Content

General information

• Air cleaner element renewal
• Automatic transmission
• Auxiliary drivebelt
• Bodywork, paint and exterior trim
• Brake
• Brake fluid
• Coolant
• Door, tailgate and bonnet
• Driveshaft rubber gaiter and CV joint
• Emission control system
• Engine compartment wiring
• Engine oil and filter
• Exhaust system
• Front wheel alignment
• Fuel filter
• Handbrake
• Idle speed
• Intensive maintenance
• Introduction
• Manual transmission oil level
• Road test
• Roadwheel nut tightness
• Seat belt
• Spark plug renewal and HT component
• Steering, suspension and roadwheel
• Timing belt
• Underbody and fuel/brake line
• Underbonnet check for fluid leaks and hose condition
• Valve clearance adjustment

HCS engine in-car repair procedures

• Auxiliary drive belt
• Compression test
• Crankshaft oil seals
• Crankshaft pulley
• Cylinder head
• Cylinder head rocker cover
• Cylinder head rocker gear
• Engine oil and filter
• Engine oil level
• Engine/transmission mountings
• Flywheel
• General information
• Oil pump
• Sump
• Timing chain cover
• Timing chain, sprockets and tensioner
• Top Dead Centre (TDC) for No 1 piston
• Valve clearances

CVH and PTE engine in-car repair procedures

• Auxiliary drivebelt
• Camshaft oil seal
• Camshaft, rocker arms and tappets
• Compression test - description and inter
• Crankshaft oil seals
• Crankshaft pulley
• Cylinder head
• Cylinder head rocker cover
• Engine oil and filter
• Engine oil level
• Engine/transmission mountings
• Flywheel/driveplate
• General information
• Oil pump
• Sump
• Timing belt
• Timing belt covers
• Timing belt tensioner and sprockets
• Top Dead Centre (TDC) for No 1 piston
• Valve clearances

Zetec engine in-car repair procedures

• Auxiliary drivebeltl
• Camshaft oil seals
• Camshafts and hydraulic tappets
• Compression test
• Crankshaft oil seals
• Crankshaft pulley
• Cylinder head
• Cylinder head cover
• Engine oil and filter
• Engine oil level
• Engine/transmission mountings
• Flywheel/driveplate
• General information
• Oil pump
• Sump
• Timing belt
• Timing belt covers
• Timing belt tensioner and sprockets
• Top Dead Centre (TDC) for No 1 piston
• Valve clearances

Engine removal and overhaul procedures

• Camshaft and tappets
• Crankshaft
• Cylinder block/crankcase
• Cylinder head
• Cylinder head and valve components
• Engine overhaul
• Engine/transmission
• General information
• Main and big-end bearings
• Piston/connecting rod assemblies
• Piston rings

Cooling, heating and ventilation systems

• Antifreeze
• Auxiliary drivebelt
• Coolant level
• Cooling system
• Cooling system electrical switches and sensors
• Cooling system hoses
• General information and precautions
• Heater/ventilation components
• Radiator and expansion tank
• Radiator electric cooling fan assembly
• Thermostat
• Underbonnet
• Water pump

Fuel system - carburettor engines

• Accelerator cable
• Accelerator pedal
• Accelerator pump diaphragm
• Air cleaner
• Automatic choke
• Carburettor
• Choke cable
• Fuel gauge sender unit
• Fuel pump
• Fuel tank
• General fuel system checks
• General information and precautions
• Idle speed and mixture check and adjustment
• Inlet manifold - removal and refitting
• Needle valve and float
• Throttle kicker control solenoid
• Throttle kicker unit
• Underbody fuel/brake line check

Fuel system - electronic fuel injection engines

• Accelerator cable
• Accelerator pedal
• Air cleaner assembly and air inlet components
• Air cleaner element
• Exhaust system
• Fuel cut-off switch
• Fuel filter
• Fuel injection system
• Fuel injection system components
• Fuel lines and fittings
• Fuel pump/fuel gauge sender unit
• Fuel pump/fuel pressure
• Fuel system
• Fuel tank
• Fuel tank filler pipe
• Fuel tank ventilation tube
• General fuel system
• General information and precautions
• Idle speed and mixture check and adjustment
• Idle speed control valve cleaning and maintenance
• Inlet manifold
• Intercooler
• Turbocharger
• Turbocharger boost control valve
• Turbocharger boost pressure
• Underbody fuel/brake line check
• Underbonnet check for fluid leaks and hose condition

Fuel system - sequential electronic fuel injection engines

• Accelerator cable
• Accelerator pedal
• Air cleaner assembly and air inlet components
• Air cleaner element
• Fuel cut-off switch
• Fuel filter
• Fuel injection system
• Fuel injection system components
• Fuel lines and fittings
• Fuel pump/fuel gauge sender unit
• Fuel pump/fuel pressure
• Fuel system
• Fuel tank
• Fuel tank filler pipe
• Fuel tank ventilation tube
• General fuel system
• General information and precautions
• Inlet manifold
• Underbody fuel/brake line
• Underbonnet check for fluid leaks and hose condition

Exhaust and emission control systems

Starting and charging systems

• Alternator
• Alternator brushes and voltage regulator
• Auxiliary drivebelt
• Battery
• Battery, bulbs and fuses
• Charging system
• Electrical fault finding
• General information, precautions and battery disconnection
• Starter motor
• Starting system

Ignition system

• Crankshaft position sensor
• Distributor cap and rotor arm
• Distributor vacuum diaphragm unit
• Distributor
• General information and precautions
• Ignition coil
• Ignition module
• Ignition system
• Ignition timing
• Ignition amplifier module (distributor ignition systems)
• Spark plug renewal

Braking system

• ABS modulator drivebelt
• Brake check
• Brake fluid level
• Brake pedal
• Brake pressure control valves
• Front brake caliper
• Front brake disc
• Front brake pads
• General information
• Handbrake adjustment
• Handbrake lever
• Handbrake primary cable
• Handbrake rear cable
• Hydraulic pipes and hoses
• Hydraulic system
• Light-laden valve
• Load-apportioning valve
• Master cylinder
• Rear brake backplate
• Rear brake drum
• Rear brake shoes
• Rear wheel cylinder
• Vacuum servo unit
• Vacuum servo unit vacuum hose and non-return valve

Suspension and steering

• Auxiliary drivebelt
• Front hub bearings
• Front spindle carrier
• Front suspension anti-roll bar
• Front suspension crossmember
• Front suspension lower arm
• Front suspension strut
• General information
• Power steering fluid cooler
• Power steering fluid level c
• Power steering hydraulic system
• Power steering pump
• Rear axle
• Rear hub bearings
• Rear shock absorber
• Rear strut
• Rear suspension
• Steering column
• Steering gear
• Steering wheel
• Suspension and steering
• Track rod end balljoint
• Tyre condition and pressure
• Wheel alignment and steering angles

Bodywork and fittings

• Body adhesive emblems
• Body trim mouldings
• Bodywork, paint and exterior trim
• Bonnet
• Bonnet latch
• Bonnet release mechanism
• Bumper and rear quarter mouldings
• Bumpers
• Centre console
• Door aperture weatherstrip
• Door window glass
• Door window regulator
• Door, tailgate and bonnet
• Exterior mirror and glass
• Facia
• Front seat and slide assembly
• Full-length sunroof
• General information
• Interior mirror
• Interior trim panels
• Maintenance
• Major body damage
• Parcel shelf support/loudspeaker housing
• Passenger grab handle
• Rear door inner trim panels
• Rear door lock, catches and handles
• Rear doors
• Rear seat
• Seat belt
• Side door inner trim panel
• Side door lock, lock cylinder and handles
• Side doors
• Side window glass
• Sill extension moulding
• Sunroof panel
• Sunroof panel seal
• Sunroof weatherseal
• Tailgate
• Tailgate inner trim panel
• Tailgate lock components
• Tailgate spoiler
• Tailgate support strut
• Wheelarch liners
• Wheelarch mouldings
• Wind deflector/radiator grille slat
• Windscreen and tailgate window glass

Body electrical systems

• Air bag
• Anti-theft systems
• Battery, bulbs and fuses
• Cigarette lighter
• Clock
• Electric window regulator motor
• Electrical fault-finding
• Exterior light units
• Fuses and relays
• General information and precautions
• Headlight and auxiliary light beam alignment
• Horn
• Instrument panel
• “Lights-on” warning module
• Radio aerial
• Radio/cassette player
• Screen washer fluid level
• Speaker balance control joystick
• Speakers
• Speedometer cable
• Switches
• Tailgate remote release motor
• Windscreen wiper motor and linkage
• Windscreen wiper pivot shaft
• Windscreen/tailgate washer system components
• Wiper arms
• Wiper blade

Glossary of technical terms