Mondeo 1993 (01.1993-07.1996) Workshop Manual Manual Pages - Full Index

Mondeo 1993 (01.1993-07.1996) Workshop Manual

• Mechanical Repairs
  • 1 General Information
    • 100 About this Manual
      • 100-01 Introduction
        • Description and Operation
          • 100-01 Introduction|General
      • 100-04 Feedback Forms
        • Description and Operation
          • What to Do if You Discover an Error
      • 100-03 How to Use this Manual
        • Description and Operation
          • Introduction
      • 100-02 Important Safety Instructions
        • Description and Operation
          • Introduction
    • 101 General Service Information
      • 101-01 Health and Safety Precautions
        • Description and Operation
          • Introduction
      • 101-02 Vehicle Identification
        • Description and Operation
          • Vehicle Identification (VIN) Plate Locations
      • 101-06 Road or Roller Testing
        • Description and Operation
          • Road or Roller Testing
      • 101-03 Standard Workshop Practices
        • Description and Operation
          • Vehicle in Workshop
      • 101-05 Solvents, Sealers and Adhesives
        • Description and Operation
          • Introduction
          • SpecificationsGeneral Specification
      • 101-04 Application and Use of Specifications
        • Description and Operation
          • Bolt Head Identification Marks ‐ Standard Hardware
  • 2 Chassis
    • 211 Wheels, Tyres
      • 211-01 Wheels, Tyres
        • SpecificationsGeneral Specifications
    • 212 Braking System, Traction Control
      • 212-01 Standard Braking System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 212-01 Standard Braking System|Description and Operation
          • Removal and Installation
            • Brake System – Hydraulic Fluid – Replace (12 154 0)
            • Disc – Front Brake – Remove and Install (one side) (12 223 0)
            • Brake Disc – Check Run‐out (both sides) (12 221 0)
            • Disc – Rear Brake – Remove and Install (one side) (12 225 0)
            • Caliper Assembly – Front – Remove and Install (one side) (12 243 0)
            • Caliper Assembly – Rear – Remove and Install (one side) (12 253 0)
            • Caliper Piston Housing – Front – Remove and Install (one side) (12 245 0)
            • Caliper Assembly – Rear – Remove and Install (one side) (Duratec‐VE Wagon) (12 253 0)
            • Cylinder – Rear Wheel – Remove and Install (one side) (12 305 0)
            • Sliding Mechanism – Rear Caliper – Replace (one side) (12 260 4)
            • Shoes – Rear Brake – Remove and Install (one side) (12 285 0)
            • Splash Shield – Rear – Remove and Install (Caliper Removed) (12 259 4)
            • Vacuum Pump – Remove and Install (12 414 0)
            • Brake Pedal – Remove and Install (12 333 0)
            • Brake Fluid Reservoir – Remove and Install (12 341 0)
            • Plate – Rear Brake Carrier – Remove and Install (one side) (12 313 0)
            • Connecting Link – Servo Operating – Remove and Install (12 338 0)
            • Servo – Remove and Install (12 451 0)
            • Lever Assembly – Handbrake (floor mounted) – Remove and Install (12 664 0)
            • Pressure Conscious Reducing Valve – Remove and Install (12 750 0)
            • Rear Cable – Handbrake – Replace (12 675 0)
            • Vacuum Hose – Servo – Replace (12 481 0)
      • 212-02 Anti‐Lock Braking System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 212-02 Anti‐Lock Braking System|Description and Operation
          • Removal and Installation
            • Hydraulic Unit (Mecatronic II) – Remove and Install (Duratec‐VE) (12 580 0)
            • Hydraulic Unit (Mecatronic II) – Remove and Install (12 580 0)
            • Hydraulic Unit (Mecatronic III) – Remove and Install (12 580 0)
            • Relay Box – Remove and Install (Duratec‐VE) (12 585 4)
            • Relay Box – Remove and Install (12 585 4)
            • Wheel Sensor – Remove and Install (one side) (12 785 0)
      • 212-03 Traction Control System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 212-03 Traction Control System|Description and Operation
          • Removal and Installation
            • Traction Control Motor – Remove and Install (12 795 0)
    • 213 Steering
      • 213-01 Power Assisted Steering
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 213-01 Power Assisted Steering|Description and Operation
          • Removal and Installation
            • Steering Gear Assembly - Remove and Install (All except LHD with ABS and Duratec‐VE) (13 116 0)
            • Bellows - Steering Rack - Replace (13 134 0)
            • Track Rod - Remove And Install (13 263 0)
            • Power Steering System - Bleed (13 416 1)
            • Steering Gear Assembly - Remove and Install (LHD with ABS and Duratec‐VE) (13 116 0)
            • Pump Assembly - Power Steering - Remove and Install (Diesel) (13 434 0)
            • Fluid Hoses - Power Steering - Remove and Install (All except LHD with ABS) (Zetec) (13 442 0)
            • Pump Assembly Power Steering - Remove and Install (Zetec) (13 434 0)
            • Pump Assembly - Power Steering - Remove and Install (Duratec‐VE) (13 434 0)
            • Fluid Hoses - Power Steering - Remove and Install (LHD with ABS) (Zeta) (13 442 0)
            • Fluid Hoses - Power Steering - Remove and Install (LHD with ABS)(Diesel) (13 442 0)
            • Fluid Cooler – Power Steering - Remove and Install (13 444 0)
            • Fluid Hoses - Power Steering - Remove and Install (All except LHD with ABS) (Diesel) (13 442 0)
            • Steering Column Assembly - Remove and Install (13 542 0)
            • Steering Wheel - Remove and Install (13 524 0)
            • Steering Wheel - Centralise (13 523 0)
            • Steering Column - Renew (13 543 0)
            • Flexible Coupling - Steering Column - Remove and Install (13 566 0)
    • 214 Front Axle, Suspension and Driveshafts
      • 214-01 Front Suspension
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 214-01 Front Suspension|Description and Operation
          • Removal and Installation
            • Toe‐In – Adjust (14 111 3)
            • Front Wheel Alignment – Check (14 111 0)
            • Subframe – Remove and Install (Duratec‐VE) (14 240 0)
            • Subframe – Remove and Install (14 240 0)
            • Arm Assembly – Lower – Left Side – Remove and Install (Manual Transmission only) (14 706 0)
            • Wheel Bearings – Front Inner and Outer – Replace (14 411 0)
            • Spindle Carrier – Remove and Install (14 343 0)
            • Bushes – Lower Arm – Replace (14 735 0)
            • Suspension Unit – Front – Remove and Install (14 781 0)
            • Arm Assembly – Lower – Right Side – Remove and Install (14 707 0)
            • Connecting Link – Stabiliser Bar – Remove and Install (14 757 0)
            • Suspension Unit – Replace (Suspension unit removed) (14 783 4)
      • 214-02 Front Axle and Driveshafts
        • SpecificationsGeneral Specifications
        • Removal and Installation
          • Seal - Inner - Left‐Hand Front Driveshaft - Renew (14 303 0)
          • Seal - Inner - Right‐Hand Front Driveshaft - Renew (14 304 0)
          • Driveshaft – Front Left – Remove and Install (14 320 0)
          • Driveshaft – Front Left – Overhaul (14 320 8)
          • Driveshaft – Front Right – Overhaul (14 321 8)
          • Driveshaft – Front Right – Remove and Install (14 321 0)
          • Bearing – Intermediate Shaft – Renew (14 331 4)
    • 215 Rear Axle and Suspension
      • 215-01 Rear Suspension (Saloon)
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 215-01 Rear Suspension (Saloon)|Description and Operation
          • Removal and Installation
            • Rear Wheel Toe Setting - Adjust (Saloon) (15 211 0)
            • Rear Axle Housing-Tube – Replace (Saloon) (15 216 0)
            • Stub Axle Rear – Remove and Install (Saloon) (15 363 0)
            • Lateral Arm - Front - Remove and Install (Saloon) (15 690 0)
            • Lateral Arm - Rear - Remove and Install (Saloon) (15 693 0)
            • Stabiliser Bar – Rear – Remove and Install (Saloon) (15 752 0)
            • Hub Assembly – Rear – Remove and Install (Saloon) (15 373 0)
            • Suspension Unit - Rear - Replace (Suspension unit removed) (Saloon) (15 783 4)
            • Suspension Unit – Rear – Remove and Install (Saloon) (15 781 0)
            • Tie Bar – Rear – Remove and Install (Saloon) (15 765 0)
      • 215-02 Rear Suspension (Wagon)
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 215-02 Rear Suspension (Wagon)|Description and Operation
          • Removal and Installation
            • Hub Assembly ‐ Rear ‐ Remove and Install (Wagon) (15 373 0)
            • Rear Axle and Suspension Assembly – Remove and Install (Wagon) (15 212 0)
            • Knuckle Assembly – Rear – Remove and Install (Wagon) (15 360 0)
            • Rear Wheel Toe Setting - Adjust (Wagon) (15 211 0)
            • Lower Arm - Rear Axle - Remove and Install (Wagon) (15 705 0)
            • Brace – Arm Support - Remove and Install (Wagon) (15 689 0)
            • Tie Bar ‐ Rear ‐ Remove and Install (Wagon) (15 765 0)
            • Stabiliser Bar - Rear Axle - Remove and Install (Wagon) (15 752 0)
            • Upper Arm - Rear Axle - Remove and Install (Wagon) (15 701 0)
            • Shock Absorber - Rear - Remove and Install (Wagon) (15 791 0)
            • Lateral Arm - Front - Remove and Install (Wagon) (15 690 0)
      • 215-03 Rear Axle and Suspension 4 x 4
        • SpecificationsGeneral Specifications
        • Removal and Installation
          • Rear Axle and Suspension Assembly - Remove and Install (15 212 0)
          • Rear Axle Assembly - Remove and Install (15 214 0)
          • Rear Axle Housing-Tube - Renew (15 216 0)
          • Shaft - Rear Axle - Remove and Install (15 321 0)
          • Spindle Carrier - Rear - Remove and Install (15 360 0)
          • Wheel Bearings - Inner and Outer - Renew (15 413 4)
          • Hub Assembly - Rear - Remove and Install (15 373 0)
          • Stub Axle Shaft - Rear - Remove and Install (15 366 0)
          • Lower Suspension Arm - Rear - Remove and Install (15 693 0)
          • Lower Suspension Arm - Front - Remove and Install (15 690 0)
          • Tie Bar - Rear - Remove and Install (15 765 0)
          • Stabiliser Bar - Rear - Remove and Install (15 752 0)
          • Bushes - Spindle Carrier - Renew - One Side (all) (15 768 4)
          • Stabiliser Bar Linkage - Remove and Install (15 755 0)
          • Bushes - Stabiliser Bar to Rear Axle - Renew (15 754 0)
          • Suspension Unit Assembly - Rear - Remove and Install (15 781 0)
  • 3 Powertrain
    • 316 Manual Transmission and Clutch
      • 316-01 MTX‐75 Transmission and Clutch
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 316-01 MTX‐75 Transmission and Clutch|Description and Operation
          • Removal and Installation
            • Transmission Assembly – Remove and Install (with Zetec engine) (16 114 0)
            • Transmission Assembly - Remove and Install (16 114 0) (with 2,5 Duratec‐VE)
            • Selector Mechanism - Dismantle and Assemble (16 284 8)
            • Transmission Assembly – Dismantle and Assemble (16 118 8)
            • Clutch Pedal Free Travel – Adjust (16 713 0)
            • Gearshift Linkage - Dismantle and Assemble (16 534 8)
            • Clutch Disc and Pressure Plate – Remove and Install (16 724 4)
            • Master Cylinder - Clutch - Remove and Install (16 856 0)
            • Hydraulic Clutch System - Bleed (16 843 0)
            • Slave Cylinder - Clutch - Remove and Install (16 862 0)
      • 316-02 Transfer Box
        • SpecificationsGeneral Specifications
        • Removal and Installation
          • Transfer Box - Remove and Install (16 331 0)
    • 317 Automatic Transmission
      • 317-01 CD4E Automatic Transmission
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 317-01 CD4E Automatic Transmission|Description and Operation
          • Removal and Installation
            • General Specifications
            • Plug - Line Pressure – Remove and Install (17 120 0)
            • Automatic Transmission Assembly - Remove and Install (1,8 and 2,0 Zetec) (17 214 0)
            • Automatic Transmission Assembly - Remove and Install (2,5 Duratec‐VE) (17 214 0)
            • Automatic Transmission Assembly - Dismantle and Reassemble (17 214 8)
            • Cover – Valve Body – Remove and Install (17 233 0)
            • Speedometer Drive Gear – Remove and Install (17 382 0)
            • Valve Body Assembly - Overhaul (17 234 8)
            • Cover – Servo Assembly – Remove and Install (17 260 0)
            • Transmission Speed Sensor (TSS) – Remove and Install (17 700 0)
            • Transmission Range Sensor - Remove and Install (17 705 0)
            • Selector Mechanism – Transmission – Remove and Install (17 675 0)
            • Gear Selector Mechanism - Dismantle and Reassemble (17 634 8)
            • Gear Selector Mechanism - Remove and Install (17 634 0)
    • 321 Basic Engine
      • 321-01 DOHC 16V Engine (Zetec-Zetec‐E)
        • SpecificationsGeneral Specifications
        • Removal and Installation
          • Compression - Engine Hot - Check (21 111 0)
          • Oil Pressure - Engine Hot - Check (21 113 0)
          • Engine and Transmission Assembly (MTX 75) - Remove and Install (21 132 0)
          • Engine and Transmission Assembly (CD4E) - Remove and Install (21 132 0)
          • Engine and Transmission Assembly - Align (21 133 0)
          • Engine – Dismantle and Reassemble (21 134 8)
          • Cylinder Head – Remove and Install (21 163 0)
          • Renew Cylinder Head (Cylinder head removed) (21 165 6)
          • Inlet Manifold Assembly - Remove and Install (21 183 0)
          • Valves – Remove and Install (all) (21 217 4)
          • Camshafts - Remove and Install (both) (21 284 0)
          • Seals - Valve Stem – Renew (all) (21 238 0)
          • Seal - Camshafts – Renew (One) (21 288 0)
          • Timing Belt – Renew (21 304 0)
          • Seal - Crankshaft Rear - Renew (21 468 4)
          • Seal - Crankshaft Front - Renew (21 467 0)
      • 321-02 1,8 TCI Diesel Engine
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 321-02 1,8 TCI Diesel Engine|Description and Operation
          • Removal and Installation
            • Compression - Engine Hot - Check (21 111 0)
            • Oil Pressure - Check - Engine (21 113 0)
            • Engine and Transmission Assembly (MTX 75) - Remove and Install (21 132 0)
            • Engine – Dismantle and Reassemble (21 134 8)
            • Cylinder Head – Remove and Install (21 163 0)
            • Valve Clearances - Adjust (21 213 0)
            • Seal - Camshaft - Replace (21 288 0)
            • Seals - Valve Stem – Renew (all) (21 238 0)
            • Seal - Auxiliary Shaft - Renew (21 556 0)
            • Seal - Crankshaft Front - Renew (21 467 0)
            • Timing Belt - Renew (21 304 0)
    • 323 Fuel System
      • 323-01 General Fuel System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 323-01 General Fuel System|Description and Operation
          • Removal and Installation
            • Element – Air Cleaner – Replace (23 184 0)
            • Air Cleaner Assembly – Remove and Install (23 174 0)
            • Fuel Filter – Remove and Install (Petrol Variants) (23 545 0)
            • Fuel Pump – Remove and Install (4x4 Variants) (23 534 0)
            • Fuel Pump – Remove and Install (4x2 Variants) (23 534 0)
            • Fuel Tank – Remove and Install (4x2 variants) (23 554 0)
            • Element – Fuel Filter – Replace (Diesel Variants) (23 546 0)
            • Fuel Filter – Remove and Install (Diesel Variants) (23 545 0)
            • Fuel Tank – Remove and Install (4x4 Saloon Variants) (23 554 0)
            • Fuel Tank – Remove and Install (4x4 Wagon Variants) (23 554 0)
            • Valve – Roll Over – Remove and Install (23 576 0)
            • Cable – Accelerator – Adjust (Variants Without Traction Control) (23 811 0)
            • Heater – Diesel Fuel – Remove and Install (23 769 0)
            • Fuel Tank Filler Pipe – Remove and Install (23 572 0)
            • Switch – Fuel Shut‐Off – Remove and Install (33 577 0)
            • Cable – Accelerator – Remove and Install (Vehicles With Traction Control) (23 826 0)
            • Cable – Accelerator – Adjust (Vehicles With Traction Control) (23 811 0)
            • Cable – Accelerator – Remove and Install (Diesel Variants) (23 826 0)
            • Cable – Accelerator – Remove and Install (Vehicles Without Traction Control) (23 826 0)
            • Cable – Accelerator – Adjust (Diesel Variants) (23 811 0)
      • 323-02 Petrol Injection Equipment
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 323-02 Petrol Injection Equipment|Description and Operation
          • Removal and Installation
            • Regulator – Fuel Pressure – Remove and Install (23 266 0)
            • Fuel Injectors – Remove and Install (23 455 0)
      • 323-03 Petrol Injection Equipment – Duratec‐VE Engines
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 323-03 Petrol Injection Equipment – Duratec‐VE Engines|Description and Operation
          • Removal and Installation
            • Regulator – Fuel Pressure – Remove and Install (23 266 0)
            • Fuel Injectors – Remove and Install (23 455 0)
      • 323-04 Petrol Injection Equipment – Duratec‐VE Engines
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 323-04 Petrol Injection Equipment – Duratec‐VE Engines|Description and Operation
          • Removal and Installation
            • Regulator – Fuel Pressure – Remove and Install (23 266 0)
            • Fuel Injectors – Remove and Install (23 455 0)
    • 324 Cooling System
      • 324-01 DOHC 16V Engines (Zetec)
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 324-01 DOHC 16V Engines (Zetec)|Description and Operation
          • Removal and Installation
            • Radiator – Remove and Install (24 254 0)
            • Fan – Remove and Install (24 212 0)
            • Cooling System ‐ Pressure Test (24 111 0)
            • Cooling System - Drain And Refill (24 122 0)
            • Thermostat – Remove and Install (24 454 0)
            • Water Pump Assembly – Remove and Install (24 404 0)
      • 324-02 1,8 l TC Diesel Engine
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 324-02 1,8 l TC Diesel Engine|Description and Operation
          • Removal and Installation
            • Radiator – Remove and Install (24 254 0)
            • Fan – Remove and Install (24 212 0)
            • Cooling System – Pressure Test (24 111 0)
            • Cooling System - Drain And Refill (24 122 0)
            • Thermostat – Remove and Install (24 454 0)
            • Water Pump Assembly – Remove and Install (24 404 0)
      • 324-03 2,5 l Duratec‐VE Engine
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 324-03 2,5 l Duratec‐VE Engine|Description and Operation
          • Removal and Installation
            • Fan – Remove and Install (24 212 0)
            • Cooling System ‐ Pressure Test (24 111 0)
            • Cooling System - Drain And Refill (24 122 0)
            • Tensioner - Drive Belt - Remove and Install (24 401 0)
            • Expansion Tank - Remove and Install (24 284 0)
            • Radiator - Remove And Install (24 254 0)
            • Water Pump Assembly – Remove and Install (24 404 0)
            • Thermostat - Remove and Install (24 454 0)
    • 325 Exhaust System
      • 325-01 Exhaust System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 325-01 Exhaust System|Description and Operation
          • Removal and Installation
            • Catalyst (DOHC 16V and 1,8 Diesel) – Remove and Install (25 250 0)
            • Exhaust System (2,5 I Duratec‐VE (4x4 Wagon)) - Renew (25 205 0)
            • Exhaust System (DOHC 16v, 25 l Duratec‐VE (4x2 and 4x4) and 1,8 Diesel) - Renew 25 205 0
            • Catalyst (2,5 l Duratec‐VE) - Remove and Install (25 250 0)
    • 326 Starting System
      • 326-01 Starting System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 326-01 Starting System|Description and Operation
          • Removal and Installation
            • Starter Motor (Zetec) - Remove And Install (26 204 0)
            • Starter Motor (Diesel) - Remove And Install (26 204 0)
            • Starter Motor (2,5 l Duratec‐VE) - Remove And Install (26 204 0)
    • 329 Engine Management
      • 329-01 DOHC 16V Engines (Zeta)
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 329-01 DOHC 16V Engines (Zeta)|Description and Operation
          • Removal and Installation
            • Sensor – Engine Coolant Temperature – Remove and Install (23 190 0)
            • Pipe – Exhaust Manifold to EGR Valve – Remove and Install (23 301 0)
            • Exhaust Gas Recirculation Valve – Remove and Install (23 312 0)
            • Electronic Pressure Transducer (EGR System) – Remove and Install (23 313 0)
            • Electronic Pressure Transducer (Pulse Air System) – Remove and Install (23 313 0)
            • Pulse Air Delivery Tubing – Remove and Install (23 316 0)
            • Idle Speed Control Valve – Remove and Install (23 323 0)
            • Control Module – Engine Management – Remove and Install (29 200 0)
            • Pulse Air Filter – Remove and Install (23 318 0)
            • Sensor – HEGO – Remove and Install (29 220 0)
            • Throttle Position Sensor – Remove and Install (23 325 0)
            • Control Module – EDIS – Remove and Install (29 205 0)
            • Sensor – Camshaft Identification – Remove and Install (29 232 0)
            • Carbon Canister – Remove and Install (4x2 Variants) (29 250 0)
            • Sensor – Mass Air Flow – Remove and Install (29 226 0)
            • Differential Pressure Transducer – Exhaust Feed – Remove and Install (29 242 0)
            • Sensor – Crankshaft Position – Remove and Install (29 230 0)
            • Carbon Canister – Remove and Install (Wagon and 4x4 Variants) (29 250 0)
            • Sensor – Air Charge Temperature – Remove and Install (29 622 0)
            • Solenoid – Current Load Control – Remove and Install (33 759 0)
            • Solenoid – Canister Purge – Remove and Install (33 772 0)
      • 329-02 1,8 l TCI Diesel Engine
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 329-02 1,8 l TCI Diesel Engine|Description and Operation
          • Removal and Installation
            • Temperature Sensor – Engine Coolant – Remove and Install (23 190 0)
            • Control Module – Engine Management – Remove and Install (29 200 0)
            • Sensor – Crankshaft Position – Remove and Install (29 230 0)
            • EGR Vacuum Flow Controller (CVT) – Remove and Install (29 260 0)
            • EGR Actuator – Remove and Install (23 312 0)
            • Actuator – Idle Speed Adjust – Reverse Gear – Remove and Install (29 315 0)
      • 329-03 Engine Management – Duratec‐VE Engines
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 329-03 Engine Management – Duratec‐VE Engines|Description and Operation
          • Removal and Installation
            • Exhaust Gas Recirculation Valve – Remove and Install (23 312 0)
            • Module – Powertrain Control– Remove and Install (29 200 0)
            • Valve – Idle Air Control – Remove and Install (23 323 0)
            • Regulator – Exhaust Gas Recirculation Vacuum – Remove and Install (23 313 0)
            • Module – Electronic Ignition System – Remove and Install (29 205 0)
            • Carbon Canister – Remove and Install (Wagon and 4x4 Variants) (29 250 0)
            • Sensor – Intake Air Temperature – Remove and Install (29 622 0)
            • Carbon Canister – Remove and Install (4x2 Variants) (29 250 0)
            • Sensor – Camshaft Position – Remove and Install (29 232 0)
            • Sensor – Crankshaft Position – Remove and Install (29 230 0)
  • 4 Electrical
    • 431 Charging System
      • 431-01 Charging System
        • Description and Operation
          • 431-01 Charging System|Description and Operation
          • Removal and Installation
            • Alternator Assembly (DOHC 16V Zeta) – Remove and Install (31 414 0)
            • Alternator Assembly (Diesel) – Remove and Install (31 414 0)
            • Regulator (Ford) – Remove and Install (31 514 0)
            • Alternator Assembly (2,5 l Duratec - VE) - Remove and Install (31 414 0)
            • Regulator (Bosch) – Remove and Install (31 514 0)
            • Tensioner – Drive Belt – Alternator (Diesel) – Remove and Install (31 415 0)
            • Tensioner – Drive Belt – Alternator (DOHC 16V Zeta) – Remove and Install (31 415 0)
        • SpecificationsGeneral Specification
    • 432 Exterior Electrical System
      • 432-01 Exterior Electrical Systems
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 432-01 Exterior Electrical Systems|Description and Operation
          • Removal and Installation
            • Headlamp and Bracket Assembly - Remove and Install (32 120 0)
            • Rear Lamp Assembly - Remove and Install (32 305 0)
            • Headlamp Assembly - Renew (one side) (Headlamp and Bracket Assembly removed) (32 121 4)
            • Headlamps - Align (both sides) (32 113 0)
            • Motor – Windscreen Wiper – Remove and Install (32 524 0)
            • Linkage - Windscreen Wiper - Remove and Install (32 554 0)
            • Wiper Arm - Adjust (All) (32 591 0)
    • 433 Interior Electrical System
      • 433-01 Basic Interior Electrical System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 433-01 Basic Interior Electrical System|Description and Operation
          • Removal and Installation
            • Lamp - Interior (Front) - Remove and Install (33 112 0)
            • Bulb - Heater Motor Switch - Replace (33 120 0)
            • Bulb - Glove Compartment Lamp - Replace (33 118 0)
            • Bulb – Light Switch Illuminating – Replace (33 129 0)
            • Bulb – Heater Control Illuminating – Replace (33 128 0)
            • Lamp - Interior (Rear) - Remove and Install (33 112 0)
            • Lamp - Interior (Front) (High‐Series) - Remove and Install (33 112 0)
            • Bulb - Hazard Warning - Replace (33 146 0)
            • Instrument Cluster Assembly - Remove and Install (33 214 0)
            • Bulb - Quadrant Lamp - Replace (33 134 0)
            • Bulb - Display Assembly Warning Indicator (Front and Rear Fog Lamps) - Replace (33 135 0)
            • Bulb – Interior Door Handle Illuminating - Replace (33 159 0)
            • Lamp - Luggage Compartment - Remove and Install (33 156 0)
            • Bulb - Vanity Mirror Lamp - Replace (33 133 0)
            • Cable – Speedometer to Speed Sender Unit - Remove and Install (33 257 0)
            • Sender Unit - Fuel Tank - Remove And Install (4x4 Variants) (33 286 0)
            • Shaft – Speedometer - Remove and Install (33 255 0)
            • Sender Unit - Temperature - Remove and Install (33 306 0)
            • Printed Circuit - Instrument Cluster - Remove and Install (Instrument Cluster Removed) (33 224 4)
            • Clock – Remove and Install (33 374 0)
            • Slip Ring - Horn - Remove and Install (33 391 0)
            • Cigarette Lighter Assembly - Remove and Install (33 384 0)
            • Lock Barrel Ignition Switch - Remove and Install (33 513 0)
            • Clockspring – Air Bag Control – Remove and Install (33 392 0)
            • Contact Finger - Horn Slip Ring - Remove and Install (33 390 0)
            • Switch - Dipper - Remove and Install (33 516 0)
            • Switch – Headlamp Levelling – Remove and Install (33 515 0)
            • Switch – Instrument Cluster Light - Remove and Install (33 518 0)
            • Switch - Light - Remove and Install (33 514 0)
            • Lock Barrel - Ignition - Overhaul (Barrel Removed) (33 513 8)
            • Switch – Direction Indicator - Remove and Install (33 522 0)
            • Switch – Door Mirror Control - Remove and Install (33 519 0)
            • Switch - Isolator - Window Operating - Remove and Install (33 531 0)
            • Switch – Sliding Roof Operating - Remove and Install (33 536 0)
            • Switch – Horn (Steering Wheel Without Air Bag) - Remove and Install (33 523 0)
            • Switch (Single) - Window Operating - Remove and Install (33 532 0)
            • Switch – Luggage Compartment Lamp - Remove and Install (33 529 0)
            • Switch (Multiple) - Window Operating - Remove and Install (33 532 0)
            • Switch – Back‐Up Lamp - Remove and Install (MTX‐75 only) (33 528 0)
            • Switch – Windscreen Wiper - Remove and Install (33 542 0)
            • Switch – Wiper Delay Control - Remove and Install (33 543 0)
            • Switch – Headlamp Wash - Remove and Install (33 545 0)
            • Switch – Brake Fluid Warning Light - Remove and Install (33 552 0)
            • Switch – Rear Wash-Wiper – Remove and Install (33 547 0)
            • Switch – Handbrake Warning Light - Remove and Install (33 546 0)
            • Switch – Stop Light - Remove and Install (33 548 0)
            • Switch – Windscreen Washer - Remove and Install (33 544 0)
            • Switch - Auxiliary-Fog Lamp - Remove and Install (33 556 0)
            • Switch - Fog Lamp Rear - Remove and Install (33 557 0)
            • Switch – Oil Pressure Warning Light - Remove and Install (33 554 0)
            • Switch - Hazard Flasher - Remove and Install (33 558 0)
            • Switch – Thermal – Radiator Fan – Remove and Install (33 555 0)
            • Switch – Overdrive Control – Remove and Install (33 562 0)
            • Control Assembly – Radiator Fan Speed – Remove and Install (33 640 0)
            • Switch - Traction Control - Remove and Install (33 609 0)
            • Vehicle Speed Sensor Unit (Cable Operated) – Remove and Install (33 654 0)
            • Switch – Heated Front Seat - Remove and Install (33 587 0)
            • Switch – Heated Rear Window - Remove and Install (33 572 0)
            • Switch – Adaptive Damping - Remove and Install (33 615 0)
            • Switch – Heated Front Window - Remove and Install (33 571 0)
            • Switch – Front Seat - Height Adjust – Remove and Install (33 585 0)
            • Module – Adaptive Damping – Remove and Install (33 648 0)
            • Relay – Horn - Remove and Install (33 737 0)
            • Vehicle Speed Sensor Unit - Remove And Install (Electrically Operated) (33 654 0)
            • Relay – Heated Rear Screen - Remove and Install (33 726 0)
            • Motor – Window Operating - Front Door - Remove and Install (33 782 0)
            • Relay – Sliding Roof - Remove and Install (33 718 0)
            • Relay – Window Operating (One Touch Down) - Remove and Install (33 732 0)
            • Motor – Window Operating – Rear Door – Remove and Install (33 783 0)
            • Steering Sensor – Adaptive Damping – Remove and Install (33 657 0)
            • Motor – Sliding Roof Operating - Remove and Install (33 786 0)
            • Motor –Seat Operating (Height Adjust ) - Front Seat - Remove and Install (33 784 0)
      • 433-02 Auxiliary Warning System
        • Description and Operation
          • 433-02 Auxiliary Warning System|Description and Operation
          • Removal and Installation
            • Bulb – Display Assembly Warning – Replace (33 135 0)
            • Sensor – Oil Level – Remove and Install (33 311 0)
            • Sender Unit – Low Air Temperature Warning – Remove and Install (33 309 0)
            • Switch – Low Coolant Warning - Remove and Install (33 606 0)
            • Control Assembly – Delay-Warning Systems - (Central Timer) – Remove and Install (33 638 0)
            • Switch - Low Washer Fluid - Remove and Install (33 607 0)
            • Switch – Luggage Compartment Lid Ajar – Remove and Install (33 509 0)
            • Display Assembly - Indicator Warning - Remove and Install (33 367 0)
            • Switch – Door Ajar – Remove and Install (33 507 0)
            • Switch – Reset – Service Indicator Lamp – Remove and Install (33 620 0)
            • Switch – Tailgate Ajar – Remove and Install (33 508 0)
            • Module – System Interface – Remove and Install (33 649 0)
            • Module – Bulb Failure – Remove and Install (33 642 0)
        • SpecificationsGeneral Specification
      • 433-03 Anti‐Theft Alarm and Double Locking Systems
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 433-03 Anti‐Theft Alarm and Double Locking Systems|Description and Operation
          • Removal and Installation
            • Switch – Hood Alarm – Remove and Install (33 539 0)
            • Switch – Anti‐Theft Alarm Inhibit - Luggage Compartment – Remove and Install (33 535 0)
            • Sensor – Scanner – Alarm System – Remove and Install (33 658 0)
            • Module – Anti‐Theft Alarm-Double Locking – Remove and Install (33 644 0)
            • Switch – Door Lock – Key Activated – Alarm System – Remove and Install (33 506 0)
            • Flasher Relays – Alarm System – Remove and Install (33 729 0)
            • Buzzer – Alarm System – Remove and Install (33 775 0)
            • Motor – Isolator - Tailgate-Luggage Compartment Lock – Remove and Install (33 789 0)
            • Sensor – Remote Control – Alarm System – Remove and Install (33 659 0)
            • Horn – Alarm System – Remove and Install (33 774 0))
      • 433-05 Speed Control
        • Description and Operation
          • 433-05 Speed Control|Description and Operation
          • Removal and Installation
            • Speed Sender Unit - Remove and Install (33 654 0)
            • Switch – Disengage – Speed Control – Remove and Install (33 502 0)
            • Actuator – Speed Control – Remove and Install (33 678 0)
            • Switch – Speed Control – Remove and Install (33 500 0)
      • 433-04 Trip Computer
        • Description and Operation
          • 433-04 Trip Computer|Description and Operation
          • Removal and Installation
            • Speed Sender Unit - Remove and Install (33 654 0)
            • Trip Computer Module ‐ Remove and Install (33 651 0)
    • 434 Heating and Ventilation
      • 434-01 Heating and Ventilation
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 434-01 Heating and Ventilation|Description and Operation
          • Removal and Installation
            • Regulator – Temperature Control – Remove and Install (34 321 0)
            • Switch - Blower Motor - Heater - Remove and Install (33 574 0)
            • Blower Motor - Heater - Remove and Install (34 374 0)
            • Radiator - Heater - Remove and Install (36 364 0)
            • Resistor Assembly – Blower Motor – Remove and Install (34 382 0)
            • Heater Assembly – Remove and Install (34 354 0)
            • Heater Assembly – Dismantle and Assemble (34 354 8) (Housing Removed)
            • Vent - Face Level (Driver Side) - Remove and Install (34 487 0)
            • Actuator - Air Supply - Footwell-Face Vents - Remove and Install (34 591 0)
            • Actuator - Air Supply - Defrost Vents - Remove and Install (34 590 0)
            • Vacuum Actuator - Air Supply - Recirculation-Fresh Air - Remove and Install (34 592 0)
            • Vent-Instrument Cluster Bezel (Driver Side) - Remove and Install (34 488 0)
            • Regulator – Air Distribution – Remove and Install (34 499 0)
      • 434-02 Air Conditioning
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 434-02 Air Conditioning|Description and Operation
          • Removal and Installation
            • Control Panel - Heating-Air Conditioning - Remove and Install (34 300 0)
            • Refrigerant Lines – Disconnect and Connect (Air Conditioning Drained)
            • Solenoid - Vacuum Actuator - Air Supply - Remove and Install (34 595 0)
            • Refrigerant - Air Conditioning - Drain and Refill (34 620 0)
            • Compressor – Air Conditioning – Remove and Install (34 626 0)
            • Low Pressure Contact Switch - Remove and Install (34 629 0)
            • Actuator - Recirculation Flap - Air Conditioning - Remove and Install (34 606 0)
            • Clutch - Compressor - Air Conditioning - Remove and Install (34 628 0)
            • Evaporator – Air Conditioning – Remove and Install (34 622 0)
            • Condenser – Air Conditioning – Remove and Install (34 632 0)
            • Line - Accumulator-Dehydrator to Condenser - Remove and Install (34 643 0)
            • Line - Accumulator-Dehydrator to Evaporator - Remove and Install (34 644 0)
            • Accumulator-Dehydrator - Air Conditioning - Remove and Install (34 630 0)
            • High Pressure Contact Switch - Remove and Install (34 631 0)
            • Sensor - Interior Temperature - Windscreen Demister - Remove and Install (34 673 0)
            • Sensor - Interior Temperature - Centre Console - Remove and Install (34 670 0)
            • Sensor - Interior Temperature - Centre Vent - Remove and Install (34 672 0)
            • Line - Evaporator to Condenser - Remove and Install (34 645 0)
            • Sensor - Interior Temperature - Footwell - Remove and Install (34 671 0)
            • Thyristor - Automatic Temperature Control - Remove and Install (34 677 0)
            • Module - Air Conditioning (Electronic-pneumatic) - Remove and Install (34 681 0)
            • Sensor - Exterior Temperature - Automatic Temperature Control - Remove and Install (34 676 0)
    • 438 Audio Systems
      • 438-01 In‐Car Entertainment
        • Description and Operation
          • 438-01 In‐Car Entertainment|Description and Operation
          • Removal and Installation
            • Compact Disc (CD) Player – Remove and Install (38 445 0)
            • Radio Loudspeaker – Front Door – Remove and Install (one) (38 268 0)
            • Control Unit – CD Player Autochanger – Remove and Install (38 447 0)
            • Radio Receiver – Remove and Install (38 212 0)
            • Radio Receiver-Cassette Player – Remove and Install (38 222 0)
            • Radio Loudspeaker – Rear Door – Remove and Install (one) (38 270 0)
            • Power Amplifier – Radio-Cassette – Remove and Install (38 456 0)
            • Autochanger – CD Player – Remove and Install (38 447 0)
            • Aerial ‐ Radio ‐ Manual ‐ Remove and Install (38 352 0)
            • Low Frequency Unit – Load Space – Remove and Install (hatchback variants only) (38 286 0)
            • Low Frequency Unit – Load Space – remove and Install (notchback variants only) (38 286 0)
  • 5 Body and Paint
    • 540 Seats, Seat Belts, Air Bags
      • 540-01 Seats
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 540-01 Seats|Description and Operation
          • Removal and Installation
            • Air Cushion – Front Seat – Remove and Install (40 110 0)
            • Cover and Pad Assembly – Cushion – Front Seat – Remove and Install (40 104 0)
            • Cover and Pad Assembly – Backrest – Front Seat – Remove and Install (40 106 0)
            • Seat Assembly – Front Bucket – Remove and Install (40 100 0)
            • Cover and Pad Assembly – Cushion – Rear Seat – Remove and Install (40 124 0)
            • Side Bolster – Rear Seat Backrest – Remove and Install (40 135 0)
            • Cover and Pad Assembly – Backrest – Rear Seat – Remove and Install (40 127 0)
            • Backrest – Rear Seat – Remove and Install (40 128 0)
            • Stowage Tray – Front Seat – Remove and Install (40 116 0)
            • Slide – Front Seat (Manual) – Replace (40 420 0)
            • Slide – Front Seat (Powered) – Replace (40 420 0)
            • Cushion – Rear Seat – Remove and Install (40 122 0)
            • Catch – Rear Seat Back – Remove and Install (40 534 0)
      • 540-03 Air Bags
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 540-03 Air Bags|Description and Operation
          • Removal and Installation
            • Module – Passenger Side – Air Bag – Remove and Install (40 701 0)
            • Module – Driver Side – Air Bag – Remove and Install (40 700 0)
            • Control Module – Air Bag – Remove and Install (33 650 0)
            • Module ‐ Air Bag(s) ‐ Deploy (40 702 0)
      • 540-02 Seat Belts
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 540-02 Seat Belts|Description and Operation
          • Removal and Installation
            • Belt and Stalk – Front Seat – Remove and Install (40 212 0)
            • Belt and Stalk – Rear Seat – Remove and Install (40 240 0)
    • 541 Body Closures
      • 541-01 Body Closures
        • SpecificationsGeneral Specifications
        • Description and Operation
          • Descrition and Operation
          • Removal and Installation
            • Cable – Hood Release – Remove and Install (41 224 0)
            • Lock Assembly – Hood – Remove and Install (41 232 0)
            • Sliding Roof Assembly – Remove and Install (41 114 0)
            • Hood Assembly – Remove and Install (41 214 0)
            • Bump Rubber – Hood – Remove and Install (41 253 0)
            • Weatherstrip – Hood – Remove and Install (41 252 0)
            • Door Assembly – Front – Remove and Install (41 315 0)
            • Handle – Door Exterior – Front – Remove and Install (41 333 0)
            • Door Assembly – Rear – Remove and Install (41 317 0)
            • Handle – Door Exterior – Rear – Remove and Install (41 333 0)
            • Barrel – Door Lock – Remove and Install (41 336 0)
            • Lock Assembly – Front Door – Remove and Install (41 351 0)
            • Strap – Door Check – Remove and Install (41 364 0)
            • Plate – Door Striker – Remove and Install (41 356 0)
            • Lock Assembly – Rear Door – Remove and Install (41 352 0)
            • Handle – Door Remote Control – Remove and Install (41 334 0)
            • Barrel – Tailgate Lock (Estate) – Remove and Install (41 664 0)
            • Barrel – Luggage Compartment Lock – Remove and Install (41 724 0)
            • Tailgate Assembly (Hatchback) – Remove and Install (41 654 0)
            • Weatherstrip – Door Aperture – Replace (41 375 0)
            • Tailgate Assembly (Estate) – Remove and Install (41 654 0)
            • Barrel – Tailgate Lock (Hatchback) – Remove and Install (41 664 0)
            • Lock Assembly – Tailgate (Hatchback) – Remove and Install (41 666 0)
            • Damper Assembly – Tailgate – Remove and Install (41 685 0)
            • Lock – Luggage Compartment – Remove and Install (41 726 0)
            • Lock Assembly – Tailgate (Estate) – Remove and Install (41 666 0)
            • Plate – Tailgate Striker (Estate) – Remove and Install (41 674 0)
            • Lid Assembly – Luggage Compartment – Remove and Install (41 714 0)
            • Flap – Fuel Filler – Remove and Install (41 816 0)
    • 542 Windows
      • 542-01 Windows
        • Description and Operation
          • 542-01 Windows|Description and Operation
          • Removal and Installation
            • Glass – Door Window – Front – (Powered) – Remove and Install (42 314 0)
            • Windscreen – Remove and Install (42 114 0)
            • Glass – Door Window – Front – (Manual) – Remove and Install (42 314 0)
            • Glass – Door Window – Rear – (Manual) – Remove and Install (42 315 0)
            • Runs - Window - Rear Door - (Silent Channel) - Replace (42 334 0)
            • Regulator Assembly – Door Window – (Front) – Remove and Install (42 338 0)
            • Runs – Window – Front Door - (Silent Channel) - Replace (42 333 0)
            • Glass – Door Window – Rear – (Powered) – Remove and install (42 315 0)
            • Regulator Assembly – Door Window – (Rear) – Remove and Install (42 338 0)
            • Glass – Rear Window – Remove and Install (42 614 0)
            • Glass – Fixed Rear Quarter Window – (Estate) – Remove and Install (42 514 0)
            • Glass – Tailgate Window – Remove and Install (Hatchback) (42 654 0)
            • Glass – Tailgate Window – Remove and Install (Estate) (42 654 0)
        • SpecificationsGeneral Specification
    • 543 Interior and Exterior Trim
      • 543-01 Interior Trim
        • SpecificationsGeneral Specification
        • Removal and Installation
          • Headlining – Replace (43 612 0)
          • `A Pillar Trim – Remove and Install (43 616 0)
          • Crash Padding – Facia – Remove and Install (43 644 0)
          • `C Pillar Trim – Remove and Install (Hatchback) (43 618 0)
          • `C Pillar Trim – Remove and Install (Estate) (43 618 0)
          • `D Pillar Trim – Remove and Install (43 619 0)
          • `B Pillar Trim – Remove and Install (43 617 0)
          • Panel – Load Space Trim – Remove and Install (43 746 0)
          • Panel – Cowl Side Trim – Remove and Install (43 735 0)
          • Capping – Load Space Trim Panel – Remove and Install (43 747 0)
          • Lock-Latch – Glove Compartment – Remove and Install (43 666 0)
          • Panel – Door Trim – Rear – Remove and Install (43 706 0)
          • Panel – Luggage Compartment Lid Trim – Remove and Install (43 745 0)
          • Panel – Tailgate Trim – Remove and Install (Hatchback) (43 744 0)
          • Bracket – Rear Parcel Shelf – Remove and Install (43 687 0)
          • Panel – Door Trim – Front – Remove and Install (43 705 0)
          • Centre Console - Remove And Install (43 814 0)
      • 543-02 Exterior Trim
        • SpecificationsGeneral Specification
        • Removal and Installation
          • Insulation Panel – Hood – Remove and Install (Petrol) (43 221 0)
          • Air Vent Panel – `D Pillar – Remove and Install (43 178 0)
          • Inner Gutter ‐ Weatherstrip ‐ Remove and Install (43 140 0)
          • Grille Assembly Cowl Top Outer – Remove and Install (43 230 0)
          • Emblem – Radiator Grille – Remove and Install (43 236 0)
          • Liner – Wheelhouse (Front) – Remove and Install (43 228 0)
          • Air Vent Panel – Rear Door Aperture – Remove and Install (43 330 0)
          • Liner – Wheelhouse (Rear) – Remove and Install (43 228 0)
          • Grille – Radiator – Remove and Install (43 232 0)
          • Applique Panel – Luggage Compartment Lid– Remove and Install (43 387 0)
          • Bumper Assembly - Front - Remove And Install (43 423 0)
          • Air Vent Panel – Inner-Outer – Rear Door – Remove and Install (43 369 0)
          • Integrated Roof Rack – Remove and Install (43 350 0)
          • Moulding – Roof – Remove and Install (43 345 0)
          • Mirror – Door – Remove and Install (43 364 0)
          • Bumper and Bracket Assembly – Rear – Remove and Install (43 443 0)
          • Side Support Pin - Bumper - Replace (Bumper Removed) (43 431 4)
          • Spoiler - Tailgate - Remove and Install (43 492 0)