Focus 2004.75 (07.2004-): Mechanical Repairs
Also for this vehicle: Focus 1999 (08.1998-12.2004), Focus RS 2003 (09.2002-).
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 Information18 pages
100-00 General Information › Description and Operation12 pages
- About This Manual
- Symbols Glossary
- Standard Workshop Practices
- Health and Safety Precautions
- Solvents, Sealants and Adhesives
- Road-Roller Testing
- Air Conditioning (A-C) System Health and Safety Precautions
- Battery and Battery Charging Health and Safety Precautions
- Engine Cooling System Health and Safety Precautions
- Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions
- Diesel Fuel System Health and Safety Precautions
- Supplemental Restraint System (SRS) Health and Safety Precautions
- 100-01 Identification Codes › Description and Operation › Identification Codes
100-04 Noise, Vibration and Harshness › Description and Operation3 pages
2 Chassis143 pages
204 Suspension38 pages
204-00 Suspension System - General Information4 pages
- Specifications
Diagnosis and Testing3 pages
- Suspension System
General Procedures2 pages
204-01 Front Suspension10 pages
Description and Operation9 pages
- Front Suspension
Diagnosis and Testing8 pages
- Specifications
204-02 Rear Suspension21 pages
- Specifications
Description and Operation20 pages
- Rear Suspension
Diagnosis and Testing19 pages
- Rear Suspension
Removal and Installation18 pages
- Wheel Hub - Vehicles With: Rear Drum Brakes
- Wheel Hub - Vehicles With: Rear Disc Brakes
- Upper Arm
- Upper Arm - Wagon
- Front Lower Arm
- Front Lower Arm - Wagon
- Rear Lower Arm - Vehicles With: Solid Stabilizer Bar Link
- Rear Lower Arm - Wagon, Vehicles With: Solid Stabilizer Bar Link
- Rear Lower Arm - Vehicles With: Ball Joint Stabilizer Bar Link
- Stabilizer Bar - Vehicles With: Solid Stabilizer Bar Link
- Stabilizer Bar - Wagon, Vehicles With: Solid Stabilizer Bar Link
- Stabilizer Bar - Vehicles With: Ball Joint Stabilizer Bar Link
- Wheel Knuckle
- Wheel Knuckle - Wagon
- Rear Shock Absorber - Wagon
- Spring
- Spring - Convertible
- Spring - Wagon
204-04 Wheels and Tires3 pages
- Specifications
Diagnosis and Testing2 pages
205 Driveline › 205-04 Front Drive Halfshafts10 pages
Description and Operation9 pages
- Front Drive Halfshafts
Diagnosis and Testing8 pages
- Front Drive Halfshafts
Removal and Installation7 pages
- Specifications
206 Brake System60 pages
206-00 Brake System - General Information › Diagnosis and Testing5 pages
206-02 Drum Brake6 pages
Diagnosis and Testing5 pages
- Drum Brake
Removal and Installation4 pages
- Specifications
206-03 Front Disc Brake10 pages
- Specifications
Diagnosis and Testing9 pages
- Front Disc Brake
Removal and Installation8 pages
206-04 Rear Disc Brake6 pages
Diagnosis and Testing5 pages
- Rear Disc Brake
Removal and Installation4 pages
- Specifications
206-05 Parking Brake and Actuation7 pages
- Specifications
Description and Operation6 pages
- Parking Brake
Diagnosis and Testing5 pages
- Parking Brake
General Procedures4 pages
206-06 Hydraulic Brake Actuation7 pages
Diagnosis and Testing6 pages
- Specifications
206-07 Power Brake Actuation6 pages
- Specifications
Diagnosis and Testing5 pages
206-09A Anti-Lock Control5 pages
- Specifications
Diagnosis and Testing4 pages
- Anti-Lock Control
Removal and Installation3 pages
206-09C Anti-Lock Control - Stability Assist8 pages
Description and Operation7 pages
- Anti-Lock Control - Stability Assist
Diagnosis and Testing6 pages
- Specifications
211 Steering System35 pages
211-00 Steering System - General Information10 pages
- Specifications
Diagnosis and Testing9 pages
- Steering System - 1.6L Duratec-16V (Sigma)
- Steering System
- Steering Gear Checks After a Collision
General Procedures6 pages
- Power Steering System Flushing - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Power Steering System Flushing - 1.6L Duratec-16V (Sigma)-1.6L Duratec-16V Ti-VCT (Sigma)
- Power Steering System Bleeding - 1.6L Duratec-16V (Sigma)
- Power Steering System Bleeding - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Power Steering System Filling - 1.6L Duratec-16V (Sigma)
- Power Steering System Filling - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
211-02 Power Steering14 pages
- Specifications
Description and Operation13 pages
Diagnosis and Testing12 pages
- Power Steering
Removal and Installation11 pages
- Power Steering Pump - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Steering Gear to Fluid Cooler Return Hose - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Power Steering Pump - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Power Steering Pump to Steering Gear Pressure Line - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Power Steering Pump to Steering Gear Pressure Line - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Power Steering Pressure Line and Return Line Assembly - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Power Steering Fluid Cooler - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Steering Gear
- Steering Angle Sensor
- Steering Gear to Power Steering Fluid Reservoir Return Line - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Steering Gear to Power Steering Fluid Reservoir Return Line - Vehicles With: Electro-Hydraulic Power Steering (EHPS)
- Power Steering
211-03 Steering Linkage5 pages
Diagnosis and Testing4 pages
- Steering Linkage
Removal and Installation3 pages
- Specifications
211-04 Steering Column5 pages
- Specifications
Diagnosis and Testing4 pages
- Steering Column
Removal and Installation3 pages
- 211-05 Steering Column Switches › Removal and Installation › Ignition Switch
3 Powertrain730 pages
303 Engine470 pages
303-00 Engine System - General Information › Description and Operation24 pages
- Engine
Diagnosis and Testing23 pages
- Engine
General Procedures22 pages
- Camshaft Bearing Journal Diameter
- Camshaft Bearing Journal Clearance
- Camshaft End Play
- Camshaft Lobe Lift
- Camshaft Surface Inspection
- Crankshaft Main Bearing Journal Diameter
- Crankshaft End Play
- Crankshaft Main Bearing Journal Clearance
- Cylinder Bore Taper
- Piston Pin to Bore Diameter
- Piston Inspection
- Piston Ring End Gap
- Piston Diameter
- Piston Pin Diameter
- Piston Ring-to-Groove Clearance
- Connecting Rod Large End Bore
- Flywheel Inspection
- Valve Stem Diameter
- Cylinder Head Distortion
- Cylinder Block Distortion
- Exhaust Manifold Cleaning and Inspection
- Bearing Inspection
303-01A Engine - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)27 pages
- Specifications
Description and Operation26 pages
- Engine
Diagnosis and Testing25 pages
- Engine
General Procedures24 pages
- Valve Clearance Adjustment
Removal and Installation23 pages
- Intake Manifold
- Crankshaft Front Seal
- Crankshaft Rear Seal
- Valve Cover
- Valve Stem Seals
- Camshafts
- Camshaft Seal
- Timing Belt - Vehicles Built Up To: 04-2005
- Timing Belt - Vehicles Built From: 04-2005
- Cylinder Head
- Oil Pan
- Oil Pump
Removal11 pages
- Engine - Vehicles With: Manual Transaxle
- Engine - Vehicles With: Automatic Transmission
- Engine Accessories
Disassembly8 pages
- Engine - Vehicles Built From: 04-2005
- Engine - Vehicles Built Up To: 04-2005
Disassembly and Assembly of Subassemblies6 pages
303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma)22 pages
- Specifications
Description and Operation21 pages
Diagnosis and Testing20 pages
- Engine
General Procedures19 pages
- Valve Clearance Adjustment
In-vehicle Repair18 pages
- Intake Manifold
- Valve Cover
- Crankshaft Front Seal
- Valve Seals
- Valves
- Camshafts
- Camshaft Seal
- Timing Belt - Vehicles Built Up To: 04-2005
- Timing Belt - Vehicles Built From: 04-2005
- Cylinder Head
- Oil Pan
- Crankshaft Rear Seal
- Oil Pump
Removal5 pages
- Engine
Disassembly4 pages
- Engine
Disassembly and Assembly of Subassemblies3 pages
- Cylinder Head
Assembly2 pages
- Engine
303-01C Engine - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)24 pages
- Specifications
Description and Operation23 pages
Diagnosis and Testing22 pages
- Engine
General Procedures21 pages
- Engine
303-01D Engine - 2.5L Duratec-ST (VI5)20 pages
- Specifications
Description and Operation19 pages
- Engine
General Procedures18 pages
- Valve Clearance Adjustment
Removal and Installation17 pages
- Crankshaft Front Seal
- Intake Manifold
- Valve Stem Seals
- Camshafts
- Timing Belt
- Exhaust Manifold
- Cylinder Head
- Oil Pan
- Crankshaft Rear Seal
- Oil Pump
Removal7 pages
- Engine
- Engine Accessories
Disassembly5 pages
- Engine
Disassembly and Assembly of Subassemblies4 pages
- Cylinder Head
Assembly3 pages
- Engine
Installation2 pages
303-01F Engine - 1.6L Duratorq-TDCi (DV) Diesel23 pages
- Specifications
Description and Operation22 pages
Diagnosis and Testing21 pages
- Engine
General Procedures20 pages
- Engine Oil Draining and Filling
In-vehicle Repair19 pages
- Intake Manifold - VIN Plate Emission Level Code: K
- Intake Manifold - VIN Plate Emission Level Code: S
- Crankshaft Front Seal
- Valve Seals
- Camshaft
- Camshaft Seal
- Timing Belt
- Exhaust Manifold - 90 PS
- Exhaust Manifold - 110 PS
- Cylinder Head
- Oil Pan
- Oil Pump
- Crankshaft Rear Seal
Removal6 pages
- Engine
303-01G Engine - 1.8L Duratorq-TDCi (Lynx) Diesel21 pages
- Specifications
Description and Operation20 pages
- Engine
Diagnosis and Testing19 pages
- Engine
General Procedures18 pages
- Valve Clearance
In-vehicle Repair17 pages
- Intake Manifold
- Valve Cover
- Crankshaft Front Seal
- Valve Seals
- Camshafts
- Camshaft Seal
- Timing Belt
- Exhaust Manifold
- Cylinder Head
- Crankshaft Rear Seal
- Oil Pan
- Oil Pump
Removal5 pages
- Engine
Disassembly4 pages
- Engine
Disassembly and Assembly of Subassemblies3 pages
- Cylinder Head
Assembly2 pages
303-01H Engine - 2.0L Duratorq-TDCi (DW) Diesel21 pages
- Specifications
Description and Operation20 pages
Diagnosis and Testing19 pages
- Engine
In-vehicle Repair18 pages
- Intake Manifold - VIN Plate Emission Level Code: K
- Crankshaft Front Seal
- Intake Manifold - VIN Plate Emission Level Code: S
- Valve Seals
- Camshafts
- Camshaft Seal
- Timing Belt
- Exhaust Manifold
- Cylinder Head
- Oil Pan
- Oil Pump
- Crankshaft Rear Seal
Removal6 pages
- Engine - Vehicles With: Manual Transmission
Disassembly5 pages
- Engine
Disassembly and Assembly of Subassemblies4 pages
- Cylinder Head
Assembly3 pages
- Engine
303-03A Engine Cooling - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)9 pages
- Specifications
Diagnosis and Testing8 pages
- Engine Cooling
General Procedures7 pages
303-03B Engine Cooling - 1.6L Duratec-16V Ti-VCT (Sigma)11 pages
- Specifications
Description and Operation10 pages
- Engine Cooling
Diagnosis and Testing9 pages
- Engine Cooling
General Procedures8 pages
303-03C Engine Cooling - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)10 pages
Description and Operation9 pages
- Engine Cooling
Diagnosis and Testing8 pages
- Engine Cooling
General Procedures7 pages
- Specifications
303-03D Engine Cooling - 2.5L Duratec-RS (VI5)-2.5L Duratec-ST (VI5)9 pages
- Specifications
Description and Operation8 pages
- Engine Cooling
Diagnosis and Testing7 pages
- Engine Cooling
General Procedures6 pages
- Cooling System Draining, Filling and Bleeding
Removal and Installation5 pages
303-03E Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel8 pages
- Specifications
Description and Operation7 pages
- Engine Cooling
Diagnosis and Testing6 pages
- Engine Cooling
General Procedures5 pages
- Cooling System Draining, Filling and Bleeding
Removal and Installation4 pages
303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel9 pages
Description and Operation8 pages
- Engine Cooling
Diagnosis and Testing7 pages
- Engine Cooling
General Procedures6 pages
- Cooling System Draining, Filling and Bleeding
Removal and Installation5 pages
- Specifications
303-03G Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel12 pages
- Specifications
Description and Operation11 pages
- Engine Cooling
Diagnosis and Testing10 pages
General Procedures9 pages
- Engine Cooling
303-04A Fuel Charging and Controls - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)7 pages
- Specifications
Description and Operation6 pages
Diagnosis and Testing5 pages
- Fuel Charging and Controls
Removal and Installation4 pages
- Fuel Charging and Controls
303-04B Fuel Charging and Controls - 1.6L Duratec-16V Ti-VCT (Sigma)7 pages
- Specifications
Description and Operation6 pages
Diagnosis and Testing5 pages
- Fuel Charging and Controls
Removal and Installation4 pages
- Fuel Charging and Controls
303-04C 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
303-04D Fuel Charging and Controls - 2.5L Duratec-RS (VI5)-2.5L Duratec-ST (VI5) › Description and Operation5 pages
- Fuel Charging and Controls
Diagnosis and Testing4 pages
- Fuel Charging and Controls
Removal and Installation3 pages
303-04E Fuel Charging and Controls - Turbocharger - 2.5L Duratec-ST (VI5) › Diagnosis and Testing2 pages
303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel12 pages
- Specifications
Description and Operation11 pages
- Fuel Charging and Controls - Vehicles With: Diesel Particulate Filter (DPF)
- Fuel Charging and Controls
Diagnosis and Testing9 pages
- Fuel Charging and Controls
General Procedures8 pages
- Fuel Injection Component Cleaning
Removal and Installation7 pages
- Fuel Injectors - VIN Plate Emission Level Code: K
- Fuel Injection Supply Manifold - VIN Plate Emission Level Code: K
- Fuel Pump - VIN Plate Emission Level Code: K
- Intake Air Shutoff Throttle - VIN Plate Emission Level Code: K
- Fuel Injectors - VIN Plate Emission Level Code: S
- Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S
- Fuel Pump - VIN Plate Emission Level Code: S
303-04G Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel7 pages
- Specifications
Description and Operation6 pages
- Fuel Charging and Controls
Diagnosis and Testing5 pages
General Procedures4 pages
- Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel
303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel12 pages
- Specifications
Description and Operation11 pages
- Fuel Charging and Controls
- Fuel Charging and Controls - Vehicles With: Diesel Particulate Filter (DPF)
Diagnosis and Testing9 pages
- Fuel Charging and Controls
General Procedures8 pages
- Fuel Injection Component Cleaning
Removal and Installation7 pages
- Fuel Injectors - VIN Plate Emission Level Code: S
- Fuel Injectors - VIN Plate Emission Level Code: K
- Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S
- Fuel Injection Supply Manifold - VIN Plate Emission Level Code: K
- Fuel Pump
- Intake Air Shutoff Throttle - VIN Plate Emission Level Code: S
- Intake Air Shutoff Throttle - VIN Plate Emission Level Code: K
303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Durator11 pages
- Specifications
Description and Operation10 pages
- Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel
- Turbocharger - 2.0L Duratorq-TDCi (DW) Diesel
Diagnosis and Testing8 pages
303-05A Accessory Drive18 pages
- Specifications
Description and Operation17 pages
- Accessory Drive - 1.8L Duratec-HE (MI4)
- Accessory Drive - 2.0L Duratorq-TDCi (DW) Diesel
Diagnosis and Testing15 pages
- Accessory Drive
Removal and Installation14 pages
- Accessory Drive Belt - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning
- Accessory Drive Belt - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning
- Accessory Drive Belt - Vehicles Built Up To: 02-2008 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Accessory Drive Belt - Vehicles Built From: 02-2008 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Accessory Drive Belt - 1.6L Duratorq-TDCi (DV) Diesel
- Accessory Drive Belt - 1.8L Duratorq-TDCi (Lynx) Diesel
- Accessory Drive Belt - 2.0L Duratorq-TDCi (DW) Diesel
- Accessory Drive Belt Tensioner - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Accessory Drive Belt Tensioner - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles With: Air Conditioning
- Accessory Drive Belt Tensioner - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles Without: Air Conditioning
- Accessory Drive Belt Tensioner - 1.8L Duratorq-TDCi (Lynx) Diesel
- Accessory Drive Belt Tensioner - 2.0L Duratorq-TDCi (DW) Diesel
- Air Conditioning (A-C) Compressor Belt - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Air Conditioning (A-C) Compressor Belt - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
303-05B Accessory Drive - 2.5L Duratec-RS (VI5)-2.5L Duratec-ST (VI5) › Description and Operation6 pages
- Accessory Drive
Diagnosis and Testing5 pages
303-06A Starting System11 pages
- Specifications
Description and Operation10 pages
- Starting System - 2.0L Duratorq-TDCi (DW) Diesel
Diagnosis and Testing9 pages
- Starting System
Removal and Installation8 pages
- Starter Motor - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Starter Motor - 1.6L Duratec-16V Ti-VCT (Sigma)
- Starter Motor - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel
- Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles With: 4-Speed Automatic Transmission (4F27E)
- Starter Motor - 1.8L Duratorq-TDCi (Lynx) Diesel
- Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles With: Automatic Transmission (CFT23)
- Starter Motor - 2.0L Duratorq-TDCi (DW) Diesel
- 303-06B Starting System - 2.5L Duratec-RS (VI5)-2.5L Duratec-ST (VI5) › Removal and Installation › Starter Motor
303-07A Engine Ignition - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)-1.6L Duratec-16V Ti-VCT (Sigma)4 pages
- Specifications
Description and Operation3 pages
Diagnosis and Testing2 pages
- Engine Ignition
303-07B Engine Ignition - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)4 pages
Description and Operation3 pages
- Specifications
303-07C Glow Plug System - 1.6L Duratorq-TDCi (DV) Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel7 pages
- Specifications
Description and Operation6 pages
- Glow Plug System
Diagnosis and Testing5 pages
303-07E Engine Ignition - 2.5L Duratec-RS (VI5)-2.5L Duratec-ST (VI5) › Diagnosis and Testing2 pages
303-08A Engine Emission Control - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)-1.6L Duratec-16V Ti-VCT (Sigma)3 pages
Description and Operation › Diagnosis and Testing2 pages
- Specifications
303-08B Engine Emission Control - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)4 pages
- Specifications
Diagnosis and Testing3 pages
- Engine Emission Control
Removal and Installation2 pages
303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel8 pages
Description and Operation7 pages
- Engine Emission Control
Diagnosis and Testing6 pages
- Specifications
303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel8 pages
- Specifications
Description and Operation7 pages
- Engine Emission Control
Diagnosis and Testing6 pages
303-08F Engine Emission Control - 1.8L Duratorq-TDCi (Lynx) Diesel › Description and Operation5 pages
- Engine Emission Control
Diagnosis and Testing4 pages
303-08G Engine Emission Control - 2.5L Duratec-RS (VI5)-2.5L Duratec-ST (VI5) › Description and Operation3 pages
- Engine Emission Control
Diagnosis and Testing2 pages
303-12A Intake Air Distribution and Filtering13 pages
- Specifications
Description and Operation12 pages
- Intake Air Distribution and Filtering - 1.8L Duratec-HE (MI4)
- Intake Air Distribution and Filtering - 1.6L Duratorq-TDCi (DV) Diesel
- Intake Air Distribution and Filtering - 1.8L Duratorq-TDCi (Lynx) Diesel
- Intake Air Distribution and Filtering - 2.0L Duratorq-TDCi (DW) Diesel
Diagnosis and Testing8 pages
- Intake Air Distribution and Filtering
Removal and Installation7 pages
- Air Cleaner - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Air Cleaner - 1.6L Duratec-16V Ti-VCT (Sigma)
- Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel
- Air Cleaner - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Air Cleaner - 1.8L Duratorq-TDCi (Lynx) Diesel
- Air Cleaner - 2.0L Duratorq-TDCi (DW) Diesel
- Charge Air Cooler - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
303-12B Intake Air Distribution and Filtering - 2.5L Duratec-ST (VI5) › Description and Operation4 pages
303-13 Evaporative Emissions4 pages
Description and Operation3 pages
- Evaporative Emissions
Diagnosis and Testing2 pages
- Specifications
303-14A Electronic Engine Controls34 pages
- Specifications
Description and Operation33 pages
- Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (Sigma)
- Electronic Engine Controls - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Electronic Engine Controls - 1.6L Duratorq-TDCi (DV) Diesel
- Electronic Engine Controls - 1.8L Duratorq-TDCi (Lynx) Diesel
- Electronic Engine Controls - 2.0L Duratorq-TDCi (DW) Diesel
Diagnosis and Testing28 pages
- Electronic Engine Controls
Removal and Installation27 pages
- Camshaft Position (CMP) Sensor - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)-1.6L Duratec-16V Ti-VCT (Sigma)
- Camshaft Position (CMP) Sensor - 1.8L Duratorq-TDCi (Lynx) Diesel
- Camshaft Position (CMP) Sensor - 1.6L Duratorq-TDCi (DV) Diesel
- Camshaft Position (CMP) Sensor - 2.0L Duratorq-TDCi (DW) Diesel
- Crankshaft Position (CKP) Sensor - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Crankshaft Position (CKP) Sensor - 1.6L Duratorq-TDCi (DV) Diesel
- Crankshaft Position (CKP) Sensor - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Crankshaft Position (CKP) Sensor - 1.8L Duratorq-TDCi (Lynx) Diesel
- Crankshaft Position (CKP) Sensor - 2.0L Duratorq-TDCi (DW) Diesel
- Cylinder Head Temperature (CHT) Sensor - 1.8L Duratorq-TDCi (Lynx) Diesel
- Powertrain Control Module (PCM) - 1.6L (Z6)
- Powertrain Control Module (PCM) - 1.6L Duratec-16V (Sigma)
- Powertrain Control Module (PCM) - Vehicles Built Up To: 03-2007 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Powertrain Control Module (PCM) - Vehicles Built From: 03-2007 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Powertrain Control Module (PCM) - 1.6L Duratorq-TDCi (DV) Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Knock Sensor (KS) - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Heated Oxygen Sensor (HO2S) - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Knock Sensor (KS) - 1.8L Duratorq-TDCi (Lynx) Diesel
- Front Knock Sensor (KS) - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Rear Knock Sensor (KS) - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Brake Pedal Position (BPP) Switch
- Engine Coolant Temperature (ECT) Sensor - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Engine Coolant Temperature (ECT) Sensor - 2.0L Duratorq-TDCi (DW) Diesel
- Variable Camshaft Timing (VCT) Oil Control Solenoid - 1.6L Duratec-16V Ti-VCT (Sigma)
- Idle Air Control (IAC) Valve - 1.6L (Z6)
- Intake Manifold Tuning (IMT) Valve - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Clutch Pedal Position (CPP) Switch
303-14B Electronic Engine Controls - 2.5L Duratec-RS (VI5)-2.5L Duratec-ST (VI5) › Description and Operation11 pages
- Electronic Engine Controls
Diagnosis and Testing10 pages
- Electronic Engine Controls
Removal and Installation9 pages
- Camshaft Position (CMP) Sensor
- Crankshaft Position (CKP) Sensor
- Heated Oxygen Sensor (HO2S)
- Knock Sensor (KS)
- Variable Valve Timing (VVT) Oil Control Solenoid
- Powertrain Control Module (PCM) - Vehicles With: PCM Security Shield
- Powertrain Control Module (PCM) - Vehicles Without: PCM Security Shield
- Mass Air Flow (MAF) Sensor
- Manifold Absolute Pressure (MAP) Sensor
307 Automatic Transmission-Transaxle77 pages
307-01A Automatic Transmission-Transaxle - Vehicles With: 4-Speed Automatic Transmission (4F27E)38 pages
- Specifications
Description and Operation37 pages
- Transaxle Description
Diagnosis and Testing36 pages
- Preliminary Inspection
- Torque Converter Diagnosis
- Shift Point Road Test
- Transaxle Drive Cycle Test
- Diagnostic Trouble Code Charts
- Transmission-Transaxle Connector Layouts
- Special Testing Procedures
- Leakage Inspection
- 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 - 1.6L Duratec-16V (Sigma)
- Transaxle - 2.0L Duratec-HE (MI4)
Disassembly17 pages
- Transaxle
Disassembly and Assembly of Subassemblies16 pages
307-01B Automatic Transmission-Transaxle - Vehicles With: Automatic Transmission (CFT23)16 pages
- Specifications
Description and Operation15 pages
- Transaxle Description
- Identification Tags
- Transmission Ranges and Power Flow
- Transmission Electronic Control System
Diagnosis and Testing11 pages
- Diagnostics
General Procedures10 pages
307-02A Transmission-Transaxle Cooling - Vehicles With: 4-Speed Automatic Transmission (4F27E)5 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Transaxle Cooling
Removal and Installation2 pages
- Transaxle Cooling
307-02B Transmission-Transaxle Cooling - Vehicles With: Automatic Transmission (CFT23) › Description and Operation3 pages
- Transaxle Cooling
Diagnosis and Testing2 pages
- 307-02D Transmission-Transaxle Cooling - Vehicles With: 6-Speed Automatic Transmission (6DCT450) › Removal and Installation › Transmission Fluid Cooler
307-05A Automatic Transmission-Transaxle External Controls - Vehicles With: 4-Speed Automatic Transmission (4F27E)7 pages
- Specifications
Description and Operation6 pages
- External Controls
Diagnosis and Testing5 pages
- External Controls
General Procedures4 pages
- Selector Lever Cable Adjustment
Removal and Installation3 pages
307-05B Automatic Transmission-Transaxle External Controls - Vehicles With: 6DCT450-CFT237 pages
Description and Operation6 pages
- External Controls
Diagnosis and Testing5 pages
- External Controls
General Procedures4 pages
- Selector Lever Cable Adjustment
Removal and Installation3 pages
- Specifications
308 Manual Transmission-Transaxle, Clutch and Transfer Case118 pages
308-00 Manual Transmission-Transaxle and Clutch - General Information7 pages
- Specifications
Diagnosis and Testing6 pages
- Manual Transaxle and Clutch
General Procedures5 pages
- Clutch System Bleeding
- Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transmission (iB5)
- Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transmission (MTX-75)
- Gearshift Cable Adjustment - Vehicles With: 6-Speed Manual Transmission (MMT6)
- Gearshift Cable Adjustment - Vehicles With: 6-Speed Manual Transmission (M66)
308-01B Clutch - Vehicles With: 5-Speed Manual Transmission (iB5) › Diagnosis and Testing2 pages
308-01C Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75)3 pages
Diagnosis and Testing2 pages
- Specifications
308-01D Clutch - Vehicles With: 6-Speed Manual Transmission (MMT6)3 pages
Diagnosis and Testing2 pages
- Specifications
308-01F Clutch - Vehicles With: 6-Speed Manual Transmission (M66)3 pages
- Specifications
Diagnosis and Testing2 pages
308-02B Clutch Controls - Vehicles With: 5-Speed Manual Transmission (iB5) › Diagnosis and Testing3 pages
- Clutch Controls
Removal and Installation2 pages
308-02C Clutch Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75)4 pages
Diagnosis and Testing3 pages
- Clutch Controls
Removal and Installation2 pages
- Specifications
308-02D Clutch Controls - Vehicles With: 6-Speed Manual Transmission (MMT6)4 pages
- Specifications
Diagnosis and Testing3 pages
- Clutch Controls
Removal and Installation2 pages
308-02F Clutch Controls - Vehicles With: 6-Speed Manual Transmission (M66)4 pages
- Specifications
Diagnosis and Testing3 pages
- Clutch Controls
Removal and Installation2 pages
308-03B Manual Transmission-Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5)19 pages
- Specifications
Description and Operation18 pages
Diagnosis and Testing17 pages
- Manual Transaxle
General Procedures16 pages
- Bearing Check
- Transmission Draining and Filling
Removal and Installation14 pages
- Halfshaft Seal LH
- Halfshaft Seal RH
Removal12 pages
- Transaxle - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Transaxle - 1.8L Duratec-HE (MI4)
Disassembly10 pages
- Transaxle - Vehicles Built From: 09-2005
- Transaxle - Vehicles Built Up To: 09-2005
Disassembly and Assembly of Subassemblies8 pages
- Manual Transaxle
308-03C Manual Transmission-Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75)17 pages
- Specifications
Description and Operation16 pages
Diagnosis and Testing15 pages
- Manual Transaxle - Vehicles With: Manual Transaxle
General Procedures14 pages
- Bearing Check
In-vehicle Repair13 pages
- Halfshaft Seal LH
- Halfshaft Seal RH
Removal11 pages
- Transaxle - 2.0L Duratec-HE (MI4)
- Transaxle - 1.6L Duratorq-TDCi (DV) Diesel
- Transaxle - 1.8L Duratorq-TDCi (Lynx) Diesel
Disassembly8 pages
- Transaxle
Disassembly and Assembly of Subassemblies7 pages
- Input Shaft
- Output Shaft
- Differential
Assembly4 pages
- Manual Transaxle
308-03D Manual Transmission-Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6)16 pages
- Specifications
Description and Operation15 pages
Diagnosis and Testing14 pages
- Manual Transaxle - Vehicles With: Manual Transaxle
General Procedures13 pages
- Bearing Check
- Fill Procedure
In-vehicle Repair11 pages
- Input Shaft Seal
- Halfshaft Seal LH
- Halfshaft Seal RH
Removal8 pages
- Transaxle - 2.0L Duratorq-TDCi (DW) Diesel
Disassembly7 pages
- Transaxle
Disassembly and Assembly of Subassemblies6 pages
- Manual Transmission
308-03F Manual Transmission-Transaxle - Vehicles With: 6-Speed Manual Transmission (M66)8 pages
- Specifications
Description and Operation7 pages
- Manual Transmission
General Procedures6 pages
- Transmission Draining and Filling
Removal and Installation5 pages
308-03G Manual Transmission-Transaxle - Vehicles With: 6-Speed Automatic Transmission (6DCT450)12 pages
- Specifications
Description and Operation11 pages
308-06B Manual Transmission-Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (iB5) › Diagnosis and Testing2 pages
308-06C Manual Transmission-Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75)4 pages
- Specifications
Diagnosis and Testing3 pages
- External Controls
Removal and Installation2 pages
308-06D Manual Transmission-Transaxle External Controls - Vehicles With: 6-Speed Manual Transmission (MMT6)4 pages
- Specifications
Diagnosis and Testing3 pages
- External Controls - Vehicles With: 6-Speed Manual Transmission (MMT6)
Removal and Installation2 pages
308-06E Manual Transmission-Transaxle External Controls - Vehicles With: 6-Speed Manual Transmission (M66) › Description and Operation3 pages
- External Controls
Removal and Installation2 pages
- 308-06F Manual Transmission-Transaxle External Controls - Vehicles With: 6-Speed Automatic Transmission (6DCT450)
309 Exhaust System20 pages
309-00A Exhaust System15 pages
- Specifications
Description and Operation14 pages
Diagnosis and Testing13 pages
- Exhaust System
Removal and Installation12 pages
- Catalytic Converter - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Catalytic Converter - Vehicles Built Up To: 08-2006 1.6L Duratec-16V Ti-VCT (Sigma)
- Catalytic Converter - Vehicles Built From: 08-2006 1.6L Duratec-16V Ti-VCT (Sigma)
- Catalytic Converter - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel
- Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V
- Catalytic Converter - 1.8L Duratorq-TDCi (Lynx) Diesel
- Catalytic Converter - 2.0L Duratorq-TDCi (DW) Diesel
- Catalytic Converter - 2.0L Duratorq-TDCi (DW) Diesel, VIN Plate Emission Level Code: V
- Diesel Particulate Filter (DPF) - 1.6L Duratorq-TDCi (DV) Diesel (110 PS)
- Exhaust Flexible Pipe
- Diesel Particulate Filter (DPF) - 2.0L Duratorq-TDCi (DW) Diesel
- Exhaust System
309-00B Exhaust System - 2.5L Duratec-RS (VI5)-2.5L Duratec-ST (VI5)5 pages
- Specifications
Removal and Installation4 pages
310 Fuel System45 pages
310-00 Fuel System - General Information › Diagnosis and Testing12 pages
- Fuel System - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)-1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Fuel System - 1.6L Duratorq-TDCi (DV) Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel
General Procedures10 pages
- Fuel System Pressure Check - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Fuel System Pressure Check - 2.5L Duratec-RS (VI5)-2.5L Duratec-ST (VI5)
- Fuel System Pressure Release - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V Ti-VCT (Sigma)-1.8L Duratec-HE (MI4)-2.0L Duratec-HE (M
- Quick Release Coupling
- Spring Lock Couplings
- Fuel Tank Draining
- Fuel Tank Draining - Vehicles With: Ethanol Capability
- Fuel Additive Tank Disposal
- Fuel Additive System Filling and Bleeding
- Fuel Additive System Service Reset Procedure Without Using Diagnostic Tool
310-01 Fuel Tank and Lines26 pages
- Specifications
Description and Operation25 pages
- Fuel Tank and Lines
Diagnosis and Testing24 pages
- Fuel Tank and Lines
Removal and Installation23 pages
- Fuel Tank - Flexible Fuel
- Fuel Tank - 1.6L Duratec-16V (Sigma)-1.6L Duratec-16V Ti-VCT (Sigma)-1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)-2.5L Duratec-ST
- Fuel Tank - 1.6L Duratec-16V (Sigma)-1.6L Duratec-16V Ti-VCT (Sigma)-1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4), Vehicles With:
- Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank, Vehicles Without:
- Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank-Fuel Fired Booster
- Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fu
- Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Fired Booster Heater, Vehicles Wi
- Fuel Additive Tank
- Fuel Pump Module
- Fuel Additive System Module
- Fuel Tank Filler Pipe
- Fuel Filter - 2.0L Duratec-HE (MI4)-2.5L Duratec-RS (VI5)-2.5L Duratec-ST (VI5)
- Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel
- Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel, Vehicles Without: Water-in-Fuel Sensor
- Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor
- Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor
- Fuel Filter Element - 1.8L Duratorq-TDCi (Lynx) Diesel
- Fuel Filter Element - 2.0L Duratorq-TDCi (DW) Diesel
- Fuel Supply Line - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)-2.5L Duratec-RS (VI5)-2.5L Duratec-ST (VI5)
- Fuel Supply Line - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Fuel Return Line - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Fuel Level Resistor Card
- Fuel Additive Tank to Fuel Tank Line
310-02 Acceleration Control5 pages
- Specifications
Diagnosis and Testing4 pages
- Acceleration Control
Removal and Installation3 pages
310-03 Speed Control › Diagnosis and Testing2 pages
4 Electrical223 pages
412 Climate Control System80 pages
412-00 Climate Control System - General Information11 pages
- Specifications
Diagnosis and Testing10 pages
- Climate Control System
General Procedures9 pages
412-01A Air Distribution and Filtering5 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Air Distribution and Filtering
Removal and Installation2 pages
- Air Distribution and Filtering
412-02A Heating and Ventilation9 pages
Description and Operation8 pages
- Heating and Ventilation
Diagnosis and Testing7 pages
- Heating and Ventilation
Removal and Installation6 pages
- Specifications
412-02B Auxiliary Heating10 pages
- Specifications
Description and Operation9 pages
- Fuel Fired Booster Heater
- Electric Booster Heater
Diagnosis and Testing7 pages
412-03 Air Conditioning23 pages
Description and Operation22 pages
- Air Conditioning
Diagnosis and Testing21 pages
- Air Conditioning
Removal and Installation20 pages
- Air Conditioning (A-C) Compressor - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Air Conditioning (A-C) Compressor - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Air Conditioning (A-C) Compressor - 2.5L Duratec-ST (VI5)
- Air Conditioning (A-C) Compressor - 1.6L Duratorq-TDCi (DV) Diesel
- Air Conditioning (A-C) Compressor - 1.8L Duratorq-TDCi (Lynx) Diesel
- Clutch and Clutch Field Coil
- Air Conditioning (A-C) Compressor - 2.0L Duratorq-TDCi (DW) Diesel
- Clutch and Clutch Field Coil - Vehicles Built Up To: 08-2005 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Compressor to Condenser Discharge Line - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Compressor to Condenser Discharge Line - 2.0L Duratorq-TDCi (DW) Diesel
- Evaporator Core Orifice
- Suction Accumulator
- Suction Accumulator - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Suction Accumulator to Compressor Line - 2.0L Duratorq-TDCi (DW) Diesel
- Condenser Core
- Condenser to Evaporator Line
- Low-Pressure Cutoff Switch
- High-Pressure Cutoff Switch
- Evaporator Outlet Line
- Evaporator Core
- Specifications
412-04 Control Components22 pages
- Specifications
Description and Operation21 pages
- Control Components
Diagnosis and Testing20 pages
- Control Components
Removal and Installation19 pages
- Climate Control Assembly - Vehicles With: Automatic Temperature Control
- Climate Control Assembly - Vehicles With: Manual Temperature Control
- Climate Control Assembly - Vehicles With: Digital Versatile Disc (DVD) Navigation System
- Climate Control Module - Vehicles Built From: 01-2008
- Climate Control Module - Vehicles Built Up To: 01-2008
- Blower Motor Switch
- Driver Side Center Register Air Discharge Temperature Sensor
- Defrost Vent-Register Blend Door Actuator - LHD
- Passenger Side Center Register Air Discharge Temperature Sensor
- Defrost Vent-Register Blend Door Actuator - RHD
- Driver Side Footwell Air Discharge Temperature Sensor
- Passenger Side Footwell Air Discharge Temperature Sensor
- Air Inlet Blend Door Actuator
- Footwell Vent-Duct Blend Door Actuator - RHD
- Footwell Vent-Duct Blend Door Actuator - LHD
- Temperature Blend Door Actuator
- Blower Motor Resistor - RHD
- Blower Motor Resistor - LHD
- Blower Motor Resistor - Vehicles Built From: 10-2005, Vehicles With: Dual Automatic Temperature Control
413 Instrumentation and Warning Systems23 pages
- 413-00 Instrument Cluster and Panel Illumination › Diagnosis and Testing › Instrument Cluster and Panel Illumination
413-01 Instrument Cluster › Description and Operation3 pages
- Instrument Cluster
Diagnosis and Testing2 pages
413-06 Horn4 pages
- Specifications
Diagnosis and Testing3 pages
- Horn
Removal and Installation2 pages
413-07 Clock › Diagnosis and Testing2 pages
413-08 Information and Message Center › Diagnosis and Testing2 pages
413-09 Warning Devices › Diagnosis and Testing2 pages
413-13A Parking Aid - Vehicles With: Rear Parking Aid › Description and Operation9 pages
- Parking Aid - Vehicles With: Rear Parking Aid
Diagnosis and Testing8 pages
- Parking Aid
General Procedures7 pages
414 Battery and Charging System32 pages
414-00 Charging System - General Information › Description and Operation3 pages
- Charging System
Diagnosis and Testing2 pages
414-01 Battery, Mounting and Cables16 pages
- Specifications
Diagnosis and Testing15 pages
- Battery
General Procedures14 pages
- Battery Disconnect and Connect
Removal and Installation13 pages
- Battery - 1.4L Duratec-16V (Sigma)-1.6L (Z6)-1.6L Duratec-16V (Sigma)-1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Battery - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Battery - 2.5L Duratec-ST (VI5)
- Battery Tray - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)-1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Battery Tray - 1.6L Duratorq-TDCi (DV) Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel
- Battery Tray - 1.6L (Z6)
- Battery Tray - 2.5L Duratec-ST (VI5)
- Battery Cables - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Battery Cables - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Battery Cables - 1.6L Duratorq-TDCi (DV) Diesel
- Battery Cables - 1.8L Duratorq-TDCi (Lynx) Diesel
- Battery Cables - 2.0L Duratorq-TDCi (DW) Diesel
- Battery Cables - 2.5L Duratec-ST (VI5)
414-02 Generator and Regulator › Description and Operation › Diagnosis and Testing11 pages
- Generator
Removal and Installation10 pages
- Generator - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)
- Generator - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)
- Generator - 1.6L Duratorq-TDCi (DV) Diesel (90 PS), VIN Plate Emission Level Code: K, Vehicles With: Air Conditioning
- Generator - 1.6L Duratorq-TDCi (DV) Diesel (90 PS), VIN Plate Emission Level Code: S, Vehicles With: Air Conditioning
- Generator - 1.6L Duratorq-TDCi (DV) Diesel (90 PS), Vehicles Without: Air Conditioning
- Generator - 1.8L Duratorq-TDCi (Lynx) Diesel, Vehicles With: Air Conditioning
- Generator - 1.8L Duratorq-TDCi (Lynx) Diesel, Vehicles Without: Air Conditioning
- Generator - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor
- Generator - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor
- Generator - 2.5L Duratec-ST (VI5)
414-05 Voltage Converter-Inverter › Description and Operation2 pages
415 Information and Entertainment Systems18 pages
415-00 Information and Entertainment System - General Information › Diagnosis and Testing3 pages
415-01A Audio Unit › Description and Operation8 pages
Diagnosis and Testing7 pages
- Audio System
Removal and Installation6 pages
- Audio Unit - Vehicles Built From: 03-2007
- Audio Unit - Vehicles Built Up To: 03-2007
- Audio Unit - Vehicles Built Up To: 01-2008, Vehicles With: Digital Versatile Disc (DVD) Navigation System
- Audio Unit - Vehicles Built From: 01-2008, Vehicles With: Digital Versatile Disc (DVD) Navigation System
- Compact Disc (CD) Changer
- Rear Auxiliary Audio Controls
- Audio System
415-02 Antenna › Diagnosis and Testing2 pages
415-03 Speakers › Description and Operation › Diagnosis and Testing2 pages
415-07 Video System › Diagnosis and Testing3 pages
417 Lighting35 pages
417-01 Exterior Lighting32 pages
- Specifications
Description and Operation31 pages
- Exterior Lighting
Diagnosis and Testing30 pages
- Stoplamps
- Turn Signal and Hazard Lamps
- Parking, Rear and License Plate Lamps
- Fog Lamps
- Reversing Lamps
- Headlamps
- Headlamp Leveling
- Trailer Lamps
General Procedures22 pages
- Headlamp Adjustment
- Headlamp Adjustment - Vehicles With: Adaptive Front Lighting
- Front Fog Lamp Adjustment
- Headlamp Masking - Vehicles With: Adaptive Front Lighting
- Headlamp Masking - Vehicles With: High Intensity Discharge Headlamps
- Headlamp Masking - Vehicles Built From: 12-2007
- Headlamp Masking - Vehicles Built Up To: 12-2007
Removal and Installation15 pages
- High Beam Headlamp Bulb - Vehicles With: High Intensity Discharge Headlamps
- Low Beam Headlamp Bulb - Vehicles Built From: 12-2007, Vehicles With: High Intensity Discharge Headlamps
- Low Beam Headlamp Bulb - Vehicles Built Up To: 12-2007, Vehicles With: High Intensity Discharge Headlamps
- Parking Lamp Bulb - Vehicles With: High Intensity Discharge Headlamps
- Headlamp Switch
- Front Fog Lamp - Vehicles Built Up To: 12-2007
- Stoplamp Switch
- Front Fog Lamp - Vehicles Built From: 12-2007
- Headlamp Leveling Rear Sensor
- Headlamp Leveling Front Sensor
- Headlamp Leveling Motor - Vehicles With: High Intensity Discharge Headlamps
- Headlamp Leveling Motor
- Headlamp Assembly
- Rear Lamp Assembly
- Rear Fog and Reversing Lamp - Convertible
- 417-02 Interior Lighting › Diagnosis and Testing › Interior Lighting
417-04 Daytime Running Lamps (DRL) › Description and Operation2 pages
418 Electrical Distribution11 pages
418-00 Module Communications Network › Description and Operation2 pages
418-01 Module Configuration › General Procedures2 pages
418-02 Wiring Harnesses7 pages
Diagnosis and Testing6 pages
- Specifications
419 Electronic Feature Group24 pages
419-01A Anti-Theft - Active3 pages
Description and Operation › Diagnosis and Testing2 pages
- Specifications
419-01B Anti-Theft - Passive › Description and Operation6 pages
Diagnosis and Testing5 pages
- Anti-Theft - Passive
419-07A Navigation System - Vehicles With: Digital Versatile Disc (DVD) Navigation System › Description and Operation4 pages
- Navigation System
Diagnosis and Testing3 pages
- Navigation System
Removal and Installation2 pages
419-07B Navigation System - Vehicles With: Travel Pilot EX › Description and Operation3 pages
- Navigation System
Diagnosis and Testing2 pages
419-08 Cellular Phone › Description and Operation4 pages
- Cellular Phone
Removal and Installation3 pages
419-10 Multifunction Electronic Modules › Description and Operation4 pages
- Module Controlled Functions
Diagnosis and Testing3 pages
- Generic Electronic Module (GEM)
Removal and Installation2 pages
5 Body and Paint372 pages
501 Body and Paint362 pages
- 501-00 Body System - General Information
501-02 Front End Body Panels › General Procedures3 pages
- Hood Alignment
Removal and Installation2 pages
501-03 Body Closures10 pages
- Specifications
General Procedures9 pages
501-05 Interior Trim and Ornamentation31 pages
Description and Operation › Removal and Installation30 pages
- A-Pillar Trim Panel
- B-Pillar Trim Panel - 3-Door
- B-Pillar Trim Panel - 4-Door-5-Door
- C-Pillar Trim Panel - 3-Door
- C-Pillar Trim Panel - 4-Door-5-Door
- C-Pillar Trim Panel - Wagon
- D-Pillar Trim Panel - 4-Door
- D-Pillar Trim Panel - 5-Door
- D-Pillar Trim Panel - Wagon
- Front Door Trim Panel - 3-Door
- Rear Door Trim Panel - Vehicles With: Manual Windows
- Front Door Trim Panel - 4-Door-5-Door-Wagon
- Rear Door Trim Panel - Vehicles With: Power Windows
- Front Scuff Plate Trim Panel
- Rear Scuff Plate Trim Panel
- Loadspace Trim Panel - 3-Door
- Loadspace Trim Panel - 5-Door
- Loadspace Trim Panel - Wagon
- Headliner - 3-Door, Vehicles With: Sliding Roof Opening Panel
- Headliner - 5-Door, Vehicles With: Sliding Roof Opening Panel
- Headliner - 3-Door, Vehicles Without: Sliding Roof Opening Panel
- Headliner - 4-Door
- Headliner - 5-Door, Vehicles Without: Sliding Roof Opening Panel
- Headliner - Wagon, Vehicles With: Sliding Roof Opening Panel
- Headliner - Wagon, Vehicles Without: Sliding Roof Opening Panel
- Headliner - Wagon, Vehicles With: Digital Versatile Disc (DVD) Player
- Rear Quarter Trim Panel - 3-Door
- Rear Quarter Trim Panel - 5-Door-Wagon
- Rear Quarter Trim Panel - Convertible
- Loadspace Trim Panel - Convertible
- Specifications
501-08 Exterior Trim and Ornamentation › Removal and Installation3 pages
501-09 Rear View Mirrors6 pages
Description and Operation5 pages
- Rear View Mirrors
Diagnosis and Testing4 pages
- Rear View Mirrors - Vehicles Without: Global Closing
Removal and Installation3 pages
- Specifications
501-10 Seating22 pages
- Specifications
Diagnosis and Testing21 pages
- Seats
Removal and Installation20 pages
- Heated Seat Switch
- Front Seat
- Front Seat Height Adjustment Motor
- Front Seat Track Motor
- Front Seat Backrest Cover - 3-Door
- Front Seat Backrest Cover - 4-Door-5-Door-Wagon
- Front Seat Backrest Cover - 4-Door-5-Door-Wagon, Vehicles With: 6-Way Power Seats
- Front Seat Backrest Cover - 2.5L Duratec-ST (VI5)
- Front Seat Cushion Cover - 3-Door
- Front Seat Cushion Cover - 4-Door-5-Door-Wagon
- Front Seat Cushion Cover - 2.5L Duratec-ST (VI5)
- Front Seat Cushion Cover - Convertible
- Rear Seat Backrest Cover
- Rear Seat Backrest Cover - 2.5L Duratec-ST (VI5)
- Rear Seat Backrest Cover - Convertible
- Rear Seat Cushion Cover - 2.5L Duratec-ST (VI5)
- Rear Seat Cushion Cover - Convertible
Disassembly and Assembly3 pages
501-11 Glass, Frames and Mechanisms29 pages
- Specifications
Description and Operation28 pages
- Glass, Frames and Mechanisms
Diagnosis and Testing27 pages
- Glass, Frames and Mechanisms - Vehicles Without: Global Closing
- Glass, Frames and Mechanisms - Vehicles With: Global Closing
General Procedures25 pages
- Door Window Motor Initialization
- Door Window Glass Adjustment - Vehicles With: Convertible Top
- Rear Quarter Window Glass Adjustment - Vehicles With: Convertible Top
Removal and Installation22 pages
- Front Door Window Glass
- Front Door Window Glass - Convertible
- Rear Door Window Glass - Vehicles With: Manual Windows
- Rear Door Window Glass - Vehicles With: Power Windows
- Rear Quarter Window Glass - 3-Door-5-Door
- Rear Quarter Window Glass - 4-Door
- Rear Quarter Window Glass - Wagon
- Rear Quarter Window Glass - Convertible
- Rear Window Glass - Convertible
- Rear Quarter Window Regulator Motor - Convertible
- Rear Window Glass - 4-Door
- Liftgate Window Glass - 3-Door-5-Door
- Liftgate Window Glass - Wagon
- Front Door Window Regulator - 3-Door
- Front Door Window Regulator - 4-Door-5-Door-Wagon
- Rear Door Window Regulator - Vehicles With: Power Windows
- Rear Door Window Regulator - Vehicles With: Manual Windows
- Front Door Window Regulator Motor - Vehicles With: Global Closing
- Rear Door Window Regulator Motor
- Front Door Window Regulator and Motor - Convertible
- Windshield Glass
- Windshield Glass - Convertible
501-12 Instrument Panel and Console6 pages
501-14 Handles, Locks, Latches and Entry Systems40 pages
- Specifications
Description and Operation39 pages
- Handles, Locks, Latches and Entry Systems
Diagnosis and Testing38 pages
- Locks, Latches and Entry Systems
General Procedures37 pages
- Remote Transmitter Programming
Removal and Installation36 pages
- Hood Latch
- Front Door Latch - 3-Door
- Front Door Latch - 3-Door, Vehicles With: Keyless Vehicle System
- Front Door Latch - 4-Door-5-Door-Wagon
- Front Door Latch - 4-Door-5-Door-Wagon, Vehicles With: Keyless Vehicle System
- Front Door Latch - Convertible
- Front Door Lock Actuator - 3-Door
- Front Door Lock Actuator - 3-Door, Vehicles With: Keyless Vehicle System
- Front Door Lock Actuator - 4-Door-5-Door-Wagon
- Front Door Lock Actuator - 4-Door-5-Door-Wagon, Vehicles With: Keyless Vehicle System
- Rear Door Lock Actuator
- Rear Door Latch
- Liftgate Latch - 3-Door-5-Door
- Liftgate Latch - Wagon
- Liftgate Latch - 4-Door
- Exterior Front Door Handle
- Exterior Rear Door Handle
- Exterior Front Door Handle - Vehicles With: Keyless Vehicle System
- Hood Lock Cylinder
- Exterior Liftgate Release Switch - 3-Door-5-Door
- Exterior Liftgate Release Switch - 3-Door-5-Door, Vehicles With: Keyless Vehicle System
- Exterior Liftgate Release Switch - Wagon
- Exterior Liftgate Release Switch - Wagon, Vehicles With: Keyless Vehicle System
- Exterior Luggage Compartment Lid Release Switch
- Exterior Luggage Compartment Lid Release Switch - Vehicles With: Keyless Vehicle System
- Ignition Lock Cylinder
- Door Latch Remote Control
- Door Lock Cylinder
- Keyless Vehicle Module
- Keyless Vehicle Module - Convertible
- Luggage Compartment Lid Latch - Convertible
- Luggage Compartment Lid Latch Actuator - Convertible
- Luggage Compartment Lid Side Latch - Convertible
Disassembly and Assembly3 pages
501-16 Wipers and Washers11 pages
- Specifications
Description and Operation10 pages
- Wipers and Washers
Diagnosis and Testing9 pages
- Wipers and Washers
General Procedures8 pages
501-17 Roof Opening Panel14 pages
- Specifications
Diagnosis and Testing13 pages
- Roof Opening Panel
General Procedures12 pages
- Water Drainage System Check and Water Leak Corrections
- Roof Opening Panel Alignment
- Roof Opening Panel Motor Initialization
Removal and Installation9 pages
- Roof Opening Panel Glass
- Roof Opening Panel Shield
- Roof Opening Panel
- Roof Opening Panel Motor
- Roof Opening Panel Rear Drain Hose - 3-Door-5-Door
- Roof Opening Panel Rear Drain Hose - Wagon
- Roof Opening Panel Rear Drain Hose - 4-Door
- Driver Side Roof Opening Panel Front Drain Hose
- Passenger Side Roof Opening Panel Front Drain Hose
501-18 Convertible Top21 pages
- Specifications
Description and Operation20 pages
- Convertible Top
Diagnosis and Testing19 pages
- Convertible Top
General Procedures18 pages
- System Bleeding
- Convertible Top Alignment
Removal and Installation16 pages
- Convertible Top Assembly
- Convertible Top Module
- Convertible Top Headliner
- Convertible Top Switch
- Rear Parcel Shelf
- Convertible Top Lift Cylinder
- Convertible Top Front Panel
- Convertible Top Rear Panel
- Convertible Top Front Latch
- Convertible Top Latch Operating Mechanism
- Header Rail Trim Panel
- Convertible Top Hydraulic Pump
- C-Pillar
- C-Pillar Weatherstrip
- Header Rail Weatherstrip
- Convertible Top Front Panel Side Weatherstrip
501-19 Bumpers13 pages
- Specifications
Removal and Installation12 pages
- Front Bumper Cover - Vehicles Built Up To: 12-2007
- Front Bumper
- Front Bumper Cover - Vehicles Built From: 12-2007
- Front Bumper Cover - 2.5L Duratec-ST (VI5)
- Rear Bumper Cover - 3-Door-5-Door
- Rear Bumper Cover - Vehicles Built From: 12-2007, 5-Door
- Rear Bumper Cover - Vehicles Built Up To: 12-2007, Wagon
- Rear Bumper Cover - Vehicles Built From: 12-2007, Wagon
- Rear Bumper Cover - Vehicles Built Up To: 12-2007, 4-Door
- Rear Bumper Cover - Vehicles Built From: 12-2007, 4-Door
- Rear Bumper Cover - 2.5L Duratec-ST (VI5)
- Rear Bumper Cover - Convertible
501-20A Safety Belt System12 pages
- Specifications
Description and Operation11 pages
Diagnosis and Testing10 pages
- Safety Belt System
Removal and Installation9 pages
- Front Safety Belt Retractor - 3-Door
- Front Safety Belt Retractor - 4-Door-5-Door-Wagon
- Front Safety Belt Retractor - Convertible
- Rear Safety Belt Retractor - 3-Door-5-Door-Wagon
- Rear Safety Belt Retractor - 4-Door
- Rear Safety Belt Retractor - Convertible
- Rear Center Safety Belt Retractor
- Safety Belt Shoulder Height Adjuster
- Safety Belt Buckle and Pretensioner
- Safety Belt System
501-20B Supplemental Restraint System24 pages
- Specifications
Description and Operation23 pages
- Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
Diagnosis and Testing22 pages
- Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
- Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) - Convertible
General Procedures20 pages
- Deployed Air Bag Disposal
- Unserviceable Air Bag Disposal
- Scrapped Vehicle Undeployed Air Bag Disposal
- Scrapped Vehicle Air Bag and Safety Belt Pretensioner Disposal - In-Vehicle Disposal
- Air Bag and Safety Belt Pretensioner Disposal
Removal and Installation15 pages
- Crash Sensor
- Side Impact Sensor
- Side Impact Sensor - Convertible
- Restraints Control Module (RCM)
- Restraints Control Module (RCM) - Convertible
- Driver Air Bag Module
- Passenger Air Bag Module - Vehicles Built Up To: 04-2006
- Passenger Air Bag Module - Vehicles Built From: 04-2006
- Side Air Bag Module
- Side Air Curtain Module - Wagon
- Side Air Curtain Module - 3-Door-5-Door
- Side Air Curtain Module - 4-Door
- Clockspring
- Roll Over Protection Unit
- Passenger Air Bag Deactivation (PAD) Switch
501-25A Body Repairs - General Information26 pages
- Specifications
Description and Operation25 pages
- Description and Usage of Body Repair Literature
- Symbols
- Health and Safety Precautions
- Environmental Regulations
- Body Construction
- Diagnosis and Damage Evaluation
- Tools and Equipment for Body Repairs
- Body Sheet Metal
- Establish Repair Method
- 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
- Plastic Repairs
- Joining Techniques
- Special Repair Techniques
- Impact of Insufficient Repair Quality
- Water Leaks
- Wind Noise
- Noise, Vibration and Harshness
501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks8 pages
- Specifications
- Specifications - Convertible
Description and Operation6 pages
501-27 Front End Sheet Metal Repairs › Removal and Installation4 pages
501-28 Roof Sheet Metal Repairs6 pages
- Specifications - Wagon
- Specifications
- Specifications - Convertible
Removal and Installation3 pages
501-29 Side Panel Sheet Metal Repairs13 pages
- Specifications
- Specifications - Convertible
Removal and Installation11 pages
- Rocker Panel - 3-Door
- Rocker Panel - 5-Door
- Rocker Panel - Wagon
- B-Pillar and Reinforcement - 3-Door
- A-Pillar Outer Panel Section and Reinforcement
- B-Pillar and Reinforcement - 5-Door
- A-Pillar Assembly - Convertible
- A-Pillar Outer Panel - Convertible
- Rocker Panel - Convertible
- Rocker Panel Inner Reinforcement - Convertible
- B-Pillar and Reinforcement - Convertible
501-30 Rear End Sheet Metal Repairs44 pages
- Specifications - 3-Door
- Specifications - 4-Door
- Specifications - Wagon
- Specifications - 5-Door
- Specifications - Convertible
Removal and Installation39 pages
- Quarter Panel LH - 3-Door
- Quarter Panel LH - 5-Door
- Quarter Panel LH - 4-Door
- Quarter Panel LH - Wagon
- Quarter-Side Panel Rear Section LH - 3-Door-5-Door
- Quarter Panel LH - Convertible
- Quarter-Side Panel Rear Section LH - 4-Door
- Quarter-Side Panel Rear Section LH - Wagon
- Quarter-Side Panel Rear Section LH - Convertible
- Inner Quarter Panel and Wheelhouse - Convertible
- Rear Inner Quarter Panel - Convertible
- Water Drain Panel - 4-Door
- Water Drain Panel - 3-Door-5-Door
- Water Drain Panel - Wagon
- Water Drain Panel Reinforcement
- Water Drain Panel Reinforcement - Wagon
- Rear Lamp Mounting Panel - Convertible
- Rear Wheelhouse Outer - 3-Door
- Rear Wheelhouse Outer - 4-Door
- Rear Wheelhouse Outer - 5-Door
- Rear Wheelhouse Outer - Wagon
- Rear Wheelhouse Outer - Convertible
- Rear Lamp Mounting Panel - 4-Door
- Back Panel - 3-Door-5-Door
- Back Panel - 4-Door
- Back Panel - Wagon
- Back Panel and Reinforcement - Convertible
- Back Panel Section - Convertible
- Rear Crossmember - Wagon
- Rear Floor Panel
- Rear Floor Panel - Wagon
- Rear Floor Panel - Convertible
- Rear Floor Panel Section
- Rear Floor Panel Section - Wagon
- Rear Floor Panel Section - Convertible
- Rear Side Member Section
- Rear Side Member Section - Wagon
- Rear Side Member Section - Convertible
- Luggage Compartment Bulkhead
501-36 Paint - General Information16 pages
- Specifications
Description and Operation15 pages
- Description and Usage of Paint Literature
- Symbols
- Environmental Regulations
- Health and Safety Precautions
- Factory Paint Application
- Paintwork Defects and Damage
- Tools and Equipment for Paint Repairs
- Refinishing Materials
- Additional Materials
- Paint Repairs
- Painting Plastic Parts
- Spot Repairs
- Color Identification and Chromatics
- Corrosion Prevention
- Tips and Tricks
502 Frame and Mounting › 502-00 Uni-Body, Subframe and Mounting System10 pages
- Specifications
Removal and Installation9 pages
- Front Axle Crossmember
- Front Axle Crossmember Front Bushing
- Front Axle Crossmember Rear Bushing
- Rear Axle Crossmember - Vehicles With: Fuel Additive Tank-Solid Stabilizer Bar Link
- Rear Axle Crossmember - Vehicles With: Ball Joint Stabilizer Bar Link-Fuel Additive Tank
- Rear Axle Crossmember - Vehicles With: Solid Stabilizer Bar Link, Vehicles Without: Fuel Additive Tank
- Rear Axle Crossmember - Vehicles With: Ball Joint Stabilizer Bar Link, Vehicles Without: Fuel Additive Tank
- Rear Axle Crossmember - Wagon, Vehicles With: Solid Stabilizer Bar Link, Vehicles Without: Fuel Additive Tank
- Rear Axle Crossmember - Wagon, Vehicles With: Fuel Additive Tank-Solid Stabilizer Bar Link