ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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General Information - About This Manual Ikon 1999 (01/2000-)
Description and Operation


This manual has been written in a format that is designed to meet the needs of technicians worldwide. The objective is to use common formats and include similar content in each manual.

This manual provides general descriptions for accomplishing diagnosis and testing, service and repair work with tested, effective techniques. Following them will help assure reliability.

Special Tools

The special tool(s) table provided at the beginning of each procedure shows all special tools required to carry out a repair. Where possible, illustrations are provided to assist in identifying the special tool required.

Important Safety Instructions

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual carrying out the work.

This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Anyone who departs from the instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or components.

Warnings, Cautions and Notes in This Manual

WARNING:Warnings are used to indicate that failure to follow a procedure correctly may result in personal injury.
CAUTION:Cautions are used to indicate that failure to follow a procedure correctly may result in damage to the vehicle or equipment being used.
NOTE:Notes are used to provide additional essential information required to carry out a complete and satisfactory repair.

As you read through this manual, you will come across WARNINGS, CAUTIONS and NOTES.

A warning, caution or note is placed at the beginning of a series of steps if it applies to multiple steps. If the warning, caution or note only applies to one step, it is placed at the beginning of the specific step (after the step number).

How to Use This Manual

This manual covers diagnosis and testing, service and repair procedures.

This manual is structured into groups and sections, with specific system sections collected together under their relevant group.

A group covers a specific portion of the vehicle. The manual is divided into five groups, General Information, Chassis, Powertrain, Electrical and Body and Paint. The number of the group is the first number of a section number.

Pages at the start of the manual list all sections available. Each section has a contents list detailing Specifications, Description and Operation, Diagnosis and Testing, In Vehicle Repairs, Disassembly and Assembly, Removal and Installation.

If components need to be removed or disassembled in sequence, the sequence will be identified numerically in a graphic and the corresponding text will be numbered accordingly.

All left and right-hand references to the vehicle are taken from a position sitting in the driver seat looking forward.

All left and right-hand references to the engine are taken from a position at the flywheel looking towards the front camshaft pulley.

Where appropriate, instructions will be given for the use of the diagnostic tool.

Overview Procedures

Overview procedures contain an exploded view illustration(s). The numbered sequence within the illustration(s) indicate the order to be followed when removing/disassembling or when installing/assembling a component. Additional information, symbol(s) or a torque figure, may also be shown alongside the component.

There are ten symbols used to give additional information when removing/disassembling or when installing/assembling a component.

Item Designation Description
1 Special tool A special tool is required for this component. There will also be a removal or installation symbol alongside the special tool symbol.
2 Install new component Discard the old component and install a new component.
3 Inspect Check the component for damage.
4 Apply sealant Apply sealant to the component as specified in the mate-rials table.
5 Apply petroleum jelly Apply petroleum jelly to the component as specified in the materials table.
6 Apply oil Apply oil to the component as specified in the materials table.
7 Apply fluid Apply fluid to the component as specified in the materials table.
8 Apply grease Apply grease to the component as specified in the mate-rials table.
9 Removal or Disassembly detail Go to the removal or disassembly detail for additional information to remove or disassemble a component
10 Installation or Assembly detail Go to the installation or assembly detail for additional information to install or assemble a component

Inspection and Verification

Visual Inspection Charts, Symptom Charts and other information charts (such as diagnostic routines) or supplement test procedures with technical specifications will navigate the user to a specific test procedure.

Symptom Chart

The symptom chart indicates symptoms, sources and actions to address a condition.

Pinpoint Tests

For electrical systems, pinpoint test steps are used to identify the source of a concern in a logical, step-by-step manner. pinpoint tests have two columns: CONDITIONS and DETAILS/RESULTS/ACTIONS.

The CONDITIONS column is used exclusively for graphics and icons (with or without captions) and the DETAILS/RESULTS/ACTIONS column provides direction to another test step or specific corrective actions.

The boxed numbers indicate the order in which the described action is to be performed.

Component Tests

A component test is used when a component is tested in multiple pinpoint tests, or if a procedure is too complicated to be formatted within a single page of the pinpoint test.


Test graphics show the measurement or test to be performed in a test step.

A representative tester graphic is used for voltmeters and ohmmeters.

If multiple measurements are made in a single graphic, the test leads are drawn with a solid line until the test lead splits to indicate the multiple measurements, at which point dashed lines are used.

Breakout box-type testers are represented by a double circle test pin. Test pins are labeled with the pin number.

Special Tools and Torque Figures

Any requirement for special tools will picture the tool, showing it in use and with its tool number shown. Torque settings will be given at the relevant point in the procedure.

Standard Workshop Practices >