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    Ford Focus Diesel - Haynes (En)

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    Ford Focus Diesel - Haynes (En)

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    pwnuk wnuk
    40 views319 pages

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    Ford Focus Diesel - Haynes (en)

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    40 views319 pages

    Ford Focus Diesel - Haynes (En)

    Uploaded by

    pwnuk wnuk

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    © All Rights Reserved
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    Contents LIVING WITH YOUR FORD FOCUS Introduction Page 0-4 Safety first! Page _0+5 Roadside repairs Ityour car won't start Page ov Jump staring Page 0-7 Wheel changing Page 08 identifying leaks Page 09 Towing Page _0+9 Weekly checks Introduction Page _0+10 Underbonnet check points Page Engine oil level Page O11 Coolant level Page Of Brake and clutch fuid level Page 0-12 Power steering fuid level Page 0-12 Tye condition and pressure Page 0-13 Washer fui level Page 0-14 Wiper blades Page 0-14 Battery Page 0-15 Bulbs and fuses Page 0-16 Lubricants and fluids Page 0*17 ‘Tyre pressures Page 0-17 MAINTENANCE Routine maintenance and servicing Page 1: Servicing specifications Page _1+2 Maintenance schedule Page 1-3 Maintenance procedures Page 1*6 Wegal Copying Itis the policy of Haynes Publishing fo actively protect its Copyrights and Trace Marks. Legal action wil be taken against anyone who untawly ‘copies the cover or contents ofthis Manual. This includ all fms of unauthorised copying ineluding digital, mechanical, and electronic in any form. Authorisation from Haynes Publishing wil only be provided expressly and in writing. Megal copying wil also be reported tothe appropriate ‘statutory authorities. Contents REPAIRS & OVERHAUL Engine and associated systems 1.Slire engine in-car repair provedures Page 2Ae1 {.Blitre engine in-carrepairprocedures Page 2B+1 2.0 litre engine in-car repair procedures Page 2804 Engine removal and overhaul procedures Page 2De1 Gooling, heating and air conditioning systems Page 3-4 Fuel and exhaust systems Page 4Aet Emission control systems i Page 4B+1 Starting and charging systems Page _5+1 Transmission Giutch Page_6+1 Manual transmission Page Tet Driveshatts Page 8+ Brakes and suspension Braking system Page 9+ Suspension and steering Page 101 Body equipment Bodywork and fitings Page 1101 Body electrical systems Page 121 Wiring diagrams Page 12024 REFERENCE Dimensions and weights Page_REF+t Fuel economy Page REF®2 Conversion factors Pago _REF®6 Buying spare paris Page REF‘? Vehicle identification numbers Page _REF®7 General repair procedures Page REF*® ‘Jacking and vehicle support Page _REF+ TToo's and working facies Page REF+10 MOT test checks Page REF*12 Fault finding Page REFS16 Glossary of technical terms Page REF*23 Index Page REF*+28 oea Introduction The original Focus model range was Introduced to the UK in 1998, it was halled 8 boing innovative and styish with excllent roadholding. The new range of Focus covered by this manual shares the attributes of its ‘ancestor, but with improved refinement and Performance, coupled with lower emissions. ‘This new Focus shares a platform with other models from Ford's stable, most noticeably the Volvo $40 and VSO range. Initially only available as @ Hatchback or Estate, the range was expanded later by the Addition of a 4-door Saloon model. Safety features include door side impact bars, airbags for the driver and front seat passenger, side airbags, head airbags, whiplash protection system (ront seats), and an advanced seat bolt system with pretensioners and load limiters. Vehicle security is enhanced, with {an engine immobiliser, shielded locks, and ‘security-coded audio equipment being ited 28 standard, a8 well as double-lacking doors ‘on most models, Three sizes of diesel engine are available, ith the 1.6 and 2.0 Ire models being shared by Citrobn and Peugeot ~ a result of joint projects between Ford and PSA (Citrotr/ Peugeot's parent company), whilst tho 1.8 litre Unit is of Ford's own design, and is carried ‘over fom the previous Focus model, Al ofthe engines are four cylinder turbo Giese units, an ‘the 1.6 and 20 tie units ave a 16-valve DOHC design. They incorporate the latest design of rect injection common rail fuel system, with a variable geometry turbocharger, intercooler, catalytic converter and exhaust particulate fiter certain markets ony). ‘The transversely-mounted engines drive the front roadwheels through either a five fof six-speed manual transmission with a ‘hydrautcally-operated clutch. “The fuily-independent suspension is by MacPherson struts and transverse lower ‘arms at the front, with multlink independent ‘Suspension athe rear; ant-ol bars ae fitted at front and rear The vacuum servo-assisted brakes are dlse at the front, and either disc or drum at the rear. An electronically-contoled Anti-lock Braking System (ABS) is fitted on a models, with Dynamic Stablity and Traction Control System (DSTO) also available. Electric power-assisted steering is standard ‘onal models. Airconditioning is avaiable, and all models have an ergonomically-designed passenger cabin with high levels of safety and ‘comfort forall passengers. Provided that regular servicing is carried ‘out in accordance with the manufacturer's recommendations, the Focus should prove a reliable and economical ear. The engine ‘compariment is well-designed, and most of the tems needing requent attention are easily accessible, Your Ford Focus manual ‘The aim of this manual ie to help you get the best value from your vehicle. It can co 20 In several ways. it can help you decide what work must be done (even should you ‘choose to get it done by a garage) It wll also provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults ‘occur. However, tis hoped that you will use the manual by tackling the work yourselt. (On simpler jobs it may even be quicker than ‘booking the car into a garage and going there twice, to leave and collect it. Perhaps most Important, a lot of money can be saved by avoiding the costs a garage must charge to ‘cover its labour and overneads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood, Tasks are described and photographed in a clear step-by-step sequence. The ilustrations are numbered by the Section number and paragraph number to Which they relate ~ if there is more than one. illustration per paragraph, the sequence is denoted alphabetical. References to the ‘let’ or ‘right’ of the vehicle are in the sense of a person in the river's Seat, facing forwards. Acknowledgements ‘Thanks are due to Draper Tools Limited, ‘ho provided some of the workshop tools, ‘and to all those people at Sparkford who helped inthe production ofthis manual ‘We take great pride in the accuracy of information vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, oF omissions from, the Information given. Safety First! o-s Working on your car can be dangerous. ‘This page shows just some of the potential risks and hazards, with the aim of creating @ safely-conscious attitude General hazards Scalding + Don't remove the ralator or expansion fark cap whl the engines hot. * Engine ot, automate transmission id or Power steering fud may aso be dangerously hot i the engine has recently been running. Burning + Boware of bus fom the exhaust system ‘and rom ary part of the engine. Brake cisca and crams can also be extremely hot immediately ater use. Crushing + Wen working under or near raised vehicle, 2 jack with axle stands, or use crive-on ramps, Never vonture ‘is only supported by a jack. + Take care If loasening or tightening high- torque nuts when the vehicle is on stands. Initia! loosening and final tightening should be done with the wheels on the ground, Fire “+ Fuels highly lammabie; fuel vapour is explosive. ‘Don't et tut spi onto a hot engine. ‘Do not smoke or allow naked lights (including plot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). * Fuel vapour is heavier than air, so don't Work on the fuel system withthe vehicle over ‘an inspection pit * Another cause of fois an electrical ‘overload or short-clruit. Take care when repairing of mocitying the vehicle wiring. ‘+ Keop a fire extinguisher handy, ofa type Suitable for use on fuel and electrical fires. Electric shock . 5; 7» + Ignition HT voltage can be dangerous, especialy io > peop wit heart Problems ore aceraker.Dontt 2 \work on or near the ‘anion system with the engine running the igntion switched on 2 ] ‘+ Mains vottage is also dangerous. Make sure that any mains-operated equipment is Correctly earthed. Mains power points should bbe protected by a residual current device (RCD) circuit breaker. Fume or gas intoxication + Exhaust fumes are poisonous; they often Contain carbon ‘monoxide, which is rapidly fatal if inhaled, Never run the engine ina ontined space such as a garage ‘with the doors shut. * Fuel vapours also Poisonous, as are the vapours from some ‘leaning solvents and paint thinners, Poisonous or irritant substances * Avoid skin contact with battery acid and with any fe, uid or lubricant, especially antireeze, brake hydraulic uid and Diesel {uel Don't syphon them by mouth. W such a ‘substance is swallowed or gets into the eyes, ‘seek medical vie. * Prolonged contact with used engine oll can ‘cause skin cancer. Wear gloves or use a barrier cream itnacessary. Change out of oil ‘soaked clothes and do not keep oly rags in your pocket. * Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame {including a cigarette. can also cause skin burns on contact. Asbestos * Asbestos dust can cause cancer if inhaled ‘or swallowed. Asbestos may be found in ‘gaskets and in brake and clutch inings. When dealing with such components itis safest fo assume that they contain asbestos. Special hazards Hydrofluoric acid + This extremly corse acid is formed tihen certain types of syntetic uber, found insome O-frgs ol eas vol hoses ee txposed to temperatures above 0%. The ruber changes into charred or sticky substance containing the ald. Once formed, the acd remains dager for ear {013 onto the sin, maybe necessary SImputao the im concemed. + pen deakog with a veticle which has Suifordafrosor with compres aieged ffomeuch a vile, wear protective gloves fe card tem aftr ve. The battery + Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care ‘when topping-up or carrying the battery. + The hydrogen gas given off bythe battery 's highly explosive. Never cause a spark or ‘allow a naked ight nearby. Be careful when ‘connecting and disconnecting battery chargers or jump leads. Air bags * Airbags can cause injury if they go off ‘accidental. Take care when removing the steering wheel and/or facia. Special storag. Instructions may apply Diesel injection equipment «+ Diese injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes. Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results. Remember. Do + Do use eye protection when using power tools, and when working under the vehicle, + Do wear gloves or use bari cream to protect your hands when necessary * Do get someone to check periodically that all is well when working alone on the vehicle. * Do keep loose clothing and long hair well ut ofthe way of moving mechanical parts, * Do remove rings, wristwatch ete, before ‘working onthe vehicle - especially the electrical system. * Do ensure that any iting or jacking ‘equipment has a safe working load rating adequate forthe job. DON'T * Don't attempt to lita heavy component which may be beyond your capabilty - get assistance. *= Don’t rush to fnish a job, or take Unvetified short cuts. = Don't use ilfiting tools which may sip and cause injury. ‘= Don't leave tools or pats ving around where someone can trip over them. Mop Up oll and fuel spils at ones, += Don't allow children or pets to play in or rear a vehicle being worked on. os Roadside repairs ‘The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more

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