Ford Fiesta 1996 2002 Workshop Manual

Factory Workshop Manual
Make
Ford
Model
Fiesta 1996 08.1995-02.2002
Engine and year
(08.1995-02.2002)
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This manual was submitted by

Anonymous
Date
1st January 2018
Ford Fiesta 1996 08.1995-02.2002 Workshop Manual ((08.1995-02.2002))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-00 General
Information > Description and Operation > About This Manual
Introduction 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 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. 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.
Graphics 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.
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-00 General
Information > Description and Operation > Health and Safety Precautions
Introduction Many of the procedures associated with vehicle maintenance and repair involve
physical hazards or other risks to health. This subsection lists, alphabetically, some of these
hazardous operations and the materials and equipment associated with them. Precautions
necessary to avoid these hazards are identified. The list is not exhaustive and all operations and
procedures, and the handling of materials, should be carried out with health and safety in mind.
Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier
should be consulted. Acids and Alkalis See also Battery Acids. For example caustic soda, sulphuric
acid. Used in batteries and cleaning materials. Irritant and corrosive to the skin, eyes, nose and
throat. Cause burns. Can destroy ordinary protective clothing. Avoid splashes to the skin, eyes and
clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath mists.
Make sure access to eye wash bottles, shower and soap are readily available for splashing
accidents. Display Eye Hazard sign. Air Bags See also Fire, Chemical Materials. Highly flammable,
explosive – observe No Smoking policy. Used as a safety restraint system mounted in the steering
wheel and passenger side of the instrument panel. The inflator contains a high-energetic propellant
which, when ignited, produces a VERY HOT GAS (2500°C). The gas generant used in air bags is
Sodium Azide. This material is hermetically sealed in the module and is completely consumed
during deployment. No attempt should be made to open an air bag inflator as this will lead to the
risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be
worn when dealing with the spillage. After normal deployment, gloves and safety goggles must be
worn during the handling process. Deployed air bags should be disposed of in a plastic bag in
accordance with local regulations at an approved chemical waste site. Following any direct contact
with gas generant. Air Bags - Do's Air Bags - Do Nots Air Conditioning Refrigerant See also
Chlorofluorocarbon, Chemical Materials Highly flammable, combustible – observe No Smoking
policy. Skin contact may result in frostbite. Instructions given by the manufacturer must be followed.
Avoid naked lights, wear suitable protective gloves and goggles. If refrigerant comes into contact
with the skin or eyes, immediately rinse the affected areas with water. Eyes should also be rinsed
with an appropriate irrigation solution and should not be rubbed. SEEK MEDICAL ASSISTANCE IF
NECESSARY. Air Conditioning Refrigerant - Do Nots Adhesives and Sealers See also Fire,
Chemical Materials. Highly flammable, flammable, combustible – observe No Smoking policy.
Generally should be stored in No Smoking areas. Cleanliness and tidiness in use should be
observed, for example disposable paper covering benches; should be dispensed from applicators
where possible; containers, including secondary containers, should be labeled appropriately.
Solvent-based Adhesives/Sealers - See Solvents Follow manufacturers instructions. Water-based
Adhesives/Sealers Those based on polymer emulsions and rubber latexes may contain small
amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and
adequate ventilation provided during use. Hot Melt Adhesives In the solid state, they are safe. In
the molten state they may cause burns and health hazards may arise from the inhalation of toxic
fumes. Use appropriate protective clothing and a thermostatically controlled heater with a thermal
cut-out and adequate extraction. Resin-based Adhesives/Sealers, for example Epoxide and
Formaldehyde Resin-based Mixing should be carried out in well ventilated areas, as harmful or
toxic volatile chemicals may be released. Skin contact with uncured resins and hardeners can
result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the skin.
Splashes can damage the eyes. Provide adequate ventilation and avoid skin and eye contact.
Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives Many are irritant, sensitizing
or harmful to the skin and respiratory tract. Some are eye irritants. Skin and eye contact should be
avoided and the manufacturers instructions followed. Cyanoacrylate adhesives (super-glues)
MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad
and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull tissue apart. Use in well
ventilated areas as vapors can cause irritation to the nose and eyes. For two-pack systems see
Resin-based and Isocyanate Adhesives/Sealers. Isocyanate (Polyurethane) Adhesives/Sealers
See also Resin-based Adhesives. Individuals suffering from asthma or respiratory allergies should
not work with or near these materials as sensitivity reactions can occur. Over exposure is irritating
to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous
system including drowsiness. In extreme cases, loss of consciousness may result. Long term
exposure to vapor concentrations may result in adverse health effects. Prolonged contact with the
skin may have a defatting effect which may lead to skin irritation and in some cases, dermatitis.
Splashes entering the eye will cause discomfort and possible damage. Any spraying should
preferably be carried out in exhaust ventilated booths, removing vapors and spray droplets from the
breathing zone. Wear appropriate gloves, eye and respiratory protection. Antifreeze See also Fire,
Solvents. For example isopropanol, ethylene glycol, methanol. Highly flammable, flammable,
combustible. Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.
Vapors may be given off from coolant antifreeze (glycol) when heated. Avoid breathing these
vapors. Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if
swallowed, can be fatal and MEDICAL ATTENTION SHOULD BE SOUGHT IMMEDIATELY.
These products must not be used in any cooling or industrial water system that is connected or
linked to general, food preparation or drinking water supplies. Asbestos See also Warning Symbols
on Vehicles at the end of this subsection. Breathing asbestos dust may cause lung damage or, in
some cases, cancer. Used in brake and clutch linings, transmission brake bands and gaskets. The
use of drum cleaning units, vacuum cleaning or damp wiping is preferred. Asbestos dust waste
should be dampened, placed in a sealed container and marked for safe disposal. If any cutting or
drilling is attempted on materials containing asbestos the item should be dampened and only hand
tools or low speed power tools used. Battery Acids See also Acids and Alkalis. Gases released
during charging are explosive. Never use naked flames or allow sparks near charging or recently
charged batteries. Make sure there is adequate ventilation. Brake and Clutch Linings and Pads
See Asbestos. Brake Fluids (Polyalkylene Glycols) See also Fire. Splashes to the skin and eyes
are slightly irritating. Avoid skin and eye contact as far as possible. Inhalation vapor hazards do not
arise at ambient temperatures because of the very low vapor pressure. Brazing See Welding.
Chemical Materials See also Legal Aspects. Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, fuels, oils and grease should
always be used with caution and stored and handled with care. They may be toxic, harmful,
corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts. The effects of
excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent;
cumulative; superficial; life threatening; or may reduce life expectancy. Chemical Materials - Do's
Chemical Materials - Do Nots Chlorofluorocarbons (CFC) There is concern in the scientific
community that CFCs and Halons are depleting the upper ozone layer which filters out harmful
ultraviolet radiation. Decreased filtration of ultraviolet radiation may result in increases in skin
cancer, cataracts and immune system suppression in humans, as well as decreased productivity of
crops and aquatic systems. CFCs are used primarily as refrigerants in vehicle air conditioning
systems and as aerosol propellants. Halons are used as fire extinguishants. Clutch Fluids See
Brake fluids. Clutch Linings and Pads See Asbestos. Corrosion Protection Materials See also
Solvents, Fire. Highly flammable, flammable – observe No Smoking policy. These materials are
varied and the manufacturers instructions must be followed. They may contain solvents, resins or
petroleum products. Skin and eye contact should be avoided. They should only be sprayed in
conditions of adequate ventilation and not in confined spaces. Cutting See Welding. Dewaxing See
Solvents and Fuels (Kerosene). Dusts Powder, dusts or clouds may be irritant, harmful or toxic.
Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion
operations. Wear respiratory protection if ventilation is inadequate. Fine dusts of combustible
material can present an explosion hazard. Avoid explosive limits and sources of ignition. Electric
Shock Electric shock can result from the use of faulty electrical equipment or from the misuse of
equipment in good condition. Make sure that electrical equipment is maintained in good condition
and frequently tested. Faulty equipment should be labeled and preferably removed from the
workstation. Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked
or otherwise damaged. Make sure that electrical equipment and flexes do not come into contact
with water. Make sure that electrical equipment is protected by the correct rated fuse. Never
misuse electrical equipment and never use equipment that is in any way faulty. The results could
be fatal. Make sure that the cables of mobile electrical equipment cannot get trapped and
damaged, such as in a vehicle hoist. Make sure that the designated electrical workers are trained
in basic First Aid. In cases of electrocution: Engine Oils See Lubricants and Grease. Exhaust
Fumes These contain asphyxiating, harmful and toxic chemicals and particles such as carbon
oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should be run only
under conditions of adequate exhaust extraction or general ventilation and not in confined spaces.
Gasoline (petrol) engine There may not be adequate warning of odor or of irritation before toxic or
harmful effects arise. These may be immediate or delayed. Diesel engine Soot, discomfort and
irritation usually give adequate warning of hazardous fume concentrations. Fibre Insulation See
also Dusts. Used in noise and sound insulation. The fibrous nature of surfaces and cut edges can
cause skin irritation. This is usually a physical and not a chemical effect. Precautions should be
taken to avoid excessive skin contact through careful organization of work practices and the use of
gloves. Fire See also Welding, Foams, Legal Aspects. Many of the materials found on or
associated with the repair of vehicles are highly flammable. Some give off toxic or harmful fumes if
burnt. Observe strict fire safety when storing and handling flammable materials or solvents,
particularly near electrical equipment or welding processes. Make sure, before using electrical or
welding equipment, that there is no fire hazard present. Have a suitable fire extinguisher available
when using welding or heating equipment. First Aid Apart from meeting any legal requirements it is
desirable for someone in the workshop to be trained in First Aid procedures. Splashes in the eye
should be flushed carefully with clean water for at least ten minutes. Soiled skin should be washed
with soap and water. In case of cold burns, from alternative fuels, place affected area in cool to
cold water. Individuals affected by inhalation of gases and fumes should be removed to fresh air
immediately. If effects persist, consult a doctor. If liquids are swallowed inadvertently, consult a
doctor giving him the information on the container or label. Do not induce vomiting unless this
action is indicated on the label. Fluoroelastomer See Viton. Foams - Polyurethane See also Fire.
Used in sound and noise insulation. Cured foams used in seat and trim cushioning. Follow
manufacturers instructions. Unreacted components are irritating and may be harmful to the skin
and eyes. Wear gloves and goggles. Individuals with chronic respiratory diseases, asthma,
bronchial medical problems, or histories of allergic diseases should not work in or near uncured
materials. The components, vapors or spray mists can cause direct irritation, sensitivity reactions
and may be toxic or harmful. Vapors and spray mists must not be inhaled. These materials must be
applied with adequate ventilation and respiratory protection. Do not remove the respirator
immediately after spraying; wait until the vapors/mists have cleared. Burning of the uncured
components and the cured foams can generate toxic and harmful fumes. Smoking, naked flames
or the use of electrical equipment during foaming operations and until vapors/mists have cleared
should not be allowed. Any heat cutting of cured foams or partially cured foams should be
conducted with extraction ventilation. See also the vehicle Body Repair Manual. Freon See Air
Conditioning Refrigerant. Fuels See also, Fire, Legal Aspects, Chemicals and Solvents. Avoid skin
contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.
Gasoline (Petrol) Highly flammable - observe No Smoking policy. Swallowing can result in mouth
and throat irritation and absorption from the stomach can result in drowsiness and
unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs,
through vomiting, is a very serious hazard. Gasoline dries the skin and can cause irritation and
dermatitis on prolonged or repeated contact. Liquid in the eye causes severe smarting. Motor
gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation, and the
concentration of gasoline vapors must be kept very low. High concentrations will cause eye, nose
and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high
concentrations will result in rapid loss of consciousness. Make sure there is adequate ventilation
when handling and using gasoline. Great care must be taken to avoid the serious consequences of
inhalation in the event of vapor build up arising from spillages in confined spaces. Special
precautions apply to cleaning and maintenance operations on gasoline storage tanks. Gasoline
should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid. Gas-oil
(Diesel Fuel) Combustible. Gross or prolonged skin contact with high boiling point gas oils may
also cause serious skin disorders including skin cancer. Kerosene (Paraffin) Used also as heating
fuel, solvent and cleaning agent. Flammable - observe No Smoking policy. Irritation of the mouth
and throat may result from swallowing. The main hazard from swallowing arises if liquid aspiration
into the lungs occurs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes
in the eye may be slightly irritating. In normal circumstances the low volatility does not give rise to
harmful vapors. Exposure to mists and vapors from kerosene at elevated temperature should be
avoided (mists may arise in dewaxing). Avoid skin and eye contact and make sure there is
adequate ventilation. Alternative Fuel Highly flammable. Observe ``NO SMOKING" signs. Make
sure there is adequate ventilation when working on alternative fuelled vehicles. Great care must be
taken to avoid the serious consequences of inhalation in the event of vapor build up in confined
spaces. Inhalation in high concentrations may cause dizziness, headache, nausea and loss of
co-ordination. Very high concentrations may result in loss of consciousness. Contact with liquefied
petroleum gas (LPG) or compressed natural gas (CNG) to the skin may cause cold burns and frost
bite. Long sleeved cotton overalls, steel toe capped safety boots and rubber neoprene gloves
should be worn during removal and installation of LPG/CNG fuel system components. LPG/CNG
fuel leaks could cause a fire and be a hazard to health that can lead to personal injury, illness or
even death. If a leak is detected, under no circumstances attempt to seal the leak by tightening the
union/connection until the fuel in the system or component is depressurized. Once tightened the
system should be checked for integrity following the specified procedures. If the fuel tank is to be
removed for service or repair the fuel must be evacuated using dedicated equipment and following
the specified procedures. Gas Cylinders See also Fire. Gases such as oxygen, acetylene, argon
and propane are normally stored in cylinders at pressures of up to 138 bar (2000 psi) and great
care should be taken in handling these cylinders to avoid mechanical damage to them or to the
valve gear attached. The contents of each cylinder should be clearly identified by appropriate
markings. Cylinders should be stored in well-ventilated enclosures, and protected from ice and
snow, or direct sunlight. Fuel gases, for example acetylene and propane, should not be stored in
close proximity to oxygen cylinders. Care should be exercised to prevent leaks from gas cylinders
and lines, and to avoid sources of ignition. Only trained personnel should undertake work involving
gas cylinders. Gases See Gas Cylinders. Gaskets (Fluoroelastomer) See Viton. General Workshop
Tools and Equipment It is essential that all tools and equipment are maintained in good condition
and that the correct safety equipment is used where required. Never use tools or equipment for any
purpose other than that for which they were designed. Never overload equipment such as hoists,
jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always
immediately apparent and may result in a fatal failure the next time that the equipment is used. Do
not use damaged or defective tools or equipment, particularly high-speed equipment such as
grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious
injury. Wear suitable eye protection when using grinding, chiseling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment, working with
asbestos-based materials or using spraying equipment. Make sure there is adequate ventilation to
control dusts, mists and fumes. High Pressure Air, Lubrication and Oil Test Equipment See also
Lubricants and Greases. Always keep high-pressure equipment in good condition, and regularly
maintained, particularly at joints and unions. Never direct a high-pressure nozzle, for example
diesel injector, at the skin as the fluid may penetrate to the underlying tissue, and cause serious
injury. Halon See CFCs. Legal Aspects There are many laws and regulations relating to health and
safety in the use and disposal of materials and equipment in a workshop. For a safe working
environment and to avoid environmental pollution, workshops should be familiar, in detail, with the
many health and safety laws and regulations within their country, published by both national and
local authorities. Lubricants and Greases Avoid all prolonged and repeated contact with mineral
oils. All lubricants and greases may be irritating to the eyes and skin. Transmission Fluids Safety
instructions Certain Transmission and Power Steering fluids supplied to Ford may contain additives
which have the potential to cause skin disease (dermatitis) to exposed persons. The dermatitis may
be irritant or allergic in nature. Risks are higher where prolonged or repeated skin contact with a
fluid may occur. These fluids are used for vehicle initial fill and service purposes. This sub-section
is to: Control measures Workplace risk assessments made under national chemical control
regulations should identify operations involving the fluids as potentially hazardous and specify
workplace control and worker awareness measures. In such circumstances, the relevant Material
Safety Datasheet (see the details specified below) which specifies hazards and control measures
in detail should be made available for guidance. Avoid unprotected skin contact with the fluids, and
in particular, avoid prolonged or repeated skin contact. Work practices should be organised so as
to minimise the potential for skin contact. This may include the use of drip trays, absorbents,
correct fluid handling equipment (funnels etc), and workplace housekeeping measures such as the
cleaning of contaminated surfaces. Personnel engaged in operations where skin contact could
occur (such as fluid draining or filling) should wear impervious gloves made from nitrile rubber,
certified to a chemical protection standard, e.g. Europe Standard EN374. This glove type is widely
available from reputable suppliers of gloves for chemical protection [including the manufacturers
Ansell-Admont (Solvex Range), North Safety products (North Nitrile Latex Gloves range), and
Marigold Industrial (Blue Nitrile range)]. If gloves become torn or contaminated on the inside they
should be replaced. Eye protection with safety glasses is appropriate. Use of an impervious apron
and arm protectors may be necessary if more extensive exposure is possible. Use of skin barrier
creams suitable for work with mineral oil products may offer some supplementary protection, but
such barrier creams should not be used in place of protective clothing. If accidental skin contact
occurs with the fluids, wash the area thoroughly with soap or skin cleanser and water. Accidental
eye contact should be dealt with as per normal first aid practices, by flushing the eyes with an eye
wash or clean cool water for 10 minutes, after which medical attention should be obtained. Remove
and launder clothing which becomes contaminated with the fluids. Do not place rags contaminated
with fluid in clothing pockets. Wash thoroughly after completing operations where skin exposure
may have occurred. It is important that personnel do not smoke, eat or drink whilst handling the
fluids or affected transmissions. These measures are designed to limit the risk from accidental
ingestion. Label any decanted fluid properly/use an equivalent label to that on original product
containers. Clean up any spills promptly using an inert absorbent and wash down contaminated
surfaces with detergent and water. Dispose of any waste fluids safely as hazardous waste. Safety
Data Sheets Safety Data Sheets, which detail specific material handling instructions and
precautions are available from the respective national sales company, and via internet
www.msds.ford.com. Used Engine Oil Prolonged and repeated contact with mineral oil will result in
the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition,
used engine oil contains potentially harmful contaminants, which may cause skin cancer. Adequate
means of skin protection and washing facilities must be provided. Do not employ used engine oils
as lubricants or for any application where appreciable skin contact is likely to occur. Environmental
Precautions Burning used engine oil in small space heaters or boilers can be recommended only
for units of approved design. If in doubt check with the appropriate local authority and manufacturer
of approved appliances. Dispose of used oil and used oil filters through authorized waste disposal
contractors or licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt,
contact the relevant local authority for advice on disposal facilities. It is illegal to pour used oil on to
the ground, down sewers or drains, or into watercourses. Noise Some operations may produce
high noise levels, which could, in time, damage hearing. In these cases, suitable ear protection
must be worn. Noise Insulation Materials See Foams, Fibre Insulation. O-Rings (Fluoroelastomer)
See Viton. Paints See also Solvents, Chemical Materials. Highly flammable, flammable - observe
No Smoking policy One Pack Can contain harmful or toxic pigments, driers and other components
as well as solvents. Spraying should be carried out only with adequate ventilation. Two Pack Can
also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturers
instructions should be followed. See also Resin-based Adhesives and Isocyanate Adhesives and
Sealers under Adhesives and Sealers. Spraying should preferably be carried out in exhausted
ventilated booths removing vapor and spray mists from the breathing zone. Individuals working in
booths should wear appropriate respiratory protection. Those doing small-scale repair work in the
open workshop should wear air-fed respirators. Pressurized Equipment See High Pressure Air,
Lubrication and Oil Test Equipment. Solder Solders are mixtures of metals such that the melting
point of the mixture is below that of the constituent metals (normally lead and tin). Solder
application does not normally give rise to toxic lead fumes, provided a gas/air flame is used.
Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be
produced. Some fumes may be produced by the application of any flame to surfaces coated with
grease, and inhalation of these should be avoided. Removal of excess solder should be
undertaken with care, to make sure that fine lead dust is not produced, which can give toxic effects
if inhaled. Respiratory protection may be necessary. Solder spillage and filings should be collected
and removed promptly to prevent general air contamination by lead. High standards of personal
hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.
Solvents See also Chemical Materials, Fuels (Kerosene), Fire. For example acetone, white spirit,
toluene, xylene, trichloroethane. Used in cleaning and dewaxing materials, paints, plastics, resins
and thinners. Some may be highly flammable or flammable. Skin contact will degrease the skin and
may result in irritation and dermatitis following repeated or prolonged contact. Some can be
absorbed through the skin in toxic or harmful quantities. Splashes in the eye may cause severe
irritation and could lead to loss of vision. Brief exposure of high concentrations of vapors or mists
will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the worst
circumstances, unconsciousness. Repeated or prolonged exposure to excessive but lower
concentrations of vapors or mists, for which there might not be adequate warning indications, can
cause more serious toxic or harmful effects. Aspiration into the lungs, for example through
vomiting, is the most serious consequence of swallowing. Avoid splashes to the skin, eyes and
clothing. Wear protective gloves, goggles and clothing if necessary. Make sure there is good
ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly
sealed. Do not use in confined spaces. When spraying materials containing solvents, for example
paints, adhesive, coatings, use extraction ventilation or personal respiratory protection in the
absence of adequate general ventilation. Do not apply heat or flame except under specific and
detailed manufacturers instructions. Sound Insulation See Fibre Insulation, Foams. Suspended
Loads There is always a danger when loads are lifted or suspended. Never work under an
unsupported, suspended or raised load, for example a suspended engine. Always make sure that
lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for the
job, in good condition and regularly maintained. Transmission Brake Bands See Asbestos.
Underseal See Corrosion Protection. Viton In common with many other manufacturers vehicles,
some components have O-rings, seals or gaskets, which contain a material known as `Viton'. Viton
is a fluoroelastomer, that is a synthetic rubber type material, which contains Fluorine. It is
commonly used for O-rings, gaskets and seals of all types. Although Viton is the most well known
fluoroelastomer, there are others, including Fluorel and Tecmoflon. When used under design
conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in
excess of 400°C, the material will not burn, but will decompose, and one of the products formed is
hydrofluoric acid. This acid is extremely corrosive and may be absorbed directly, through contact,
into the general body system. O-rings, seals or gaskets which have been exposed to very high
temperatures will appear charred or as a black sticky substance. DO NOT; under any
circumstances touch them or the attached components. Enquiries should be made to determine
whether Viton or any other fluoroelastomer has been used in the affected O-ring, seal or gasket. If
they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious, as the material may
be Viton or any fluoroelastomer. If Viton or any other fluoroelastomers have been used, the
affected area should be decontaminated before the commencement of work. Disposable heavy
duty plastic gloves should be worn at all times, and the affected area washed down using wire wool
and a limewater (calcium hydroxide) solution to neutralize the acid before disposing of the
decomposed Viton residue and final cleaning of the area. After use, the plastic gloves should be
discarded carefully and safely. Welding See also Fire, Electric Shock, Gas Cylinders. Welding
processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding. Resistance
Welding This process may cause particles of molten metal to be emitted at a high velocity, and the
eyes and skin must be protected. Arc Welding This process emits a high level of ultra-violet
radiation, which may cause arc-eye, and skin burns to the operator and to other persons nearby.
Gas-shielded welding processes are particularly hazardous in this respect. Personal protection
must be worn, and screens used to shield other people. CONTACT LENS WEARERS ARE
ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc
spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This
may result in blindness when the lens is removed from the eye. Metal spatter will also occur, and
appropriate eye and skin protection is necessary. The heat of the welding arc will produce fumes
and gases from the metals being welded, the rods and from any applied coatings or contamination
on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these
should be avoided. The use of extraction ventilation to remove the fumes from the working area
may be necessary particularly in cases where the general ventilation is poor, or where considerable
welding work is anticipated. In extreme cases or confined spaces where adequate ventilation
cannot be provided, air-fed respirators may be necessary. Gas Welding (and Cutting)
Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to
prevent leakage of these gases, with consequent risk of fire and explosion. The process will
produce metal spatter and eye and skin protection is necessary. The flame is bright, and eye
protection should be used, but the ultra-violet emission is much less than that from arc welding,
and lighter filters may be used. The process itself produces few toxic fumes, but such fumes and
gases may be produced from coatings on the work, particularly during cutting away of damaged
body parts, and inhalation of the fumes should be avoided. In brazing, toxic fumes may be
produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods
containing cadmium are used. In this event particular care must be taken to avoid inhalation of
fumes and expert advice may be required. SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE
ANY WELDING OR CUTTING TAKES PLACE ON VESSELS, WHICH HAVE CONTAINED
COMBUSTIBLE MATERIALS, FOR EXAMPLE BOILING OR STEAMING OUT OF FUEL TANKS.
Warning Symbols on Vehicles Decals showing warning symbols will be found on various vehicle
components. These decals must not be removed. The warnings are for the attention of
owners/operators and persons carrying out service or repair operations on the vehicle. The most
commonly found decals are reproduced below together with an explanation of the warnings. White
Spirit See Solvents.
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-01 Identification
Codes > Description and Operation > Identification Codes
The vehicle identification plate is located in the engine compartment on the front body
crossmember. The codes stamped on the plate during production enable precise details of the
vehicle build specification to be established. The Vehicle Identification Number (VIN) may also be
checked through the windshield. Vehicle Identification Number VIN Position 1, 2 and 3 — World
Manufacturer Identifier VIN Position 4 and 10 — Body Type VIN Positions 5 and 6 — Constant X
VIN Position 7 — Product Source Company VIN Position 8 — Assembly Plant VIN Position 9 —
Model Range VIN Position 11 — Year of Manufacture VIN Position 12 — Month of Manufacture -
up to 2000 Month of Manufacture - 2000 Onwards VIN Position 13 to 17 — Five Digit Number
Vehicle serial number Vehicle Certification Label (typical) or VIN Plate Item 1 to 6: Vehicle
Certification Label Item 7: Smoke Value (Diesel only) Item 8 and 9: Variants Item 10: Emission
Level Codes Item 11: Body Color Codes For vehicles built in continental plants, the second digit of
the paint code denotes the original model year of that colours introduction. For vehicles built in UK
plants, the second digit of the paint code denotes the current model year. Item 12: Interior Trim
Codes Item 13: Transaxle Final Drive Ratio Item 14: Transaxle Codes Item 15: Engine Codes Item
16: Hand of Drive
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-00 Suspension System - General
Information > Diagnosis and Testing > General Procedures > Front Toe Adjustment
Check Adjustment
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Wheel Bearing
Adapter for 204-158 (Thrust Pad) 204-158-01 (14-038-01) Collet for 205-295 204-158 (14-038)
Remover, Bearing (Main Tool) 205-295 (15-050A) Installer, Rear Hub Oil Seal 205-075 (15-036)
Installer/Aligner, Crankshaft Rear Oil Seal 303-171-03 (21-102-03) Installer, Front Wheel Bearing
204-160 (14-040) Installer, Front Hub Oil Seal 204-256 (14-046) Removal Installation
and Operation > Diagnosis and Testing > Removal and Installation > Lower Arm
Removal Installation
and Operation > Diagnosis and Testing > Removal and Installation > Front Stabilizer Bar
Alignment Pins, Subframe 205-316 (15-097A) Removal Installation

and Operation > Diagnosis and Testing > Removal and Installation > Wheel Knuckle
Separator, Ball Joint 211-020 (13-006) Adaptor for 204-158 204-158-01 (14-038-01) Lever, Wheel
Knuckle 204-159 (14-039) Installer, Halfshaft 204-161 (14-041) Removal Installation
and Operation > Diagnosis and Testing > Removal and Installation > Lower Arm Ball Joint
and Operation > Diagnosis and Testing > Removal and Installation > Front Strut and Spring Assembly
Lever, Wheel Knuckle 204-159 (14-039) Removal Installation

and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Strut and Spring
Assembly
Compressor, Coil Spring 204-167 (14-042) Adapters for 204-157 204-167-01 (14-042-01)
Disassembly Assembly
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02A Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Beam Axle
and Operation > Diagnosis and Testing > Removal and Installation > Trailing Arm Bushing
Remover/Installer, Pivot Bushing 205-342 (15-110) Adaptor for 205-342 205-342-01 (15-110-01)
Adaptor for 205-342 205-342-02 (15-110-02) Removal Installation
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Spindle
and Operation > Diagnosis and Testing > Removal and Installation > Rear Strut and Spring Assembly
and Operation > Diagnosis and Testing > Removal and Installation > Rear Wheel Bearing
Installer, Front Hub Oil Seal 204-066 (14-018) Installer, Wheel Hub Bearing Cone and Oil Seal
205-101 (15-051) Remover, Oil Seal 303-112 (21-051) Removal Installation
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Rear Strut and Spring
Assembly
Compressor, Coil Spring 204-167 (14-042) Adapters for 204-167 307-278 (15-111) Disassembly
Assembly
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02B Rear Suspension - Courier >
Description and Operation > Rear Suspension
The Courier has a rear axle assembly design that is unlike any rear axle assembly that has ever
been used on the Fiesta range. The Courier rear axle assembly consists of two trailing arms
connected by a V-shaped section beam, two rear axle carriers, two stabiliser and two torsion bars
fixed at the centre by a connecting link. The axle carriers are secured to the body by four bolts. The
axle assembly is also supported by two shock absorbers.
Description and Operation > Diagnosis and Testing > Removal and Installation > Axle
Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Stabilizer Bar
Slide Hammer 205-047 (15-011) Adaptor for 205-047 205-011-03 (15-011-03) Alignment Fixture,
Rear Suspension 205-305 (15-087) Removal Installation
Description and Operation > Diagnosis and Testing > Removal and Installation > Wheel Hub
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Halfshaft LH
Installer, drive halfshaft 204-161 (14-041) Remover, drive halfshaft 308-256 (16-089) Removal
Installation
and Operation > Diagnosis and Testing > Removal and Installation > Front Halfshaft RH
Installer, drive halfshaft 204-161 (14-041) Boot clamp tightening tool 204-169 (14-044) Removal
Installation
and Operation > Diagnosis and Testing > Removal and Installation > Inner Constant Velocity (CV) Joint Boot
Boot clamp tightening tool 14-044 Removal Installation

and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Halfshaft LH
Boot clamp tightening tool 204-169 (14-044) Disassembly Assembly

and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Halfshaft RH
Boot clamp tightening tool 204-169 (14-044) Separating tool 205-310 (15-091) Bridge, drive pinion
bearing remover 205-311 (15-092) Disassembly Assembly
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02A Drum Brake > Description and
Operation > Diagnosis and Testing > Removal and Installation > Brake Drum
Operation > Diagnosis and Testing > Removal and Installation > Brake Shoes
Operation > Diagnosis and Testing > Removal and Installation > Wheel Cylinder
Operation > Diagnosis and Testing > Removal and Installation > Brake Backing Plate
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02B Drum Brake - Courier >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Shoes - Courier
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Diagnosis and Testing > Removal and Installation > Brake Pads
Brake piston retracting tool 12-014 Removal Installation

Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Parking Brake Cable Adjustment
Adjustment
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Parking Brake
Control
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Parking Brake
Warning Indicator Switch
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Courier > Description and Operation > Diagnosis and Testing > Removal and Installation > Cable and Conduit
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-06 Hydraulic Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Pedal
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-07 Power Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Vacuum Pump
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control - Traction
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Hydraulic Control Unit (HCU)
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Wheel Speed Sensor
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Front Wheel Speed Sensor
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Front Wheel Speed Sensor Ring
Adaptor, Thrust Pad, Wheel Hub 204-158-01 (14-038-01) Remover, Bearing 205-310 (15-091)
Remove/Installer, Crankshaft Bearing 303-433 (21-185) Removal Installation
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Wheel Speed Sensor Ring
Remove/Installer, Crankshaft Bearing 303-433 (21-185) Removal Installation

Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Diagnosis and Testing > Steering System
Principles of Operations The steering wheel rotational movement is transferred to the steering gear
through the steering column shaft. The steering gear converts this rotational movement, through
the action of the rack and pinion gear into lateral movement. This movement in turn is transferred
to the wheel knuckle through the tie-rods and tie-rod ends. Hydraulic fluid under pressure is
supplied to the steering gear by the power steering pump. As the steering wheel is rotated, the
hydraulic fluid is allowed to pass through the steering gear valve to one side of a double-acting
piston, dependent on which direction the steering wheel is rotated. The fluid moves the piston,
which forms part of the steering gear, giving power assistance to the effort required to turn the front
road wheels. Variants fitted with the 1.8L DI engine and air-conditioning have an Electro-hydraulic
power steering pump fitted. The pump is controlled by the EEC V Powertrain Control Module
(PCM) and starts to work as soon as the engine is running. Inspection and Verification Visual
Inspection Chart Symptom Chart Symptom Chart PINPOINT TEST A : THE
ELECTRO-HYDRAULIC POWER STEERING PUMP IS INOPERATIVE Component Tests Steering
Linkage Inspect the steering gear boots for cuts, deterioration, twisting or distortion. make sure the
boots are secure. Install new boots or clamps as necessary.
Information > Diagnosis and Testing > General Procedures > Power Steering System Flushing
Information > Diagnosis and Testing > General Procedures > Power Steering System Flushing - Vehicles Built Up To:
02-2000 1.8L Duratorq-TDDi (Lynx) Diesel
Information > Diagnosis and Testing > General Procedures > Power Steering System Flushing - Vehicles Built From:
02-2000 1.8L Duratorq-TDDi (Lynx) Diesel, Vehicles With: Air Conditioning
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-01 Manual Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear
Separator, ball joint 13-006 Removal Installation

Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump - Vehicles Built From: 01-1999
1.3L Endura-E (HCS), Vehicles Without: Air Conditioning
Expander, Teflon seal 13-015 Remover, power steering pump pulley 13-022 Installer, camshaft
pulley 21-192 Removal Installation
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump - Vehicles Built From: 02-2000
1.8L Diesel, Vehicles With: Air Conditioning
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear Pinion Seal
Adaptor for 16-042A-01 16-042A Remover, oil seal 21-143 Remover, oil seal 21-151 Removal
Installation
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear
Separator, ball joint 211-020 (13-006) Expander, Teflon seal 211-188 (13-015) Alignment pins,
subframe 205-316 (15-097A) Socket, hydraulic line union 211-268A (13-026A) Removal Installation
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Fluid Cooler
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump to Steering Gear Pressure Line
- 1.4L-1.6L
Socket, Hydraulic Line Union Nut 211-269 (13-027) Socket, Hydraulic Line Union Nut 211-268A
(13-026A) Expander, Teflon Seal 211-188 (13-015) Removal Installation
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear to Fluid Cooler Return Hose
Socket, Hydraulic Line Union Nut 211-268A (13-026A) Expander, Teflon Seal 211-188 (13-015)
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Description and Operation > Diagnosis and Testing > Removal and Installation > Tie Rod End
Separator, ball joint 13-006 Removal Installation

Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Description and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear Boot
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-04 Steering Column > Description
and Operation > Removal and Installation > Steering Wheel
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-05 Steering Column Switches >
Description and Operation > Diagnosis and Testing > Steering Column Switches
Inspection and Verification Visual Inspection Chart Symptom Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : THE IGNITION SWITCH IS INOPERATIVE PINPOINT TEST B : NO POWER
IN ACC PINPOINT TEST C : NO POWER IN RUN PINPOINT TEST D : NO POWER IN START
PINPOINT TEST E : THE MULTIFUNCTION SWITCH/HAZARD WARNING SWITCH DOES NOT
OPERATE CORRECTLY
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-05 Steering Column Switches >
Description and Operation > Diagnosis and Testing > Removal and Installation > Steering Column Multifunction Switch
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Bearing Journal Diameter
> Diagnosis and Testing > General Procedures > Camshaft Bearing Journal Clearance
> Diagnosis and Testing > General Procedures > Camshaft End Play
1. End play = maximum value minus minimum value

> Diagnosis and Testing > General Procedures > Camshaft Surface Inspection
> Diagnosis and Testing > General Procedures > Crankshaft End Play
> Diagnosis and Testing > General Procedures > Camshaft Lobe Lift
> Diagnosis and Testing > General Procedures > Piston Diameter
> Diagnosis and Testing > General Procedures > Crankshaft Main Bearing Journal Diameter
> Diagnosis and Testing > General Procedures > Piston Ring End Gap
> Diagnosis and Testing > General Procedures > Piston Pin to Bore Diameter
> Diagnosis and Testing > General Procedures > Piston Pin Diameter
> Diagnosis and Testing > General Procedures > Piston Inspection
> Diagnosis and Testing > General Procedures > Piston Ring-to-Groove Clearance
> Diagnosis and Testing > General Procedures > Connecting Rod Large End Bore
> Diagnosis and Testing > General Procedures > Cylinder Head Distortion
> Diagnosis and Testing > General Procedures > Valve Stem Diameter
> Diagnosis and Testing > General Procedures > Valve Seat Inspection
> Diagnosis and Testing > General Procedures > Flywheel Inspection
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.3L Endura-E (HCS) >
Description and Operation > Engine
General The basic engine for the Fiesta is the Endura-E engine. This familiar 1,3 liter engine has
been revised and is now available in two versions with 37 kW (50 PS) and 44 kW (60 PS). The 37
kW variant will only be available in Germany and Austria. The main changes to the previous model
include sequential, electronically controlled multiport fuel injection, a new aluminium oil pan and a
thermoplastic intake manifold. From '99 1/2 MY the mass air flow (MAF) and the intake air
temperature (IAT) sensor are no longer installed. The new temperature/manifold absolute pressure
(T-MAP) sensor will be integral with the intake manifold. Cylinder Block Thread repairs to the
cylinder block are permitted provided that Helicoil thread inserts are used. The remaining material
thickness must be at least 3,2 mm for diameters up to 9,5 mm and at least 4,8 mm for larger
diameters. Water plugs must not be removed. Crankshaft The crankshaft runs on five bearings.
The bearing caps are numbered at the factory and should be refitted accordingly during installation.
The first main bearing has a seat for the tensioning arm of the chain tensioner. The crankshaft and
the main bearing caps have colored marks which indicate their size. With the bearing caps these
marks are on the bearing caps themselves, and on the crankshaft the colored marks are on the
crank webs. Cylinder Head The cast iron cylinder head is positioned on the cylinder block with two
sleeves, and fastened with ten bolts. The cylinder head mating face is allowed to show distortion of
0,25 mm over the whole length. Thread repairs are permitted provided that Helicoil thread inserts
are used. Cylinder Head Gasket The cylinder head gasket is made of aramide fiber with filler and
must be renewed every time it is removed. The gasket is steel-coated for protection around the oil
pressure bore and the cylinder bore. Pistons The pistons are made of an aluminium-silicone alloy,
and have three piston rings: Barrel faced plane ring (top) Napier ring (middle) Oil scraper ring
(bottom) Piston rings can be renewed separately, without reworking the cylinder liners. On
installation, the piston ring gaps must be distributed around the circumference and spaced at least
90 degrees apart. The arrows on the piston crown point forwards. Oil Pan On installation, the
tightening sequence for the bolts must be observed. Renew the gasket of the aluminium oil pan if
there is any visible damage to it. Sealer should be applied to the cylinder block when installing the
oil pan. Thread repairs on the oil pan are permitted provided Helicoil thread inserts are used. Intake
Manifold The intake manifold is made of thermoplastic. This design has two advantages: it reduces
weight and conducts less heat than the die-cast version. The use of plastic also improves the flow
characteristics, reduces the tendency to condensation at cold start and improves the response of
the engine during a warm start. Valve Train The valve timing is controlled by the crankshaft via a
single roller chain to the low lying camshaft. The camshaft transmits the timing actions to the valves
via tappets, push rods and a rocker shaft. Thermostat The gasket of the thermostat housing must
be renewed every time the thermostat housing is fitted.
Description and Operation > General Procedures > Valve Clearance
Description and Operation > General Procedures > In-vehicle Repair > Intake Manifold
Description and Operation > General Procedures > In-vehicle Repair > Crankshaft Front Seal
Installer, timing cover oil seal 303-091 (21-046) Remover, crankshaft oil seal 303-293 (21-143)
Description and Operation > General Procedures > In-vehicle Repair > Crankshaft Rear Seal
Adapter for 303-172 303-171-01 (21-102-01) Adapter for 303-172 303-171-02 (21-102-02A)
Adapters for 303-171-02 303-171-04 (21-102-04) Installer/aligner, crankshaft rear oil seal 303-172
(21-102) Remover, crankshaft rear oil seal 303-336 (21-151) Immobilizing tool, flywheel 303-393
(21-168) Aligner, clutch disk 308-204 (16-067)
Description and Operation > General Procedures > In-vehicle Repair > Valve Seals
Replacer, valve stem seals 303-037 (21-007 A) Compressor, valve spring 303-060 (21-024)
Adapter for 303-060 303-060-01 (21-024-01) Adapter for 303-060 303-060-05 (21-024-05) Installer,
valve collets 303-362 (21-156) Adapter, air supply (cylinder head) 303-363 (21-157) Pliers, valve
stem oil seal 303-390 (21-165) Removal Installation
Description and Operation > General Procedures > In-vehicle Repair > Cylinder Head
Angle gauge 303-174 (21-540) Removal Installation

Description and Operation > General Procedures > In-vehicle Repair > Removal > Engine
Separator, ball joint 211-020 (13-006) Engine lifting bracket 303-122 (21-068A) Remover/installer,
coolant hose clip 303-397 (24-003) Remover, drive halfshaft 308-237 (16-087) Remover, drive
halfshaft 308-256 (16-089) Removal
Description and Operation > General Procedures > In-vehicle Repair > Removal > Disassembly > Engine
Immobilizing tool, flywheel 303-393 (21-168) Assembly stand 303-435 (21-187) Mounting frame for
303-435 303-435-02 (21-050 A) Disassembly
Description and Operation > General Procedures > In-vehicle Repair > Removal > Disassembly > Disassembly and
Assembly of Subassemblies > Assembly > Engine
Installer, timing cover oil seal 303-091 (21-046) Adapter for 303-172 303-171-01 (21-102-01)
Adapter for 303-172 303-171-02 (21-102-02A) Adapters for 303-171-02 303-171-04 (21-102-04)
Installer/aligner, crankshaft rear oil seal 303-172 (21-102) Angle gauge 303-174 (21-540)
Immobilizing tool, flywheel 303-393 (21-168) Assembly stand 303-435 (21-187) Mounting frame for
303-435 303-435-02 (21-050A) Aligner, clutch disc 308-204 (16-067) Assembly 1. Coat the spark
plug threads with lubricant .
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 1.25L-1.4L Zetec-SE
(Sigma)-1.6L > Description and Operation > Diagnosis and Testing > General Procedures > Valve Clearance
Compressor, valve clearance adjustment 303-563 (21218) Remover/installer, valve adjusting shim
303-563-01 (21801) Spark plug connector pliers 303-622 (21226) Adjust
(Sigma)-1.6L > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Crankshaft
Front Seal
Remover, crankshaft oil seal 303-293 (21143) Installer, crankshaft oil seal 303-395 (21171)
(Sigma)-1.6L > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Valve Seals
Installer, valve stem oil seals 303-037 (21007A) Compressor, valve spring 303-361 (21155)
Adapter for 303 - 361 303-361-04 (2115504) Adapter for 303 - 361 303-361-05 (2115505) Installer,
valve collets 303-362 (21156) Connector, air supply (cylinder head) 303-363 (21157) Pliers, valve
stem seals 303-508 (21211) Removal Installation
(Sigma)-1.6L > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Camshaft
Universal Flange Holding Wrench 205-072 (15030A) Pliers, Valve Shim 303-196 (21107) Installer,
Crankshaft Seal 303-395 (21171) Removal Installation
(Sigma)-1.6L > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Timing Belt
Universal Flange Holding Wrench 205-072 (15-030A) Alignment Plate, Camshaft 303-376
(21-162B) Compressor, Belt Tensioner 303-429 (21-180) Socket, Spark Plug 303-499 (21-202)
Timing Peg, Crankshaft TDC 303-507 (21-210) Installer, Crankshaft Vibration Damper 303-510
(21-214) Pliers, Spark Plug Connector 303-622 (21-226) Locking Tool, Crankshaft 303-748
(21-259) Removal Installation
(Sigma)-1.6L > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal >
Engine - Vehicles With: Automatic Transaxle
Separator, ball joint 211-020 (13-006) Remover/installer, coolant hose clip 303-397 (24-003)
Remover, halfshaft 308-237 (16-087) Removal
Engine - Vehicles With: Manual Transaxle
Remover, halfshaft 308-237 (16-087) Remover, halfshaft 308-256 (16-089) Remover/installer,

coolant hose clip 303-397 (24-003) Removal
Disassembly > Engine
Slide Hammer 205-047 (15–011) Universal Flange Holding Wrench 205-072 (15-030A) Pliers,
Valve Shim 303-196 (21-107) Alignment Plate, Camshaft 303–376 (21-162B) Socket, Cylinder
Head Bolt 303-392 (21-167) Locking Tool, Flywheel 303–393 (21-168) Compressor, Belt Tensioner
303–429 (21-180) Mounting Stand 303-435 (21-187) Mounting Bracket for 303-435 303-435-06
(21-031B) Mounting Plate for 303-435-06 303-435-14A (21-212) Socket, Spark Plug 303–499
(21-202) Pliers, Spark Plug Connector 303–622 (21-226) Adapter for 205-047 303–633 (21–227)
Disassembly
Disassembly > Disassembly and Assembly of Subassemblies > Cylinder Head
Disassembly > Disassembly and Assembly of Subassemblies > Assembly > Engine
Universal Flange Holding Wrench 205-072 (15-030A) Lifting Bracket, Engine 303-122 (21-068A)
Gauge, Bolt Angle 303-174 (21-540) Pliers, Valve Shim 303-196 (21-107) Alignment Plate,
Camshaft 303-376 (21-162B) Socket, Cylinder Head Bolt 303-392 (21-167) Locking Tool, Flywheel
303-393 (21-168) Installer, Crankshaft Seal 303-395 (21-171) Compressor, Belt Tensioner 303-429
(21-180) Mounting Stand 303-435 (21-187) Mounting Bracket for 303-435 303-435-06 (21-031B)
Mounting Plate for 303-435-06 303-435-14A (21-212) Socket, Spark Plug 303-499 (21-202) Timing
Peg, Crankshaft TDC 303-507 (21-210) Installer, Crankshaft Vibration Damper 303-510 (21-214)
Locking Tool, Crankshaft 303-748 (21-259) Aligner, Clutch Plate 308-204 (16-067) Assembly 1.
Stage 1: 3 Nm 2. Stage 2: 10 Nm
Disassembly > Disassembly and Assembly of Subassemblies > Assembly > Installation > Engine - Vehicles With: Automatic
Transaxle
Separator, ball joint 211-020 (13-006) Remover/installer, coolant hose clip 303-397 (24-003)
Installation
Disassembly > Disassembly and Assembly of Subassemblies > Assembly > Installation > Engine - Vehicles With: Manual
Transaxle
Remover/installer, radiator hose clip 303-397 (24-003) Installation

Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 1.4L PTE (CVH) >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Intake Manifold
Remover/installer, cooling hose clamp 24-003 Removal

Description and Operation > Diagnosis and Testing > In-vehicle Repair > Crankshaft Front Seal
Installer, Oil Seal 21-093 A Remover, Oil Seal 21-096 Remover, Timing Belt Pulley 21-098
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Valve Seals
Valve spring compressor 21-097 Installer, valve collets 21-156 Adaptor, air supply cylinder 21-157
Remover, valve stem oil seals 21-165 Removal Installation
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Camshaft
Installer, oil seal 21-094 Remover, oil seal 21-096 Tension gauge, timing belt 21-113 Removal
Installation
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Timing Belt
Tension Gauge, Timing Belt 21-113 Locking Tool, Crankshaft 21-168 Removal Installation
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Cylinder Head
Angle gauge 21-540 Remover/installer, cooling hose clamp 24-003 Removal Installation
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Oil Pan
Lifting bracket, engine 21-068 A Engine support bar 21-140 Adaptor for 21-140 21-140-01
Separator, Oil Pan 21-179 Adaptor for 21-140 21-140-03 Adaptor for 21-140 21-140-07 Removal
Installation
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Removal > Engine
Remover, drive shaft 16-087 Removing tool, drive shaft 16-089 Lifting bracket, engine 21-068A
Remover/installer, cooling hose clamp 24-003 Removal
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Removal > Disassembly > Engine
Aligner, clutch plate 16-067 Mounting bracket 21-064 Retaining bolts for 21 - 064 21-064-01
Crankshaft front oil seal installer 21-093 A Crankshaft rear oil seal installer 21-095 Remover, oil
seal 21-096 Remover, timing belt pulley 21-098 Tension gauge, timing belt 21-113 Mounting plate
Mounting plate Locking tool, crankshaft 21-168 Separator, sump 21-179 Angle gauge 21-540
Disassembly
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and
Assembly of Subassemblies > Cylinder Head
Remover, oil seal 21-051 Installer, oil seal 21-094 Installer, valve collets 21-156 Remover, valve
stem oil seals 21-165 Disassembly Assembly
Assembly of Subassemblies > Assembly > Engine
Aligner, clutch plate 16-067 Mounting bracket 21-064 Retaining bolts for 21 - 064 21-064-01
Crankshaft front oil seal installer 21-093 A Crankshaft rear oil seal installer 21-095 Remover, oil
seal 21-096 Remover, timing belt pulley 21-098 Tension gauge, timing belt 21-113 Mounting plate
Mounting plate Locking tool, crankshaft 21-168 Separator, sump 21-179 Angle gauge 21-540
Assembly of Subassemblies > Assembly > Installation > Engine
Lifting bracket, engine 21-068A Remover/installer, cooling hose clamp 24-003 Installation
Description and Operation > Engine
The PTE engine (54 kW/73 PS) is equipped with sequential multiport fuel injection (SFI). PTE
means the engine has a Pent roof-shaped combustion chamber, high Torque and low Emissions.
P=Pent roof T=high Torque E=low Emission The engine has a camshaft with an extra cam for the
camshaft position sensor (CMP sensor). This is necessary to support the sequential multiport fuel
ignition (SFI). Engine Code and Engine Serial Number on Cylinder Block 1. Engine code. - 2.
Engine serial number Description of Engine Code (F4B)
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01D Engine - 1.8L Endura-DE (Kent)
Diesel > Description and Operation > Engine
The 44kW (60PS) indirect injection Diesel engine is based on the familiar swirl chamber Diesel
engine which has been revised in line with the latest technology. The engine not only conforms to
European Emission Regulations, but also meets all other expectations in relation to fuel
consumption, quiet running, flexibility and power delivery. Crankshaft The crankshaft runs in five
main bearings. Thrust half bearings are fitted at the third bearing to control the crankshaft end float.
Timing belt pulley - crankshaft The timing belt pulleys used to drive the valve train and fuel injection
pump are a sliding fit on the crankshaft and are retained by the crankshaft central bolt. The fuel
injection pump drive pulley is positively located by pins that locate into the crankshaft on one
surface and the camshaft timing belt pulley on the other. On the front pulley there is an O-ring seal
which must be renewed during every installation. It is important not to assemble the O-ring seal dry;
always lubricate it with clean engine oil prior to installation. Crankshaft central bolt The crankshaft
central bolt is a "Torque to Yield bolt" which must be renewed each time it is undone. Camshaft
timing belt The toothed timing belt drives the camshaft and maintains the correct relationship
between camshaft and crankshaft. The timing belt tension is maintained by the automatic tensioner.
However, the first time the belt is tensioned, the adjusting cam is used. The camshaft timing pulley
is a taper fit on the camshaft and is retained by friction applied by a clamping bolt. Valve tappets &
adjusting shims The camshaft operates the valves directly via the valve tappets. Adjustment shims
are available for setting the valve clearances. The thickness of each shim is marked on one face.
Cylinderhead The cylinder head gasket is available in three thicknesses. A particular piston
protrusion requires a certain thickness of gasket and this is determined by the number of notches
on the gasket thickness indicator. Crankshaft oil seals Both the front and rear oil seals are made
from PTFE and therefore must be fitted dry. When supplied as a service parts, both oil seals have a
support ring which should only be removed after fitting. Some support rings may drop out of their
own accord after an oil seal has been fitted. Crankcase ventilation The crankcase ventilation valve
is on the upper surface of the valve cover. Like all crankcase ventilation components, the valve
must always be kept clean to ensure optimal engine operation.
Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Valve Clearance
Compressor, bucket tappets 21-106 Pliers, valve adjustment shims 21-107 Remover/installer,
cooling hose clamp 24-003
Diesel > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Crankshaft Front
Seal
Universal flange holding wrench 15-030 A Timing peg, crankshaft TDC position 21-104 Engine
support bar 21-140 Adapter for 21-140 21-140-01 Adapter for 21-140 21-140-02 Adapter for
21-140 21-140-03 Centering tool, remover and installer, oil seal 21-148 A Remover, crankshaft
timing pulley 21-200 Angle gauge, bolt tightening 21-540 Timing pin, injection pump timing 23-019
Timing pin, injection pump timing 23-029 Removal Installation
Diesel > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Auxiliary Shaft
Seal
Installation
Diesel > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Timing Belt -
Vehicles With: Automatic Timing Belt Tensioner
Timing pin, crankshaft TDC 303-193 (21104) Engine support bar 303-290 (21140) Adapter for
303-290 (21140) 303-290-01 (2114001) Adapter for 303-290 (21140) 303-290-02 (2114002)
Adapter for 303-290 (21140) 303-290-03 (2114003) Timing tool, camshaft 303-376 (21162B)
Universal flange holding wrench 205-072 (15030A) Removal Installation
Diesel > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal > Engine
Remover, driveshaft 16-087 21-068 A Engine lifting bracket 21-068 A Engine lifting bracket
Remover/installer, radiator hose clamps 24-003 Removal
Diesel > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal >
Disassembly > Engine
Universal flange holding wrench 15-030A Mounting bracket, engine 21-031B Socket, cylinder head
bolts 21-164 Crankshaft locking tool 21-168 Puller, crankshaft timing belt pulley 21-200 Socket,
injectors 23-045 Disassembly
Disassembly > Disassembly and Assembly of Subassemblies > Cylinder Head
Universal flange holding wrench 15-030A 21-007 A Installer, valve stem seals 21-007 A Installer,
valve stem seals Valve spring compressor 21-024 Adaptor for 21-024 21-024-05 Installer, oil seal
21-110 Installer, valve stem collets 21-156 Pliers, valve stem oil seals 21-165 Socket, injectors
23-045 Disassembly Assembly
Disassembly > Disassembly and Assembly of Subassemblies > Assembly > Engine
Universal flange holding wrench 15-030A Aligner, clutch disk 16-067 Mounting bracket, engine
21-031B Timing pin, crankshaft TDC position 21-104 Centring tool, remover and installer, oil seal
21-148A Adjustment tool, camshaft TDC 21-162B Socket, cylinder head bolts 21-164 Locking tool,
crankshaft 21-168 Aligner, crankshaft rear oil seal 21-217 Angle gauge, bolt tightening 21-540
Timing pin, injection pump 23-019 Timing pin, injection pump 23-029 Socket, injectors 23-045
Timing pin, crankshaft position sensor (CKP sensor) 23-049 Remover/installer, cooling hose clamp
24-003 Assembly
Disassembly > Disassembly and Assembly of Subassemblies > Assembly > Installation > Engine
Remover, driveshaft 16-087 21-068 A Engine lifting bracket 21-068 A Engine lifting bracket
Remover/installer, radiator hose clamps 24-003 Installation
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01E Engine - 1.8L Endura-DI (Lynx)
Diesel > Description and Operation > Engine
The 55kW (75PS) diesel engine with direct injection is based on the familiar swirl chamber diesel,
but it has been brought up-to-date to the latest technology level. This engine therefore complies
with the stage II emissions standard and with all other requirements made on new generation
assemblies with regard to fuel consumption, quiet running, flexibility and power output. Crankshaft
The five main bearing crankshaft has thrust half rings on the third main bearing that determine the
crankshaft end float. Crankshaft timing sprocket The crankshaft timing sprocket drives the injection
pump sprocket by means of a chain drive. The crankshaft timing sprocket is held in position only by
the clamping pressure of the center bolt. The crankshaft timing sprocket is located to ensure
accurate positioning. Timing belt drive The cambelt is driven by the injection pump timing pulley
and transmits the valve timing onto the overhead camshaft. The tension of the timing belt drive is
maintained by an automatic timing belt tensioner. The initial setting of the timing belt tension is
carried out by the adjustment cam. The camshaft timing pulley is retained on the camshaft by
means of a taper. The required frictional force is applied to the camshaft by a central bolt. Valve
tappet, adjusting shims The camshaft timing is transmitted to the valve springs by eight bucket
tappets. Adjusting shims are available for adjusting the valve clearance. The thickness of these is
indicated on the underside. Cylinder Head Cylinder head gaskets of various thicknesses are
available. Dependent on the piston projection, a certain thickness is assigned to the engine. This is
indicated by indentations on the cylinder head gasket. The cylinder head gasket is an MLS (Multi
Layered Steel) gasket. The gasket consists of three steel layers. The steel layers are coated with
rubber. Because of this design the service life is increased, and because the gasket does not settle
when installed, the cylinder head bolts can be tightened with a lower clamping force. Because of
this rubber outer coating the gasket is easily grooved, and therefore must not be cleaned with
anything sharp. Crankshaft oil seals The front and rear oil seals are made of PTFE and must be
free from oil when installed. Both oil seals are supplied with a support ring as a spare part. This
may not be removed until after assembly, or it may drop out of the oil seal of its own accord.
Crankcase ventilation The crankcase ventilation valve is located on the top of the cylinder head
cover. To ensure optimal engine performance, this valve and all PCV hoses must be free of
contaminants at all times. Oil Pan The oil pan is made of steel. It is sealed with liquid, silicone
based sealant (WSE-M4G-323-A6). The oil pan will be pressed inwards if the engine is supported
on a workshop jack. This may cause the oil flow into the oil intake pipe to stop. The oil drain plug
has an O-ring seal, which can be used many times.
Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Timing Belt
Clamping Tool, Boot Retaining Clamp 204-169 (14-044) Universal Flange Holding Wrench 205-072
(15-030A) Timing Peg, Crankshaft TDC 303-193 (21-104) Support Bar, Engine 303-290A
(21-140A) Adapter for 303-290A 303-290-01 (21-140-01) Adapter for 303-290A 303-290-02
(21-140-02) Adapter for 303-290A 303-290-03A (21-140-03A) Adapter for 303-290A 303-290-06
(21-140-06) Alignment Plate, Camshaft 303-376 (21-162B) Locking Tool, Flywheel 303-393
(21-168) Remover, Camshaft Sprocket 303-651 (21-229) Removal Installation
Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Camshaft
Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Camshaft Seal
Remover, Crankshaft Seal 303-293 Installer, Camshaft Seal 303-199A Removal Installation
Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Cylinder Head
Engine Lifting Bracket 303-122 (21-068A) Angle Gauge, Bolt Tightening 303-174 (21-540)
Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Intake Manifold
Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Exhaust Manifold
Remover/installer, coolant hose clip 303-397 (24-003) Removal Installation

Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Removal > Engine
Engine lifting bracket 303-122 (21-068 A) Remover/installer, cooling hose clamp 303-397 (24-003)
Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Removal > Disassembly > Engine
Slide Hammer 205-047 (15-011) Universal Flange Holding Wrench 205-072 (15-030A) Locking
Tool, Flywheel 303-393 (21-168) Remover/Installer, Hose Clamp 303-397 (24-003) Mounting Stand
303-435 (21-187) Mounting Bracket for 303-435 (21-187) 303-435-06 (21-031B) Adapter for
205-047 303-633 (21-227) Remover, Camshaft Sprocket 303-651 (21-229) Remover, Fuel Injection
Pump Pulley 310-095 (23-067)
Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Removal > Disassembly > Disassembly
and Assembly of Subassemblies > Cylinder Head
Installer, Valve Stem Seal 303-037 (21-007A) Compressor, Valve Spring 303-060 (21-024) Adapter
for 303-060 (21-024) 303-060-05 (21-024-05) Installer, Camshaft Seal 303-199A (21-110 A)
Installer, Valve Stem Collets 303-362 (21-156) Pliers, Valve Stem Seal 303-390 (21-165) Socket,
Cylinder Head Temperature Sensor 303-680 (21-239) Disassembly Assembly
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Cooling System Draining, Filling and Bleeding - 1.25L-1.3L
Endura-E (HCS)-1.4L-1.6L-1.8L Endura-DE (Kent) Diesel
Drain Refill
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Water Pump - Vehicles Built From:
01-1999 1.3L Endura-E (HCS)
Remover/Installer, cooling hose clamp 24-003 Removal Installation

Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Water Pump - Vehicles Built Up To:
01-1999 1.3L Endura-E (HCS)
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Radiator - 1.3L Endura-E (HCS)
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Thermostat - 1.25L-1.4L Zetec-SE
(Sigma)
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Water Pump - 1.25L-1.4L Zetec-SE
(Sigma)
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Radiator - 1.25L-1.4L Zetec-SE
(Sigma)
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Thermostat - 1.4L PTE (CVH)
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Water Pump - 1.4L PTE (CVH)
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Radiator - 1.4L PTE (CVH)
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Cooling Fan Motor - 1.4L PTE
(CVH)
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Water Pump - 1.6L
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Radiator - 1.6L
Remover/Installer, Cooling Hose Clamp 303–397 (24–003) Removal Installation

Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Radiator - 1.8L Endura-DE (Kent)
Diesel
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Water Pump - 1.8L Endura-DE
(Kent) Diesel
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Thermostat - 1.8L Endura-DI (Lynx)
Diesel
Remover/Installer, Cooling Hose Clamp 303–397 (24–003) Removal Installation

Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Water Pump - 1.8L Endura-DI
(Lynx) Diesel
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Coolant Expansion Tank
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04B Fuel Charging and Controls -
1.25L-1.4L Zetec-SE (Sigma)-1.6L > Description and Operation > Diagnosis and Testing > Removal and Installation >
Throttle Body - 1.6L
1.25L-1.4L Zetec-SE (Sigma)-1.6L > Description and Operation > Diagnosis and Testing > Removal and Installation >
Throttle Body - Vehicles Built From: 02-2000 1.25L
1.25L-1.4L Zetec-SE (Sigma)-1.6L > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Charging Wiring Harness - 1.6L
1.25L-1.4L Zetec-SE (Sigma)-1.6L > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Charging Wiring Harness - Vehicles Built From: 02-2000 1.25L
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04D Fuel Charging and Controls - 1.8L
Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Fuel
Injectors
Socket SW 27, injectors 310-046 (23-034) Removal Installation

Injection Pump
Timing Peg, Crankshaft TDC 303-193 (21-104) Support Bar, Engine 303-290 (21-140) Adapter for
303-290 303-290-01 (21-140-01) Adapter for 303-290 303-290-02 (21-140-02) Adapter for 303-290
303-290-03 (21-140-03) Timing Peg, Fuel Injection Pump Timing 310-018 (23-019) Timing Peg,
Fuel Injection Pump Timing 310-033 (23-029) Removal Installation
Injection Pump - 1.8L Endura-DI (Lynx) Diesel
Hand Vacuum/Pressure Pump 416–D001 (23–036A) Puller, Injection Pump Pulley 310-095
(23-067) Removal Installation
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04E Fuel Charging and Controls -
Turbocharger > Description and Operation > Diagnosis and Testing > Removal and Installation > Turbocharger
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - 1.25L-1.4L Zetec-SE (Sigma)
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - Vehicles Built Up To: 01-1999 1.3L
Endura-E (HCS)
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - Vehicles Built From: 01-1999 1.3L
Endura-E (HCS)
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - 1.8L Endura-DE (Kent) Diesel
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - 1.8L Endura-DI (Lynx) Diesel
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - 1.8L Endura-DE (Kent) Diesel,
Vehicles With: Air Conditioning
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - 1.4L PTE (CVH)
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt Tensioner - 1.25L-1.4L Zetec-SE
(Sigma)
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt Tensioner - 1.6L
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-06 Starting System > Description and
Operation > Diagnosis and Testing > Removal and Installation > Starter Motor - 1.3L Endura-E (HCS)
Operation > Diagnosis and Testing > Removal and Installation > Starter Motor - 1.25L-1.4L Zetec-SE (Sigma)
Operation > Diagnosis and Testing > Removal and Installation > Starter Motor - 1.4L PTE (CVH)
Operation > Diagnosis and Testing > Removal and Installation > Starter Motor - 1.8L Endura-DE (Kent) Diesel
Operation > Diagnosis and Testing > Removal and Installation > Starter Motor - 1.8L Endura-DI (Lynx) Diesel
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07 Engine Ignition > Description and
Operation > Diagnosis and Testing > Removal and Installation > Ignition Coil - 1.25L-1.4L Zetec-SE (Sigma)
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08A Engine Emission Control -
1.25L-1.4L Zetec-SE (Sigma) > Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust
Gas Recirculation (EGR) Valve
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08B Engine Emission Control - 1.8L
Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Gas Recirculation (EGR)
Valve
Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Manifold to Exhaust Gas
Recirculation (EGR) Valve Tube
Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Gas Recirculation (EGR)
Valve - 1.8L Endura-DE (Kent) Diesel
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-12 Intake Air Distribution and Filtering >
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Cleaner Intake Pipe
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Cleaner
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Cleaner - Vehicles Built From: 02-2000
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-13 Evaporative Emissions > Description
and Operation > Diagnosis and Testing > Removal and Installation > Evaporative Emission Canister Purge Valve
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14A Electronic Engine Controls - 1.3L
Endura-E (HCS) > Description and Operation > Diagnosis and Testing > Removal and Installation > Mass Air Flow (MAF)
Sensor
Endura-E (HCS) > Description and Operation > Diagnosis and Testing > Removal and Installation > Power Steering
Pressure (PSP) Switch
Endura-E (HCS) > Description and Operation > Diagnosis and Testing > Removal and Installation > Throttle Position (TP)
Sensor
Endura-E (HCS) > Description and Operation > Diagnosis and Testing > Removal and Installation > Manifold Absolute
Pressure (MAP) Sensor
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14B Electronic Engine Controls -
1.25L-1.4L Zetec-SE (Sigma) > Description and Operation > Diagnosis and Testing > Removal and Installation > Camshaft
Position (CMP) Sensor
1.25L-1.4L Zetec-SE (Sigma) > Description and Operation > Diagnosis and Testing > Removal and Installation > Crankshaft
Position (CKP) Sensor
1.25L-1.4L Zetec-SE (Sigma) > Description and Operation > Diagnosis and Testing > Removal and Installation > Camshaft
Position (CMP) Sensor - 1.6L
1.25L-1.4L Zetec-SE (Sigma) > Description and Operation > Diagnosis and Testing > Removal and Installation > Idle Air
Control (IAC) Valve
1.25L-1.4L Zetec-SE (Sigma) > Description and Operation > Diagnosis and Testing > Removal and Installation > Crankshaft
Position (CKP) Sensor - 1.6L
1.25L-1.4L Zetec-SE (Sigma) > Description and Operation > Diagnosis and Testing > Removal and Installation > Idle Air
Control (IAC) Valve - Vehicles Built From: 02-2000 1.25L
1.25L-1.4L Zetec-SE (Sigma) > Description and Operation > Diagnosis and Testing > Removal and Installation > Engine
Coolant Temperature (ECT) Sensor
1.25L-1.4L Zetec-SE (Sigma) > Description and Operation > Diagnosis and Testing > Removal and Installation > Knock
Sensor (KS) - 1.6L
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14C Electronic Engine Controls - 1.4L
PTE (CVH) > Description and Operation > Diagnosis and Testing > Removal and Installation > Crankshaft Position (CKP)
Sensor
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14D Electronic Engine Controls - 1.8L
Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Crankshaft Position (CKP)
Sensor - 1.8L Endura-DE (Kent) Diesel
Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Engine Coolant Temperature
(ECT) Sensor
Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Cylinder Head Temperature
(CHT) Sensor - 1.8L Endura-DE (Kent) Diesel
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 307 Automatic Transmission-Transaxle > 307-01
Automatic Transmission-Transaxle > Description and Operation > In-vehicle Repair > Manual Control Lever Shaft and Seal
Automatic Transmission-Transaxle > Description and Operation > In-vehicle Repair > Speedometer Driven Gear
Automatic Transmission-Transaxle > Description and Operation > In-vehicle Repair > Removal > Transaxle
Remover, driveshaft 16-087 Engine support bar 21-140 Adapter for 21-140 21-140-01 Adapter for
21-140 21-140-02 Adapter for 21-140 21-140-03 Removal
Automatic Transmission-Transaxle > Description and Operation > In-vehicle Repair > Removal > Disassembly > Transaxle
Remover, pinion gear oil seal 205-078 (15-048) Remover, bearing (base tool) 205-295 (15-050 A)
Removal drift, differential bearing cups 205-176 (15-074) Remover, axle oil seal 303-112 (21-051)
Mounting frame for 303-435 307-200 (17-032) Extractor, oil pump 307-203 (17-034) Primary unit
locking tool 307-204 (17-035) Remover, housing half (secondary unit) 307-205 (17-036) Remover,
housing half (primary unit) 307-206 (17-037) Remover, secondary unit 307-207 (17-038) Remover,
sensor shaft 307-208 (17-039) Spring washer compressor 307-209 (17-040) Holding clamp, control
piston 307-211 (17-042 A) Secondary unit dummy spacer 307-215 (17-046) Collet for 205-295
307-216 (17-047) Collet for 205-295 307-217 (17-048) Disassembly
Automatic Transmission-Transaxle > Description and Operation > In-vehicle Repair > Removal > Disassembly >
Disassembly and Assembly of Subassemblies > Differential
Adapter for 204-158 (thrust element) 204-158-01 (14-038-01) Installer, differential bearing 205-062
(15-025 A) Remover, bearing (base tool) 205-295 (15-050 A) Collet for 205-295 308-197 (16-062)
Disassembly and Assembly of Subassemblies > Assembly > Transaxle
Dial gauge stand 205 - 070 (15 - 022 A) Remover, pinion gear oil seal 205 - 078 (15 - 048)
Installer, drive halfshaft oil seal 308 - 039 (16 - 018) Installer, input shaft oil seal 308 - 041 (16 -
020) Extractor, oil pump 307 - 203 (17 - 034) Primary unit locking tool 307 - 204 (17 - 035)
Remover, housing half (primary unit) 307 - 206 (17 - 037) Remover, secondary unit 307 - 207 (17 -
038) Remover, sensor shaft 307 - 208 (17 - 039) Spring washer compressor 307 - 209 (17 - 040)
Installer, input shaft oil seal 307 - 210 (17 - 041) Guide sleeve, forward clutch piston 307 - 213 (17 -
044) Guide sleeve, reverse clutch piston 307 - 214 (17 - 045) Gauge bar for measuring adjusting
shim 307 - 300 (17 - 055) Compressor, valve spring 303 - 060 (21 - 024) Adaptor for 303-060 303 -
060 - 02 (21 - 024 - 02) Assembly
Disassembly and Assembly of Subassemblies > Assembly > Installation > Transaxle
Installation
Automatic Transmission-Transaxle External Controls > Description and Operation > General Procedures > Selector Lever
Cable Adjustment
Automatic Transmission-Transaxle External Controls > Description and Operation > General Procedures > Removal and
Installation > Selector Lever Assembly
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-00 Manual Transmission-Transaxle and Clutch - General Information > Description and Operation > Diagnosis
and Testing > General Procedures > Clutch Disc Check
1. Oil fouling 2. Burn marks 3. Thickness (wear limit: 7,0 mm) 4. Check springs
and Testing > General Procedures > Clutch Master Cylinder Check
and Testing > General Procedures > Clutch Pressure Plate Check
1. Broken or worn diaphragm spring tongues 2. Burn marks 3. Scoring 4. Flatness

and Testing > General Procedures > Clutch Slave Cylinder Check
and Testing > General Procedures > Clutch Pedal Freeplay Adjustment
and Testing > General Procedures > Gearshift Linkage Adjustment
Case > 308-01 Clutch > Description and Operation > Clutch
Clutch Components The clutch transfers the engine power to the transmission. The clutch consists
of a friction disc and a pressure plate which is bolted to the flywheel. When the clutch pedal is
operated the power transmission from the engine to the transmission is interrupted. The clutch is
therefore engaged when the pedal is not depressed. Pressing down the pedal disengages the
clutch.
Case > 308-01 Clutch > Description and Operation > Diagnosis and Testing > Removal and Installation > Clutch Disc and
Pressure Plate
Aligner, Clutch Disk 308-204 (16-067) Removal Installation

Case > 308-02 Clutch Controls > Description and Operation > Diagnosis and Testing > Removal and Installation > Clutch
Master Cylinder
Case > 308-02 Clutch Controls > Description and Operation > Diagnosis and Testing > Removal and Installation > Clutch
Slave Cylinder
Case > 308-03 Manual Transmission-Transaxle > Description and Operation > Diagnosis and Testing > General
Procedures > Bearing Check
Procedures > In-vehicle Repair > Input Shaft Seal
Remover, oil seal 303-336 (21-151) Removal Installation

Procedures > In-vehicle Repair > Halfshaft Seal LH
Drive halfshaft oil seal installer 308-039 (16-018) Remover, drive halfshaft oil seal 308-208
(16-074) Remover, front drive halfshaft 308-273 (16-089) Removal Installation
Procedures > In-vehicle Repair > Halfshaft Seal RH
Installer, halfshaft oil seal 308-039 (16-018) Remover, oil seal 308-112 (21-051) Remover,
Halfshaft 308-237 (16-087) Remover, Halfshaft 308-256 (16-089) Installation
Procedures > In-vehicle Repair > Removal > Transaxle - 1.3L Endura-E (HCS)
Extractor pin, drive shaft 16-087 Remover, front axle driveshaft 16-089 Engine support bar 21-140
Adapter for 21-140 21-140-01 Adapter for 21-140 21-140-03 Removal
Procedures > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Selector Plate
Slide Hammer 205-102 (15-053) Remover/Installer Selector Shaft Oil Seal 308-040 (16-019)
Procedures > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Input Shaft
Installer, Extension Housing Bushing/Oil Seal 308-045 (16-015) Disassembly 1. Discard the input
shaft snap ring and the ball bearing. Assembly
Procedures > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Output Shaft
Remover, Bearing (Main Tool) 205-295 (15-050A) Installer, Extension Housing Bushing Oil Seal
308-045 (16-015) Collet for 205-295 307-217 (17-048) Disassembly 1. Discard the output shaft
snap ring and the ball bearing. 1. Discard the output shaft bearing cone. Assembly
Procedures > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Differential
Adapter for 204-158 (Thrust Pad) 204-158-01 (14-038-01) Installer, Differential Bearing 205-062
(15-025A) Remover, Bearing (Main Tool) 205-295 (15-050A) Collet for 205-295 308-197 (16-062)
Disassembly 1. Remove the pinion gears and plastic thrust elements. Assembly 1. Install the pinion
gears and plastic thrust elements. 2. Discard the old spur gear bolts.
Procedures > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Assembly >
Transaxle - Vehicles Built Up To: 07-2000
Installer, Rear Hub Bearing Cone/Oil Seal 205-296 (15-085) Compressor, Valve Spring 303-060
(21-024) Adapter for 303-060 303-060-02 (21-024-02) Adapter for 303-060 303-060-07 (21-024-07)
Installer, Halfshaft Oil Seal 308-039 (16-018) Installer, Input Shaft Bearing Cone 308-041 (16-020)
Installer, Extension Housing Bushing/Oil Seal 308-045 (16-015) Assembly 1. The thickness of the
adjusting shims must be rounded down to the nearest tenth of a millimeter if the attained value is
0.05 mm or less and rounded up if the attained value is 0.06 mm or more. 1. Example: Adjusting
shim = 3.80 mm + 0.73 mm + 0.40 mm - 4.42 mm = 0.51 mm. 1. Secure the bearing outer race
using a suitable center punch .
Transaxle - Vehicles Built From: 07-2000
Installer, Rear Hub Bearing Cone/Oil Seal 205-296 (15-085) Compressor, Valve Spring 303-060
(21-024) Adapter for 303-060 303-060-02 (21-024-02) Adapter for 303-060 303-060-07 (21-024-07)
Mounting Stand 303-435 (21-187) Installer, Halfshaft Oil Seal 308-039 (16-018) Installer, Input
Shaft Bearing Cone 308-041 (16-020) Installer, Extension Housing Bushing Oil Seal 308-045
(16-015) Installer, Input Shaft Snap Ring 308-076 (16-031) Assembly 1. The thickness of the
adjusting shims must be rounded down to the nearest tenth of a millimeter if the attained value is
0.05 mm or less and rounded up if the attained value is 0.06 mm or more. 1. Example: Adjusting
shim = 3.80 mm + 0.73 mm + 0.40 mm - 4.42 mm = 0.51 mm. 1. Secure the bearing race using a
suitable center punch .
Installation > Transaxle - 1.25L-1.4L Zetec-SE (Sigma)-1.6L
Engine support bar 21-140 Adapter for 21-140 21-140-01 Adapter for 21-140 303-290-02
(21-140-02) Adapter for 21-140 303-290-03 (21-140-03) Installation
Installation > Transaxle - 1.8L Diesel
Boot clamp tightening tool 204-169 (14-044) Installation

Case > 308-03 Manual Transmission-Transaxle > Description and Operation > Manual Transaxle
Overview The aluminium transmission housing features reinforcement ribs for additional strength.
Liquid sealer is used between the two halves of the transmission (WSS - M2G348-A5) and the end
cover (WSE - M4G323 - A4). On transmissions using liquid sealer the end cover is painted black.
In addition to this, components in the transmission have been modified although their design has
not been changed. The iB5 manual transmission is a "2 shaft transmission". The clutch is operated
hydraulically. On a "2 shaft transmission" all gearwheels are constantly in mesh. Each gear ratio is
achieved through one pair of gearwheels. The direction of rotation of the output shaft is reversed
for reverse gear by using an idler gearwheel. All gearwheels are helically splined, synchronized
(except reverse gear) and run on friction bearings. This reduces noise to a minimum and provides
easy gear changing, together with low weight and compactness. The spring loaded return slide in
the external gearshift mechanism is eliminated by fitting a selector lever relay with return spring
inside the transmission. Components of the iB5 Manual Transmission Overview When the
transmission is in neutral none of the gearwheels are connected to the output shaft by the
synchronizer clutches. No power is transferred to the differential. Internal Gearshift Mechanism
Input shaft Output shaft Double synchronization Double synchronization The first and second gears
are double synchronised. Because a second synchronizer ring is used, the effective surface
compared with the simple synchronizer is approximately doubled. Ease of gear changing is
considerably improved through double synchronization. The double synchronization components
are: inner synchronizer ring, synchronizer cone, outer synchronizer ring and synchronizer hub. The
conical surface on the gearwheel is no longer present. Synchronisation is achieved through the two
synchronizer rings and the synchronizer cone which fits on the gearwheel. Differential The basic
components of the differential are: The transmission and differential are located inside an
aluminium two part housing which is connected to the engine by a flange. The input shafts are
splined. Driving torque is transferred to the differential cage by the crownwheel which is bolted to it.
Inside the differential housing are the differential pinions which are located on a spindle, and the
drive halfshaft pinions which are connected to the front drive halfshafts by splines. When there is a
speed difference between the two front wheels (for instance when driving through a curve), the
front drive halfshaft pinions are able to turn on the differential pinions. Power Flow Neutral First
gear Second gear Third gear Fourth gear Fifth gear Reverse gear The reverse gear idler is driven
by the input shaft and its purpose is to reverse the direction of rotation of the output shaft when
reverse gear is engaged. The reverse gear idler is carried on a needle roller bearing on the idler
shaft, and also on a mounting. The detent mechanism and the gear selector finger are mounted on
a sleeve in the selector mechanism housing, and they use a spring-loaded ball keep the chosen
gear engaged until another gear is selected. The selector lock mechanism has three selector
positions.
Case > 308-06 Manual Transmission-Transaxle External Controls > Description and Operation > Diagnosis and Testing >
Removal and Installation > Gearshift Linkage
Removal and Installation > Gearshift Stabilizer Bar Bushing
Installer 308-045 (16-015) Removal Installation

Removal and Installation > Gearshift Stabilizer Bar
Removal and Installation > Disassembly and Assembly > Shift Lever
Installer, Extension Housing Bushing/Oil Seal 308-045 (16-015) Disassembly Assembly

Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 309 Exhaust System > 309-00 Exhaust System >
Description and Operation > Diagnosis and Testing > Removal and Installation > Catalytic Converter
Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Flexible Pipe - Vehicles Built
From: 03-1998 1.3L Endura-E (HCS)
Description and Operation > Diagnosis and Testing > Removal and Installation > Catalytic Converter - 1.25L-1.4L Zetec-SE
(Sigma)
Description and Operation > Diagnosis and Testing > Removal and Installation > Catalytic Converter - 1.8L Diesel
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01A Fuel Tank and Lines -
1.25L-1.3L-1.4L-1.6L > Description and Operation > Diagnosis and Testing > Removal and Installation > Inertia Fuel Shutoff
(IFS) Switch
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01B Fuel Tank and Lines - 1.8L
Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Filter Element
Installation
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01C Fuel Tank and Lines - Pickup
> Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Pump Module
Remover/installer, socket wrench 23-051 Remover/installer, fuel pump/sender unit 23-052

Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-02 Acceleration Control >
Description and Operation > Diagnosis and Testing > General Procedures > Accelerator Cable Adjustment - 1.3L Endura-E
(HCS)
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-02 Acceleration Control >
Description and Operation > Diagnosis and Testing > General Procedures > Accelerator Cable Adjustment - 1.8L Diesel
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Description and Operation > Diagnosis and Testing > General Procedures > Spring Lock
Coupling
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Description and Operation > Diagnosis and Testing > General Procedures > Air
Conditioning (A-C) Clutch Air Gap Adjustment
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-01 Air Distribution and
Filtering > Description and Operation > Diagnosis and Testing > Removal and Installation > Center Registers
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02 Heating and
Ventilation > Description and Operation > Diagnosis and Testing > Removal and Installation > Heater Control Valve
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02 Heating and
Ventilation > Description and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly >
Heater Core Housing
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Clutch and Clutch Field Coil
Description and Operation > Diagnosis and Testing > Removal and Installation > Evaporator Core Orifice
Separator, quick-release coupling 1/2" (blue) 412-027 (34-001) Remover/installer, fixed orifice tube
412-034 (34-004) Remover, faulty fixed orifice tube 412-035 (34-005) Removal Installation
Description and Operation > Diagnosis and Testing > Removal and Installation > Suction Accumulator
Disconnect Tool, Spring Lock Coupling 5/8 inch (black) 412 - 038 (34 - 003) Removal Installation
Description and Operation > Air Conditioning
The gaseous refrigerant is sucked in by the compressor and then compressed. As a result of this
compression, the refrigerant heats up to a temperature between 70 degrees Celsius and 110
degrees Celsius. The gas is then pumped to the condenser. The condenser has numerous cooling
fins through which the gas is pumped. The gaseous refrigerant is then cooled by the passing flow
of fresh air or, depending on the model, by the auxiliary fan until it condenses. The condensed, i.e.
liquid refrigerant is then passed through a fixed orifice tube. Downstream of the fixed orifice tube
the pressure and therefore the temperature of the refrigerant drop rapidly. The fixed orifice tube is
mounted upstream of the entrance to the evaporator, in which the refrigerant then evaporates. This
cools the evaporator and at the same the passing air flow. The cooled air passes through the air
distribution system of the heater/air conditioning system to reach the inside of the vehicle. The
gaseous refrigerant is then passed through the collector/dehydrator before it is drawn into the
compressor again and the cooling system cycle repeats itself. Air conditioning components
(Zetec-SE engine shown) Air conditioning components (Zetec-SE engine shown) Compressor The
compressor draws the gaseous refrigerant out of the evaporator. The compressor pumps the
gaseous refrigerant to the condenser. As a result of this compression, the gaseous refrigerant
heats up to between 70 degrees Celsius and 110 degrees Celsius. Condenser In the condenser,
the heated, pressurized, gaseous refrigerant condenses to form a liquid under high pressure. As
this occurs, the stored heat is given up to the passing air by the condenser.
Accumulator/dehydrator Any moisture present in the refrigerant is extracted in the
collector/dehydrator. The collector/dehydrator also ensures that the refrigerant evaporates
completely. It thus protects the compressor from "liquid hammer". Fixed orifice tube The filter
screen at the inlet of the fixed orifice tube filters out any particles present in the refrigerant. Due to
the calibrated internal diameter of the fixed orifice tube, only a certain quantity of refrigerant
corresponding to the pressure can pass through it. Therefore the throughput quantity is limited.
High-pressure switch Two pressure-sensitive switches are contained in the high pressure switch.
One of these switches acts as a safety switch to prevent excessive system pressure. The second
switch switches the condenser auxiliary fan on to its second setting at 20,7 bar and off again at
17,2 bar. This switching process improves the performance of the system in cases of excessive
heat. Low-pressure switch If the pressure and the temperature drop together in the evaporator, and
the temperature approaches freezing point, there is a danger that the evaporator will ice up, and
therefore lose its cooling ability. The low pressure switch will then switch off the compressor at 1.5
Bar, and when the pressure has risen suitably, switches it back on at 2.9 Bar. Introduction -
Freshline Available since 04/1998 as a cooling van. The condenser in the refrigeration system is
identical with that of the usual air conditioning system. A special evaporator and a modified
compressor are used. The system pressure is controlled using an expansion valve. The all-round
insulation of the refrigerated compartment is made of a material with a particularly high heat
insulation value. The inner cladding is made of coated high-impact plastic (ABS) and is safe for use
with foodstuffs. No air conditioning is available for the passenger compartment if the vehicle has a
refrigeration system. The evaporator installed in production remains in the vehicle after conversion,
but must not be connected. The refrigeration system is the same as that used in the Transit
refrigerated van. There is additional de-icing equipment fitted, which prevents icing up of the
evaporator and resultant loss of cooling ability. This is done by a "de-icing line", which takes hot,
gaseous refrigerant from the line between the compressor and condenser and feeds it into the
evaporator. This de-icing procedure can either be performed manually by pressing a button on the
operating panel, or set to occur automatically once an hour. The water which condenses is passed
through a tube to the outside. General During the winter months the air conditioning should be
switched on for approx. 10 minutes to ensure that the sealing of the system remains intact. To do
this, set the temperature control switch to "Warm" and the A/C switch to recirculated air to turn on
the air conditioning. Refrigerant losses of approx. 100 g/year can occur. The condition of the
refrigerant lines and clamps should be checked, particularly for signs of chafing. The system should
generally be refilled after approximately two years. To prevent the evaporator from icing up, the air
conditioning does not work at temperatures below 3°C. If during a leakage inspection of the air
conditioning a leak is detected on a compressor shaft seal, then this seal should not be renewed
immediately. However, if the seal is still leaking after running the air conditioning for 15 minutes
then a new one should be installed. Procedure when water enters the footwell from the air
conditioning system Please check the following points and repair affected vehicles accordingly.
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03B Auxiliary Climate
Control > Diagnosis and Testing > Removal and Installation > Auxiliary Blower Motor
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03B Auxiliary Climate
Control > Diagnosis and Testing > Removal and Installation > Auxiliary Climate Control Assembly
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-00
Instrument Cluster and Panel Illumination > Description and Operation > Diagnosis and Testing > Instrument Cluster and
Panel Illumination
Inspection and Verification Visual Inspection Chart Symptom Chart Pinpoint Tests PINPOINT
TEST A : THE CONTROL ILLUMINATION IS INOPERATIVE PINPOINT TEST B : THE
INSTRUMENT CLUSTER ILLUMINATION IS INOPERATIVE PINPOINT TEST C : THE CLIMATE
CONTROL/INTEGRATED CONTROL PANEL ILLUMINATION IS INOPERATIVE - VEHICLES
WITHOUT AIR CONDITIONING (A/C) PINPOINT TEST D : THE CLIMATE
CONTROL/INTEGRATED CONTROL PANEL ILLUMINATION IS INOPERATIVE - VEHICLES
WITH A/C PINPOINT TEST E : THE AUDIO UNIT ILLUMINATION IS INOPERATIVE PINPOINT
TEST F : THE HAZARD LAMP SWITCH ILLUMINATION IS INOPERATIVE PINPOINT TEST G :
THE MULTIFUNCTION SWITCH ASSEMBLY ILLUMINATION IS INOPERATIVE (AIR BAG
DEACTIVATION WARNING, STABILITY ASSIST, FRONT WINDOW DEFROST OR REAR
WINDOW DEFROST) PINPOINT TEST H : THE NAVIGATION SYSTEM DISPLAY MODULE
ILLUMINATION IS INOPERATIVE PINPOINT TEST I : THE SELECTOR LEVER ILLUMINATION
IS INOPERATIVE - VEHICLES WITH 4-SPEED AUTOMATIC TRANSAXLE (AW81-40LE)
PINPOINT TEST J : THE GEARSHIFT LEVER ILLUMINATION IS INOPERATIVE - VEHICLES
WITH AUTOMATED GEARSHIFT PINPOINT TEST K : THE DVD PLAYER ILLUMINATION IS
INOPERATIVE
Instrument Cluster and Panel Illumination > Description and Operation > Diagnosis and Testing > Removal and Installation
> Instrument Cluster Bulb
Instrument Cluster > Description and Operation > Diagnosis and Testing > Removal and Installation > Instrument Cluster
Instrument Cluster > Description and Operation > Diagnosis and Testing > Removal and Installation > Instrument Cluster
Printed Circuit
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-06 Horn >
Diagnosis and Testing > Horn
PINPOINT TEST A : HORN DOES NOT SOUND
Diagnosis and Testing > Removal and Installation > Horn
Diagnosis and Testing > Removal and Installation > Horn Switch
Warning Devices > Description and Operation > Diagnosis and Testing > Warning Devices
PINPOINT TEST A : THE CLOCK IS INOPERATIVE PINPOINT TEST B : THE CLOCK DOES
NOT OPERATE CORRECTLY
Warning Devices > Description and Operation > Diagnosis and Testing > Removal and Installation > Low Washer Fluid
Warning Indicator Switch
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-13 Parking
Aid > Diagnosis and Testing > Parking Aid
Principles of Operation The parking aid system detects objects behind the vehicle when the vehicle
reverse gear select input to the parking aid module is enabled. The parking aid module does this by
calculating the distance to an object by the use of four parking aid sensors mounted in the rear
bumper. The sensors can detect objects approximately 1.5m to the rear of the vehicle. An
intermittent warning tone is generated from the speaker in the parking aid speaker. The interval
between the tones decreases as the vehicle gets closer to an object. When an object is detected
within 30cm of the sensors, the warning tone becomes continuous. Refer to the Owner Guide for
the parking aid speaker operation. A short tone will sound from the parking aid speaker as a
system check when the ignition switch is turned to position II and reverse gear is engaged. The
system will always enable when the ignition switch is turned to position II and reverse gear is
engaged. The parking aid system will be disabled if reverse gear is disengaged or if a concern is
detected in one of the four parking aid sensors or the parking aid module. When the parking aid
system is enabled and a concern is detected, the system will indicate this by a continuous tone
from the parking aid speaker. If a short circuit is detected in the parking aid resistance plug, the
system will indicate this by emitting an audible tone from the parking aid speaker for three seconds
followed by a break for three seconds. This sequence will be repeated until reverse gear is
disengaged. Inspection and Verification Visual Inspection Chart Parking Aid Module Reset
Procedure Self-Diagnostic Mode Audible Tone Sequence Symptom Chart Symptom Chart Pinpoint
Test PINPOINT TEST A : PARKING AID IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
Component Tests Parking Aid Sensor Wiring Harness
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-01 Battery,
Mounting and Cables > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Battery
Installation > Battery Tray
Installation > Battery to Starter Motor Solenoid Cable - 1.3L Endura-E (HCS)
Installation > Battery to Starter Motor Solenoid Cable - 1.6L
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-02 Generator and
Regulator > Description and Operation > Diagnosis and Testing > Removal and Installation > Generator - Vehicles Built Up
To: 01-1999 1.3L Endura-E (HCS), Vehicles With: Air Conditioning-Power Steering
Regulator > Description and Operation > Diagnosis and Testing > Removal and Installation > Generator - Vehicles Built
From: 01-1999 1.3L Endura-E (HCS), Vehicles With: Air Conditioning-Power Steering
Regulator > Description and Operation > Diagnosis and Testing > Removal and Installation > Generator - 1.6L
Regulator > Description and Operation > Diagnosis and Testing > Removal and Installation > Generator - 1.25L-1.4L
Zetec-SE (Sigma)
Regulator > Description and Operation > Diagnosis and Testing > Removal and Installation > Generator - 1.8L Endura-DE
(Kent) Diesel
Regulator > Description and Operation > Diagnosis and Testing > Removal and Installation > Generator - 1.8L Endura-DI
(Lynx) Diesel
Regulator > Description and Operation > Diagnosis and Testing > Removal and Installation > Generator - 1.8L Endura-DE
(Kent) Diesel, Vehicles With: Air Conditioning
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 415 Information and Entertainment Systems > 415-02
Antenna > Description and Operation > Diagnosis and Testing > Removal and Installation > Antenna
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Headlamp Assembly
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Headlamp Leveling Motor
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01A Anti-Theft - Active
> Description and Operation > Diagnosis and Testing > Removal and Installation > Door Lock Switch
> Description and Operation > Diagnosis and Testing > Removal and Installation > Door Ajar Switch
> Description and Operation > Diagnosis and Testing > Removal and Installation > Anti-Theft Alarm Horn
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01B Anti-Theft -
Passive > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Passive
Anti-Theft System (PATS) Transceiver
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-10 Multifunction
Electronic Modules > Description and Operation > Removal and Installation > Generic Electronic Module (GEM)
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-03 Body Closures >
Description and Operation > General Procedures > Liftgate Alignment
Adjustment
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05A Interior Trim and
Ornamentation > Description and Operation > Removal and Installation > Rear Door Trim Panel
Ornamentation > Description and Operation > Removal and Installation > Front Door Trim Panel
Ornamentation > Description and Operation > Removal and Installation > Liftgate Trim Panel
Ornamentation > Description and Operation > Removal and Installation > A-Pillar Trim Panel
Ornamentation > Description and Operation > Removal and Installation > B-Pillar Trim Panel
Installation
Ornamentation > Description and Operation > Removal and Installation > C-Pillar Trim Panel
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05B Interior Trim and
Ornamentation - Courier > Description and Operation > Removal and Installation > Loadspace Trim Panel
Ornamentation - Courier > Description and Operation > Removal and Installation > B-Pillar Trim Panel
Ornamentation - Courier > Description and Operation > Removal and Installation > Front Headliner
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-09 Rear View Mirrors >
Description and Operation > Diagnosis and Testing > Removal and Installation > Exterior Mirror Control Switch
Description and Operation > Diagnosis and Testing > Removal and Installation > Exterior Mirror
Description and Operation > Diagnosis and Testing > Removal and Installation > Exterior Mirror Glass
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Seats
Inspection and Verification Visual Inspection Chart Symptom Chart Symptom Chart PINPOINT
TEST A : THE POWER SEAT IS INOPERATIVE
and Operation > Diagnosis and Testing > Removal and Installation > Rear Seat Cushion
and Operation > Diagnosis and Testing > Removal and Installation > Front Seat Cushion - Vehicles Built From: 01-1999
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Seat Cushion -
Vehicles Built Up To: 01-1999
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Seat Cushion -
Vehicles Built From: 01-1999
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Rear Seat Cushion
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Seat Backrest -
Vehicles Built From: 01-1999
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Seat Backrest -
Vehicles Built Up To: 01-1999
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Rear Seat Backrest
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11A Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > General Procedures > Door Window Glass Adjustment
Adjustment
Mechanisms > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation >
Front Door Window Glass
Mechanisms > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Rear
Quarter Window Glass
Door Window Glass
Liftgate Window Glass
Door Window Regulator and Motor
Windshield Glass
Front Door Glass Top Run
Door Glass Top Run
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11B Glass, Frames and
Mechanisms - Courier > Description and Operation > Removal and Installation > Rear Door Window Glass
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11B Glass, Frames and
Mechanisms - Courier > Description and Operation > Removal and Installation > Second Row Side Window Glass - Courier
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-12 Instrument Panel and
Console > Description and Operation > Removal and Installation > Instrument Panel - Vehicles Built Up To: 12-1996
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Front Door Latch
> Hood Latch
> Rear Door Latch
> Rear Door Lock Cylinder - Courier
> Ignition Lock Cylinder
> Liftgate Lock Cylinder
> Liftgate Latch
> Door Lock Cylinder
C Spanner 41-020 Removal Installation

> Hood Latch Release Handle
> Disassembly and Assembly > Door Lock Cylinder
> Liftgate Latch Actuator
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-16 Wipers and Washers >
Description and Operation > Wipers and Washers
All functions are initiated by means of a multi-function switch which is operated by the wiper lever
on the right of the steering column. The circuits of the windshield/rear window wash/wipe system
are protected via fuse F12 (20 A, in the central junction box CJB). The associated wiring diagrams
are contained in the Wiring Diagrams Binder, see subsection 501-16. Precise information relating
to the location of the components is contained in the Wiring Diagrams Binder (component location
chart and views of the components, see subsection 501-16). Windshield wiper The windshield
wiper comprises the following parts: Windshield wiper functions The windshield wiper motor can
run at two speeds and incorporates a park position limit switch. It is controlled by the multi-function
switch on the steering column and by the wiper delay relay. After switching on the ignition (position
II) the following five wiper functions are available: Wiper lever in the OFF position If the wiper lever
is moved from any other setting to the OFF position, then the windshield wiper motor continues to
run at slow speed until the wipers reach the park position. This is effected through a second circuit
via the limit switch, which supplies a voltage to the windshield wiper motor after it has been
switched off. The voltage supply remains intact until the limit switch interrupts the circuit through
the wiper delay relay (normally closed contact) and the multi-function switch to the windshield wiper
motor. Wiper lever in the WIPE ONCE position Press the wiper lever up until resistance is felt and
then release it. The windshield wipers perform an individual slow wipe. Current is supplied to the
windshield wiper motor via the multi-function switch. Wiper lever in the INTERMITTENT position
Press the wiper lever down. The windshield wipers perform intermittent slow wipes. The wiper
delay time is set to 9 seconds. The multi-function switch sends a 12 V signal to the wiper delay
relay, which picks up in 9 second intervals and supplies a voltage to the windshield wiper motor.
The flow of current is routed through the wiper delay relay (normally open contact) and the
multi-function switch (connector C65b, pin 8) to the windshield wiper motor. Wiper lever in the
SLOW WIPE position Press the wiper lever up one notch. The wipers operate at slow speed.
Current flows through the multi-function switch to the windshield wiper motor. Wiper lever in the
FAST WIPE position Press the wiper lever up two notches. The wipers operate at high speed.
Current flows through the multi-function switch to the windshield wiper motor. Windshield washer
The windshield washer comprises the following parts: Two functions are available depending on
how the wipers are operating: Wiper lever in the OFF or INTERMITTENT position The windshield
wiper and washer pump operate as long as the end of the wiper lever is pressed in. The washer
pump stops immediately when the wiper lever is released. The windshield wipers perform two more
wipe cycles before they return to intermittent operation (INTERMITTENT position) or stop at the
park position (OFF position). Current flows from the multi-function switch (connector C65b, pin 2)
via the washer pump back to the multi-function switch (connector C65b, pin 1). The multi-function
switch makes the ground connection when it is set to WINDSHIELD WASHER ON. Wiper lever in
the position SLOW WIPE or FAST WIPE The washer system operates together with the windshield
wiper as long as the end of the wiper lever is pressed in. The washer pump stops immediately
when the wiper lever is released. The current flows through the same circuit as described before.
Rear wiper The rear wiper comprises the following parts: Rear window wiper Pull the wiper lever
one notch towards the steering wheel to switch it on. The wiper operates continuously at constant
speed. Once it is switched off the wiper motor returns to the park position before stopping. The
current flows from the multi-function switch to the rear wiper motor. A second circuit supplies the
wiper motor with voltage via the limit switch after it is switched off. The voltage supply is interrupted
when the limit switch reaches the park position and breaks the circuit. Both circuits go through the
tailgate contact switch. The spring-loaded pins in the contact switch are pressed onto the contact
plate to make the electrical circuit. Opening the tailgate interrupts both circuits at the contact plate.
Tailgate contact switch Contact plate Rear washer system Pull the wiper lever right to the steering
wheel to turn it on. The system operates until the lever is released, after which the lever
automatically returns to its rest position. The rear washer draws its wash water from the same
washer reservoir as the windshield washer (see windshield washer system), and the water is also
pumped by the same washer pump. In this case the washer pump operates in the opposite
direction of rotation to the direction for washing the windshield. This means that the current flows in
the opposite direction to when washing the windshield: from the multi-function switch (connector
C65b, pin 1) via the washer pump back to the multi-function switch (connector C65b, pin 2). The
latter makes the ground connection when active. Washer fluid level warning light This consists of
the following components: The warning light comes on when the washer reservoir is only a quarter
full. This is sensed by a switch which is activated by a float in the washer reservoir. When there is
sufficient fluid in the washer reservoir the switch makes a connection to ground with one of the
digital inputs on the auxiliary warning module. It opens when the fluid level drops to a quarter full.
This then prompts the auxiliary warning module to switch on the washer fluid level warning light.
The warning light goes out when the washer fluid level is topped up and the switch in the reservoir
closes again.
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Windshield Washer
Pump
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Windshield Washer
Reservoir
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-17 Roof Opening Panel >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Roof Opening
Panel
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-17 Roof Opening Panel >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Disassembly and
Assembly > Drive Cables and Guide Rails
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-19A Bumpers > Description
and Operation > Removal and Installation > Rear Bumper
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-19A Bumpers > Description
and Operation > Removal and Installation > Front Bumper
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-19B Bumpers - Courier >
Description and Operation > Removal and Installation > Rear Bumper
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-19B Bumpers - Courier >
Description and Operation > Removal and Installation > Bumper Cover
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20A Safety Belt System >
Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Safety Belt Retractor
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20A Safety Belt System >
Description and Operation > Diagnosis and Testing > Removal and Installation > Front Safety Belt Retractor
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Air Bag Supplemental Restraint System (SRS)
Vehicle built up to 09/1999 Vehicle built 09/1999 onwards Vehicles with side air bag The
supplementary restraint system (SRS) has been specifically designed to protect the driver and
passenger from sustaining severe facial and upper body injuries in the event of a serious impact.
The SRS is designed to deploy only in the event of a collision, with the ignition in the RUN position
and where the safety belts on their own are no longer sufficient to protect the occupants. However,
the SRS will deploy regardless of whether or not an occupant is wearing a safety belt. Optimum
protection can only be achieved when used in conjunction with a conventional three-point safety
belt. The safety belts form an integral part of the SRS. Vehicles built up to 09/1999 utilize a direct
current (DC) firing strategy. Vehicles built 09/1999 onwards utilize an alternating current (AC) firing
strategy. The driver, wearing the safety belt provided, should position the seat as far back as is
practical, so that the steering wheel can be reached with arms slightly angled, thereby leaving a
gap between the steering wheel and the driver. The passenger, wearing the safety belt provided,
should not position himself or herself so that the air bag cover is in direct contact with the
occupants' body. The front air bags and safety belt buckle pretensioners will deploy in the event of
a direct front impact or when the impact angle is up to 30 degrees from the left or right of the
vehicle center line. The air bag(s) and safety belt buckle pretensioners will deploy only once. In a
collision in which they deployed at the first impact, the air bags and safety belt buckle pretensioners
will not reduce the risk of injury in a subsequent impact. In the event of a side impact, in which the
side air bags deploy, the front air bags will still deploy in a subsequent front impact, provided that
the front impact exceeds the triggering threshold. Under certain circumstances, although the
damage sustained by the vehicle may look extensive, the impact may remain below the triggering
threshold of the SRS and the air bags will not deploy. In such circumstances the safety belts would
provide sufficient protection for the occupants. The visible VIN plate, which shows the air bag
symbol and either X1 or X2 dependant on the number of air bags fitted, is attached to the
windshield edge of the instrument panel. Vehicles equipped with side air bag modules can be
identified by an embossed AIRBAG logo on the seat fabric adjacent to the air bag module. The
SRS consists of the following components: The air bag control module governs the operation of the
whole system, including the diagnostics element. It contains two frontal impact sensors; a crash
sensor and a safing sensor. The crash sensor produces a signal corresponding to the rate of
deceleration. The safing sensor detects only deceleration. These two sensors are connected in
series and if they both sense a deceleration in excess of a predetermined limit, the air bag control
module will deploy the front air bag module(s) and the safety belt buckle pretensioners. The front
air bags are not designed to deploy in side or rear impacts where the air bag(s) will not offer
additional protection to the occupant(s). In exceptional circumstances the front air bags may deploy
in a side impact which results in a sudden total loss of forward motion. The air bag control module
will always deploy the safety belt buckle pretensioner before or at the same time as the air bag(s)
and in that sequence only. In the event of a side impact, the air bag control module will deploy the
corresponding side air bag, even if the respective seat is not occupied, when the level of impact is
sufficiently great that the air bag could reduce the risk of injury. Deployment is dependent on the
signal received from the side impact sensor. The side air bags are not designed to deploy in a
mainly frontal or rear impact where the side air bag will not offer additional protection to the
occupant. The air bag control module performs continual system diagnostics. In the event of a fault
being detected the warning indicator is illuminated either constantly or intermittently. The behavior
of the warning indicator depends on the type of fault present. The warning indicator is located in the
instrument cluster. The safety belt buckle pretensioners reduce any slack, which may exist in the
safety belt webbing, keeping the occupant in their seat during the impact and air bag deployment.
The wiring harness provides power to the air bag control module from the vehicle supply and hence
to the air bag module(s), side impact sensors (if equipped with side air bags), safety belt buckle
pretensioners and the warning indicator. The air bag sliding contact is designed to carry signals
between the air bag control module and the driver air bag module. The air bag sliding contact is
fitted to the steering column and consists of fixed and moving parts connected by a coiled Mylar
tape with integral conducting tracks. The Mylar tape is able to `wind up' and `unwind' as the
steering wheel (to which the moving part is attached) is turned, maintaining electrical contact at all
times between the air bag control module and the driver air bag module. The air bag sliding contact
is used in order to achieve the high degree of circuit integrity required critical safety system SRS
When the air bag(s) deploy, they remain fully inflated for only a fraction of a second and start to
deflate immediately, cushioning the occupant. The high speed of inflation along with the
surrounding events and noise from the impact can give the impression that the air bag(s) did not
deploy to their full extent. In certain circumstance slight grazing or minor friction burns can result
from air bag deployment. There are two processes which are involved: The driver, passenger and
side air bag modules consist of the following components which cannot be disassembled: Driver
and passenger air bag module inflator The inflator is screwed into a metal cup-shaped container.
The air bag is then folded on top of the inflator and the whole sub-assembly is closed by the cover.
The driver air bag module is fitted to the steering wheel, the cover forming the outer surface of the
steering wheel boss. The cover has invisible `split lines' moulded in its surfaces allowing the air bag
to easily exit though the cover when the system deploys. The passenger air bag module is located
above the glove compartment and is integrated into the instrument panel to provide an unobtrusive
appearance. The cover is a one-piece moulding held by five clips and a short retaining strap. As
the air bag deploys, the cover is forced free of the clips, but remains attached to the instrument
panel by the short retaining strap. Side air bag module The side air bag modules are integrated into
the front seat backrests providing an unobtrusive appearance. The unique seat cover has been
designed to accommodate air bag deployment. When the side air bag is deployed the stitched
seam of the seat cover adjacent to the side air bag module splits, allowing the air bag to exit the
seat back unobstructed. The purpose of the inflator is to generate the gas needed to fill the air bag.
It consists of a high strength steel casing filled with a solid propellant charge and an electrically
activated igniter. The igniter is activated by a signal from the air bag control module, which in turn
ignites the propellant charge. The very rapid burning of the propellant produces sufficient gas to fill
the air bag(s). As the gases expand they cool, preventing heat damage to the air bag. The driver
air bag module has one inflator and an air bag, with a filled volume of 30 liters. The passenger air
bag module had two inflators and an air bag on vehicles built up to 04/1997, revised to a single
inflator and an air bag on vehicles built 04/1997 onwards. The passenger air bag has a filled
volume of 60 liters. The side air bag modules each have one inflator and an air bag which has a
filled volume of 12 liters. The air bag(s) are a one-piece woven item with a silicon coating to provide
flame and heat protection in the vicinity of the inflator. The shapes of the passenger and side air
bags (when equipped) are tailored to the vehicles proportions. In order to prevent the folds of the
air bag from sticking together in its tightly stowed position, the fabric may be treated with talcum
powder. When the air bag(s) deploy, some of the fine powder is blown into the vehicle. This powder
is visible as a dust cloud and also has a characteristic odour. The particles soon settle and do not
represent a health risk. The dust cloud is not a sign of external combustion outside the air bag
inflator cartridge. The SRS will communicate concerns detected during a driving cycle or after initial
key ON by means of a warning indicator located in the instrument cluster. If a concern is detected,
the air bag control module will communicate by flashing the warning indicator to give a lamp flash
code (LFC) and a diagnostic trouble code (DTC) is logged by the air bag control module in a
non-volatile memory. The DTC can be downloaded using WDS/FDS 2000. For additional
information, refer to Diagnosis and Testing in this section. Lamp Flash Codes (LFC)
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Diagnosis and Testing > Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) - Vehicles Built Up To: 09-1999
Simulator, Airbag 418-037 Simulator, Airbag/Pyrotechnic Safety Belt 418-047A Inspection and
Verification Visual Inspection Chart If a concern is detected, the air bag control module will
communicate by flashing the warning indicator within the instrument cluster to give a diagnostic
trouble code (DTC). If more than one active code is detected at the same time, the DTC for the
code with the highest priority rank will be displayed first. The flash codes do not denote the priority
of the code, i.e. flash code one does not necessarily mean this is ranked priority one. Normal
operation: When the ignition is turned on the air bag warning indicator will illuminate for
approximately five seconds then extinguish, thus indicating the system has NO faults at this time.
Symptom Chart Symptom Chart Diagnosing Concerns Without Hard Diagnostic Trouble Codes If a
customer has a concern with abnormal warning indicator operation which is not present when the
vehicle comes into the workshop, follow the procedures contained within this section. Speak with
the customer to see if a particular set of conditions occur before attempting to diagnose the fault.
Pinpoint Tests Pinpoint Tests PINPOINT TEST A : AIR BAG WARNING LIGHT ILLUMINATED ALL
THE TIME PINPOINT TEST B : NO AIR BAG WARNING INDICATOR PINPOINT TEST C : AIR
BAG WARNING INDICATOR CONDITION ONE FLASH PINPOINT TEST D : WARNING
INDICATOR CONDITION TWO FLASHES PINPOINT TEST E : WARNING INDICATOR
CONDITION THREE FLASHES PINPOINT TEST F : WARNING INDICATOR CONDITION FOUR
FLASHES Drivers side Passengers side
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Complete Panel Replacement-Partial Replacement
Repairs always mean intervention in the body shell structure and thus also intervention in the
vehicle's passive security system. The use of complete replacement or sectional replacement as
the best solution must always be weighed up before starting a repair. Complete replacement In a
complete replacement, the original connections are largely reused. A complete replacement is
advantageous if the damaged body part can be detached from its original connections and a
completely new part can be fitted without creating additional joints (e.g. liftgate). A complete
replacement is necessary if there is no sectional replacement solution. Sectional replacement
Sectional replacement (sectional repair) means the replacement of a section of the body shell
structure. Sectional repairs fulfill their purpose above all if the replacement of a complete part is too
time-consuming and thus not economical. Approved sectional repairs are clearly defined in the
model-specific body literature. These requirements must be complied with. Advantages of sectional
repair Sectional repair offers many advantages for correct repair of accidental damage. For the
sectional repairs approved by the factory and described in the model-specific body workshop
literature/technician's information, some spare parts (service parts) specially prepared for sectional
repairs are offered via the spare parts sales department. Decision-making criteria Depending on
the type and extent of the damage, the advantages of carrying out sectional replacement in the
area concerned must be weighed up against complete replacement. The following are always
crucial for the decision: In addition, Ford must have given its approval for a sectional replacement
solution in the damaged area. Depending on the damaged areas, further facts are to be taken into
account when deciding for or against sectional repair:
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 502 Frame and Mounting > 502-00 Uni-Body,
Subframe and Mounting System > Description and Operation > Removal and Installation > Subframe
Separator, ball joint 13-006 Guide pins, subframe 15-097A Removal Installation
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Complete Panel Replacement-Partial Replacement
Repairs always mean intervention in the body shell structure and thus also intervention in the
vehicle's passive security system. The use of complete replacement or sectional replacement as
the best solution must always be weighed up before starting a repair. Complete replacement In a
complete replacement, the original connections are largely reused. A complete replacement is
advantageous if the damaged body part can be detached from its original connections and a
completely new part can be fitted without creating additional joints (e.g. liftgate). A complete
replacement is necessary if there is no sectional replacement solution. Sectional replacement
Sectional replacement (sectional repair) means the replacement of a section of the body shell
structure. Sectional repairs fulfill their purpose above all if the replacement of a complete part is too
time-consuming and thus not economical. Approved sectional repairs are clearly defined in the
model-specific body literature. These requirements must be complied with. Advantages of sectional
repair Sectional repair offers many advantages for correct repair of accidental damage. For the
sectional repairs approved by the factory and described in the model-specific body workshop
literature/technician's information, some spare parts (service parts) specially prepared for sectional
repairs are offered via the spare parts sales department. Decision-making criteria Depending on
the type and extent of the damage, the advantages of carrying out sectional replacement in the
area concerned must be weighed up against complete replacement. The following are always
crucial for the decision: In addition, Ford must have given its approval for a sectional replacement
solution in the damaged area. Depending on the damaged areas, further facts are to be taken into
account when deciding for or against sectional repair:

Ford Fiesta 1996 2002 Workshop Manual

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Alignment Pins, Subframe 205-316 (15-097A) Removal Installation

Lever, Wheel Knuckle 204-159 (14-039) Removal Installation

Boot clamp tightening tool 14-044 Removal Installation

Boot clamp tightening tool 204-169 (14-044) Disassembly Assembly

Brake piston retracting tool 12-014 Removal Installation

Remove/Installer, Crankshaft Bearing 303-433 (21-185) Removal Installation

Separator, ball joint 13-006 Removal Installation

Separator, ball joint 13-006 Removal Installation

1. End play = maximum value minus minimum value

Angle gauge 303-174 (21-540) Removal Installation

Remover, halfshaft 308-237 (16-087) Remover, halfshaft 308-256 (16-089) Remover/installer,

Remover/installer, radiator hose clip 303-397 (24-003) Installation

Remover/installer, cooling hose clamp 24-003 Removal

Remover/installer, coolant hose clip 303-397 (24-003) Removal Installation

Remover/Installer, cooling hose clamp 24-003 Removal Installation

Remover/Installer, Cooling Hose Clamp 303–397 (24–003) Removal Installation

Remover/Installer, Cooling Hose Clamp 303–397 (24–003) Removal Installation

Socket SW 27, injectors 310-046 (23-034) Removal Installation

1. Broken or worn diaphragm spring tongues 2. Burn marks 3. Scoring 4. Flatness

Aligner, Clutch Disk 308-204 (16-067) Removal Installation

Remover, oil seal 303-336 (21-151) Removal Installation

Boot clamp tightening tool 204-169 (14-044) Installation

Installer 308-045 (16-015) Removal Installation

Installer, Extension Housing Bushing/Oil Seal 308-045 (16-015) Disassembly Assembly

Remover/installer, socket wrench 23-051 Remover/installer, fuel pump/sender unit 23-052

C Spanner 41-020 Removal Installation

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