Puma 1998 (06.1997-12.2001) Workshop Manual
- Mechanical Repairs
- 1 General Information
- 100 Service Information
- 100-00 General Information
- 100-01 Identification Codes
- Description and Operation
- 100-02 Jacking and Lifting
- Description and Operation
- 100-04 Noise, Vibration and Harshness
- Description and Operation
- Noise, Vibration and Harshness (NVH)
- Diagnosis and Testing
- 100-04 Noise, Vibration and Harshness|Specifications
- Description and Operation
- 100 Service Information
- 2 Chassis
- 204 Suspension
- 204-00 Suspension System - General Information
- 204-00 Suspension System - General Information|Specifications
- Diagnosis and Testing
- Suspension System
- General Procedures
- 204-01 Front Suspension
- 204-01 Front Suspension|Specifications
- Description and Operation
- Diagnosis and Testing
- Front Suspension
- Removal and Installation
- Front Suspension
- Diagnosis and Testing
- 204-02 Rear Suspension
- 204-02 Rear Suspension|Specifications
- Description and Operation
- Rear Suspension
- Diagnosis and Testing
- Rear Suspension
- Removal and Installation
- Rear Wheel Bearing
- Beam Axle
- Wheel Spindle
- Trailing Arm Bushing
- Rear Strut and Spring Assembly
- Disassembly and Assembly
- 204-04 Wheels and Tires
- 204-04 Wheels and Tires|Specifications
- Description and Operation
- Diagnosis and Testing
- Wheels and Tires
- Removal and Installation
- Wheels and Tires
- Diagnosis and Testing
- 204-00 Suspension System - General Information
- 205 Driveline
- 205-04 Front Drive Halfshafts
- 205-04 Front Drive Halfshafts|Specifications
- Description and Operation
- Front Drive Halfshafts
- Diagnosis and Testing
- Front Drive Halfshafts
- Removal and Installation
- Front Halfshaft LH
- Front Halfshaft RH
- Outer Constant Velocity (CV) Joint
- Disassembly and Assembly
- 205-04 Front Drive Halfshafts
- 206 Brake System
- 206-00 Brake System - General Information
- 206-00 Brake System - General Information|Specifications
- Description and Operation
- Brake System
- Diagnosis and Testing
- Brake System
- General Procedures
- 206-02 Drum Brake
- 206-02 Drum Brake|Specifications
- Description and Operation
- Diagnosis and Testing
- Drum Brake
- Removal and Installation
- Drum Brake
- Diagnosis and Testing
- 206-03 Front Disc Brake
- Description and Operation
- Front Disc Brake
- Diagnosis and Testing
- Front Disc Brake
- Removal and Installation
- 206-03 Front Disc Brake|Specifications
- Description and Operation
- 206-05 Parking Brake and Actuation
- Description and Operation
- Parking Brake
- Diagnosis and Testing
- Parking Brake
- General Procedures
- Parking Brake Cable Adjustment
- Removal and Installation
- 206-05 Parking Brake and Actuation|Specifications
- Description and Operation
- 206-06 Hydraulic Brake Actuation
- Description and Operation
- Hydraulic Brake Actuation
- Diagnosis and Testing
- Hydraulic Brake Actuation
- Removal and Installation
- 206-06 Hydraulic Brake Actuation|Specifications
- Description and Operation
- 206-07 Power Brake Actuation
- 206-07 Power Brake Actuation|Specifications
- Description and Operation
- Brake Booster
- Diagnosis and Testing
- Power Brake System
- Removal and Installation
- 206-09 Anti-Lock Control - Traction Control
- Description and Operation
- Anti-Lock Control - Traction Control
- Diagnosis and Testing
- 206-09 Anti-Lock Control - Traction Control|Specifications
- Description and Operation
- 206-00 Brake System - General Information
- 211 Steering System
- 211-00 Steering System - General Information
- 211-00 Steering System - General Information|Specifications
- Description and Operation
- Steering System
- Diagnosis and Testing
- Steering System
- General Procedures
- 211-02 Power Steering
- Description and Operation
- 211-02 Power Steering|Specifications
- 211-03 Steering Linkage
- 211-03 Steering Linkage|Specifications
- Description and Operation
- Diagnosis and Testing
- Steering Linkage
- Removal and Installation
- Steering Linkage
- Diagnosis and Testing
- 211-04 Steering Column
- 211-04 Steering Column|Specifications
- Description and Operation
- Steering Column
- Removal and Installation
- 211-05 Steering Column Switches
- Description and Operation
- Steering Column Switches
- Diagnosis and Testing
- Steering Column Switches
- Removal and Installation
- Description and Operation
- 211-00 Steering System - General Information
- 204 Suspension
- 3 Powertrain
- 303 Engine
- 303-00 Engine System - General Information
- Description and Operation
- 303-00 Engine System - General Information|Engine
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- General Procedures
- Camshaft Bearing Journal Diameter
- Camshaft Bearing Journal Clearance
- Camshaft Lobe Lift
- Camshaft End Play
- Crankshaft End Play
- Cylinder Bore Taper
- Piston Ring End Gap
- Piston Diameter
- Piston Ring-to-Groove Clearance
- Connecting Rod Bearing Journal Clearance
- Flywheel Clutch Surface Inspection
- Cylinder Head Distortion
- Description and Operation
- 303-01A Engine - 1.7L
- 303-01A Engine - 1.7L|Specifications
- Description and Operation
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- General Procedures
- Valve Clearance
- In-vehicle Repair
- Intake Manifold
- Valve Cover
- Crankshaft Front Seal
- Valve Seals
- In-vehicle Repair|Valves
- Camshafts
- Camshaft Seal
- Timing Belt
- Exhaust Manifold
- Cylinder Head
- Oil Pressure Switch
- In-vehicle Repair|Oil Pan
- Removal
- In-vehicle Repair|Engine
- Disassembly
- In-vehicle Repair|Disassembly|Engine
- Disassembly and Assembly of Subassemblies
- Cylinder Head
- Assembly
- Assembly|Engine
- Installation
- 303-01A Engine - 1.7L|Engine
- Diagnosis and Testing
- 303-01B Engine - 1.4L Zetec-SE (Sigma)-1.6L
- 303-01B Engine - 1.4L Zetec-SE (Sigma)-1.6L|Specifications
- Description and Operation
- 303-01B Engine - 1.4L Zetec-SE (Sigma)-1.6L|Engine
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- General Procedures
- Valve Clearance
- In-vehicle Repair
- Intake Manifold
- Valve Cover
- Crankshaft Front Seal
- Camshafts
- Valve Seals
- Camshaft Seal
- Timing Belt
- Exhaust Manifold
- Cylinder Head
- In-vehicle Repair|Oil Pan
- Removal
- In-vehicle Repair|Engine
- Disassembly
- In-vehicle Repair|Disassembly|Engine
- Disassembly and Assembly of Subassemblies
- Cylinder Head
- Assembly
- Assembly|Engine
- Installation
- 303-03 Engine Cooling
- Description and Operation
- Engine Cooling
- Diagnosis and Testing
- Engine Cooling
- General Procedures
- Cooling System Draining, Filling and Bleeding
- Removal and Installation
- 303-03 Engine Cooling|Specifications
- Description and Operation
- 303-04 Fuel Charging and Controls
- 303-04 Fuel Charging and Controls|Specifications
- Description and Operation
- Diagnosis and Testing
- Fuel Charging and Controls
- Removal and Installation
- Fuel Charging and Controls
- Diagnosis and Testing
- 303-05 Accessory Drive
- 303-05 Accessory Drive|Specifications
- Description and Operation
- Accessory Drive
- Diagnosis and Testing
- Removal and Installation
- Accessory Drive
- 303-06 Starting System
- 303-06 Starting System|Specifications
- Description and Operation
- Starting System
- Diagnosis and Testing
- Starting System
- Removal and Installation
- 303-07 Engine Ignition
- Description and Operation
- Engine Ignition
- Diagnosis and Testing
- Engine Ignition
- Removal and Installation
- 303-07 Engine Ignition|Specifications
- Description and Operation
- 303-08 Engine Emission Control
- 303-08 Engine Emission Control|Specifications
- Description and Operation
- Diagnosis and Testing
- Engine Emission Control
- Removal and Installation
- Engine Emission Control
- Diagnosis and Testing
- 303-12 Intake Air Distribution and Filtering
- Description and Operation
- Diagnosis and Testing
- Intake Air Distribution and Filtering
- Removal and Installation
- Intake Air Distribution and Filtering
- Diagnosis and Testing
- Description and Operation
- 303-13 Evaporative Emissions
- Description and Operation
- Evaporative Emissions
- Diagnosis and Testing
- Evaporative Emissions
- Removal and Installation
- Description and Operation
- 303-14 Electronic Engine Controls
- 303-14 Electronic Engine Controls|Specifications
- Description and Operation
- Electronic Engine Controls
- Diagnosis and Testing
- Electronic Engine Controls
- Removal and Installation
- Camshaft Position (CMP) Sensor
- Crankshaft Position (CKP) Sensor
- Power Steering Pressure (PSP) Switch
- Powertrain Control Module (PCM)
- Throttle Position (TP) Sensor
- Idle Air Control (IAC) Valve
- Engine Coolant Temperature (ECT) Sensor
- Mass Air Flow (MAF) Sensor
- Intake Air Temperature (IAT) Sensor
- Heated Oxygen Sensor (HO2S)
- 303-00 Engine System - General Information
- 308 Manual Transmission-Transaxle, Clutch and Transfer Case
- 308-00 Manual Transmission-Transaxle and Clutch - General Information
- Description and Operation
- 308-00 Manual Transmission-Transaxle and Clutch - General Information|Specifications
- 308-01 Clutch
- 308-01 Clutch|Specifications
- Description and Operation
- Diagnosis and Testing
- Diagnosis and Testing|Clutch
- Removal and Installation
- 308-01 Clutch|Clutch
- Diagnosis and Testing
- 308-02 Clutch Controls
- 308-02 Clutch Controls|Specifications
- Description and Operation
- Diagnosis and Testing
- Clutch Controls
- Removal and Installation
- Clutch Controls
- Diagnosis and Testing
- 308-03 Manual Transmission-Transaxle
- 308-03 Manual Transmission-Transaxle|Specifications
- Description and Operation
- Manual Transaxle
- Diagnosis and Testing
- Manual Transaxle
- General Procedures
- Bearing Check
- In-vehicle Repair
- Input Shaft Seal
- Halfshaft Seal LH
- Halfshaft Seal RH
- Speedometer Driven Gear
- Removal
- Transaxle
- Disassembly
- Transaxle
- Disassembly and Assembly of Subassemblies
- Selector Plate
- Input Shaft
- Differential
- Mainshaft
- Assembly
- 308-06 Manual Transmission-Transaxle External Controls
- 308-06 Manual Transmission-Transaxle External Controls|Specifications
- Description and Operation
- Diagnosis and Testing
- External Controls
- Removal and Installation
- External Controls
- Diagnosis and Testing
- 308-00 Manual Transmission-Transaxle and Clutch - General Information
- 309 Exhaust System
- 309-00 Exhaust System
- Description and Operation
- Exhaust System
- Diagnosis and Testing
- Exhaust System
- Removal and Installation
- 309-00 Exhaust System|Specifications
- Description and Operation
- 309-00 Exhaust System
- 310 Fuel System
- 310-00 Fuel System - General Information
- 310-00 Fuel System - General Information|Specifications
- Description and Operation
- Diagnosis and Testing
- Fuel System
- General Procedures
- Fuel System
- Diagnosis and Testing
- 310-01 Fuel Tank and Lines
- 310-01 Fuel Tank and Lines|Specifications
- Description and Operation
- Fuel Tank and Lines
- Diagnosis and Testing
- 310-02 Acceleration Control
- Description and Operation
- Acceleration Control
- Diagnosis and Testing
- Acceleration Control
- General Procedures
- Description and Operation
- 310-00 Fuel System - General Information
- 303 Engine
- 4 Electrical
- 412 Climate Control System
- 412-00 Climate Control System - General Information
- 412-00 Climate Control System - General Information|Specifications
- Description and Operation
- Climate Control System
- Diagnosis and Testing
- 412-01 Air Distribution and Filtering
- Description and Operation
- Air Distribution and Filtering
- Diagnosis and Testing
- Removal and Installation
- Air Distribution and Filtering
- Description and Operation
- 412-02 Heating and Ventilation
- Description and Operation
- Heating and Ventilation
- Diagnosis and Testing
- Heating and Ventilation
- Removal and Installation
- Blower Motor
- Heater Core Housing
- Heater Core
- Disassembly and Assembly
- Heater Control Valve
- 412-02 Heating and Ventilation|Specifications
- Description and Operation
- 412-03 Air Conditioning
- 412-03 Air Conditioning|Specifications
- Description and Operation
- Diagnosis and Testing
- Air Conditioning
- Removal and Installation
- Air Conditioning (A-C) Compressor
- Clutch and Clutch Field Coil
- Evaporator Core
- Suction Accumulator
- Evaporator Core Orifice
- Low-Pressure Cutoff Switch
- Condenser Core
- High-Pressure Cutoff Switch
- Evaporator to Condenser Suction Line
- Suction Accumulator to Compressor Line
- Suction Accumulator to Evaporator Line
- Air Conditioning
- Diagnosis and Testing
- 412-04 Control Components
- Description and Operation
- Diagnosis and Testing
- Control Components
- Removal and Installation
- Control Components
- Diagnosis and Testing
- Description and Operation
- 412-00 Climate Control System - General Information
- 413 Instrumentation and Warning Systems
- 413-00 Instrument Cluster and Panel Illumination
- Description and Operation
- Removal and Installation
- Instrument Cluster and Panel Illumination
- Description and Operation
- 413-01 Instrument Cluster
- 413-01 Instrument Cluster|Specifications
- Description and Operation
- Instrument Cluster
- Diagnosis and Testing
- 413-06 Horn
- Description and Operation
- 413-06 Horn|Horn
- Diagnosis and Testing
- Diagnosis and Testing|Horn
- Removal and Installation
- 413-06 Horn|Specifications
- Description and Operation
- 413-07 Clock
- Diagnosis and Testing
- 413-09 Warning Devices
- Description and Operation
- Warning Devices
- Diagnosis and Testing
- Description and Operation
- 413-13 Parking Aid
- Diagnosis and Testing
- 413-00 Instrument Cluster and Panel Illumination
- 414 Battery and Charging System
- 414-00 Charging System - General Information
- Description and Operation
- Charging System
- Diagnosis and Testing
- Charging System
- General Procedures
- Description and Operation
- 414-01 Battery, Mounting and Cables
- Description and Operation
- Battery and Cables
- Diagnosis and Testing
- Diagnosis and Testing|Battery
- General Procedures
- Battery Disconnect
- Removal and Installation
- 414-01 Battery, Mounting and Cables|Specifications
- Description and Operation
- 414-02 Generator and Regulator
- Description and Operation
- 414-02 Generator and Regulator|Specifications
- 414-00 Charging System - General Information
- 415 Information and Entertainment Systems
- 415-00 Information and Entertainment System - General Information
- Diagnosis and Testing
- 415-01 Audio Unit
- Description and Operation
- Audio System
- Diagnosis and Testing
- Audio System
- Removal and Installation
- Description and Operation
- 415-02 Antenna
- Description and Operation
- Diagnosis and Testing
- Diagnosis and Testing|Antenna
- Removal and Installation
- 415-02 Antenna|Antenna
- Diagnosis and Testing
- Description and Operation
- 415-03 Speakers
- 415-00 Information and Entertainment System - General Information
- 417 Lighting
- 417-01 Exterior Lighting
- 417-01 Exterior Lighting|Specifications
- Description and Operation
- Exterior Lighting
- Diagnosis and Testing
- Headlamps
- Stoplamps
- Turn Signal and Hazard Lamps
- Parking, Rear and License Plate Lamps
- Reversing Lamps
- Fog Lamps
- General Procedures
- Headlamp Adjustment
- Removal and Installation
- 417-02 Interior Lighting
- Description and Operation
- Interior Lighting
- Diagnosis and Testing
- Description and Operation
- 417-01 Exterior Lighting
- 418 Electrical Distribution
- 418-00 Module Communications Network
- Description and Operation
- Communications Network
- Diagnosis and Testing
- Description and Operation
- 418-00 Module Communications Network
- 419 Electronic Feature Group
- 419-01A Anti-Theft - Active
- Description and Operation
- Anti-Theft - Active
- Diagnosis and Testing
- Anti-Theft - Active
- Removal and Installation
- Description and Operation
- 419-01B Anti-Theft - Passive
- Description and Operation
- Anti-Theft - Passive
- Diagnosis and Testing
- Description and Operation
- 419-10 Multifunction Electronic Modules
- 419-10 Multifunction Electronic Modules|Specifications
- Description and Operation
- Diagnosis and Testing
- Module Controlled Functions
- 419-01A Anti-Theft - Active
- 412 Climate Control System
- 5 Body and Paint
- 501 Body and Paint
- 501-03 Body Closures
- 501-03 Body Closures|Specifications
- Description and Operation
- Body Closures
- General Procedures
- 501-05 Interior Trim and Ornamentation
- Description and Operation
- Interior Trim
- Removal and Installation
- 501-05 Interior Trim and Ornamentation|Specifications
- Description and Operation
- 501-08 Exterior Trim and Ornamentation
- 501-08 Exterior Trim and Ornamentation|Specifications
- Description and Operation
- 501-09 Rear View Mirrors
- Description and Operation
- Rear View Mirrors
- Diagnosis and Testing
- Rear View Mirrors
- Removal and Installation
- Description and Operation
- 501-10 Seating
- Description and Operation
- 501-10 Seating|Seats
- Diagnosis and Testing
- Diagnosis and Testing|Seats
- Removal and Installation
- Front Seat
- Front Seat Cushion - Vehicles Built From: 01-1999
- Front Seat Backrest - Vehicles Built From: 01-1999
- Rear Seat Cushion
- Front Seat Cushion - Vehicles With: Sports Seats
- Front Seat Backrest - Vehicles With: Sports Seats
- Disassembly and Assembly
- Front Seat Cushion - Vehicles Built Up To: 01-1999
- Front Seat Cushion - Vehicles Built From: 01-1999
- Rear Seat Cushion - Vehicles Built Up To: 01-1999
- Front Seat Backrest - Vehicles Built Up To: 01-1999
- Front Seat Backrest - Vehicles Built From: 01-1999
- Rear Seat Backrest - Vehicles Built Up To: 01-1999
- Front Seat Cushion - Vehicles With: Sports Seats
- Front Seat Backrest - Vehicles With: Sports Seats
- 501-10 Seating|Specifications
- Description and Operation
- 501-11 Glass, Frames and Mechanisms
- 501-11 Glass, Frames and Mechanisms|Specifications
- Description and Operation
- Glass, Frames and Mechanisms
- Diagnosis and Testing
- Glass, Frames and Mechanisms
- General Procedures
- 501-12 Instrument Panel and Console
- Description and Operation
- Instrument Panel
- Removal and Installation
- Description and Operation
- 501-14A Handles, Locks, Latches and Entry Systems
- Description and Operation
- 501-14A Handles, Locks, Latches and Entry Systems|Specifications
- 501-14B Handles, Locks, Latches and Entry Systems
- Description and Operation
- 501-16 Wipers and Washers
- 501-16 Wipers and Washers|Specifications
- Description and Operation
- Wipers and Washers
- Diagnosis and Testing
- Wipers and Washers
- General Procedures
- 501-19 Bumpers
- 501-19 Bumpers|Specifications
- Description and Operation
- 501-19 Bumpers|Bumpers
- Removal and Installation
- 501-20A Safety Belt System
- Description and Operation
- 501-20A Safety Belt System|Specifications
- 501-20B Supplemental Restraint System
- 501-20B Supplemental Restraint System|Specifications
- Description and Operation
- Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
- Diagnosis and Testing
- 501-25 Body Repairs - General Information
- 501-25 Body Repairs - General Information|Specifications
- Description and Operation
- Description and Usage of Body Repair Literature
- Health and Safety Precautions
- 501-25 Body Repairs - General Information|Symbols
- Environmental Regulations
- Body Construction
- Body Sheet Metal
- Diagnosis and Damage Evaluation
- Tools and Equipment for Body Repairs
- Establish Repair Method
- Alignment Check
- Complete Panel Replacement-Partial Replacement
- Straightening
- Corrosion 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
- Impact of Insufficient Repair Quality
- Water Leaks
- Noise, Vibration and Harshness
- Wind Noise
- 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks
- 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks|Specifications
- Description and Operation
- Body and Frame
- General Procedures
- 501-27 Front End Sheet Metal Repairs
- 501-28 Roof Sheet Metal Repairs
- Removal and Installation
- 501-28 Roof Sheet Metal Repairs|Specifications
- 501-29 Side Panel Sheet Metal Repairs
- 501-30 Rear End Sheet Metal Repairs
- 501-30 Rear End Sheet Metal Repairs|Specifications
- Removal and Installation
- Quarter Panel LH
- Quarter-Side Panel Rear Section LH
- Quarter-Side Panel Front Section
- Inner Quarter Panel and Wheelhouse
- Water Drain Panel
- Rear Outer Wheelhouse Half Section
- Rear Outer Wheelhouse Half
- Back Panel
- Back Panel and Reinforcement
- Back Panel Section
- Rear Floor Panel Section RH
- Rear Side Member Section
- 501-03 Body Closures
- 501 Body and Paint
- 1 General Information
- Body and Paint
- 5 Body and Paint
- 501 Body and Paint
- 501-25 Body Repairs - General Information
- 501-25 Body Repairs - General Information|Specifications
- Description and Operation
- Description and Usage of Body Repair Literature
- 501-25 Body Repairs - General Information|Symbols
- Health and Safety Precautions
- Environmental Regulations
- Body Construction
- Body Sheet Metal
- Diagnosis and Damage Evaluation
- Tools and Equipment for Body Repairs
- Establish Repair Method
- Alignment Check
- Complete Panel Replacement-Partial Replacement
- Straightening
- Corrosion 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
- Impact of Insufficient Repair Quality
- Water Leaks
- Wind Noise
- Noise, Vibration and Harshness
- 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks
- 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks|Specifications
- Description and Operation
- Body and Frame
- General Procedures
- 501-27 Front End Sheet Metal Repairs
- Removal and Installation
- 501-28 Roof Sheet Metal Repairs
- Removal and Installation
- 501-28 Roof Sheet Metal Repairs|Specifications
- 501-29 Side Panel Sheet Metal Repairs
- 501-30 Rear End Sheet Metal Repairs
- 501-30 Rear End Sheet Metal Repairs|Specifications
- Removal and Installation
- Quarter Panel LH
- Quarter-Side Panel Rear Section LH
- Quarter-Side Panel Front Section
- Inner Quarter Panel and Wheelhouse
- Water Drain Panel
- Rear Outer Wheelhouse Half Section
- Rear Outer Wheelhouse Half
- Back Panel
- Back Panel Section
- Back Panel and Reinforcement
- Rear Floor Panel Section RH
- Rear Side Member Section
- 501-25 Body Repairs - General Information
- 501 Body and Paint
- 5 Body and Paint