Content

Operation and maintenance

• Replacing the air filter element
• Transmission fluid level
• Change transmission fluid
• Secondary drive belt check and replacement
• Body structure, paint
• Brake test
• Replacing the brake fluid
• Replacement of ONZZH
• Door, tailgate and hood
• Protective rubber cover for propeller shaft and CV
• Checking the emission control system
• Engine compartment wiring check
• Engine oil and filter change
• Checking the release system
• Wheel alignment
• Replacing the fuel filter
• Handbrake adjustment
• Idling speed
• Cleaning the idle speed control valve
• Intensive service
• Introduction
• Transmission oil level
• Run test
• Seat belt check
• Replacing the spark plug
• Suspension and wheel
• Replacing the timing belt
• Underbody and fuel / brake pipe
• Underbonnet
• Valve clearance adjustment

HCS engine interior repairs

• Secondary drive belt check and replacement
• Compression test - description and interpretation
• Crankshaft oil seals
• Crankshaft pulley
• Cylinder head
• Head valve cover
• Cylinder head valve train
• Engine oil and filter change
• Engine oil level
• Flywheel
• Oil pump
• Pallet

CVH and PTE engine in-vehicle repairs

• Secondary drive belt check and replacement
• Camshaft oil seal
• Camshaft, rocker arms and knuckles
• Compression test
• Crankshaft oil seals
• Crankshaft pulley
• Cylinder head
• Cylinder head valve cover
• Engine oil and filter change
• Engine oil level
• Engine / gear settings
• Flywheel / drive plate
• Oil pump
• Pallet
• Toothed belt drive
• Timing belt covers
• Tensioning mechanism of the toothed belt drive and sprocket

Zetec engine interior repair operations

• Camshaft oil seals
• Camshafts and hydraulic knuckles
• Compression test - description and interpretation
• Crankshaft oil seals
• Crankshaft pulley
• Cylinder head
• Cylinder head coating
• Engine oil and filter change
• Engine oil level
• Engine / gear settings
• Flywheel / drive plate
• Oil pump
• Pallet
• Toothed belt drive
• Timing belt covers
• Tensioning mechanism of the toothed belt drive and sprocket

Machine delete and rebuild procedures

• Camshaft and knuckles
• Crankshaft
• Cylinder block / crankcase
• Cylinder head
• Cylinder head and valve components
• Engine
• Machine rebuild
• Removing engine / gear
• Bottom head bearings
• Piston / connecting rod assemblies

Cooling, heating and ventilation systems

• Antifreeze
• Secondary drive belt check
• Cooling system
• Cooling system electrical switches and sensors
• Coolant hoses
• General information and precautions
• Heater / ventilation components
• Radiator and expansion tank
• Cooling fan electrical assembly
• Thermostat
• Underbonnet

Fuel system

• Accelerator cable
• Fuel control pedal
• Air purifier
• Replacing the filter element of the air filter
• Automatic air damper
• Carburetor
• Throttle cable
• Fuel flow meter sensor
• Fuel pump
• Fuel tank
• Fuel filler pipe
• Fuel tank ventilation pipe
• General information and precautions
• Idle speed and mixture
• Exhaust manifold
• Needle valve
• Fuel / brake pipe

Exhaust and emission control systems

• Catalytic converter
• Checking the emission control system
• Fuel vapor management system
• Exhaust manifold
• Exhaust system
• Checking the release system
• General information
• Positive crankcase ventilation
• Pneumatic impulse system

Start and charging systems

• Alternator
• Ancillary drive belt inspection
• Battery
• Charging system
• General information, precautions and battery disconnection
• Starter
• Charging systems

Ignition system

• Crankshaft angle sensor
• Breaker cover and rotor arm
• Distributor vacuum diaphragm unit
• Distributor
• General information and precautions
• Ignition coil
• Ignition module
• Ignition amplifier module
• Spark plugs

Braking system

• ABS modulator drive belt check
• Brake test
• Replacing the brake fluid
• Brake pedal
• Brake pressure control valves
• Front brake caliper
• Front brake disc
• Front brake pads
• General information
• Handbrake adjustment
• Hand brake lever
• Handbrake ignition primary wire
• Rear handbrake cable
• Hydraulic pipes and hoses
• Hydraulic system
• Load distribution valve (ABS models)
• Master cylinder
• Drum brake rear shield
• Rear brake drum
• Rear brake pads
• Rear working brake cylinder
• Vacuum servo
• Servo vacuum hose and non-return valve

Suspension and steering

• Secondary drive belt check and replacement
• Front hub bearings
• Headstock head
• Front suspension anti-roll bar
• Crossmember front suspension
• Front suspension lower arm
• Front suspension strut
• General information
• Power steering hydraulic system
• Power steering pump
• Rear axle
• Rear axle pivot bushings
• Rear bearings
• Rear shock absorber
• Back pillar
• Rear suspension anti-roll bar
• Rear suspension assembly
• Rear suspension components
• Rear suspension height for passenger car
• Steering column
• Steering gear
• Steering gear rubber protective coatings
• Steering wheel
• Tie rod end ball joint
• Wheel alignment and steering angles

Body structure and fittings

• Hull emblems
• Body glass profiles
• Body structure, paint
• Hood
• Bonnet lock
• Bumper and rear linings
• Central control
• Door, tailgate and hood
• Outside mirror and glass
• Panel
• Front seat
• Interior mirror
• Interior trim panels
• Rear door trim panels
• Rear doors
• Back seat
• Seat belts
• Side door trim panel
• Spoiler

Electrical systems

• Airbag
• Air bag clock spring
• Airbag control module
• Anti-theft systems
• Fuses and Relays
• Headlamp and auxiliary light beam alignment
• Dashboard
• Dashboard components
• Radio antenna
• Radio / cassette player
• Washer fluid level
• Speakers
• Speedometer cable
• Switches
• Wiper motor
• Wiper hinge axle