Content

Operating instructions

Maintenance

• Dimensions and weight
• Lubricants and fluids
• Tire pressures
• Service specifications
• Identification number
• Weekly checks
• Part A: Maintenance - Gasoline Engines
• Every 15,000 km or 12 months
• Every 36,000km or 2 years
• Every 50,000 km or 3 years
• Every 3 years
• Part B: Maintenance - Diesel Engines
• Every 7,500 km or 6 months
• Every 15,000 km or 12 months
• Every 30,000 km
• Every 45,000 km
• Every 60,000 km
• Every 3 years, regardless of mileage
• Every 4 years, regardless of mileage

Repair of HCS and Endura-E engines in the engine compartment

• Specifications
• General description
• Compression check - description
• Installing the piston of cylinder No. 1 at TDC
• Cylinder head valve cover - removing and installing
• Valve clearances - check and adjust
• Cylinder head valve train - removal, inspection and installation
• Cylinder head - removal and installation
• Crankshaft pulley - removal and installation
• Main drive chain cover - removal and installation
• Main drive chain, sprockets and tensioner - removal, inspection and installation
• Pallet - removal and installation
• Oil pump - removal and installation
• Oil pump - bulkhead and inspection
• Crankshaft oil seals - replacement
• Engine / transmission mounts - inspect and replace
• Flywheel - removal, inspection and installation

Repair of CVH and PTE engines in the engine compartment

• Specifications
• General description
• Compression check - description
• Installing the piston of the cylinder No. 1 at TDC
• Cylinder head valve cover - removing and installing
• Valve clearances - general description
• Crankshaft pulley - removal and installation
• Toothed belt covers - removing and installing
• Toothed drive belt - removing, installing and tension adjustment
• Timing belt and sprocket tensioner - removal, inspection and installation
• Camshaft oil seal - replacement
• Camshaft, rocker arms and valve tappets - removal, inspection and installation
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump - removal and installation
• Oil pump - bulkhead and inspection
• Crankshaft oil seals - replacement
• Engine / transmission mounts - replacement
• Flywheel / drive disc - removal, inspection and installation

Repair of Zetec and Zetec-E engines in the engine compartment

• Specifications
• General description
• Compression check - description
• Installing the piston of cylinder No. 1 at TDC
• Valve cover - removal and installation
• Valve clearances - general description
• Crankshaft pulley - removal and installation
• Toothed belt covers - removing and installing
• Toothed drive belt - removal, installation and adjustment
• Timing belt and sprocket tensioner - removal, inspection and installation
• Camshaft oil seals - replacement
• Camshafts and hydraulic tappets - removal, inspection and installation
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump - removal, inspection and installation
• Crankshaft oil seals - replacement
• Flywheel / drive disc - removal, inspection and installation
• Engine / transmission mounts - inspect and replace

Diesel engine - repair operations in the car

• Specifications
• General description
• Compression and leak testing of component joints - description and interpretation
• Top dead center (TDC) for piston1 - location
• Valve clearances - check and adjust
• Crankshaft pulley / vibration damper - removal and installation
• Toothed belt covers - removing and installing
• Toothed drive belt and fuel pump drive belt - removal, inspection and installation
• Tensioners and sprockets - removal, inspection and installation
• Camshaft oil seal - replacement
• Intermediate shaft oil seal - replacement
• Camshaft and valve lifters - removal, inspection and installation
• Cylinder head - removal, inspection and installation
• Pallet - removal and installation
• Oil pump - removal, inspection and installation
• Crankshaft oil seals - replacement
• Flywheel - removal, inspection and installation
• Engine / transmission mounts inspection and replacement

Removing and rebuilding the engine

• Specifications
• General description
• Engine / transmission removal - preparation and precautions
• Engine - removal and installation (HCS and Endura-E)
• Engine / transmission - removal and installation (CVH and PTE)
• Engine / transmission - removal and installation
• Engine overhaul - preliminary information
• Cylinder head disassembly
• Cylinder head and valve components - cleaning and inspection
• Cylinder head assembly
• Intermediate shaft (diesel engine) - removal, inspection and installation
• Camshaft and tappets - removal, inspection and installation (HCS and Endura-E)
• Piston / connecting rod assemblies - removal and inspection
• Crankshaft - removal and inspection
• Crankcase / crankcase - cleaning and inspection
• Main and connecting rod bearings - inspection
• Engine overhaul - assembly sequence
• Piston rings - installation
• Crankshaft - installing and checking the main bearing running clearance
• Piston / connecting rod assemblies - installing and checking connecting rod bearing running clearance
• Engine - starting after bulkhead

Cooling, heating and ventilation systems

• Specifications
• General description and precautions
• Antifreeze - general description
• Coolant hoses - disconnecting and replacing
• Thermostat - removal, check and installation
• Assembling the radiator fan - checking, removing and installing
• Electrical switches and sensors of the cooling system - check, removal and installation
• Radiator and expansion tank - removal, inspection and installation
• Water pump (HCS and Endura-E engines) - removal and installation
• Water pump (CVH and PTE engines) - removal and installation
• Water pump (Zetec and Zetec-E engines) - removal and installation
• Heating / ventilation system components - removal and installation
• Heater / air conditioning controls - removal and installation
• Air conditioning system - general description and precautions
• Air conditioning components - removal and installation

Fuel system - carburetor engines

• Specifications
• General description and precautions
• Air filter - removal and installation
• Throttle cable (models with manual transmission) - removal, installation and adjustment
• Throttle cable (cam plate) (models with automatic transmission CTX) - adjustment
• Gas pedal - removal and installation
• Choke cable - removal, installation and adjustment
• Fuel priming pump - check, removal and installation
• Fuel tank - removal, inspection and installation
• Fuel level sensor - removal and installation
• Overflow valve - removal and installation
• Fuel filler pipe - removal and installation
• Carburetor (Weber TLDM) - description
• Carburetor (Weber TLDM) - adjusting increased idle speed
• Regulator needle and float (Weber TLDM carburetor) - removal, installation and adjustment
• Throttle switch unit (Weber TLDM carburetor) - removal, installation and adjustment
• Carburetor (Weber TLDM) - removal and installation
• Carburetor (Weber TLDM) - disassembly, cleaning, inspection and assembly
• Carburetor (Weber TLD) - description
• Carburetor (Weber TLD) - adjusting increased idle speed
• Float regulator needle and float (Weber TLD carburetor) - removal, installation and adjustment
• Automatic choke (Weber TLD carburetor) - adjustment
• Automatic choke (Weber TLD carburetor) - removal, inspection and installation
• Carburetor (Weber TLD) - removal and installation
• Carburetor (Weber TLD) - disassembly, cleaning, inspection and assembly
• Intake manifold - removal and installation

Central fuel injection system (CFi)

• Specifications
• General description and precautions
• Fuel system - pressure relief
• Fuel lines and connections - general description
• Air filter assembly and air intake components - removal and installation
• Throttle cable - removal, installation and adjustment
• Gas pedal - check and install
• Fuel priming pump / fuel pressure - check
• Fuel tank - removal, inspection and installation
• Fuel priming pump / fuel level sensor removal and installation
• "Overflow valve - removal and installation
• Fuel cut-off switch - removal and installation
• Fuel injection system - check
• Fuel injection system components - removal and installation
• Intake manifold - removal and installation

Electronic fuel injection (EFi)

• Specifications
• General description and precautions
• Fuel system - pressure relief
• Fuel lines and joints - general description
• Air filter assembly and air intake components - removal and installation
• Gas pedal cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Fuel priming pump / fuel pressure - check
• Fuel tank - removal, inspection and installation
• Fuel priming pump / fuel level sensor - removal and installation
• Overflow valve - removal and installation
• Fuel cut-off switch - removal and installation
• Fuel injection system - check
• Fuel injection system components - removal and installation
• Intake manifold - removal and installation

Electronic sequential fuel injection (SEFi)

• Specifications
• General description and precautions
• Fuel system - pressure relief
• Fuel lines and joints - general description
• Air filter assembly and air intake components - removal and installation
• Gas pedal cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Fuel priming pump / fuel pressure - check
• Fuel tank - removal, inspection and installation
• Fuel priming pump / fuel level sensor removal and installation
• Overflow valve - removal and installation
• Fuel cut-off switch - removal and installation
• Fuel injection system - check
• Fuel injection system components - removal and installation
• Intake manifold - removal and installation

Exhaust system and exhaust gas aftertreatment system

• Specifications
• General description
• Exhaust system - repair
• Exhaust manifold - removal, inspection and installation
• Catalytic converter - general description and precautions
• Crankcase ventilation system - checking and replacing components
• Fuel vapor retaining system - checking and replacing components
• Exhaust gas recirculation - checking and replacing components
• Exhaust manifold air injection system - checking and replacing components

Fuel and exhaust systems - diesel models

• Specifications
• General description and precautions
• Fuel system - filling and bleeding
• Fuel system - pollution
• Air filter assembly and intake duct components - removal and installation
• Throttle cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Fuel tank - removal and installation
• Fuel level sensor - removal and installation
• Fuel tank overflow valve - removal and installation
• Fuel filler pipe removal and installation
• Idle speed - check and adjust
• Cold crank lever cable - adjustment, removal and installation
• Idle speed control system - adjustment, removal and installation
• Maximum engine speed - check and adjust
• Injection timing - check and adjustment
• High pressure fuel pump - removal and installation
• Injection pipes - removal and installation
• Fuel injectors - removal, inspection and installation
• Fuel cut-off solenoid valve - removal and installation
• Fuel heater - removal and installation
• Collectors - removal and installation
• Exhaust system - general description and replacement of components

Starting and charging systems

• Specifications
• General description, precautions and disconnecting the battery
• Finding a short circuit in an electrical circuit - general description
• Battery - test and charge
• Battery - removal and installation
• Charging system - test
• Generator - removal and installation
• Alternator brushes and voltage regulator - replacement
• Launch system - test
• Starter - removal and installation
• Starter - test

Ignition system - petrol models

• Specifications
• General description and precautions
• Ignition system - health check
• Ignition coil - check, removal and installation
• Ignition module (carburetor engines) - removal and installation
• Ignition module (engines with fuel injection system) - removal and installation
• Ignition timing - check
• Crankshaft angle sensor - removing and installing

Preheating system - diesel models

Clutch

Mechanical transmission

• Specifications
• General description
• Shift rod - adjustment
• Rod and gear lever - removal and installation
• Speedometer drive gear - removal and installation
• Oil seals - replacement
• Reversing light switch - removal and installation
• Mechanical transmission (B5 and iB5) - removal and installation
• Mechanical transmission (MTX-75) - removal and installation
• Mechanical transmission overhaul - general description

Automatic transmission

• Specifications
• General description and precautions
• Drive mode switch cable - removal, installation and adjustment
• Movement mode selection mechanism - removal and installation
• Speedometer drive gear - removal and installation
• Seals - replacement
• Automatic transmission - removal and installation
• Bulkhead automatic transmission - general description
• Starter blocker - removal and installation

Drive shafts

• Specifications
• General description
• Drive shafts - removal and installation
• Protective cover for inner CV joint - replacement
• Protective cover for outer CV joint - replacement
• Drive shafts - inspection and overhaul

Braking system

• Specifications
• General description
• Front brake pads - replacement
• Front brake caliper - removal, bulkhead and installation
• Front brake disc - inspection, removal and installation
• inspection and installation
• Rear drum brake pads - replacement
• Rear brake cylinder - removal, bulkhead and installation
• Rear brake support plate - removal and installation
• Rear disc brake pads - replacement
• Rear disc brake caliper - removal, bulkhead and installation
• Rear brake disc - inspection, removal and installation
• Master cylinder - removal, bulkhead and installation
• Brake pedal - removal and installation
• Brake pedal pusher - removal and installation
• Brake pipes and hoses - replacement
• Hydraulic brake system - bleeding
• Vacuum booster unit - serviceability check, removal and installation
• Vacuum hose and amplifier unidirectional valve - removal, service check and installation
• Hand brake pads (models with disc brakes) - replacement
• Hand brake lever - removal and installation
• Primary handbrake cable - removal and installation
• Main handbrake cable - removal and installation
• Valves for regulating pressure in the brake system - removal and installation
• Brake force compensator (Van model) - removal and installation
• Brake Compensator (Van Models) - adjustment
• Anti-lock braking system (ABS) - general description
• ABS components - removal and installation

Suspension and steering gear

• Specifications
• General description
• Front steering knuckle - removal and installation
• Front wheel bearings (23 Spline Drive Shaft) - replacement
• Front wheel hub bearings (25 Spline Drive Shaft) - replacement
• Front suspension strut - removal and installation
• Front suspension strut - disassembly, inspection and assembly
• Front suspension anti-roll bar - removal and installation
• The lower arm of the front suspension - removal and installation
• Underframe - removal and installation
• Rear wheel bearings - replacement
• Rear pillar (Hatchback and Sedan models) - removal and installation
• Rear pillar (Hatchback and Sedan models) - disassembly, inspection and assembly
• Rear axle (Hatchback, Sedan and Estate models) - removal and installation
• Rear axle pivot bolt bush (models) Hatchback, Sedan and Station wagon) - replacement
• Rear shock absorber (Station wagon and Van models) - removal, service check and installation
• Rear spring springs (Station wagon models) - removal and installation
• Rear leaf spring, its shackle and bushings (Van models) - removal, inspection and installation
• Rear axle (Van models) - removal and installation
• Steering wheel - removal and installation
• Steering column - removal and installation
• Steering column - bulkhead
• Rubber steering covers - replacement
• Steering gear (without amplifier) ??- removal and installation
• Steering gear (with power) - removal and installation
• Power steering pump - removing and installing
• Hydraulic power steering - bleed
• Tie rod end ball joint - removal and installation
• Wheel alignment angles - general description

Auto body

• Specifications
• General description
• Body and underbody - service
• Upholstery and rugs - care
• Minor damage to the body - restoration
• Significant damage to the body - restoration
• Bumpers - removal and installation
• Hood - removing, installing and adjusting position
• Bonnet cable - removal and installation
• Bonnet lock - removal and installation
• Door trim panel - removal and installation
• Door glass - removal and installation
• Window regulator mechanism - removal and installation
• Door lock, lock cylinder and handles - removal and installation
• Door - removal and installation
• Outside mirror - removal and installation
• Interior mirror - removal and installation
• Trunk lid - removal, installation and adjustment
• Trunk lock components - removal and installation
• Luggage compartment door - removal, installation and adjustment
• Support pillar of a tailgate - removal and installation
• Tailgate lock components - removal and installation
• Central locking system control unit - removal and installation
• Hatch - check and adjust
• Roof panel - removal and installation
• Hatch seal - removal and installation
• Seats - removal and installation
• Interior trim panels - removal and installation
• Front panel - removal and installation
• Center console - removal and installation
• Wheel arch liners - removal and installation
• Radiator grill - removal and installation

Engine electrical systems

• Specifications
• General description and precautions
• Electrical troubleshooting - general description
• Fuses and relays - general description
• Switches - removal and installation
• Lamps (external lighting fixtures) - replacement
• Lamps (interior lighting) - replacement
• External lighting devices - removal and installation
• Light beam direction - check and adjust
• Dashboard - removal and installation
• Dashboard components - removal and installation
• Speedometer cable - removal and installation
• Cigarette lighter - removal and installation
• Watch - removal and installation
• Sound signal - removal and installation
• Wiper arms - removal and installation
• Wiper motor and rod - removal and installation
• Wiper hinge pivot - removing and installing
• Rear door wiper motor assembly - removal and installation

Troubleshooting

Wiring diagrams (wiring diagrams)