Mondeo 2001 (10.2000-02.2007): Mechanical Repairs
Also for this vehicle: Mondeo 1993 (01.1993-07.1996), Mondeo 1997 (08.1996-09.2000), Mondeo 2007.5 (02.2007-).
General
Body & interior
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
1 General Information › 100 Service Information12 pages
100-00 General Information › Description and Operation5 pages
- 100-01 Identification Codes › Description and Operation › Identification Codes
100-02 Jacking and Lifting › Description and Operation4 pages
100-04 Noise, Vibration and Harshness › Diagnosis and Testing2 pages
2 Chassis129 pages
204 Suspension38 pages
204-00 Suspension System - General Information5 pages
- Specifications
Diagnosis and Testing4 pages
- Suspension System
General Procedures3 pages
204-01 Front Suspension13 pages
- Specifications
Description and Operation12 pages
- Front Suspension
- Front Suspension - 3.0L Duratec-ST (VE6)
- Front Suspension - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel, Vehicles With: 5-Speed Automatic Transm
Diagnosis and Testing9 pages
- Front Suspension
Removal and Installation8 pages
- Front Wheel Bearing
- Front Wheel Bearing - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel, Vehicles With: 5-Speed Automatic Tra
- Lower Arm
- Front Stabilizer Bar
- Front Stabilizer Bar Bushing
- Wheel Knuckle
- Front Strut and Spring Assembly
- Disassembly and Assembly › Front Strut and Spring Assembly
204-02 Rear Suspension17 pages
- Specifications
Description and Operation16 pages
- Rear Suspension
Diagnosis and Testing14 pages
- Rear Suspension
Removal and Installation13 pages
- Wheel Hub
- Front Lower Arm - 4-Door-5-Door
- Rear Lower Arm - 4-Door-5-Door
- Rear Lower Arm - Wagon
- Tie Bar - 4-Door-5-Door
- Wheel Knuckle - 4-Door-5-Door
- Wheel Knuckle - Wagon
- Rear Shock Absorber - Wagon
- Rear Strut and Spring Assembly - 4-Door-5-Door
- Spring - Wagon
- Crossmember - 4-Door-5-Door
- Crossmember - Wagon
- Disassembly and Assembly › Rear Strut and Spring Assembly
- Rear Suspension - 3.0L Duratec-ST (VE6)
204-04 Wheels and Tires3 pages
- Specifications
Diagnosis and Testing2 pages
205 Driveline › 205-04 Front Drive Halfshafts7 pages
- Specifications
Description and Operation6 pages
Diagnosis and Testing5 pages
- Front Drive Halfshafts
Removal and Installation4 pages
- Front Drive Halfshafts
206 Brake System51 pages
206-00 Brake System - General Information › Description and Operation5 pages
- Brake System
Diagnosis and Testing4 pages
- Emergency Brake Assist (EBA)
- Brake System
General Procedures2 pages
206-03 Front Disc Brake3 pages
Description and Operation2 pages
- Specifications
206-04 Rear Disc Brake5 pages
Description and Operation4 pages
- Rear Disc Brake
Diagnosis and Testing3 pages
- Rear Disc Brake
Removal and Installation2 pages
- Specifications
206-05 Parking Brake and Actuation6 pages
- Specifications
Description and Operation5 pages
- Parking Brake
Diagnosis and Testing4 pages
- Parking Brake
General Procedures3 pages
- Parking Brake Cable Adjustment
Removal and Installation2 pages
206-06 Hydraulic Brake Actuation7 pages
- Specifications
Description and Operation6 pages
Diagnosis and Testing5 pages
- Hydraulic Brake Actuation
Removal and Installation4 pages
- Hydraulic Brake Actuation
206-07 Power Brake Actuation5 pages
- Specifications
Description and Operation4 pages
- Brake Booster
Diagnosis and Testing3 pages
- Power Brake System
Removal and Installation2 pages
206-09A Anti-Lock Control8 pages
- Specifications
Description and Operation7 pages
206-09B Anti-Lock Control - Traction Control5 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Anti-Lock Control - Traction Control
Removal and Installation2 pages
- Anti-Lock Control - Traction Control
206-09C Anti-Lock Control - Stability Assist7 pages
- Specifications
Description and Operation6 pages
Diagnosis and Testing5 pages
- Anti-Lock Control - Stability Assist
211 Steering System33 pages
211-00 Steering System - General Information9 pages
Description and Operation8 pages
- Steering System
Diagnosis and Testing7 pages
- Steering System
- Steering Gear Checks After a Collision
General Procedures5 pages
- Power Steering System Flushing - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)
- Power Steering System Flushing - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
- Power Steering System Flushing - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma)
- Power Steering System Bleeding
- Power Steering System Filling
- Specifications
211-02 Power Steering9 pages
- Specifications
Description and Operation8 pages
- Power Steering
Diagnosis and Testing7 pages
- Power Steering
Removal and Installation6 pages
- Power Steering Pump - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)
- Power Steering Pump - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
- Power Steering Pump - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel
- Power Steering Pump Pulley - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)
- Steering Gear
- Power Steering Pump to Steering Gear Pressure Line - 3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
211-03 Steering Linkage6 pages
- Specifications
Description and Operation5 pages
Diagnosis and Testing4 pages
- Steering Linkage
Removal and Installation3 pages
- Steering Linkage
211-04 Steering Column9 pages
- Specifications
Description and Operation8 pages
- Steering Column
Diagnosis and Testing6 pages
- Steering Column - 3.0L Duratec-ST (VE6)
3 Powertrain478 pages
303 Engine282 pages
303-00 Engine System - General Information › Diagnosis and Testing4 pages
303-01A Engine - 1.8L Duratec-SCi (MI4)19 pages
- Specifications
Description and Operation18 pages
Diagnosis and Testing17 pages
- Engine
General Procedures16 pages
- Valve Clearance Adjustment
In-vehicle Repair15 pages
- Engine
303-01B Engine - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)20 pages
- Specifications
Description and Operation19 pages
Diagnosis and Testing18 pages
- Engine
General Procedures17 pages
- Valve Clearance Adjustment
In-vehicle Repair16 pages
- Engine
303-01C Engine - 2.5L Duratec-VE (VE6)23 pages
- Specifications
Diagnosis and Testing22 pages
- Engine
In-vehicle Repair21 pages
- Upper Intake Manifold
- Valve Cover LH
- Valve Cover RH
- Crankshaft Pulley
- Crankshaft Front Seal
- Valve Seals
- Valve Springs
- Camshaft Seal
- Exhaust Manifold LH
- Exhaust Manifold RH
- Oil Pan
- Crankshaft Rear Seal
Removal9 pages
- Engine - Vehicles With: MTX-75-5-Speed Manual Transaxle
- Engine - Vehicles With: MMT6-6-Speed Manual Transaxle
- Engine - Vehicles With: 5F31J-5-Speed Automatic Transmission
Disassembly6 pages
- Engine
Disassembly and Assembly of Subassemblies5 pages
303-01D Engine - 3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)24 pages
- Specifications
Description and Operation23 pages
Diagnosis and Testing22 pages
- Engine
In-vehicle Repair21 pages
- Upper Intake Manifold
- Valve Cover LH
- Valve Cover RH
- Crankshaft Pulley
- Crankshaft Front Seal
- Crankshaft Rear Seal
- Valve Springs
- Valve Seals
- Exhaust Manifold LH - 3.0L Duratec-SE (VE6)
- Camshaft Seal
- Exhaust Manifold RH - 3.0L Duratec-SE (VE6)
- Exhaust Manifold LH - 3.0L Duratec-ST (VE6)
- Exhaust Manifold RH - 3.0L Duratec-ST (VE6)
- Oil Pan
Removal7 pages
- Engine - Vehicles With: MTX-75-5-Speed Manual Transaxle
- Engine - Vehicles With: MMT6-6-Speed Manual Transaxle
Disassembly5 pages
- Engine
Disassembly and Assembly of Subassemblies4 pages
- Cylinder Head
Assembly3 pages
- Engine - 3.0L Duratec-ST (VE6)
303-01E Engine - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel25 pages
- Specifications
Description and Operation24 pages
Diagnosis and Testing23 pages
- Engine
In-vehicle Repair22 pages
- Intake Manifold
- Valve Cover
- Valve Cover - Vehicles With: Common Rail Fuel Injection
- Crankshaft Front Seal
- Engine Front Cover
- Valve Springs
- Valve Seals
- Valves
- Camshafts
- Camshaft Seal
- Exhaust Manifold
- Cylinder Head
- Oil Pan
- Oil Pump
- Crankshaft Rear Seal
Removal7 pages
- Engine - Vehicles With: MTX-75-5F31J-5-Speed Automatic Transmission-5-Speed Manual Transaxle
- Engine - Vehicles With: MMT6-6-Speed Manual Transaxle
Disassembly5 pages
- Engine
Disassembly and Assembly of Subassemblies4 pages
- Engine
303-03 Engine Cooling20 pages
- Specifications
Description and Operation19 pages
- Engine Cooling
- Engine Cooling - 3.0L Duratec-ST (VE6)
Diagnosis and Testing17 pages
- Engine Cooling
General Procedures16 pages
- Cooling System Draining, Filling and Bleeding - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)
- Cooling System Draining, Filling and Bleeding - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
- Cooling System Draining, Filling and Bleeding - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Durato
Removal and Installation13 pages
- Thermostat Housing - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Thermostat - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
- Water Pump - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)
- Thermostat - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel
- Water Pump - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
- Water Pump - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel
- Radiator
- Radiator - 1.8L Duratec-SCi (MI4)
- Cooling Fan Motor and Shroud - 1.8L Duratec-SCi (MI4)
- Cooling Fan Motor and Shroud
- Cooling Fan Motor and Shroud - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Di
- Coolant Outlet Connector - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Bypass Tube - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
303-04A Fuel Charging and Controls - 1.8L Duratec-SCi (MI4)9 pages
- Specifications
Description and Operation8 pages
- Fuel Charging and Controls
Diagnosis and Testing7 pages
303-04B Fuel Charging and Controls - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)7 pages
Description and Operation6 pages
- Fuel Charging and Controls
Diagnosis and Testing5 pages
- Fuel Charging and Controls
Removal and Installation4 pages
- Specifications
303-04C Fuel Charging and Controls - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)9 pages
Description and Operation8 pages
- Fuel Charging and Controls
Diagnosis and Testing7 pages
- Fuel Charging and Controls
Removal and Installation6 pages
- Throttle Body - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)
- Throttle Body - 3.0L Duratec-ST (VE6)
- Fuel Injection Supply Manifold - 2.5L Duratec-VE (VE6)
- Fuel Injection Supply Manifold - 3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
- Fuel Charging Wiring Harness - 2.5L Duratec-VE (VE6)
- Fuel Charging Wiring Harness - 3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
- Specifications
303-04D Fuel Charging and Controls - 2.0L Duratorq-Di-TDDi (Puma) Diesel7 pages
- Specifications
Description and Operation6 pages
- Fuel Charging and Controls
Diagnosis and Testing5 pages
- Fuel Charging and Controls
Removal and Installation4 pages
303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel9 pages
Description and Operation8 pages
- Fuel Charging and Controls
Diagnosis and Testing7 pages
- Fuel Charging and Controls
General Procedures6 pages
- Specifications
303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Du6 pages
- Specifications
Description and Operation5 pages
- Turbocharger
Diagnosis and Testing4 pages
- Turbocharger
Removal and Installation3 pages
303-05 Accessory Drive9 pages
- Specifications
Description and Operation8 pages
- Accessory Drive
- Accessory Drive - 3.0L Duratec-ST (VE6)
Diagnosis and Testing6 pages
- Accessory Drive
Removal and Installation5 pages
- Accessory Drive Belt - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
- Accessory Drive Belt - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)
- Accessory Drive Belt - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel
- Power Steering Pump Belt - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel
- Coolant Pump Belt - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
303-06 Starting System7 pages
Description and Operation6 pages
- Starting System
Diagnosis and Testing5 pages
- Starting System
Removal and Installation4 pages
- Starter Motor - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel, Vehicles With: 6-Speed Manual Transmission
- Starter Motor - 2.5L Duratec-VE (VE6), Vehicles With: 5-Speed Manual Transmission (MTX-75)
- Starter Motor - 3.0L Duratec-ST (VE6), Vehicles With: MTX-75-5-Speed Manual Transmission (MTX-75)
- Starter Motor - 3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6), Vehicles With: MMT6-6-Speed Manual Transmission (MMT6)
- Specifications
303-07A Engine Ignition - 1.8L Duratec-SCi (MI4)3 pages
Description and Operation2 pages
- Specifications
303-07B Engine Ignition - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)2 pages
303-07C Engine Ignition - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)4 pages
Diagnosis and Testing3 pages
- Engine Ignition
Removal and Installation2 pages
- Specifications
303-07D Glow Plug System - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel6 pages
- Specifications
Description and Operation5 pages
Diagnosis and Testing4 pages
- Glow Plug System
303-08A Engine Emission Control - 1.8L Duratec-SCi (MI4)6 pages
Description and Operation5 pages
- Engine Emission Control
Diagnosis and Testing4 pages
- Specifications
303-08B Engine Emission Control - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)5 pages
- Specifications
Description and Operation4 pages
- Engine Emission Control
Diagnosis and Testing3 pages
- Engine Emission Control
Removal and Installation2 pages
303-08C Engine Emission Control - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma)11 pages
Description and Operation10 pages
- Engine Emission Control
Diagnosis and Testing9 pages
- Engine Emission Control - Vehicles With: Electronic Exhaust Gas Recirculation (EGR) Valve
- Engine Emission Control - Vehicles With: Vacuum Exhaust Gas Recirculation (EGR) Valve
Removal and Installation7 pages
- Exhaust Gas Recirculation (EGR) Valve - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma
- Exhaust Gas Recirculation (EGR) Valve - 2.0L Duratorq-TDCi (Puma) Diesel, Vehicles With: Electronic Exhaust Gas Recirculation (E
- Exhaust Gas Recirculation (EGR) Valve - 2.0L Duratorq-TDCi (Puma) Diesel, Vehicles With: Diesel Particulate Filter (DPF)
- Exhaust Gas Recirculation (EGR) Valve - 2.2L Duratorq-TDCi (Puma) Diesel, VIN Plate Emission Level Code: 7
- Exhaust Gas Recirculation (EGR) Cooler
- Exhaust Gas Recirculation (EGR) Valve Outlet Tube
- Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube
- Specifications
303-12 Intake Air Distribution and Filtering › Description and Operation8 pages
- Intake Air Distribution and Filtering
- Intake Air Distribution and Filtering - 1.8L Duratec-SCi (MI4)
- Intake Air Distribution and Filtering - 3.0L Duratec-ST (VE6)
Diagnosis and Testing5 pages
- Intake Air Distribution and Filtering
Removal and Installation4 pages
- Air Cleaner Intake Pipe - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)
- Air Cleaner Intake Pipe - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Pu
- Air Cleaner Intake Pipe - 3.0L Duratec-ST (VE6)
- Charge Air Cooler - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel
303-13 Evaporative Emissions › Description and Operation6 pages
Diagnosis and Testing5 pages
- Evaporative Emissions
303-14A Electronic Engine Controls - 1.8L Duratec-SCi (MI4)10 pages
- Specifications
Description and Operation9 pages
- Electronic Engine Controls
Diagnosis and Testing8 pages
303-14B Electronic Engine Controls - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)7 pages
- Specifications
Description and Operation6 pages
- Electronic Engine Controls
Diagnosis and Testing5 pages
303-14C Electronic Engine Controls - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)7 pages
- Specifications
Description and Operation6 pages
- Electronic Engine Controls - 3.0L Duratec-ST (VE6)
- Electronic Engine Controls - 2.5L Duratec-VE (VE6)
Diagnosis and Testing4 pages
- Electronic Engine Controls
Removal and Installation3 pages
303-14D Electronic Engine Controls - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Pu9 pages
- Specifications
Description and Operation8 pages
- Electronic Engine Controls
Diagnosis and Testing7 pages
- Electronic Engine Controls
Removal and Installation6 pages
307 Automatic Transmission-Transaxle77 pages
307-01A Automatic Transmission-Transaxle - Vehicles With: 4-Speed Automatic Transmission (CD4E)33 pages
- Specifications
Description and Operation32 pages
- Transaxle Description
Diagnosis and Testing31 pages
- Diagnostic Strategy
- Preliminary Inspection
- Diagnostics
- Diagnosis By Symptom
General Procedures27 pages
- Transmission Fluid Drain and Refill
In-vehicle Repair26 pages
- Transmission Fluid Pan, Gasket and Filter
- Main Controls
- Turbine Shaft Speed (TSS) Sensor
- Output Shaft Speed (OSS) Sensor
- Halfshaft Seal LH
- Halfshaft Seal RH
- Transmission Range (TR) Sensor
Removal19 pages
- Transaxle - 2.0L Duratec-HE (MI4)
Disassembly18 pages
- Transaxle
Disassembly and Assembly of Subassemblies17 pages
- Chain Sprockets
- Torque Converter Housing
- Final Drive Carrier and Differential Assembly
- Forward-Coast-Direct Clutch Cylinder and Reverse Clutch Drum - Assembly
- Forward-Coast-Direct Clutches
- Forward One-Way Clutch
- Low One-Way Clutch Assembly
- Main Control Valve Body
- Transaxle Case
- Pump Assembly
- Reverse Clutch
- Torque Converter One-Way Clutch Check
- Planetary Gearsets and Chain Drive Parts
- Torque Converter Flushing
- Torque Converter Cleaning and Inspection
Assembly2 pages
307-01B Automatic Transmission-Transaxle - Vehicles With: 5-Speed Automatic Transmission (5F31J)22 pages
- Specifications
Description and Operation21 pages
- Automatic Transaxle
- Identification Tags
- Transmission Ranges and Power Flow
- Transaxle Electronic Control System
Diagnosis and Testing17 pages
- Diagnostic Strategy
- Diagnostic Trouble Code Charts
General Procedures15 pages
307-02A Transmission-Transaxle Cooling - Vehicles With: 4-Speed Automatic Transmission (CD4E)4 pages
- Specifications
Description and Operation3 pages
- Transaxle Cooling
Removal and Installation2 pages
307-02B Transmission-Transaxle Cooling - Vehicles With: 5-Speed Automatic Transmission (5F31J)4 pages
Description and Operation3 pages
- Specifications
307-05A Automatic Transmission-Transaxle External Controls - Vehicles With: 4-Speed Automatic Transmission (CD4E)7 pages
Description and Operation6 pages
- External Controls
Diagnosis and Testing5 pages
- External Controls
General Procedures4 pages
- Specifications
307-05B Automatic Transmission-Transaxle External Controls - Vehicles With: 5-Speed Automatic Transmission (5F31J)7 pages
- Specifications
Description and Operation6 pages
Diagnosis and Testing5 pages
- External Controls
General Procedures4 pages
- Selector Lever Cable Adjustment
Removal and Installation3 pages
- External Controls
308 Manual Transmission-Transaxle, Clutch and Transfer Case79 pages
308-00 Manual Transmission-Transaxle and Clutch - General Information5 pages
- Specifications
Diagnosis and Testing4 pages
308-01A Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75)5 pages
- Specifications
Description and Operation4 pages
- Clutch
Diagnosis and Testing2 pages
- Clutch - 3.0L Duratec-ST (VE6)
308-01B Clutch - Vehicles With: 6-Speed Manual Transmission (MMT6)4 pages
Description and Operation3 pages
- Clutch
Diagnosis and Testing2 pages
- Specifications
308-02A Clutch Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75)5 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Clutch Controls
Removal and Installation2 pages
- Clutch Controls
308-02B Clutch Controls - Vehicles With: 6-Speed Manual Transmission (MMT6)5 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Clutch Controls
Removal and Installation2 pages
- Clutch Controls
308-03A Manual Transmission-Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75)22 pages
- Specifications
Description and Operation21 pages
- Manual Transaxle
Diagnosis and Testing20 pages
- Manual Transaxle
General Procedures19 pages
- Fill Procedure
- Drain Procedure
- Bearing Check
In-vehicle Repair16 pages
- Halfshaft Seal LH
- Halfshaft Seal RH
- Vehicle Speed Sensor (VSS)
Removal13 pages
- Transaxle - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Transaxle - 2.5L Duratec-VE (VE6)
- Transaxle - 3.0L Duratec-ST (VE6)
- Transaxle - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel
Disassembly9 pages
- Transaxle
Disassembly and Assembly of Subassemblies8 pages
308-03B Manual Transmission-Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6)22 pages
- Specifications
Description and Operation21 pages
- Manual Transmission
Diagnosis and Testing20 pages
- Manual Transaxle
General Procedures19 pages
- Drain Procedure
- Fill Procedure
- Bearing Check
In-vehicle Repair16 pages
- Halfshaft Seal LH
- Halfshaft Seal RH
Removal14 pages
- Transaxle - 1.8L Duratec-SCi (MI4)
- Transaxle - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Transaxle - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)
- Transaxle - 2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel
Disassembly10 pages
- Transaxle
Disassembly and Assembly of Subassemblies9 pages
308-06A Manual Transmission-Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75)6 pages
- Specifications
Description and Operation5 pages
- External Controls
Diagnosis and Testing4 pages
- External Controls
Removal and Installation3 pages
308-06B Manual Transmission-Transaxle External Controls - Vehicles With: 6-Speed Manual Transmission (MMT6)5 pages
- Specifications
Description and Operation4 pages
- External Controls
Diagnosis and Testing3 pages
- External Controls
Removal and Installation2 pages
309 Exhaust System › 309-00 Exhaust System12 pages
- Specifications
Description and Operation11 pages
- Exhaust System
- Exhaust System - 3.0L Duratec-ST (VE6)
Removal and Installation9 pages
- Dual Catalytic Converter Y-Pipe
- Catalytic Converter - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)
- Catalytic Converter - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Catalytic Converter LH - 3.0L Duratec-ST (VE6)
- Catalytic Converter RH - 3.0L Duratec-ST (VE6)
- Catalytic Converter - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel
- Exhaust Flexible Pipe
- Diesel Particulate Filter (DPF)
- Diesel Particulate Filter (DPF) Differential Pressure Sensor
310 Fuel System28 pages
310-00 Fuel System - General Information › Diagnosis and Testing8 pages
310-01 Fuel Tank and Lines12 pages
- Specifications
Description and Operation11 pages
- Fuel Tank and Lines
Diagnosis and Testing10 pages
- Fuel Tank and Lines
Removal and Installation9 pages
- Fuel Pump Module
- Fuel Tank
- Fuel Level Sensor
- Fuel Pump - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel
- Fuel Tank Filler Pipe
- Fuel Filter - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)-2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0
- Fuel Filter - 2.0L Duratorq-Di-TDDi (Puma) Diesel
- Fuel Filter - 2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel
- Fuel Level Resistor Card
- 310-02B Acceleration Control - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Di › Diagnosis and Testing › Acceleration Control
- 310-02A Acceleration Control - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)-2.5L Duratec-VE (VE6)-3.0L Dur › Diagnosis and Testing › Acceleration Control
310-03 Speed Control6 pages
- Specifications
Description and Operation5 pages
- Speed Control
Diagnosis and Testing4 pages
- Speed Control
General Procedures3 pages
- Speed Control Deactivator Switch Adjustment
Removal and Installation2 pages
4 Electrical184 pages
412 Climate Control System54 pages
412-00 Climate Control System - General Information10 pages
- Specifications
Diagnosis and Testing9 pages
412-01A Air Distribution and Filtering › Description and Operation3 pages
- Air Distribution and Filtering
Diagnosis and Testing2 pages
412-02A Heating and Ventilation7 pages
Description and Operation6 pages
- Heating and Ventilation
Diagnosis and Testing5 pages
- Specifications
412-02B Auxiliary Heating7 pages
- Specifications
Description and Operation6 pages
- Electric Booster Heater
- Fuel Fired Booster Heater
Diagnosis and Testing4 pages
412-03 Air Conditioning17 pages
- Specifications
Description and Operation16 pages
Diagnosis and Testing15 pages
- Air Conditioning
Removal and Installation14 pages
- Air Conditioning (A-C) Compressor - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)-2.5L Duratec-VE (VE6)-3.0
- Air Conditioning (A-C) Compressor - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Pum
- Clutch and Clutch Field Coil - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)-2.5L Duratec-VE (VE6)-3.0L Dur
- Clutch and Clutch Field Coil - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Di
- Evaporator Core
- Evaporator Core Orifice
- Suction Accumulator
- Low-Pressure Cutoff Switch
- High-Pressure Cutoff Switch
- Condenser Core
- Compressor Manifold and Tube Assembly - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma
- Compressor Manifold and Tube Assembly - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)-2.5L Duratec-VE (VE6)
- Condenser to Evaporator Line
- Evaporator Outlet Line
- Air Conditioning
412-04 Control Components › Description and Operation10 pages
- Control Components - Vehicles Built Up To: 06-2003
- Control Components - Vehicles Built From: 06-2003
Diagnosis and Testing8 pages
- Control Components
Removal and Installation7 pages
- Climate Control Assembly - Vehicles Built Up To: 06-2003
- Climate Control Assembly - Vehicles With: Digital Versatile Disc (DVD) Navigation System
- Climate Control Assembly - Vehicles Built From: 06-2003
- Climate Control Module
- Center Register Air Discharge Temperature Sensor - Vehicles With: Digital Versatile Disc (DVD) Navigation System
- Center Register Air Discharge Temperature Sensor
- Footwell Air Discharge Temperature Sensor
413 Instrumentation and Warning Systems20 pages
- 413-00 Instrument Cluster and Panel Illumination › Diagnosis and Testing › Instrument Cluster and Panel Illumination
413-01 Instrument Cluster › Description and Operation5 pages
413-06 Horn3 pages
- Specifications
Diagnosis and Testing2 pages
413-07 Clock › Diagnosis and Testing2 pages
413-08 Information and Message Center › Description and Operation2 pages
413-09 Warning Devices › Diagnosis and Testing3 pages
- Warning Devices
General Procedures2 pages
413-13 Parking Aid › Description and Operation4 pages
414 Battery and Charging System15 pages
414-00 Charging System - General Information › Description and Operation3 pages
- Charging System
Diagnosis and Testing2 pages
414-01 Battery, Mounting and Cables4 pages
- Specifications
Diagnosis and Testing3 pages
- Battery
General Procedures2 pages
414-02 Generator and Regulator8 pages
- Specifications
Description and Operation7 pages
- Generator
- Generator - 3.0L Duratec-ST (VE6)
Diagnosis and Testing5 pages
- Generator
Removal and Installation4 pages
415 Information and Entertainment Systems20 pages
415-00 Information and Entertainment System - General Information › Diagnosis and Testing2 pages
415-01A Audio Unit › Description and Operation7 pages
- Audio System - Vehicles Built From: 06-2003
Diagnosis and Testing6 pages
415-02 Antenna › Description and Operation3 pages
- Antenna
Diagnosis and Testing2 pages
- 415-03 Speakers › Diagnosis and Testing › Speakers
415-07 Video System › Description and Operation7 pages
- Video System - Vehicles Built Up To: 06-2003
Diagnosis and Testing5 pages
- Video System - Vehicles Built From: 06-2003
417 Lighting24 pages
417-01 Exterior Lighting21 pages
- Specifications
Description and Operation20 pages
- Exterior Lighting
- Exterior Lighting - Vehicles With: Autolamps
Diagnosis and Testing18 pages
- Headlamps
- Stoplamps
- Turn Signal and Hazard Lamps
- Parking, Rear and License Plate Lamps
- Fog Lamps
- Reversing Lamps
- Trailer Lamps
- Headlamp Leveling
General Procedures10 pages
- 417-02 Interior Lighting › Diagnosis and Testing › Interior Lighting
417-04 Daytime Running Lamps (DRL) › Description and Operation2 pages
418 Electrical Distribution9 pages
418-00 Module Communications Network4 pages
- Specifications
Description and Operation3 pages
- Communications Network
Diagnosis and Testing2 pages
- 418-01 Module Configuration › General Procedures › Module Configuration
418-02 Wiring Harnesses4 pages
- Specifications
Removal and Installation3 pages
419 Electronic Feature Group42 pages
419-01A Anti-Theft - Active6 pages
- Specifications
Description and Operation5 pages
- Anti-Theft - Active
Diagnosis and Testing3 pages
- Anti-Theft - Active
Removal and Installation2 pages
- Anti-Theft - Active - 3.0L Duratec-ST (VE6)
419-01B Anti-Theft - Passive › Description and Operation7 pages
419-07A Navigation System - Vehicles With: Travel Pilot DX › Description and Operation3 pages
- Navigation System
Diagnosis and Testing2 pages
419-07B Navigation System - Vehicles With: Travel Pilot EX › Description and Operation4 pages
- Navigation System
Diagnosis and Testing3 pages
- Navigation System
Removal and Installation2 pages
419-07C Navigation System - Vehicles With: Digital Versatile Disc (DVD) Navigation System › Description and Operation5 pages
- Navigation System
Diagnosis and Testing4 pages
419-07D Navigation System - Vehicles With: 9000 Vehicle Navigation Radio (VNR) › Description and Operation3 pages
- Navigation System
Diagnosis and Testing2 pages
419-07E Navigation System - Vehicles With: Traffic Pro › Description and Operation2 pages
419-08 Cellular Phone9 pages
- Specifications - Vehicles With: Voice Control
Description and Operation8 pages
- Cellular Phone - Vehicles With: Voice Control
- Cellular Phone - Vehicles Without: Voice Control
Diagnosis and Testing6 pages
419-10 Multifunction Electronic Modules › Description and Operation3 pages
5 Body and Paint219 pages
501 Body and Paint215 pages
501-02 Front End Body Panels3 pages
- Specifications
General Procedures2 pages
501-03 Body Closures2 pages
501-05 Interior Trim and Ornamentation7 pages
Description and Operation6 pages
- Specifications
- 501-08 Exterior Trim and Ornamentation - 3.0L Duratec-ST (VE6) › Description and Operation › Exterior Trim
501-09 Rear View Mirrors6 pages
Description and Operation5 pages
- Rear View Mirrors - Vehicles Built From: 06-2003
Diagnosis and Testing4 pages
- Rear View Mirrors
Removal and Installation3 pages
- Specifications
501-10 Seating25 pages
- Specifications
Description and Operation24 pages
- Seats
- Seats - 3.0L Duratec-ST (VE6)
- Seats - Vehicles With: Climate Controlled Seats
Diagnosis and Testing21 pages
- Seats - Vehicles Built Up To: 06-2003
- Seats - Vehicles Built From: 06-2003
Removal and Installation19 pages
- Front Seat
- Front Seat Backrest - Vehicles Without: Climate Controlled Seats
- Front Seat Backrest - Vehicles With: Climate Controlled Seats
- Front Seat Cushion - Vehicles Without: Climate Controlled Seats
- Front Seat Cushion - Vehicles With: Climate Controlled Seats
- Rear Seat Backrest - Vehicles Built Up To: 03-2002
- Rear Seat Backrest - Vehicles Built From: 03-2002
- Rear Seat Backrest Latch
- Rear Seat Cushion - Vehicles With: Heated Rear Seat
- Climate Controlled Seat Switch
Disassembly and Assembly9 pages
- Front Seat Cushion - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)-2.5L Duratec-VE (VE6)-3.0L Duratec-SE (V
- Front Seat Cushion - 3.0L Duratec-ST (VE6)
- Front Seat Cushion - Vehicles With: Climate Controlled Seats
- Front Seat Backrest - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)-2.5L Duratec-VE (VE6)-3.0L Duratec-SE (
- Front Seat Backrest - 3.0L Duratec-ST (VE6)
- Front Seat Backrest - Vehicles With: Climate Controlled Seats
- Rear Seat Cushion - Vehicles With: Integrated Child Safety Seat
- Rear Seat Cushion - Vehicles With: Heated Rear Seat
- Rear Seat Backrest
501-11 Glass, Frames and Mechanisms16 pages
Description and Operation15 pages
- Glass, Frames and Mechanisms - 3.0L Duratec-ST (VE6)
Diagnosis and Testing14 pages
- Glass, Frames and Mechanisms
General Procedures13 pages
- Door Window Motor Initialization
Removal and Installation12 pages
- Front Door Window Glass
- Rear Door Window Glass
- Rear Quarter Window Glass - 4-Door-5-Door
- Rear Quarter Window Glass - Wagon
- Rear Window Glass - 4-Door
- Rear Window Glass - 5-Door
- Rear Window Glass - Wagon
- Windshield Glass
- Rear Door Window Regulator
- Front Door Window Regulator and Motor
- Rear Door Window Regulator and Motor
- Heated Windshield Switch and Heated Rear Window Switch Assembly - Vehicles Built From: 06-2003
- Specifications
501-12 Instrument Panel and Console6 pages
501-14 Handles, Locks, Latches and Entry Systems10 pages
- Specifications
Description and Operation9 pages
- Handles, Locks, Latches and Entry Systems
- Handles, Locks, Latches and Entry Systems - 3.0L Duratec-ST (VE6)
Diagnosis and Testing7 pages
- Locks, Latches and Entry Systems
General Procedures6 pages
501-16 Wipers and Washers9 pages
- Specifications
Description and Operation8 pages
- Wipers and Washers - Vehicles Built From: 06-2003
Diagnosis and Testing7 pages
- Wipers and Washers
General Procedures6 pages
501-17 Roof Opening Panel9 pages
- Specifications
Description and Operation8 pages
- Roof Opening Panel
Diagnosis and Testing7 pages
- Roof Opening Panel
General Procedures6 pages
501-19 Bumpers5 pages
- Specifications
Description and Operation4 pages
501-20A Safety Belt System11 pages
- Specifications
Description and Operation10 pages
501-20B Supplemental Restraint System20 pages
- Specifications
Description and Operation19 pages
- Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) - Vehicles Built Up To: 06-2003
- Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) - Vehicles Built From: 06-2003
Diagnosis and Testing17 pages
- Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
General Procedures16 pages
501-25 Body Repairs - General Information26 pages
- Specifications
Description and Operation25 pages
- Description and Usage of Body Repair Literature
- Health and Safety Precautions
- Symbols
- Environmental Regulations
- Body Construction
- Diagnosis and Damage Evaluation
- Body Sheet Metal
- Establish Repair Method
- Tools and Equipment for Body Repairs
- Straightening
- Alignment Check
- Complete Panel Replacement-Partial Replacement
- Corrosion Damage-Corrosion Repair
- Corrosion Prevention
- Cutting Technique
- Sealer, Underbody Protection Material and Adhesives
- Panel Beating Technique and Smart Repairs
- Paintless Dent Removal
- Joining Techniques
- Plastic Repairs
- Special Repair Techniques
- Water Leaks
- Impact of Insufficient Repair Quality
- Wind Noise
- Noise, Vibration and Harshness
501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks › Description and Operation4 pages
- Body and Frame
General Procedures3 pages
501-27 Front End Sheet Metal Repairs › Removal and Installation5 pages
501-28 Roof Sheet Metal Repairs4 pages
- Specifications
Removal and Installation3 pages
501-29 Side Panel Sheet Metal Repairs5 pages
- Specifications
Removal and Installation4 pages
501-30 Rear End Sheet Metal Repairs25 pages
- Specifications
Removal and Installation24 pages
- Quarter Panel - 4-Door
- Quarter Panel - 5-Door
- Quarter Panel - Wagon
- Inner Quarter Panel and Wheelhouse - 4-Door
- Inner Quarter Panel and Wheelhouse - 5-Door
- Inner Quarter Panel and Wheelhouse - Wagon
- Water Drain Panel Section - 5-Door
- Water Drain Panel - Wagon
- Rear Wheelhouse Outer - 4-Door
- Rear Wheelhouse Outer - 5-Door
- Rear Wheelhouse Outer - Wagon
- Rear Lamp Mounting Panel - 5-Door
- Rear Lamp Mounting Panel - 4-Door
- Back Panel
- Back Panel - Wagon
- Back Panel Section - Wagon
- Rear Floor Panel
- Rear Floor Panel - Wagon
- Rear Floor Panel Section RH
- Rear Floor Panel Section LH - Wagon
- Rear Crossmember - Wagon
- Rear Crossmember Section - Wagon
- Rear Side Member Section
- Rear Side Member Section - Wagon
501-36 Paint - General Information16 pages
- Specifications
Description and Operation15 pages
- Description and Usage of Paint Literature
- Health and Safety Precautions
- Symbols
- Environmental Regulations
- Factory Paint Application
- Paintwork Defects and Damage
- Tools and Equipment for Paint Repairs
- Additional Materials
- Refinishing 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 System4 pages
- Specifications
Removal and Installation3 pages