|Disassembly|Engine
- Disassembly and Assembly of Subassemblies
- Cylinder Head
- Assembly
- Assembly|Engine
- Installation
- 303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel|Engine
- Diagnosis and Testing
- 303-01F Engine - 2.0L Duratorq-TDCi (DW) Diesel
- 303-01F Engine - 2.0L Duratorq-TDCi (DW) Diesel|Specifications
- Description and Operation
- 303-01F Engine - 2.0L Duratorq-TDCi (DW) Diesel|Engine
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- In-vehicle Repair
- Intake Manifold - VIN Plate Emission Level Code: S
- Intake Manifold - VIN Plate Emission Level Code: K
- Crankshaft Front Seal
- Valve Seals
- Camshafts
- Camshaft Seal
- Timing Belt
- Exhaust Manifold
- Cylinder Head
- In-vehicle Repair|Oil Pan
- Oil Pump
- Crankshaft Rear Seal
- Removal
- In-vehicle Repair|Engine
- Disassembly
- In-vehicle Repair|Disassembly|Engine
- Disassembly and Assembly of Subassemblies
- Cylinder Head
- Assembly
- Assembly|Engine
- Installation
- 303-03A Engine Cooling - 1.6L Duratec-16V (Sigma)
- 303-03A Engine Cooling - 1.6L Duratec-16V (Sigma)|Specifications
- Diagnosis and Testing
- 303-03B Engine Cooling - 1.6L Duratec-16V Ti-VCT (Sigma)
- 303-03B Engine Cooling - 1.6L Duratec-16V Ti-VCT (Sigma)|Specifications
- Description and Operation
- Engine Cooling
- Diagnosis and Testing
- 303-03C Engine Cooling - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- 303-03C Engine Cooling - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)|Specifications
- Description and Operation
- Engine Cooling
- Diagnosis and Testing
- General Procedures
- Engine Cooling
- 303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel
- 303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel|Specifications
- Diagnosis and Testing
- Engine Cooling
- General Procedures
- Cooling System Draining, Filling and Bleeding
- Removal and Installation
- 303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel
- 303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel|Specifications
- Description and Operation
- Engine Cooling
- Diagnosis and Testing
- Engine Cooling
- General Procedures
- 303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel
- Description and Operation
- Engine Cooling
- Diagnosis and Testing
- Engine Cooling
- General Procedures
- 303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel|Specifications
- Description and Operation
- 303-04A Fuel Charging and Controls - 1.6L Duratec-16V (Sigma)
- 303-04A Fuel Charging and Controls - 1.6L Duratec-16V (Sigma)|Specifications
- Diagnosis and Testing
- Fuel Charging and Controls
- Removal and Installation
- 303-04B Fuel Charging and Controls - 1.6L Duratec-16V Ti-VCT (Sigma)
- Diagnosis and Testing
- Fuel Charging and Controls
- Removal and Installation
- 303-04B Fuel Charging and Controls - 1.6L Duratec-16V Ti-VCT (Sigma)|Specifications
- Diagnosis and Testing
- 303-04C Fuel Charging and Controls - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- 303-04C Fuel Charging and Controls - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)|Specifications
- Description and Operation
- Fuel Charging and Controls
- Diagnosis and Testing
- Fuel Charging and Controls
- Removal and Installation
- 303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel
- 303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel|Specifications
- Description and Operation
- Fuel Charging and Controls
- Fuel Charging and Controls - Vehicles With: Diesel Particulate Filter (DPF)
- Diagnosis and Testing
- Fuel Charging and Controls
- General Procedures
- Fuel Injection Component Cleaning
- Removal and Installation
- Fuel Injectors - VIN Plate Emission Level Code: S
- Fuel Injectors - VIN Plate Emission Level Code: K
- Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S
- Fuel Injection Supply Manifold - VIN Plate Emission Level Code: K
- Fuel Pump - VIN Plate Emission Level Code: S
- Intake Air Shutoff Throttle - VIN Plate Emission Level Code: K
- Fuel Pump - VIN Plate Emission Level Code: K
- 303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel
- 303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel|Specifications
- Description and Operation
- Fuel Charging and Controls
- Fuel Charging and Controls - Vehicles With: Diesel Particulate Filter (DPF)
- Diagnosis and Testing
- Fuel Charging and Controls
- General Procedures
- Fuel Injection Component Cleaning
- Removal and Installation
- Fuel Injectors - VIN Plate Emission Level Code: S
- Fuel Injectors - VIN Plate Emission Level Code: K
- Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S
- Fuel Injection Supply Manifold - VIN Plate Emission Level Code: K
- Fuel Pump
- Intake Air Shutoff Throttle - VIN Plate Emission Level Code: S
- Intake Air Shutoff Throttle - VIN Plate Emission Level Code: K
- Fuel Metering Valve
- 303-04F Fuel Charging and Controls - Turbocharger
- 303-04F Fuel Charging and Controls - Turbocharger|Specifications
- Description and Operation
- Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel
- Diagnosis and Testing
- 303-04G Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel
- 303-04G Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel|Specifications
- Description and Operation
- Fuel Charging and Controls
- Diagnosis and Testing
- 303-05 Accessory Drive
- 303-05 Accessory Drive|Specifications
- Description and Operation
- Accessory Drive - 1.6L Duratorq-TDCi (DV) Diesel
- Accessory Drive - 1.6L Duratec-16V (Sigma)
- Accessory Drive - 1.8L Duratec-HE (MI4)
- Accessory Drive - 1.8L Duratorq-TDCi (Lynx) Diesel
- Accessory Drive - 2.0L Duratorq-TDCi (DW) Diesel
- Diagnosis and Testing
- Accessory Drive
- Removal and Installation
- Accessory Drive Belt - 1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning
- Accessory Drive Belt - 1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning
- Accessory Drive Belt - Vehicles Built Up To: 02-2008 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Accessory Drive Belt - Vehicles Built From: 02-2008 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Accessory Drive Belt - 1.6L Duratorq-TDCi (DV) Diesel
- Accessory Drive Belt - 2.0L Duratorq-TDCi (DW) Diesel
- Accessory Drive Belt Tensioner - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Accessory Drive Belt - 1.8L Duratorq-TDCi (Lynx) Diesel
- Accessory Drive Belt Tensioner - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles With: Air Conditioning
- Accessory Drive Belt Tensioner - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles Without: Air Conditioning
- Accessory Drive Belt Tensioner - 2.0L Duratorq-TDCi (DW) Diesel
- Accessory Drive Belt Tensioner - 1.8L Duratorq-TDCi (Lynx) Diesel
- Air Conditioning (A-C) Compressor Belt - 1.6L Duratec-16V (Sigma)
- Air Conditioning (A-C) Compressor Belt - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- 303-06 Starting System
- Description and Operation
- Starting System - 2.0L Duratorq-TDCi (DW) Diesel
- Diagnosis and Testing
- Starting System
- Removal and Installation
- Starter Motor - 1.6L Duratec-16V (Sigma)
- Starter Motor - 1.6L Duratec-16V Ti-VCT (Sigma)
- Starter Motor - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel
- Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles With: Automatic Transaxle
- Starter Motor - 2.0L Duratorq-TDCi (DW) Diesel
- Starter Motor - 1.8L Duratorq-TDCi (Lynx) Diesel
- 303-06 Starting System|Specifications
- Description and Operation
- 303-07A Engine Ignition - 1.6L Duratec-16V (Sigma)
- 303-07A Engine Ignition - 1.6L Duratec-16V (Sigma)|Specifications
- Description and Operation
- Engine Ignition
- Diagnosis and Testing
- Removal and Installation
- Engine Ignition
- 303-07B Engine Ignition - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- 303-07B Engine Ignition - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)|Specifications
- Description and Operation
- Diagnosis and Testing
- Engine Ignition
- Removal and Installation
- Engine Ignition
- Diagnosis and Testing
- 303-07C Glow Plug System - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Description and Operation
- Glow Plug System
- Diagnosis and Testing
- 303-07C Glow Plug System - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel|Specifications
- Description and Operation
- 303-08A Engine Emission Control - 1.6L Duratec-16V (Sigma)
- 303-08A Engine Emission Control - 1.6L Duratec-16V (Sigma)|Specifications
- Diagnosis and Testing
- Engine Emission Control
- Removal and Installation
- 303-08B Engine Emission Control - 1.8L Duratec-HE (MI4)
- Diagnosis and Testing
- Engine Emission Control
- Removal and Installation
- 303-08B Engine Emission Control - 1.8L Duratec-HE (MI4)|Specifications
- Diagnosis and Testing
- 303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel
- 303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel|Specifications
- Description and Operation
- Engine Emission Control
- Diagnosis and Testing
- Engine Emission Control
- Removal and Installation
- Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube - VIN Plate Emission Level Code: S
- Exhaust Gas Recirculation (EGR) Valve
- Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube - VIN Plate Emission Level Code: K
- Exhaust Gas Recirculation (EGR) Cooler
- Positive Crankcase Ventilation (PCV) Valve
- Crankcase Vent Oil Separator
- 303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel
- 303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel|Specifications
- Description and Operation
- Engine Emission Control
- Diagnosis and Testing
- 303-08E Engine Emission Control - 1.8L Duratorq-TDCi (Lynx) Diesel
- 303-08E Engine Emission Control - 1.8L Duratorq-TDCi (Lynx) Diesel|Specifications
- Description and Operation
- Diagnosis and Testing
- Engine Emission Control
- 303-12 Intake Air Distribution and Filtering
- 303-12 Intake Air Distribution and Filtering|Specifications
- Description and Operation
- Intake Air Distribution and Filtering - 1.6L Duratec-16V (Sigma)
- Intake Air Distribution and Filtering - 1.8L Duratec-HE (MI4)
- Intake Air Distribution and Filtering - 1.6L Diesel
- Intake Air Distribution and Filtering - 1.8L Duratorq-TDCi (Lynx) Diesel
- Intake Air Distribution and Filtering - 2.0L Duratorq-TDCi (DW) Diesel
- Intake Air Distribution and Filtering - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Diagnosis and Testing
- Intake Air Distribution and Filtering
- Removal and Installation
- Air Cleaner - 1.6L Duratec-16V (Sigma)
- Air Cleaner - 1.6L Duratec-16V Ti-VCT (Sigma)
- Air Cleaner - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel
- Air Cleaner - 2.0L Duratorq-TDCi (DW) Diesel
- Air Cleaner - 1.8L Duratorq-TDCi (Lynx) Diesel
- Charge Air Cooler - 1.6L Duratorq-TDCi (DV) Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- 303-13 Evaporative Emissions
- 303-13 Evaporative Emissions|Specifications
- Description and Operation
- Evaporative Emissions
- Diagnosis and Testing
- Removal and Installation
- Evaporative Emissions
- 303-14 Electronic Engine Controls
- 303-14 Electronic Engine Controls|Specifications
- Description and Operation
- Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (Sigma)
- Electronic Engine Controls - 1.6L Duratorq-TDCi (DV) Diesel
- Electronic Engine Controls - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Electronic Engine Controls - 1.8L Duratorq-TDCi (Lynx) Diesel
- Electronic Engine Controls - 1.8L Duratec-HE (MI4)
- Electronic Engine Controls - 2.0L Duratorq-TDCi (DW) Diesel
- Diagnosis and Testing
- Electronic Engine Controls
- Removal and Installation
- Camshaft Position (CMP) Sensor - 1.6L Duratec-16V (Sigma)
- Camshaft Position (CMP) Sensor - 1.6L Duratorq-TDCi (DV) Diesel
- Camshaft Position (CMP) Sensor - 2.0L Duratorq-TDCi (DW) Diesel
- Camshaft Position (CMP) Sensor - 1.8L Duratorq-TDCi (Lynx) Diesel
- Crankshaft Position (CKP) Sensor - 1.6L Duratorq-TDCi (DV) Diesel
- Crankshaft Position (CKP) Sensor - 1.6L Duratec-16V (Sigma)
- Crankshaft Position (CKP) Sensor - 2.0L Diesel
- Crankshaft Position (CKP) Sensor - 1.8L Duratorq-TDCi (Lynx) Diesel
- Cylinder Head Temperature (CHT) Sensor - 1.8L Duratorq-TDCi (Lynx) Diesel
- Engine Coolant Temperature (ECT) Sensor - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Powertrain Control Module (PCM) - 1.6L Duratec-16V (Sigma)
- Powertrain Control Module (PCM) - Vehicles Built Up To: 03-2007 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Powertrain Control Module (PCM) - Vehicles Built From: 03-2007 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Powertrain Control Module (PCM) - 1.6L Duratorq-TDCi (DV) Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Heated Oxygen Sensor (HO2S) - 1.6L Duratec-16V (Sigma)
- Knock Sensor (KS) - 1.6L Duratec-16V (Sigma)
- Knock Sensor (KS) - 1.8L Duratorq-TDCi (Lynx) Diesel
- Rear Knock Sensor (KS) - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Front Knock Sensor (KS) - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Brake Pedal Position (BPP) Switch
- Engine Coolant Temperature (ECT) Sensor - 2.0L Duratorq-TDCi (DW) Diesel
- Intake Manifold Tuning (IMT) Valve - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Variable Camshaft Timing (VCT) Oil Control Solenoid - 1.6L Duratec-16V Ti-VCT (Sigma)
- 303-00 Engine System - General Information
- 307 Automatic Transmission-Transaxle
- 307-01A Automatic Transmission-Transaxle - Vehicles With: Automatic Transmission (CFT23)
- 307-01A Automatic Transmission-Transaxle - Vehicles With: Automatic Transmission (CFT23)|Specifications
- Description and Operation
- Transaxle Description
- Identification Tags
- Transmission Ranges and Power Flow
- Transmission Electronic Control System
- Diagnosis and Testing
- Diagnostics
- General Procedures
- Transmission Fluid Level Check
- Transmission Fluid Drain and Refill
- In-vehicle Repair
- 307-01B Automatic Transmission-Transaxle - Vehicles With: 4-Speed Automatic Transmission (4F27E)
- 307-01B Automatic Transmission-Transaxle - Vehicles With: 4-Speed Automatic Transmission (4F27E)|Specifications
- Description and Operation
- Transaxle Description
- General Procedures
- Transmission Fluid Drain and Refill
- In-vehicle Repair
- Transmission Fluid Pan, Gasket and Filter
- Main Controls
- Turbine Shaft Speed (TSS) Sensor
- Halfshaft Seal LH
- Output Shaft Speed (OSS) Sensor
- Halfshaft Seal RH
- Transmission Range (TR) Sensor
- Removal
- Transaxle - 2.0L Duratec-HE (MI4)
- Disassembly
- Transaxle
- Disassembly and Assembly of Subassemblies
- Final Drive Carrier and Differential Assembly
- Pump Assembly
- Transfer Shaft
- Direct and Reverse Clutch Assembly
- Forward Clutch
- Direct Clutch
- Reverse Clutch
- Planetary Assembly
- Main Control Valve Body
- Transaxle Case
- Torque Converter
- Torque Converter Leak Check
- Torque Converter End Play Check
- Assembly
- Transaxle
- Installation
- 307-02A Transmission-Transaxle Cooling - Vehicles With: Automatic Transmission (CFT23)
- Description and Operation
- Transaxle Cooling
- Removal and Installation
- 307-02A Transmission-Transaxle Cooling - Vehicles With: Automatic Transmission (CFT23)|Specifications
- Description and Operation
- 307-02B Transmission-Transaxle Cooling - Vehicles With: 4-Speed Automatic Transmission (4F27E)
- 307-02B Transmission-Transaxle Cooling - Vehicles With: 4-Speed Automatic Transmission (4F27E)|Specifications
- Description and Operation
- Transaxle Cooling
- Removal and Installation
- 307-05A Automatic Transmission-Transaxle External Controls - Vehicles With: Automatic Transmission (CFT23)
- 307-05A Automatic Transmission-Transaxle External Controls - Vehicles With: Automatic Transmission (CFT23)|Specifications
- Description and Operation
- External Controls
- Diagnosis and Testing
- External Controls
- General Procedures
- Selector Lever Cable Adjustment
- Removal and Installation
- Selector Lever Cable
- Selector Lever Assembly
- Disassembly and Assembly
- 307-05B Automatic Transmission-Transaxle External Controls - Vehicles With: 4-Speed Automatic Transmission (4F27E)
- 307-05B Automatic Transmission-Transaxle External Controls - Vehicles With: 4-Speed Automatic Transmission (4F27E)|Specifications
- Description and Operation
- External Controls
- General Procedures
- Selector Lever Cable Adjustment
- Removal and Installation
- Selector Lever Assembly
- Selector Lever Cable
- Disassembly and Assembly
- 307-01A Automatic Transmission-Transaxle - Vehicles With: Automatic Transmission (CFT23)
- 308 Manual Transmission-Transaxle, Clutch and Transfer Case
- 308-00 Manual Transmission-Transaxle and Clutch - General Information
- 308-00 Manual Transmission-Transaxle and Clutch - General Information|Specifications
- Description and Operation
- Manual Transaxle and Clutch
- Diagnosis and Testing
- Manual Transaxle and Clutch
- General Procedures
- 308-01A Clutch - Vehicles With: 5-Speed Manual Transmission (iB5)
- Diagnosis and Testing
- Diagnosis and Testing|Clutch
- Removal and Installation
- 308-01A Clutch - Vehicles With: 5-Speed Manual Transmission (iB5)|Specifications
- Diagnosis and Testing
- 308-01B Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75)
- 308-01B Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75)|Specifications
- Diagnosis and Testing
- Diagnosis and Testing|Clutch
- Removal and Installation
- 308-01C Clutch - Vehicles With: 6-Speed Manual Transmission (MMT6)
- 308-01C Clutch - Vehicles With: 6-Speed Manual Transmission (MMT6)|Specifications
- Diagnosis and Testing
- Diagnosis and Testing|Clutch
- Removal and Installation
- 308-02A Clutch Controls - Vehicles With: 5-Speed Manual Transmission (iB5)
- 308-02A Clutch Controls - Vehicles With: 5-Speed Manual Transmission (iB5)|Specifications
- Description and Operation
- Diagnosis and Testing
- Clutch Controls
- Removal and Installation
- Clutch Controls
- Diagnosis and Testing
- 308-02B Clutch Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75)
- 308-02B Clutch Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75)|Specifications
- Diagnosis and Testing
- Clutch Controls
- Removal and Installation
- 308-02C Clutch Controls - Vehicles With: 6-Speed Manual Transmission (MMT6)
- 308-02C Clutch Controls - Vehicles With: 6-Speed Manual Transmission (MMT6)|Specifications
- Diagnosis and Testing
- Clutch Controls
- Removal and Installation
- 308-03A Manual Transmission-Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5)
- 308-03A Manual Transmission-Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5)|Specifications
- Description and Operation
- Manual Transaxle
- Diagnosis and Testing
- Manual Transaxle
- General Procedures
- Bearing Check
- In-vehicle Repair
- Halfshaft Seal LH
- Halfshaft Seal RH
- Vehicle Speed Sensor (VSS)
- Removal
- Transaxle - 1.6L Duratec-16V (Sigma)-1.6L Duratec-16V Ti-VCT (Sigma)
- Transaxle - 1.8L Duratec-HE (MI4)
- Disassembly
- Transaxle
- Disassembly and Assembly of Subassemblies
- 308-03B Manual Transmission-Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75)
- Diagnosis and Testing
- Manual Transaxle - Vehicles With: Manual Transaxle
- General Procedures
- Bearing Check
- In-vehicle Repair
- Halfshaft Seal LH
- Halfshaft Seal RH
- Removal
- Transaxle - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Transaxle - 1.6L Duratorq-TDCi (DV) Diesel
- Transaxle - 1.8L Duratorq-TDCi (Lynx) Diesel
- Disassembly
- Transaxle
- Disassembly and Assembly of Subassemblies
- 308-03B Manual Transmission-Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75)|Specifications
- Diagnosis and Testing
- 308-03C Manual Transmission-Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6)
- 308-03C Manual Transmission-Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6)|Specifications
- Diagnosis and Testing
- Manual Transaxle - Vehicles With: Manual Transaxle
- General Procedures
- Fill Procedure
- Bearing Check
- In-vehicle Repair
- Input Shaft Seal
- Halfshaft Seal LH
- Halfshaft Seal RH
- Selector Mechanism
- Removal
- Transaxle - 2.0L Duratorq-TDCi (DW) Diesel
- Disassembly
- Transaxle
- Disassembly and Assembly of Subassemblies
- 308-06A Manual Transmission-Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (iB5)
- Description and Operation
- External Controls
- Diagnosis and Testing
- External Controls
- Removal and Installation
- 308-06A Manual Transmission-Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (iB5)|Specifications
- Description and Operation
- 308-06B Manual Transmission-Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75)
- Diagnosis and Testing
- External Controls
- Removal and Installation
- 308-06B Manual Transmission-Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75)|Specifications
- Diagnosis and Testing
- 308-06C Manual Transmission-Transaxle External Controls - Vehicles With: 6-Speed Manual Transmission (MMT6)
- 308-06C Manual Transmission-Transaxle External Controls - Vehicles With: 6-Speed Manual Transmission (MMT6)|Specifications
- Diagnosis and Testing
- Removal and Installation
- External Controls
- 308-00 Manual Transmission-Transaxle and Clutch - General Information
- 309 Exhaust System
- 309-00 Exhaust System
- 309-00 Exhaust System|Specifications
- Description and Operation
- Exhaust System
- Removal and Installation
- Catalytic Converter - 1.6L Duratec-16V (Sigma)
- Catalytic Converter - Vehicles Built Up To: 03-2007 1.6L Duratec-16V Ti-VCT (Sigma)
- Catalytic Converter - Vehicles Built From: 03-2007 1.6L Duratec-16V Ti-VCT (Sigma)
- Catalytic Converter - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel
- Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V
- Catalytic Converter - 1.8L Duratorq-TDCi (Lynx) Diesel
- Catalytic Converter - 2.0L Duratorq-TDCi (DW) Diesel
- Catalytic Converter - 2.0L Duratorq-TDCi (DW) Diesel, VIN Plate Emission Level Code: V
- Diesel Particulate Filter (DPF) - 1.6L Duratorq-TDCi (DV) Diesel (110 PS)
- Exhaust Flexible Pipe
- Diesel Particulate Filter (DPF) - 2.0L Duratorq-TDCi (DW) Diesel
- 309-00 Exhaust System
- 310 Fuel System
- 310-00 Fuel System - General Information
- Diagnosis and Testing
- Fuel System - 1.6L Duratec-16V (Sigma)-1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Fuel System - Vehicles With: Fuel Additive Tank
- Fuel System - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- General Procedures
- Fuel System Pressure Check - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Fuel System Pressure Release
- Quick Release Coupling
- Spring Lock Couplings
- Fuel Tank Draining
- Fuel Additive Tank Disposal
- Fuel Additive System Filling and Bleeding
- Fuel Additive System Service Reset Procedure Using Diagnostic Tool
- Fuel Additive System Service Reset Procedure Without Using Diagnostic Tool
- Diagnosis and Testing
- 310-01 Fuel Tank and Lines
- 310-01 Fuel Tank and Lines|Specifications
- Description and Operation
- Fuel Tank and Lines
- Diagnosis and Testing
- Fuel Tank and Lines
- Removal and Installation
- Fuel Tank - 1.6L Duratec-16V (Sigma)-1.6L Duratec-16V Ti-VCT (Sigma)-1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank
- Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fuel Additive Tank
- Fuel Additive System Module
- Fuel Additive Tank
- Fuel Pump Module
- Fuel Tank Filler Pipe
- Fuel Filter - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel
- Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor
- Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor
- Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel, Vehicles Without: Water-in-Fuel Sensor
- Fuel Filter Element - 2.0L Duratorq-TDCi (DW) Diesel
- Fuel Filter Element - 1.8L Duratorq-TDCi (Lynx) Diesel
- Fuel Supply Line - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Fuel Supply Line - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Fuel Return Line - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Fuel Additive Tank to Fuel Tank Line
- Fuel Level Resistor Card
- 310-02 Acceleration Control
- 310-02 Acceleration Control|Specifications
- Description and Operation
- Acceleration Control
- Diagnosis and Testing
- Acceleration Control
- Removal and Installation
- 310-03 Speed Control
- Diagnosis and Testing
- Speed Control
- Removal and Installation
- Diagnosis and Testing
- 310-00 Fuel System - General Information
- 303 Engine
- 4 Electrical
- 412 Climate Control System
- 412-00 Climate Control System - General Information
- 412-00 Climate Control System - General Information|Specifications
- Diagnosis and Testing
- Climate Control System
- General Procedures
- Spring Lock Coupling
- Air Conditioning (A-C) Clutch Air Gap Adjustment
- Electronic Leak Detection
- Fluorescent Dye Leak Detection
- Air Conditioning (A-C) System Recovery, Evacuation and Charging
- Refrigerant Oil Adding
- Contaminated Refrigerant Handling
- Air Distribution System Cleaning
- Vacuum Leak Detection
- 412-01A Air Distribution and Filtering
- 412-01A Air Distribution and Filtering|Specifications
- Description and Operation
- Diagnosis and Testing
- Air Distribution and Filtering
- Removal and Installation
- Air Distribution and Filtering
- Diagnosis and Testing
- 412-02A Heating and Ventilation
- 412-02A Heating and Ventilation|Specifications
- Description and Operation
- Diagnosis and Testing
- Heating and Ventilation
- Removal and Installation
- Blower Motor - LHD
- Blower Motor - RHD
- Heater Core and Evaporator Core Housing
- Heater Core - LHD
- Heater Core - RHD
- Disassembly and Assembly
- Heating and Ventilation
- Diagnosis and Testing
- 412-02B Auxiliary Heating
- 412-02B Auxiliary Heating|Specifications
- Description and Operation
- Auxiliary Heater
- Fuel Fired Booster Heater
- Diagnosis and Testing
- Fuel Fired Booster Heater
- Electric Booster Heater
- Removal and Installation
- 412-03 Air Conditioning
- 412-03 Air Conditioning|Specifications
- Description and Operation
- Air Conditioning
- Diagnosis and Testing
- Air Conditioning
- Removal and Installation
- Air Conditioning (A-C) Compressor - 1.6L Duratec-16V (Sigma)
- Air Conditioning (A-C) Compressor - 1.6L Duratorq-TDCi (DV) Diesel
- Air Conditioning (A-C) Compressor - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Air Conditioning (A-C) Compressor - 1.8L Duratorq-TDCi (Lynx) Diesel
- Air Conditioning (A-C) Compressor - 2.0L Duratorq-TDCi (DW) Diesel
- Clutch and Clutch Field Coil
- Clutch and Clutch Field Coil - Vehicles Built Up To: 08-2005 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Evaporator Core
- Evaporator Core Orifice
- Suction Accumulator
- Suction Accumulator - 1.6L Duratec-16V (Sigma)
- Condenser Core
- Compressor to Condenser Discharge Line - 2.0L Duratorq-TDCi (DW) Diesel
- Compressor to Condenser Discharge Line - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Low-Pressure Cutoff Switch
- High-Pressure Cutoff Switch
- Suction Accumulator to Compressor Line - 2.0L Duratorq-TDCi (DW) Diesel
- Condenser to Evaporator Line
- Evaporator Outlet Line
- 412-04 Control Components
- 412-04 Control Components|Specifications
- Description and Operation
- Control Components
- Diagnosis and Testing
- Control Components
- Removal and Installation
- Climate Control Assembly - Vehicles With: Automatic Temperature Control
- Climate Control Assembly - Vehicles With: Manual Temperature Control
- Climate Control Assembly - Vehicles With: Digital Versatile Disc (DVD) Navigation System
- Climate Control Module - Vehicles Built From: 01-2008
- Climate Control Module - Vehicles Built Up To: 01-2008
- Blower Motor Switch
- Footwell Air Discharge Temperature Sensor
- Center Register Air Discharge Temperature Sensor
- Center Register Air Discharge Temperature Sensor - Vehicles Built Up To: 01-2008, Vehicles With: Digital Versatile Disc (DVD) Na
- Center Register Air Discharge Temperature Sensor - Vehicles Built From: 01-2008, Vehicles With: Digital Versatile Disc (DVD) Nav
- Driver Side Temperature Blend Door Actuator
- Air Inlet Blend Door Actuator
- Passenger Side Temperature Blend Door Actuator
- Defrost Vent-Register Blend Door Actuator - LHD
- Defrost Vent-Register Blend Door Actuator - RHD
- Footwell Vent-Duct Blend Door Actuator - LHD
- Blower Motor Resistor - LHD
- Footwell Vent-Duct Blend Door Actuator - RHD
- Blower Motor Resistor - RHD
- Blower Motor Resistor - Vehicles Built From: 10-2005, Vehicles With: Dual Automatic Temperature Control
- 412-00 Climate Control System - General Information
- 413 Instrumentation and Warning Systems
- 413-00 Instrument Cluster and Panel Illumination
- Description and Operation
- Instrument Cluster and Panel Illumination
- Diagnosis and Testing
- Description and Operation
- 413-01 Instrument Cluster
- Description and Operation
- Instrument Cluster
- Diagnosis and Testing
- Instrument Cluster
- Removal and Installation
- Description and Operation
- 413-06 Horn
- 413-06 Horn|Specifications
- Diagnosis and Testing
- Diagnosis and Testing|Horn
- Removal and Installation
- 413-07 Clock
- Diagnosis and Testing
- Diagnosis and Testing|Clock
- Removal and Installation
- Diagnosis and Testing
- 413-08 Information and Message Center
- Diagnosis and Testing
- Removal and Installation
- Information and Message Center
- Diagnosis and Testing
- 413-09 Warning Devices
- Diagnosis and Testing
- Warning Devices
- General Procedures
- Diagnosis and Testing
- 413-13A Parking Aid - Vehicles With: Front Parking Aid
- Description and Operation
- Parking Aid - Vehicles With: Front Parking Aid
- Diagnosis and Testing
- Parking Aid
- General Procedures
- Azimuth System Check
- Elevation System Check
- Removal and Installation
- Description and Operation
- 413-13B Parking Aid - Vehicles With: Rear Parking Aid
- Description and Operation
- Parking Aid - Vehicles With: Rear Parking Aid
- Diagnosis and Testing
- Parking Aid
- General Procedures
- Azimuth System Check
- Elevation System Check
- Removal and Installation
- Description and Operation
- 413-00 Instrument Cluster and Panel Illumination
- 414 Battery and Charging System
- 414-00 Charging System - General Information
- Description and Operation
- Charging System
- Diagnosis and Testing
- Charging System
- General Procedures
- Description and Operation
- 414-01 Battery, Mounting and Cables
- Diagnosis and Testing
- Diagnosis and Testing|Battery
- General Procedures
- Battery Disconnect and Connect
- Removal and Installation
- Battery - 1.6L Duratec-16V (Sigma)-1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Battery - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Battery Tray - 1.6L Duratec-16V (Sigma)-1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Battery Tray - 1.6L Duratorq-TDCi (DV) Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Battery Cables - 1.6L Duratec-16V (Sigma)
- Battery Cables - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Battery Cables - 1.6L Duratorq-TDCi (DV) Diesel
- Battery Cables - 2.0L Duratorq-TDCi (DW) Diesel
- Battery Cables - 1.8L Duratorq-TDCi (Lynx) Diesel
- 414-01 Battery, Mounting and Cables|Specifications
- Diagnosis and Testing
- 414-02 Generator and Regulator
- 414-02 Generator and Regulator|Specifications
- Removal and Installation
- Generator - 1.6L Duratec-16V (Sigma)
- Generator - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Generator - 1.6L Duratorq-TDCi (DV) Diesel (90 PS), VIN Plate Emission Level Code: S, Vehicles With: Air Conditioning
- Generator - 1.6L Duratorq-TDCi (DV) Diesel (90 PS), VIN Plate Emission Level Code: K, Vehicles With: Air Conditioning
- Generator - 1.6L Duratorq-TDCi (DV) Diesel (90 PS), Vehicles Without: Air Conditioning
- Generator - 1.6L Duratorq-TDCi (DV) Diesel (110 PS)
- Generator - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor
- Generator - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor
- Generator - 1.8L Duratorq-TDCi (Lynx) Diesel, Vehicles With: Air Conditioning
- Generator - 1.8L Duratorq-TDCi (Lynx) Diesel, Vehicles Without: Air Conditioning
- 414-05 Voltage Converter-Inverter
- Description and Operation
- Direct Current-Alternating Current (DC-AC) Inverter
- Removal and Installation
- Description and Operation
- 414-00 Charging System - General Information
- 415 Information and Entertainment Systems
- 415-00 Information and Entertainment System - General Information
- Diagnosis and Testing
- 415-01A Audio Unit
- Description and Operation
- Audio System
- Diagnosis and Testing
- Audio System
- Removal and Installation
- Description and Operation
- 415-02 Antenna
- Diagnosis and Testing
- 415-03 Speakers
- Diagnosis and Testing
- Speakers
- Removal and Installation
- Diagnosis and Testing
- 415-07 Video System
- General Procedures
- Digital Versatile Disc (DVD) Player Serial Number Retrieval
- Removal and Installation
- General Procedures
- 415-00 Information and Entertainment System - General Information
- 417 Lighting
- 417-01 Exterior Lighting
- 417-01 Exterior Lighting|Specifications
- Description and Operation
- Exterior Lighting
- Diagnosis and Testing
- Headlamps
- Stoplamps
- Turn Signal and Hazard Lamps
- Parking, Rear and License Plate Lamps
- Fog Lamps
- Reversing Lamps
- Trailer Lamps
- Headlamp Leveling
- General Procedures
- Headlamp Adjustment
- Headlamp Masking - Vehicles Built Up To: 03-2007
- Headlamp Masking - Vehicles Built From: 03-2007
- Headlamp Masking - Vehicles With: Adaptive Front Lighting
- Headlamp Masking - Vehicles With: High Intensity Discharge Headlamps
- Front Fog Lamp Adjustment
- Removal and Installation
- High Beam Headlamp Bulb - Vehicles With: High Intensity Discharge Headlamps
- Parking Lamp Bulb - Vehicles With: High Intensity Discharge Headlamps
- Low Beam Headlamp Bulb - Vehicles With: High Intensity Discharge Headlamps
- Headlamp Switch
- Stoplamp Switch
- Front Fog Lamp - Vehicles Built Up To: 03-2007
- Front Fog Lamp - Vehicles Built From: 03-2007
- Headlamp Leveling Rear Sensor
- Headlamp Leveling Front Sensor
- Headlamp Leveling Motor - Vehicles With: High Intensity Discharge Headlamps
- Headlamp Leveling Motor
- Headlamp Assembly
- 417-02 Interior Lighting
- Diagnosis and Testing
- 417-04 Daytime Running Lamps (DRL)
- Description and Operation
- Daytime Running Lamps (DRL)
- Diagnosis and Testing
- Description and Operation
- 417-01 Exterior Lighting
- 418 Electrical Distribution
- 418-00 Module Communications Network
- Description and Operation
- Communications Network
- Diagnosis and Testing
- Description and Operation
- 418-01 Module Configuration
- General Procedures
- 418-02 Wiring Harnesses
- 418-02 Wiring Harnesses|Specifications
- Diagnosis and Testing
- 418-00 Module Communications Network
- 419 Electronic Feature Group
- 419-01A Anti-Theft - Active
- Diagnosis and Testing
- Anti-Theft - Active
- Removal and Installation
- 419-01A Anti-Theft - Active|Specifications
- Diagnosis and Testing
- 419-01B Anti-Theft - Passive
- Description and Operation
- Anti-Theft - Passive
- Diagnosis and Testing
- Anti-Theft - Passive
- General Procedures
- Description and Operation
- 419-07A Navigation System - Vehicles With: Digital Versatile Disc (DVD) Navigation System
- Description and Operation
- Navigation System
- Diagnosis and Testing
- Navigation System
- Removal and Installation
- Description and Operation
- 419-07B Navigation System - Vehicles With: Travel Pilot EX
- Description and Operation
- Navigation System
- Diagnosis and Testing
- Navigation System
- Removal and Installation
- Description and Operation
- 419-08 Cellular Phone
- Description and Operation
- Cellular Phone
- Removal and Installation
- Description and Operation
- 419-10 Multifunction Electronic Modules
- Description and Operation
- Module Controlled Functions
- Diagnosis and Testing
- Generic Electronic Module (GEM)
- Removal and Installation
- Description and Operation
- 419-01A Anti-Theft - Active
- 412 Climate Control System
- 5 Body and Paint
- 501 Body and Paint
- 501-02 Front End Body Panels
- 501-03 Body Closures
- 501-05 Interior Trim and Ornamentation
- 501-05 Interior Trim and Ornamentation|Specifications
- Removal and Installation
- A-Pillar Trim Panel
- B-Pillar Trim Panel
- C-Pillar Trim Panel
- D-Pillar Trim Panel
- Front Door Trim Panel - Vehicles Built Up To: 03-2007
- Front Door Trim Panel - Vehicles Built From: 03-2007
- Rear Door Trim Panel - Vehicles Built Up To: 03-2007, Vehicles With: Manual Windows
- Rear Door Trim Panel - Vehicles Built Up To: 03-2007, Vehicles With: Power Windows
- Front Scuff Plate Trim Panel
- Rear Door Trim Panel - Vehicles Built From: 03-2007
- Rear Scuff Plate Trim Panel
- Loadspace Trim Panel
- Headliner
- Glass Roof Panel Blind
- 501-08 Exterior Trim and Ornamentation
- Removal and Installation
- 501-09 Rear View Mirrors
- 501-09 Rear View Mirrors|Specifications
- Description and Operation
- Rear View Mirrors
- Diagnosis and Testing
- 501-10 Seating
- 501-10 Seating|Specifications
- Description and Operation
- 501-10 Seating|Seats
- Diagnosis and Testing
- Seats - Vehicles Built Up To: 06-2004
- Seats - Vehicles Built From: 06-2004
- Removal and Installation
- Front Seat
- Heated Seat Switch
- Front Seat Backrest Cover
- Front Seat Backrest Cover - Vehicles With: 6-Way Power Seats
- Front Seat Height Adjustment Motor
- Front Seat Track Motor
- Front Seat Cushion Cover
- Rear Outer Seat Backrest Cover
- Rear Outer Seat Cushion Cover
- Rear Center Seat Cushion Cover
- Rear Center Seat Backrest Cover
- Disassembly and Assembly
- 501-11 Glass, Frames and Mechanisms
- 501-11 Glass, Frames and Mechanisms|Specifications
- Diagnosis and Testing
- Glass, Frames and Mechanisms - Vehicles With: Front and Rear Power Windows
- Glass, Frames and Mechanisms - Vehicles With: Front Power Windows
- General Procedures
- Door Window Motor Initialization
- Removal and Installation
- Front Door Window Glass
- Rear Door Window Glass - Vehicles With: Manual Windows
- Rear Quarter Window Glass
- Rear Door Window Glass - Vehicles With: Power Windows
- Liftgate Window Glass
- Rear Door Window Regulator - Vehicles With: Power Windows
- Front Door Window Regulator
- Rear Door Window Regulator - Vehicles With: Manual Windows
- Front Door Window Regulator Motor - Vehicles With: Front Power Windows
- Rear Door Window Regulator Motor
- Front Door Window Regulator Motor - Vehicles With: Front and Rear Power Windows
- Windshield Glass - Vehicles Built Up To: 11-2004
- Windshield Glass - Vehicles Built From: 11-2004
- Glass Roof Panel
- 501-12 Instrument Panel and Console
- 501-12 Instrument Panel and Console|Specifications
- Removal and Installation
- 501-14 Handles, Locks, Latches and Entry Systems
- 501-14 Handles, Locks, Latches and Entry Systems|Specifications
- Diagnosis and Testing
- Locks, Latches and Entry Systems
- General Procedures
- Remote Transmitter Programming
- Removal and Installation
- 501-16 Wipers and Washers
- 501-16 Wipers and Washers|Specifications
- Description and Operation
- Wipers and Washers
- Diagnosis and Testing
- 501-17 Roof Opening Panel
- 501-17 Roof Opening Panel|Specifications
- Diagnosis and Testing
- Roof Opening Panel
- General Procedures
- 501-19 Bumpers
- 501-20A Safety Belt System
- 501-20A Safety Belt System|Specifications
- Description and Operation
- Diagnosis and Testing
- Safety Belt System
- 501-20B Supplemental Restraint System
- 501-20B Supplemental Restraint System|Specifications
- Description and Operation
- Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
- Diagnosis and Testing
- Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) - Vehicles Built Up To: 06-2004
- Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) - Vehicles Built From: 06-2004
- General Procedures
- Deployed Air Bag Disposal
- Unserviceable Air Bag Disposal
- Scrapped Vehicle Undeployed Air Bag Disposal
- Scrapped Vehicle Air Bag and Safety Belt Pretensioner Disposal - In-Vehicle Disposal - Vehicles Built Up To: 06-2004
- Scrapped Vehicle Air Bag and Safety Belt Pretensioner Disposal - In-Vehicle Disposal - Vehicles Built From: 06-2004
- Air Bag and Safety Belt Pretensioner Disposal
- Removal and Installation
- Crash Sensor
- Side Impact Sensor
- Restraints Control Module (RCM)
- Driver Air Bag Module - Vehicles Built Up To: 06-2004
- Passenger Air Bag Module - Vehicles Built Up To: 06-2004
- Driver Air Bag Module - Vehicles Built From: 06-2004
- Passenger Air Bag Module - Vehicles Built Up To: 10-2005
- Passenger Air Bag Module - Vehicles Built From: 10-2005
- Side Air Bag Module
- Side Air Curtain Module
- Clockspring - Vehicles Built Up To: 06-2004
- Clockspring - Vehicles Built From: 06-2004
- Passenger Air Bag Deactivation (PAD) Switch
- 501-25A Body Repairs - General Information
- 501-25A Body Repairs - General Information|Specifications
- Description and Operation
- Description and Usage of Body Repair Literature
- 501-25A Body Repairs - General Information|Symbols
- Health and Safety Precautions
- Environmental Regulations
- Body Construction
- Diagnosis and Damage Evaluation
- Body Sheet Metal
- Establish Repair Method
- Tools and Equipment for Body Repairs
- Alignment Check
- Complete Panel Replacement-Partial Replacement
- Straightening
- Corrosion Prevention
- Corrosion Damage-Corrosion Repair
- Sealer, Underbody Protection Material and Adhesives
- Cutting Technique
- Panel Beating Technique and Smart Repairs
- Paintless Dent Removal
- Joining Techniques
- Plastic Repairs
- Special Repair Techniques
- Impact of Insufficient Repair Quality
- Water Leaks
- Wind Noise
- Noise, Vibration and Harshness
- 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks
- 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks|Specifications
- Description and Operation
- Body and Frame
- General Procedures
- 501-27 Front End Sheet Metal Repairs
- 501-28 Roof Sheet Metal Repairs
- Removal and Installation
- 501-28 Roof Sheet Metal Repairs|Specifications
- 501-29 Side Panel Sheet Metal Repairs
- 501-30 Rear End Sheet Metal Repairs
- 501-36 Paint - General Information
- 501-36 Paint - General Information|Specifications
- Description and Operation
- Description and Usage of Paint Literature
- 501-36 Paint - General Information|Symbols
- Health and Safety Precautions
- Environmental Regulations
- Factory Paint Application
- Paintwork Defects and Damage
- Tools and Equipment for Paint Repairs
- Refinishing Materials
- Additional Materials
- Paint Repairs
- Painting Plastic Parts
- Spot Repairs
- Corrosion Prevention
- Color Identification and Chromatics
- Tips and Tricks
- 502 Frame and Mounting
- 502-00 Uni-Body, Subframe and Mounting System
- 502-00 Uni-Body, Subframe and Mounting System|Specifications
- Removal and Installation
- Front Axle Crossmember
- Rear Axle Crossmember - Vehicles With: Solid Stabilizer Bar Link-Fuel Additive Tank
- Rear Axle Crossmember - Vehicles With: Solid Stabilizer Bar Link, Vehicles Without: Fuel Additive Tank
- Rear Axle Crossmember - Vehicles With: Ball Joint Stabilizer Bar Link-Fuel Additive Tank
- Rear Axle Crossmember - Vehicles With: Ball Joint Stabilizer Bar Link, Vehicles Without: Fuel Additive Tank
- 502-00 Uni-Body, Subframe and Mounting System
- 501 Body and Paint
- 1 General Information
- Body and Paint
- 5 Body and Paint
- 501 Body and Paint
- 501-25A Body Repairs - General Information
- 501-25A Body Repairs - General Information|Specifications
- Description and Operation
- Description and Usage of Body Repair Literature
- 501-25A Body Repairs - General Information|Symbols
- Environmental Regulations
- Health and Safety Precautions
- Body Construction
- Body Sheet Metal
- Diagnosis and Damage Evaluation
- Tools and Equipment for Body Repairs
- Establish Repair Method
- Alignment Check
- Complete Panel Replacement-Partial Replacement
- Straightening
- Corrosion Prevention
- Corrosion Damage-Corrosion Repair
- Sealer, Underbody Protection Material and Adhesives
- Cutting Technique
- Panel Beating Technique and Smart Repairs
- Paintless Dent Removal
- Joining Techniques
- Plastic Repairs
- Special Repair Techniques
- Impact of Insufficient Repair Quality
- Water Leaks
- Wind Noise
- Noise, Vibration and Harshness
- 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks
- 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks|Specifications
- Description and Operation
- Body and Frame
- General Procedures
- 501-27 Front End Sheet Metal Repairs
- Removal and Installation
- Fender Apron Panel Section
- Fender Apron Panel Reinforcement
- Front Side Member Section
- Click to view this Labor Time
- Front Side Member and Fender Apron Panel LH
- Removal and Installation
- 501-28 Roof Sheet Metal Repairs
- Removal and Installation
- 501-28 Roof Sheet Metal Repairs|Specifications
- 501-29 Side Panel Sheet Metal Repairs
- 501-30 Rear End Sheet Metal Repairs
- 501-36 Paint - General Information
- 501-36 Paint - General Information|Specifications
- Description and Operation
- Description and Usage of Paint Literature
- 501-36 Paint - General Information|Symbols
- Health and Safety Precautions
- Environmental Regulations
- Factory Paint Application
- Paintwork Defects and Damage
- Tools and Equipment for Paint Repairs
- Refinishing Materials
- Paint Repairs
- Additional Materials
- Painting Plastic Parts
- Spot Repairs
- Corrosion Prevention
- Color Identification and Chromatics
- Tips and Tricks
- 501-25A Body Repairs - General Information
- 501 Body and Paint
- 5 Body and Paint
