Content

General information

• Vehicle specifications
• Passport data

Operation

• Governing bodies
• Instrument cluster

Safety precautions for maintenance and repair

Operation

• Car keys
• Doors
• Hood
• Luggage compartment
• Fuel gauge, filler flap and fueling
• Central castle
• Remote control
• Immobilizer
• Emergency switch
• Fuel supply systems
• Steering column
• Front seats
• Rear seat, increased luggage compartment
• Seat belts
• Airbags
• Gear shift lever (manual)
• Gear selector lever (automatic gearbox)
• Parking brake
• Ignition switch
• Controls and instruments
• Governing bodies
• Instrument cluster
• Hazard warning lights
• Sound signal
• Electronic clock
• Interior lighting and lighting
• Instrument combinations
• Outdoor lighting and direction indicators
• Windshield and tailgate cleaners and washers
• Heated windshield and rear windows
• Heating, ventilation and air conditioning
• Glove box
• Power windows
• Rearview mirrors
• Cigarette lighter and ashtrays
• Sun visors
• Engine start

Safety precautions for maintenance and repair

Maintenance

• Checking the car before leaving
• Topping up the washer fluid reservoir
• Removing the wiper blades
• Checking the oil level in the crankcase
• Changing engine oil and oil filter
• Checking the condition of the brake system
• Checking the condition of the exhaust system
• Checking the condition of the transmission, suspension and steering
• Checking condition and replacing spark plugs

Service recommendations

• Automatic transmission
• Checking the oil level in a manual gearbox
• Checking the coolant level
• Coolant replacement
• Checking the fluid level in the power steering reservoir
• Checking the brake fluid level in the reservoir tank of the hydraulic brake system and clutch
• Bleeding hydraulic brake system, replacing brake fluid bleeding hydraulic clutch
• Replacing the air filter element
• Replacing the filter element for the interior ventilation
• Replacing the fuel filter
• Checking and replacing the drive belt for auxiliary units of Zetec-E 1.8i / 2.0i engines
• Checking and replacing the drive belt of the auxiliary units of the Duratec engine
• Checking the condition of the timing belt of the Zetec-E 1.8i / 2.0i engines
• Replacing the timing belt of the Zetec-E 1.8i / 2.0i engines
• Battery maintenance
• Checking the condition of wheels and tires
• Wheel replacement
• Wheel shift scheme
• Replacing the car key battery
• Checking and adjusting thermal clearances in the valve drive of Zetec-E 1.8i / 2.0i engines

Car care

• Car wash
• Preservation and protection of paintwork
• Interior cleaning
• Wheels and tires

Preparation for the state technical inspection

• Preparation for technical inspection
• The list of malfunctions and conditions under which the operation of a car is prohibited
• General information on passing the state technical inspection

Engine

• DURATEC 1.6i engine
• Design description
• Oil pressure sensor replacement
• Gasket replacement
• Cylinder head covers
• Replacing the front crankshaft oil seal
• Replacing the crankshaft rear oil seal
• Removing the oil pan and cleaning the oil intake grid
• Powertrain support replacement
• Removing and installing powertrain
• Engine repair recommendations
• Engine ZETEC-E
• Design description
• Oil pressure sensor replacement
• Replacing the camshaft oil seal
• Replacing the front crankshaft oil seal
• Replacing the crankshaft rear oil seal
• Removing the engine oil pan and cleaning the oil intake grid
• Powertrain support replacement
• Removing and installing powertrain
• Engine repair recommendations

Power system

• Checking the pressure in the fuel system
• Removing and installing fuel tank
• Replacing the fuel pump
• Replacing the fuel gauge gauge
• Removing and installing fuel rail
• Checking and replacing nozzles
• Pressure regulator replacement
• Replacing the throttle cable
• Removing and installing throttle body
• Removing and installing the engine idle regulator Zetec-E 1.8i / 2.0i
• Removing and installing engine idle control Duratec 1,6i
• Removing and installing the receiver
• Fuel vapor recovery system
• Engine management system
• Design description
• Removing the engine control module
• Relays and fuses

Engine management systems

• Replacing the sync sensor
• Replacing the temperature sensor
• Checking and replacing the throttle position sensor
• Replacing the camshaft position sensor for Zetec-E 1.8i / 2.0i 142 engines
• Duratec 1.6i engine camshaft position sensor replacement
• Replacing the oxygen concentration sensor
• Replacing the absolute pressure and air temperature sensor Duratec 1,6i engine
• Replacing the Zetec-E 1.8i / 2.0i engine mass air flow sensor
• Speed ??sensor replacement
• Replacing the ignition module

Cooling system

• Replacing the temperature sensor removing, checking and installing the thermostat
• Removing and installing the expansion tank
• Replacing the radiator fan motor
• Removing and installing a radiator
• Removing and installing coolant pump

Exhaust system

• Design description
• Replacing suspension pads
• Exhaust systems
• Replacing the exhaust pipe
• Replacing exhaust system components
• Removing and installing exhaust manifold

Grip

• Design description
• Checking the clutch pedal
• Replacing the clutch cover and clutch plate
• Replacing the clutch pedal sensor
• Replacing the clutch hydraulic hose
• Replacing the clutch slave cylinder and release bearing
• Removing and installing pedal and clutch master cylinder

Gearbox

• Design description
• Gearbox control adjustment
• Replacing the front wheel drive oil seal
• Removing and installing gearbox
• Gearbox repair recommendations
• Removing and installing gearbox control mechanism
• Replacing transmission control cable
• Determining the technical condition of an automatic transmission

Front wheel drive

• Design description
• Removing and installing front wheel drives
• Removing the constant velocity joint outer hinge
• Removing the constant velocity joint inner joint
• Intermediate bearing bearing replacement

Front suspension

• Design description
• Front wheel alignment
• Removing and installing front suspension arm
• Removing and installing shock absorber strut
• Suspension strut repair
• Replacing the anti-roll bar
• Replacing anti-roll bar
• Replacing the front wheel bearing

Rear suspension

• Design description
• Shock absorber replacement
• Suspension spring replacement
• Replacing the upper arm
• Replacing the lower front arm
• Replacing trailing arm
• Replacing the lower rear arm
• Replacing the anti-roll bar
• Replacing anti-roll bar
• Suspension arms
• Removing and installing rear suspension
• Replacing the hub bearing
• Rear wheel alignment

Steering

• Design description
• Removing air from the hydraulic drive of the power steering
• Removing and installing steering wheel

Brake system

• Design description
• Removing and installing brake master cylinder
• Removing and installing a vacuum amplifier
• Replacing the caliper disc
• Replacing the brake disc
• Replacing the front wheel brake hose
• Replacing the wheel cylinder of the drum brake
• Replacing the brake hose of the rear wheel
• Replacing the tip of the parking brake cable
• Parking brake adjustment
• Replacing wheel speed sensors

Electrical equipment

• General information
• Checking electrical circuits
• Ignition switch
• Fuse and relay mounting blocks
• Generator
• Starter
• Lighting, light and sound alarms
• Replacing the headlight bulbs
• Removing the headlamp
• Replacing the headlight range control electric drive
• Removing the fog lamp, replacing the lamp
• Removing the side direction indicator, replacing the lamp
• Replacing the reverse sensor
• Removing and installing taillights, replacing lamps
• Removing and installing a ceiling light for a luggage compartment of a car with a sedan body, replacing a lamp
• Removing the optional brake light, replacing bulbs
• Removing license plate lights, replacing bulbs
• Removing the interior light, replacing the lamp
• Removing the glove compartment light, replacing the lamp
• Removing and installing shift paddles
• Removing the alarm switch
• Removing and installing a sound signal
• Removing and installing watches
• Windshield and tailgate cleaners and washers
• Removing and installing windshield wiper
• Removing the electric window washer pump
• Removing and installing tailgate glass cleaner
• Testing devices
• Removing instrument cluster
• Replacing instrument cluster lights
• Removing and installing airbag control unit
• Removing and installing the radio
• Removing the speaker

Body

• Design description
• Removing the radiator lining
• Removing the hood lock and its drive
• Removing the hood
• Front fender liner removal
• Removing the front bumper
• Front wing removal
• Removing the exterior rearview mirror
• Removing the front door trim
• Removing the front door glass
• Removing the front door power window mechanism
• Removing the front door lock
• Removing, installing and adjusting the front door
• Removing the rear door trim
• Removing the rear door glass
• Removing the rear window regulator
• Removing the rear door lock
• Removing, installing and adjusting the rear door
• Removing the rear bumper
• Removing the luggage compartment lid and door lock

Diagnostics of malfunctions

• Engine and its systems
• Clutch
• Manual gearbox
• Automatic transmission
• Front wheel drive
• Brake system
• Suspension and steering
• Electrical equipment

Applications

• Repair tool
• Tightening torques for critical threaded connections
• Applicable fuels, lubricants and operating fluids
• Lamps used in the car

Electrical diagrams

• Generator connection diagram
• Engine starting system (on a car with a manual transmission)
• Engine starting system (on a car with an automatic transmission)
• Fuel pump activation circuit
• The scheme of inclusion of nozzles and the regulator of idling
• Connection diagram for mass air flow sensor and oxygen sensor
• Connection diagram for coolant temperature and throttle position sensors
• Immobilizer activation scheme
• The scheme for switching on the electric fan of the radiator of the engine cooling system in a car without air conditioning
• The scheme of inclusion of electric fans of the radiator of the engine cooling system on a car with air conditioning
• The scheme of inclusion of the solenoid valve purge adsorber, camshaft position sensors, engine speed, pressure in the power steering system
• The scheme of inclusion of speed sensors and clutch pedals
• Ignition system diagram
• Electrical scheme of an automatic transmission
• Power supply circuit diagram for the ABS electronic control unit with traction control (TCS)
• ABS electronic control unit
• Power supply circuit diagram for the ABS electronic control unit with traction control (TCS) and Electronic Stability Program (ESP)
• Scheme of inclusion of sensors of speed of rotation of wheels and control lamp ABS
• Circuit diagram for wheel speed sensors, ABS and TCS warning lamps
• Headlamp electrical inclusion circuit
• Headlight Switching Pattern
• Turn-on lamp for side light bulbs on a station wagon
• Turn-on lamp for side light lamps on a car with a sedan body
• Turn-on lamp for side-light lamps on a hatchback car
• Scheme of inclusion of brake light lamps on a car with an automatic transmission
• Wiring diagram for brake lights on a car with an automatic transmission and Electronic Stability Program (ESP)
• Wiring diagram for brake lights on a car with a manual gearbox and ABS
• Wiring diagram for brake lights on a car with a manual transmission and Electronic Stability Program (ESP)
• Alarm and direction switching diagram
• Rear fog lamp wiring diagram
• Fog lamp and rear fog lamp wiring diagram
• License plate light activation scheme
• Turn-on lamp circuit for reversing light on a car with a manual gearbox
• Turn-on lamp for reversing light on a car with automatic transmission
• Scheme of inclusion of lighting plafonds Scheme of inclusion of an electric drive and electric heating of exterior rear-view mirrors
• Front seat heating circuit diagram
• Air conditioning compressor clutch connection diagram
• Connection diagram for electric driver's seat height adjustment
• Front-door lock locking actuators (central locking with double locking)
• Security alarm activation scheme
• Immobilizer sensor switching scheme
• Airbag control unit wiring diagram
• Heater electric fan inclusion diagram
• Connection diagram for electric locks of rear door locks and door limit switches (with a central lock with double locking)
• Connection diagram for the control panel for the heating, ventilation and air conditioning system
• The circuit diagram of the instrument cluster (warning lamps for fuel reserve, battery charge, engine malfunction, overdrive)
• The circuit diagram of the instrument cluster (indicator lights, high beam headlights and instrument lighting)
• The circuit diagram of the instrument cluster (warning lamps of the brake system and emergency oil pressure in the engine)
• Circuit diagram of the time delay unit and the heating, ventilation and air conditioning systems
• Circuit diagram of the time delay unit and instrument cluster
• Circuit diagram of the time delay unit, interior lighting and window cleaners