Focus RS 2003 (09.2002-) Workshop Manual Manual Pages - Full Index

Focus RS 2003 (09.2002-) Workshop Manual

• Mechanical Repairs
  • 1 General Information
    • 100 Service Information
      • 100-00 General Information
        • Description and Operation
          • About This Manual
          • Standard Workshop Practices
          • Health and Safety Precautions
          • Road-Roller Testing
          • Solvents, Sealants and Adhesives
      • 100-01 Identification Codes
        • Description and Operation
          • Identification Codes
      • 100-02 Jacking and Lifting
        • Description and Operation
          • 100-02 Jacking and Lifting|Lifting
          • 100-02 Jacking and Lifting|Jacking
      • 100-04 Noise, Vibration and Harshness
        • Description and Operation
          • Noise, Vibration and Harshness (NVH)
          • Diagnosis and Testing
            • Noise, Vibration and Harshness (NVH)
            • General Procedures
              • Powertrain-Drivetrain Mount Neutralizing
  • 2 Chassis
    • 204 Suspension
      • 204-00 Suspension System - General Information
        • Diagnosis and Testing
          • Suspension System - 2.0L Duratec-RS (Zetec)
          • General Procedures
            • Front Toe Adjustment
            • Rear Toe Adjustment
            • Suspension Design Height Setting - 2.0L Duratec-RS (Zetec)
            • Wheel Bearing Inspection
        • Specifications - 2.0L Duratec-RS (Zetec)
      • 204-01 Front Suspension
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Diagnosis and Testing
            • Front Suspension
            • Removal and Installation
              • Wheel Bearing - 2.0L Duratec-RS (Zetec)
              • Lower Arm - 2.0L Duratec-RS (Zetec)
              • Stabilizer Bar - 2.0L Duratec-RS (Zetec)
              • Wheel Knuckle - 2.0L Duratec-RS (Zetec)
              • Strut and Spring Assembly - 2.0L Duratec-RS (Zetec)
              • Disassembly and Assembly
                • Strut and Spring Assembly
          • Front Suspension - 2.0L Duratec-RS (Zetec)
      • 204-02 Rear Suspension
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Rear Suspension - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Rear Suspension
            • Removal and Installation
              • Wheel Hub - 2.0L Duratec-RS (Zetec)
              • Wheel Bearing - 2.0L Duratec-RS (Zetec)
              • Front Lower Arm - 2.0L Duratec-RS (Zetec)
              • Rear Lower Arm - 2.0L Duratec-RS (Zetec)
              • Stabilizer Bar - 2.0L Duratec-RS (Zetec)
              • Upper Arm - 2.0L Duratec-RS (Zetec)
              • Wheel Knuckle - 2.0L Duratec-RS (Zetec)
              • Wheel Spindle - 2.0L Duratec-RS (Zetec)
              • Diagnosis and Testing|Removal and Installation|Spring
              • Shock Absorber - 2.0L Duratec-RS (Zetec)
              • Crossmember - 2.0L Duratec-RS (Zetec)
      • 204-04 Wheels and Tires
        • Diagnosis and Testing
          • Wheels and Tires
          • Removal and Installation
            • Wheel and Tire - 2.0L Duratec-RS (Zetec)
        • 204-04 Wheels and Tires|Specifications
    • 205 Driveline
      • 205-04 Front Drive Halfshafts
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Diagnosis and Testing
            • Front Drive Halfshafts - 2.0L Duratec-RS (Zetec)
            • Removal and Installation
              • Halfshaft LH - 2.0L Duratec-RS (Zetec)
              • Halfshaft RH - 2.0L Duratec-RS (Zetec)
              • Intermediate Shaft - 2.0L Duratec-RS (Zetec)
              • Constant Velocity (CV) Joint Boot - 2.0L Duratec-RS (Zetec)
              • Inner Constant Velocity (CV) Joint Boot - 2.0L Duratec-RS (Zetec)
              • Disassembly and Assembly
                • Halfshaft LH
                • Halfshaft RH
          • Front Drive Halfshafts - 2.0L Duratec-RS (Zetec)
    • 206 Brake System
      • 206-00 Brake System - General Information
        • Description and Operation
          • Brake System - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Brake System - 2.0L Duratec-RS (Zetec)
            • General Procedures
              • Brake System Bleeding
              • Brake System Pressure Bleeding
              • Brake Disc Runout Check
              • Brake System Leak Check
      • 206-03 Front Disc Brake
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Front Disc Brake - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Front Disc Brake
            • Removal and Installation
              • Brake Pads - 2.0L Duratec-RS (Zetec)
              • Brake Caliper - 2.0L Duratec-RS (Zetec)
              • Brake Disc - 2.0L Duratec-RS (Zetec)
              • Disassembly and Assembly
                • Brake Caliper
      • 206-04 Rear Disc Brake
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Diagnosis and Testing
            • Rear Disc Brake
            • Removal and Installation
              • Brake Caliper - 2.0L Duratec-RS (Zetec)
              • Brake Pads - 2.0L Duratec-RS (Zetec)
              • Brake Disc - 2.0L Duratec-RS (Zetec)
          • Rear Disc Brake - 2.0L Duratec-RS (Zetec)
      • 206-05 Parking Brake and Actuation
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Diagnosis and Testing
            • Parking Brake - 2.0L Duratec-RS (Zetec)
            • General Procedures
              • Parking Brake Cable Adjustment - 2.0L Duratec-RS (Zetec)
              • Removal and Installation
                • Parking Brake Control - 2.0L Duratec-RS (Zetec)
                • Parking Brake Cable - 2.0L Duratec-RS (Zetec)
          • Parking Brake - 2.0L Duratec-RS (Zetec)
      • 206-06 Hydraulic Brake Actuation
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Hydraulic Brake Actuation - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Hydraulic Brake Actuation
            • Removal and Installation
              • Brake Pedal - 2.0L Duratec-RS (Zetec)
              • Brake Master Cylinder - 2.0L Duratec-RS (Zetec) RHD
              • Brake Master Cylinder - 2.0L Duratec-RS (Zetec) LHD
              • Brake Fluid Reservoir - 2.0L Duratec-RS (Zetec)
      • 206-07 Power Brake Actuation
        • Description and Operation
          • Brake Booster - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Power Brake System
            • Removal and Installation
              • Brake Booster - 2.0L Duratec-RS (Zetec) LHD
              • Brake Booster - 2.0L Duratec-RS (Zetec) RHD
        • 206-07 Power Brake Actuation|Specifications
      • 206-09A Anti-Lock Control
        • 206-09A Anti-Lock Control|Specifications
        • Description and Operation
          • Anti-Lock Control
          • Diagnosis and Testing
            • Anti-Lock Control
            • Removal and Installation
              • Hydraulic Control Unit (HCU) - 2.0L Duratec-RS (Zetec)
              • Anti-Lock Brake System (ABS) Module - 2.0L Duratec-RS (Zetec) RHD
              • Anti-Lock Brake System (ABS) Module - 2.0L Duratec-RS (Zetec) LHD
              • Rear Wheel Speed Sensor
              • Rear Wheel Speed Sensor Ring - 2.0L Duratec-RS (Zetec)
      • 206-09B Anti-Lock Control - Traction Control
        • 206-09B Anti-Lock Control - Traction Control|Specifications
        • Description and Operation
          • Diagnosis and Testing
            • Anti-Lock Control - Traction Control
            • Removal and Installation
              • Rear Wheel Speed Sensor
              • Hydraulic Control Unit (HCU)
          • Anti-Lock Control - Traction Control
    • 211 Steering System
      • 211-00 Steering System - General Information
        • Description and Operation
          • Steering System - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Steering System
            • General Procedures
              • Power Steering System Flushing - 1.4L-1.6L-1.8L-2.0L-2.0L Duratec-RS (Zetec)
              • Power Steering System Filling
              • Power Steering System Bleeding
        • 211-00 Steering System - General Information|Specifications
      • 211-02 Power Steering
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Power Steering - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Power Steering
            • Removal and Installation
              • Power Steering Pump Pulley - 2.0L Duratec-RS (Zetec)
              • Power Steering Pump to Steering Gear Pressure Line - 2.0L Duratec-RS (Zetec)
              • Power Steering Pump - 2.0L Duratec-RS (Zetec)
              • Power Steering Fluid Cooler - 2.0L Duratec-RS (Zetec)
              • Steering Gear
              • Steering Gear Bushing
      • 211-03 Steering Linkage
        • 211-03 Steering Linkage|Specifications
        • Description and Operation
          • Diagnosis and Testing
            • Steering Linkage
            • Removal and Installation
              • Diagnosis and Testing|Removal and Installation|Tie Rod
              • Steering Gear Boot
              • Tie Rod End
          • Steering Linkage
      • 211-04 Steering Column
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Steering Column - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Steering Column
            • Removal and Installation
              • Steering Wheel
              • Steering Column - 2.0L Duratec-RS (Zetec)
              • Disassembly and Assembly
                • Steering Column - 2.0L Duratec-RS (Zetec)
      • 211-05 Steering Column Switches
        • Diagnosis and Testing
          • Steering Column Switches - 2.0L Duratec-RS (Zetec)
          • Removal and Installation
            • Ignition Switch - 2.0L Duratec-RS (Zetec)
  • 3 Powertrain
    • 303 Engine
      • 303-00 Engine System - General Information
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Diagnosis and Testing
          • Engine - 2.0L Duratec-RS (Zetec)
          • General Procedures
            • Camshaft Bearing Journal Diameter
            • Camshaft Bearing Journal Clearance
            • Camshaft End Play
            • Camshaft Surface Inspection
            • Crankshaft Main Bearing Journal Diameter
            • Camshaft Lobe Lift
            • Crankshaft End Play
            • Crankshaft Main Bearing Journal Clearance
            • Piston Inspection
            • Cylinder Bore Taper
            • Piston Pin to Bore Diameter
            • Piston Diameter
            • Piston Ring End Gap
            • Piston Ring-to-Groove Clearance
            • Piston Pin Diameter
            • Connecting Rod Large End Bore
            • Flywheel Inspection
            • Valve Stem Diameter
            • Cylinder Block Distortion
            • Cylinder Head Distortion
            • Exhaust Manifold Cleaning and Inspection
            • Bearing Inspection
            • Valve Seat Inspection
      • 303-01F Engine - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • 303-01F Engine - 2.0L Duratec-RS (Zetec)|Engine
          • Diagnosis and Testing
            • Diagnosis and Testing|Engine
            • General Procedures
              • Valve Clearance
              • In-vehicle Repair
                • Intake Manifold
                • Crankshaft Front Seal
                • In-vehicle Repair|Valves
                • Valve Springs
                • Valve Seals
                • Camshafts
                • Camshaft Seal
                • Timing Belt
                • Exhaust Manifold
                • Cylinder Head
                • In-vehicle Repair|Oil Pan
                • Oil Cooler
                • Oil Pump
                • Crankshaft Rear Seal
                • Removal
                  • In-vehicle Repair|Engine
                  • Disassembly
                    • In-vehicle Repair|Disassembly|Engine
                    • Assembly
                      • Assembly|Engine
                      • Installation
                        • Assembly|Installation|Engine
        • 303-01F Engine - 2.0L Duratec-RS (Zetec)|Specifications
      • 303-03 Engine Cooling
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Engine Cooling - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Engine Cooling - 2.0L Duratec-RS (Zetec)
            • General Procedures
              • Cooling System Draining, Filling and Bleeding - 2.0L Duratec-RS (Zetec)
              • Cooling System Backflushing
              • Cooling System Flushing
              • Removal and Installation
                • Thermostat - 2.0L Duratec-RS (Zetec)
                • Thermostat Housing - 2.0L Duratec-RS (Zetec)
                • Radiator - 2.0L Duratec-RS (Zetec)
                • Cooling Fan Motor and Shroud - 2.0L Duratec-RS (Zetec)
                • Coolant Expansion Tank
      • 303-04I Fuel Charging and Controls - 2.0L Duratec-RS (Zetec)
        • 303-04I Fuel Charging and Controls - 2.0L Duratec-RS (Zetec)|Specifications
        • Description and Operation
          • Diagnosis and Testing
            • Fuel Charging and Controls
            • Removal and Installation
              • Throttle Body
              • Fuel Charging Wiring Harness
              • Fuel Injection Supply Manifold
              • Fuel Injectors
          • Fuel Charging and Controls
      • 303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Turbocharger
          • Diagnosis and Testing
            • Turbocharger
            • Removal and Installation
              • Turbocharger
        • 303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratec-RS (Zetec)|Specifications
      • 303-05 Accessory Drive
        • 303-05 Accessory Drive|Specifications
        • Description and Operation
          • Accessory Drive
          • Diagnosis and Testing
            • Accessory Drive
            • Removal and Installation
              • Accessory Drive Belt
              • Accessory Drive Belt Tensioner
              • Accessory Drive Belt Idler Pulley
      • 303-06 Starting System
        • 303-06 Starting System|Specifications
        • Description and Operation
          • Starting System - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Starting System - 2.0L Duratec-RS (Zetec)
            • Removal and Installation
              • Starter Motor - 2.0L Duratec-RS (Zetec)
      • 303-07F Engine Ignition - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Engine Ignition
          • Diagnosis and Testing
            • Removal and Installation
              • Ignition Coil Pack
            • Engine Ignition
        • 303-07F Engine Ignition - 2.0L Duratec-RS (Zetec)|Specifications
      • 303-08E Engine Emission Control - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Engine Emission Control
          • Diagnosis and Testing
            • Engine Emission Control
            • Removal and Installation
              • Positive Crankcase Ventilation (PCV) Hose
              • Positive Crankcase Ventilation (PCV) Valve
              • Valve Cover Vent Oil Separator
        • 303-08E Engine Emission Control - 2.0L Duratec-RS (Zetec)|Specifications
      • 303-12 Intake Air Distribution and Filtering
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Intake Air Distribution and Filtering - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Intake Air Distribution and Filtering - 2.0L Duratec-RS (Zetec)
            • General Procedures
              • Charge Air Cooler Cooling System Draining, Filling and Bleeding - 2.0L Duratec-RS (Zetec)
              • Removal and Installation
                • Air Cleaner Intake Pipe - 2.0L Duratec-RS (Zetec)
                • Air Cleaner - 2.0L Duratec-RS (Zetec)
                • Charge Air Cooler - 2.0L Duratec-RS (Zetec)
                • Charge Air Cooler Radiator - 2.0L Duratec-RS (Zetec)
                • Charge Air Cooler Water Pump - 2.0L Duratec-RS (Zetec)
      • 303-13 Evaporative Emissions
        • Description and Operation
          • Evaporative Emissions - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Evaporative Emissions
            • Removal and Installation
              • Evaporative Emission Canister
              • Evaporative Emission Canister Purge Valve - 2.0L Duratec-RS (Zetec)-2.0L Duratec-ST (Zetec)
      • 303-14 Electronic Engine Controls
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Electronic Engine Controls - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Electronic Engine Controls
            • Removal and Installation
              • Camshaft Position (CMP) Sensor - 1.6L Zetec-E (Zetec)-1.8L-2.0L
              • Crankshaft Position (CKP) Sensor - 1.6L Zetec-E (Zetec)-1.8L-2.0L
              • Powertrain Control Module (PCM)
              • Power Steering Pressure (PSP) Switch - 1.6L Zetec-E (Zetec)-1.8L-2.0L
              • Idle Air Control (IAC) Valve - 2.0L Duratec-RS (Zetec)
              • Heated Oxygen Sensor (HO2S) - 1.8L-2.0L
              • Cylinder Head Temperature (CHT) Sensor - 1.6L Zetec-E (Zetec)-1.8L-2.0L
              • Clutch Pedal Position (CPP) Switch
    • 308 Manual Transmission-Transaxle, Clutch and Transfer Case
      • 308-00 Manual Transmission-Transaxle and Clutch - General Information
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Manual Transaxle and Clutch
          • Diagnosis and Testing
            • Manual Transaxle and Clutch - 2.0L Duratec-RS (Zetec)
            • General Procedures
              • Clutch System Bleeding - Vehicles With: MTX-75-Manual Transaxle
              • Gearshift Cable Adjustment - 2.0L Duratec-RS (Zetec)
      • 308-01C Clutch - 2.0L Duratec-RS (Zetec)
        • 308-01C Clutch - 2.0L Duratec-RS (Zetec)|Specifications
        • Description and Operation
          • Diagnosis and Testing
            • Diagnosis and Testing|Clutch
            • Removal and Installation
              • Clutch Disc and Pressure Plate
          • 308-01C Clutch - 2.0L Duratec-RS (Zetec)|Clutch
      • 308-02C Clutch Controls - 2.0L Duratec-RS (Zetec)
        • 308-02C Clutch Controls - 2.0L Duratec-RS (Zetec)|Specifications
        • Description and Operation
          • Clutch Controls
          • Diagnosis and Testing
            • Clutch Controls
            • Removal and Installation
              • Clutch Master Cylinder
              • Clutch Slave Cylinder
      • 308-03C Manual Transmission-Transaxle - 2.0L Duratec-RS (Zetec)
        • 308-03C Manual Transmission-Transaxle - 2.0L Duratec-RS (Zetec)|Specifications
        • Description and Operation
          • Diagnosis and Testing
            • Manual Transaxle - Vehicles With: Manual Transaxle
            • General Procedures
              • Drain Procedure
              • Fill Procedure
              • Bearing Check
              • In-vehicle Repair
                • Halfshaft Seal LH
                • Halfshaft Seal RH
                • Removal
                  • Transaxle
                  • Disassembly
                    • Transaxle
                    • Disassembly and Assembly of Subassemblies
                      • Input Shaft
                      • Output Shaft
                      • Assembly
                        • Transaxle
                        • Installation
                          • Transaxle
          • Manual Transaxle
      • 308-06C Manual Transmission-Transaxle External Controls - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • External Controls
          • Diagnosis and Testing
            • External Controls
            • Removal and Installation
              • Gearshift Linkage
              • Disassembly and Assembly
                • Gearshift Lever
              • Gearshift Cables
        • 308-06C Manual Transmission-Transaxle External Controls - 2.0L Duratec-RS (Zetec)|Specifications
    • 309 Exhaust System
      • 309-00 Exhaust System
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Exhaust System - 2.0L Duratec-RS (Zetec)
          • Removal and Installation
            • Catalytic Converter - 2.0L Duratec-RS (Zetec)
    • 310 Fuel System
      • 310-00A Fuel System - General Information
        • Description and Operation
          • Fuel System - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Fuel System - 2.0L Duratec-RS (Zetec)
            • General Procedures
              • Fuel System Pressure Release - 2.0L Duratec-RS (Zetec)
              • Quick Release Coupling
              • Fuel Tank Draining
              • Spring Lock Couplings
      • 310-01A Fuel Tank and Lines
        • 310-01A Fuel Tank and Lines|Specifications
        • Description and Operation
          • Fuel Tank and Lines
          • Diagnosis and Testing
            • Fuel Tank and Lines
            • Removal and Installation
              • Fuel Tank
              • Fuel Pump Module
              • Fuel Tank Filler Pipe
              • Inertia Fuel Shutoff (IFS) Switch
              • Fuel Filter
      • 310-02 Acceleration Control
        • Description and Operation
          • Acceleration Control
          • Diagnosis and Testing
            • Acceleration Control
            • Removal and Installation
              • Accelerator Pedal
              • Accelerator Cable - 2.0L Duratec-RS (Zetec)
              • Accelerator Cable - 2.0L Duratec-ST (Zetec) LHD
              • Accelerator Cable - 2.0L Duratec-ST (Zetec) RHD
  • 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
      • 412-01 Air Distribution and Filtering
        • Description and Operation
          • Diagnosis and Testing
            • Air Distribution and Filtering
            • Removal and Installation
              • Pollen Filter
          • Air Distribution and Filtering
      • 412-02A Heating and Ventilation
        • Description and Operation
          • Heating and Ventilation
          • Diagnosis and Testing
            • Heating and Ventilation
            • Removal and Installation
              • Blower Motor
              • Heater Core and Evaporator Core Housing
              • Disassembly and Assembly
                • Heater Core Housing
              • Heater Core
        • 412-02A Heating and Ventilation|Specifications
      • 412-03 Air Conditioning
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Diagnosis and Testing
            • Air Conditioning
            • Removal and Installation
              • Air Conditioning (A-C) Compressor
              • Clutch and Clutch Field Coil
              • Evaporator Core Orifice
              • Suction Accumulator
              • Low-Pressure Cutoff Switch
              • Condenser Core
              • High-Pressure Cutoff Switch
          • Air Conditioning
      • 412-04 Control Components
        • Description and Operation
          • Control Components
          • Diagnosis and Testing
            • Control Components
            • Removal and Installation
              • Climate Control Assembly
              • Air Distribution Cable Control Assembly
              • Air Inlet Blend Door Actuator
    • 413 Instrumentation and Warning Systems
      • 413-00 Instrument Cluster and Panel Illumination
        • Diagnosis and Testing
          • Instrument Cluster and Panel Illumination - 2.0L Duratec-RS (Zetec)
      • 413-01 Instrument Cluster
        • Description and Operation
          • Instrument Cluster - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Instrument Cluster - 2.0L Duratec-RS (Zetec)
            • Removal and Installation
              • Instrument Cluster
      • 413-06 Horn
        • Description and Operation
          • 413-06 Horn|Horn
          • Diagnosis and Testing
            • Diagnosis and Testing|Horn
            • Removal and Installation
              • Horn Switch
        • 413-06 Horn|Specifications
      • 413-07 Clock
        • Description and Operation
          • 413-07 Clock|Clock
          • Diagnosis and Testing
            • Removal and Installation
              • Diagnosis and Testing|Removal and Installation|Clock
            • Diagnosis and Testing|Clock
      • 413-08 Information and Message Center
        • Description and Operation
          • Information and Message Center
          • Diagnosis and Testing
            • Removal and Installation
              • Message Center
            • Information and Message Center
      • 413-09 Warning Devices
        • Description and Operation
          • Diagnosis and Testing
            • Warning Devices
          • Warning Devices - 2.0L Duratec-RS (Zetec)
    • 414 Battery and Charging System
      • 414-00 Charging System - General Information
        • Description and Operation
          • Diagnosis and Testing
            • Charging System
            • General Procedures
              • Battery Charging
      • 414-01 Battery, Mounting and Cables
        • Description and Operation
          • Battery and Cables - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Diagnosis and Testing|Battery
            • General Procedures
              • Battery Disconnect
              • Removal and Installation
                • General Procedures|Removal and Installation|Battery
                • Battery Cables - 2.0L Duratec-RS (Zetec)
        • 414-01 Battery, Mounting and Cables|Specifications
      • 414-02 Generator and Regulator
        • Description and Operation
          • Diagnosis and Testing
            • Generator
            • Removal and Installation
              • Generator - 1.6L Zetec-E (Zetec)-1.8L-2.0L-2.0L Duratec-RS (Zetec)
        • 414-02 Generator and Regulator|Specifications
    • 415 Information and Entertainment Systems
      • 415-00 Information and Entertainment System - General Information
        • 415-00 Information and Entertainment System - General Information|Specifications
        • Diagnosis and Testing
          • Audio System
          • Audio System - Vehicles Without: High Output Amplifier and Subwoofer
      • 415-01 Audio Unit
        • Description and Operation
          • Diagnosis and Testing
            • Audio System
            • Removal and Installation
              • Compact Disc (CD) Changer
              • Audio Unit
      • 415-02 Antenna
        • Description and Operation
          • Diagnosis and Testing
            • Diagnosis and Testing|Antenna
            • Removal and Installation
              • Antenna Base
              • Antenna Cable - LHD
          • 415-02 Antenna|Antenna
      • 415-03 Speakers
        • Description and Operation
          • Speakers
          • Diagnosis and Testing
            • Speakers
            • Removal and Installation
              • Rear Door Speaker
              • Front Door Speaker
              • Quarter Panel Speaker
    • 417 Lighting
      • 417-01 Exterior Lighting
        • 417-01 Exterior Lighting|Specifications
        • Description and Operation
          • Exterior Lighting
          • Diagnosis and Testing
            • Headlamps
            • Headlamp Leveling
            • Stoplamps
            • Turn Signal and Hazard Lamps
            • Parking, Rear and License Lamps
            • Fog Lamps
            • Reversing Lamps
            • General Procedures
              • Headlamp Adjustment
              • Headlamp Masking
              • Headlamp Mounting Bracket Repair
              • Front Fog Lamp Adjustment
              • Removal and Installation
                • Lamp Switch
                • Headlamp Assembly
                • Headlamp Leveling Motor
                • Front Fog Lamp
      • 417-02 Interior Lighting
        • Description and Operation
          • Interior Lighting
          • Diagnosis and Testing
            • Interior Lighting - Vehicles Built Up To: 08-2001
            • Interior Lighting - Vehicles Built From: 08-2001
      • 417-04 Daytime Running Lamps (DRL)
        • Description and Operation
          • Daytime Running Lamps (DRL)
          • Diagnosis and Testing
            • Daytime Running Lamps (DRL)
    • 418 Electrical Distribution
      • 418-00 Module Communications Network
        • Description and Operation
          • Communications Network
          • Diagnosis and Testing
            • Communications Network
      • 418-01 Module Configuration
        • General Procedures
          • Module Configuration
    • 419 Electronic Feature Group
      • 419-01A Anti-Theft - Active
        • Description and Operation
          • Anti-Theft - Active - 2.0L Duratec-RS (Zetec)
          • Diagnosis and Testing
            • Anti-Theft - Active - 2.0L Duratec-RS (Zetec), Vehicles With: Anti-Theft Alarm Horn with Integral Battery
      • 419-01B Anti-Theft - Passive
        • Description and Operation
          • Anti-Theft - Passive
          • Diagnosis and Testing
            • Removal and Installation
              • Passive Anti-Theft System (PATS) Transceiver
            • Anti-Theft - Passive
      • 419-08 Cellular Phone
        • Description and Operation
          • Cellular Phone
          • Diagnosis and Testing
            • Cellular Phone
            • Removal and Installation
              • Cellular Phone Antenna
              • Handset Holder
      • 419-10 Multifunction Electronic Modules
        • Description and Operation
          • Diagnosis and Testing
            • Generic Electronic Module (GEM) - 2.0L Duratec-RS (Zetec)
            • Removal and Installation
              • Generic Electronic Module (GEM)
  • 5 Body and Paint
    • 501 Body and Paint
      • 501-00 Body System - General Information
        • 501-00 Body System - General Information|Specifications
        • Description and Operation
          • 501-00 Body System - General Information|Body
          • Diagnosis and Testing
            • Body System
      • 501-02 Front End Body Panels
        • 501-02 Front End Body Panels|Specifications
        • Description and Operation
          • Front End Body Panels
          • General Procedures
            • Hood Alignment
            • Removal and Installation
              • Cowl Panel Grille
              • Fender Splash Shield
              • General Procedures|Removal and Installation|Fender
      • 501-03 Body Closures
        • 501-03 Body Closures|Specifications
      • 501-05 Interior Trim and Ornamentation
        • 501-05 Interior Trim and Ornamentation|Specifications
        • Description and Operation
          • Interior Trim
          • Removal and Installation
            • A-Pillar Trim Panel
            • C-Pillar Trim Panel - 3-Door-5-Door-Wagon
            • B-Pillar Trim Panel
            • Front Door Trim Panel
            • Rear Quarter Trim Panel
            • Scuff Plate Trim Panel
            • Headliner - 2.0L Duratec-RS (Zetec)
      • 501-09 Rear View Mirrors
        • 501-09 Rear View Mirrors|Specifications
        • Description and Operation
          • Rear View Mirrors
          • Diagnosis and Testing
            • Rear View Mirrors
            • Removal and Installation
              • Exterior Mirror
      • 501-10 Seating
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Removal and Installation
          • Front Seat
          • Front Seat Backrest - 2.0L Duratec-RS (Zetec)
          • Rear Seat Backrest Latch - 2.0L Duratec-RS (Zetec)
          • Rear Seat Backrest
          • Disassembly and Assembly
            • Front Seat Cushion - 2.0L Duratec-RS (Zetec)
            • Front Seat Backrest - 2.0L Duratec-RS (Zetec)
            • Rear Seat Cushion - 2.0L Duratec-RS (Zetec)
            • Rear Seat Backrest - 2.0L Duratec-RS (Zetec)
      • 501-11 Glass, Frames and Mechanisms
        • Description and Operation
          • Glass, Frames and Mechanisms
          • Diagnosis and Testing
            • Glass, Frames and Mechanisms - 2.0L Duratec-RS (Zetec)
            • General Procedures
              • Door Window Motor Initialization
              • Removal and Installation
                • Front Door Window Glass - 2.0L Duratec-RS (Zetec)
                • Rear Window Glass - 2.0L Duratec-RS (Zetec)
                • Rear Quarter Window Glass - 2.0L Duratec-RS (Zetec)
                • Door Window Regulator Motor - 2.0L Duratec-RS (Zetec)
                • Front Door Window Regulator and Motor
                • Front Door Glass Top Run - 2.0L Duratec-RS (Zetec)
                • Windshield Glass - 2.0L Duratec-RS (Zetec)
        • 501-11 Glass, Frames and Mechanisms|Specifications
      • 501-12 Instrument Panel and Console
        • Removal and Installation
          • Instrument Panel - 2.0L Duratec-RS (Zetec)
          • Floor Console - 2.0L Duratec-RS (Zetec)
      • 501-14 Handles, Locks, Latches and Entry Systems
        • 501-14 Handles, Locks, Latches and Entry Systems|Specifications
        • Description and Operation
          • Handles, Locks, Latches and Entry Systems
          • Diagnosis and Testing
            • Locks, Latches and Entry Systems
            • General Procedures
              • Remote Transmitter Programming - Vehicles With: Radio Frequency Keyless Entry
              • Remote Transmitter Programming
              • Remote Keyless Entry Transmitter Programming
              • Removal and Installation
                • Hood Latch
                • Front Door Latch
                • Rear Door Latch
                • Liftgate Latch
                • Exterior Door Handle
                • Hood Lock Cylinder
                • Ignition Lock Cylinder - 2.0L Duratec-RS (Zetec)
                • Door Lock Cylinder
                • Door Latch Remote Control
                • Liftgate Lock Cylinder - 3-Door-4-Door-5-Door
      • 501-16 Wipers and Washers
        • Description and Operation
          • Wipers and Washers
          • Diagnosis and Testing
            • Wipers and Washers
            • General Procedures
              • Windshield Wiper Blade and Pivot Arm Adjustment
              • Removal and Installation
                • Windshield Wiper Motor
                • Rear Window Wiper Motor
                • Windshield Washer Pump and Reservoir
        • 501-16 Wipers and Washers|Specifications
      • 501-19 Bumpers
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Removal and Installation
          • Front Bumper Cover - 2.0L Duratec-RS (Zetec)
          • Rear Bumper Cover - 2.0L Duratec-RS (Zetec)
      • 501-20A Safety Belt System
        • 501-20A Safety Belt System|Specifications
        • Diagnosis and Testing
          • Safety Belt System
          • Removal and Installation
            • Rear Safety Belt Retractor - 2.0L Duratec-RS (Zetec)
            • Front Safety Belt Retractor - 2.0L Duratec-RS (Zetec)
            • Safety Belt Shoulder Height Adjuster - 2.0L Duratec-RS (Zetec)
            • Rear Center Safety Belt Retractor - 2.0L Duratec-RS (Zetec)
            • Safety Belt Buckle and Pretensioner
            • Safety Belt Buckle
      • 501-20B Supplemental Restraint System
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Diagnosis and Testing
          • Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
          • Diagnostic Instructions - Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) - 2.0L Duratec-RS (Zetec)
          • Pinpoint Tests - Air Bag Supplemental Restraint System (SRS) - 2.0L Duratec-RS (Zetec)
          • General Procedures
            • Deployed Air Bag Disposal
            • Unserviceable Air Bag Disposal
            • Scrapped Vehicle Undeployed Air Bag Disposal
            • Removal and Installation
              • Air Bag Control Module - 2.0L Duratec-RS (Zetec)
              • Driver Air Bag Module
              • Passenger Air Bag Module - 2.0L Duratec-RS (Zetec)
              • Clockspring
      • 501-25A Body Repairs - General Information
        • Description and Operation
          • Body Repairs
      • 501-25B Body Repairs - Corrosion Protection
        • Description and Operation
          • Corrosion Protection
      • 501-25C Body Repairs - Plastic Repairs
        • Description and Operation
          • Plastic Repairs
      • 501-25D Body Repairs - Water Leaks
        • Description and Operation
          • Water Leaks
      • 501-25E Body Repairs - Wind Noise
        • Description and Operation
          • Wind Noise
      • 501-25F Body Repairs - Paintless Dent Removal
        • Description and Operation
          • Paintless Dent Removal
      • 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks
        • Description and Operation
          • Body and Frame
          • General Procedures
            • Underbody Tolerance Check
            • Frame Tolerance Check
            • Body Tolerance Check
      • 501-25G Body Repairs - Noise, Vibration and Harshness
        • Description and Operation
          • Noise, Vibration and Harshness
      • 501-27 Front End Sheet Metal Repairs
        • Removal and Installation
          • Hood Hinge RH
          • Front Fender LH
          • Hood Latch Panel
          • Fender Apron Panel Reinforcement
          • Front Crossmember
          • Fender Apron Panel Inner Reinforcement
          • Front Side Member Section
          • Side Member Deformation Element
          • Front Side Member and Fender Apron Panel RH
      • 501-28 Roof Sheet Metal Repairs
        • 501-28 Roof Sheet Metal Repairs|Specifications
        • Removal and Installation
          • Roof Panel - 5-Door
      • 501-29 Side Panel Sheet Metal Repairs
        • 501-29 Side Panel Sheet Metal Repairs|Specifications
        • Removal and Installation
          • A-Pillar Outer Panel Section and Reinforcement
          • Rocker Panel - 3-Door
          • Door Half Hinge
          • Rocker Panel Front Section - 3-Door
          • B-Pillar and Reinforcement - 3-Door
      • 501-30 Rear End Sheet Metal Repairs
        • 501-30 Rear End Sheet Metal Repairs|Specifications
        • Removal and Installation
          • Quarter Panel - 2.0L Duratec-RS (Zetec)
          • Quarter-Side Panel Front Section - 3-Door
          • Quarter-Side Panel Rear Section LH - 3-Door
          • Inner Quarter Panel - 3-Door
          • Inner Quarter Panel Rear Section - 3-Door
          • Rear Outer Wheelhouse Half - 2.0L Duratec-RS (Zetec)
          • Back Panel - 5-Door
          • Rear Floor Panel - 5-Door
          • Rear Floor Panel Section - 5-Door
          • Rear Side Member Section - 5-Door
    • 502 Frame and Mounting
      • 502-00 Uni-Body, Subframe and Mounting System
        • Specifications - 2.0L Duratec-RS (Zetec)
        • Description and Operation
          • Frame Assembly
          • Removal and Installation
            • Crossmember - 2.0L Duratec-RS (Zetec)
• Body and Paint
  • 5 Body and Paint
    • 501 Body and Paint
      • 501-25A Body Repairs - General Information
        • Description and Operation
          • Body Repairs
      • 501-25C Body Repairs - Plastic Repairs
        • Description and Operation
          • Plastic Repairs
      • 501-25B Body Repairs - Corrosion Protection
        • Description and Operation
          • Corrosion Protection
      • 501-25D Body Repairs - Water Leaks
        • Description and Operation
          • Water Leaks
      • 501-25E Body Repairs - Wind Noise
        • Description and Operation
          • Wind Noise
      • 501-25F Body Repairs - Paintless Dent Removal
        • Description and Operation
          • Paintless Dent Removal
      • 501-25G Body Repairs - Noise, Vibration and Harshness
        • Description and Operation
          • Noise, Vibration and Harshness
      • 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks
        • Description and Operation
          • Body and Frame
          • General Procedures
            • Underbody Tolerance Check
            • Frame Tolerance Check
            • Body Tolerance Check
      • 501-27 Front End Sheet Metal Repairs
        • Removal and Installation
          • Front Fender LH
          • Click to view this Labor Time
          • Hood Hinge RH
          • Hood Latch Panel
          • Front Crossmember
          • Fender Apron Panel Reinforcement
          • Fender Apron Panel Inner Reinforcement
          • Front Side Member Section
          • Side Member Deformation Element
          • Front Side Member and Fender Apron Panel RH
      • 501-28 Roof Sheet Metal Repairs
        • Removal and Installation
          • Roof Panel - 5-Door
        • 501-28 Roof Sheet Metal Repairs|Specifications
      • 501-29 Side Panel Sheet Metal Repairs
        • 501-29 Side Panel Sheet Metal Repairs|Specifications
        • Removal and Installation
          • A-Pillar Outer Panel Section and Reinforcement
          • Door Half Hinge
          • Rocker Panel - 3-Door
          • Rocker Panel Front Section - 3-Door
          • B-Pillar and Reinforcement - 3-Door
      • 501-30 Rear End Sheet Metal Repairs
        • 501-30 Rear End Sheet Metal Repairs|Specifications
        • Removal and Installation
          • Quarter-Side Panel Front Section - 3-Door
          • Quarter Panel - 2.0L Duratec-RS (Zetec)
          • Quarter-Side Panel Rear Section LH - 3-Door
          • Inner Quarter Panel Rear Section - 3-Door
          • Inner Quarter Panel - 3-Door
          • Back Panel - 5-Door
          • Rear Outer Wheelhouse Half - 2.0L Duratec-RS (Zetec)
          • Rear Floor Panel Section - 5-Door
          • Rear Floor Panel - 5-Door
          • Rear Side Member Section - 5-Door